Test Methods for Workability and Rheology of Fresh Concrete

Eric P. Koehler W.R. Grace & Co.

ACI Fall Convention November 2009

Outline

Categorization of Workability Tests

Listing of Workability Tests

Conventional Concrete Self-Consolidating Concrete Paste, Mortar, Paste Mortar Grout

Choosing the Right Test

Test Methods for Workability and Rheology of Fresh Concrete 2

ACI 238 Report

Report categorizes and lists 69 test methods for workability and rheology
Compiled from literature search T t have varying degrees of industry Tests h i d fi d t adoption New tests continue to being developed Todays Presentation: Based on ACI 238 Report

Tests cover workability and rheology

Workability - that property of freshly mixed concrete or mortar which determines the ease and homogeneity with which it can be mixed, placed, consolidated, consolidated and finished (ACI) (ACI). Rheology the scientific description of the flow and deformation of matter

Workability is broadly defined: no single test measures all aspects of workability Tests are available for many different applications
Filling ability, finishability pumpability ability finishability, pumpability, passing ability, segregation resistance, etc.
Test Methods for Workability and Rheology of Fresh Concrete 3

Categorization of Test Methods

Test T t can be categorized in many different ways. b t i di diff t Empirical vs. Fundamental
Empirical (Workability): Tests simulate placement condition and measure a

value ( l (such as di t h distance or ti ) th t i specific t th t t method time) that is ifi to the test th d
Difficult to compare results from one test to another Multiple tests needed to describe different aspects of workability

Fundamental (Rheology): Measure fundamental physical entities that are not specific to a test method
Results from different rheometers have been shown to be correlated Results can be used to describe multiple aspects or workability

Static vs. Dynamic

Static: Concrete deforms under its on weight Dynamic: External energy (e.g. vibration) is added to cause deformation of concrete

Maximum Particle Size

Paste Mortar Concrete

Workability Level
Test Methods for Workability and Rheology of Fresh Concrete 4

Categorization of Test Methods

ACI 238 report uses categorization scheme proposed by NIST t t i ti h db
CATEGORY Confined Flow Free Flow DEFINITION The material flows under its own weight or under applied pressure through a narrow orifice orifice. The material either flows under its own weight, without any confinement, or an object penetrates the material by gravitational settling. The material flows under the influence of applied vibration. The vibration is applied using a vibrating table, dropping the base supporting the material, an external vibrator, or an internal vibrator. The material is sheared between two surfaces, one or both of which are rotating. The material is subjected to relative higher forces than in other tests due to its stiff consistency (no slump). EXAMPLES Compaction Factor Slump Test

Vibration

Vebe Test

Rotational Rheometers Tests for Very High Yield Stress Concrete*

Parallel plate, coaxial cylinders, impeller rheometers Intensive Compaction Test

*not part of original NIST classification

Reference: Hackley, V. A., and Ferraris C. F., 2001, The Use of Nomenclature in Dispersion Science and Technology, Special Report 960-3, National Institute of Standards and Technology, Gaithersburg, MD.
Test Methods for Workability and Rheology of Fresh Concrete 5

Categorization of Test Methods: 69 Tests

ACI 238 report uses categorization scheme proposed by NIST t t i ti h db

Test Methods for Workability and Rheology of Fresh Concrete 6

Concrete: Confined Flow Tests

Compaction Factor Test Free Orifice (Orimet) Test K-Slump Tester

Test Methods for Workability and Rheology of Fresh Concrete 7

Concrete: Confined Flow Tests

Compaction Factor Test
Procedure
Fill top section with uncompacted concrete Allowed concrete to drop to middle section, then to bottom cylinder Measure mass of concrete in bottom cylinder due to dropping into cylinder (partially compacted) Measure mass of concrete in bottom cylinder compacted by rodding (fully compacted)

Results expressed as: masspartially compacted/massfully compacted Suitable for full range of concrete yield stresses

Test Methods for Workability and Rheology of Fresh Concrete 8

Concrete: Confined Flow Tests

Free Orifice (Orimet) Test
Procedure
Place concrete in apparatus Open door at bottom of orifice Measure time for concrete to discharge through orifice

Steel bars may be added to assess passing ability of SCC Developed for concrete mixtures that were too fluid for slump test

Test Methods for Workability and Rheology of Fresh Concrete 9

Concrete: Confined Flow Tests

K-Slump Tester
Standardized as ASTM C 1362 Procedure
Insert tube into concrete Allow mortar to flow into tube for 60 s Lower plunger to top of mortar; depth = K slump K-slump Remove tube from concrete Allow mortar to flow out tube Lower plunger to top of mortar; depth = W

Results
K-slump related to slump W related to compactability p y K-W related to segregation resistance

Suitable for low- and mediumyield stress concretes

Test Methods for Workability and Rheology of Fresh Concrete 10

Concrete: Free Flow Tests

Cone Penetration Test Delivery-Chute Depth Meter Delivery-Chute Torque Meter Flow Trough Test Kelly Ball Test Modified Slump Test Moving Sphere Viscometer Ring Penetration Test SLump Rate Machine (SLRM) Slump Test Surface Settlement Test

Test Methods for Workability and Rheology of Fresh Concrete 11

Concrete: Free Flow Tests

Kelly Ball Test
Formerly ASTM C 360, now discontinued Procedure
Position cylinder on top of concrete surface Release cylinder Measure penetration depth

Results correlated to slump for a given concrete mixture proportion

Slump Test
St d di d as ASTM C 143 Standardized Procedure
Fill cone with concrete in three layers, compacting each layer Remove slump cone Measure distance concrete subsides

Results have been shown to be correlated to yield stress, density, and to a lesser extent plastic viscosity
Test Methods for Workability and Rheology of Fresh Concrete 12

Concrete: Free Flow Tests

Modified Slump Test
Procedure is the same as the slump test, but the time for concrete to settle 100 mm is determined Yield stress is calculated from density and slump Plastic viscosity is calculated from density and time to slump 100 mm

SLump Rate Machine (SLRM)

Automated device that measures vertical slump, horizontal slump flow, and time to slump Yi ld stress i calculated as a f Yield t is l l t d function of d ti f density and slump fl it d l flow Plastic viscosity is calculated as a function of density, slump, slump flow, and time to slump

Test Methods for Workability and Rheology of Fresh Concrete 13

Concrete: Vibration Tests

Angles Flow Box Test Compaction Test Flow Table Test (DIN) ( ) Inverted Slump Cone Test LCL Flow Test Powers Remolding T t P R ldi Test Settlement Column Segregation Test Thaulow Tester Vebe Consistometer Vertical Pipe Apparatus Vibrating Slope Apparatus Vibratory Flow Meter Vibropenetrator Wigmore Consistometer
Test Methods for Workability and Rheology of Fresh Concrete 14

Concrete: Vibration Tests

Compaction Test
Standardized as EN 12350-4 Procedure
Fill container without compaction Apply vibration to compact concrete Measure distance concrete compacts

Results calculated as height of concrete divided by height of container

Flow Table Test (DIN Test)

Standardized as EN 12350-5 Procedure
Fill cone in 2 layers, compacting each layer Remove cone Lift plate 15 times Measure horizontal spread

A li bl t f ll range of slumps Applicable to full f l

Test Methods for Workability and Rheology of Fresh Concrete 15

Concrete: Vibration Tests

Settlement Column Segregation Test
Procedure
Fill column with concrete Allow concrete to remain undisturbed for 1 minute Subject concrete to 20 drops on drop table in 1 minute Allow concrete to remain undisturbed for 5 minutes Obtain samples from top and bottom sections, discard middle section Wash samples through 5 mm sieve to retain coarse aggregate

Results expressed as ratio of coarse aggregate in top section to coarse aggregate in bottom section Results indicate susceptibility to segregation

Test Methods for Workability and Rheology of Fresh Concrete 16

Concrete: Vibration Tests

Vebe Consistometer
Standardized as ASTM C 1170 and EN 12350-3 Procedure
Fill slump cone with concrete Remove slump cone Move plastic disk over concrete Optional: apply surcharge load Vibrate specimen Measure time until mortar is in full contact with disk t t ith di k

Suitable for concrete with slumps less than 50 mm Use of slump cone to form specimen may be omitted

Test Methods for Workability and Rheology of Fresh Concrete 17

Concrete: Rotational Rheometers

Bertta Apparatus BML Viscometer BTRHEOM Rheometer CEMAGREF-IMG Concrete Truck Mixer as a Rheometer Consolis Rheomixer CONVI Visco-Probe FHPCM Fresh Concrete Tester 101 ICAR Rheometer IBB Rheometer Mixer Devices Powers and Wiler Plastometer Rheometer-4SCC Soil Direct Shear Test Tattersall Two-Point Device
Test Methods for Workability and Rheology of Fresh Concrete 18

Concrete: Rotational Rheometers

Rheometers shear concrete through rotational movement. Rheometers must be uniquely designed for concrete (primarily due to large aggregate size)

Typical Rheometer Geometries

Coaxial Cylinders Parallel Plate Impeller

Test Methods for Workability and Rheology of Fresh Concrete 19

Concrete: Rotational Rheometers

Results can be expressed as a flow curve in:
Relative units (torque vs. speed) ( ), y Absolute units (shear stress vs. shear rate), determined by calculation or calibration

Raw Measurements (Relative Units) (R l ti U it )

Calculated/Calibrated Results (Absolute U it ) (Ab l t Units)

Shear Stress, (Pa) r

To orque (Nm m)

= 0 + &

The Bingham Model

slope = plastic viscosity () intercept = yield stress (0)

slope = H

intercept = G

Speed (rps) ( ps)

Shear Rate, & (1/s) , ( )

Test Methods for Workability and Rheology of Fresh Concrete 20

Concrete Rheology: Non-Steady State

Flow Curve Test
concrete sheared at various rates

Concrete exhibits different rheology when at rest than when flowing.

Static Yield Stress minimum shear stress to initiate flow from rest Dynamic Yield Stress minimum shear stress to maintain flow after breakdown of thixotropic structure Plastic Viscosity change in shear stress per change in shear rate, above yield stress Thixotropy reversible, time-dependent reduction in viscosity in material subject to shear

S Shear Stres (Pa) ss

area between up and down curves due to thixotropy

slope = plastic viscosity

intercept = dynamic yield stress

Shear Rate (1/s)

Stress Growth Test

concrete sheared at constant lo rate constant, low maximum stress from rest = static yield stress

Torque (Nm)

Time (s)
Test Methods for Workability and Rheology of Fresh Concrete 21

Concrete Rheometers
Tattersall Two-Point Rheometer T tt ll T P i t Rh t IBB Rheometer Rh t ICAR Rheometer Rh t

BTRHEOM Rheometer

BML Viscometer

Rheometer 4 SCC

Test Methods for Workability and Rheology of Fresh Concrete 22

Concrete Rheometer: Mixer Measurements

Devices to Measure Workability or Rheology in a Mixer Ready Mix Truck Stationary Mixer
hydraulic pressure sensor

CONVI Visco-Probe: Measures torque on rod and shaft in planetary mixer speed of mixer, probe varies due to planetary motion, enabling calculation of rheological parameters

control unit slump display (in.)

Sl Slump: M Measurements of hydraulic t f h d li pressure (torque) and drum speed can be used to calculate slump. Rheology: Measuring at multiple drums speeds is analogous to concrete rheometer.

Consolis RheoMixer: Measures torque to operate planetary mixer at various speeds, reports rheological parameters

Test Methods for Workability and Rheology of Fresh Concrete 23

Concrete: Tests for Very High Yield Stress Mixtures

Intensive Compaction Test Kango Hammer Test Proctor Test

Test Methods for Workability and Rheology of Fresh Concrete 24

Concrete: Tests for Very High Yield Stress Mixtures

Intensive Compaction Test
Utilizes gyratory compactor, which applies compression and shear forces. forces Procedure
Fill specimen with known mass of concrete Start application of compression and shear, continuously recording volume Plot density and shear force vs. number of cycles

Results can be evaluated as number of cycles to reach certain density or density after certain number o cyc es u be of cycles. Final compacted specimen can be tested for strength.

Test Methods for Workability and Rheology of Fresh Concrete 25

Tests for Self-Consolidating Concrete (SCC)

Confined Flow Tests
Fill-Box Test L-Box Test Simulated Soffit Test U-Box Test V Funnel Test V-Funnel

Free Flow Tests

J-Ring Test Slump Flow Test

Stability Tests
Column Segregation Test Penetration Test for Segregation Wet Sieving Stability Test

Test Methods for Workability and Rheology of Fresh Concrete 26

Tests for Self-Consolidating Concrete (SCC)

Sh hear Stress (Pa) s,
SCC is defined by its workability
Filling ability flow and consolidate under its own mass without vibration Passing ability pass through confined spaces Segregation resistance maintain homogeneous distribution of constituents
Static segregation resistance applicable when concrete is at rest Dynamic segregation resistance applicable when concrete is flowing

Conventional Concrete 0 Near zero yield stress 0 Similar plastic viscosity i it SCC

Shear Rate, & (1/s)

In terms of rheology, SCC exhibits:

Near-zero yield stress: allows concrete to flow under its own mass Similar plastic viscosity to conventional concrete: ensures segregation resistance

Yield stress is the main difference between SCC and conventional concrete.
Test Methods for Workability and Rheology of Fresh Concrete 27

Tests for Self-Consolidating Concrete (SCC)

ASTM t t are available to measure the three SCC properties i d tests il bl t th th ti independently. d tl Filling Ability
Slump Flow ASTM C 1611

Passing Ability
J-Ring ASTM C 1621

Segregation Resistance
Column Segregation ASTM C 1610

Cone used in inverted or upright position Measure: Slump flow horizontal spread T50 time to spread 50 mm VSI visual stability index i d

Slump cone placed in middle of j-ring Measure: Difference in slump flow with and without jring Change in height between inside and outside of ring (not standardized)
Test Methods for Workability and Rheology of Fresh Concrete

Column filled with concrete and left undisturbed for 15 minutes Measure: easu e Difference in coarse aggregate content in top and bottom quarters

28

Tests for Self-Consolidating Concrete (SCC)

L-Box
Concrete is placed in vertical section and allowed to flow into horizontal section Results are expressed as
Blocking ratio: H2/H1 Time to flow 200 or 400 mm

U-Box
Concrete is placed in one side of box and allowed to flow into other side Results expressed as height of concrete on each side of b t h id f box

Test Methods for Workability and Rheology of Fresh Concrete 29

Tests for Self-Consolidating Concrete (SCC)

Penetration Test for Segregation Resistance
Concrete is placed in inverted slump cone, concrete is allowed l t i ll d to stabilize for certain time, penetration head is positioned above concrete and released. Penetration depth is correlated to segregation resistance for given mixture proportion

Wet-Sieve Stability Test S S

Concrete is placed in bucket and left undisturbed for 15 min, then a portion of concrete is poured from 500 mm onto a 5 mm sieve Results are expressed as ratio of mass passing sieve to mass poured on sieve
Test Methods for Workability and Rheology of Fresh Concrete 30

Tests for Self-Consolidating Concrete (SCC)

V-Funnel Test
Concrete is placed in funnel, the gate at the bottom of the funnel is opened, and time for all concrete to discharge from funnel is measured Results have been shown to be correlated to viscosity

Test Methods for Workability and Rheology of Fresh Concrete 31

Tests for Paste, Mortar, and Grout

Flow Cone and Marsh Cone Tests Lombardi Plate Miniflow and Minislump Test Rotational Rheometers Turning Tube Viscometer Vicat Needle Test ViscoCorder Wuerpel Device

Test Methods for Workability and Rheology of Fresh Concrete 32

Tests for Paste, Mortar, and Grout

Mini Slump Mini-Slump Test Flow Cone Test

Tests for paste, mortar, and grout are frequently adaptations of tests for concrete
Mini-slump or mini-flow tests Flow cone or marsh cone Rotational rheometers

Other tests include:

Lombardi plate test p Turning tube viscometer Vicat needle test Wuerpel test Lombardi Plate Test L b di Pl t T t

Test Methods for Workability and Rheology of Fresh Concrete 33

How to Choose the Right Test

Things to consider when choosing a test:
Parameters measured: workability or rheology gg Ruggedness Workability range Aggregate size restrictions Cost Sample size Time to test Complexity and training requirements Data analysis requirements g Size and weight Number of people required Electricity requirements

Test Methods for Workability and Rheology of Fresh Concrete 34

Summary

Numerous concrete workability tests are available, with new tests continuing to be developed There are numerous aspects of workability and different ranges of workability, resulting in the need for different tests Rheology provides a fundamental description of flow, which can be related to different concrete applications Rheometers are available for use in the lab and field

Test Methods for Workability and Rheology of Fresh Concrete 35