Dynamic segregation monitoring of concrete

A concrete monitoring system for detecting dynamic segregation in a concrete mix contained in a rotatable mixer drum, the drum having an inner wall with at least one blade spirally-mounted on the inner wall for agitating or mixing the concrete during mixer drum rotation, the system comprising:

• a system processor programmed to monitor at a rate of at least ten times per drum rotation at least one rheology parameter of concrete contained in a rotating drum by measuring the energy or hydraulic pressure required for rotating the concrete-containing drum as a function of time and thereby to obtain an instantaneous value for the rheology parameter (“instantaneous rheology value”), the processor programmed to average the monitored rheology values for the rheology parameter in question over a period of time to obtain an averaged value for the rheology parameter (“averaged rheology value”);
• the system processor further programmed to deploy a dynamic segregation detection protocol to detect dynamic segregation based on instantaneous rheology value,
• wherein the dynamic segregation detection protocol comprises monitoring the concrete while the mixer drum is rotating at a constant rotation speed and detecting when a change in the monitored instantaneous rheology value meets or exceeds a Constant Speed Departure Value (“CSDV limit”);
• and
• the system processor is further programmed, upon or after detecting that the CSDV limit is met or exceeded, to initiate at least one of the following:
• (i) sending of an alarm or indication to a concrete mix plant, a dispatch center, an operator of the concrete delivery truck, or to some or all of these, to confirm that segregation is detected;
• (ii) changing of mixer drum rotation rate;
• (iii) introducing at least one chemical admixture into the concrete-containing mixer drum for mitigating segregation of the concrete;
• (iv) transmitting of data to a dispatch center, concrete mix plant, or other remote site for adjusting concrete mix design in subsequent concrete batches;
• or
• (v) performing any combination or all of the foregoing;
• and
• wherein the system processor is electrically or electronically connected to a sensor for sensing rotational speed of motor or hydraulic pressure drive used for rotating the concrete mixer drum.