Koehler Rheology v1

Tenth CANMET/ACI International Conference on Recent Advances in
Concrete Technology and Sustainability Issues

Use of Rheology to Design, Specify, and
Manage Self-Consolidating Concrete
Eric Koehler
W.R. Grace & Co.
Tenth CANMET/ACI International Conference on Recent Advances in Concrete Technology and Sustainability Issues
2
Outline
Rheology
Definition
Measurement
SCC Rheology
Specification
Design
Management
Case Studies
Formwork pressure
Segregation resistance
Pumpability
3
Concrete Rheology
Rheology is the scientific description of
flow.
The rheology of concrete is measured
with a concrete rheometer, which
determines the resistance of concrete
to shear flow at various shear rates.
Concrete rheology measurements are
typically expressed in terms of the
Bingham model, which is a function of:
Yield stress: the minimum stress to initiate
or maintain flow (related to slump)
Plastic viscosity: the resistance to flow once
yield stress is exceeded (related to
stickiness)
Concrete rheology provides many
insights into concrete workability.
Slump and slump flow are a function of
concrete rheology.
Shear Rate, (1/s)
S
h
e
a
r

S
t
r
e
s
s
,

(
P
a
)

q
t
=
q t =
Results
The Bingham Model
t t + =
0
slope = plastic viscosity ()
intercept = yield stress (t
0
)
Flow Curve
4
Workability and Rheology
Workability: The ease with which
[concrete] can be mixed, placed,
consolidated, and finished to a
homogenous condition. (ACI
Definition)
Workability tests are typically
empirical
Tests simulate placement condition and
measure value (such as distance or
time) that is specific to the test method
Difficult to compare results from one test
to another
Multiple tests needed to describe
different aspects of workability
Rheology provides a fundamental
measurement
Results from different rheometers have
been shown to be correlated
Results can be used to describe multiple
aspects or workability
ACI 238.1R-08 report describes 69
workability and rheology tests.
5
Concrete Flow Curves (Constitutive Models)

q t =
t t

+ =
0
b
a t t

+ =
0
b
a t t

+ =
0
b
a t t

+ =
0
b
a t t

+ =
0
b
a t t

+ =
0
Flow curves represent shear stress vs. shear rate
Bingham model is applicable to majority of concrete
Other models are available and can be useful for specific
applications (e.g. pumping)
Very stiff concrete behaves more as a solid than a liquid. Such
mixtures are not described by these models.
6
Concrete Rheology: Non-Steady State
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

Shear Rate (1/s)
S
h
e
a
r

S
t
r
e
s
s

(
P
a
)

Time (s)
T
o
r
q
u
e

(
N
m
)

concrete sheared at constant, low rate
Flow Curve Test
Stress Growth Test
concrete sheared at various rates
maximum stress from rest
= static yield stress
area between up and down
curves due to thixotropy
slope = plastic viscosity
intercept =
dynamic
yield stress
Concrete exhibits different rheology
when at rest than when flowing.
Thixotropy is especially critical in highly flowable concretes.
7
Thixotropy Manifestation in Rheology Measurements
Increase in shear rate causes
gradual breakdown of
thixotropic structure
Decrease in shear rate allows
re-building of thixotropic
structure
Change in shear stress due to
change in thixotropic structure
must be taken into account
when:
Measuring rheology
Flow curve area
Stress growth
Proportioning concrete for
applications

8
Thixotropy Manifestation in Concrete Delivery
Change in yield stress from mixing through delivery and placement
Dynamic Yield Stress
Full Breakdown,
No Thixotropy
Static Yield Stress of
Non - Agitated SCC
No Breakdown, Full
Thixotropy

Static Yield Stress
of SCC During
Placement
Time from Mixing
Y
i
e
l
d

S
t
r
e
s
s

Concrete is partially
agitated during transit ,
preventing full build - up
of at - rest structure
Concrete is discharged into forms
resulting shearing causes full
breakdown of at-rest structure t u
Concrete is in formwork;
a t - rest structure rebuilds
and static yield stress
increases
9
Rheology Measurement: Typical Geometry
Rheometers must be uniquely designed for concrete (primarily
due to large aggregate size)
Results can be expressed in relative units (torque vs. speed) or
absolute units (shear stress vs. shear rate)

Coaxial Cylinders Parallel Plate Impeller
Typical Rheometer Geometry Configurations
10
Concrete Rheometers
Tattersall Two-Point Rheometer IBB Rheometer ICAR Rheometer
BML Viscometer BTRHEOM Rheometer
11
ICAR Rheometer
Example Test Protocols
Stress Growth Test
Protocol: rotate vane at 0.05 rps, concrete maintained at rest
before test
Results: static yield stress (peak stress)
Flow Curve Test
Protocol: Immediately after stress growth test, increase vane
speed in 8 increments from 0.05 to 0.50 rps, maintain 0.50 rps
for 20 s, reduce speed in 8 increments from 0.50 to 0.05 rps
Results: thixotropy (area between up and down curves), dynamic
yield stress (intercept of down curve), plastic viscosity (slope of
down curve)
Vane Geometry
H: 5 in (125 mm)
D: 5 in (125 mm)
ICAR rheometer was used for the case studies described in this presentation.
12
SCC Rheology
SCC is designed to flow under its own
mass, resist segregation, and meet
other requirements (e.g. mechanical
properties, durability, formwork
pressure, pump pressure)
Compared to conventional concrete,
SCC exhibits:
Significantly lower yield stress (near zero):
allows concrete to flow under its own mass
Similar plastic viscosity: ensures
segregation resistance
Plastic viscosity must not be too high
or too low
Too high: concrete is sticky and difficult to
pump and place
Too low: concrete is susceptible to
segregation
Thixotropy is more critical for SCC due
to low yield stress

Shear Rate, (1/s)
S
h
e
a
r

S
t
r
e
s
s
,

(
P
a
)

q
t
=
q t =

t
0

t
0

Similar plastic
viscosity
Near zero
yield stress
Conventional
Concrete
SCC
Yield stress is the main difference between SCC and conventional concrete.
13
SCC: Specification
SCC workability is described in terms of the following:
Filling ability
Passing ability
Segregation resistance (stability)
Static segregation resistance
Dynamic segregation resistance
Each property should be evaluated independently
Minimum requirements for each property vary by application
14
SCC: Specification
Property Laboratory
(Pre-Qualification)
Field
(Quality Control)
Filling Ability
(Slump Flow)
Yes. Yes. Provides indirect measurement of yield
stress and plastic viscosity.
Passing Ability
(J-Ring)
Yes. No. Depends primarily on aggregates, paste
volume, slump flow.
Segregation Resistance
(Column Segregation)
Yes. Check robustness across typical changes
in materials (especially water)
No. Variations mainly depend on paste
rheology (water).
Slump Flow
ASTM C 1611
J-Ring
ASTM C 1621
Column Segregation
ASTM C 1610
Filling Ability Passing Ability Segregation Resistance
Test requirements vary between lab and field.
ASTM tests are available to measure the three SCC properties independently.
By confirming robustness in lab and closely controlling materials, fewer tests may be needed in field.
15
SCC: Specification
Slump flow vs. yield stress for single
mixture proportion, variable HRWR
R
2
= 0.90
0
1
2
3
4
5
6
7
8
9
10
0 30 60 90 120
Plastic Viscosity (Pa.s)
T
2
0

(
s
)
T
20
vs. plastic viscosity
Reference: Koehler, E.P., Fowler, D.W. (2008). Comparison of Workability Test
Methods for Self-Consolidating Concrete Submitted to Journal of ASTM International.
Empirical workability tests are a function of rheology.
Rheology provides greater insight into workability.
16
SCC: Design
Compared to conventional concrete, SCC proportions typically
exhibit:
Lower coarse aggregate content (S/A = 0.50 vs. 0.40)
Smaller maximum aggregate size (3/4 or less vs. up to 1 )
Higher paste volume (28-40% vs. 25-30%)
Higher powder content (cementitious and non-cementitious, >700 lb/yd
3
)
Low water/powder ratio (0.30-0.40)
Polycarboxylate-based HRWR (to achieve high slump flow)
17
SCC: Design
Both the mixture proportions and the admixture can be tailored to
the application.

Precast vs. ready mix
SCC vs. conventional concrete
Formwork pressure
Pumpability
Mixing
Stickiness and Cohesion
Form surface finish
Finishability
18
SCC: Design
Reference: Koehler, E.P., Fowler, D.W. (2007). ICAR Mixture Proportioning
Procedure for SCC International Center for Aggregates Research, Austin, TX.
Yield
Stress
Plastic
Viscosity
Aggregate max. size (increase)

Aggregate grading (optimize)

Aggregate angularity

Aggregate shape (equidimensional)

Paste volume (increase)

Water/powder (increase)

Fly ash

Slag

Silica fume (low %)

Silica fume (high %)

VMA

HRWR

AEA

Yield Stress (Pa)
P
l
a
s
t
i
c

V
i
s
c
o
s
i
t
y

(
P
a
.
s
)

AEA
Silica Fume
HRWR
Water
Effects of Materials and Mixture Proportions on Rheology
19
SCC: Design
0
5
10
15
20
25
30
0 30 60 90 120
Elapsed Time (Minutes)
S
l
u
m
p

F
l
o
w

(
i
n
c
h
e
s
)
PC 068
PC 059
PC 915
w/c = 0.35
0
50
100
150
200
250
0 30 60 90 120
D
y
n
a
m
i
c

Y
i
e
l
d

S
t
r
e
s
s

(
P
a
)
PC 068
PC 059
PC 915
w/c = 0.35
0
20
40
60
80
100
120
0 30 60 90 120
P
l
a
s
t
i
c

V
i
s
c
o
s
i
t
y

(
P
a
.
s
)
PC 068
PC 059
PC 915
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0 30 60 90 120
T
h
i
x
o
t
r
o
p
y

(
N
m
/
s
)
PC 068
PC 059
PC 915
w/c = 0.35
3 Different HRWRs | Same Slump Flow | Same Mix Design | Different Rheology
R
e
f
e
r
e
n
c
e
:

J
e
k
n
a
v
o
r
i
a
n
,

A
.
,

K
o
e
h
l
e
r
,

E
.
P
.
,

G
e
a
r
y
,

D
.
,

M
a
l
o
n
e
,

J
.

(
2
0
0
8
)
.

C
o
n
c
r
e
t
e

R
h
e
o
l
o
g
y

w
i
t
h

H
i
g
h
-
R
a
n
g
e

W
a
t
e
r
-
R
e
d
u
c
e
r
s

w
i
t
h

E
x
t
e
n
d
e
d

S
l
u
m
p

F
l
o
w

R
e
t
e
n
t
i
o
n

P
r
o
c
e
e
d
i
n
g
s

o
f

S
C
C

2
0
0
8
,

C
h
i
c
a
g
o
,

I
l
l
i
n
o
i
s
.

20
SCC: Design
Concrete can be modeled as a concentration suspension. These model can
be used to design mixture proportions.
=Huggins coefficient
=solid volume concentration
=intrinsic viscosity
=viscosity of suspension
=viscosity of suspending medium
Factors Sub-Factors
Aggregates
Maximum Size
Grading
Shape
Paste Volume
Filling Ability
Passing Ability
Robustness
Paste Composition
Water
Powder
Air
Reference: Koehler, E.P., Fowler, D.W.
(2007). ICAR Mixture Proportioning
Procedure for SCC International Center for
Aggregates Research, Austin, TX.
ICAR Mixture Proportioning Procedure
Based on concrete as concentrated
suspension of aggregates in paste
Includes equation for calculating
required paste volume.
21
SCC: Management
The workability box is an effective
way to ensure production
consistency
Definition: Zone of rheology
associated with acceptable workability
(self-flow and segregation resistance)
Mixture proportions affect
rheology; therefore, controlling
rheology is an effective way to
control mixture proportions
Workability boxes are mixture-
specific
SCC encompasses a wide range of
materials and rheology
Rheology appropriate for one set of
materials may be inappropriate for
another set of materials
Larger workability box corresponds to
greater robustness
0
5
10
15
20
25
30
35
40
45
50
0 50 100 150
Yield Stress (Pa)
P
l
a
s
t
i
c

V
i
s
c
o
s
i
t
y

(
P
a
.
s
)
Low Flow
Good
Segregation
Example
Requires Vibration
Segregation
Good
22
SCC Case Studies

Formwork pressure


Pumpability

23
SCC Case Study: Formwork Pressure
Formwork pressure is related to
concrete rheology
Pressure is known to increase with slump
SCC often exhibits high formwork
pressure due to its high fluidity
Concrete is at rest in forms, therefore,
static yield stress is relevant
Static yield stress is affected by dynamic
yield stress and thixotropy
SCC is placed in lifts, which takes
advantage of thixotropy
SCC must be designed to flow under
its own mass and exert low formwork
pressure
Low dynamic yield stress (self flow)
Fast increase in static yield stress
(reduced formwork pressure)

24
Reference: Koehler, E.P., Keller, L., and Gardner, N.J. (2007). Field Measurements of
SCC Rheology and Formwork Pressure Proceedings of SCC 2007, Ghent, Belgium
0
100
200
300
400
500
600
0 20 40 60 80 100 120
Time from Placement, Minutes
D
y
n
a
m
i
c

Y
i
e
l
d

S
t
r
e
s
s

(
P
a
)
Mix 1 (Base)
Mix 2 (Increased
CA)
Mix 3 (Lower w/cm,
Different Admix)
-0.1
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0 20 40 60 80 100 120
Time from Placement, Minutes
T
h
i
x
o
t
r
o
p
i
c

B
r
e
a
k
d
o
w
n

A
r
e
a

(
N
m
/
s
)
Mix 1 (Base)
Mix 2 (Increased
CA)
Mix 3 (Lower w/cm,
Different Admix)
Peterborough Trial 2 - July 12, 2006
Concrete temperature 20C
-10
-5
0
5
10
15
20
25
30
35
40
11.0 11.5 12.0 12.5 13.0
Time (Hour + Decimal)
L
a
t
e
r
a
l

P
r
e
s
s
u
r
e

(
k
P
a
)
Cell 13 (Hyd.Pres. 36.1 kPa)
Peterborough Trial 3 - Sept 20, 2006,
Concrete temperature 21C
-20
0
20
40
60
80
100
10.0 10.5 11.0 11.5 12.0 12.5 13.0
Time (Hour + Decimal)
L
a
t
e
r
a
l

P
r
e
s
s
u
r
e

(
k
P
a
)
Mix 1 and 2: Fast increase in yield stress and thixotropy low
formwork pressure
Mix 3: Slow increase in yield stress and thixotropy high formwork
pressure

Results confirm that high static yield stress
reduces formwork pressure.
25
Options to Reduce SCC Formwork Pressure
Select concrete with fast build-up of static yield stress
Attributable to thixotropy
Must achieve concurrent with low dynamic yield stress
Place concrete in lifts to allow build-up of thixotropic structure
Limit pour heights and rates based on concrete rheology
Do not vibrate concrete

26
SCC Case Study: Segregation Resistance
SCC consists of aggregates suspended in a thixotropic, Bingham
paste
Paste must exhibit proper rheology to suspend a particular set of
aggregates
Static yield stress > minimum static yield stress: no segregation
Static yield stress < minimum static yield stress: rate of descent of aggregate
depends on paste yield stress and viscosity
Reference Equation
Beris, A. N., Tsamopoulos, J.A., Armstrong,
R.C., and Brown, R.A. (1985). Creeping motion
of a sphere through a Bingham plastic, J ournal
of Fluid Mech., 158, 219-244.
Jossic, L., and Magnin, A. (2001). Drag and
Stability of Objects in a Yield Stress Fluid,
AIChE J ournal, 47(12). 2666-2672.
Saak, A.W., Jennings, H.M., and Shah, S.P.
(2001). New Methodology for Designing Self-
Compacting Concrete, ACI Materials J ournal,
98(6), 429-439.
( )R g
fluid sphere
t > ) 09533 . 0 (
0
( )R g
fluid sphere
t > ) 124 . 0 (
0
( )R g
fluid sphere
t >
3
4
0
Buoyancy + Resisting Force
-Paste rheology
-Paste density
-Aggregate morphology
-Neighboring aggregates (lattice
effect)
Gravitational Force
-Aggregate density
-Aggregate size
Equations relating descent of sphere to rheology
Reference: Koehler, E.P., and Fowler, D.W. (2008). Static and Dynamic
Yield Stress Measurements of SCC Proceedings of SCC 2008, Chicago, IL.
27
SCC Case Study: Segregation Resistance
0
5
10
15
20
25
30
35
40
45
50
0 20 40 60 80 100
Dynamic Yield Stress, 0 min. (Pa)
P
l
a
s
t
i
c

V
i
s
c
o
s
i
t
y
,

0

m
i
n
.

(
P
a
.
s
)
Column Seg<10%
Column Seg>10%
-0.05
0.00
0.05
0.10
0.15
0.20
0 20 40 60 80 100
Dynamic Yield Stress, 0 min. (Pa)
T
h
i
x
o
t
r
o
p
y
y
,

0

m
i
n
.

(
N
m
/
s
)
Column Seg<10%
Column Seg>10%
Segregation resistance increased with:
Higher yield stress (static and dynamic yield stress assumed equal initially)
Higher plastic viscosity
Higher thixotropy
Reference: Koehler, E.P., and Fowler, D.W. (2008). Static and Dynamic
Yield Stress Measurements of SCC Proceedings of SCC 2008, Chicago, IL.
28
SCC Case Study: Pumpability
Concrete moves through a
pump line as a plug
surrounded by a sheared
region at the walls.
Higher viscosity increases
pumping pressure, reduces flow
rate
Unstable mixes may cause
blocking
Pumping concrete in high-rise
buildings presents unique
challenges
High strength mixes often have
low w/cm, resulting in high
concrete viscosity
Blockage can result in significant
jobsite delays
(
(
|
|
.
|
\
|
+
|
|
.
|
\
|
=
4
0 0
4
3
1
3
4
1
8
w w
L
PR
Q
t
t
t
t
t
Buckingham-Reiner Equation
sheared
region
plug flow
region
flow
shear stress = yield stress
wall at stress shear
radius tube
rate flow
=
=
=
w
R
Q
t
length tube
pressure
=
=
L
P
29
Duke Energy Building, Charlotte, NC
52 Story Office Tower (764 ft) with 9 story building
annex
8 Story Parking Structure 95 ft below street level
Concrete Mixture Requirements
Compressive Strength
5,000 psi to 18,000 psi (35 to 124 MPa)
Modulus of Elasticity
4.6 to 8.0 x 10
6
psi (32 to 55 GPa)
Workability
27 +/- 2 inch spread (690 +/- 50 mm)
To meet compressive strength and elastic
modulus requirements, the high strength
concrete mixtures were proportioned with:
Low w/c
Silica fume
High-modulus crushed coarse aggregate
The resulting mixture exhibited:
High viscosity
High pump pressure
30
31

VMA and/or other changes in
mixture proportions were shown to
increase pumpability by reducing
concrete viscosity.
Role of VMA in reducing viscosity:
VMA results in shear-thinning behavior
Increased viscosity (thickens) concrete at rest
and at low shear rates: beneficial for reduced
formwork pressure and increased segregation
resistance
Decreased viscosity (thins) at high shear rates:
beneficial for improved pumpability
Reduced pump stroke time confirmed
in field mix with VMA
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0.00 0.10 0.20 0.30
Rotation Speed (rps)
T
o
r
q
u
e

(
N
m
)
#1: baseline
#4: Increase paste vol
#4: +VMA
#5: Increase w/cm
#5: +VMA
#6: Change agg
#6: +VMA
32
Conclusions
Concrete rheology is a useful tool for specifying, designing, and
managing SCC.
Static yield stress important for at-rest conditions
Dynamic yield stress important for flowing conditions
Plastic viscosity important for stickiness and cohesion
Thixotropy important for at-rest conditions
Rheology can be optimized to ensure concrete performance.
Self-consolidating concrete: low dynamic yield stress, adequate plastic
viscosity and thixotropy
Reduced formwork pressure: increased static yield stress (due to
thixotropy)
Increased segregation resistance: increased static yield stress (due to
thixotropy) and viscosity
Increased pumpability: reduced plastic viscosity, stable mixture

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