RU2135427C1 - Method of designing cement mixture (variants), method of preparing final cement mix, method of preparing final dry cement mix, cement mex, and final cement mix - Google Patents

Abstract

FIELD: building industry. SUBSTANCE: method is used for determining proportions of sand, cement, coarse-grain filler, water, fly ash, agents for trapping air and fillers to prepare concrete mix having desired strength and settling at minimum cost. Optimization process includes combination of mathematical models which characterize individual components. Process also optimizes useful life of cement mixture. EFFECT: desired characteristics of strength, settling and useful life. 37 cl, 36 dwg

Description

 The present invention relates to hydraulic cement compositions, products made from such compositions, and methods of processing such hydraulic cement compositions and products. More specifically, the present invention is directed to the creation of systems and processes for optimizing the functional properties and design characteristics of cement materials while minimizing manufacturing costs, which uses the method of microstructural engineering, which is part of the technology of materials. In addition, the present invention is directed to the creation of systems and processes to determine the required changes in the processing parameters when using a specific technological process when changing the composition of the raw materials, providing reproducible receipt of the material with uniform functional properties and design characteristics.

2. Technology Overview
Hydraulic cement materials were first used in ancient Rome about two thousand years ago as a binder for mortars (which currently, as a rule, are a mixture of cement, water and sand) and concrete (which currently, as a rule, are a mixture of cement, water and aggregates such as sand and / or gravel). Subsequently, knowledge regarding hydraulic cement materials was lost and these materials were rediscovered in 1829 by J. Ampin in England. After 1829, concrete found application in various fields, as it is a relatively inexpensive material and can easily be shaped under a wide variety of conditions. It is also important that the versatility of concrete is enhanced due to the lack of requirements for highly qualified workforce and the lack of need for specialized equipment in the manufacture of conventional concrete products. For more than a hundred years, concrete has not only been used as one of the main building materials, but also used in the infrastructure of all the main structures used by modern society, such as pipes, sidewalks, road curbs, bridges, highways, supports, foundations and dams.

 Materials based on hydraulic cement are formed by mixing cement with water in order to obtain a cement paste. In a typical cement paste, the ratio of water to cement is from 0.1 to 1. In the present patent description, the term "cement paste" refers, inter alia, to a liquid mixture of cement and water. As a rule, when water is added to cement in a cement paste, a hydration reaction begins, but this reaction does not end. When water is added to hydraulic cement, the synthetic clinker minerals that make up the cement react chemically with water, resulting in a new multiphase structure, described as a “CSH” gel or calcium silicate hydrate. As a result of this reaction, a mixture of water with cement sets and hardens, binding aggregate particles and forming plaster or concrete.

 One of the most important areas of use of hydraulic cement compositions is the manufacture of concrete. In the present description and patent claims, the term "concrete" is broadly defined as an inorganic composite material, including cement paste used as the main binder material, the properties of which are formed under conditions close to environmental conditions. (The difference between concrete and inorganic ceramic materials is that it does not heat up to several hundred degrees in order to form compounds during sintering, but cures by hydration). Concrete is a solid and durable building material made by mixing a water-cement mixture with one or more aggregates, including sand, gravel, other mining materials, metals and (or) metal alloys.

 In modern advanced concrete grades (used, for example, for a tunnel between France and England or for the connecting section of a large ring road in Denmark), the mixture can contain up to 12-15 different components. These components may include, for example, three grades of sand, three grades of coarse aggregate and one grade of special-purpose cement, fly ash, silica fume, two types of additives to plasticize the mixture and reduce water concentration, reagents for trapping air, setting accelerators, retarders and water. In addition to all of these components, other variables affecting the characteristics of the final product are manufacturing techniques and equipment.

 Typically, the two most important design criteria for cement materials are (a) the rheological characteristics of the yield strength of fresh concrete and (b) the compressive strength of concrete, measured 28 days after the start of the curing process. The flow characteristics are usually measured by filling a 30 cm high conical vessel with freshly mixed concrete. After that, the conical vessel is removed, and the cone of freshly mixed concrete is left without external support. The amount of concrete precipitation (i.e., the value of decreasing the height of the cone vertically) characterizes its fluidity. The compressive strength of concrete is usually tested by breaking tests on cylindrical specimens under load, which are conducted after curing for 28 days. Strength is measured in pounds per square inch, inch (pounds per square inch) or MPa (megapascals).

 Other design parameters, such as permeability, diffusion of chlorides (which is important to prevent corrosion and, therefore, ensure the durability of the entire structure), heat cracking, shrinkage during drying, plastic shrinkage, resistance to sulfates, reactions of alkaline compounds with silica and the number of microdefects, also have a direct impact on the strength and durability of concrete. Many of the above parameters depend on the porosity of concrete. Microdefects are usually caused by phenomena such as the formation of cement milk and the delamination of the constituent components of concrete, which are usually associated with an unsatisfactory calculation of the structure of concrete. (The “protrusion of cement milk” is the process of migration of water to the upper surface of freshly laid concrete and its accumulation on the surface or under coarse aggregate. “Separation” is a phenomenon that occurs when there is no internal adhesion between the concrete particles and the associated separation of the cement mortar from coarse aggregate).

 The same properties that lead to the widespread use of concrete (i.e., low cost, ease of use, availability of raw materials) have led to insufficient knowledge of concrete, which does not allow us to develop and fully utilize the potential capabilities of this material. In the past, it was easier to change the composition of a mixture than to try to understand the interdependencies and the influence of various components. Because of this, the technical capabilities of cement-based materials remained limited.

 After many decades of practical experience, the technology for manufacturing concrete products has become a system of instructions, rules and standards based on empirical results obtained by changing the composition of cement mixtures. These instructions are an attempt to ensure uniformity in obtaining concrete with specified characteristics. In the United States of America, generally accepted standards for the design of concrete structures are empirical formulas developed by Committee 211 of the American Institute of Concrete ("ACI") and outlined in ACI Guidelines 211.1-81, Practical Guidelines for Choosing Material Proportions for Normal, Heavy, and Mass Concrete. Although other countries apply slightly different standards, the resulting formulations are mostly similar to each other and subject to the same disadvantages.

 These empirical standards allow the concrete manufacturer to determine the recommended amounts of cement, sand (specific type), coarse aggregate (specific type) and water to form concrete mixtures for concrete mixtures at the “concrete plant”, “pre-mix plant” or “construction site”. specified functional characteristics - first of all, the characteristics of draft and strength. Unfortunately, the complex compositions and various properties of materials, environmental conditions and purposes led to the fact that the processing of materials based on cements remained a craft based on trial and error, and did not become a process based on science and technology.

 A typical approach to the development of concrete mix according to ACI 211 standards is to select the recommended mix composition with the specified characteristics of precipitation and strength. After this, concrete is kneaded and the actual sludge is determined. As a result of the presence of variables such as size, shape, type and size range of sand, coarse aggregate and cement, as well as variations in mixing procedures and environmental conditions, the actual settlement usually does not match the theoretical. In accordance with this, additional batches are carried out with a varying amount of water until a mixture with the required precipitate is obtained.

 The resulting concrete is then placed in cylinders and cured within 28 days. The resulting cement cylinders are then subjected to loading in order to determine their actual compressive strength. If the actual strength does not correspond to the theoretical one, then the process is repeated using the new recommended mixture composition with increased or decreased theoretical strength (depending on the actual strength of the previous mixture). It is easy to see that this process can be very lengthy and often expensive.

 The process used before the present invention has several disadvantages. The most obvious is the fact that this process does not take into account the variability of the characteristics of the components, as a result of which it is necessary to perform trial batches in order to obtain the required precipitation and strength characteristics. The use of test mixtures leads to serious delays, since curing requires at least 28 days. Moreover, this may require significant costs associated with both the preparation and testing of mixtures, and with delays prior to testing. In addition, even in the case of obtaining a mixture that meets the requirements for sludge and strength, there is no guarantee that this mixture has the lowest cost.

 Additional tests may reveal the fact that by changing the range of particle sizes or proportions of sand, coarse aggregate and cement, you can get a cheaper mixture with the same or even more accurate characteristics of precipitation and strength, corresponding to the specified values. And finally, after determining an acceptable mixture composition for a given set of materials, it is often very difficult, or even impossible, to maintain uniformity of characteristics (i.e., precipitation and strength) due to natural variations in the properties of raw materials.

Another calculation method is to first produce a series of different concrete mixtures with the addition of various components, including additives, and changing their proportions. Additives may include fly ash, silica fume, reagents to reduce the amount of water, pozzolan, fillers and reagents to trap air, which affect the concrete sludge and strength. The mixtures are selected from among those close to the recommended composition that has the required theoretical characteristics of precipitation and strength. However, to vary a concrete mix with 13 components at 10 different experimental levels, 10 ¹³ combinations will be required.

 Computer programs have been developed, such as the program of Shieldstone & Associate, Inc. , Dallas, Texas, which takes into account these problems and attempts to evaluate and sort large databases on the composition of the mixtures in order to select the optimal composition of the mixture using this raw material. In general, the Shieldstone system attempts to combine the particle size distributions of known concrete mixtures with the particle size distribution of existing raw materials to ensure similar characteristics of concrete mixtures. Such programs, however, did not have much success and did not receive distribution, since an almost infinite number of different types of components can be used in the mix for any given locality.

 For example, although no more than three types of coarse aggregate are usually used in a mixture, the number of actual sizes and surface textures of different types of coarse aggregate particles, which in turn affects the properties of the mixture, can vary almost to infinity. Accordingly, it is extremely difficult to match the characteristics of a mixture made from existing raw materials with the empirical results obtained for mixtures made from other raw materials. The problem becomes even more complicated as the number of available components increases. Moreover, the creation of a new mixture on the basis of empirical results obtained for the previous mixture can neither lead to improvement of the new mixture nor to the optimality or maximum efficiency of the new mixture.

 Therefore, it is practically impossible and impractical to use conventional test methods or empirical tables compiled on the basis of previous results in order to determine with certain certainty and accuracy which types and proportions of the components of a multicomponent mixture will allow to obtain a mixture composition that provides the required characteristics of precipitation and strength and has a minimum cost for each concrete party of the made concrete. Even if it is possible to obtain a mixture with the required sludge and strength, the durability of concrete is still in question. Almost any combination of aggregates will provide the required strength and sludge if enough water and cement are added. However, as the amount of added water increases, the durability of the manufactured concrete structures decreases. Accordingly, the application of the above process does not guarantee that the selected mixture will provide maximum durability.

 Attempts have also been made to simulate certain aspects or characteristics of concrete mixtures. For example, the Bolomey and Feret equations are an attempt to simulate the strength of concrete and mortar obtained after 28 days, respectively. Similarly, the Larrard equation is an attempt to correlate the effect of particle packing on the strength of mixtures containing cement, fly ash and silica fume, while the Popovic formula is an attempt to correlate the water content of the mixture with the resulting sediment or formability of the mixture.

 However, for a number of reasons, such equations practically did not find recognition and application in the concrete industry. First, and most importantly, no mutual dependencies were found between the equations. Therefore, although these equations may be useful in evaluating a particular parameter, they cannot be used independently in developing the structure of the mixture with the accurate optimization of all characteristics. Secondly, empirical studies have revealed discrepancies between the theoretical results of the above equations and the actual experimental values obtained. Finally, these equations are usually designed to be used for standard mixtures based on sand, cement and coarse aggregate and do not take into account the effects of air bubbles present in the mixture or the addition of modern additives such as fillers, fly ash, silica fume and other pozzollans.

 Concrete mixing problems are often exacerbated in concrete plants, which cannot afford the luxury of testing a mixture before using it. Due to the difficulty of controlling the flow characteristics and the loss of fluidity of fresh “uncured” concrete with a long period of time before pouring into the mold (sometimes reaching up to 10 hours after mixing), most of the concrete mortar is produced in concrete plants located relatively close to the construction site. Therefore, the operators of such plants are trained to evaluate concrete materials “by sight and touch,” and not to determine the structure of concrete using scientific methods.

 The prevailing practical method used in concrete plants is the use of fixed dosing (i.e., obtaining the desired mixes) using computer systems, which allows you to combine materials with varying characteristics in order to obtain hardened concrete with specified characteristics. However, one of the main traditional problems in the production of uniform concrete with predictable characteristics is the fact that the constituent materials used change from day to day and even from one batch to another and from one site to another. As a result, the characteristics of concrete materials have high standard deviations.

 Therefore, in the concrete industry, it is necessary to use the principle of setting the composition of the mixture with a margin of functional characteristics, which makes it possible to compensate for the inability to ensure uniformity of the manufactured material. The theoretical standard strength is attributed to the standard concrete mix based on the strength of the test cylinders after curing for at least 28 days. Depending on the number of cylinders tested and the standard deviation of the test results, actual strength values may differ significantly from theoretical. In contrast, the more uniform the concrete produced, the less margin it will require.

 The practice of assigning formulations with excess parameters in combination with an unsatisfactory initial formulation of the composition is much more expensive than it might seem at first glance, both for the manufacturer and for society as a whole. After setting design and functional criteria for a concrete batch of concrete, the manufacturer cannot simply produce products that, on average, will meet each of these criteria. The manufacturer must design products that meet the minimum criteria, assuming the worst combination of characteristics of all the materials used.

 For example, the quality and grade of existing cement can range from A (the worst combination) to B (the best combination). Similarly, the quality and grade of each type of aggregate can also range from C to D. The quality of sand will range from E to F. Even the quality of water and other additives can vary in a given range; however, these fluctuations are usually less important than fluctuations in the quality of cement, sand and coarse aggregate.

 The range of variation in the characteristics of any given type of cement, sand or aggregate material can be quite large, since obtaining raw materials with a narrow range of variation in characteristics and with uniform quality and particles of the same size will be very expensive. As it turned out, the overestimation of the characteristics of concrete material provides higher efficiency than the use of guaranteed homogeneous raw materials with controlled quality.

 Therefore, when processing concrete, the manufacturer should consider that at any given time the quality of the sand corresponds to category “A” (worst quality), the quality of the aggregate corresponds to category “C” (worst quality) and the quality of cement corresponds to category “E” (worst quality). It immediately becomes apparent that the types and volumes of the materials actually used should differ significantly from those necessary to achieve a given result.

 As a result, a more expensive product can be obtained having an excess margin of compressive strength reaching several thousand pounds / sq. inch. Nevertheless, at any given time, the strength of the manufactured product can range from only adequate to overstated by 50%. In a market with a high level of competition, this leads to a minimum or even zero profit, or, in the worst case, to the desire to “cut corners” and produce a poor-quality product that may collapse sooner or later.

 The principle of setting an excessive margin of safety is also reflected in the proportions of the various components. This means that an excess amount of sand is usually added to a mixture with a predetermined composition to provide internal adhesion of the particles of the mixture and to prevent its separation or leakage of cement milk. However, adding excess sand results in a more porous and less durable mixture. As a rule, an excessive amount of cement is also added to the mixture to provide sufficient strength, but this increases the cost of the product.

 Moreover, even despite the fact that the concrete plant operator will significantly increase the estimated margin of safety, he can never be sure that the product will have the specified operational characteristics. This is due not only to the variation in the characteristics of the starting materials, but also to the fact that operators usually use standard mixes (or formulations) to provide a given set of functional parameters. Such formulations are empirical and based on averaged historical experience, but still cast doubt on the characteristics of any particular product. The operator can never be sure that he uses exactly the same materials that were used to determine the composition of the standard mixture, and that these materials will provide the same results.

 An additional problem encountered in the everyday practice of the concrete industry is that, due to the aforementioned variation in the characteristics of materials, concrete truck drivers usually take some measures to independently change or "adjust" the ductility or flow characteristics of concrete, changing them compared to those of concrete possessed while loading a concrete truck at a concrete plant. An assessment has been made showing that at approximately 70% of the concrete supply, water is usually added to the concrete mortar in order to increase its fluidity or “improve appearance”. As a result, the ratio of water to cement increases, and the compressive strength of concrete decreases. In other countries, it was found that such practices had serious consequences, and this was prohibited. Consequently, the preparation of concrete at concrete plants is associated with an additional drawback consisting in the absence of control over the concrete mixture after its removal from the concrete plant and in the unpredictability of product quality.

 A known method of designing a cement mixture and a method of manufacturing a cement mixture in which there are the above disadvantages containing cement, water and aggregate (fine and coarse) with the determination of the proportion of cement, water and aggregate in accordance with the composition optimization procedure, comprising the following steps: a) obtaining batches of hydraulic cement and batches of aggregate, which are used to obtain a hydrated cement mixture, and hydraulic cement and aggregate contain many individual particles, having an average diameter and packing density, b) the choice of a given precipitation of the cement mixture cone before hardening and a given final hydrated strength after curing (see the Handbook of building materials for factory and building laboratories, M., 1961, pp. 74-75, p. 91-92, pp. 119-129).

 Based on the foregoing, it is easy to understand that in this branch of technology technological processes and manufacturing methods are required that ensure uniform and predictable production of homogeneous cement compositions and products that are guaranteed to meet specified quality requirements and specified functional requirements.

 Another significant achievement in this industry will be the possibility of uniform and predictable manufacture of cement compositions and products that are guaranteed to meet specified design and functional requirements while minimizing the need for excessive design margin of safety and, thereby, reducing manufacturing costs.

 In addition, a significant achievement in this industry will be the possibility of uniform and predictable production of homogeneous cement compositions and products, despite the scatter in the quantitative and qualitative characteristics of the raw materials used (i.e., cement, sand, gravel, aggregate, water and additives).

 Another significant achievement in this industry will be the creation of new compositions and processes for the manufacture of cement mixtures and products with such predicted characteristics that will eliminate the need to change the product received by the concrete truck driver or at the delivery point.

 Another significant achievement in this industry will be the creation of new processes for calculating concrete, thanks to which cement compositions will predictably provide the required characteristics of strength, settlement and durability.

 Another significant achievement in this industry will be the creation of new compositions and processes for calculating the composition of concrete, which will eliminate the need to apply the approximation method through trial and error.

 Another significant achievement in this industry will be the creation of new compositions and processes for calculating the composition of concrete, which will ensure the optimality and greatest economic efficiency of the composition of the mixture for concrete, including various components and additives.

 Another achievement will be the creation of new processes for changing technological processes for the manufacture of cement compositions and products in "real time" in order to respond to changes in raw materials entering the site.

 Such cement compositions, products and methods are disclosed in the present patent description and are the subject of this patent application.

SUMMARY OF THE INVENTION
The present invention relates to hydraulic cement compositions, products made from such compositions, and systems for the manufacture and processing of such hydraulic cement compositions and concrete products, which optimize the functional properties and design characteristics of cement materials while minimizing manufacturing costs. Instead of the empirical trial and error method, which throughout history has been used to calculate concrete mixtures, the scientific method of material technology is used, which makes it possible to ensure the required qualitative characteristics and functional properties of cement materials using microstructural engineering.

 The process of optimizing the structure of the present invention consists of twelve different steps.

 Stage 1 consists in ensuring the maximum packing density of the dry cement mixture, including cement and at least one or more types of aggregate (“types” correspond to aggregates with particles whose sizes fall within a certain range. In ordinary mixtures, usually one type of fine aggregate, for example sand, and one type of coarse aggregate, for example gravel). An appropriate combination of different types of aggregates will increase the packing density of the concrete mix and can maximize the packing density of the mix particles.

 Studies have shown that in the case of mixtures with a packing density of particles approaching the maximum, the characteristics of concrete both in the raw and in the solid state increase. Thus, as we approach the maximum packing density of the concrete particles, we optimize characteristics such as formability, strength, permeability, chloride diffusion resistance, and durability. This is because only a minimal amount of water must be added to a mixture with a maximum particle packing density, which provides increased internal adhesion of the particles, preventing the protrusion of cement milk and ensuring a minimum separation of the components at a point corresponding to the maximum packing density, which, in turn, reduces the cost of the mixture.

 The proportions of cement and various types of fine-grained and coarse aggregate, necessary to ensure maximum packing density of particles, are determined by theoretical calculation of packing density for all combinations of raw materials. By comparing the packing density for different compositions, it is possible to determine the value of the maximum packing density of the particles and the corresponding percentage ratio of the components by volume.

 Stage 2 is to determine the initial optimal composition of the concrete mixture, which will not only provide an approaching maximum packing density of the particles, but will also have sufficient internal adhesion to prevent the emergence of cement milk or delamination and will provide the required values of strength and sedimentation. The approach on the basis of which this optimization method was developed consists in determining the initial value of the unit cost of the initial composition, which ensures the closest packing density of the particles, as well as the required strength, draft and internal adhesion characteristics, after which this initial value is compared with the unit cost mixtures having the same characteristics, but different ratios of fine and coarse aggregate. By comparing the unit cost of each of the optimal mixtures with varying ratios of fine-grained and coarse-grained aggregate, it is possible to identify the most economical mixture with the given characteristics.

 The initial optimal mixture is determined by choosing a mixture that not only ensures the closest packing density of the particles, which will ensure optimal performance, but also include a sufficient amount of sand to provide internal adhesion and prevent the protrusion of cement milk and delamination of concrete components. Then determine the packing density of the mixture and the amount of water required to give the mixture the desired precipitation. Based on this information, the strength of the resulting mixture is calculated, after which the calculated value is compared with the specified strength. If the design strength is too low or high, then, respectively, increase or decrease the cement content while maintaining a constant ratio of fine-grained and coarse aggregate. The above process is repeated for the new mixture and continues until a mixture with the required strength and precipitation characteristics is obtained for a given ratio of fine-grained and coarse-grained aggregate. The resulting mixture is called the initial optimal mixture.

 At stage 3, the unit values of the optimal mixtures are compared for each specific ratio of fine-grained and coarse-grained aggregate to determine the composition of the mixture, optimized both in terms of functional characteristics and cost. This process is most logical by determining the ratio of fine-grained and coarse-grained aggregate for the initial mixture identified in stage 2. After this, an increment in the volume of fine-grained aggregate and a corresponding increment in the volume of coarse-grained aggregate are set, thereby setting a new value for the ratio of fine-grained and coarse-grained aggregate. Then determine the composition and cost of the optimal mixture for the new ratio of fine-grained and coarse aggregate, after which the obtained values are compared with the values obtained for the previous optimal mixture. If the new optimal mixture is cheaper, then a new change in the ratio of fine-grained and coarse-grained aggregate is made and a new calculation of the optimal composition and cost is performed, after which they are compared with previous values. This process continues until the new mixture becomes more expensive than the previous one (or until the maximum possible amount of fine-grained aggregate is reached), after which the calculation cycle is terminated, since the previous mixture is the best.

 At stages 4-7, the effect obtained by adding various additives to the standard concrete mixture is determined, including, respectively, fly ash, silica fume, reagents to reduce the amount of water and fillers. Reagents to reduce the amount of water are added in order to reduce the amount of water required to ensure a given precipitation of the mixture. Fly ash and fillers are added as a substitute for cement and are used, in particular, in low-strength concrete in order to reduce the cost of materials, as well as to reduce the amount of water required to ensure a given settlement of the mixture.

 Fly ash, silica fume and pozzolans also have certain cement-like characteristics and independently contribute to increasing the strength of concrete. The use of micrograin silica is usually associated with an increase in the amount of water required to provide a given precipitation of the mixture, while the use of other pozzolans can lead to both an increase and a decrease in the amount of water required depending on the chemical composition and morphology of this pozzolan.

 At step 8, the above processes are combined into a group of internal cycles, during which increments of the content of components and calculation of the proportions of fine aggregate, cement, coarse aggregate, mixed water, fly ash, fine silica and reagent are performed to reduce the amount of water that will provide concrete mixtures with the required characteristics and minimum cost.

 At stage 9, the influence of reagents for capturing air is considered, and the required amount of these reagents is calculated and adjusted to ensure a sufficient specified air content in the resulting concrete structure. Reagents for capturing air are added in order to ensure high frost resistance of concrete.

 At step 10, a correction factor for the optimization process is determined, which allows you to refine the estimate of the resulting precipitation. Typically, this is done by plotting to compare the theoretical and real water content at the same rainfall value. Then, the correlation between the results is calculated, and the obtained correlation coefficient is included in the computing process to increase the accuracy of the results.

 At stage 11, the durability or porosity of concrete is determined, which can be included in the optimization process as one of the parameters characterizing the quality. Selecting a mixture based on the durability parameter ensures that the selected mixture has sufficient durability for its intended use.

 Finally, at step 12, a method is described for accurately determining the volume or weight of components required to obtain exactly the given yield or volume of the final mixture. In this process, the particle packing parameters and the amount of space between the particles are taken into account.

 Further, the present invention is directed to the creation of systems to determine the required changes in the processing parameters when changing the composition of the starting raw materials, thereby providing reproducible receipt of the material with uniform functional properties and design characteristics. According to the present invention, hydrated cement compositions with high density and strength can be made. It has been demonstrated that by adjusting the parameters in accordance with the present invention, it is possible to provide minimal or almost imperceptible delamination or protrusion of cement milk in fresh concrete.

 Thus, using the technological methods of the present invention, it is possible to produce a whole family of new concrete with increased strength and durability.

Brief Description of the Drawings
To state the methods for achieving the above and other advantages of the invention, a more detailed description of the invention is briefly described above, with reference to specific methods of implementing the invention illustrated in the accompanying drawings. Given that these drawings reflect only typical ways of implementing the invention and, therefore, do not limit its scope, the invention will be described in detail in expanded form using the accompanying drawings.

 In FIG. 1 is a graph of particle packing density for a ternary mixture consisting of cement, silica sand (0-2 mm) and crushed granite (8-16 mm).

 In FIG. 2 is a graph of particle packing density of FIG. 1, which shows lines showing a method for determining the composition depending on the density indicated on the graph.

 In FIG. Figure 3 shows a graph for comparing the experimental and theoretical particle packing densities (according to the Toufar / Toufar / model) for a ternary mixture of cement, fine gravel (3/8 ") and sand.

 In FIG. 4 is a graph for comparing the experimental and adjusted theoretical particle packing densities for the mixture of FIG. 3.

 In FIG. 5 is a graph of particle packing density with pseudoparticle lines.

 In FIG. 6 is a graph of experimental strength values for different mixtures in comparison with the corresponding theoretical strength values for the mixture according to the Feret equation.

 In FIG. 7 is a graph used to compare experimental and theoretical strength values for the mixtures of FIG. 6.

 In FIG. 8 (A) - (B) presents a logical block diagram of an optimization system.

 In FIG. 9 shows the hierarchical structure of the logical block diagram of FIG. 8 (B).

 In FIG. 10 shows the correlation between the adjusted theoretical values of the packing density and the experimentally determined packing density of sand particles and fine gravel according to Example 1.

 In FIG. 11 shows the correlation between the adjusted theoretical values of the packing density of the ternary system and the experimentally determined packing density of the system consisting of particles of cement, sand and fine gravel according to example 1.

 In FIG. 12 shows the correlation between the actual and theoretical amount of water for the mixtures of example 1.

 In FIG. 13 shows the correlation between air content and sediment for the mixtures of example 1.

 In FIG. 14 shows the correlation between the actual and calculated precipitation for the mixtures of example 1.

 In FIG. 15 shows the correlation between the actual and theoretical amount of water for the mixtures of example 2.

 In FIG. 16 shows the correlation between air content and sediment for the mixtures of example 2.

 In FIG. 17 shows the correlation between the actual and calculated precipitation for the mixtures of example 2.

 In FIG. 18 shows the correlation between the actual and theoretical amount of water for the mixtures of example 3.

 In FIG. 19 shows the correlation between air content and sediment for the mixtures of example 3.

 In FIG. 20 shows the correlation between the actual and estimated settlement for the mixtures of example 3.

 In FIG. 21 shows the correlation between the actual and theoretical amount of water for the mixtures of example 4.

 In FIG. 22 shows the correlation between air content and sediment for the mixtures of example 4.

 In FIG. 23 shows the correlation between the actual and estimated settlement for the mixtures of example 4.

 In FIG. 24 shows the correlation between the actual and theoretical amount of water for the mixtures of example 6.

 In FIG. 25 shows the correlation between air content and sediment for the mixtures of example 6.

 In FIG. 26 shows the correlation between the actual and calculated settlement for the mixtures of example 6.

 In FIG. 27 shows the packing density of the particles for fine gravel of Example 18.

 In FIG. 28 shows the average diameter of fine gravel in Example 18.

 In FIG. 29 shows the packing density of the sand particles of Example 19.

 In FIG. 30 shows the average sand particle diameter of Example 19.

 In FIG. 31 shows the packing density of particles of a typical crushed stone with an average size of 1 ″ in Example 20.

 In FIG. 32 shows the average diameter of a typical crushed stone with an average size of 1 ″ in Example 20.

 In FIG. 33 is a graph of particle packing density for the three coarse aggregates of Example 32.

Detailed Description of Preferred Embodiments
The present invention relates to hydraulic cement compositions, products made from such compositions, and methods of processing such hydraulic cement compositions and products. More specifically, the present invention is directed to the creation of systems for optimizing the functional properties and design characteristics of cement materials while minimizing manufacturing costs, which uses the method of microstructural engineering, which is part of the technology of materials. In addition, the present invention is directed to the creation of systems that can determine the required changes in processing parameters when using a specific process when changing the composition of the raw materials, providing reproducible production of products with uniform functional properties and design characteristics.

I. General Description
A. Development of formulations using microstructural engineering
As already mentioned, the instructions, regulations and standards that are currently commonly used in the processing of cement and concrete materials are based on averaged empirical results obtained over several decades. To compensate for the dispersion of characteristics that occurs as a result of the application of such standards, in designing products from concrete materials, an excessive margin of safety is set to ensure that the resulting cement-based products will have the specified characteristics.

 In contrast, the present invention employs a material technology method that allows using microstructural engineering to create concrete with the desired characteristics and properties. In accordance with this approach, mathematical models were developed, which were then combined with models known in the art, in order to obtain new models designed to accurately determine the strength, precipitation and durability parameters for a concrete mixture based on the developed composition of the components. Using these models, you can accurately determine the composition of the mixture, which allows you to optimize the specified characteristics and properties while minimizing the cost of materials. Moreover, models can also be used to identify the need to add additives such as fillers, reagents to reduce the amount of water, reagents to hold air, silica fume, fly ash and other pozzolans; and (if such additives are necessary) to determine the amount of these additives required to optimize the composition of the mixture.

 Microstructural engineering is a method of imparting to the microstructure of hydraulically settable compositions certain desirable, predetermined properties necessary for the final product. The method of microstructural engineering also allows you to take into account the cost of materials, the variation in the parameters of the process and possible problems. In other words, the method of microstructural engineering, unlike the traditional method of trial and error, manufacturing and testing, allows you to develop compositions with predictable given characteristics of strength, weight, precipitation and formability, porosity, permeability, durability, cost, environmental neutrality, and also allows you to solve various technological issues.

 To develop any specific products, you can use a huge variety of different types of raw materials, the number of which is estimated at about 50 - 80 thousand. The raw materials can be materials of various broad classes, such as metals, polymers, elastomers, ceramics, glass, composite materials and cements. Within a certain class, there is some similarity of characteristics, processing methods and applications. For example, ceramics has a high elastic modulus, while for polymers this value is low; metals can be shaped by casting and forging, while composite materials require layering or special molding methods.

 However, the division of the characteristics of materials into classes poses a certain danger; this can lead to narrow specialization (when the metallurgist knows nothing about ceramics) and to conservative thinking ("we use steel because we always used it"). It was the narrow specialization and conservative thinking that limited the consideration of the use of hydraulically settable materials for the manufacture of various products. Nevertheless, after realizing the fact that cement materials have a very wide scope and can be created using microstructural engineering methods, the possibility of their use for the manufacture of various products becomes almost unlimited.

 In the present invention, a microstructural engineering strategy is used to create controlled cement raw materials. This approach is based on material technology, which is a scientific discipline that focuses on identifying relationships between new materials, processing methods, microstructure, and functional characteristics, as shown in the table below. 1.

 The theoretical basis is to understand how the various technological processes used to process the required raw materials affect the microstructure, and accordingly, the characteristics of the products obtained. Understanding of these relationships allows you to purposefully replace materials and use different technological methods for the manufacture of products with specified functional characteristics.

 The material technology method has been demonstrated on a wide variety of materials, including steel, polymers, composite materials, semiconductors and, more recently, superconductors. For all of these diverse materials, the material technology method leads to a new generation of highly efficient materials. Thanks to the technology of materials, it is possible to model the relationships between processing methods, microstructure and characteristics, which allows us to develop specific products with optimized characteristics and optimal cost, based on scientific understanding, and not on trial and error.

 Applying the material technology method to concrete is not an easy task due to the complexity of the structure inherent in cement materials. The relationships that allow you to control and optimize the microstructure and characteristics of concrete are interdependent and difficult to identify. The complex nature of hundreds of chemical reactions that occur during cement hydration, along with a wide variation in the parameters of raw materials, a variety of technological methods, methods for handling products, curing metols, etc., led to the prevailing opinion in the industry that concrete does not belong to the number of verifiable materials with fairly predictable characteristics that allow the use of the material technology method. In the historical aspect, the researchers only recorded changes in the microstructure and characteristics of concrete. The generally accepted conclusion was that modeling would be of little use or would be impossible at all.

 One of the aspects of concrete that makes it difficult to apply the scientific approach of materials technology is the relationship between the “raw” (at an early stage) and the subsequent “hardened” (solidified) state, as well as the optimization of parameters for these states. For example, other formulations other than those that provide high strength and low permeability are required to ensure optimal settlement and formability. This obvious contradiction between the various characteristics of the material (required during preparation and pouring in comparison with the period after curing) was considered an irreparable contradiction, for the solution of which the engineer and worker must find the optimal compromise.

 For these reasons, to date, the science and technology of cement-based materials has not been related to practice, and the industry has not used a comprehensive approach to understand the relationships between processing, microstructure and characteristics. In the present invention, the material technology method is used for microstructural engineering of concrete, which will allow specialists in the industry to apply this new approach and process, which gives amazing results. For the design of new cement materials, each stage is presented in table. I was subjected to analysis and categorization, as shown in table. II.

 After that, empirical models were developed that describe the influence of materials processing methods on the microstructure and, therefore, on the functional characteristics of the cement products obtained. These empirical models were refined (i.e., increasing or narrowing the modeling volume and limiting the parameters by introducing certain constants) to create models that would be suitable for testing. Then, the tested models were combined into a single system designed for the development and manufacture of specific products with specified characteristics.

 The resulting system disclosed in the present invention can perform several functions. First of all, it should be noted the possibility of a predictable determination of the relationship between each component and the previously indicated stage, which allows us to develop and produce excellent concrete at a low cost. More specifically, the system allows you to determine which combination of materials, including additives, should be used to obtain a cement mixture with the required parameters of sedimentation and final strength at a minimum cost. The system also allows you to determine which combination of available materials should be used to obtain a mixture with desired characteristics. In addition, the system allows you to determine which combination of materials should be used to obtain a mixture with maximum durability or any specified durability without protruding cement milk or delaminating components. Additional functions of the system will be described below or will become apparent from the following description and patent claims.

 This system can be built in the form of a series of sequential steps for calculation using nomograms without the use of computer technology, or in the form of a computer program. In the process of formulating the mixture, the user must enter the specified values of strength and precipitation; density indicators of natural packing and average particle diameter of the aggregate and cement used; characteristics of fly ash, silica fume, fillers, a reagent to reduce the amount of water, a reagent for trapping air or other pozzolans (if these additives are to be used); as well as the unit cost of each concrete component. Then, using this process, the compositions of mixtures are revealed that will allow you to get concrete with the specified characteristics. After that, the unit cost of the mixtures of these compounds is calculated and the obtained data are compared with each other to reveal the cheapest concrete mixture with the given characteristics.

B. Particle packaging
To fully understand the optimization process of the present invention, it is necessary to learn some basic principles of concrete mechanics. As already mentioned, one of the problems in modeling concrete is the apparent contradiction between optimizing performance for wet and cured concrete.

 Among the characteristics of raw concrete is sludge, which is a specific measure of the rheological function of the water and cement contents. The more water is introduced into the cement mixture, the lower the viscosity of the cement paste becomes and the lower the friction forces between the aggregate particles, and, consequently, the greater the sediment. In turn, the high value of precipitation leads to an increase in formability, which simplifies the pouring and surface treatment of concrete. However, different designs require different values of draft - in the range from 0 to 23 cm.

 Among the characteristics of hardened concrete are strength and porosity. These characteristics also depend on the water content, but in inverse proportion. The more water is introduced into the cement mixture, the lower the concentration of cement becomes, which leads to a decrease in the final strength of concrete. In addition, mixtures with a high water content are often subject to delamination or protrusion of cement milk.

 The "protrusion of cement milk" is a process of migration of water to the upper surface of freshly laid concrete, due to the deposition of a heavier aggregate. Migration of water increases the ratio of water to cement near the upper surface of concrete, which, accordingly, leads to weakening and lowering of the resistance of the surface layer. "Stratification" is the separation of cement mortar (cement, water and sand) from coarse aggregate, which leads to deterioration of the homogeneity of the material, the appearance of areas with insufficient cement content, reduced strength and increased porosity and permeability. And finally, a high water content also leads to an increase in porosity throughout the volume of solidified concrete, which reduces its durability.

 However, the researchers found that the best characteristics for wet and cured concrete can be obtained in the case of such mixtures, the composition of which provides a packing density of particles close to maximum. The packing density depends on the method of packing particles, which is the choice of particle sizes and proportions of the content of materials that ensure filling large voids with small particles, between which small voids are formed, again filled with even smaller particles, and so on until the maximum particle packing density is reached. Ideally, the concrete structure can be formed due to the most efficient packing of coarse aggregate, subsequent packing of fine aggregate between the coarse aggregate particles and the final filling of the remaining small volumes between the particles with the paste.

To understand the relationship between wet and hardened characteristics, consider “A” dry concrete mix with a packing density of 0.5, having a volume of one cubic meter, which is then mixed with water in volume X. Since the packing density of the particles is less than one, part of the volume (i.e. 0.5 m ³ ) represents air voids or intermediate volumes between particles that will subsequently be filled with water.

Now, if the particle size in the mixture "A" is changed so as to increase the packing density of the particles to 0.8, then the total volume of the new mixture will be less and will be 0.625 m ³ since the volume of air voids inside the mixture was reduced to 0.125 m ³ . Thus, if the same amount of water X is added to a new mixture with a density of 0.8, then the sediment will increase, since water, which was previously used to fill air voids, is now used to envelop particles and reduce friction between them.

 Alternatively, as the particle packing density increases, the amount of added water can also be reduced, thereby increasing the strength of concrete while maintaining the same sludge value. Therefore, as we approach the maximum packing density of the particles, the characteristics for both wet and cured concrete are optimized, since only a minimal amount of water needs to be added to the mix to ensure a given settlement.

 However, it should be noted that as we approach the maximum packing density of particles, tendencies toward separation and protrusion of cement milk increase. This is due to the fact that at the maximum packing density of the particles in the mixture, sand or a fine-grained aggregate will not be enough to create a sufficiently cohesive matrix, which is a support for the aggregate. As a result, delamination occurs, worsening uniformity and reducing the strength of the resulting concrete.

 Determining the composition of the mixture, providing the maximum packing density of the particles, also allows you to get an economic effect. As a rule, cement is the most expensive component in a concrete mix. In order to ensure a structure with adequate cohesion (i.e., with sufficient forces of internal adhesion of the particles), it is necessary to introduce a sufficient amount of cement to cover all the aggregate particles, and it is also preferable to fill the voids inside the concrete mixture. (If the voids between the aggregate particles are filled with cement, and not with water, then the strength of concrete increases). Upon reaching the maximum packing density of the particles, the surface area of the particles and the volume of voids between them are minimized, which minimizes the amount of cement required. Accordingly, the cost of concrete is also minimized. Of course, the identification of the cheapest mixture is made taking into account the cost of various components.

 Sometimes cheaper are mixtures with a lower packing density of particles. For example, the cheapest component is usually sand. Accordingly, mixtures with a low concentration of cement and a high concentration of sand will be the cheapest. However, with an increase in the percentage of sand and with a corresponding departure from the structure with a maximum packing density of particles, porosity increases, which leads to a decrease in the durability of the mixture.

 The ability to accurately and predictably control the packing of particles in solution provides the ability to control the systemic rheology of the mixture. The rheological characteristics of the system are partially related to the viscosity and yield strength of the mixture and are a function of both macro-rheology and micro-rheology. Macroreology describes the relationship between solid particles, determined by the nature of their packaging. By selectively controlling the particle size distribution in the mixture while maintaining a constant water content or lubricating component of the mixture, the viscosity and yield strength of the mixture can be purposefully changed.

 Controlling the systemic rheology of the mixture is an important factor in ensuring economical mass production of thin-walled containers and other products similar to those described in the patent application “Hydraulically settable containers and other products for storage, distribution and packaging of food and beverages and methods for their manufacture”, which was previously included to the present application by reference. Mixtures with low viscosity are easier to give the desired shape, and therefore, such mixtures are usually preferred at the stage of forming the container product. However, after the container is molded, it is preferable that the mixture has a sufficiently high yield strength to ensure the form stability of the container product without external support, making it possible for mass production of containers. To optimize the viscosity and yield strength of the mixture, particle packing control can be applied.

 Micro-rheology is a function of those components of the system that have the qualities of a lubricant and fill or overfill the space between the "macroparticles". By modifying lubricants (which can be water, reagents for modifying rheological characteristics, plasticizers or other materials), the viscosity and yield strength can be chemically changed. Micro-rheological characteristics can also be changed physically - by changing the shape and size of the particles, for example, by using chopped fibers, plate mica, rounded particles of silica fume, or particles of crushed raw cement, which will interact differently with lubricants.

 Although the theory of particle packing is known, there are certain difficulties with the fast, accurate and uniform determination of the sizes and proportions of the given components, which are necessary to ensure maximum packing density of the particles. The present invention allows to solve this problem by creating a mathematical model that provides an accurate determination of the packing density for a mixture with a given volume ratio of components comprising at least one type of aggregate and cement. To determine the maximum packing density of particles, the packing density is calculated for all combinations of the volumetric content of the components of the feed.

II. The process of optimizing the structure of the mixture
The following is a detailed description of the theoretical foundations, mathematical models and steps necessary to accurately and reproducibly determine the optimal proportions of cement, water, sand, coarse aggregate and additives (such as reagents for reducing the amount of water, reagents for trapping air, fillers, fly ash, micrograin silica and other pozzolans) necessary to obtain a concrete mixture with the desired characteristics in both raw and solid state at a minimum cost.

 Stage 1 consists in ensuring the maximum packing density and the corresponding composition of the dry concrete mixture, including cement and one or more types of aggregate.

 Stage 2 is to determine the initial optimal composition of the concrete mixture, which will provide a packing density of particles approaching the maximum, and at the same time will have the required strength, sediment and cohesion with a certain ratio of fine-grained and coarse-grained aggregate.

 At stage 3, a comparison is made of the unit cost values of the optimal mixtures for each optimal mixture with a certain ratio of fine-grained and coarse-grained aggregate to determine the mixture that is optimal in all respects.

 At steps 4–7, methods for accounting for the effects obtained by independently adding various additives to the standard concrete mixture, including, respectively, fly ash, silica fume, reagents to reduce the amount of water, and fillers, are considered.

 Stage 8 is carried out using a logical scheme and iterative cycles used to determine the composition of the best optimal mixture with the desired characteristics at the lowest cost. The mixture includes fine-grained aggregate, cement, coarse aggregate, mixed water, fly ash, reagents to reduce the amount of water, reagents for trapping air, fillers, silica fume and other pozzolans with the required characteristics and minimum cost.

 At step 9, the resulting mixture is modified to provide an appropriate concentration of reagent for trapping air and, accordingly, the required air content in the product.

 At step 10, a method for determining the correction factor for the optimization process is described, which allows you to refine the estimate of the resulting precipitation and thereby further optimize the results.

 At step 11, means are provided for determining the durability of the mixture, ensuring that the selected mixture has sufficient durability for its intended use.

 Finally, at step 12, a method is described for accurately determining the volume or weight of the mixture components required to obtain a given yield or volume of the final mixture.

Stage 1. Maximum packing density
The first stage of the optimization process is to determine the maximum packing density and the corresponding volume of each component of the dry cement mixture. The terms "concrete mixture", "cement mixture" or "mixture", used in the present description and the attached patent claims, are intended to generically denote compositions comprising at least one type of cement and at least one type of aggregate to which you can add water and various additives. The term "mortar", as used in the present description and the attached patent claims, is intended to mean a mixture that contains only cement and one type of aggregate. Compositions of other mixtures, including stucco and dry stucco, can also be formulated according to the present invention.

 The terms “aggregate” or “aggregates” used in the present description and the attached patent claims are intended to mean a variety of crushed and natural stones and minerals. However, for use in the framework of the present invention, they must be sound and meet certain standards for optimal technical use: they must be clean, solid, dense, strong, durable particles free from absorbed chemicals, clay or humus coatings, and other fine grains materials that can affect the hydration and bonds provided in the cement paste.

 For some mixtures, it is advisable to use aggregates designed to reduce weight and (or) increase the insulating characteristics of the mixture. Examples of useful aggregates include perlite, vermiculite, sand, gravel, gravel, limestone, glass beads, aerogels, xerogels, sea gel, mica, clay, synthetic clay, alumina, silica, fly ash, microgranular silica, lamellar alumina, kaolin, microspheres , hollow glass spheres, porous ceramic spheres, gypsum dihydrate, calcium carbonate, calcium aluminate, cork, seeds, light polymers, xonotlite (crystalline calcium silica gel), lightweight foam clay, unreacted cement particles, pumice, layered stone and other mining materials. Unreacted cement particles can also be considered as “aggregate” in the broad sense of the term.

 In the framework of the present invention, in addition to the usual aggregates used in the cement industry, a variety of other aggregates can be combined with hydraulic cements, including fillers, hardeners, metals and metal alloys (such as stainless steel, calcium aluminate, iron, copper, silver and gold), balls or hollow spherical materials (such as glass, polymers and metals), sawdust, beads, powders (such as silica powder, or microgranular silica), as well as fibers (such as graphite, silica refractory, alumina, glass, polymer, organic fibers and other types of fibers commonly used for the manufacture of various composite materials). As aggregates of the present invention, even materials such as seeds, starches, gelatins and agar materials can be used.

 Studies have shown that the packing density of particles in a mixture increases when two or more types of aggregate are used with different average particle sizes. Accordingly, the term “aggregate”, as used herein and in the accompanying patent claims, is often further defined as fine aggregate and coarse aggregate. To obtain improved particle packaging, it is desirable that the ratio of the average particle sizes of the coarse and fine aggregate aggregate is about 3: 1, preferably about 5: 1, and most preferably about 7: 1. Typically, sand is used as a fine aggregate. Sand consists of particles with a diameter of about 8 mm or less. Conventional coarse aggregate typically contains particles ranging in size from about 2 to 165 mm. In embodiments of the present invention involving the manufacture of thin-walled products, it may be preferable that the particle size of the aggregate exceeds the particle size of the cement by no more than twenty times. Such aggregate will typically consist of particles with a diameter of less than 2 mm.

 The terms "fine aggregate" and "coarse aggregate" used in the present description and the accompanying patent claims are not intended to limit a range of sizes, but are simply used to indicate that one type of aggregate contains larger particles than the other type. For example, in a cement mixture containing two types of sand, sand with larger particles will be called coarse aggregate.

 The term "type" as used in the present description and the attached patent claims in relation to aggregate, cement and other solid particles, refers to both the type of material used and the particle size range. For example, although a coarse aggregate typically consists of particles from 2 to 165 mm in size, one type of coarse aggregate may consist of particles from 2 to 8 mm, while another type may consist of particles from 8 to 16 mm. As will be shown below, the optimal packing density of the particles of the mixture can be ensured by the selective combination of different types of aggregates. Studies have shown that those types of aggregates that consist of particles with a certain average size, but are characterized by a large range of size dispersion, usually provide a higher packing density.

 The cement used in the present invention belongs to the family of cements known as hydraulic cements. Hydraulic cement is characterized by hydration products resulting from a reaction with water. Hydraulic cements should be distinguished from other types of cements, such as polymer organic cements. The term "hydraulic powder cement" as used herein includes the original clinker as well as crushed, crushed, ground and processed clinker at various stages of formation of cement powder with different particle sizes.

 Examples of cements known in the industry are: a large family of Portland cements (including ordinary Portland cement without gypsum), calcium aluminate cements (including calcium aluminate cements without setting agents), plaster materials, silicate cements (including β-dicalcium silicates, tricalcium silicates and their mixtures), gypsum cements, phosphate cements and cements based on magnesium oxychloride. The term "hydraulic cement" also includes other types of cement, such as α-dicalcium silicate, which acquires the properties of a hydraulic binder under the hydration conditions provided by the present invention. The term "cement" is also intended to include fillers, fly ash, silica fume, and other pozzolans. Hydraulic cements usually consist of particles ranging in size from 0.1 microns to 100 microns.

 All volumetric indicators used in the present patent description, unless otherwise specified, are expressed as a fraction of the total solids content in the mixture. The term “total solids content”, as used herein and in the accompanying patent claims, refers to the content of cement, aggregate, and (if required) fillers, fly ash, silica fume, and other pozzolans. Thus, the total content of aggregate and cement in the standard mixture is always 1.0. Volumetric indicators of the amount of water and air in the mixture are also expressed as a fraction of the volume of solids. Therefore, a value of 0.3 for the volume of water in the mixture corresponds to a volume of water equal to 30% of the total volume of solids in the mixture. Accordingly, the total volume of the mixture, including water, will be 1.3.

Здесь d - диаметр частиц, R(D) - накопленная вероятность того, что диаметр будет меньше d, d' - диаметр, для которого R(d') = 0,368, что соответствует 36,8% остатка на сите при просеивании, а n - наклон линии, определяемой путем построения графика зависимости процентного количества частиц, остающихся на сите, от размера ячеек сита.The types of aggregate and cement of the present invention further vary in average diameter (d ') and natural packing density (φ) of the particles. These values are determined experimentally and are used in calculating the theoretical packing density of the particles of the resulting concrete mixture. The average particle size is determined by plotting the particle size distribution of each material in accordance with the Rosin-Rammler-Sperling-Bennett distribution described by the following equation:

Here d is the particle diameter, R (D) is the accumulated probability that the diameter will be less than d, d 'is the diameter for which R (d') = 0.368, which corresponds to 36.8% of the sieve residue during sieving, and n - the slope of the line, determined by plotting the percentage of particles remaining on the sieve, on the size of the mesh cells.

где W_M = вес материала;
SG_M = удельный вес материала; и
V_M = объем материала.The packing density of each type of material (φ) is determined by pouring the material into a cylinder whose diameter is at least ten times the diameter of the largest particle of the material. Then the cylinder is tapped on a hard surface until the material is completely densified. After measuring the height of the material in the cylinder and the weight of the material, the packing density is determined by the following formula:

where W _M = weight of the material;
SG _M = specific gravity of the material; and
V _M = volume of material.

 Thus, a quantitative determination of the particle volume is performed as a function of the morphological characteristics of the particles, specific surface area and other specific surface characteristics.

 The maximum particle packing density of a conventional three-component mixture, including cement, one type of fine aggregate and one type of coarse aggregate, is determined by incrementing the volume of each component of the mixture and calculating the corresponding packing density. Then, various values of the packing density are plotted on a triangular graph of the packing density, which makes it possible to identify the composition that provides the maximum packing density.

As an example in FIG. 1 is a graph of packing density for a ternary mixture consisting of cement, silica sand (0-2 mm) and crushed granite (8-16 mm). Side (A) of the graph determines the volume percentage of fine aggregate (sand); side (B) determines the volume percentage of cement; and side (C) determines the volume percentage of coarse aggregate (crushed granite). The values inside the triangle correspond to the packing density at various percent volume contents of the mixture components. Reading the values of the graph is performed in the following order:
1 (a). Select the desired packing density on the triangle. For example, in FIG. 2, the point "Z" is selected, which displays the value of the maximum packing density of particles for a given mixture.

 1 (b). Determine the cement content in concrete percentages expressed in volume percent, which is necessary to obtain the packing density corresponding to the “Z” point, for which a horizontal line 20 should be drawn from the “Z” point to side (B) of the triangle. The value at the intersection of line 20 and side (B) of the triangle is the percentage of cement required to obtain the desired packing density. In the example shown in FIG. 2, the percentage (by volume) of cement is about 10%.

 1 (s). Determine the percentage of fine-grained aggregate in concrete mix expressed in volume percent, which is necessary to obtain a packing density corresponding to the “Z” point, for which a horizontal line 22 should be drawn from the “Z” point to the side (A) of the triangle. The value at the intersection of line 22 and side (A) of the triangle is the percentage of fine aggregate needed to obtain the desired packing density. In this example, the percentage (by volume) content of fine aggregate is about 30%.

 1 (d). Since the sum of the percentage of the components of the mixture should be 100%, it turns out that when the content of the mixture is 10% cement and 30% fine aggregate, the content of coarse aggregate should be 60%. However, the same value can also be determined from the graph of the packing density by drawing a line 24 parallel to side (A); the line starts at point "Z" and intersects with side (C). The value at the intersection of line 24 and side (C) of the triangle is the percentage of coarse aggregate. As shown in FIG. 2, this value is about 60%. Using this method, you can determine the composition of the mixture for any packing density shown in the graph, or, in the reverse order, determine the packing density for any given mixture composition.

Здесь r₁ = объем частиц меньшего размера;
r₂ = объем частиц большего размера;
d₁ = диаметр частиц меньшего размера;
d₂ = диаметр частиц большего размера;
φ₁= плотность упаковки частиц меньшего размера,
φ₂= плотность упаковки частиц большего размера.The packing densities shown on the graph were determined using the Toufar, Klose, and Born models (Toufar, Klose, and Born) (hereinafter referred to as the “Toufar model”) used with a correction factor. The Tufar model is a formula for calculating the packing density for binary (double) mixtures:

Here r ₁ = volume of smaller particles;
r ₂ = larger particle size;
d ₁ = smaller particle diameter;
d ₂ = larger particle diameter;
φ ₁ = packing density of smaller particles,
φ ₂ = packing density of larger particles.

 Other models can also be used to calculate the packing density of two-component mixtures. Applicable models include the Aim and Larrard models described in an article by V. Johansen and P.J. Andersen, “Particle Packaging and Concrete Properties,” see Concrete Materials Science II. p. 118-122, American Society of Ceramics (1991), which is incorporated herein by reference.

To increase the accuracy of the Tufar model, a comparison was made of the experimental particle packing density for the ternary mixture with the corresponding theoretical packing density calculated by the Tufar model. As shown in FIG. 3, performed for a ternary mixture of cement, fine gravel (3/8 '') and sand, a comparison revealed a linear correlation between theoretical and experimental values of packing density. However, the theoretical values obtained by the Tufar model slightly exceeded the actual experimental values. To compensate for this discrepancy, the values according to the Tufar model were adjusted in accordance with the correlation between theoretical and experimental, ordinary values. The equation for determining the adjusted packing density for concrete is as follows:
P _C = 0.9940 P _T - 0.00895 (4)
The variable P _C means the adjusted packing density, and P _T means the experimental or simulated packing density obtained using the Tufar model. Thus, substituting the values obtained by the Tufar model in place of P _T in this equation and determining the P _C values, one can determine the adjusted theoretical value of the concrete packing density with an error of no more than 2% of the actual packing density.

 The accuracy of the adjusted Tufara model is shown in FIG. 4, which shows a graph intended to compare the experimental and adjusted theoretical particle packing density. In the remainder of this patent description, all references to the application and results of the Tufar model will also imply the use of a correction equation, regardless of whether it is mentioned or not. The constants used in the correction equation (equation (4)) are applied regardless of the type of material being packaged. However, the values of these constants are partially based on experimental data on the packing density and, therefore, can vary depending on the number and accuracy of experiments.

 Since the packing density can be calculated only for two-component mixtures using the Tufar model, packing density values are first calculated for line (C) on the packing density graph (i.e., for a line showing the percentage of coarse aggregate). On line (C), the mixture contains only coarse aggregate and fine aggregate, without the addition of cement. For example, referring again to FIG. 2, the corresponding composition for the packing density on line (C), where the percentage of coarse aggregate is 50%, will be as follows: 50% coarse aggregate, 50% fine aggregate and 0% cement.

The packing density along line (C) is first calculated by changing the composition of the mixture of coarse aggregate and fine aggregate in increments of 1%. For example, the value of φ is first determined using the Tufar model (equation (3)), where r ₁ = 0.01, which means 1 vol.% Fine aggregate, and r ₂ = 0.99, which means 99 vol.% Coarse aggregate , d ₁ is the experimental value of d 'for a fine-grained aggregate, d ₂ is the experimental value of d' for a coarse-grained aggregate, φ ₁ is the experimental value of φ for a fine-grained aggregate, and φ ₂ is the experimental value of φ for a coarse-grained aggregate.

After determining the packing density φ for a given mixture composition, this value is corrected using the previously described correcting equation (4). The resulting value is then plotted at the corresponding point on the line (C) of the packing density graph. In the second calculation, all the numerical values remain the same, except that now r ₁ = 0.02, which corresponds to 2% of fine-grained aggregate, and r ₂ = 0.98, which corresponds to 98% of coarse-grained aggregate. This process continues until the values of φ are calculated for all combinations of volumes of fine-grained aggregate and coarse-grained aggregate with increments of 1%.

 It is clear that the smaller the increment is used when changing the percentage of various components, the more accurate the final results. However, to simplify the examples and descriptions of the present invention, increments of 1% were used.

 The above process can also be used to calculate the maximum packing density of the mortar particles. As indicated above, the mortar is a two-component mixture consisting of cement and one type of aggregate. By defining line (A) as a line reflecting the volumetric content of cement, and line (C) as a line reflecting the volumetric content of aggregate, and then introducing gradually changing values of the cement and aggregate content in the Tufara model, one can determine all possible packing densities for two-component mixture along the line (C). The highest value of the packing density on line (C) will correspond to the composition of the mixture of cement and aggregate, which ensures the maximum packing density of particles.

 When determining the maximum packing density of particles of a three-component mixture, after determining the packing density values along line (C), the Tufar model is also used to calculate the values inside the triangle. Since the Tufar model is used only to calculate the packing density of a two-component mixture, pseudoparticles are specified that display a combination of different ratios of fine-grained and coarse-grained aggregate along the base line. Then the packing density values inside the triangle can be calculated for a two-component mixture consisting of pseudoparticles and cement.

 Each mixture of pseudoparticles and cement is represented as a line of pseudoparticles drawn inside a triangle. In FIG. 5 shows a series of lines of pseudoparticles 26 extending from the top of triangle 28 to a line (C) representing the volume content of coarse aggregate. Since the volume content of coarse aggregate can vary from 0% to 100%, there are a total of 100 individual lines of pseudoparticles. Each line displays a pseudo-particle in which the ratio of fine-grained and coarse-grained aggregate is determined by the value at the point of intersection with the line of content of coarse-grained aggregate. For example, a line connected to a point that corresponds to a coarse aggregate content of 1% displays a pseudoparticle consisting of 1% coarse aggregate and 99% fine aggregate. As you move along the line of pseudoparticles vertically in the direction of the apex of triangle 28, the percentage of cement increases, and the percentage of pseudoparticles decreases proportionally; however, the ratio of fine to coarse aggregate remains constant.

 Then, the packing density graph is completed by calculating and plotting the packing density values for each 1 percent increment in the volumetric cement content along each of the lines of pseudoparticles. These points of the packing density graph are most easily determined by drawing a horizontal line 30 (see Fig. 5) for each value of the percentage of cement so that each horizontal line 30 intersects with each line of pseudoparticles 26. The intersection points 32 are the points at which the values are calculated packing density. The values necessary to determine the packing density according to the Tufar model can be determined using the previously described method of reading numerical values from the packing density graph.

For example, the first line of pseudoparticles is drawn from the top of the triangle to a point representing 1% of the coarse aggregate content on line (C). Then, the value of the packing density on the line of pseudoparticles corresponding to 1 vol. % cement. To calculate the packing density, the Tufara model is used, in which r ₁ represents the volumetric content of small particles (cement) equal to 0.01; r ₂ represents a volumetric content of pseudoparticles of 0.99; φ ₁ - experimentally determined cement packing density; φ ₂ is the packing density of pseudoparticles equal to the previously adjusted and calculated packing density of the mixture consisting of 1% coarse aggregate and 99% fine-grained aggregate; d ₁ is equal to the experimentally determined value of d 'for cement; and finally, d ₂ is equal to the average diameter of the pseudoparticles. The value of d ₂ is determined using the following equation:
d ₂ - r ₁ d ' ₁ + r ₂ d' ₂ (5)
In the above equation, the values of r ₁ and ₂ are equal to the volume of fine-grained aggregate and coarse-grained aggregate in the mixture, for which the value of the packing density is determined. The values of r ₁ and r _{2 are} determined by reading the values from the graph of the packing density, as described above. Finally, the d ′ ₁ and d ′ ₂ values are the experimental d ′ values for the fine aggregate and coarse aggregate, respectively. After determining the packing density, an adjustment is made using the correction factor described above to more accurately display the true packing density values, which are then plotted on the packing density graph.

 After determining the density values of the package and applying them to the graph, contour lines can be drawn inside the triangle by connecting points with the same package density. Then you can determine the maximum density and the corresponding percentage composition of the mixture, for which the graph should find the value of the maximum packing density of the particles and determine the appropriate composition of the mixture, as described above.

 If the concrete mixture contains two types of fine-grained aggregate or two types of coarse-grained aggregate, i.e. consists of four components, then using the Tufar model a pseudoparticle is created in which the packing density and average diameter reflect both types of fine-grained aggregate or coarse-grained aggregate. Then, the previously described method for determining the maximum packing density of particles of a three-component mixture can be applied using this pseudoparticle instead of a fine-grained or coarse-grained component.

 The packing density of the pseudoparticles corresponds to the maximum packing density of the particles of two fine-grained aggregates or two coarse-grained aggregates. The maximum packing density is determined by comparing all packing density values for different ratios of the percentage of the two components. This is the same process that is used to determine the packing density of fine-grained aggregate and coarse-grained aggregate along line (C) in the graph of packing density.

The average pseudoparticle diameter d ' _p is determined by the formula:
d ' _p = r ₁ d' ₁ + r ₂ d ' ₂ (6)
Here r ₁ and r ₂ correspond to the percentage of two types
coarse aggregate or fine aggregate for a mixture with a maximum packing density of particles, and the values d ' ₁ and d' ₂ correspond to the average diameter of the two types of fine aggregate or coarse aggregate, respectively.

In cases where the concrete mixture contains three types of fine aggregate or coarse aggregate, you can also use a pseudoparticle in which the packing density and average diameter represent different types of fine aggregate or coarse aggregate. The packing density of the pseudo-particle corresponds to the maximum packing density of the particles of a three-component mixture of fine aggregates or coarse aggregates and are determined in the same way as was used to determine the maximum packing density of particles of a three-component mixture of cement, fine aggregate and coarse aggregate. The average diameter of the pseudoparticle is determined by the formula:
d ' _p = r ₁ d' ₁ + r ₂ d ' ₂ + r ₃ d' ₃ (7)
Here, as before, the r values correspond to the percentage of each type of fine aggregate or coarse aggregate in the mixture having the maximum packing density, and the d ' _p values correspond to the average particle diameter of each type of fine aggregate and coarse aggregate, respectively.

 If a concrete mix contains four or more types of fine-grained aggregate or coarse-grained aggregate, then the packing density and the average diameter of the pseudoparticle, which displays the two coarsest materials, are first determined. Then this pseudoparticle is combined with the next smaller particle, resulting in a two-component package, which in turn is determined using a new pseudoparticle, which has new values of the packing density and average diameter. Then the new pseudoparticle is combined with the next smaller particle, and this process continues until all the different types of coarse aggregate or fine aggregate are included.

 Of course, two or more types of cement can also be added to the mixture. However, the particle size of the cement is so small that the combination of different types of cement, as a rule, does not significantly affect the packing density of the particles in the mixture. However, in some applications, for example, when packing powder particles or finely divided mortar, the combination of several types of cement may be significant. In such cases, cement of different types can be represented as a pseudoparticle in the same manner as that used for fine aggregate and coarse aggregate.

 The above process is a method for determining the packing density of particles for all possible combinations of this raw material. Therefore, by comparison, it is possible to determine which components will provide the maximum packing density of the particles. By varying the types of technological raw materials using a variety of materials, you can create a database that allows you to select those types of components that will give the highest value of the maximum packing density of particles.

Stage 2. Performance optimization
The second stage is an optimization process designed to identify the optimal concrete mix with the specified strength and precipitation characteristics at a certain ratio of fine-grained and coarse-grained aggregate. Almost any combination of aggregates will provide the required strength and sludge if enough water and cement are added. However, the present invention provides a method for determining the minimum volumes of cement and water added to a mixture with a predetermined ratio of fine-grained and coarse aggregate in order to obtain a concrete mixture with the desired characteristics.

 Since the final price of concrete depends on the market price of its constituent components, the present invention can be used to identify the cheapest mixture by calculating and comparing the unit cost of each mixture with varying ratios of fine-grained and coarse-grained aggregate. At this stage, a method is described for determining the optimal composition of the mixture for a given ratio of fine-grained and coarse-grained aggregate. At the next stage 3, a procedure is described for comparing the cost indicators for each optimal mixture with varying ratios of fine-grained and coarse-grained aggregate.

 To determine the composition of a concrete mixture with the specified strength and precipitation characteristics, first of all, it is necessary to determine the amount of water that is required to ensure a given precipitation of the previously selected mixture. After determining the amount of water, you can get the value of the final strength of concrete. If the final strength is greater or less than required, then the amount of cement required to obtain the required strength is estimated, which gives a new composition of the mixture. Then, the amount of water necessary to ensure the required precipitation of the new mixture is again determined, and this process is repeated until the set and theoretical strength are ensured. Through this process, the amount of cement required to provide a given strength is minimized, which minimizes the cost of concrete.

More specifically, this process is carried out in the form of the following steps:
2 (a). The initial mixture, having a packing density close to maximum, which allows you to optimize the characteristics of concrete without separation of the components or protrusion of cement milk, is selected (as described for step 1) by finding the point of maximum particle packing density on the packing density graph and determining the corresponding volumetric content of the components mixtures. The corresponding volumes of cement, fine aggregate and coarse aggregate for the point corresponding to the maximum packing density of particles are determined in the form of variables V _{C (MP)} , V _{F (MP)} and V _{CA (MP)} , the sum of which is 1.0. After that, the volume of cement is maintained at a constant level, the volume of fine-grained aggregate increases by an amount called the cohesion margin, and the volume of coarse aggregate decreases by the same amount. Thus, the parameters of the mixture move horizontally to the left on the graph of packing density. The corresponding mixture is called the starting mixture.

The corresponding volumes of the components of the initial mixture are determined using the equations:
V _C = V _{C (Mp)} (8)
V _F = V _{F (MP)} + CF (9)
V _CA = V _{CA (MP)} - CF (10)
The CF variable is the cohesion margin and is usually about 0.5. Using the cohesion margin ensures a sufficient amount of fine-grained aggregate in the mixture, which will make it possible to obtain a mixture with sufficient cohesion, which prevents the separation or protrusion of cement milk. In mixtures located on the packing density graph to the right of the initial mixture, delamination or protrusion of cement milk will usually occur. The cohesion margin can vary from about 0 to 0.15, depending on the type of concrete. For low-strength concrete, a high coefficient of safety of cohesion is required, reaching approximately 0.15, while for high-strength concrete, a low coefficient of safety of cohesion of less than 0.05 is required.

 The ratio of fine-grained and coarse-grained aggregate in the initial mixture is determined by the line of pseudoparticles passing from the top of the triangle on the packing density graph through the point of the initial mixture to the line of coarse-grained aggregate. The following describes a method for determining the optimum concrete mix along this particular line of pseudoparticles.

 2 (b). The packing density of the particles of the initial concrete mixture is determined by the method described for stage 1.

Здесь φ - - плотность упаковки частиц смеси, определенная на этапе 2(с), и W₁ - объем воды, требуемый для обеспечения осадки смеси, составляющей 1 см. Значение W₁ представляет собой долю от объема твердых веществ в составе смеси.2 (s). The amount of mixed water required to provide a predetermined precipitation for the initial concrete mixture is determined. This amount of water is determined in two doses. First, the amount of water necessary to ensure a precipitation of the mixture of 1 cm is determined, for which the following formula is used:

Here, φ is the packing density of the particles of the mixture, determined in step 2 (c), and W ₁ is the volume of water required to ensure precipitation of the mixture, which is 1 cm. The value of W ₁ is a fraction of the volume of solids in the mixture.

 Studies have found that equation (11) is usually the most accurate when determining the amount of water required for a sediment mixture to be 1 cm. Although, as it has been established, the actual precipitation can have a range of up to 2.5 cm, the choice of precipitation in 1 cm is not critical since in step 9 of the present invention, the discrepancies between the amount of added water and the actual sediment are corrected.

Здесь W₁ - ранее определенный объем воды, необходимый для обеспечения осадки в 1 см,
W₂ - объем воды, необходимый для обеспечения заданной осадки,
S₁ - 1,0, что отображает осадку в 1,0 см, и
S₂ - заданная осадка в см.After the value of W ₁ for the precipitation of 1 cm is calculated, the amount of water required to provide the specified precipitation is calculated by the Popovic formula as follows:

Here W ₁ is the previously determined volume of water necessary to ensure a precipitation of 1 cm,
W ₂ - the amount of water necessary to ensure a given precipitation,
S ₁ - 1.0, which displays a draft of 1.0 cm, and
S ₂ - the specified draft in cm

Здесь σ - - теоретическая прочность бетонной смеси на сжатие после отверждения в течение 28 дней, выраженная в МПа,
V_C - объем цемента в смеси,
W₂ - объем воды, требуемой для обеспечения заданной осадки смеси, определенный на этапе 2(с),
K = постоянная Фере.2 (d). Based on the results of steps 2 (a) -2 (c), it is possible to determine the compressive strength of the resulting concrete mixture after curing for 28 days, for which the Fere equation is used:

Here σ - is the theoretical compressive strength of the concrete mixture after curing for 28 days, expressed in MPa,
V _C is the volume of cement in the mixture,
W ₂ - the amount of water required to provide a given precipitation of the mixture, determined in step 2 (c),
K = Feret constant.

Здесь %ВОЗД - оценка объемного содержания воздуха в смеси. Объем воздуха в смеси меняется в зависимости от типа используемого смесителя, объема мелкозернистого заполнителя в смеси и типов присадок, добавляемых в смесь. Объем воздуха может быть оценен специалистами в данной отрасли и обычно составляет около 1-2% при осадке свыше 10 см и около 2-4% при осадке менее 10 см.The Feret constant used in accordance with the present invention is not a true constant, but depends on the type of mixing apparatus used. It has been found that the value of this constant is usually from about 250 to 600. For mixers with pallets, the typical value of this constant is 280; for agitators with a reverse direction of rotation of the rotor, a typical value is about 340; and for mixers with high shear, about 340-450. High shear mixers and methods for their use are described in United States Patent No. 4,225,247 "Mixing and Stirring Device" and United States Patent No. 4,552,463 "Method and Apparatus for Preparing Colloidal Solutions". The value of the constant K for this mixer can be obtained by solving the above equation for K using empirical values of σ obtained using the appropriate mixer. The value of K can also vary depending on the type of aggregate, and the value of V _A (air volume in the mixture) is determined by the following equation:

Here% RET is an estimate of the volumetric air content in the mixture. The volume of air in the mixture varies depending on the type of mixer used, the volume of fine aggregate in the mixture and the types of additives added to the mixture. The volume of air can be estimated by specialists in this industry and usually is about 1-2% with a draft of more than 10 cm and about 2-4% with a draft of less than 10 cm.

In FIG. Figure 6 shows the results of comparing the strength of a concrete mixture after curing for 28 days, obtained by the Fere equation and by actual measurements of the strength of concrete. As can be seen in FIG. 6, the line of best fit deviates from the line of direct proportionality. By correlating the values of theoretically calculated strength and experimental (or actual) strength, it is possible to provide a more accurate determination of strength using the following correction equation:
σ _C = 1.351σ _T -7.930 (15)
Introducing the theoretical values of the strength σ _T obtained by the Fere equation, we can obtain the adjusted value of the strength σ _C. The error of the equation for adjusting the strength values is shown in FIG. 7, which plots experimental strength values versus theoretical strength obtained using a correction equation. In the remainder of this patent description, all references to the application and results of the Fere equation will also imply the use of a correction equation, regardless of whether or not this is mentioned.

 The constants used in the correction equation (equation (15)) are partially based on experimental strength data and, therefore, can vary depending on the number and accuracy of experiments. In addition, equation (13) for strength after curing for 28 days is based on the assumption that coarse aggregate particles and fine aggregate particles are more durable than hardened cement paste, which is usually true if benign aggregates are used. An exception is the use of limestone, which is a very weak aggregate.

 The Feret equation is also based on the assumption of using standard or normalized methods for mixing, pouring, finishing and curing concrete, described by the American Concrete Institute ("ACI") in ACI 304-85 "Instructions for dispensing, mixing, transporting and pouring concrete", report ACI Committee 304 (American Concrete Institute, 1985); and in ACI 308-81, Standard Concrete Curing Methods, ACI Committee 308 (American Concrete Institute, Revised 1986) report, which are incorporated herein by reference.

Здесь V_C(N) - объем цемента в новой смеси,
W₂ - объем воды, необходимый для обеспечения заданной осадки для исходной или предыдущей смеси,
%ВОЗД = оценка объемного содержания воздуха в смеси,
K = постоянная Фере, зависящая от типа смесителя, и
σ_D= заданная прочность в МПа.2 (e). The obtained value of compressive strength σ / is compared with a given strength. If the theoretical strength of the mixture is less than the specified, then steps 2 (b) - 2 (e) are repeated by replacing the original mixture with a new mixture with the corresponding new packing density. The composition of the new mixture, necessary to ensure a given strength, is determined by increasing or decreasing the volume of cement. A rough estimate of the volume of cement required to provide a given strength is determined by substituting the value of the specified strength in the Fere equation and its resolution relative to the corresponding volume of cement in accordance with the following equation:

Here V _{C (N)} is the volume of cement in the new mixture,
W ₂ - the amount of water required to provide a given precipitation for the original or previous mixture,
% AIR = Estimated air volume in the mixture,
K = Feret constant, depending on the type of mixer, and
σ _D = specified strength in MPa.

When changing the volume of cement for a new mixture, it is necessary to normalize the volume of fine aggregate and coarse aggregate, so that the total volume of fine aggregate, coarse aggregate and cement in the amount of 1.0. However, the ratio of fine to coarse aggregate remains constant. In accordance with this, the volume of fine-grained aggregate and coarse-grained aggregate in the new mixture is determined using the equations:
V _{F (N)} = r _F - (1 -V _{C (N)} ) (17)
V _{CA (N)} = r _CA - (1-V _{C (N)} ) (18)
Here r _F and r _CA are respectively proportions of fine-grained and coarse-grained aggregate and are constants for each line of pseudoparticles. These relationships are determined by the equations:
r _F = V _F / (V _F + V _CA ) (19)
r _CA = V _CA / (V _F + V _CA ) (20)
This new mixture corresponds to the point on the packing density graph where the line of pseudoparticles described in step 2 (a) intersects the horizontal line drawn from the point of the new cement volume determined by equation (16). As the volume of cement changes, it moves up or down along the line of pseudoparticles.

 Steps 2 (b) -2 (d) are repeatedly repeated until the theoretical strength of the mixture is equal to the specified strength. The resulting mixture for a given ratio of fine-grained and coarse-grained aggregate will have a given precipitate and strength when using a minimum amount of cement and water.

 For some low-strength concrete, the amount of cement required can be very small. However, to create a sufficiently cohesive matrix of the concrete mixture, which is required to prevent separation of the components, the mixture should usually contain at least 10% cement. Thus, the volume of cement can only be reduced until the resulting strength becomes equal to the specified strength or until the volume of cement becomes equal to 10%. However, as described below, in the case of fillers, the volume of cement may be less than 10%.

 The above process can also be used for mortar by replacing the values used for the ratio of fine-grained and coarse aggregate with the corresponding values for the aggregates used in the mortar. The determined composition, including cement, aggregate and water, allows you to get a mortar with the required characteristics of precipitation and strength using a minimum amount of cement. It is also assumed that the resulting mortar mix will be cost optimized. Although it is possible to formulate such mixtures with a high percentage of cement and a low percentage of coarse aggregate, which will have the required sludge and at least the required strength, such mixtures are almost never cheaper, due to the relatively high cost of cement.

Stage 3: Cost Optimization
As mentioned above, at this stage, a method is described for determining the unit cost of the optimal concrete mix and comparing the values obtained for each ratio of fine-grained and coarse-grained aggregate, which allows us to make a mixture that is optimal in all respects. In general terms, for this, we first need to determine the value of the unit cost of the initial optimal mixture identified in stage 2. Then we determine the optimal composition and the corresponding unit cost for the second optimal mixture having a new ratio of fine-grained and coarse-grained aggregate.

 A new ratio of fine-grained and coarse-grained aggregate is obtained by reducing the volumetric content of coarse aggregate by 1% and a corresponding increase in the volumetric content of fine-grained aggregate. Then the unit cost of the second optimal mixture is compared with the unit cost of the initial mixture. If the price of the initial mixture is less than the price of the second mixture, then the composition of the initial mixture is the most economical and the process ends. If the second mixture turns out to be cheaper than the initial one, then the next change in the ratio of fine-grained and coarse-grained aggregate is made to obtain a third optimal mixture. Then, the cost comparison is repeated until the cheapest mixture is obtained.

More specifically, the cost optimization process is performed using the following steps:
3 (a). Determine the unit cost of the optimal mixture obtained in step 2 based on the unit cost of cement, fine aggregate and coarse aggregate used in the mixture.

 3 (b). Using the same packing density graph that was used in stage 2, determine the new ratio of fine-grained and coarse aggregate by reducing the volume of coarse aggregate by 0.01 and increasing the volume of fine-grained aggregate by 0.01. This new ratio of fine-grained and coarse-grained aggregate is determined using the line of pseudoparticles connecting the top of the triangle with the volume content of coarse aggregate, which will be 1% less than this value for the initial mixture (shifted to the left).

 3 (s). Repeat step 2 along a new line of pseudoparticles until the optimal mixture for the new ratio of fine-grained and coarse aggregate is determined. Such a mixture is called the second optimal mixture. The initial mixture used on the new line of pseudoparticles has the same volume of cement as the optimal mixture on the previous line of pseudoparticles.

 3 (d). Determine the unit cost of the second optimal mixture determined in step 3 (c). If the price of the second optimal mixture is higher than the price of the initial optimal mixture, then the composition of the initial mixture is the most economical and the process ends. If the price of the second optimal mixture is less than the price of the initial optimal mixture, then the next change in the ratio of fine-grained and coarse aggregate is performed, as described for step 3 (b), and the composition of the third optimal mixture is determined in accordance with steps 2 (b) -2 (e ) The cost of the third optimal mixture is compared with the cost of the previous (in this case, the second) optimal mixture to reveal a cheaper mixture. This process continues until the most economical composition is found or the maximum percentage of fine aggregate is reached.

 In a preferred embodiment of the present invention, the percentage of sand in the concrete mixture should not exceed 80%, even if such a composition would be cheaper. This is due to the fact that as you move left along the packing density graph due to an increase in the volume of fine aggregate or sand, the porosity of the resulting concrete increases, which accordingly reduces the durability of the mixture.

 At 80 percent sand content, the durability of concrete becomes so low that it makes it unsuitable for almost any application, except for those where a particularly low strength is specified, as well as for mortars in which there is no aggregate. Thus, a concrete mixture that is optimal in all respects is defined as a mixture with specified characteristics and a minimum unit cost, or as a mixture with specified characteristics and containing 80% sand. However, as mentioned above, the present system can be modified to calculate mortars containing only cement and one aggregate. In such cases, the volume of sand may exceed 80%. In addition, the permissible amount of fine aggregate can be set by the user of the system, taking into account the required durability of concrete and particle size of the aggregate.

 The combination of steps 1-3 characterizes the methods for determining the composition of a mixture of cement, water and aggregate, which has a given draft and strength. The amount of water added to the mixture can be minimized in order to maximize strength. The proportions of fine aggregate, coarse aggregate and cement can be optimized to minimize the cost of the mixture. Moreover, using the above process, it is possible to uniformly and accurately formulate mixtures having predetermined characteristics regardless of changes in raw material parameters.

 Steps 1-3 can also be used to determine the composition of the mixture with the highest durability. As will be described later for step 11, the mixture with the highest durability is defined as the mixture with the lowest porosity. This is because, as a rule, as the porosity increases, the durability of the mixture decreases. Studies have established that the porosity of a mixture decreases as particle packing density increases. Consequently, mixtures with a packing density close to maximum will have the greatest durability.

 Stage 4. Fly Ash.

 Additives or additives are those ingredients of concrete that are different from cement, fine aggregate, coarse aggregate and water and added to the mixture before mixing or during mixing to change the characteristics or cost of concrete. The present invention includes a mathematical model for displaying the effect of adding the following additives to a concrete mix: pozzolans (such as fly ash and silica fume), reagents for reducing the amount of water, reagents for trapping air and fillers. Due to the inclusion of these models in the previously described optimization process, it is possible to determine the composition of optimal concrete mixtures in which such additives are included.

 Pozzolan is a silicon or silicon-aluminum material, which in itself almost does not have the properties of cement, but in a finely divided form and in the presence of water enters into a chemical reaction with calcium, sodium and potassium hydroxides released during cement hydration, and forms compounds with cement properties. Two of the pozzolans that are most commonly used in this industry and which are contemplated by the present invention are fly ash (fly ash) and micrograin silica (silica dust).

 Fly ash is a mineral additive obtained by burning powdered coal in power plants. The composition of fly ash mainly includes silicate glass containing silica, alumina, iron and calcium. In a smaller proportion, fly ash also contains magnesium, sulfur, sodium, potassium and carbon. Unlike particles obtained by grinding, such as cement particles having sharp edges, fly ash consists of spherical particles. Particle sizes can range from 1 micron to 100 microns, but typically less than 20 microns.

 For a mixture in which part of the cement is replaced with an equal volume of fly ash, usually less water is required to obtain the same sludge value as in a mixture containing only cement. This is due to the reduced activity of fly ash during the hydration reaction, as well as the spherical shape of the fly ash particles, which together provides a reduction in the friction forces between the particles of the mixture. Thus, fly ash can be used as a substitute for cement to increase the sediment and formability of the mixture without increasing the amount of added water. Alternatively, fly ash can serve as a substitute for cement in order to reduce the amount of water added to the mixture while maintaining the same sludge, thereby reducing the ratio of water to cement. In addition to increasing the formability of the mixture, fly ash has some characteristics of hydraulic cement, which helps to increase the strength of the resulting concrete.

 If fly ash is included in the concrete mix, the same process as described for steps 1-3 can be used to determine the most economical mix composition. However, several modified formulas are used to determine the amount of water required to provide a given draft and the resulting strength.

 In general, at the initial stage of the process, the operations of steps 1 and 2 are repeated to determine the optimal composition of the mixture (without additives), which has the specified strength and precipitation characteristics at a certain ratio of fine-grained and coarse-grained aggregate. Taking into account the composition of the resulting optimal mixture, part of the volumetric cement content is replaced in small increments with fly ash. As the percentage of fly ash increases, the unit cost of each mixture is calculated and compared with the cost of the previous mixture to determine the cheapest mixture for a given ratio of fine-grained and coarse aggregate.

 Then the value of the ratio of fine-grained and coarse-grained aggregate is changed by moving to the left by 1% on the graph of packing density. The above process is repeated to determine the cheapest mixture using fly ash with a new ratio of fine to coarse aggregate. Then, the unit cost values of the optimal mixtures are compared for different values of the ratio of fine-grained and coarse-grained aggregate to reveal the cheapest mixture. The process continues by moving to the left along the graph of the packing density until a completely optimized mixture is obtained containing fly ash and possessing predetermined characteristics.

A specific process of cost optimization of a mixture containing fly ash includes the following steps:
4 (a). Determining the composition of the optimal mixture (without additives) that has the specified characteristics of sludge and strength at the initial value of the ratio of fine-grained and coarse-grained aggregate is the same process that is described for steps 1 and 2.

 4 (b). Determination of the composition of the optimal mixture with the addition of fly ash at the initial value of the ratio of fine-grained and coarse-grained aggregate. Based on the composition obtained in stage 2, replace 1% of the cement volume with an equal volume of fly ash and calculate the resulting strength. As for the packing density graph, the volume of fly ash is included with the volume of cement. It has been experimentally established that fly ash particles have practically the same average diameter d and the same natural packing density φ as cement particles. Thus, the volumetric content of the cement material remains constant, despite the replacement of cement with fly ash. However, if the average size and natural packing density of the particles of fly ash will differ significantly from the similar characteristics of cement, then cement, as described for stage 1, can be represented as a pseudoparticle corresponding to the combination of cement and fly ash. The same principle applies when adding silica fume, fillers and other pozzolans, as will be described below. Determining the significance of differences depends on the required accuracy of the results.

Здесь W_FA - достигаемое за счет применения летучей золы сокращение объема воды, необходимой для обеспечения заданной осадки, которое определяется по уравнению:

Здесь W₁ = ранее определенный объем воды, необходимой для обеспечения осадки в 1 см для стандартной смеси, и
%FA = объемное содержание летучей золы в смеси цемента и летучей золы.Studies have established that if the total volume of cement and fly ash contains fly ash of 37%, then this provides an approximately 6 percent reduction in the amount of water needed to obtain the required sludge. Actual reductions in water consumption may vary slightly depending on different types of fly ash and can be empirically determined. Therefore, the volume of water necessary to ensure a given precipitation of a concrete mixture containing fly ash is determined using the modified Popovich equation:

Here, W _FA is the reduction in the volume of water required to ensure a given precipitation, achieved by using fly ash, which is determined by the equation:

Here W ₁ = a previously determined volume of water necessary to provide a precipitation of 1 cm for a standard mixture, and
% FA = volumetric content of fly ash in a mixture of cement and fly ash.

Здесь K₂ - постоянная, известная под названием показателя прочностных реакций и характеризующая прочность, обеспечиваемую единицей объема летучей золы, в сравнении с прочностью, обеспечиваемой равным объемом цемента. Обычно значение этой постоянной составляет от 0,3 до 0,6 и может быть определено конкретно для используемого типа летучей золы, W₂ и V_A - те же величины, которые ранее были определены на этапе 2(d), и V_FA - объем летучей золы в смеси, рассчитываемый с помощью следующего уравнения:
V_FA = %FA • (V_C+FA/100) (24)
Здесь V_C+FA - общий объем цемента и летучей золы, который можно определить по графику плотности упаковки, где он представлен в виде объема цемента, и
V_C - объем цемента в смеси, рассчитываемый с помощью следующего уравнения:
V_C = V_C+FA - V_FA (25)
4(с). Сравнение значения прочности, получаемой для смеси с использованием летучей золы, с заданным значением прочности. Если получаемая прочность будет отличаться от заданной, то составляют новую смесь, оценивая объем цемента и летучей золы, необходимый для обеспечения требуемой прочности смеси, причем в новой смеси будет использовано то же соотношение объемов цемента и летучей золы. Новый объем цемента рассчитывается по следующему уравнению:

Здесь σ_D= = заданная прочность в МПа, и K, K₂, V_A, W₂ и %FA были ранее определены на этапе 4(b).Then the value of W ₂ can be used to calculate the strength achieved after curing within 28 days. Although fly ash has some characteristics of a hydratable material, its contribution to the overall strength of the mixture will be less than the contribution of an equal volume of cement. In accordance with this, to calculate the strength of concrete achieved after curing within 28 days, in the case of the use of fly ash, the modified Fere formula is used:

Here K ₂ is a constant, known under the name of the indicator of strength reactions and characterizing the strength provided by the unit volume of fly ash, in comparison with the strength provided by an equal volume of cement. Typically, the value of this constant is from 0.3 to 0.6 and can be determined specifically for the type of fly ash used, W ₂ and V _A are the same values that were previously determined in step 2 (d), and V _FA is the volume fly ash in a mixture calculated using the following equation:
V _FA =% FA • (V _{C + FA} / 100) (24)
Here V _{C + FA} is the total volume of cement and fly ash, which can be determined from the packing density graph, where it is presented as the volume of cement, and
V _C - the volume of cement in the mixture, calculated using the following equation:
V _C = V _{C + FA} - V _FA (25)
4 (s). Comparison of the strength value obtained for a mixture using fly ash with a given strength value. If the obtained strength will differ from the set, then make up a new mixture, estimating the volume of cement and fly ash, necessary to ensure the required strength of the mixture, and in the new mixture will use the same ratio of the volumes of cement and fly ash. The new cement volume is calculated by the following equation:

Here, σ _D = = the specified strength in MPa, and K, K ₂ , V _A , W ₂ and% FA were previously determined in step 4 (b).

Определения всех переменных были приведены выше.The volume of fly ash in the new mixture is calculated by the equation:

The definitions of all variables were given above.

 The corresponding normalized volumes of fine aggregate and coarse aggregate can be calculated in accordance with equations (17) and 18 used in step 2 (e). After this, steps 4 (b) and 4 (c) are repeated until a mixture is obtained in which the calculated strength is equal to the specified strength.

 4 (d). Calculate the unit cost of the mixture in step 4 (c), which contains 1% fly ash, and compare with the cost of the mixture in step 4 (a), which does not contain fly ash. If the cost of the mixture in step 4 (c) is less, then steps 4 (b) -4 (d) are repeated by replacing with fly ash another 1% of the volume of cement in the mixture in step 4 (a). Steps 4 (b) -4 (d) are repeated with an increase in the volume of fly ash until the cheapest blend using fly ash is obtained or the volume content of fly ash exceeds 30%. In mixtures where the fly ash content exceeds 30%, the gelation of cement is not enough to prevent the separation of components and the protrusion of cement milk from concrete. In addition, since hydroxyl ions from cement are required for hydration of fly ash, a large dosage of fly ash cannot be recommended to provide the required strength.

 4 (e). As in the case of stage 3, the process continues by changing the ratio of fine-grained and coarse aggregate by reducing the volume content of coarse aggregate by 1%, which corresponds to a left shift of 1% according to the packing density graph. Using mixtures based on the new fine to coarse aggregate ratio, steps 4 (a) -4 (d) are repeated until the cheapest mixture, including fly ash and having the specified strength and precipitation characteristics, is determined.

 4 (f). Calculate the unit cost of the mixture in step 4 (e) and compare it with the cost of the mixture in step 4 (d). If the mixture in step 4 (e) is cheaper, then step 4 (e) is repeated, moving another 1% according to the packing density graph, thereby changing the value of the ratio of fine-grained and coarse-grained aggregate. This process continues by changing the ratio of fine-grained and coarse-grained aggregate until the cheapest mixture, including fly ash, is obtained or until the volume content of fine-grained aggregate reaches 80%, as mentioned above.

 Other pozzolans added to the concrete mix exhibit similar behavior. By way of example (but not as limiting the scope of the invention), such pozzolans include blast furnace slag, pyrex, diatomaceous earth, opal trait, clay, slate, volcanic tuff and pumice. Such pozzolans can be included in the optimization process using the above equations, into which the corresponding values of the coefficients of reduction in the amount of water and indicators of strength reactions should be introduced. As a rule, no more than two pozzolans are added to the concrete mixture, since an additional increase in their quantity does not give either an economic effect or an improvement in the characteristics of the material.

Stage 5: Micrograin and Silica
Silica fume, also called silica dust, is also among the pozzolanic additives, but differs from other pozzolans in its particularly large specific surface area and the way it affects the concrete mix. Silica fume is a product of the recovery of highly purified quartz during firing together with coal in an electric arc furnace in the manufacture of silicon or ferrosilicon alloys. In fact, silica fume is silica in an amorphous form. Since particles of this material form in a state suspended in air, they have a spherical shape, like particles of fly ash. However, the particles of silica fume are extremely small and usually have a diameter of less than 1 μm, with an average diameter of 0.1 μm.

 The composition of the optimal mixture using silica fume can be determined in the same way that was used to determine the proper amount of fly ash from step 4; however, other formulas should be used to determine the required amount of water and ultimate strength. Unlike fly ash, silica fume requires more water to provide the same sludge, but silica gives the cement mixture a higher strength. Regarding the packing density graph, the volume of silica fume is also considered part of the volume of cement in the mixture. If desired, you can use pseudoparticles that display a combination of cement and silica fume.

Здесь W_SF - требуемое за счет применения микрозернистого кремнезема увеличение объема воды, необходимой для обеспечения заданной осадки, которое определяется по уравнению:

Здесь %SF = объемное содержание микрозернистого кремнезема в смеси цемента и микрозернистого кремнезема.Studies have found that replacing 20 vol.% Cement with an appropriate volume of silica fume will result in an approximately 20 percent increase in the amount of water required to provide the desired precipitation. (The actual increase in the amount of water may vary for different types of silica fume, but this parameter is easy to determine empirically). In accordance with this calculation, the percentage of water required to obtain a mixture including silica fume and having a given precipitate is determined using the following equation:

Here W _SF is the increase in water volume required by the use of silica fume, necessary to ensure a given precipitation, which is determined by the equation:

Here,% SF = volumetric content of microgranular silica in the mixture of cement and microgranular silica.

Здесь V_SF - объем микрозернистого кремнезема в смеси, рассчитываемый с помощью следующего уравнения:
V_SF = %SF • (V_C+SF/100) (31)
Здесь V_C+SF - общий объем цемента и микрозернистого кремнезема, который можно определить по графику плотности упаковки, где он представлен в виде объема цемента, и
V_C - объем цемента в смеси, рассчитываемый с помощью следующего уравнения:
V_C = V_C+SF - V_SF , (32)
K₃ - постоянная активности, характеризующая прочность, обеспечиваемую единицей объема микрозернистого кремнезема, в сравнении с прочностью, обеспечиваемой равным объемом цемента. Обычно значение этой постоянной составляет от 1,5 до 4, причем предпочтительным значением является 2. Фактическое значение этой постоянной может определяться для данного типа микрозернистого кремнезема эмпирическим способом. K, W₂ и V_A - те же величины, которые ранее были определены на этапе 2(d).Then the value of W ₂ can be used to calculate the strength of concrete, achieved after curing within 28 days. Taking into account the cementing characteristics of microgranular silica, the modified Feret equation for calculating the strength of concrete with microgranular silica, achieved after curing for 28 days, is as follows:

Here, V _SF is the volume of silica fume in the mixture, calculated using the following equation:
V _SF =% SF • (V _{C + SF} / 100) (31)
Here, V _{C + SF} is the total volume of cement and micrograin silica, which can be determined from the packing density graph, where it is presented as the volume of cement, and
V _C - the volume of cement in the mixture, calculated using the following equation:
V _C = V _{C + SF} - V _SF , (32)
K ₃ - constant activity, characterizing the strength provided by the unit volume of silica fume, in comparison with the strength provided by an equal volume of cement. Typically, the value of this constant is from 1.5 to 4, with a preferred value of 2. The actual value of this constant can be determined empirically for a given type of silica fume. K, W ₂ and V _A are the same quantities that were previously determined in step 2 (d).

 These formulas for calculating the amount of water and strength can be included in the process described in step 4 in order to determine the optimal composition of the concrete mixture, including micro-grained silica and having a given precipitate and strength at a minimum cost.

Здесь σ_D = заданная прочность в МПа;
K, K₃, V_A, W₂ и %SF были определены ранее.As indicated for stage 4 (c), if the design strength is not equal to the specified, then it is possible to calculate the approximate volumes of cement and silica fume necessary to achieve the specified strength. The new cement volume is calculated by the following equation:

Here, σ _D = specified strength in MPa;
K, K ₃ , V _A , W ₂ and% SF were previously determined.

Определения всех переменных были указаны выше. Соответствующие нормализованные объемы мелкозернистого заполнителя и крупнозернистого заполнителя можно рассчитать в соответствии с уравнениями, приведенными для этапа 2(e).The volume of micrograin silica in the new mixture is calculated according to the following equation, so as to ensure a constant value for the ratio of cement to micrograin silica:

The definitions of all variables were indicated above. The corresponding normalized volumes of fine aggregate and coarse aggregate can be calculated in accordance with the equations given for step 2 (e).

 Similarly to fly ash, the volume of microgranular silica should not exceed 20% of the total volume of cement and microgranular silica. Concentrations in excess of 20% can lead to a limitation of the hardening of the mixture and to shrinkage cracking upon drying, which is due to the large specific surface area of the particles of silica fume.

 Step 6. Reagent for reducing the amount of water.

 Additives to reduce the amount of water are used to reduce the consumption of mixed water, necessary to obtain concrete with a given sediment or formability. Typical reagents for reducing the amount of water contain 30 weight. % of active components, including lignosulfates, hydroxylated carboxylic acids and sulfonated condensate of naphthalene-formaldehyde, which can reduce the amount of water required to obtain the desired precipitate by about 15%. Particularly active reagents for reducing the amount of water, also referred to as superplasticizers, usually contain 40% by weight of active components, including a sulfonated condensate of melamine-formaldehyde, a sulfonated condensate of naphthalene-formaldehyde and lignosulfonate, which can reduce the amount of water needed to obtain the required amount by about 30% precipitation. Reagents for reducing the amount of water may also include a setting retarder that slows down the hardening process of concrete. However, unlike fly ash, the reagents to reduce the amount of water do not have cementing properties and therefore mainly affect the strength of cement only by changing the ratio of water to cement.

 Reagents to reduce the amount of water usually function by adsorbing them to the surface of cement particles. In this case, a negative charge is created on the surfaces of the particles, which leads to their mutual repulsion. Due to this mechanism of action, reagents for reducing the amount of water can be considered as some kind of dispersant. It was found that normal and especially active reagents to reduce the amount of water provide the same reduction in the amount of water at an equivalent concentration of active ingredients.

 The main difference between normal and especially active reagents for reducing the amount of water is that especially active reagents for reducing the amount of industrial water usually have a higher concentration of active dispersing ingredients and a lower concentration of setting retarders. Thus, the type of reagent used in this mixture to reduce the amount of water can be taken into account during the optimization process using the normalization process described below.

 In addition, since reagents for reducing the amount of water contain a setting retarder, usually no more than 1% (by weight of cement) of a normal reagent solution is added to the concrete mixture to reduce the amount of water and no more than 2% of particularly active reagents are used to reduce the amount of water. If these concentrations are exceeded, then the concrete may not harden at all. Particularly active reagents to reduce the amount of water can be used in higher concentrations, since they contain a lower concentration of setting retarders.

 Assuming that only reagents are added to the standard concrete mixture to reduce the amount of water, the process for determining the optimal mixture will be the same as that used in step 4 to determine the optimal mixture with the inclusion of fly ash. The only difference is the change in the formulas for calculating the required amount of mixed water and strength. The process begins by determining the optimal composition of the mixture for the first value of the ratio of fine-grained and coarse-grained aggregate. Then gradually added volumes of reagents are added to the mixture to reduce the amount of water. Then, the calculation and comparison of the unit cost of these mixtures is performed to determine the optimal composition of the mixture, including reagents to reduce the amount of water, at the initial value of the ratio of fine-grained and coarse-grained aggregate. Then change the value of the ratio of fine-grained and coarse aggregate and the process is repeated. By comparing the unit cost values of the optimal mixtures for each value of the ratio of fine-grained and coarse aggregate, it is possible to determine the optimal composition of the mixture containing reagents to reduce the amount of water.

 Since the general process of determining the optimal composition of the mixture using a reagent to reduce the amount of water will be the same as the process described for stage 4, only the modified formulas of stage 4 are discussed in detail below. After determining the optimal composition of the mixture, the additive is added with the initial ratio of fine-grained to coarse-grained aggregate reagent to reduce the amount of water in an amount of 0.1% by weight of cement in an optimal mixture. The ultimate strength is calculated using the Fere equation. However, to calculate the final strength, it is necessary to determine the amount of water required to provide a given precipitation of the mixture containing the reagent to reduce the amount of water.

 To formulate a formula for calculating the amount of water required for a mixture using such a reagent, it is necessary to normalize various types of reagents to reduce the amount of water. Particularly active reagents for reducing the amount of water typically contain 40% by weight of the active ingredients. The addition of such a reagent to the cement mixture in an amount of 2% (based on the weight of cement) leads to a 30 percent reduction in the amount of water required to provide a given precipitate. Studies have found that the relationship between the concentration of the added reagent to reduce the amount of water and the reduction in the required amount of water is almost linear. If the above-described especially active reagent for reducing the amount of water is taken as standard, then in accordance with this, all such reagents can be normalized. For example, adding 1% reagent, in which the concentration of active ingredients is only 30%, is considered similar to adding 0.75% of a standard reagent to reduce the amount of water. This is due to a 0.25% reduction in the concentration of the active ingredient in the new reagent to reduce the amount of water.

Здесь W_WR - достигаемое за счет применения такого реагента снижение объема воды, необходимого для обеспечения заданной осадки, которое определяется по уравнению:

Здесь W₁ = ранее определенный объем воды, необходимый для обеспечения осадки в 1 см, и
%WR = объемное содержание реагента для сокращения количества воды в смеси, выраженное в процентах от веса цемента.Based on the parameters of a standard reagent to reduce the amount of water, the percentage of water required to provide a given precipitation of a mixture containing such a reagent is determined using the following equation:

Here W _WR is the reduction in water volume achieved through the use of such a reagent, necessary to ensure a given precipitation, which is determined by the equation:

Here W ₁ = a previously determined volume of water necessary to ensure a precipitation of 1 cm, and
% WR = volumetric reagent content to reduce the amount of water in the mixture, expressed as a percentage of the weight of cement.

Then the value of W ₂ can be used to calculate the strength of concrete, achieved after curing within 28 days. Since reagents for reducing the amount of water do not independently contribute to the strength of concrete, the same formulas used in step 2 can be used to calculate the strength of concrete achieved after curing within 28 days. Typically, the volume of reagent used to reduce the amount of water in a mixture is so it is small that the change in the volume of the mixture as a result of the addition of this reagent is not taken into account. However, if desired, the amount of reagent to reduce the amount of water can be taken into account. That part of the composition of this reagent, which is water, can be subtracted from the amount of water added to the mixture. The remainder of the reagent to reduce the amount of water is solids, which can replace part of the cement, similar to how the cement was replaced with fly ash and silica fume in steps 4 and 5, respectively.

 Since the amount of water required to ensure a given precipitation decreases when using a reagent to reduce the amount of water, the ratio of water to cement in the mixture also decreases, which leads to an increase in the strength of the resulting mixture. Thus, the amount of cement can be reduced until the composition of the mixture with the required strength and sludge and containing 0.1% of the reagent to reduce the amount of water is determined. Then a cost analysis is performed, and if the mixture with the reagent to reduce the amount of water is cheaper, then another 0.1% of the reagent is added to the mixture to reduce the amount of water. The above process is repeated in the order described in step 4 until an optimal mixture is found that includes a reagent to reduce the amount of water. However, as mentioned above, reagents to reduce the amount of water are usually added at a concentration not exceeding 2% by weight of cement. Exceeding this concentration can lead to an increase in the duration of concrete curing to an almost unacceptable level.

 Typically, reagents to reduce the amount of water are not added to low strength concrete. Since such mixtures require only a minimal amount of cement, the addition of expensive reagents to reduce the amount of water is economically inefficient. However, in the case of high-strength concrete, the addition of a reagent to reduce the amount of water can provide a significant reduction in the required amount of cement, which, in turn, determines the economic efficiency of using such reagents.

Stage 7. Fillers
Fillers are another type of additive that can be considered in the optimization process. The cement content required to ensure cohesion (internal adhesion) of the concrete mixture and to prevent the separation of components and protrusion of cement milk, is usually at least 10% of the total volume of cement, fine aggregate and coarse aggregate. However, some low strength concrete can achieve a given strength at a cement concentration of less than 10%. In such cases, you can use inexpensive fillers with particles whose sizes are approximately equal to the size of the cement particles, which allows you to compensate for the difference between the amount of cement necessary to achieve a given strength, and 10% required to obtain a cohesive mixture.

 Fillers usually do not have cementitious properties and do not directly contribute to the strength of the resulting concrete. However, just like fly ash, fillers allow (in comparison with cement) to reduce the amount of water required to ensure a given precipitation, and, accordingly, can indirectly affect the sediment and the strength of the resulting concrete. For example (but not as a limitation on the scope of the invention), such fillers may include calcium carbonate, dolomite, granite, basalt, and ore rocks milled to produce particles that are similar in size to particles of fly ash - less than 100 microns in diameter. The reduction in the amount of water required to obtain a given precipitate is achieved due to the approximately spherical shape of the filler particles and the absence of hydration reactions.

 Fillers are usually introduced into the concrete mix regardless of pozzolan or other additives. Since fillers are used only for low-strength concrete, the addition of pozzolans, in which the strength is half that of cement and more than twice as high, will only increase the cost of the mixture.

 As indicated in the consideration of the previous stages, the minimum volumetric cement content necessary to prevent the separation of components and protrusion of cement milk is about 10%. However, due to the fillers, the volumetric content of cement can be further reduced, for which a part of the cement is replaced by the filler. As for the packing density graph, despite the replacement of cement with fillers, the percentage of cement remains constant at 10%, since the filler particles have the same packing characteristics as the cement particles. However, as already mentioned, in cases where the average particle diameters and the natural packing density of the filler particles will differ significantly from the similar cement parameters, the combination of fillers and cement can be displayed in the form of pseudoparticles.

Здесь W_F - достигаемое за счет применения наполнителей сокращение объема воды, необходимой для обеспечения заданной осадки, которое определяется по уравнению:

Здесь %FIL = объемное содержание наполнителей в смеси цемента и летучей золы.When using fillers, the amount of mixed water required to ensure a given precipitation is reduced by about the same amount as in the case of the addition of fly ash. Thus, the amount of water required to provide a given precipitation of the mixture containing fillers is determined using the following equation:

Here W _F - achieved through the use of fillers, the reduction in the volume of water necessary to ensure a given precipitation, which is determined by the equation:

Here% FIL = volumetric content of fillers in the mixture of cement and fly ash.

Then the value of W ₂ can be used to calculate the strength achieved after curing within 28 days. Since the fillers do not contribute to the strength of concrete, the same formulas used in stage 2 are used to calculate the strength of concrete achieved after curing for 28 days and to estimate the volume of cement required to obtain a given strength.

Stage 8. The system of optimization of the overall structure
After studying the optimization process of a concrete mixture with one additive, used in combination with cement, fine aggregate, coarse aggregate and water, the various processes can be combined into a system using internal cycles, which allows you to determine the optimal composition of the mixture, including certain combinations of additives, including fly ash , silica fume and reagent to reduce the amount of water. Below, by way of example (but not to limit the scope of the present invention), such a system is described using the logic block diagram shown in FIG. 8 (A) - (B).

 Of course, there are various ways to build and implement a real system. However, this system is built on a unified theoretical basis, consisting in the calculation of all possible combinations of cement, fine-grained aggregate, coarse aggregate and various additives that provide the specified characteristics of strength and precipitation. A comparison is then made of the cost of each mixture to determine the cheapest of all mixtures. Thus, the appropriate composition will be the best of all possible compositions. In practice, no calculation is required for all mixtures. In accordance with the system described below, as soon as it is established that the mixture becomes more expensive after increasing the proportion of fine-grained aggregate in the ratio of fine-grained and coarse-grained aggregate, a further change in the ratio of fine-grained and coarse-grained aggregate becomes impractical, since all new mixtures for a given volume of cement will be more expensive.

 In FIG. 8 (A) to (B), a list of all types of cement, fine aggregate and coarse aggregate to be used as part of the mixture is entered into box 34. The types of components are classified according to the average particle diameter d 'and packing density φ, as shown in box 36. As mentioned in Step 1, all types of fine aggregate and coarse aggregate are reduced to single pseudoparticles of fine aggregate and coarse aggregate, as shown in rectangle 38.

 Then, in rhombus 40, the system asks whether micrograin silica will be included in the mixture. If the microgranular silica is not included, then in the rectangle 42 the maximum amount of the microgranular silica is 0. If the microgranular silica can be used, then its maximum number should be entered in the rectangle 44. As mentioned in the consideration of stage 5, the volume of silica fume, as a rule, does not exceed 20% of the volume of cement material. In relation to the system described here, the term "cement materials" includes cement, fly ash and silica fume. In rhombus and rectangles 46-50, the same information is requested for reagents to reduce the amount of water, and in rhombus and rectangles 52-56 the same information is requested for fly ash.

After selecting the additives, the initial parameters are determined, for which the value of the previous best cost X _{BEST is} equal to infinity, and the volumes of the reagent to reduce the amount of water, fly ash and silica fume are equal to zero, as shown in rectangles 58-62. Now the system is prepared to determine the composition and cost of the initial mixture, which has the specified characteristics of strength and precipitation. This process is carried out according to the logic circuit 64 shown in FIG. nine.

 The optimization process begins with box 66, where the maximum particle packing density for a given combination of cement, fine aggregate and coarse aggregate is calculated. The value of the maximum packing density of the particles is determined in accordance with the process described in the consideration of step 1. Then, the composition of the mixture at the maximum packing density of the particles is specified using the cohesion factor shown in rectangle 68, which makes it possible to determine the composition of the initial mixture shown in rectangle 70, in which no delamination of components or protrusion of cement milk will be observed. In box 69, the initial value of the optimal cost is set equal to infinity, intended for subsequent comparison with the actual cost.

 In box 72, the amount of water required to provide a given precipitation is calculated. Based on the required amount of water, the final strength of the mixture is determined, shown in rectangle 74. In rhombus 76, the calculated and specified strengths are compared. If we assume that the calculated strength will not be equal to the specified, then the approximate volume of cement required to ensure the given strength is calculated in rectangle 78.

 Next, in box 78, the volume of fine-grained aggregate and coarse-grained aggregate is normalized, so that in the new mixture the volumes of cement, fine-grained aggregate and coarse-grained aggregate total 1.0, while maintaining the ratio of fine-grained and coarse-grained aggregate. All the above calculations are performed using the equations given in the consideration of stage 2.

 Having introduced the new composition of the mixture, the system returns to rectangle 72 by cyclic branch 79, after which the process is repeated for the new mixture by calculating the required amount of water and final strength and then comparing the calculated strength with the given. The cycle 79 is repeated until the calculated strength becomes equal to the specified one, after which the cost of the mixture is calculated in rectangle 80. Then, in rhombus 82, the cost of the mixture in rectangle 80 is compared with the cost of the optimal mixture. Since the initial value of the optimal cost was equated to infinity, the first mixture with the specified characteristics will be considered optimal, and the values of the volume of cement, fine-grained aggregate, coarse-grained aggregate, as well as the cost of the mixture are entered as optimal in rectangle 84.

 Then, in rhombus 86, the system compares the volume of fine aggregate with the maximum allowable volume of fine aggregate. As indicated in the consideration of step 2, this value is usually about 80% of the volume of solids. If the volume of fine-grained aggregate in the mixture is less than the maximum permissible volume of fine-grained aggregate, the system moves to box 88, where a new value for the ratio of fine-grained and coarse aggregate is determined by increasing the volume of fine-grained aggregate by 1% and a corresponding decrease in the volume of coarse-grained aggregate; cement volume is kept constant. Then the system returns to rectangle 70 by cyclic branch 89, and the process is repeated, starting from determining the content of cement, fine-grained aggregate and coarse-grained aggregate with a new ratio of fine-grained and coarse-grained aggregate, which will ensure equality of the calculated and specified strength of the mixture.

 After the composition of the mixture with the specified characteristics is determined with the new ratio of fine-grained to coarse aggregate, the cost of this mixture is calculated in box 80 and the obtained value is compared with the value of the previously determined optimal mixture. If the cost of the new mixture is lower, the new mixture becomes optimal and cycle 89 continues by setting a new ratio of fine-grained and coarse-grained aggregate in box 88. Cycle 89 continues until it is completed through diamond 82 or diamond 86. Cycle 89 ends through rhombus 86 if the volume of fine-grained aggregate in the new optimal mixture is not less than the specified maximum volume of fine-grained aggregate. Cycle 89 can also end through rhombus 82 if the cost of the new mixture is higher than the value of the previously determined optimal mixture. At the point of completion of cycle 89, the optimal composition is the best in all respects mixture of cement, fine aggregate and coarse aggregate, which has a given strength and sludge at a minimum cost.

 In rhombus 90, a comparison is made of the cost of the optimal mixture defined in rectangle 84 with the cost of the cheapest mixture. Since the initial value of the lowest cost in rectangle 58 is initially equated to infinity, the value of the lowest cost in rectangle 84 is first equal to the cost of the optimal mixture in rectangle 84 at the time of exit from cycle 89. Box 92 contains data on the composition and cost of the best mixture.

 Then the system begins to carry out a series of internal cycles in which increments of volumes of microgranular silica, fly ash and reagent are carried out to reduce the amount of water. The values of the cost of each of the optimal mixtures are compared, after which the parameters of the best mixture are written in box 92. In rhombus 94, it is found out whether the content of fine-grained silica in the mixture is less than the specified maximum value for the content of fine-grained silica. If the answer is yes, the volume of silica fume in the cementitious material increases by 1%, as shown in box 96. Then, through cyclic branch 97, the system returns to cycle 64. Using the formulas in step 5, in cycle 64, by changing the ratio of fine-grained and coarse aggregate now determines the composition and cost of mixtures containing microgranular silica and having the desired characteristics; while the value of the ratio of the volume of fine-grained silica to the volume of cement materials remains constant for each mixture.

 Cycle 89 continues by measuring the ratio of fine-grained and coarse-grained aggregate until the new mixture becomes more expensive than the previous mixture, which will be revealed by comparing the values in diamond 82, or until the maximum allowable value of the volume of fine-grained aggregate is reached. After fulfilling any of these conditions, the system returns to rhombus 90, and the cost of the optimal mixture in rectangle 84 is compared with the cost of the previous optimal mixture. If the cost of the optimal mixture is less, then the composition of this optimal mixture becomes the new best composition. The system then checks to see if the maximum allowable volume of silica fume has been reached. If this value is not achieved, then another 1% of the cement material is replaced by fine-grained silica. Then, cycle 98 is repeated to reveal a new optimal mixture with the newly set ratio of the volume of microgranular silica and the volume of cement material. Cycle 98 is continuously repeated until the volume of silica fume in the mixture reaches the maximum allowable value.

 After reaching the maximum allowable volume of silica fume in the rhombus 100, it is determined whether the maximum allowable content of fly ash in the mixture has been reached. If the maximum content has not yet been reached, then in the rectangle 102 1% of the cement material is replaced by fly ash. Then, the system returns to rectangle 62 via cyclic branch 104, where the volume of microgranular silica is reset to zero and a new entry into cycle 64 is made.

 Now, in cycle 64, the formulas described in Step 4 are used to determine the optimal composition of the mixture consisting of cement, 1% fly ash (based on the volume of cement material) of micro-silica, fine-grained aggregate and coarse-grained aggregate. After the volume of silica fume is reached the maximum permissible value, the system exits cycle 98 and the volume content of fly ash is again increased by 1%. Then the volume of silica fume is again reset to zero and gradually increases as cycle 98 is run for a composition with two percent fly ash. This cycle continues until the maximum permissible content of fly ash is reached.

 Then, in rhombus 106, it is determined whether the maximum allowable value of the volume of the reagent is exceeded to reduce the amount of water. If the maximum content is not exceeded, then a reagent is added to the mixture to reduce the amount of water at a concentration of 0.1% by weight of the cement material. The system then repeats cycles 98 and 10 for each increment of reagent concentration to reduce the amount of water.

 Each time the composition of the optimal mixture is revealed, the cost is compared with the value of the best mixture stored in box 92. Thus, when the maximum allowable value of the volume of the reagent is reached to reduce the amount of water and the system finishes its work by exiting through oval 112, the parameters of the best the mixtures stored in rectangle 92 are the parameters of the cheapest mixture with the specified characteristics of precipitation and strength and selected on the basis of all possible combinations cement, fly ash, silica fume, a reagent for reducing the amount of water, fine aggregate and coarse aggregate.

Здесь W_SF и W_FA соответствуют определениям, приведенным при рассмотрении этапов 4 и 5.If cement is combined only with fly ash or only with micrograin silica, then the calculation of the required volume of water and the final strength of the mixture is carried out using the formulas in steps 4 and 5, respectively. However, in cases where cement, fly ash and silica fume are used in the same mixture, the equations below should be used. The volume of water required to ensure a given precipitation of the mixture containing silica fume and fly ash is determined by the equation:

Here, W _SF and W _FA correspond to the definitions given in steps 4 and 5.

Здесь
V_SF = %SF • (V_T/100) (41)
V_FA = %FA • (V_T/100) (42)
V_C = V_T - V_SF - V_FA (43)
Здесь V_T - общий объем цемента, мелкозернистого заполнителя и летучей золы в смеси. Другие переменные ранее были определены на этапах 4 и 5.Based on the calculated value of W _{2, the} final strength for rectangle 74 can be calculated using a modified Fere equation:

Here
V _SF =% SF • (V _T / 100) (41)
V _FA =% FA • (V _T / 100) (42)
V _C = V _T - V _SF - V _FA (43)
Here V _T is the total volume of cement, fine aggregate and fly ash in the mixture. Other variables were previously defined in steps 4 and 5.

где все переменные были ранее определены на этапах 4 и 5.If the design strength is not equal to the specified value, then the indicative values for new volumes of cement, fly ash and silica fume can be calculated using the following equations, respectively:

where all the variables were previously defined in steps 4 and 5.

 When using the above equations, the ratios of volumes of cement, fly ash and silica fume to the total volume of cement materials remain constant. The corresponding volumes of cement and coarse aggregate can be determined using the equations in step 2.

 And finally, as described in more detail when considering step 6, reagent additives to reduce the amount of water are taken into account only when determining the amount of water required to provide a given precipitation. Thus, regardless of whether the reagent to reduce the amount of water is added to a mixture of cement and fly ash, a mixture of cement and microgranular silica, or to a mixture of cement, fly ash and microgranular silica, the above equations are changed only by subtracting the amount of water required to provide predetermined precipitation, reduced as a result of the addition of this reagent.

Здесь значения W_FA, W_SF и W_WR были определены соответственно на этапах 4, 5 и 6.For example, the volume of water required to provide a given precipitation for a mixture containing cement, fly ash, silica fume, reagent to reduce the amount of water, fine aggregate and coarse aggregate is determined using the following equation:

Here, the values of W _FA , W _SF and W _WR were determined in steps 4, 5, and 6, respectively.

 It should be noted that in the optimization process, you can also take into account the effects of other pozzolans or additives, for which another cycle is simply added to the iterative calculation process. Similarly, the above system can take into account the addition of fillers, but since fillers are almost never introduced into mixtures containing other additives, the same result will be obtained.

 Step 9. Reagent for trapping air.

 In contrast to the additives described above, reagents for capturing air are not modeled as part of the optimization process, and therefore, the corresponding adjustment is made on the fact. Reagents for capturing air are additives that stabilize the air bubbles that are formed during the mixing process. For this, a decrease in the surface tension coefficient of water is used. The reagent to reduce the amount of water forms a water-repellent film, the strength of which is sufficient to hold and stabilize air bubbles. Unlike natural air bubbles, the bubbles formed through the use of a reagent to reduce the amount of water are extremely small - their diameter is from 10 to 1000 microns.

 The main advantages of increasing the percentage of air voids in the concrete mixture are the increase in frost resistance (resistance to freezing and thawing of concrete in a humid environment), as well as in improving the formability of the concrete mixture. Water freezing in wet concrete causes osmotic and hydraulic pressure in the capillaries and pores of the cement paste and aggregate. These cyclic pressures that occur during freezing and thawing can cause the concrete structure to swell and lose its strength. Air voids provide a reduction in these pressures, since they play the role of empty chambers into which thawing water can enter without creating undesirable internal pressure in the concrete structure.

 Reagents for capturing air slightly increase the sediment and improve the formability of the concrete mixture due to the formation of air bubbles through which the particles of the mixture can move, which reduces the friction forces between the particles. In addition, due to the inclusion of air bubbles in the cement paste, the volume of the paste increases, which increases the amount of paste that envelops the aggregate particles and reduces the friction between them. Typical reagents for reducing water include wood resin salts (vinzol resin), some synthetic detergents, sulfonated lignin salts, petroleum acid salts, protein materials salts, fatty and resinous acids and their salts, alkyl benzene sulfonates and sulfonated hydrocarbon salts.

Typically, reagents for capturing air are added at a concentration of 0.02% to 0.2% by weight of cement (depending on the type and amount of solids in the composition of the reagent for capturing air), which provides an increase in air content to 4-10% of the volume concrete. The required concentration of reagent for capturing air depends on the cohesive characteristics of the concrete mixture. In the optimization process, a dosage of additives to the mixture is usually used that meets the recommendations of the supplier enterprises. Sika's Sika Aer ^® Air Capture Reagent is added at a concentration of 0.04% by weight of cement and provides an air concentration of about 5% of concrete volume.

 After actually obtaining the optimal mixture, you can determine the actual air content in the mixture. If, after the completion of the optimization process, the air content in a given draft will be higher or lower in comparison with the value of the air content adopted during step 2 (c), then the optimization process can be repeated using the adjusted value of the air content in the mixture, or the mixture may be reformulated using an appropriate amount of reagent to capture air. The air content can also be modeled as described for step 10. As with the reagent for reducing the amount of water, the percentage of reagent for trapping air in the mixture is usually so small that this reagent itself is not taken into account when determining the volume of the mixture. However, the final increase in air volume in the mixture is taken into account when determining the strength of the mixture.

 Stage 10. Adjustment of systems.

 After developing the system in step 8, you can apply the linear regression method to increase the accuracy of the results provided by the system. In general terms, this is accomplished by plotting a theoretically calculated volume of mixed water required to provide a given draft, depending on the actual volume of mixed water required to provide a given draft.

In practice, the above process includes the following steps:
10 (a). Determine the theoretical volume of water required to ensure a given precipitation of the optimal mixture determined at step 8. This volume corresponds to the value of W ₂ according to the Popovich formula and is the same volume that is used to determine the final strength of the optimal mixture after curing for 28 days.

 10 (b). Physically add the theoretical volume of water to the optimal mixture in step 8. Then, experimentally determine the actual precipitation and air content in the mixture. As a result of the approximations used in the optimization process, discrepancies between the actual and theoretical values of precipitation and air content can often be observed.

10 (s). Using the Popovich formula, determine the amount of water W ₂ necessary for the given mixture to have the actual sediment determined in step 10 (b). Thus, after steps 10 (b) and 10 (c), the actual and theoretical values for the volume of water required to provide a given precipitation for a given mixture will be obtained.

 10 (d). Repeat steps 10 (a) -10 (d) for different values of a given draft. These steps should be repeated at least three times, and the accuracy of the final results will be the higher, the more times these steps are repeated. In this way, two sets of values will be obtained corresponding to the actual and theoretical volumes of water required to provide a given precipitation.

 10 (e). Build a graph based on the values obtained in step 10 (d), where the actual volumes of water required to provide a given precipitation will be deposited along the y axis, and the theoretical volumes of water required to provide a given precipitation will be deposited along the x axis. Studies have found that such a graph is usually linear.

10 (f). Formulate a linear relationship in step 10 (e) as follows:
W _2C = (W ₂ • m) + b (48)
Here W _2c is the actual amount of water required to provide a given precipitation (in practice, this value is the adjusted theoretical amount of water required to provide a given precipitation)
W ₂ - theoretical amount of water required to provide a given precipitation,
m is the slope of the line on the graph in step 10 (e), and
b is the point of intersection with the y axis.

10 (g). Build a graph of experimentally determined air content depending on experimentally determined precipitation values for the respective mixtures. Define the correlation as the following relationship:
RETURN _FACT = (DRAFT • m) + b (49)
Here, the air _fact is the volume of air in the mixture with the corresponding precipitation,
SEDIMENT - sediment of this mixture,
m is the slope of the line showing the dependence of the actual precipitation on the corresponding air content, and
b is the intersection point of this oblique line with the y axis.

10 (h). The formula in step 10 (f) is included in the optimization process so that after determining the theoretical volume of water required to ensure a given precipitation using the Popovich equation, the obtained value of W _{2 is} entered into equation (48) in step 10 (f). Then, a corrected or refined value of W _2c is determined, which determines the amount of water required to provide a given precipitation. Then, the predetermined precipitation value is entered into equation (49) in order to determine the volume of air in the mixture. The obtained values of the air volume and the corrected volume of water are introduced into the Fere equation to calculate the strength of the mixture. After that, the optimization process continues in the above order. Thus, the amount of precipitation can be estimated with an error of ± 2 cm.

 Stage 11. Durability.

 The above optimization process can also be used to ensure that the selected mixture has sufficient durability appropriate to its purpose. Durability is defined as the ability of a structure to maintain its integrity over a long period of time and is measured in this patent by a measure of porosity. Mixtures with high porosity usually have an excessive concentration of water or fine aggregate and, therefore, have low durability. The total porosity of the mixture can be determined using the following equation, assuming that the hydration of the cement is already 80% complete.

Здесь W_W - вес воды на один кубический метр бетона,
W_C - вес цемента на один кубический метр бетона, и
%ВОЗД - процентное содержание воздуха в смеси, определяемое относительно содержания твердых веществ в составе смеси.

Here W _W is the weight of water per cubic meter of concrete,
W _C is the weight of cement per cubic meter of concrete, and
% AIR - the percentage of air in the mixture, determined relative to the solids content in the mixture.

 Thus, the above equation can be used in determining precipitation and strength to ensure proper mixture characteristics. This is done as follows: after it becomes clear that the mixture has sufficient strength and sediment, the total porosity can be calculated to determine whether it corresponds to a given porosity. If the specified porosity is insufficient, it is possible to increase the percentage volumetric content of cement, which allows to reduce the porosity of the structure and ensure its sufficient durability.

 Step 12. Product Yield.

 After determining the proportions of the fully optimized components of the mixture, it is desirable to provide the possibility of such a calculation of the volume of the components, which will ensure the required output or volume of the mixture. In currently used processes, the yield of the mixture is usually overestimated. Typically, the volume of the proposed mixture is calculated by dividing the weight of each component by its corresponding density in order to obtain the volume of each component. Then the volumes of all components are added up to obtain the total volume of the resulting mixture.

 However, this method does not take into account the packing density of particles and, therefore, does not take into account the amount of space remaining between the particles in the mixture. As a result, the actual volume of the mixture exceeds the calculated value. Excessive concrete is not only an expensive process in the sense of wasting materials, time and energy, but also causes problems in the safe disposal of excess material.

 In contrast, the present invention includes a method for calculating the yield of a mixture, taking into account the volume of air contained in the mixture. The process involves dividing the volume of each component (determined using the optimization process described above) by the total volume of the mixture and then multiplying the respective fractions by the required volume of the mixture. These calculations allow you to determine the actual volume of each component that must be introduced into the mixture in order to obtain a given volume of the mixture. In turn, the volume of the components can be multiplied by their respective specific gravity to determine the weight of each component that should be introduced into the mixture in order to obtain a given weight yield of the mixture.

For example, the volume of cement required to produce 100 m ^{3 of a} given mixture can be determined using the following equation:
Cement volume = (V _C / V _T ) • 100 (51)
Here V _C is the volume of cement in the mixture, determined at stage 10 of the optimization process and presented in the form of fractional solids in the mixture. The total solids content (i.e., cement, fine aggregate, coarse aggregate, and (if used) fly ash and silica fume) is 1.0.

Здесь процентное содержание воздуха в смеси (%ВОЗД) можно определить эмпирически с помощью пробного замеса. Используя вышеприведенное уравнение для каждого из компонентов смеси, можно точно определить объем каждого компонента, требуемый для получения заданного выхода смеси.V _T is the total volume of the optimized mixture determined in step 8. The value of V _{T is} obtained by adding the volume of water W introduced into the mixture to the volume of solids (which is 1.0 in total) and dividing the resulting amount by the volume of air contained in the mixture. Thus, the total volume is calculated by the following formula:

Here, the percentage of air in the mixture (% UHP) can be determined empirically using a trial batch. Using the above equation for each of the components of the mixture, you can accurately determine the volume of each component required to obtain a given yield of the mixture.

 To date, numerous experiments have been performed to compare concrete mixtures calculated by conventional methods with those in which the composition was determined using the optimization process described above. The following are specific examples of the use of the optimization process according to the invention, as well as a comparison of conventional and optimized mixtures.

Example 1
Sand and fine gravel were mixed with Type 1 Portland cement to form a concrete mix for the foundation containing fine gravel. First, the characteristics of the aggregates were determined in order to determine the values of d 'and the packing density of each component (see table 3):
The packing of a two-component mixture of sand and coarse aggregate was calculated according to the Tufar model and correlated with experimental values, as described above when considering Step 1. In FIG. 10 shows the correlation between the adjusted theoretical packing density and the experimental packing density of a mixture of sand and fine gravel. The fact that the line of best approximation corresponds to a directly proportional dependence indicates the accuracy of the mathematical model. In FIG. 11 shows the correlation between the adjusted values of the theoretical packing density of the three-component mixture and the experimental values of the packing density of the three-component mixture of cement, sand and fine gravel. From FIG. 11, it can be seen that the model for evaluating particle packing characteristics is accurate.

Based on the above input parameters, the previously described models were used to evaluate the composition of the mixture with fine gravel, containing a maximum of 55% sand of the total volume of cement, sand and fine gravel and having a strength of 24 MPa. The estimated precipitation was 5 cm and the air content was 2.0 vol.%. The first optimized mixture composition was as follows:
Cement - 289.9 kg / m ³
Sand - 1109.3 kg / m ³
Fine gravel - 693.1 kg / m ³
Water - 200.5 kg / m ³
φ - 0.804
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel), the concrete mixture was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 5.0 cm
Actual air content - 3.8 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 2 in order to correct and simulate the actual ratio of precipitation and water content.

The same materials were used to simulate the second composition of the mixture with a maximum sand content of 55 vol.%, Strength 25 MPa, draft 15 cm and an expected air content of 2.0%. The following assessment of the composition of the mixture was obtained:
Cement - 309.2 kg / m ³
Sand - 1076.0 kg / m ³
Fine gravel - 672.3 kg / m ³
Water - 215.1 kg / m ³
φ - 0.807
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel), the concrete mixture was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 22.0 cm
Actual air content - 3.3 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 2 in order to correct and simulate the actual ratio of precipitation and water content. In FIG. 12 shows the relationship between the actual and theoretical amount of water for the first two batches (marked with numbers 1 and 2). Based on the first two points of the graph, the actual water volume is correlated with the theoretical water volume, taking into account the observed precipitation in accordance with the following equation:
W _act = 0.609W _theory + 0.116
This equation is now used to adjust the calculated theoretical amount of water in step 2.

In FIG. 4 shows the dependence of the actual measured air content on the actual precipitation for the first two batches (indicated by numbers 1 and 2). Based on the first two points of the graph, the actual air content is correlated with precipitation in accordance with the equation:
UZD _fact = -0.029 • DRAINAGE + 3.947
This equation is now used to predict the actual air content entered into the Fere equation.

 After the initial simulation of actual settlement values and actual air content in concrete, derived models can now be used to accurately estimate concrete settlement. Using the same materials mentioned above, the following estimates of precipitation and air content for concrete were obtained with a maximum sand content of 55 vol.% And a strength of 25 MPa (see table 4).

 After each batch was completed, the theoretical water content for the actual precipitation was calculated and the obtained values were plotted on the graph shown in FIG. 12. An increase in the number of points provides an increase in the accuracy of estimating the actual draft. Similarly, in order to improve the accuracy of estimating the air content, the actual air content values were plotted on the graph shown in FIG. 13. The dependence of the actual draft on the design draft is shown in FIG. 14. As can be seen from FIG. 14, the first two precipitation values are usually inaccurate. By registering the actual values of precipitation and air content and entering this information into the model via the feedback line, accuracy can be improved to more accurately record subsequent precipitation values. The error is about 2.0 cm.

 As shown in this example, the advantage over conventional calculation methods is that now, to refine the model and predict the composition of concrete with exact values of strength, air content and precipitation at the lowest possible cost of materials, it is practically necessary to calculate only two composition of the mixture.

Example 2
Sand and fine gravel were mixed with Type 1 Portland cement to form a concrete mix intended for foundations containing fine gravel. With the same initial parameters that were indicated in example 1, the previously described methods were used to assess the composition of the mixture based on fine gravel with a maximum sand content of 50 vol.% Of the total volume of cement, sand and fine gravel and with a strength of 25 MPa. The proposed precipitation value was 5 cm and the air content 2.5 vol.%. The first optimized mixture composition was as follows:
Cement - 257.8 kg / m ³
Sand - 1030.4 kg / m ³
Fine gravel - 864.3 kg / m ³
Water - 171.0 kg / m ³
φ - 0.804
After adding an additional amount of water equal to the absorption volume by aggregates (1.2% by weight of sand and 1.4% by weight of fine gravel), the concrete mix was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 2.5 cm
Actual air content - 3.0 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 2 in order to correct and simulate the actual ratio of precipitation and water content.

The same materials were used to simulate the second composition of the mixture with a maximum sand content of 50 vol.%, Strength 25 MPa, draft 15 cm and an expected air content of 2.0%. The following assessment of the composition of the mixture was obtained:
Cement - 275.3 kg / m ³
Sand - 1025.4 kg / m ³
Fine gravel - 819.6 kg / m ³
Water - 189.4 kg / m ³
φ - 0.809
After adding an additional amount of water equal to the absorption volume by aggregates (1.2% by weight of sand and 1.4% by weight of fine gravel), the concrete mix was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft 5.5 cm
Actual air content - 2.7 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 2 in order to correct and simulate the actual ratio of precipitation and water content. In FIG. 15 shows the relationship between the actual and theoretical amount of water for the first two batches (marked with numbers 1 and 2). Based on the first two points of the graph, the actual water volume is correlated with the theoretical water volume, taking into account the observed precipitation in accordance with the following equation:
W _act = 1.740W _theory - 0.124
This equation is now used to adjust the calculated theoretical amount of water in step 2. As can be seen from FIG. 15, there was some kind of error in determining the first precipitation value - point N 1 is completely offset. Unfortunately, the model for kneading N 3 is now based on kneading N 1 and 2. As will be shown below, experiments with an increased number of kneads allow you to adjust the model and improve the accuracy of predicting precipitation using this program.

 After the initial simulation of the actual settlement values and the actual air content in concrete, derivative models can now be used to accurately estimate concrete settlement. Using the same materials mentioned above, the following estimates of precipitation and air content were obtained for concrete with a maximum sand content of 50 vol.% And a strength of 25 MPa (see table 5).

 After each batch, the theoretical water content for the actual precipitation was calculated, and the obtained values were plotted on the graph shown in FIG. 15. The increase in the number of points provides an increase in the accuracy of estimating the actual precipitation. Similarly, in order to improve the accuracy of estimating the air content, the actual air content values were plotted on the graph shown in FIG. 16. In FIG. 17 shows the dependence of the actual draft on the calculated. As can be seen from FIG. 17, only the draft values for batches N1 and 2 were inaccurate. After correcting the deviations of the model, the remaining mixtures gave the correct draft.

 The result is concrete with the exact values of strength, air content and precipitation at the lowest possible cost of materials.

Example 3
Sand and fine gravel were mixed with Type 1 Portland cement and fly ash to form a concrete mix for the foundation containing fine gravel. With the same initial parameters that were indicated in Example 1, the previously described models for mixtures containing fly ash were used to assess the composition of the mixture based on fine gravel with a maximum sand content of 60 vol. % of the total volume of cement, sand and fine gravel; with a maximum content of fly ash of 30%; and with a strength of 30 MPa. The proposed precipitation value was 5 cm and the air content was 2.0 vol.%. The first optimized mixture composition was as follows:
Cement - 298.8 kg / m ³
Fly ash - 128.0 kg / m ³
Sand - 1220.4 kg / m ³
Fine gravel - 461.9 kg / m ³
Water - 190.5 kg / m ³
φ - 0.805
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel), the concrete mixture was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 3.5 cm
Actual air content - 3.1 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 4 in order to correct and simulate the actual ratio of precipitation and water content.

The same materials were used to simulate the second composition of the mixture with a maximum sand content of 60 vol.%, A 30% content of fly ash, a strength of 30 MPa, a draft of 15 cm and an expected air content of 2.0%. The following assessment of the composition of the mixture was obtained:
Cement - 333.8 kg / m ³
Fly ash - 134.8 kg / m ³
Sand - 1188.1 kg / m ³
Fine gravel - 397.5 kg / m ³
Water - 213.1 kg / m ³
φ - 0.801
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel), the concrete mixture was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 19.5 cm
Actual air content - 1.8 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 4 in order to correct and simulate the actual ratio of precipitation and water content. In FIG. 18 shows the relationship between the actual and theoretical amount of water for the first two batches (marked with numbers 1 and 2). Based on the first two points of the graph, the actual volume of water is correlated with the theoretical volume of water in accordance with the following equation:
W _act = 0.489W _theory + 0.127
This equation is now used to adjust the calculated theoretical amount of water in step 4.

In FIG. 19 shows the dependence of the actual measured air content on the actual precipitation for the first two batches (indicated by numbers 1 and 2). Based on the first two points of the graph, the actual air content is correlated with precipitation in accordance with the equation:
UZD _fact = -0.081 • DRAINAGE + 3.384
This equation is now used to predict the actual air content used in determining the strength of the mixture.

 After the initial simulation of the actual settlement values and the actual air content in concrete, derivative models can now be used to accurately estimate concrete settlement. Using the same materials mentioned above, the following estimates of precipitation and air content for concrete were obtained with a maximum sand content of 60 vol.%, A fly ash content of 30% and a strength of 30 MPa (see table 6).

 After each batch, the theoretical water content for the actual precipitation was calculated, and the obtained values were plotted on the graph shown in FIG. 18. The increase in the number of points provides an increase in the accuracy of the estimate of actual precipitation. Similarly, in order to improve the accuracy of estimating the air content, the actual air content values were plotted on the graph shown in FIG. 19. In FIG. 20 also shows the dependence of the actual draft on the calculated. As can be seen from FIG. 20, the values of the actual draft turned out to be quite close to the values of the estimated draft for most batches.

 The result is concrete (containing fly ash) with the exact values of strength, air content and precipitation at the lowest possible cost of materials.

Example 4
Sand and fine gravel were mixed with Type 1 Portland cement and an air capture reagent to produce a concrete mix for the foundation containing fine gravel. With the same initial parameters that were indicated in example 1, the previously described models in steps 9 and 10 were used to assess the composition of the mixture based on fine gravel with a maximum sand content of 60 vol. % of the total volume of cement, sand and fine gravel, with a reagent content for air capture of 0.04%, and with a strength of 25 MPa. The estimated precipitation was 20 cm and the air content was 3.0 vol.%. The first optimized mixture composition was as follows:
Cement - 347.6 kg / m ³
The content of the reagent for capturing air - 0.139 kg / m ³
Sand - 1182.2 kg / m ³
Fine gravel - 532.0
Water - 208.6 kg / m ³
φ - 0.806
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel), the concrete mixture was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 15.2 cm
Actual air content - 6.3 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 2 in order to correct and simulate the actual ratio of precipitation and water content.

The same materials were used to simulate the second composition of the mixture with a maximum sand content of 60 vol.%, A reagent content for air capture of 0.04%, a strength of 25 MPa, a draft of 15 cm and an expected air content of 4.0%. The following assessment of the composition of the mixture was obtained:
Cement - 339.2 kg / m ³
The content of the reagent for capturing air - 0.136 kg / m ³
Sand - 1197.6 kg / m ³
Fine gravel - 538.9 kg / m ³
Water - 192.8 kg / m ³
φ - 0.806
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel), the concrete mixture was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 3.0 cm
Actual air content - 5.9 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated by the method described in step 2 in order to correct and simulate the actual ratio of precipitation and water content. In FIG. 21 shows the relationship between the actual and theoretical amount of water for the first two batches (marked with numbers 1 and 2). Based on the first two points of the graph, the actual volume of water is correlated with the theoretical volume of water in accordance with the following equation:
W _act = 0.893W _theory + 0.083
This equation is now used to adjust the calculated theoretical amount of water in step 2.

In FIG. 22 shows the dependence of the actual measured air content on the actual precipitation for the first two batches (indicated by numbers 1 and 2). Based on the first two points of the graph, the actual air content is correlated with precipitation in accordance with the equation:
UZD _fact = 0,033 • DRAFT + 5,802
This equation is now used to predict the actual air content used in determining the strength of the mixture.

 After the initial simulation of actual settlement values and actual air content in concrete, derived models can now be used to accurately estimate concrete settlement. Using the same materials mentioned above, the following estimates of precipitation and air content for concrete were obtained with a maximum sand content of 60 vol.%, A reagent content for air capture of 0.04% and a strength of 25 MPa (see table 7).

 After each batch, the theoretical water content for the actual precipitation was calculated, and the obtained values were plotted on the graph shown in FIG. 21. As in other cases, an increase in the number of points provides an increase in the accuracy of estimating the actual precipitation. Similarly, in order to improve the accuracy of estimating the air content, the actual air content values were plotted on the graph shown in FIG. 22. In FIG. 23 also shows the dependence of the actual draft on the calculated. As can be seen from FIG. 23, the actual draft values turned out to be quite close to the calculated draft values for most batches.

 The result is concrete (containing a reagent for capturing air) with the exact values of strength, air content and precipitation at the lowest possible cost of materials.

Example 5
It was necessary to determine the composition of low-strength concrete, in which calcium carbonate is used as a filler. Concrete was designed for a strength of 15 MPa and a maximum sand content of 60 vol.% Of the total volume of cement, aggregate, sand and fine gravel. To ensure good cohesion, at least 10% of cement and filler of the total volume of cement, filler, sand and fine gravel should be used. After setting up the model for the first two batches, as described in example 1 and example 2, the following mixture was calculated to obtain a draft of 3.5 cm:
Cement - 201.4 kg / m ³
Filler - 74.1 kg / m ³
Sand - 1220.4 kg / m ³
Fine gravel - 461.9 kg / m ³
Water - 190.5 kg / m ³
When using filler, only the amount of cement that is necessary to provide the required strength is introduced into the mixture; the required cohesion is provided by the filler. If the filler were not used, then in order to provide the required cohesion, an additional amount of cement would have to be added to the mixture, but in this case the optimum concrete would have a strength of 20.7 MPa. Comparing these two compounds, it is possible to determine the reduction in the cost of materials through the use of filler, amounting to 3.60 dollars / m ³ .

Example 6
Sand and fine gravel were mixed with Type 1 Portland cement and superplasticizer to produce a concrete mix for the foundation containing fine gravel. With the same initial parameters that were indicated in Example 1, the previously described models for reagents for reducing the amount of water in step 8 were used to assess the composition of the mixture based on fine gravel with a maximum sand content of 50 vol.% Of the total volume of cement, sand and fine gravel with a maximum WRDA-19 content of 2% by weight of cement and with a strength of 35 MPa. The proposed precipitation value was 2 cm and the air content was 9.0 vol.%. The first optimized mixture composition was as follows:
Cement - 383.0 kg / m ³
WRDA-19 - 7.7 kg / m ³
Sand - 991.7 kg / m ³
Fine gravel - 711.1 kg / m ³
Water - 142.0 kg / m ³
φ - 0.813
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel) and subtracting the volume of water contained in WRDA-19 (60% water), the concrete mix was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual draft - 5.0 cm
Actual air content - 7.9 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated according to the method described in step 8 in order to correct and simulate the actual ratio of precipitation and water content.

The same materials were used to simulate the second composition of the mixture with a maximum sand content of 50 vol.%, 2% WRDA-19, strength 35 MPa, draft 4 cm and an expected air content of 9.0%. The following assessment of the composition of the mixture was obtained:
Cement - 397.6 kg / m ³
WRDA-19 - 8.0 kg / m ³
Sand - 990.8 kg / m ³
Fine gravel - 676.3 kg / m ³
Water - 150.9 kg / m ³
fi - 0.813
After adding an additional amount of water equal to the absorption volume by aggregates (1.01% by weight of sand and 1.42% by weight of fine gravel) and subtracting the volume of water contained in WRDA-19 (60% water), the concrete mix was mixed in a drum mixer for 3 minutes, after which the values of precipitation and air content were measured:
Actual Draft - 7.3 cm
Actual air content - 0.5 vol.%
Based on the registered experimental values of precipitation and air content, the theoretical amount of water was calculated according to the method described in step 8 in order to correct and simulate the actual ratio of precipitation and water content. In FIG. 24 shows the relationship between the actual and theoretical amount of water for the first two batches (marked with numbers 1 and 2). Based on the first two points of the graph, the actual volume of water is correlated with the theoretical volume of water in accordance with the following equation:
W _fact = 1.423W _theory - 0.125
This equation is now used to adjust the calculated theoretical amount of water in step 8.

In FIG. 16 shows the dependence of the actual measured air content on the actual precipitation for the first two batches (indicated by numbers 1 and 2). Based on the first two points of the graph, the actual air content is correlated with precipitation in accordance with the equation:
UZD _fact = -0.174 • DRAINAGE + 8.770
This equation is now used to predict the actual air content in step 8.

 After the initial simulation of the actual settlement values and the actual air content in concrete, algorithms and derived models can now be used to accurately estimate concrete settlement. Using the same materials mentioned above, the following estimates of precipitation and air content for concrete were obtained with a maximum sand content of 50 vol.%, A WRDA-19 content of 2%, and a strength of 35 MPa (see Table 8).

 After each batch was completed, the theoretical water content for the actual precipitation was calculated and the obtained values were plotted on the graph shown in FIG. 24. The increase in the number of points provides an increase in the accuracy of the estimate of actual precipitation. Similarly, in order to improve the accuracy of estimating the air content, the actual air content values were plotted on the graph shown in FIG. 25. In FIG. 26 also shows the dependence of the actual draft on the calculated. As can be seen from FIG. 26, the actual draft values turned out to be quite close to the calculated draft values for most batches.

 The result is concrete (containing a reagent to reduce the amount of water) with exact values of strength, air content and precipitation at the lowest possible cost of materials.

Example 7
The contractor demanded to bring concrete to the construction site with a loss of sludge not exceeding 5.0 cm in half an hour. The strength of concrete should be 35 MPa, and the sludge at the construction site should be 10.0 cm.

 The concrete composition was calculated as in Example 6, but instead of using the maximum WRDA-19 superplasticizer concentration of 2%, a combination of a normal reagent was used to reduce the amount of water and superplasticizer to reduce precipitation loss. The maximum recommended dosage of 1.0% normal plasticizer (WRDA-79) and 1.0% superplasticizer (WRDA-19) was added in order to achieve a maximum calculated concentration of 2.0%.

Cement - 414 kg / m ³
WRDA-19 - 4.1kg / m ³
WRDA-77 - 4.1kg / m ³
Sand - 967kg / m ³
Fine gravel - 660 kg / m ³
Water - 142 kg / m ³
Draft - 15.5 cm
Air - 10.3%
0.5 hours after the delivery to the construction site, the concrete had a draft of 11.5 cm, while the draft of the mixture containing only superplasticizer was 8.5 cm.

 This result demonstrates the predictability of precipitation when using both normal and highly active reagents to reduce the amount of water.

Example 8
The composition of the concrete mixture was determined according to ACI 211.1.89, "Practical Recommendations on the Selection of Proportions of Materials for Normal, Heavy and Mass Concrete" to provide a compressive strength of 25 MPa and a settlement of 5 cm. The cost of the materials used was:
Cement - $ 74.96 / ton
Sand - $ 5.60 / ton
Coarse aggregate - 11.02 dollars / ton
The maximum particle size of the coarse aggregate was 10 mm, and the sand grain modulus was 2.34 - 2.4.

The following mixture was developed in accordance with ACI recommendations:
Cement - 330 kg / m ³
Sand - 954 kg / m ³
Coarse aggregate - 762 kg / m ³
Water - 205 kg / m ³
Air - 3%
Draft - 3-5 cm
Cost - 38.39 USD / m ³
In accordance with the above system, the following mixture was determined:
Cement - 303 kg / m ³
Sand - 1192 kg / m ³
Coarse aggregate - 573 kg / m ³
Water - 195 kg / m ³
Air - 4.0%
Draft - 4.7 cm
Cost - $ 35.60 / m ³
The values of precipitation, air content and strength were determined experimentally.

This example demonstrates the advantage of the above method in comparison with the ACI standard, namely, that the actual values of precipitation and strength were obtained while saving costs of 2.79 dollars / m ³ .

Example 9
The composition of the concrete mixture was determined according to ACI 211.1.89, "Practical Recommendations on the Selection of Proportions of Materials for Normal, Heavy and Mass Concrete," in order to provide a compressive strength of 25 MPa and a draft of 10 cm. The cost of the materials used was:
Cement - $ 74.96 / ton
Sand - $ 5.60 / ton
Coarse aggregate - 11.02 dollars / ton
The maximum particle size of the coarse aggregate was 10 mm, and the sand grain modulus was 2.34 -2.4.

The following mixture was developed in accordance with ACI recommendations:
Cement - 362 kg / m ³
Sand - 875 kg / m ³
Coarse aggregate - 762 kg / m ³
Water - 225 kg / m ³
Air - 3%
Draft - 8-10 cm
Cost - $ 40.35 / m ³
In accordance with the above system, the following mixture was determined:
Cement - 312 kg / m ³
Sand - 1174 kg / m ³
Coarse aggregate - 565 kg / m ³
Water - 212 kg / m ³
Air - 4.3%
Draft - 11.2 cm
Cost - 36.11 USD / m ³
The values of precipitation, air content and strength were determined experimentally.

This example demonstrates the advantage of the above method in comparison with the ACI standard, namely, that the actual values of precipitation and strength were obtained while saving costs of $ 4.24 / m ³
Example 10
The composition of the concrete mixture was determined according to ACI 211.1.89, "Practical Recommendations on the Selection of Proportions of Materials for Normal, Heavy and Mass Concrete," in order to provide a compressive strength of 25 MPa and a settlement of 15 cm. The cost of the materials used was:
Cement - $ 74.96 / ton
Sand - $ 5.60 / ton
Coarse aggregate - 11.02 dollars / ton
The maximum particle size of the coarse aggregate was 10 mm, and the sand grain modulus was 2.34 - 2.4.

The following composition of the mixture was determined:
Cement - 387kg / m ³
Sand - 816 kg / m ³
Coarse aggregate - 762 kg / m ³
Water - 240 kg / m ³
Air - 3.0%
Draft - 15-18 cm
Cost - 41.90 dollars / m ³
In accordance with the above algorithms, the following mixture composition was calculated:
Cement - 303 kg / m ³
Sand - 1192 kg / m ³
Coarse aggregate - 573 kg / m ³
Water - 195 kg / m ³
Air - 4.0%
Draft - 4.7 cm
Cost - 35.6 USD / m ³
The values of precipitation, air content and strength were determined experimentally.

This example demonstrates the advantage of the above method in comparison with the ACI standard, namely that the actual values of precipitation and strength were obtained while saving costs of $ 6.30 / m ³
Example 11
The concrete plant produced pumping concrete mixture based on fine gravel, intended for foundation work. A mixture with a draft of 10 cm and a compressive strength of 13.8 MPa had the following composition:
Cement - 329 kg / m ³
Sand - 1224 kg / m ³
Fine gravel - 530 kg / m ³
Water - 214 kg / m ³
Cost - $ 37.24 / m ³
The composition of the mixture was changed using the above system to obtain a draft of 10 cm and a strength of 16.6 MPa. Strength was somewhat overstated in order to create a calculated margin.

Cement - 242 kg / m ³
Sand - 1165 kg / m ³
Fine gravel - 602 kg / m ³
Water - 234 kg / m ³
Cost - $ 31.20 / m ³
Using the proposed calculation method, 6.04 dollars per 1 m ^{3 of} concrete were saved.

Example 12
The concrete plant produced pumping concrete mixture based on fine gravel, intended for foundation work. A mixture with a draft of 10 cm and a compressive strength of 17.2 MPa had the following composition:
Cement - 368 kg / m ³
Sand - 1205 kg / m ³
Fine gravel - 517 kg / m ³
Water - 214 kg / m ³
Cost - 39.93 USD / m ³
The composition of the mixture was changed using the above system to obtain a draft of 10 cm and a strength of 20.0 MPa (increase in strength by 2.8 MPa). Strength was somewhat overstated in order to create a calculated margin.

Cement - 277 kg / m ³
Sand - 1172 kg / m ³
Fine gravel - 574 kg / m ³
Water - 231 kg / m ³
Cost - $ 33.60 / m ³
Using the proposed calculation method, 6.04 dollars per 1 m ^{3 of} concrete were saved, and good quality of concrete was also ensured.

Example 13
The concrete plant produced pumping concrete mixture based on fine gravel, intended for foundation work. A mixture with a draft of 10 cm and a compressive strength of 20.7 MPa had the following composition:
Cement - 368 kg / m ³
Sand - 1188 kg / m ³
Coarse aggregate - 513 kg / m ³
Water - 214 kg / m ³
Air - 1.5%
Cost - 41.73 dollars / m ³
The composition of the mixture was changed using the above system to obtain a draft of 10 cm and a strength of 23.5 MPa. Strength was somewhat overstated in order to create a calculated margin.

Cement - 307 kg / m ³
Sand - 1177 kg / m ³
Coarse aggregate - 547 kg / m ³
Water - 229 kg / m ³
Air - 1.5%
Cost - 35.57 USD / m ³
Using the proposed calculation method, 6.16 dollars per 1 m ^{3 of} concrete were saved, and good quality of concrete was also ensured.

Example 14
The concrete plant produced concrete mix based on 1-inch crushed stone, having a draft of 10 cm and a compressive strength of 13.8 MPa. Typical mixture composition:
Cement - 265 kg / m ³
Sand - 820 kg / m ³
Crushed stone - 972 kg / m ³
Water - 211 kg / m ³
Air - 1.5%
Cost - 35.18 USD / m ³
The composition of the mixture was changed using the above system to obtain a draft of 10 cm and a strength of 16.6 MPa. Strength was somewhat overstated in order to create a calculated margin.

Cement - 224 kg / m ³
Sand - 1203 kg / m ³
Crushed stone - 642 kg / m ³
Water - 210 kg / m ³
Air - 1.5%
Cost - $ 32.00 / m ³
Using the proposed calculation method, 3.18 dollars per 1 m ^{3 of} concrete were saved, and good quality of concrete was ensured.

Example 15
The concrete plant produced concrete mix based on 1-inch crushed stone, with a draft of 10 cm and a compressive strength of 17.2 MPa. Typical mixture composition:
Cement - 294 kg / m ³
Sand - 814 kg / m ³
Crushed stone - 968 kg / m ³
Water - 206 kg / m ³
Air - 1.5%
Cost - $ 37.08 / m ³
The composition of the mixture was changed using the above system to obtain a draft of 10 cm and a strength of 20.0 MPa. Strength was somewhat overstated in order to create a calculated margin.

Cement - 252 kg / m ³
Sand - 1211 kg / m ³
Crushed stone - 615 kg / m ³
Water - 208 kg / m ³
Air - 1.5%
Cost - 33.59 USD / m ³
Using the proposed calculation method, 3.49 dollars per 1 m of concrete were saved, and good quality of concrete was also ensured.

Example 16
The concrete plant produced concrete mix based on 1-inch crushed stone, having a draft of 10 cm and a compressive strength of 20.7 MPa. Typical mixture composition:
Cement - 323 kg / m ³
Sand - 810 kg / m ³
Crushed stone - 962 kg / m ³
Water - 200 kg / m ³
Air - 1.5%
Cost - $ 39.24 / m ³
The composition of the mixture was changed using the above system to obtain a draft of 10 cm and a strength of 23.5 MPa. Strength was somewhat overstated in order to create a calculated margin.

Cement - 276 kg / m ³
Sand - 1204 kg / m ³
Crushed stone - 611 kg / m ³
Water - 204 kg / m ³
Air - 1.5%
Cost - 35.18 USD / m ³
Using the proposed calculation method, 4.06 dollars per 1 m ^{3 of} concrete were saved, and good quality of concrete was also ensured.

Example 17
The concrete plant produced concrete mix based on 1-inch crushed stone, having a draft of 10 cm and a compressive strength of 27.6 MPa. Typical mixture composition:
Cement - 376 kg / m ³
Sand - 783 kg / m ³
Crushed stone - 936 kg / m ³
Water - 204 kg / m ³
Air - 1.5%
Cost - 42,99 dollars / m ³
The composition of the mixture was changed using the above system to obtain a draft of 10 cm and a strength of 30.4 MPa. Strength was somewhat overstated in order to create a calculated margin.

Cement - 336 kg / m ³
Sand - 1168 kg / m ³
Crushed stone - 593 kg / m ³
Water - 207 kg / m ³
Air - 1.5%
Cost - 38.04 USD / m ³
Using the proposed calculation method, 4.95 dollars per 1 m ^{3 of} concrete were saved, and good quality of concrete was also ensured.

Example 18
In conventional batch production of concrete, the weighing of individual components is carried out with ever increasing accuracy. With the help of modern equipment, it is now possible to weigh water with an error of not more than 1 l / m ³ . However, despite the very accurate weighing of all components, when registering the values of precipitation, there was a large scatter of results for different mixes of concrete. If a precipitation value that is too low is recorded, then usually water is added, which leads to an overestimation of the ratio of water to cement and, consequently, an uncontrolled decrease in compressive strength. However, if the precipitation value is too high, delamination of the components and protrusion of cement milk can be observed, which can lead to the appearance of internal defects and to a general deterioration in the quality of concrete.

 A series of experiments at a concrete plant showed that the average particle size d 'and packing density φ have a large spread. In FIG. Figure 27 shows the packing density of fine gravel checked once a day. The figure shows the lines of the average, minimum and maximum packing density. In FIG. 28 shows the value of d ′ for the fine gravel samples of FIG. 27. And in this case, the figure shows the lines of the average, minimum and maximum particle diameter. Based on FIG. 18 and 19, it can be concluded that the observed dispersion of fine gravel characteristics is large and causes the observed dispersion of precipitation in the manufacture of concrete. The results indicate the need for continuous monitoring of the variation in the characteristics of materials in order to improve the overall quality of concrete.

Example 19
Analogously to example 18, a daily spread of the characteristics of typical sand was measured. The results are shown in FIG. 29 and 30. As you can see, a large scatter in the values of d 'and packing density was found.

 The results indicate the need for continuous monitoring of the variation in the characteristics of materials in order to improve the overall quality of concrete.

Example 20
Analogously to example 19, a daily spread of the characteristics of typical sand was measured. The results are shown in FIG. 31 and 32. As you can see, a large scatter in the values of d 'and packing density was found.

 The results indicate the need for continuous monitoring of the variation in the characteristics of materials in order to improve the overall quality of concrete.

Example 21
It was found that the dispersion of the characteristics of the materials, shown in examples 18, 19 and 20, has a significant effect on the settlement of the concrete being produced and, therefore, on the amount of water required to provide a given precipitation, and on the amount of cement required to provide a given strength.

When calculating the mixture based on fine gravel considered in Example 11, it was found that when sand and fine gravel are combined in accordance with the range of characteristics shown in FIG. 27-32, that is, with a combination of the maximum and minimum packing densities of these components, the cost of design concrete with a draft of 10 cm and a strength of 13.8 MPa would be:
With the worst packaging - 32.17 dollars / m ³
Savings in comparison with a normal mixture - 5.07 dollars / m ³
With the best packaging - $ 30.47 / m ³
Savings compared to the normal mixture - 6.77 dollars / m ³
The results indicate the cost-effectiveness of developing concrete composition with controlling the characteristics of materials.

Example 22
It was found that the dispersion of the characteristics of the materials, shown in examples 18, 19 and 20, has a significant effect on the settlement of the concrete being produced and, therefore, on the amount of water required to provide a given precipitation, and on the amount of cement required to provide a given strength.

When calculating the mixture based on fine gravel considered in Example 12, it was found that when sand and fine gravel are combined in accordance with the range of characteristics shown in FIG. 27-32, i.e., with a combination of the maximum and minimum packing densities of these components, a calculated concrete with a draft of 10 cm and a strength of 17.2 MPa would cost:
At the worst packaging - $ 34.25 / m ³
Savings compared to the normal mixture - $ 5.68 / m ³
With the best packaging - $ 32.16 / m ³
Savings compared to the normal mixture - $ 7.77 / m ³
The results indicate the cost-effectiveness of developing concrete composition with controlling the characteristics of materials.

Example 23
It was found that the dispersion of the characteristics of the materials, shown in examples 18, 19 and 20, has a significant effect on the settlement of the concrete being produced and, therefore, on the amount of water required to provide a given precipitation, and on the amount of cement required to provide a given strength.

When calculating the mixture based on fine gravel considered in Example 13, it was found that with a combination of sand and fine gravel in accordance with the range of characteristics shown in FIG. 27-32, i.e., with a combination of the maximum and minimum packing densities of these components, a calculated concrete with a draft of 10 cm and a strength of 20.7 MPa would cost:
With the worst packaging - $ 36.19 / m ³
Savings in comparison with a normal mixture - 5.54 dollars / m ³
With the best packaging - $ 33.78 / m ³
Savings compared to the normal mixture - $ 7.95 / m ³
The results indicate the cost-effectiveness of developing concrete composition with controlling the characteristics of materials.

Example 24
It was found that the dispersion of the characteristics of the materials, shown in examples 18, 19 and 20, has a significant effect on the settlement of the concrete being produced and, therefore, on the amount of water required to provide a given precipitation, and on the amount of cement required to provide a given strength.

When calculating the mixture based on 1-inch crushed stone, considered in Example 14, it was found that with a combination of sand and crushed stone in accordance with the range of characteristics shown in FIG. 27-32, i.e., with a combination of the maximum and minimum packing densities of these components, a calculated concrete with a draft of 10 cm and a strength of 13.8 MPa would cost:
At the worst packaging - $ 32.70 / m ³
Savings in comparison with a normal mixture - $ 2.48 / m ³
With the best packaging - $ 31.74 / m ³
Savings compared to the normal mixture - $ 3.44 / m ³
The results indicate the cost-effectiveness of developing concrete composition with controlling the characteristics of materials.

Example 25
It was found that the dispersion of the characteristics of the materials, shown in examples 18, 19 and 20, has a significant effect on the settlement of the concrete being produced and, therefore, on the amount of water required to provide a given precipitation, and on the amount of cement required to provide a given strength.

When calculating the mixture based on 1-inch crushed stone, considered in Example 15, it was found that with a combination of sand and crushed stone in accordance with the range of characteristics shown in FIG. 27-32, i.e., with a combination of the maximum and minimum packing densities of these components, a calculated concrete with a draft of 10 cm and a strength of 17.2 MPa would cost:
At the worst packaging - $ 34.40 / m ³
Savings in comparison with a normal mixture - 2.68 dollars / m ³
With the best packaging - 33.34 dollars / m ³
Savings compared to the normal mixture - $ 3.74 / m ³
The results indicate the cost-effectiveness of developing concrete composition with controlling the characteristics of materials.

Example 26
It was found that the dispersion of the characteristics of the materials, shown in examples 18, 19 and 20, has a significant effect on the settlement of the concrete being produced and, therefore, on the amount of water required to provide a given precipitation, and on the amount of cement required to provide a given strength.

When calculating the mixture based on 1-inch crushed stone, considered in example 16, it was found that with a combination of sand and crushed stone in accordance with the range of characteristics shown in FIG. 27-32, i.e., with a combination of the maximum and minimum packing densities of these components, a calculated concrete with a draft of 10 cm and a strength of 20.7 MPa would cost:
With the worst packaging - $ 36.10 / m ³
Savings in comparison with a normal mixture - $ 3.14 / m ³
With the best packaging - $ 34.82 / m ³
Savings compared to the normal mixture - 4.42 dollars / m ³
The results indicate the cost-effectiveness of developing concrete composition with controlling the characteristics of materials.

Example 27
It was found that the dispersion of the characteristics of the materials, shown in examples 18, 19 and 20, has a significant effect on the settlement of the concrete being produced and, therefore, on the amount of water required to provide a given precipitation, and on the amount of cement required to provide a given strength.

When calculating the mixture based on 1-inch crushed stone, considered in example 17, it was found that with a combination of sand and crushed stone in accordance with the range of characteristics shown in FIG. 27-32, i.e., with a combination of the maximum and minimum packing densities of these components, a calculated concrete with a draft of 10 cm and a strength of 27.6 MPa would cost:
At the worst packaging - $ 39.17 / m ³
Savings compared to the normal mixture - $ 3.82 / m ³
With the best packaging - $ 37.58 / m ³
Savings compared to the normal mixture - 5.41 dollars / m ³
The results indicate the cost-effectiveness of developing concrete composition with controlling the characteristics of materials.

Example 28
The results shown in examples 21-27, demonstrated that the operational control of the spread of the values of d 'and the packing density of the materials used in the manufacture of concrete, provides:
increasing the uniformity of flow characteristics,
increasing the uniformity of strength characteristics,
increasing the uniformity of the quality characteristics of concrete,
reduction in material costs.

 The results showed that the dynamic calculation of the mixture, in which the composition of the mixture changes with changing materials, is a new method for developing the composition of concrete. This method guarantees obtaining optimal concrete characteristics when changing the characteristics of materials.

Example 29
Concretes designed for different sludge according to examples 1-7, showed excellent cohesion in the absence of visible signs of separation of the components or protrusion of cement milk.

Example 30
Concrete designed in examples 8-10 had good cohesion and showed slight signs of separation of the components or protrusion of cement milk in comparison with mixtures of conventional composition, calculated according to the recommendations of the American Concrete Institute (ACI).

Example 31
Concretes designed according to examples 8-10 had good cohesion and showed slight signs of separation of the components or protrusion of cement milk in comparison with conventional mixes made in concrete plants.

Example 32
Three types of coarse aggregate (granite with a particle size in the range of 2-8 mm, granite with a particle size in the range of 8-16 mm and granite with a particle size in the range of 16-32 mm) were supposed to be used in the construction of a concrete bridge with high durability and the proposed term service for 100 years. For this reason, porosity should be minimized, and concrete should have formability with a minimum water content.

 Therefore, optimization of the packing of aggregate particles was performed to improve the formability of concrete. The values of packing density and average particle size are given in table. 4.

 The indicative packaging of the three types of coarse aggregate is shown in FIG. 33. As can be seen from the figure, the maximum packing is 0.68 and is achieved with the following composition, given in table. ten.

 With an optimal combination of aggregates, concrete with very good formability was obtained, which met the technical requirements of the contractor, and the amount of superplasticizer could be reduced in comparison with that used in standard mixtures of the contractor, which was equivalent to saving $ 400,000.00.

 Based on the foregoing, it can be concluded that the present invention provides novelty processes and methods for the uniform and predictable manufacture of homogeneous cement mixes and products that will be guaranteed to meet specified quality requirements and have specified performance characteristics.

 The present invention also provides uniform and predictable new cement compositions and products having predetermined design and operational characteristics while minimizing the need to create an excessive margin of safety for cement materials and thereby minimizing manufacturing costs.

 The present invention also provides methods for the uniform and predictable manufacture of such uniform cement compositions and products, even though the use of raw materials (i.e. cement, sand, gravel, aggregates, water and additives) with varying quality characteristics and parameters.

 The present invention also provides new compositions and processes for the manufacture of cement compositions and products, the quality of which is guaranteed to be such that concrete truck drivers do not need to change the parameters of the mixture.

 In addition, the present invention provides methods for the manufacture of cement compositions and products that will have sufficient durability for their intended use.

 Further, the present invention provides new processes for calculating the composition, providing the required characteristics of strength, precipitation and durability of cement compositions.

 The present invention also provides new compositions and processes for calculating concrete, eliminating the need for approximation by trial and error.

 Moreover, the present invention also provides new compositions and processes for calculating concrete, providing an optimal mix for a particular concrete made from a variety of components and additives, while ensuring maximum economic efficiency.

 And finally, the present invention provides new processes for changing technological processes for the manufacture of cement compositions and products "in real time" when changing the characteristics of raw materials entering the place of work.

 The present invention can be implemented in other specific forms without departing from its essence and essential characteristics. The described embodiments of the present invention in all respects should be considered as purely illustrative and not limiting the scope of the invention. Therefore, the scope of the invention is indicated in the attached patent claims, and not in the foregoing description. All changes within the meaning and range of equivalence of the patent claims are included in the scope of the invention.

Claims (36)

 1. The method of designing a cement mixture, including cement, water and aggregate, with the determination of the proportion of cement, water and aggregate in accordance with the optimization procedure of the composition, which provides a cement mixture with a given strength and sediment, without the usual tests by trial and error moreover, this method includes the following steps: a) obtaining a batch of hydraulic cement and a batch of aggregate that must be mixed together to obtain the final hydrated cement mixture, and the batch of guide a cement contains many individual particles having an average diameter and a packing density of particles, the batch of aggregate also contains many individual particles having an average diameter and a packing density of particles; b) the choice of a given cone precipitation for the final hydrated cement mixture before hardening and a given strength of the final hydrated cement mixture after curing, characterized in that it also includes the following steps: c) measuring the average particle diameter for individual particles in a batch of hydraulic cement; g) measuring the density of the packing of particles in a batch of hydraulic cement; e) measuring the average particle diameter for individual particles in a batch of aggregate; f) measuring the packing density of particles in a batch of aggregate; g) the construction of a hypothetical cyx cement mixture from the obtained hydraulic cement and aggregate having an initial proportion of hydraulic cement and aggregate; h) calculation of the packing density of particles of a hypothetical dry cement mixture based on: 1) the average diameter of individual particles in a batch of hydraulic cement; 2) the packing density of particles in a batch of hydraulic cement; 3) the average diameter of the individual particles of the batch of aggregate; 4) packing density of particles of a batch of aggregate; and 5) the proportions of hydraulic cement and aggregate in a hypothetical dry cement mixture; i) calculation based on the packing density of the particles of the hypothetical dry cement mixture, the calculated amount of water, which, when mixed with the hypothetical dry cement mixture, gives a hypothetical hydrated cement mixture having a predetermined cone settlement; j) calculation, based on the estimated amount of water calculated in step (s), of the calculated strength of the hypothetical hydrated cement mixture after curing; k) calculation of the difference between the calculated strength of the hypothetical hydrated cement mixture after curing and the specified strength; and m) changing the initial proportion of hydraulic cement and aggregate of the hypothetical dry cement mixture to design one or a large number of subsequent hypothetical dry cement mixtures and then repeating steps (h) - (l) for each subsequent hypothetical dry cement mixture until the difference between design strength and specified strength, calculated for one or more consecutive iterations of stage (h), will not be in an acceptable deviation range in relation to a given strength, and therefore entifitsiruya one or more optimal proportions of hydraulic cement and aggregate.  2. The method according to p. 1, characterized in that the proportion of hydraulic cement and aggregate changes during the design of each subsequent new hypothetical dry cement mixture in step (m), so that the difference between the calculated strength and the specified strength, calculated at each successively repeated stage ( m) will be less than the difference between the calculated strength and the specified strength, calculated at each previous iteration of the stage (m).  3. The method of claim 1, characterized in that it further includes the step of mixing together water and at least part of the batch of hydraulic cement and part of the aggregate to obtain the final cement mixture, in which the proportion of hydraulic cement and aggregate is basically the same as at least one of one or more optimal proportions of hydraulic cement and aggregate specified in paragraph 2.  4. The method according to p. 1, characterized in that it further includes the step of mixing together at least part of the batch of hydraulic cement and part of the aggregate to obtain the final dry cement mixture, in which the proportion of hydraulic cement and aggregate is basically the same as at least one of one or more optimal proportions of hydraulic cement and aggregate specified in paragraph 2.  5. The method according to p. 4, characterized in that it further includes the step of mixing water with the final dry cement mixture to form the final hydrated cement mixture, in which the cone sediment is in principle similar to a predetermined cone precipitate.  6. The method according to p. 5, characterized in that the water is included in an amount essentially similar to the amount of water calculated in step (s) for a hypothetical dry cement mixture having a proportion of hydraulic cement and aggregate, closely corresponding to the proportion of hydraulic cement and aggregate in final dry cement mix.  7. The method according to p. 1, characterized in that the fine aggregate is used as a filler.  8. The method according to p. 7, characterized in that the fine-grained aggregate contains individual particles with different diameters.  9. The method according to p. 7, characterized in that sand is used as a fine-grained aggregate.  10. The method according to p. 1, characterized in that as a filler using coarse aggregate.  11. The method according to p. 10, characterized in that the coarse aggregate contains individual particles with different diameters.  12. The method according to claim 1, characterized in that the hydraulic cement contains many different types of hydraulic cement.  13. The method according to p. 1, characterized in that the proportion of hydraulic cement and aggregate is designed so as to maximize the packing density of the particles of the cement mixture.  14. The method according to p. 1, characterized in that step (g) includes replacing a portion of hydraulic cement with pozzolan when designing a hypothetical dry cement mix, the calculations in steps (i) and (k) being adjusted for the effect of pozzolan on the cone sediment and the strength of a hypothetical hydrated cement mixture.  15. The method according to p. 14, characterized in that silica dust is used as pozzolan.  16. The method of claim 14, characterized in that fly ash is used as pozzolan.  17. The method according to p. 14, characterized in that step (g) includes designing such a hypothetical dry cement mixture that a hypothetical hydrated cement mixture made from it contains a reagent to reduce the amount of water, and the calculations in steps (i) and ( j) are regulated for the effect of said reagent on sediment cone and the strength of a hypothetical hydrated cement mixture.  18. The method according to p. 1, characterized in that step (g) includes filling a portion of the hydraulic cement with the filler when designing a hypothetical dry cement mixture, the hypothetical dry cement mixture having an initial proportion of hydraulic cement, aggregate and filler, and the calculation is stage (h) is adjusted to influence the filler on the packing density of the particles of the hypothetical dry cement mixture.  19. The method according to p. 1, characterized in that it further includes a calculation step based on the estimated amount of water from step (s) and the proportion of hydraulic cement and aggregate, the estimated durability of the hypothetical hydrated cement mixture after curing.  20. The method according to p. 1, characterized in that the final hydrated cement mixture is a mortar.  21. The method according to p. 1, characterized in that the final hydrated cement mixture is a plaster mortar.  22. The method according to p. 1, characterized in that the final hydrated cement mixture is concrete.  23. The method according to p. 1, characterized in that Portland cement is used as hydraulic cement.  24. The method according to p. 1, characterized in that it further includes the step of comparing the unit cost of production for each of one or more optimal proportions of hydraulic cement, fine aggregate and coarse aggregate specified in step (m), to determine the proportion of hydraulic cement, fine aggregate and coarse aggregate having the lowest unit cost.  25. The method according to p. 1, characterized in that it includes the step of comparing the unit cost for each of the hypothetical dry cement mixtures designed in steps (g) and (m) to determine the proportion of hydraulic cement, fine aggregate and coarse aggregate having the lowest unit cost of production.  26. A method for designing a cement mixture comprising cement, water, coarse aggregate and fine aggregate, with the proportion of cement, water, coarse aggregate and fine aggregate being determined in accordance with the composition optimization procedure, which provides a cement mixture having a predetermined strength and sludge without using routine trial by trial and error; moreover, this method includes the following steps: a) obtaining a batch of hydraulic cement, a batch of fine-grained particulate aggregate and a batch of coarse aggregate that must be mixed together in selected proportions to form the final hydrated cement mixture, and the batch of hydraulic cement contains many individual particles having an average diameter and the packing density of the particles, and the batch of fine aggregate contains many individual particles having an average diameter and density of up forging particles, and a batch of coarse aggregate contains many individual particles having an average particle diameter and packing density; b) the choice of a given cone precipitation for the final hydrated cement mixture before hardening and a given strength of the final hydrated cement mixture after curing, characterized in that it also includes the following steps: c) measuring the average particle diameter for individual particles in a batch of hydraulic cement; g) measuring the density of the packing of particles in a batch of hydraulic cement; e) measuring the average particle diameter for individual particles in a batch of fine aggregate; f) measuring the packing density of particles in a batch of fine aggregate; g) measuring the average diameter of individual particles in a batch of coarse aggregate; h) measuring the packing density of particles in a batch of coarse aggregate; i) the construction of a hypothetical dry cement mixture from a batch of hydraulic cement, a batch of fine aggregate and a batch of coarse aggregate in selected proportions to obtain the initial proportion of hydraulic cement, fine aggregate and coarse aggregate; j) calculation of the packing density of particles of a hypothetical dry cement mixture based on: 1) the average diameter of individual particles in a batch of hydraulic cement; 2) particle packing density in a batch of hydraulic cement; 3) the average diameter of individual particles in a batch of fine-grained aggregate; 4) the packing density of particles in a batch of fine-grained aggregate; 5) the average diameter of individual particles in a batch of coarse aggregate; 6) the packing density of particles in a batch of coarse aggregate; and 7) the proportions of hydraulic cement, fine aggregate and coarse aggregate in a hypothetical dry cement mixture; k) a calculation based on the packing density of the particles of a hypothetical dry cement mixture of the estimated amount of water that, when mixed with a hypothetical dry cement mixture, gives a hypothetical hydrated cement mixture having a predetermined cone settlement; l) calculation based on the estimated amount of water calculated in step (l), the estimated strength of the hypothetical hydrated cement mixture after curing; m) calculation of the difference between the calculated strength for a hypothetical hydrated cement mixture after curing and the specified strength; and o) changing the initial proportion of hydraulic cement, fine aggregate and coarse aggregate of a hypothetical dry cement mixture to design one or more consecutive hypothetical dry cement mixtures and repeating steps (k) to (n) for each subsequent hypothetical dry cement mixture until when the difference between the strength and the specified strength, calculated for one or more consecutive iterations of stage (n), does not affect the acceptable range eniya in relation to the desired strength, thereby identifying one or more optimal proportions of hydraulic cement and aggregate.  27. The method according to p. 26, characterized in that the proportion of hydraulic cement, fine aggregate and coarse aggregate is changed during the design of each subsequent new hypothetical dry cement mixture in step (o), so that the difference between the calculated strength and the specified strength, calculated at each sequentially repeating step (o) will be calculated less than the difference between the calculated strength and the specified strength calculated in each previous iteration of step (o).  28. The method according to p. 26, characterized in that it further includes the step of mixing together in relative proportions a batch of hydraulic cement, a batch of fine aggregate and coarse aggregate to obtain a final dry cement mixture in which the proportion of hydraulic cement, fine aggregate and coarse aggregate is in principle similar to at least one of one or more optimal proportions of hydraulic cement, fine aggregate and coarse fillers specified in Sec. 28.  29. The method according to p. 28, characterized in that it further includes the step of mixing water with the final dry cement mixture to form the final hydrated cement mixture, in which the sediment cone is basically similar to a given sediment cone.  30. The method according to p. 29, characterized in that the water is included in an amount essentially similar to the amount of water calculated in step (l) for a hypothetical dry cement mixture, which has a proportion of hydraulic cement and aggregate, most closely corresponding to the proportion of hydraulic cement and aggregate in the final dry cement mixture.  31. The method according to p. 26, characterized in that it further includes the step of comparing the unit cost of production for each of one or more optimal proportions of hydraulic cement, fine aggregate and coarse aggregate determined in step (o), to determine the proportion hydraulic cement, fine aggregate and coarse aggregate having the lowest unit cost.  32. The method according to p. 26, characterized in that it further includes the step of comparing the cost per unit of production for each of the hypothetical dry cement mixtures designed in steps (i) and (o) to determine the proportion of hydraulic cement, fine aggregate and coarse-grained aggregate having the lowest unit cost of production.  33. A method of manufacturing a final dry cement mixture comprising cement and aggregate, with the determination of the proportion of cement and aggregate in accordance with the composition optimization procedure, which subsequently produces a cement mixture with a given strength and sludge without the use of conventional trial and error tests; moreover, this method includes the following steps: a) obtaining a batch of hydraulic cement and a batch of aggregate that must be mixed together to form the final hydrated cement mixture, and the batch of hydraulic cement contains many individual particles having an average particle diameter and packing density, and the batch of aggregate contains many individual particles having an average particle diameter and packing density; b) the choice of a given cone precipitation for the final hydrated cement mixture before hardening and a given strength for the final hydrated cement mixture after curing, characterized in that it also includes the following steps: c) measuring the average diameter of individual particles in the batch of hydraulic cement; g) measuring the density of the packing of particles in a batch of hydraulic cement; d) measurement of the average diameter of individual particles in the aggregate batch; f) measuring the packing density of particles in a batch of aggregate; g) designing a hypothetical cement mixture from a batch of hydraulic cement and a batch of aggregate having an initial proportion of hydraulic cement and aggregate; h) calculation of the packing density of particles of a hypothetical dry cement mixture based on: 1) the average diameter of individual particles in a batch of hydraulic cement; 2) particle packing density in a batch of hydraulic cement; 3) the average diameter of the individual particles in the aggregate batch; 4) the packing density of particles in a batch of aggregate; and 5) the proportions of hydraulic cement and aggregate in a hypothetical dry cement mixture; i) a calculation based on the packing density of the particles of the hypothetical dry cement mixture of the estimated amount of water that, when mixed with the hypothetical dry cement mixture, gives a hypothetical hydrated cement mixture having a predetermined cone settlement; j) calculation based on the estimated amount of water calculated in step (s), the design strength for the hypothetical hydrated cement mixture after curing; k) calculation of the difference between the calculated strength of the hypothetical hydrated cement mixture after curing and the specified strength; m) changing the initial proportion of hydraulic cement and aggregate of a hypothetical dry cement mixture to design one or more subsequent hypothetical dry cement mixtures, followed by repeating steps (h) - (l) for each subsequent hypothetical dry cement mixture until the difference between calculated strength and specified strength, calculated in one or more consecutive iterations of stage (h), will not be within the acceptable range of deviations relative to the specified th strength, thereby identifying one or more optimal proportions of hydraulic cement and aggregate; m) mixing together at least a portion of a batch of hydraulic cement and a batch of aggregate to obtain a final dry cement mixture in which the proportion of hydraulic cement and aggregate is in principle similar to at least one of one or more optimal proportions of hydraulic cement and aggregate defined at the stage (m).  34. A method of manufacturing a final cement mixture comprising cement, water and aggregate, characterized in that the proportions of cement, water and aggregate are determined in accordance with the composition optimization procedure, which provides a cement mixture with a given strength and sediment without the use of conventional tests by samples and errors, and this method includes the following steps: a) obtaining a batch of hydraulic cement and a batch of aggregate, which must be mixed together to form the final hydrated cement a mixture, the batch of hydraulic cement contains many individual particles having an average particle diameter and packing density, and the aggregate batch contains many individual particles having an average particle diameter and packing density; b) the choice of the specified cone precipitation for the final hydrated cement mixture before hardening and the specified strength of the final hydrated cement mixture after curing; c) measuring the average diameter of individual particles in a batch of hydraulic cement; g) measuring the density of the packing of particles in a batch of hydraulic cement; d) measurement of the average diameter of individual particles in the aggregate batch; f) measuring the packing density of particles in a batch of aggregate; g) designing a hypothetical cement mixture from a batch of hydraulic cement and a batch of aggregate having an initial proportion of hydraulic cement and aggregate; h) calculation of the packing density of particles of a hypothetical dry cement mixture based on: 1) the average diameter of individual particles in a batch of hydraulic cement; 2) particle packing density in a batch of hydraulic cement; 3) the average diameter of the individual particles in the aggregate batch; 4) the packing density of particles in a batch of aggregate; and 5) the proportions of hydraulic cement and aggregate in a hypothetical dry cement mixture; i) a calculation based on the packing density of the particles of the hypothetical dry cement mixture of the estimated amount of water that, when mixed with the hypothetical dry cement mixture, gives a hypothetical hydrated cement mixture having a predetermined cone settlement; j) calculation based on the estimated amount of water calculated in step (s), the design strength for the hypothetical hydrated cement mixture after curing; k) calculation of the difference between the calculated strength of the hapotetic hydrated cement mixture after curing and the specified strength; m) changing the initial proportion of hydraulic cement and aggregate hydraulic dry cement mixture for the design of one or more subsequent hypothetical dry cement mixtures with subsequent repetition of ethanes (h) - (l) for each subsequent hypothetical dry cement mixture until the difference between the calculated strength and a given strength, calculated in one or more consecutive iterations of stage (h), will not fall within an acceptable range of deviations with respect to a given strength and thereby identifying one or more optimal proportions of hydraulic cement and aggregate; m) mixing together water, at least a portion of the batch of hydraulic cement and at least a portion of the batch of aggregate to obtain the final cement mixture, in which the proportion of hydraulic cement and aggregate is in principle similar to at least one of one or more optimal proportions of hydraulic cement and aggregate identified in step (m).  35. Cement mixture, characterized in that it is designed by the method according to any one of paragraphs. 1-32.  36. The final cement mixture, characterized in that it is made by the method according to p. 33 or 34.

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