US 8,408,781 B2 · System, method and apparatus for entraining air in concrete

Abstract

A method of preparing a concrete composition includes utilizing a controller to control a process including circulating process water in a process water supply loop for a predetermined period while monitoring and controlling the temperature and flow rate of the process water, circulating aqueous-based air entrainment solution in an aqueous-based air entrainment solution supply loop for the predetermined period and controlling the flow rate of the aqueous-based air entrainment solution and after the predetermined period of time in which the flow of process water and aqueous-based air entrainment solution have stabilized, simultaneously actuating valves to divert and mix the process water, the aqueous-based air entrainment solution and compressed air to produce an air-entrained foam and mixing the foam with a concrete composition.

A system for preparing an air entrainment composition for use with in preparing a concrete composition, comprising:

a controller for controlling the system, the controller including one or more communications interfaces for communicating with system components and a data storage device for storing predetermined process parameters;
a process water supply circuit for providing temperature controlled process water for producing an air-entrained foam, including:
a process water supply tank having a temperature monitoring device and a level detecting device, the temperature monitoring device and level detecting device providing signals to the controller indicating the level of process water in the water supply tank and the temperature of the process water in the process water supply tank;
a closed loop circulating system for controlling the temperature of the water in the process water supply tank including a circulating pump, a water heater and or a water cooler, the circulating pump pumping water from the process water supply tank through the water heater and/or water cooler and back to the process water supply tank to control the temperature of the process water, wherein the controller receives a signal from the temperature monitoring device and energizes or de-energizes the circulating pump, water heater and/or water cooler based upon a preprogrammed temperature set point;
a process water circulating loop including a process water supply pump that pumps water from the process water supply tank through the process water circulating loop and back to the process water supply tank, a first variable speed drive for driving the pump and a flow meter for determining the flow rate of process water in the process water circulating loop whereby the controller receives a signal from the flow meter and controls the speed of the first variable speed drive based upon a preprogrammed set point;
a first valve in the process water circulating loop, the first valve diverting process water from the process water circulating loop to produce foam under the control of the controller;
an aqueous-based air entrainment solution supply circuit for providing an aqueous-based air entrainment solution for producing an air-entrained foam, including:
an aqueous-based air entrainment solution batch tank having an aqueous-based air entrainment solution level detecting device for monitoring the level of aqueous-based air entrainment solution in the batch tank;
an aqueous-based air entrainment solution circulating loop including an aqueous-based air entrainment solution supply pump that pumps aqueous-based air-entrainment solution the aqueous-based air-entrainment solution batch tank through the aqueous-based air-entrainment solution circulating loop and back to the aqueous-based air-entrainment solution batch tank, a second variable speed drive for driving the aqueous-based air-entrainment solution supply pump and an aqueous-based air entrainment solution flow meter for determining the flow rate of aqueous-based air-entrainment solution in the aqueous-based air-entrainment solution circulating loop whereby the controller receives a signal from the aqueous-based air-entrainment solution flow meter to control the speed of the second variable speed drive to control the flow rate of aqueous-based air-entrainment solution in the aqueous-based air-entrainment solution circulating loop;
second valve in the aqueous-based air-entrainment solution circulating loop, the second valve diverting aqueous-based air-entrainment solution under the control of the controller to produce air-entrained foam;
a compressed air supply for supplying compressed air for producing an air-entrained foam, including:
a pressure regulator operating under the control of the controller for regulating the pressure of the compressed air;
an air supply valve for providing a consistent volume of air under the control of the controller to produce air-entrained foam;
a mixing chamber, the mixing chamber receiving process water and aqueous-based air-entrainment solution diverted by first and second valves, respectively, and wherein the process water and aqueous-based air-entrainment solution are blended in the mixing chamber;
a stationary mixer, the stationary mixer receiving process water, aqueous-based air-entrainment solution and compressed air and mixing the process water, aqueous-based air-entrainment solution and compressed air to produce an air-entrained foam;
and
a discharge line, for discharging the air-entrained foam for mixing with a concrete composition to produce air-entrained concrete.

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System, method and apparatus for entraining air in concrete

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System, method and apparatus for entraining air in concrete

Life of this patent

Abstract

Claims20