Claims:WE CLAIM:

1. A process for preparing a dry concrete mix for use in construction of concrete walls, said process comprising:
(b) receiving, by a user input receiving module, user inputs pertaining to: a grade of concrete to be prepared, a Water : Binder (W/B) ratio, an Aggregate : Binder (A/B) ratio, and a type of application;
(c) selecting, by a material selection module, a set of dry concrete mixes based on the received user inputs, the set of dry concrete mixes differing from each other in terms of at least one of: a compressive and flexural strength as developed after a predetermined amount of time period, a workability parameter, a cohesiveness factor; a pumpability factor, a durability parameter, and a cost associated parameter;
(d) receiving, by the user input receiving module, user input pertaining at least one technical parameter of the concrete wall, the technical parameter being at least one of: lateral stability failure criteria, thermal resistance properties, acoustic insulation properties, and earthquake resistance properties;
(e) determining, by a structural optimization module, a optimum structural design configuration of concrete wall meeting the at least one technical parameter and at the same time which is commercially most feasible;
(f) selecting, by the structural optimization module, an optimum compressive and flexural strength of concrete meeting the optimum structural design configuration of the concrete wall as determined;
(g) selecting, by the material selection module, a dry concrete mix from the set of dry concrete mixes thus selected in step (b) based on the at least on the optimum compressive and flexural strength of concrete; and
(h) transmitting, by a transmitting module to a mixing unit, information pertaining to the dry concrete mix thus selected in step (f) thereby causing the mixing unit to prepare the dry concrete mix, the information pertaining to the dry concrete mix including:
a. information as to quantity of a binder content,
b. information as to quantity of a fine aggregate content,
c. information as to quantity of a coarse aggregate content,
d. the information as to quantity of the binder content including: information as to quantity of a pozzoloan content and information as to quantity of a cement content;
e. the information as to quantity of the pozzoloan content including: information as to quantity of a first pozzoloan fraction of a first size, information as to quantity a second pozzoloan fraction of a second size, and information as to quantity a third pozzoloan fraction of a third size; and
f. the information as to quantity of the cement content including: information as to quantity of a first cement fraction of a first size, information as to quantity a second cement fraction of a second size, and information as to quantity a third cement fraction of a third size.

2. The process as claimed in claim 1, wherein causing the mixing unit to prepare the dry concrete mix comprises receiving by the mixing unit the information pertaining to the dry concrete mix as transmitted by the transmitting module.

3. The process as claimed in claim 2, wherein causing the mixing unit to prepare the dry concrete mix comprises:
a. weighing the binder content as per information as to quantity of the binder content;
b. weighing the fine aggregate content as per information as to quantity of the fine aggregate content;
c. weighing the coarse aggregate content as per information as to quantity of the coarse aggregate content;
d. mixing the weighed quantities of binder content, fine aggregate content, and coarse aggregate content to obtain the dry concrete mix.

4. The process as claimed in claim 3, wherein weighing the binder content comprises:
a. weighing pozzoloan content as per information as to quantity of the pozzoloan content; and
b. weighing cement content as per information as to quantity of the cement content.

5. The process as claimed in claim 3, wherein weighing the pozzoloan content comprises:
a. weighing first pozzoloan fraction as per information as to quantity of the first pozzoloan fraction of the first size;
b. weighing second pozzoloan fraction as per information as to quantity of the second pozzoloan fraction of the second size; and
c. weighing third pozzoloan fraction as per information as to quantity of the third pozzoloan fraction of the third size.

6. The process as claimed in claim 3, wherein weighing the cement content comprises:
a. weighing first cement fraction as per information as to quantity of the first cement fraction of the first size;
b. weighing second cement fraction as per information as to quantity of the second cement fraction of the second size; and
c. weighing third cement fraction as per information as to quantity of the third cement fraction of the third size.

7. The process as claimed in claim 1, the information pertaining to the dry concrete mix optionally including information as to quantity of at least one additive.

8. The process as claimed in claim 7, wherein causing the mixing unit to prepare the dry concrete mix comprises:
a. weighing at least one additive as per information as to quantity of the at least one additive; and
b. mixing the weighed quantity of the at least one additive with the binder content, the fine aggregate content, and the coarse aggregate content to obtain the dry concrete mix.

9. A dry concrete mix for use in construction of concrete walls, said dry concrete mix comprising:
(c) a binder content; and
(d) an aggregate content;
wherein:
• a weight ratio of aggregate to binder being in the range of 9 to 11 : 1 to 3;
• the aggregate content including a fine aggregate content and a coarse aggregate content, a weight ratio of the fine aggregate content to coarse aggregate content being in the range of 40 to 70 : 30 to 60;
• the binder content including a pozzoloan content and a cement content, the pozzoloan content being in a weight percentage of 50 to 90 % of the binder content and the remaining being constituted by the cement content;
• the pozzoloan content including 40 to 70 wt% of a first pozzoloan fraction of a first size, 20 to 40 wt% of a second pozzoloan fraction of a second size, and 5 to 15 wt% of a third pozzoloan fraction of a third size;
• the cement content including 40 to 70 wt% of a first cement fraction of a first size, 20 to 40 wt% of a second cement fraction of a second size, and 5 to 15 wt% of a third cement fraction of a third size.

10. The dry concrete mix as claimed in claim 9, further comprising of at least 1 additive in the range of 0.25 kgs to 4 kgs per cubic meter of the dry mix concrete.

11. The dry concrete mix as claimed in claim 10, wherein the at least one additive comprises fibres having a length in the range of 10 to 30 mm and diameter in the range of 1 to 3 mm.

12. The dry concrete mix as claimed in claim 11, wherein the fibres are made of a polymeric material selected from a group comprising polyethylene, polypropylene, a polyester, and a mixture of the same.

13. The dry concrete mix as claimed in claim 11, wherein the fibres are hollow fibres having a tensile strength in the range of 300 N/mm2 to 2000 N/mm2.

14. The dry concrete mix as claimed in claim 13, wherein the hollow fibres are filled with air.

15. The dry concrete mix as claimed in claim 13, wherein the hollow fibres are filled with a low viscosity non-reactive liquid.

16. A system for making concrete walls, said system comprising:
a mixing unit adapted to mix a binder and water to obtain a slurry, the mixing unit being further adapted to mix an aggregate component with the slurry to obtain a concrete component;
a transporting unit adapted to transport the concrete component;
a concrete component discharging unit adapted to receive the concrete component from the transporting unit and discharge the same within a form-work;
a motion imparting means adapted to receive the concrete component discharging unit and impart motion to the concrete component discharging unit;
an acoustic transmitter being adapted to transmit acoustic waves in a direction of discharge of the concrete component;
an acoustic receiver adapted to receive reflected acoustic waves and produce output signal corresponding to the reflected acoustic waves thus received; and
a processing and controlling unit adapted to receive the output signal thus produced by the acoustic receiver, the processing and controlling unit adapted to determine a concrete wall quality parameter, the processing and controlling unit being further adapted to control operation of at least one of the mixing unit, the transporting unit, and the motion imparting means based on the concrete wall quality parameter thus determined.

17. The system for making concrete walls as claimed in claim 16, wherein the mixing unit comprises at least one of: a high speed mixer comprising a speed control unit and a narrow discharge mouth or a mixer with an adapted spout.

18. The system for making concrete walls as claimed in claim 16, wherein the transporting unit comprises at least one of: boom pump, line pump, and a tower crane-bucket system.

19. The system for making concrete walls as claimed in claim 16, wherein the concrete component discharging unit comprises at least one of: a boom pump, a pump having a nozzle size in the range of 20 to 100 mm, and a 3-D printing technique for pouring concrete.

20. The system for making concrete walls as claimed in claim 16, wherein the acoustic transmitter is mounted on the concrete component discharging unit.

21. The system for making concrete walls as claimed in claim 16, wherein the acoustic transmitter is mounted on the motion imparting means.

22. The system for making concrete walls as claimed in claim 16, wherein the acoustic transmitter is further adapted to transmit acoustic waves in a direction other than a direction of discharge of the concrete component.

23. The system for making concrete walls as claimed in claim 16, wherein the acoustic receiver is mounted on the concrete component discharging unit.

24. The system for making concrete walls as claimed in claim 16, wherein the acoustic receiver is mounted on the motion imparting means.

25. The system for making concrete walls as claimed in claim 16, wherein the concrete wall quality parameter includes at least one of: an estimate of a density of the wall, an estimate of a compressive and flexural strength that may be developed after a predetermined amount of time period, an estimate of optimal design thickness of the wall based on the above criteria, an estimate of a level of resistance faced by the concrete while flowing through the form work, a consistency index of the concrete component, presence of blow holes on the surface of the concrete wall, and presence of voids within the concrete wall, and a height of fall of the concrete.

26. The system for making concrete walls as claimed in claim 16, wherein the processing and controlling unit is adapted to increase or decrease a time period of mixing by the mixing unit.

27. The system for making concrete walls as claimed in claim 16, wherein the processing and controlling unit is adapted to increase or decrease a rate of transport of the concrete component by the transporting unit.

28. The system for making concrete walls as claimed in claim 16, wherein the processing and controlling unit is adapted to control a relative position of the concrete component discharging unit with respect to the form work by controlling the motion imparting means.
Dated this 20th day of March, 2019
Rajeshwari H
IN/PA-358
Agent for the Applicant
, Description:

FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

DRY CONCRETE MIXTURE FOR CONSTRUCTING CONCRETE WALLS, A PROCESS AND SYSTEM FOR PREPARING THE SAME AND A SYSTEM FOR CONSTRUCTING CONCRETE WALLS

Saroj Vanijya Private Limited, an Indian Company of 7th floor, 3A Ecospace, Plot No. 2F/11, New Town, Rajarhat, West Bengal 700156, Kolkata, India

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF THE INVENTION:
The present invention relates to a dry concrete mixture for use in construction of concrete walls and a process and a system for preparing said dry concrete mix. The invention further relates to a system for making concrete walls.

BACKGROUND OF THE INVENTION:
Walls are integral part of structures, whether they be residential, industrial or any other type. They are often visualized as separators between different parts of a used area.

Buildings usually have a basic RCC frame, consisting of columns, beams, shear walls, slabs etc. After the frame is built (or partially built), masonry wall construction commences, and thereafter, plastering commences, with the finishing works coming at the last. A structure known as formwork is used to build concrete frames having specific slab cycles, which is dependent on the expanse area of the project, the type of concrete used, and infrastructure management and its related planning cycles.

Lot of improvements have happened over time in terms “formworks” and its related RCC designs. Because of the improvements, it is now possible to have custom designed formworks, which can jump from floor to floor with typical floor plans, which can reduce the total project time, manpower and its related cost drastically. If the concrete and RCC are designed properly, the cost reduction can be much more evident in terms of materials and infrastructure adopted also, hence reducing the total project cost to even greater extents.

Mivan shuttering is one such example, which has specially designed 4 mm thick aluminium formwork custom designed for projects, and which follow typical floor plans through the height of the structure.

Buildings having RCC frame and masonry walls provide flexibility in terms of changing floor plan. In buildings having masonry walls, the floor plan can be changed whenever required, before or after the construction of the masonry walls, as it is easy to shift the wall locations by demolishing masonry walls. Also, placement of connections, conduits etc. are easy in 6”, 8” thick masonry walls. The conduits can be placed even after the construction of the masonry walls.

However, buildings having concrete walls (in addition to the basic RCC frame) are a subject of increasing interest. In such buildings, masonry walls are being replaced (either partially or fully) by concrete walls.

Some of the general disadvantages of masonry walls over concrete walls include:
Masonry Walls Concrete Walls
The thermal coefficient of expansion between masonry wall and concrete beam or column are different, hence there are chances of development of cracks due to thermal variations. Since walls and beams/columns are of same material, the development of cracks may hardly occur, due to thermal effects.
Plastering is definitely required before painting, hence this increase both cost as well as time as well as an anaesthetic look. Uniformity of paint is at stake, and absorption of paint by the surfaces is higher, requiring more coats of putty and paint combination. Plastering may be avoided when walls are cast with perfectly finished concrete. Painting requires minimum putty, and uniformity of paint is better, and chances of absorption of paint is mitigated.
They are usually manually constructed to plumb and line, and there are all chances of the plumb and line going out of place, resulting in more consumption of plaster/putty/paint to bring it back to plumb. Going out of plumb and line also increases the risk of development of structural cracks in the masonry due to non-uniformly distributed loads. The formwork accurately ensures the plumb and line, hence reducing the risk of more consumption of putty/paint, plastering is completely avoided though, due to smooth finish of the concrete. The load bearing walls are perfectly aligned to line and plumb, hence no chances of development of cracks.
Masonry walls are generally constructed by stalking bricks or blocks in a pattern, and usage of masonry mortar to join the block to one another, and caulking a mortar mix at the junction between walls and horizontal members. This creates a chance of mortar shrinking in some areas, and this resulting in crack formation in the plasters, which subsequently reflects on the painted surfaces. It is to be noted that such a phenomenon has a tendency to repeat, even after rectification. Due to monolithic construction of walls and slabs, there is no possibility of appearance of such cracks at all, keeping the durability of the painted surface intact.
Since masonry walls are cast after the frame is constructed, with a huge time gap, and also that plastering has to be done on such walls which further delays the time for finishing to commence, the total time in which a project is completed, to handing over is substantially high. Also, the specialized labour component involved in construction of masonry, plasters etc. accounts for much higher cost inculcation. Hence, the time component as well as the labour component combined together, the cost is very high. Repair and rehabilitation cost may be added as an extra component adding up to the total project cost. Since the slab cycle is greatly reduced, and also due to the facts that time for masonry construction and plastering/curing etc. are eliminated, the project time considerably reduces, sometimes to extent of 50% and above. Also, the specialized labour component involved in masonry construction and plastering are eliminated. Hence, the time component as well as the labour component combined together, the project cost is substantially eliminated. Repair and rehabilitation cost are almost completely eliminated.
Due to discontinuities in material properties, such as joints etc, the thermal and acoustic insulation properties are poor. A homogeneously casted thin concrete wall of considerable density, has proven abilities of increased acoustic and thermal insulation properties than any masonry wall.
Has high permeability to external water, and higher absorption properties, leading to lesser durability. Very less or negligible surface absorption properties, hence ensuring the durability of the painted structure.
When prone to earthquakes, or lateral loads, the masonry wall is more subject to failure along mortar joints or collapse, which results in huge loss of life and property. Specially designed RCC walls, in terms of structural requirements and special materials adopted, are able to impart.

Thus, we see here that the advantages of concrete walls over masonry walls are dominating enough to consider concrete walls as a potential replacement to masonry walls.

While constructing buildings with concrete walls, the following scenario is most often encountered. The casting of concrete walls and the frame structures is by a uniform grade of concrete, all poured in a single pour per floor. In these type of buildings, the concrete walls can be of a standard thickness (which may be in the range of 100-200 mm), and are typically load bearing walls. Sometimes, a basic difference in the thickness is maintained between the columns/beams and concrete walls. Sometimes, additional factors may be taken into consideration for sizing of the portions of the building and one of the additional factor which is taken into consideration includes whether or not the building is being constructed near sea shores. No special attention is paid to the nature of the concrete which will be used for construction of the building, except for simply specifying that a concrete having certain compressive strength is to be used.

Because of the above approach, neither is the building design optimum nor is the selection of concrete for construction of the various parts of the building optimum.

Thus, a need has been felt to provide system and method approach for combined approach consisting of structural optimization module as well as material optimization module to achieve the best fitting desired properties for particular concrete wall application.

SUMMARY OF THE INVENTION:
This summary is provided to introduce a selection of concepts in a simplified format that is further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

Broadly speaking, the present invention adopts a method of preparing a dry concrete mix for use in construction of concrete walls. The present invention provides a method of preparing a dry concrete mix based on implementation of a combined optimization model involving structural optimization and material science optimization such that the dry concrete mix can be used for construction of concrete walls having enhanced properties such as increased lateral stability, increased acoustic insulation properties, increased thermal resistance properties, increased earthquake resistant properties, etc.

In an aspect of the invention there is provided a process for preparing and packaging of dry mix construction material, said process comprising the steps of receiving, by a user input receiving module, user inputs pertaining to: a grade of concrete to be prepared, a Water : Binder (W/B) ratio, an Aggregate : Binder (A/B) ratio, and a type of application. The method further comprises selecting, by a material selection module, a set of dry concrete mixes based on the received user inputs, the set of dry concrete mixes differing from each other in terms of at least one of: a compressive and flexural strength as developed after a predetermined amount of time period, a workability parameter, a cohesiveness factor; a pumpability factor, a durability parameter, and a cost associated parameter.

The method further comprises receiving, by the user input receiving module, user input pertaining at least one technical parameter of the concrete wall, the technical parameter being at least one of: lateral stability failure criteria, thermal resistance properties, acoustic insulation properties, and earthquake resistance properties. The method further comprises determining, by a structural optimization module, an optimum structural design configuration of concrete wall meeting the at least one technical parameter and at the same time which is commercially most feasible.

The method further comprises selecting, by the structural optimization module, an optimum compressive and flexural strength of concrete meeting the optimum structural design configuration of the concrete wall as determined. The method further comprises selecting, by the material selection module, a dry concrete mix from the set of dry concrete mixes thus selected based on the at least on the optimum compressive and flexural strength of concrete. The method further comprises transmitting, by a transmitting module to a mixing unit, information pertaining to the dry concrete mix thus selected thereby causing the mixing unit to prepare the dry concrete mix.

The invention furthermore provides a system for preparing the dry concrete mix for use in construction of concrete walls. The system in particular comprises a user input receiving module, adapted to receive user inputs pertaining to: a grade of concrete to be prepared, a Water : Binder (W/B) ratio, an Aggregate : Binder (A/B) ratio, and a type of application. The system further comprises a material selection module adapted to select a set of dry concrete mixes based on the received user inputs, the set of dry concrete mixes differing from each other in terms of at least one of: a compressive and flexural strength as developed after a predetermined amount of time period, a workability parameter, a cohesiveness factor; a pumpability factor, a durability parameter, and a cost associated parameter.

The user input receiving module system is further adapted to receive, user input pertaining at least one technical parameter of the concrete wall, the technical parameter being at least one of: lateral stability failure criteria, thermal resistance properties, acoustic insulation properties, and earthquake resistance properties. The system further comprises a structural optimization module adapted to determine, an optimum structural design configuration of concrete wall meeting the at least one technical parameter and at the same time which is commercially most feasible.

The structural optimization module is further adapted to select, an optimum compressive and flexural strength of concrete meeting the optimum structural design configuration of the concrete wall as determined. The material selection module is further adapted to select, a dry concrete mix from the set of dry concrete mixes thus selected based on the at least on the optimum compressive and flexural strength of concrete. The system further comprises a transmitting module adapted to transmit to a mixing unit, information pertaining to the dry concrete mix thus selected thereby causing the mixing unit to prepare the dry concrete mix.

In an embodiment of the invention, the dry concrete mix for use in construction of concrete walls comprises: a binder content; and an aggregate content. In an embodiment of the invention, a weight ratio of aggregate to binder being in the range of 9 to 11 : 1 to 3. In a further embodiment of the invention, the aggregate content including a fine aggregate content and a coarse aggregate content, a weight ratio of the fine aggregate content to coarse aggregate content being in the range of 40 to 70 : 30 to 60.

In a further embodiment of the invention, the binder content including a pozzoloan content and a cement content, the pozzoloan content being in a weight percentage of 50 to 90 % of the binder content and the remaining being constituted by the cement content. In a further more embodiment of the invention, the pozzoloan content including 40 to 70 wt% of a first pozzoloan fraction of a first size, 20 to 40 wt% of a second pozzoloan fraction of a second size, and 5 to 15 wt% of a third pozzoloan fraction of a third size.

In a further embodiment of the invention, the cement content includes 40 to 70 wt% of a first cement fraction of a first size, 20 to 40 wt% of a second cement fraction of a second size, and 5 to 15 wt% of a third cement fraction of a third size.

In an embodiment, the present invention further provides a system for making concrete walls. In particular, the system comprises a mixing unit adapted to mix a binder and water to obtain a slurry, the mixing unit being further adapted to mix an aggregate component with the slurry to obtain a concrete component. In an embodiment of the invention, the system further comprises a transporting unit adapted to transport the concrete component.

In an embodiment of the invention, the system further comprises a concrete component discharging unit adapted to receive the concrete component from the transporting unit and discharge the same within a form-work. In a further embodiment of the invention, the system further comprises a motion imparting means adapted to receive the concrete component discharging unit and impart motion to the concrete component discharging unit.

In a further embodiment of the invention, the system further comprises an acoustic transmitter being adapted to transmit acoustic waves in a direction of discharge of the concrete component. In a further more embodiment of the invention, wherein the system further comprises an acoustic receiver adapted to receive reflected acoustic waves and produce output signal corresponding to the reflected acoustic waves thus received. In a further embodiment of the invention, the system further comprises a processing and controlling unit adapted to receive the output signal thus produced by the acoustic receiver.

In an embodiment of the invention, the processing and controlling unit is adapted to determine a concrete wall quality parameter. In another embodiment of the invention, the processing and controlling unit is further adapted to control operation of at least one of the mixing unit, the transporting unit, and the motion imparting means based on the concrete wall quality parameter thus determined.

These and other features, aspects, and advantages of the present subject matter will be better understood with reference to the following description and appended claims. This summary is provided to introduce a selection of concepts in a simplified form. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

BRIEF DESCRIPTION OF DRAWINGS
The detailed description is described with reference to the following figures. It should be noted that the description and figures are merely examples of the present subject matter and are not meant to represent the subject matter itself.

FIGURE 1 demonstrates a process (100) for preparing a dry mix construction material as implemented by a control system, in accordance with an example implementation of the present subject matter.

FIGURE 2 illustrates a process (200) for preparing the dry mix construction material, as implemented by a mixing system in accordance with an example implementation of the present subject matter.

FIGURE 3 illustrates a detailed flow diagram of the step of weighing the binder content, in accordance with an example implementation of the present subject matter.

FIGURE 4 illustrates a detailed flow diagram of the step of weighing the pozzoloan content, in accordance with an example implementation of the present subject matter.

FIGURE 5 illustrates a detailed flow diagram of the step of weighing the cement content, in accordance with an example implementation of the present subject matter.

FIGURE 6 depicts a block diagram of a system (600) for preparing the dry mix construction material, in accordance with an example implementation of the present subject matter.

FIGURE 7 depicts a block diagram of a system (700) for preparing the concrete walls, in accordance with an example implementation of the present subject matter.

DETAILED DESCRIPTION
For convenience, before further description of the present disclosure, certain terms employed in the specification, and examples are collected here. These definitions should be read in the light of the remainder of the disclosure and understood as by a person of skill in the art. The terms used herein have the meanings recognized and known to those of skill in the art, however, for convenience and completeness, particular terms and their meanings are set forth below.

The terms “dry concrete mix”, “dry construction mix”, and “dry ready-mixed construction material”, are to be used interchangeably.

The term “concrete” refers to a composition comprising cement, aggregates and optionally supplementary cementitious material.

The term “raw material” refers to the separate constituents of a concrete mix comprising cement, aggregates, and optionally supplementary cementitious material used to prepare the dry concrete mix.

The articles “a”, “an” and “the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article.

The terms “comprise” and “comprising” are used in the inclusive, open sense, meaning that additional elements may be included. It is not intended to be construed as “consists of only”.

Referring to Figure 1, there is illustrated a flow chart of a process (100) for preparing a dry concrete mix. The process (100) may be implemented by a control system, whose details will be described later. The dry concrete mix thus obtained may be used for construction of concrete walls. As shown in Figure 1, the process (100) comprises receiving (102), by a user input receiving module, user inputs pertaining to: a grade of concrete to be prepared, a Water : Binder (W/B) ratio, an Aggregate : Binder (A/B) ratio, and a type of application.

The process (100) further comprises selecting (104), by a material selection module, a set of dry concrete mixes based on the received user inputs, the set of dry concrete mixes differing from each other in terms of at least one of: a compressive and flexural strength as developed after a predetermined amount of time period, a workability parameter, a cohesiveness factor; a pumpability factor, a durability parameter, and a cost associated parameter.

The process (100) further comprises receiving (106), by the user input receiving module, user input pertaining at least one technical parameter of the concrete wall, the technical parameter being at least one of: lateral stability failure criteria, thermal resistance properties, acoustic insulation properties, and earthquake resistance properties. The process (100) further comprises determining (108), by a structural optimization module, an optimum structural design configuration of concrete wall meeting the at least one technical parameter and at the same time which is commercially most feasible.

In the following paragraphs some of the ways to perform the optimization is illustrated. The optimization for example, may be based on ETABS/RCDC modelling of various combinations of RCC frame systems, RCC wall systems, RCC masonry systems, etc. In the optimization process, the technical parameter as provided by the user i.e. the lateral stability failure criteria, the thermal resistance properties, the acoustic insulation properties, and/or the earthquake resistance properties was considered as the operand for study.

Example 1:
By way of a non-limiting example, a Brick wall and Concrete Wall were subjected to an optimization process. In the optimization process, target was set to obtain certain level of lateral stability failure criteria, and/or attain certain level of thermal resistance properties, and/or attain certain level of acoustic insulation, and/or attain certain level of earthquake resistance. Once a particular structural model met with the set target, the quantity of raw materials used for constructing each type of structural model was calculated and is provided in Table 1 herein below:

Table 1
BRICK WALL CONCRETE WALL
REBAR CONCRETE REBAR CONCRETE
(KGS) (CUM) (KGS) (CUM)
FOOTINGS 802 38.5 536 24.9
COLUMNS 4593 20.5 3212 20.5
BEAMS 7050 54 6126 54
SLABS 2985 54.5 2985 54.5
TOTAL 15430 167.5 12859 153.9
% SAVING 16.66% 8.12%

It can be seen from Table 1 that compared to a Brick Wall System, a Concrete wall system provided substantial advantage in terms of amount of raw material being used and hence would provide substantial cost benefit while meeting the same technical parameter.

Example 2:
By way of another non-limiting example, a non-load bearing masonry wall (i.e. a 230 mm brick wall) of about 120m2 area was replaced with walls of the following types a 150 mm thick solid block wall, a 50 mm thick RCC wall, a 75 mm thick RCC wall, a 100 mm thick RCC wall, a 150 mm thick RCC wall, and a system having two - 50 mm thick RCC walls with a separation distance of 50 mm. It was observed that all of the walls met with a base level of lateral stability failure criteria, and/or attained base level of thermal resistance properties, and/or attained base level of acoustic insulation, and/or attained base level of earthquake resistance. Thereafter, the cost for constructing each type of wall was calculated and is provided in Table 2 herein below:

Table 2
Case Details Cost (INR)
Case 1 230 mm Thick Brick Wall 189,600.00
Case 2 150 mm Thick Solid Block Wall 168,000.00
Case 3 50 mm Thick RCC Wall 97,500.00
Case 4 75 mm Thick RCC Wall 114,875.00
Case 5 100 mm Thick RCC Wall 136,980.00
Case 6 150 mm Thick RCC Wall 169,420.00
Case 7 Two - 50 mm Thick RCC Walls with 50 mm separation 183,000.00

While performing the cost calculations, the cost of the raw materials were taken as per
Table 3 provided herein below.

Table 3
Material Price (INR)
M25 4600/CUM
FE500 55/KG
EPS Spacer 325/SQM
Block Masonry 600/SQM
Brick Masonry 780/SQM
Plastering 400/SQM
Shuttering 250/SQM

It can be seen from Table 2 that a 50 mm thick RCC wall constructed of M25 grade of concrete provided substantial cost advantage while meeting the same technical parameter.

Example 3:
By way of another non-limiting example, following types of structural models namely a RCC Wall System with M40 grade of concrete, a RCC Wall System with M100 grade of concrete, a RCC Wall System with M100 grade of concrete only for walls, a RCC Frame System with M40 grade of concrete, a RCC Frame System with M100 grade of concrete, and a RCC Frame System with M100 grade of concrete only for walls were subjected to an optimization process in relation to a slender configuration of 30 floors. In the optimization process, target was set to obtain certain level of lateral stability failure criteria, and/or attain certain level of thermal resistance properties, and/or attain certain level of acoustic insulation, and/or attain certain level of earthquake resistance. Once a particular structural model met with the set target, the cost for constructing each type of structural model was calculated and is provided in Table 4 herein below:
Table 4
Case No. Details Cost (INR)
Case 8 RCC Wall System with M40 grade of concrete 151,388,925.00
Case 9 a RCC Wall System with M100 grade of concrete 206,407,115.00
Case 10 a RCC Wall System with M100 grade of concrete only for walls 168,135,940.00
Case 11 RCC Frame System with M40 grade of concrete 324,787,765.00
Case 12 RCC Frame System with M100 grade of concrete 383,341,960.00
Case 13 RCC Frame System with M100 grade of concrete only for walls 323,237,680.00

While performing the cost calculations, the amount of the raw materials were taken as per Table 5 provided herein below.

Table 5
Case No. Concrete Quantity (CUM) REBAR Quantity (KGS) Shuttering Quantity (SQM)
Case 8 13196 1021435 90528
Case 9 13203 820793 90528
Case 10 13203 823408 90528
Case 11 17537 3524853 50375
Case 12 17525 2997652 50340
Case 13 17537 3087556 50340

While performing the cost calculations, the price of the raw materials were taken as per Table 6 provided herein below.

Table 6
Material Price (INR)
M40 5500/CUM
M100 10500/CUM
FE500 55/KG
Block Masonry 600/SQM
Plastering 400/SQM
Shuttering 250/SQM

It can be seen from Table 4 that RCC Wall System with M40 grade of concrete provided substantial cost advantage while meeting the same technical parameter. It can be furthermore observed from Table 4 that RCC Wall System with M100 grade of concrete only for walls provides the next best advantage while meeting the same technical parameters.

The process (100) further comprises selecting (110), by the structural optimization module, an optimum compressive and flexural strength of concrete meeting the optimum structural design configuration of the concrete wall as determined. The process (100) further comprises selecting (112), by the material selection module, a dry concrete mix from the set of dry concrete mixes thus selected based on the at least on the optimum compressive and flexural strength of concrete.

The process (100) further comprises transmitting (114), by a transmitting module to a mixing system, information pertaining to the dry concrete mix thus selected thereby causing the mixing system to prepare the dry concrete mix.

In an embodiment of the invention, the information pertaining to the dry concrete mix includes:
a. information as to quantity of a binder content,
b. information as to quantity of a fine aggregate content,
c. information as to quantity of a coarse aggregate content,
d. the information as to quantity of the binder content including: information as to quantity of a pozzoloan content and information as to quantity of a cement content;
e. the information as to quantity of the pozzoloan content including: information as to quantity of a first pozzoloan fraction of a first size, information as to quantity a second pozzoloan fraction of a second size, and information as to quantity a third pozzoloan fraction of a third size; and
f. the information as to quantity of the cement content including: information as to quantity of a first cement fraction of a first size, information as to quantity a second cement fraction of a second size, and information as to quantity a third cement fraction of a third size.

It may be noted that the information pertaining to the dry concrete mix optionally include information pertaining to at least one additive. For example, the information pertaining to at least one additive may include information as to quantity of the at least one additive. By way of another example, the information pertaining to at least one additive may include the chemical composition of the at least one additive.

Now referring to Figure 2, there is illustrated the process (200) involved in preparing the dry concrete mix at the end of the mixing system.

In particular, the information pertaining to the dry concrete mix as transmitted by the transmitting module of the control system is received (202) by the mixing system.

In response to receiving the information, the mixing system is adapted to:
• weigh (204) the binder content as per information as to quantity of the binder content;
• weigh (206) the fine aggregate content as per information as to quantity of the fine aggregate content;
• weigh (208) the coarse aggregate content as per information as to quantity of the coarse aggregate content; and
• mix (210) the weighed quantities of binder content, fine aggregate content, and coarse aggregate content to obtain the dry concrete mix.

As stated above, the information pertaining to the dry concrete mix optionally include information as to at least one additive. Thus, in case the information pertaining to the dry concrete mix includes information as to at least one additive, the mixing system is adapted to weigh (212) at least one additive as per information as to the at least one additive. In such an event, the mixing system is adapted to mix (210) the weighed quantity of the at least one additive with the binder content, the fine aggregate content, and the coarse aggregate content to obtain the dry concrete mix.

Now referring to Figure 3, it can be seen that the step of weighing the binder content (204) comprises:
• weighing (302) pozzoloan content as per information as to quantity of the pozzoloan content; and
• weighing (304) cement content as per information as to quantity of the cement content.

Now referring to Figure 4, it can be seen that the step of weighing the pozzoloan content (302) comprises:
• weighing (402) first pozzoloan fraction as per information as to quantity of the first pozzoloan fraction of the first size;
• weighing (404) second pozzoloan fraction as per information as to quantity of the second pozzoloan fraction of the second size; and
• weighing (406) third pozzoloan fraction as per information as to quantity of the third pozzoloan fraction of the third size.

Likewise, referring to Figure 5, it can be observed that the step of weighing (304) the cement content comprises:
• weighing (502) first cement fraction as per information as to quantity of the first cement fraction of the first size;
• weighing (504) second cement fraction as per information as to quantity of the second cement fraction of the second size; and
• weighing (506) third cement fraction as per information as to quantity of the third cement fraction of the third size.

Now referring to Figure 6, there is illustrated a block diagram of a system (600) for preparing the dry concrete mix for use in construction of concrete walls in accordance with an embodiment of the invention. The system includes a control system (602) that implements the process as showed in Figure 1 and a mixing system (604) that implement the process as showed in Figure 2, wherein the control system (602) is operably interconnected to the mixing system (604). The control system (602), may include a user input receiving module (606), adapted to receive user inputs pertaining to: a grade of concrete to be prepared, a Water : Binder (W/B) ratio, an Aggregate : Binder (A/B) ratio, and a type of application. The control system (602) may further comprise a material selection module (608) operably linked to the user input receiving module (606). The material selection module (608) is adapted to select a set of dry concrete mixes based on the received user inputs, the set of dry concrete mixes differing from each other in terms of at least one of: a compressive and flexural strength as developed after a predetermined amount of time period, a workability parameter, a cohesiveness factor; a pumpability factor, a durability parameter, and a cost associated parameter.

The user input receiving module (606) is further adapted to receive, user input pertaining at least one technical parameter of the concrete wall, the technical parameter being at least one of: lateral stability failure criteria, thermal resistance properties, acoustic insulation properties, and earthquake resistance properties. The control system (602) further comprises a structural optimization module (610) operably linked to the user input receiving module (606). The structural optimization module (610) is adapted to determine, an optimum structural design configuration of concrete wall meeting the at least one technical parameter and at the same time which is commercially most feasible.

The structural optimization module (610) is further adapted to select, an optimum compressive and flexural strength of concrete meeting the optimum structural design configuration of the concrete wall as determined. The material selection module (608) is further adapted to select, a dry concrete mix from the set of dry concrete mixes thus selected based on the at least on the optimum compressive and flexural strength of concrete. The control system (602) further comprises a transmitting module (612) operably linked to the material selection module (608). The transmitting module (612) is further adapted to transmit to the mixing system (604), information pertaining to the dry concrete mix thus selected thereby causing the mixing system (604) to prepare the dry concrete mix.

In an embodiment of the invention, the information pertaining to the dry concrete mix includes:
a. information as to quantity of a binder content,
b. information as to quantity of a fine aggregate content,
c. information as to quantity of a coarse aggregate content,
d. the information as to quantity of the binder content including: information as to quantity of a pozzoloan content and information as to quantity of a cement content;
e. the information as to quantity of the pozzoloan content including: information as to quantity of a first pozzoloan fraction of a first size, information as to quantity a second pozzoloan fraction of a second size, and information as to quantity a third pozzoloan fraction of a third size; and
f. the information as to quantity of the cement content including: information as to quantity of a first cement fraction of a first size, information as to quantity a second cement fraction of a second size, and information as to quantity a third cement fraction of a third size.

It may be noted that the information pertaining to the dry concrete mix optionally include information pertaining to at least one additive. For example, the information pertaining to at least one additive may include information as to quantity of the at least one additive. By way of another example, the information pertaining to at least one additive may include the chemical composition of the at least one additive.

The mixing system (604) may in turn comprises a receiving unit (614) adapted to receive the information pertaining to the dry concrete mix thus selected.

The mixing system (604) may further comprise at least one weighing and mixing apparatus (616). The at least one weighing unit and mixing apparatus (616) is adapted to: weigh the binder content as per information as to quantity of the binder content; weigh the fine aggregate content as per information as to quantity of the fine aggregate content; weigh the coarse aggregate content as per information as to quantity of the coarse aggregate content; and mix the weighed quantities of binder content, fine aggregate content, and coarse aggregate content to obtain the dry concrete mix.

As indicated above, the information pertaining to the dry concrete mix optionally include information as to at least one additive. In such case, the at least one weighing and mixing apparatus (616) is further adapted to weigh at least one additive as per information as to the at least one additive and mix the weighed quantity of the at least one additive with the binder content, the fine aggregate content, and the coarse aggregate content to obtain the dry concrete mix.

In a preferred embodiment of the invention, the at least one weighing and mixing apparatus (616) is adapted to:
• weigh pozzoloan content as per information as to quantity of the pozzoloan content; and
• weigh cement content as per information as to quantity of the cement content.

In a more preferred embodiment of the invention, the at least one weighing and mixing apparatus (616) is adapted to:
• weigh first pozzoloan fraction as per information as to quantity of the first pozzoloan fraction of the first size;
• weigh second pozzoloan fraction as per information as to quantity of the second pozzoloan fraction of the second size; and
• weigh third pozzoloan fraction as per information as to quantity of the third pozzoloan fraction of the third size.

In a furthermore preferred embodiment of the invention, the at least one weighing and mixing apparatus (616) is adapted to:
• weigh first cement fraction as per information as to quantity of the first cement fraction of the first size;
• weigh second cement fraction as per information as to quantity of the second cement fraction of the second size; and
• weigh third cement fraction as per information as to quantity of the third cement fraction of the third size.

Thus, following the process as illustrated in Figures 1 to 5 leads to a dry concrete mix. In an embodiment of the invention, the dry concrete mix is suited for use in construction of concrete walls. In an embodiment of the invention, the dry concrete mix comprises:
(a) a binder content; and
(b) an aggregate content;
wherein:
• a weight ratio of aggregate to binder being in the range of 9 to 11 : 1 to 3;
• the aggregate content including a fine aggregate content and a coarse aggregate content, a weight ratio of the fine aggregate content to coarse aggregate content being in the range of 40 to 70 : 30 to 60;
• the binder content including a pozzoloan content and a cement content, the pozzoloan content being in a weight percentage of 50 to 90 % of the binder content and the remaining being constituted by the cement content;
• the pozzoloan content including 40 to 70 wt% of a first pozzoloan fraction of a first size, 20 to 40 wt% of a second pozzoloan fraction of a second size, and 5 to 15 wt% of a third pozzoloan fraction of a third size;
• the cement content including 40 to 70 wt% of a first cement fraction of a first size, 20 to 40 wt% of a second cement fraction of a second size, and 5 to 15 wt% of a third cement fraction of a third size.

In an embodiment of the invention, the dry concrete mix further comprises of at least 1 additive in the range of 0.25 kgs to 4 kgs per cubic meter of the dry mix concrete.

In another embodiment of the invention, the at least one additive comprises fibres having a length in the range of 10 to 30 mm and diameter in the range of 1 to 3 mm.

In yet another embodiment of the invention, the fibres are made of a polymeric material selected from a group comprising polyethylene, polypropylene, a polyester, and a mixture of the same.

In still another embodiment of the invention, the fibres are hollow fibres having a tensile strength in the range of 300 N/mm2 to 2000 N/mm2.

In a further embodiment of the invention, the hollow fibres are filled with air.

In a furthermore embodiment of the invention, the hollow fibres are filled with a low viscosity non-reactive liquid.

Since the dry concrete mix is suited for use in construction of concrete walls, as shown in Figure 7, the present invention further provides a system (700) for making concrete walls. The system (700) comprises a mixing unit (702) adapted to mix a binder and water to obtain a slurry, the mixing unit (702) being further adapted to mix an aggregate component with the slurry to obtain a concrete component. The system (700) further comprises a transporting unit (704) adapted to transport the concrete component. The system (700) further comprises a concrete component discharging unit (706) adapted to receive the concrete component from the transporting unit (704) and discharge the same within a form-work. The system (700) further comprises a motion imparting means (708) adapted to receive the concrete component discharging unit (706) and impart motion to the concrete component discharging unit (706).

The system (700) further comprises an acoustic transmitter (710) being adapted to transmit acoustic waves in a direction of discharge of the concrete component; The system (700) further comprises an acoustic receiver (712) adapted to receive reflected acoustic waves and produce electrical signal corresponding to the reflected acoustic waves thus received. The system (700) further comprises a processing and controlling unit (714) adapted to receive the electrical signal from the acoustic receiver. The processing and controlling unit (714) being adapted to determine a concrete wall quality parameter based on the electrical signal thus received. The processing and controlling unit (714) being further adapted to control operation of at least one of the mixing unit (702), the transporting unit (704), the concrete component discharging unit (706), and the motion imparting means (708) based on the concrete wall quality parameter thus determined.

In an embodiment of the invention, the mixing unit comprises at least one of: a high speed mixer comprising a speed control unit and a narrow discharge mouth or a mixer with an adapted spout..

In another embodiment of the invention, the transporting unit comprises at least one of: boom pump, line pump, and a tower crane-bucket system.

In yet another embodiment of the invention, the concrete component discharging unit comprises at least one of: a boom pump, a pump having a nozzle size in the range of 20 to 100 mm, and a 3-D printing technique for pouring concrete.

In an embodiment of the invention, the acoustic transmitter is mounted on the concrete component discharging unit. In another embodiment of the invention, the acoustic transmitter is mounted on the motion imparting means.

In yet another embodiment of the invention, the acoustic transmitter is further adapted to transmit acoustic waves in a direction other than a direction of discharge of the concrete component.

In still another embodiment of the invention, the acoustic receiver is mounted on the concrete component discharging unit. In a further embodiment of the invention, the acoustic receiver is mounted on the motion imparting means.

In an embodiment of the invention, the concrete wall quality parameter includes at least one of: an estimate of a density of the wall, an estimate of a compressive and flexural strength that may be developed after a predetermined amount of time period, an estimate of optimal design thickness of the wall based on the above criteria, an estimate of a level of resistance faced by the concrete while flowing through the form work, a consistency index of the concrete component, presence of blow holes on the surface of the concrete wall, and presence of voids within the concrete wall, and a height of fall of the concrete.

In another embodiment of the invention, the processing and controlling unit is adapted to increase or decrease a time period of mixing by the mixing unit.

In yet another embodiment of the invention, the processing and controlling unit is adapted to increase or decrease a rate of transport of the concrete component by the transporting unit.

In still another embodiment of the invention, the processing and controlling unit is adapted to increase or decrease a rate of discharge of the concrete component from the concrete component discharging unit.

In a further embodiment of the invention, the processing and controlling unit is adapted to control a relative position of the concrete component discharging unit with respect to the form work by controlling the motion imparting means.

While certain present preferred embodiments of the invention have been illustrated and described herein, it is to be understood that the invention is not limited thereto. Clearly, the invention may be otherwise variously embodied, and practiced within the scope of the following claims.