WO2019012547A1

WO2019012547A1 - Method for manufacturing a dry mix construction material and system thereof

Info

Publication number: WO2019012547A1
Application number: PCT/IN2017/050368
Authority: WO
Inventors: Binod Kumar BAWRI; Saroj BAWRI; Malvika Bawri
Original assignee: Saroj Vanijya Private Limited
Priority date: 2017-07-13
Filing date: 2017-08-31
Publication date: 2019-01-17
Also published as: AR112503A1

Abstract

The present invention discloses a method and a system for manufacturing a dry mix construction material. Accordingly, user-input indicative of initial design parameters for manufacturing the dry mix construction material is received and at least one dry mix construction material from a plurality of dry mix construction material designs is selected based on the initial design parameters. Based on the selected at least one dry mix construction material, (a) at least one hydraulic material, (b) at least one a fine aggregate, (c) a coarse aggregate, (d) at least one powder based additive, and (e) at least one optional pozzolanic material are selected from respective plurality of sub-groups of materials. Thereafter (a) the hydraulic material, (b) the fine aggregate, (c) the coarse aggregate, (d) the powder based additive, and (e) the optional pozzolanic material thus selected are mixed to obtain the at least one dry mix construction material.

Description

METHOD FOR MANUFACTURING A DRY MIX CONSTRUCTION

MATERIAL AND SYSTEM THEREOF TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing a dry mix construction material and a system thereof.

BACKGROUND ART

[0002] Typically, manufacturing/production of the dry mix construction material such as concrete and the ancillary concrete materials such as plaster, mortar, cement reinforced sawdust materials, etc., (hereinafter collectively referred to as "DMC") used for any infrastructure development project, include mixing of various materials such as hydraulic material(s), coarse aggregates, fine aggregates, additive(s), and/or pozzolonic material(s). To obtain a DMC of specific property or design requirement, different materials having different properties/characteristics are selected and mixed in appropriate amounts/weights. Various solutions are now available that allow user (such as plant operator and individual developing the DMC) to enter design information including that of constituent materials and view the mix design based on the entered design information.

[0003] In one solution for developing a concrete mix design, a system allows a user to input a set of initial design parameters (such as required average compressive strength) for the design, and to specify various design criteria (such as the cementitious materials, aggregates, and admixtures to be used in the design) using a series of input screens. The system then displays several key initial design parameters and design criteria within a design criteria and parameters summary that is displayed on a single "worksheet screen." One or more of these criteria and/or parameters is displayed in user-modifiable format. Upon pressing a "calculate" button, the system displays an initial set of design specifications that meet the specified design parameters and criteria. The user may then modify any of the user- modifiable design parameters and criteria. In response such modifications, the system immediately generates an updated set of specifications that satisfies the revised criteria.

[0004] In one solution for producing concrete, a system enables measuring constituents of a premix composition for a concrete mix with an automatic control device; mixing these constituents together essentially without through human power to prepare a premix composition for a concrete mix according to properties required of the concrete; storing the premix composition; measuring the mass of a slurry composition of the premix composition with an automatic control device essentially without through human power; and kneading and mixing the slurry composition with cement, coarse aggregate, water, and a chemical admixture. The system further allows kneading and mixing the above slurry composition of the premix composition with cement, coarse aggregate, fine aggregate and water in the concrete production plant.

[0005] In one solution design optimization methods are used to design concrete mixtures having optimized properties, including desired strength and slump at minimal cost. The design optimization methods use a computer-implemented process that is able to design and virtually "test" millions of hypothetical concrete compositions using mathematical algorithms that interrelates a number of variables that affect strength, slump, cost and other desired features. The design optimization procedure utilizes a constant K (or K factor) within Feret's strength equation that varies (e.g., logarithmically) with concrete strength for any given set of raw material inputs and processing equipment. As such, the binding efficiency or effectiveness of hydraulic cement increases with increasing concentration so long as the concrete remains optimized. Further, the computer-implemented process includes accurately measures the raw materials to minimize variation between predicted and actual strength, and controlling water content throughout the manufacturing and delivery process.

[0006] In one solution, a system or equipment prepares a concrete mixture based on comprising a powder, a granular material (including a massive material) and a liquid, such as water, wherein design of mix proportion is determined and properties of the mixture before and after hardening are predicted and controlled. Accordingly, the equipment is constructed so that materials are supplied to a mixer from a cement measuring hopper, a fine aggregate measuring hopper, a coarse aggregate measuring hopper, a first water measuring tank, a second water measuring tank, and a water reducing admixture measuring tank. Individual materials are supplied and measured in the hoppers or measuring tanks from storage tanks and supply sources. Signals from sensors mounted on the hoppers and measuring tanks are transmitted to a control panel. A set value is input from setting section into the control panel and displayed on a display. When the signal obtained by the above- described supply and measuring conforms to this set value, the supply of the material from the storage tanks or supply sources stops. The mixer is provided with a motor, receives the materials from the above-described hoppers or measuring tanks and is driven to prepare an intended mixture. [0007] In one solution, materials used in preparing concrete including aggregates are proportioned in order to obtain an optimum proportion of the concrete mix components. The mix design procedure is optimized by determining the maximum packing of the aggregate ingredients that produce a workable and acceptable concrete. This maximum aggregate packing or volumetric optimization assists to minimize the paste portion of the mix which contains the most expensive ingredients resulting in an acceptable concrete quality in both its plastic (fresh) and hardened states, thereby obtaining an acceptable concrete at a lower total cost.

[0008] These solutions rely either on user-input or pre-stored pre-mix concrete composition data related to constituent materials. Such pre-stored pre-mix concrete composition data related to constituent materials is either based on volumetric optimization or targeted towards obtaining concrete of specific properties. However, these solutions do not give flexibility in selecting individual constituent materials itself for manufacturing the dry concrete or DMC. Thus, there is a need for a solution that overcomes these deficiencies.

SUMMARY

[0009] In accordance with the purposes of the invention, the present invention as embodied and broadly described herein, relates to a method for manufacturing a dry mix construction material and a system thereof.

[0010] Accordingly, user-input indicative of initial design parameters for manufacturing the dry mix construction material is received and at least one dry mix construction material from a plurality of dry mix construction material designs is selected based on the initial design parameters. Based on the selected at least one dry mix construction material, (a) at least one hydraulic material, (b) at least one fine aggregate, (c) a coarse aggregate, (d) at least one powder based additive, and (e) at least one optional pozzolanic material are selected. As such, the selection further includes (i) selecting the hydraulic material from a plurality of sub-groups of hydraulic materials; (ii) selecting the fine aggregate from a plurality of sub-groups of fine aggregates; (iii) selecting the powder based additive from a plurality of sub-groups of powder based additives and (iv) selecting the optional pozzolanic material from a plurality of sub-groups of pozzolanic material. Thereafter (a) the hydraulic material, (b) the fine aggregate, (c) the coarse aggregate, (d) the powder based additive, and (e) the optional pozzolanic material thus selected are mixed to obtain the at least one dry mix construction material. [0011] The advantages of the present invention include, but are not limited to, enabling flexibility in selecting individual constituent materials itself for manufacturing concrete. This enhances a user-experience greatly as a vast number of permutations and combinations in the raw material selection are available for various dry mix construction material compositions.

[0012] This together with the other aspects of the present invention along with the various features of novelty that characterized the present disclosure is pointed out with particularity in claims annexed hereto and forms a part of the present invention. For better understanding of the present disclosure, its operating advantages, and the specified objective attained by its uses, reference should be made to the accompanying descriptive matter in which there are illustrated exemplary embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The advantages and features of the present invention will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawings, in which:

[0014] Fig. 1 illustrates an example network environment involving a system for manufacturing dry mix construction material (DMC), according to an embodiment of the present invention.

[0015] Fig. 2 illustrates an example block diagram involving various components of the system for manufacturing the DMC, according to the embodiment of the present invention.

[0016] Figs. 3a to 3f illustrate an example flowchart that generally illustrates a first example method for manufacturing the DMC, according to the embodiment of the present invention.

[0017] Fig. 4 illustrates an example flowchart that generally illustrates a second example method for manufacturing the DMC, according to the embodiment of the present invention.

[0018] Like reference numerals refer to like parts throughout the description of several views of the drawing.

DESCRIPTION OF THE INVENTION

[0019] The exemplary embodiments described herein detail for illustrative purposes are subjected to many variations. It should be emphasized, however, that the present invention is not limited to a method for manufacturing dry mix construction material (DMC) and a system thereof. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

[0020] Unless otherwise specified, the terms, which are used in the specification and claims, have the meanings commonly used in the field of construction and/or construction material production process and machines involved therein. Specifically, the following terms have the meanings indicated below.

[0021] The terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0022] The terms "having", "comprising", "including", and variations thereof signify the presence of a component.

[0023] The term "ash" or "fly ash" refers here to coal combustion products that are generated as industrial wastes in coal-fired thermal power stations.

[0024] The terms "Site Mix Construction", "Ready Mix Construction" and

"Dry Mix Construction" are interchangeably referred to hereinafter as "SMC", "RMC" and "DMC" respectively.

[0025] The term "dry mix construction materials" refers here to the construction materials used for various construction purposes such as construction for building structure construction, construction for road and runway pavement, construction for building dams and flyovers, and/or construction for building underground and underwater structures and includes materials such as dry mix concrete, and ancillary concrete materials such as plaster, mortar and/or cement reinforced saw dust materials.

[0026] The term "ancillary construction materials" refers here to the plaster materials, mortar, repairing cement admixture, and/or reinforced cement admixtures.

[0027] The term "hydraulic material(s)" refers to cements which are capable of setting and hardening under water.

[0028] The term "pozzolanic material(s)" refers to a siliceous or siliceous and aluminous material, which in itself possesses little or no cementing property, but will in a finely divided form - and in the presence of moisture - chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties. [0029] The term "powder based additive(s)" refers to synthetic or natural occurring materials or compounds or agents which are capable of improving the physical and chemical properties of the dry mix construction and ancillary construction materials. [0030] The industrial waste referred to herein include but not limited to the industrial wastes from thermal power plants or cool burning units, mining industry, blast furnace slag.

[0031] Fig. 1 illustrates example network environment 100 involving a system 101 for implementing a method for manufacturing a dry mix construction material (DMC), according to an embodiment of the present invention. Examples of the dry mix construction material include concrete and ancillary concrete materials such as plaster, mortar, cement reinforced sawdust materials, etc. The network environment 100 can be a DMC manufacturing plant and the system 101 can be an electronic device capable of sending/receiving data over a communication network. Examples of the system 101 include, but not limited to, server, personal desktop, laptop, tablet, notebook, personal digital assistant, and special purpose devices. Examples of the communication network include wired network and wireless network

[0032] The system 101 is communicatively coupled over the communication network (represented via dashed arrows) with a plurality of material storage units (MSUs) that store materials required for producing the DMC. The materials include plurality hydraulic materials, fine aggregates, coarse aggregates, powder based additives, and an optional pozzolanic materials. Each of these materials, except for coarse aggregates, are graded and grouped based on various grouping parameters/characteristics.

[0033] Accordingly, the plurality of sub-groups of hydraulic materials are grouped based on (a) chemical properties of hydraulic materials, (b) physical properties of hydraulic materials, and (c) particle size distribution (PSD) of hydraulic materials. Such grouping may be performed, prior to the storing, by using techniques as known in the art. Examples of the hydraulic materials include ordinary cement, Portland cement, limestone fines, and silica fume. In addition to the grouping parameters, the grouping may further be based on supplier, cost, specific gravity, class, and, grade. As such, MSU 102 includes various sub-storage units corresponding to each of the sub-groups of hydraulic material. In an example, the MSU 102 includes hydraulic materials sub-grouped as HM1, HM2, HM3, ... HMn. [0034] The plurality of sub-groups of fine aggregates are grouped based on

PSD. Such grouping may be performed, prior to the storing, by using techniques as known in the art. As such, MSU 103 includes various sub-storage units corresponding to each of the sub-groups of fine aggregates. In an example, the MSU 103 includes fine aggregates sub- grouped as FA1, FA2, FA3, ... FAn.

[0035] The plurality of sub-groups of powder based additives (or interchangeably referred to as powder based admixtures) are grouped based on chemical properties of the powder based additives. Such grouping can be as Set-Retarding additives; Air entrainment additives; Water-reducing additives; Accelerating concrete admixtures; Shrinkage reducing concrete admixtures; super-plasticizers; and Corrosion-inhibiting admixtures. Such grouping may be performed, prior to the storing, by using techniques as known in the art. Examples of the powder based additives include cellulosic material, starch material, lignosulphonate salts, hydrocarbolic acid salts, stearate salt of alkali metal group or alkaline earth metal group, Sulphonated Melamine Formaldehyde, Sulphonated Naphthalene Formaldehyde, Poly Carboxylic Ether, salts of nitrate, salts of nitrite, salts of formate, salts of thiocyanate, Calcium Ligno-sulphonates, Carbohydrates derivatives, fatty acid salts or vinsol resin, hydroxide salt of alkali metal group or alkaline earth metal group and the like. As such, MSU 104 includes various sub-storage units corresponding to each of the sub-groups of powder based additives. In an example, the MSU 104 includes powder based additives sub- grouped as PBA1, PBA2, PBA3, ... PBAn.

[0036] The plurality of sub-groups of pozzolanic materials are grouped based on (a) particle size distribution (PSD) of the pozzolanic material, (b) mechanical properties of the pozzolanic material, and (c) chemical properties of the pozzolanic material. Such grouping may be performed, prior to the storing, by using techniques as known in the art. Examples of the hydraulic materials include fly ash, ground granulated blastfurnace slag (GGBS), volcanic ash, finely ground quartz, mechanically modified fly ash, mechanically modified pond ash, chemically modified fly ash, and chemically modified pond ash. As such, MSU 105 includes various sub-storage units corresponding to each of the sub-groups of pozzolanic materials. In an example, the MSU 102 includes pozzolanic materials sub- grouped as PM1, PM2, PM3, ... PMn.

[0037] As would be understood, the size of coarse aggregates depends upon a required strength of the DMC. In general for strength up-to 200 kg/cm2, aggregates up-to 40 millimeter (mm) may be used; and for strength above 300 kg/cm2 aggregate up-to 20 mm may be used. Typically, graded aggregates are desirable for making DMC as the space between larger particles is effectively filled by smaller particles to produce a high-degree of particle packing structure. In one example, the graded aggregates can be 'continuous' aggregate (also known as 'well-graded' or 'combined' aggregate), wherein the aggregate includes particles of a wide range of sizes. In another example, the graded aggregates can be 'gap-graded' aggregate, wherein the aggregate lacks one or more intermediate size. As such, the MSU 106 corresponds to a coarse aggregate mixture comprising of at least two types of coarse aggregates based on their normal maximum size and gradation. In one example, the mixture can be a graded 20 mm down sized combined coarse aggregate obtained by blending a 20 mm down sized single size coarse aggregate with a 12.5 mm downsized graded coarse aggregate. The at least two types of coarse aggregates are separately procured and stored in separate sub-storage units within the MSU 106. The at least two types of coarse aggregates are never intermixed within the MSU 106 but rather the mixture of the two types of aggregates is fetched based on required strength or property of the DMC. In one example, the two types of aggregates are fetched together such that a mixture is formed while being transported to next stage. In another example, the two types of aggregates are fetched individually; mix together to form a mixture, and then the mixture is transported to next stage.

[0038] Further, the system 101 is communicatively coupled over the communication network (represented by dashed arrows) with a blending unit 107 (or interchangeably referred to a mixer). The plurality of MSUs is operatively coupled with the blending unit 107 via a plurality of conveyers (represented by solid arrows) for transporting the materials from individual MSUs to the blending unit 107. The blending unit 107 blends or mixes the materials to manufacture DMC with desired cementitious property as per user/ site requirements. The DMC formed after blending in the blending unit 107 is transferred to a silo 108 for dispatching and/ or storage via the plurality of conveyers (represented by solid arrows). The blending unit 107 and the silo 108 are operatively coupled with each other. Thus, the system 101 controls the selection of the materials from each of the MSUs and working of the blending unit 107. As would be understood, the system 101, the MSUs, the blending unit 107, and the silo 108 are operated by a technician or a plant operator for manufacturing the DMC.

[0039] Fig. 2 illustrates an example block diagram 200 involving various components of the system 101 for manufacturing the DMC, according to the embodiment of the present invention. The system 101 includes a receiving unit 201, design selection unit (DSU) 202, and a material selection and analysis unit (MSAU) 203. The receiving unit 201 receives user- input indicative of initial design parameters for manufacturing the DMC. The user-input can provided via a user-interface displayed on a display unit 204. The user-input can be a touch based input or input provide via input device such as keyboard. In one example, the user-interface can be a web interface accessible over the communication network. In one example, the user-interface can be a client-based interface. Examples of such display device 204 can be a display monitor such as LED screens. In one implementation, the display device 204 may itself be the I/O unit. In an example, the display device 204 can be a touch-based display.

[0040] Based on the initial design properties, the DSU 202 selects at least one dry mix construction material from a plurality of dry mix construction material designs based on the initial design parameters. To this end, the DSU 202 may fetch a list 205 plurality of dry mix construction material designs stored in a memory 206. Based on the at least one dry mix construction material thus selected, the MSAU 203 selects (a) at least one hydraulic material, (b) at least one fine aggregate, (c) at least one powder based additive, and (d) at least one optional pozzolanic material from a plurality of respective sub-groups, and (e) a coarse aggregate. Upon selecting the materials, the MSAU 203 enables the blending unit 107 to mix the materials thus selected by fetching the materials from the MSUs (102-106).

[0041] In one implementation, the MSAU 203 may determine an availability of (a) the hydraulic material, (b) the fine aggregate, (c) the powder based additive and (d) the optional pozzolanic material thus selected prior to the mixing. To this end, the MSAU 203 may fetch an inventory 207 of the materials stored in the MSUs (102-106) from the memory 206. Based on said availability, the MSAU 203 enables the blending unit 107 to mix the materials. In one implementation, the inventory 207 may be updated instantaneously whenever material is removed from their respective MSU. In one implementation, the inventory 207 may be updated periodically. In one implementation, the MSAU 203 may receive data from one or more sensors coupled to each of the MSUs and update the inventory 207 based on the data. In one implementation, any other module/unit of the system 101 may receive data from one or more sensors coupled to each of the MSUs and update the inventory 207 based on the data. Such data may include information about of total amount/weight of material initially present in the MSU, amount of material removed from the MSU, and remaining amount of material present in the MSU. [0042] In an implementation, the MSAU 203 may provide a recommendation of the at least one dry mix construction material from the list 205 of the plurality of DMC designs based on the initial design parameters on the display unit 204. The receiving unit 202 then receives a user-input indicative of selection of the at least one DMC from the recommendation. Upon receiving user- input, the MSAU 203 selects the at least one DMC.

[0043] In an implementation, the MSAU 203 may provide a recommendation of at least one hydraulic material and amount of the at least one hydraulic material based on the at least one dry mix construction material thus selected. The receiving unit 202 then receives a user-input indicative of selection of the hydraulic material from the recommendation. Upon receiving user-input, the MSAU 203 selects the hydraulic material.

[0044] In an implementation, the MSAU 203 may provide a recommendation of at least one fine aggregate and amount of the at least one fine aggregate based on the at least one dry mix construction material thus selected. The receiving unit 202 then receives a user-input indicative of selection of the fine aggregate from the recommendation. Upon receiving user-input, the MSAU 203 selects the fine aggregate.

[0045] In an implementation, the MSAU 203 may provide a recommendation of at least one powder based additive and amount of the at least one powder based additive based on the at least one dry mix construction material thus selected. The receiving unit 202 then receives a user-input indicative of selection of the powder based additive from the recommendation. Upon receiving user-input, the MSAU 203 selects the powder based additive.

[0046] In an implementation, the MSAU 203 may provide a recommendation of at least one optional pozzolanic material and amount of the at least one optional pozzolanic material based on the at least one dry mix construction material thus selected. The receiving unit 202 then receives a user-input indicative of selection of the optional pozzolanic material from the recommendation. Upon receiving user-input, the MSAU 203 selects the optional pozzolanic material.

[0047] In an implementation, the MSAU 203 may provide a recommendation of coarse aggregate and amount of the coarse aggregate based on the at least one dry mix construction material thus selected. As described earlier, the coarse aggregate is a mixture of at least two types of coarse aggregates based on their normal maximum size and gradation.

As such, the recommendation indicates the composition of the coarse aggregates. [0048] Further, the system 101 includes a processor 208 that communicates with other elements within the system 101 via a system interface or bus 209. The processor 208 can be a central processing unit (CPU), a graphics-processing unit (GPU), or both. Further, the memory 206 may be read only memory (ROM), random access memory (RAM), and a combination of both. The memory 206 may store instructions necessary for functioning of the system 101 and executed by the processor 208.

[0049] In one implementation, the receiving unit 201, the DSU 202, and the

MSAU 203 may be available as a single construction mix module 210. In one implementation, the construction mix module 210 can be part of or internal to the processor 208. In one implementation, the construction mix module 210 can be part of or internal to the memory 206. In one implementation, the construction mix module 210 can be external to the processor 208, as illustrated in the figure. In one implementation, the construction mix module 210 can be external to the memory 206, as illustrated in the figure. In one implementation, the construction mix module 210 may be either a software module or a hardware module or a combination of both.

[0050] The system 101 may further include other input/output (I/O) unit 211 such as a keyboard or pointing device that is used in combination with a monitor. The system 101 may further include at least one storage device (not shown in the figure), such as a hard disk drive, a floppy disk drive, a CD ROM drive, or optical disk drive, for storing information on various computer-readable media, such as a hard disk, a removable magnetic disk, or a CD-ROM disk. As will be appreciated by one of ordinary skill in the art, each of these storage devices is connected to the bus 209 by an appropriate interface. The storage devices and their associated computer-readable media provide nonvolatile storage for the system 101. It is important to note that the computer-readable media described above could be replaced by any other type of computer-readable media known in the art. Such media include, for example, magnetic cassettes, flash memory cards, and digital video disks.

[0051] The system 101 may further include a network interface 212, for interfacing and communicating with other elements of the communication network. It will be appreciated by one of ordinary skill in the art that one or more of the system 101 components may be located geographically remotely from other system 101 components. Furthermore, one or more of the components may be combined, and additional components performing functions described herein may be included in the system 101. [0052] although specific units/modules have been illustrated in the figure and described above, it should be understood that the system 101 may include other hardware modules or software module or combinations as may be required for performing various functions. The construction mix module 210 and several other aspects and features of the system 101 according to the present invention are discussed in more detail below.

[0053] Figs. 3a-3f illustrates an example flowchart that generally illustrates a first example method 300 for manufacturing the DMC that is implemented by the system 101, according to the embodiment of the present invention. As indicated above, the construction mix module 210 controls the general operation of the system 101 as the system 101 accepts information from a user and enables manufacturing of the DMC based on that information.

[0054] As illustrated in Fig. 3a, at step 301, the system 101 receives one or more initial design parameters for manufacturing the DMC as a user-input. The user-input can be a touch-based input or an input received via the I/O unit 211. As indicated earlier, a user- interface is displayed on the display unit 204 to allow a user to enter the initial design parameters of the DMC such as: (1) an application of the DMC; (2) strength of the DMC; (3) workability requirements of the DMC; (4) a maximum water to cement ratio; (5) a required slump; (6) air entrainment value; (7) an indication of exposure of the DMC; (8) cohesiveness properties with substrate; (9) adhesion properties with substrate; (10) durability; (11) curing related properties; (12) permeability; (13) surface absorption; (14) density related properties; and (15) unit weight related properties.

[0055] The user-interface may include various data fields for entering the initial design parameters. In one example, the user-interface can be a web interface accessible over the communication network. In one example, the user-interface can be a client-based interface. In one example, the user-input is provided by a technician or a plant operator present at the plant. In one example, the user-input is provided by an individual or an end- user, who is not present at the plant, developing a DMC. In such example, the user-interface may accessed on a display unit of a device located remotely from the system 101 and is communicatively coupled with the system 101 over the communication network. In such example, the received user-input is transmitted from the device to the system 101.

[0056] At step 302, based on the initial design parameters, the system 101 selects at least one DMC from a plurality of DMC designs. To this end, the DSU 202 defines a desired cementitious property of the DMC based on values of the initial design parameters. The DSU 202 then fetches the list 205 of the plurality of the DMC designs from the memory 206. Based on the desired cementitious property thus defined and the list 205 of the plurality of the DMC designs, the DSU 202 selects at least one DMC.

[0057] Table 1 below illustrates an example of the list 205 of the plurality of the DMC designs pre-stored in the memory 206. The list 205 of the plurality of the DMC designs defines mapping of cementitious property of a DMC and its corresponding constituent materials, i.e., (a) the hydraulic material(s), (b) the fine aggregate(s), (c) the powder based additive(s), and (d) the optional pozzolanic material(s). Table 1

[0058] In the above table, column CP indicates cementitious property of a

DMC; and column DMCD (i.e., dry mix construction material design) indicates a name/indicator of a corresponding DMC which will provide the CP that pre-defined based on design parameters. As indicated earlier, the constituent materials are further sub-grouped into a plurality of sub-groups based on various grouping characteristics/parameters. The values in table are indicative of amount/weight percentage or mix ratio of the constituent material to be used in preparing the DMC. The values in the table are for the sake of understanding and illustration purposes only. Actual values may vary.

[0059] Thus, the hydraulic materials are grouped into three groups HMl,

HM2, and HM3 based on their (a) chemical properties, (b) physical properties, and (c) particle size distribution (PSD). Accordingly, columns HMl, HM2, and HM3 indicate the mix ratio of hydraulic materials that is required to be present in the corresponding DMCD. As would be understood, out of 100% as weight percentage of the DMC, weight percentage or mix ratio of the hydraulic materials will be in range of 0 to 100% and averaging in the range of 40% to 70%. Therefore, the value in the table indicates weight percentage in the same range.

[0060] Likewise, the fine aggregates are grouped into three groups as FA1,

FA2, and FA3 based on their PSD. Accordingly, columns FA1, FA2, and FA3 indicate the mix ratio of fine aggregates that is required to be present in the DMCD.

[0061] Likewise, the powder based additives are grouped into two groups

AD1 and AD2 based on their chemical properties. Accordingly, columns AD1 and AD2 indicate the mix ratio of powder based additives that are required to be present in the DMCD. As would be understood, the powder based additives are only added in trace amount. As such, out of 100% as weight percentage of the DMC, the weight percentage or mix ratio of the powder based additives will be in range of 1% to 5% of the weight percentage of the hydraulic material(s) and the optional pozzolanic material(s). Therefore, the value in the table indicates weight percentage in the same range.

[0062] Likewise, the pozzolanic materials are grouped into two groups PM1 and PM2 based on their (a) PSD, (b) mechanical properties, and (c) chemical properties. Accordingly, columns PM1 and PM2 indicate the mix ratio of pozzolonic materials that are optionally required to be present in the DMCD. As would be understood, out of 100% as weight percentage of the DMC, weight percentage or mix ratio of the pozzolonic materials will be in range of 10% to 90% and averaging in the range of 30% to 60%. Therefore, the value in the table indicates weight percentage on the same range.

[0063] In addition, the list 205 may include other parameters/characteristics of each of the constituent materials apart from mix ratio/ amount/weight. The parameters include, but not limited to, the above mentioned grouping characteristics, supplier, cost, specific gravity, replacement ratio, class, and, grade, and their value. As such, each of the sub-groups may include same type of materials from different suppliers, having different cost, specific gravity, replacement ratio, class, and grade. For example, the sub-group HM1 may further include hydraulic material HM1A from supplier A at cost $X, hydraulic material HM1B from supplier B at cost $XZ, and hydraulic material HM1C from supplier C at cost $Y. In another example, the sub-group PM1 may further include pozzolanic material PM1A from supplier Sa at cost $X3 having replacement ratio 5% of weight and pozzolanic material PM1B from supplier Sb at cost $ZX having replacement ratio 10% of weight. Each of these sub-groupings enables individual selection of constituent materials, thereby increasing the flexibility of manufacturing the DMC. [0064] As would be understood, such cementitious properties are pre-defined based on techniques and/or experiments as prevalent in the industry or as specified in various domestic and international standards. Consequently, the table 1 and the list 205 may be updated periodically. In addition, the same or substantially similar cementitious properties may be obtained by using different mix ratios of constituent materials of same type or of different types, as illustrated in Table 1 and briefly described below.

[0065] Cementitious properties Ά' & Ά may indicate DMC designs as

DMCl and DMC6, respectively, having high strength and high durability functions along with water-proof function. For sake of clarity, both Ά' & ΆΓ are highlighted in the table. However, DMCl and DMC2 have different compositions and/or mix ratios. DMCl is mix composition of 6 materials comprising of two types of hydraulic materials HM1 & HM3, two types of fine aggregates FA1 & FA2, one type of additive AD1, and one type of pozzolonic material PM1. DMC6 is mix composition of 5 materials comprising of two types of hydraulic materials HM1 & HM2, one type of fine aggregate FA2, one type of additive AD2, and one type of pozzolonic material PM2.

[0066] Cementitious property 'B' may indicate a DMC design DMC2 as having high strength and a high-fluidity function along with alkali silica reaction inhibition function. DMC2 is a mix composition of 5 materials comprising of one type of hydraulic material HM2, two types of fine aggregates FA1 & FA3, one type of additive AD2, and one type of pozzolonic material PM2.

[0067] Cementitious property 'C & 'CI ' may indicate DMC designs as

DMC3 and DMC7, respectively, having a high-fluidity function along with high strength and water-proof function. For sake of clarity, both 'C & 'CI ' are highlighted in the table. However, DMC3 and DMC7 have different compositions and/or mix ratios. DMC3 is mix composition of 9 materials comprising of three types of hydraulic materials HM1, HM2, & HM3, two types of fine aggregates FA2 & FA3, two types of additives AD1 and AD2, and two types of pozzolonic materials PM1 & PM2. DMC7 is mix composition of 6 materials comprising of two types of hydraulic materials HM1 & HM2, two types of fine aggregates FA1 & FA2, one type of additive AD2, and one type of pozzolonic material PM1.

[0068] Cementitious property 'D' may indicate a DMC design DMC4 as having a water-proof function and durability function. DMC4 is a mix composition of 6 materials comprising of one type of hydraulic material HM3, one type of fine aggregate FA1, two types of additive AD1 & AD2, and two types of pozzolonic materials PM1 & PM2. [0069] Cementitious property Έ' may indicate a DMC design DMC5 having durability, waterproof, high- strength, and high-fluidity functions. DMC2 is a mix composition of 7 materials comprising of two types of hydraulic materials HM1 & HM2, two types of fine aggregates FA2 & FA3, one type of additive AD1, and two types of pozzolonic materials PM1 & PM2.

[0070] Thus using the Table 1 as reference, in one example, the DSU 202 may define cementitious properties as 'A' and Ά , and accordingly select both the DMC designs as DMC1 and DMC6. In another example, the DSU 202 may define cementitious properties as Έ', and accordingly select the DMC design as DMC5.

[0071] In one implementation, upon selecting, the DSU 202 may provide a recommendation of the at least one dry mix construction material thus selected based on the initial design parameters on the display unit 204 at step 303. The recommendation may be provided using a user-interface, which displays the defined cementitious property, the selected DMC design, and the initial design parameters. The user-interface may display the data in editable format.

[0072] At step 304, the receiving unit 201 receives user- input indicative of either selection of the at least one dry mix construction material or any changes in the initial design parameters. At step 305, if the DSU 202 determines the user-input is indicative of changes in the initial design parameters, the process flows back to step 302. If the DSU 202 determines the user-input is indicative of selection of the at least one dry mix construction material from the recommendation, the process flows to next step 306 as indicated in Fig. 3b, represented by A.

[0073] In one implementation, the DSU 202 may not provide the recommendation at step 303. In such implementation, the process directly flows from step 302 to 306.

[0074] As illustrated in Fig. 3b, at step 306, the MSAU 203 selects at least one hydraulic material from the plurality of sub-groups of hydraulic materials. Accordingly, the MSAU 203 may fetch the list 205 of the plurality of the DMC designs from the memory 206 and select the hydraulic material(s) corresponding to the selected at least one DMC. Thus, continuing from above examples with reference to Table 1, in one example, the MSAU 203 selects hydraulic materials HM1 & HM3 for DMC1 and HM1 & HM2 for DMC6. In another example, the MSAU 203 selects hydraulic materials HM1 & HM2 for DMC5. [0075] In one implementation, upon selecting, the MSAU 203 may provide a recommendation of the at least one hydraulic material thus selected and amount/weight of the least one hydraulic material as required to be mixed in the DMC on the display unit 204 at step 307. The MSAU 203 provides the recommendation of the amount from the list 205, as indicated in Table 1. In addition, the recommendation may include supplier, cost, specific gravity, replacement ratio, class, and, grade, and their value, as present in the list 205. The recommendation may be provided using a user-interface, which displays aforementioned information in editable format.

[0076] At step 308, the receiving unit 201 receives user-input indicative of either selection of the at least one hydraulic material or any changes in the displayed information. At step 309, if the MSAU 203 determines the user-input is indicative of changes in the displayed information such as change in supplier, cost, amount, the process flows back to step 305. If the MSAU 203 determines the user- input is indicative of selection of the at least one hydraulic material from the recommendation, the process flows to next step 310 as indicated in Fig. 3c, represented by B.

[0077] In one implementation, the MSAU 203 may not provide the recommendation at step 307. In such implementation, the process directly flows from step 306 to 310.

[0078] As illustrated in Fig. 3c, at step 310, the MSAU 203 selects at least one fine aggregate from the plurality of sub-groups of fine aggregates. Accordingly, the MSAU 203 may fetch the list 205 of the plurality of the DMC designs from the memory 206 and select the fine aggregate(s) corresponding to the selected at least one DMC. Thus, continuing from above examples with reference to Table 1, in one example, the MSAU 203 selects fine aggregates FA1 & FA2 for DMC1 and FA2 for DMC6. In another example, the MSAU 203 selects fine aggregates FA2 & FA3 for DMC5.

[0079] In one implementation, upon selecting, the MSAU 203 may provide a recommendation of the at least one fine aggregate thus selected and amount/weight of the least one fine aggregate as required to be mixed in the DMC on the display unit 204 at step 311. The MSAU 203 provides the recommendation of the amount and other information from the list 205, as indicated in Table 1, as described at step 306. The recommendation may be provided using a user-interface, which displays aforementioned information in editable format. [0080] At step 312, the receiving unit 201 receives user- input indicative of either selection of the at least one fine aggregate or any changes in the displayed information. At step 313, the MSAU 203 determines the user-input is indicative of changes in the displayed information (as indicated at step 309), the process flows back to step 310. If the MSAU 203 determines the user-input is indicative of selection of the at least one fine aggregate from the recommendation, the process flows to next step 314 as indicated in Fig. 3d, represented by C.

[0081] In one implementation, the MSAU 203 may not provide the recommendation at step 311. In such implementation, the process directly flows from step 310 to 314.

[0082] As illustrated in Fig. 3d, at step 314, the MSAU 203 selects at least one powder based additive from the plurality of sub-groups of powder based additives. Accordingly, the MSAU 203 may fetch the list 205 of the plurality of the DMC designs from the memory 206 and select the powder based additive(s) corresponding to the selected at least one DMC. Thus, continuing from above examples with reference to Table 1, in one example, the MSAU 203 selects powder based additive AD1 for DMC1 and DMC6. In another example, the MSAU 203 selects powder based additive AD1 for DMC5.

[0083] In one implementation, upon selecting, the MSAU 203 may provide a recommendation of the at least one powder based additive thus selected and amount/weight of the least one powder based additive as required to be mixed in the DMC on the display unit 204 at step 315. The MSAU 203 provides the recommendation of the amount and other information from the list 205, as indicated in Table 1, as described at step 306. The recommendation may be provided using a user-interface, which displays aforementioned information in editable format.

[0084] At step 316, the receiving unit 201 receives user- input indicative of either selection of the at least one powder based additive or any changes in the displayed information. At step 317, if the MSAU 203 determines the user-input is indicative of changes in the displayed information (as indicated at step 309), the process flows back to step 313. If the MSAU 203 determines the user-input is indicative of selection of the at least one fine aggregate from the recommendation, the process flows to next step 318.

[0085] It would be understood that addition of pozzolonic material is optional based on the cementitious property. Thus, if the MSAU 203 determines pozzolonic material is required to be added to the DMC at step 318, the process flows to step 319 as indicated in in Fig. 3e, represented by D. If the MSAU 203 determines pozzolonic material is not required to be added to the DMC at step 318, the process flows to step 323 as indicated in Fig. 3f, represented by E. In one implementation, the MSAU 203 may not provide the recommendation at step 315. In such implementation, the process directly flows from step 314 to either step 319 or step 323.

[0086] As illustrated in Fig. 3e, at step 319, the MSAU 203 selects at least one pozzolonic material from the plurality of sub-groups of pozzolonic materials. Accordingly, the MSAU 203 may fetch the list 205 of the plurality of the DMC designs from the memory 206 and select the pozzolonic material(s) corresponding to the selected at least one DMC. Thus, continuing from above example with reference to Table 1, in one example, the MSAU 203 selects pozzolonic materials PMl for DMCl and PM2 for DMC6. In another example, the the MSAU 203 selects pozzolonic materials PMl & PM2 for DMC5.

[0087] In one implementation, upon selecting, the MSAU 203 may provide a recommendation of the at least one pozzolonic material thus selected and amount/weight of the least one pozzolonic material as required to be mixed in the DMC on the display unit 204 at step 320. The MSAU 203 provides the recommendation of the amount and other information from the list 205, as indicated in Table 1, as described at step 306. The recommendation may be provided using a user-interface, which displays aforementioned information in editable format.

[0088] At step 321, the receiving unit 201 receives user-input indicative of either selection of the at least one pozzolonic material or any changes in the displayed information. At step 322, if the MSAU 203 determines the user-input is indicative of changes in the displayed information (as indicated at step 307), the process flows back to step 319. If the MSAU 203 determines the user-input is indicative of selection of the at least one pozzolonic material from the recommendation, the process flows to next step 323 as indicated in Fig. 3f, represented by E.

[0089] As illustrated in Fig. 3f, at step 323, the MSAU 203 selects the coarse aggregate as a mixture of at two types of coarse aggregates based on the selected at least one DMC. As indicated earlier, the coarse aggregate is a mixture of at least two types of coarse aggregate based on their normal maximum size and gradation such that the mixture fulfills the desired cementitious property of the selected DMC.

[0090] In one implementation, upon selecting, the MSAU 203 may provide a recommendation of the composition of the coarse aggregates and the amount on the display unit 204 at step 324. The recommendation may be provided using a user-interface, which displays aforementioned information in editable format.

[0091] At step 325, the receiving unit 201 receives user-input indicative of either selection of the coarse aggregate or any changes in the displayed information. At step 326, the MSAU 203 determines the user-input is indicative of changes in the displayed information (as indicated at step 309), the process flows back to step 323. If the MSAU 203 determines the user-input is indicative of selection of the coarse aggregate from the recommendation, the process flows to next step 327.

[0092] At step 327, the MSAU determines an availability of (a) the at least one hydraulic material selected at step 306, (b) the at least one fine aggregate selected at step 310, (c) the at least one powder based additive selected at step 314 and (d) the optional at least one pozzolanic material selected at step 319; and (e) the coarse aggregate. The MSAU 203 accordingly fetches the inventory 207 stored in the memory 206 to determine the availability.

[0093] If the MSAU 203 determines the availability is not in accordance with the required amount/weight of the constituent materials as selected at respective steps, the process flows to the respective steps for re-selection of materials. If the MSAU 203 determines the availability in accordance with the required amount/weight of the constituent materials as selected at respective steps, the process flows to next step 329.

[0094] At step 329, the MSAU 203 enables transportations of materials from the respective MSUs and directs the blending unit 107 to mix the constituent materials to form the DMC. The DMC is then transmitted to the silo 108 for dispatch or storage.

[0095] In one implementation, the DSU 202 and the MSAU 203 may not provide any recommendation at respective steps, as indicated earlier. In such implementation, the system 101 implements a second example method 400 as illustrated in Fig. 4 according to the embodiment of the present invention. As illustrated in Fig. 4, at step 401, the system 101 receives one or more initial design parameters for manufacturing the DMC as a user-input, as described at step 301. At step 402, based on the initial design parameters, the system 101 selects at least one DMC from the plurality of DMC designs in a manner as described at step 302.

[0096] At step 403, the MSAU 203 selects (a) at least one hydraulic material,

(b) at least one fine aggregate, (c) a coarse aggregate, (d) at least one powder based additive, and (e) an optional pozzolanic material. As such, the MSAU 203 selects the at least one hydraulic material from the plurality of sub-groups of hydraulic materials in a manner as described at step 306. The MSAU 203 then selects the at least one fine aggregate from the plurality of sub-groups of fine aggregates in a manner as described at step 310. The MSAU 203 then selects the at least one powder based additive from the plurality of sub-groups of powder based additives in a manner as described at step 314. As described earlier, the MSAU 203 then selects the at least one pozzolonic material based on requirement from the plurality of sub-groups of pozzolonic materials, as described at step 319. The MSAU 203 then finally selects the coarse aggregators, as described at step 323.

[0097] At step 404, the MSAU 203 directs the blending unit 107 to mix the selected constituent materials, as described at step 329. In one implementation, prior to mixing at step 404, the DSU 202 and the MSAU 203 may display the selection(s) of DMC and constituent materials on the display unit 204. This enables the user to verify the selections and make any modifications, if and as required.

[0098] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

Claims

A method for manufacturing a dry mix construction material, said method comprising: - receiving user-input indicative of initial design parameters for manufacturing the dry mix construction material; - selecting at least one dry mix construction material from a plurality of dry mix construction material designs based on the initial design parameters; - based on the at least one dry mix construction material thus selected, selecting (a) at least one hydraulic material, (b) at least one fine aggregate, (c) a coarse aggregate, (d) at least one powder based additive, and (e) at least one optional pozzolanic material, the selection further comprising: o selecting the at least one hydraulic material from a plurality of subgroups of hydraulic materials; o selecting the at least one fine aggregate from a plurality of sub-groups of fine aggregates; o selecting the at least one powder based additive from a plurality of sub-groups of powder based additives and o selecting the at least one optional pozzolanic material from a plurality of sub-groups of pozzolanic material; and - mixing (a) the hydraulic material, (b) the fine aggregate, (c) the coarse aggregate, (d) the powder based additive, and (e) the optional pozzolanic material thus selected to obtain the at least one dry mix construction material. The method as claimed in claim 1, wherein the initial design parameters comprises one or more of: a. an application of the dry mix construction material; b. strength of the dry mix construction material; c. workability requirements of the dry mix construction material; d. a maximum water to cement ratio; e. a required slump; f. air entrainment value; g. an indication of exposure of the dry mix construction material; h. cohesiveness properties with substrate; i. adhesion properties with substrate; j. durability; k. curing related properties;

1. permeability;

m. surface absorption;

n. density related properties; and

o. unit weight related properties.

The method as claimed in claim 2, wherein a desired cementitious property of the dry mix construction material is defined based on values of the initial design parameters.

The method as claimed in claim 1, wherein the plurality of sub-groups of hydraulic materials are grouped based on (a) chemical properties of hydraulic materials, (b) physical properties of hydraulic materials, and (c) particle size distribution (PSD) of hydraulic materials.

The method as claimed in claim 4, wherein the hydraulic materials include ordinary cement, Portland cement, limestone fines, and silica fume.

The method as claimed in claim 1, wherein the plurality of sub-groups of fine aggregates is grouped based on particle size distribution (PSD).

The method as claimed in claim 1, wherein the plurality of sub-groups of powder based additives is grouped based on chemical properties of the powder based additives.

The method as claimed in claim 1, wherein the plurality of sub-groups of pozzolanic materials are grouped based on (a) particle size distribution (PSD) of the pozzolanic material, (b) mechanical properties of the pozzolanic material, and (c) chemical properties of the pozzolanic material.

The method as claimed in claim 8, wherein the pozzolanic materials includes fly ash, ground granulated blastfurnace slag (GGBS), volcanic ash, finely ground quartz, mechanically modified fly ash, mechanically modified pond ash, chemically modified fly ash, and chemically modified pond ash.

The method as claimed in claim 1, further comprises:

- determining an availability of (a) the at least one hydraulic material, (b) the at least one fine aggregate, (c) the at least one powder based additive and (d) the at least one optional pozzolanic material thus selected, and (e) the coarse aggregate for the at least one dry mix construction material; and

- mixing the (a) the at least one hydraulic material, (b) the at least one fine aggregate, (c) the coarse aggregate, (d) the at least one powder based additive and (e) the at least one optional pozzolanic material based on said availability.

The method as claimed in claim 1, further comprises:

- providing a recommendation of the at least one dry mix construction material based on the initial design parameters on a display unit; and

- receiving user-input indicative of selection of the at least one dry mix construction material.

The method as claimed in claim 1, further comprises:

- providing a recommendation of at least one hydraulic material and at least amount of the at least one hydraulic material based on the at least one selected dry mix construction material on a display unit; and

- receiving user-input indicative of selection of the hydraulic material.

The method as claimed in claim 1, further comprises:

- providing a recommendation of at least one fine aggregate and at least amount of the at least one fine aggregate based on the at least one selected dry mix construction material on a display unit; and

- receiving user-input indicative of selection of the hydraulic material.

The method as claimed in claim 1, further comprises: - providing a recommendation of at least one powder based additive and at least amount of the at least one powder based additive based on the at least one selected dry mix construction material on a display unit; and

- receiving user-input indicative of selection of the powder based additive.

The method as claimed in claim 1, further comprises:

- providing a recommendation of at least one optional pozzolanic material and at least amount of the at least one optional pozzolanic material based on the at least one selected dry mix construction material on a display unit; and

- receiving user-input indicative of selection of the optional pozzolanic material.

The method as claimed in claim 1, further comprises:

- providing a recommendation of coarse aggregate and amount of the least coarse aggregate based on the at least one selected dry mix construction material on a display unit; and

- receiving user-input indicative of selection of the coarse aggregate.

A system for implementing a method of manufacturing a dry mix construction material, said system comprising:

- a receiving unit to receive user-input indicative of initial design parameters for manufacturing the dry mix construction material;

- a design selection unit to select at least one dry mix construction material from a plurality of dry mix construction material designs based on the initial design parameters; and

- a material selection and analysis unit to:

o select (a) at least one hydraulic material, (b) at least one fine aggregate, (c) a coarse aggregate, (d) at least one powder based additive, and (e) at least one optional pozzolanic material based on the at least one dry mix construction material thus selected, the selection further comprising:

^■ selecting the at least one hydraulic material from a plurality of sub-groups of hydraulic materials; ^■ selecting the at least one fine aggregate from a plurality of subgroups of fine aggregates;

^■ selecting the at least one powder based additive from a plurality of sub-groups of powder based additives and

^■ selecting the at least one optional pozzolanic material from a plurality of sub-groups of pozzolanic material; and

enable mixing of (a) the hydraulic material, (b) the fine aggregate, (c) the coarse aggregate, (d) the powder based additive, and (e) the optional pozzolanic material thus selected in a blending unit to obtain the at least one dry mix construction material.