Koehler Rheology v1

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
Outline
 Rheology
• Definition
• Measurement
 SCC Rheology
• Specification
• Design
• Management
 Case Studies
• Formwork pressure
• Segregation resistance
• Pumpability
Tenth CANMET/ACI International Conference on Recent Advances in Concrete Technology and Sustainability Issues
2
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 Results
Bingham model, which is a function of:
• Yield stress: the minimum stress to initiate Flow Curve
 
Shear Stress,  (Pa)
or maintain flow (related to slump)
The Bingham Model
• Plastic viscosity: the resistance to flow once    0  
yield stress is exceeded (related to
stickiness) slope = plastic viscosity ()
 Concrete rheology provides many
insights into concrete workability.
intercept = yield stress (0)
• Slump and slump flow are a function of
concrete rheology.
   (1/s)
Shear Rate,
3
Workability and Rheology
 Workability: “The ease with which ACI 238.1R-08 report describes 69
[concrete] can be mixed, placed, workability and rheology tests.
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
4
Concrete Flow Curves (Constitutive Models)
 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.
   0  a b
   0  
  0  a0 
b
a b
  
  0  a0 
b
a b
5
Concrete Rheology: Non-Steady State
Flow Curve Test
concrete sheared at various rates
Shear Stress (Pa)

Concrete exhibits different rheology area between up and down
curves due to thixotropy
when at rest than when flowing.
Static Yield Stress

minimum shear stress to initiate flow from
rest slope = plastic viscosity
Dynamic Yield Stress

intercept =
minimum shear stress to maintain flow after dynamic Shear Rate (1/s)
breakdown of thixotropic structure yield stress
Stress Growth Test
Plastic Viscosity concrete sheared at constant, low rate
change in shear stress per change in shear maximum stress from rest
rate, above yield stress = static yield stress
Torque (Nm)
Thixotropy
reversible, time-dependent reduction in
viscosity in material subject to shear
Thixotropy is especially critical in highly flowable concretes.

Time (s)
6
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
7
Thixotropy Manifestation in Concrete Delivery
Change in yield stress from mixing through delivery and placement
Static Yield Stress of

Non-Agitated SCC
No Breakdown, Full Static Yield Stress
Thixotropy of SCC During
Yield Stress
Placement
Concrete is in formwork;
at-rest structure rebuilds
and static yield stress
increases
Dynamic Yield Stress
Full Breakdown,
No Thixotropy
Concrete is partially Time from Mixing

agitated during transit,
Concrete is discharged into forms
preventing full build-up
resulting shearing causes full
of at-rest structure
breakdown of at-rest structure
tu
8
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)
Typical Rheometer Geometry Configurations

Coaxial Cylinders Parallel Plate Impeller
9
Concrete Rheometers
Tattersall Two-Point Rheometer IBB Rheometer ICAR Rheometer
BTRHEOM Rheometer BML Viscometer
10
ICAR Rheometer
ICAR rheometer was used for the case studies described in this presentation.
Vane Geometry 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
H: 5 in (125 mm) Results: thixotropy (area between up and down curves), dynamic
D: 5 in (125 mm) yield stress (intercept of down curve), plastic viscosity (slope of
down curve)
11
SCC Rheology
Conventional
 SCC is designed to flow under its own
 
Concrete
Shear Stress,  (Pa)

mass, resist segregation, and meet 
other requirements (e.g. mechanical
properties, durability, formwork 0 Similar plastic
pressure, pump pressure)
viscosity
 Compared to conventional concrete, Near zero
SCC exhibits: yield stress SCC
• Significantly lower yield stress (near zero): 
allows concrete to flow under its own mass
0
• Similar plastic viscosity: ensures
segregation resistance
 Plastic viscosity must not be too high    (1/s)
Shear Rate,
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
Yield stress is the main difference between SCC and conventional concrete.
12
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
13
SCC: Specification
ASTM tests are available to measure the three SCC properties independently.
Filling Ability Passing Ability Segregation Resistance
Slump Flow J-Ring Column Segregation
ASTM C 1611 ASTM C 1621 ASTM C 1610
Test requirements vary between lab and field.

Property Laboratory Field
(Pre-Qualification) (Quality Control)
Filling Ability Yes. Yes. Provides indirect measurement of yield
(Slump Flow) stress and plastic viscosity.
Passing Ability Yes. No. Depends primarily on aggregates, paste
(J-Ring) volume, slump flow.
Segregation Resistance Yes. Check robustness across typical changes No. Variations mainly depend on paste
(Column Segregation) in materials (especially water) rheology (water).
By confirming robustness in lab and closely controlling materials, fewer tests may be needed in field.
14
SCC: Specification
Empirical workability tests are a function of rheology.
Rheology provides greater insight into workability.
Slump flow vs. yield stress for single

T20 vs. plastic viscosity
mixture proportion, variable HRWR
10
2
9 R = 0.90
8
7
6
T20 (s)
5
4
3
2
1
0
0 30 60 90 120
Plastic Viscosity (Pa.s)
Reference: Koehler, E.P., Fowler, D.W. (2008). “Comparison of Workability Test
Methods for Self-Consolidating Concrete” Submitted to Journal of ASTM International.
15
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 ½”)
• Higher paste volume (28-40% vs. 25-30%)
• Higher powder content (cementitious and non-cementitious, >700 lb/yd3)
• Low water/powder ratio (0.30-0.40)
• Polycarboxylate-based HRWR (to achieve high slump flow)
16
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
• Segregation resistance
• Mixing
• “Stickiness” and “Cohesion”
• Form surface finish
• Finishability
17
SCC: Design
Effects of Materials and Mixture Proportions on Rheology
Yield Plastic
Stress Viscosity
Aggregate max. size (increase)  
Aggregate grading (optimize)  

Aggregate angularity  
Silica Fume Aggregate shape (equidimensional)  
HRWR
Paste volume (increase)  
Water/powder (increase)  
AEA
Fly ash  
Slag  
Water Silica fume (low %)  
Silica fume (high %)  
Yield Stress (Pa) VMA  
HRWR  
AEA  
Reference: Koehler, E.P., Fowler, D.W. (2007). “ICAR Mixture Proportioning

Procedure for SCC” International Center for Aggregates Research, Austin, TX.
18
SCC: Design
3 Different HRWRs | Same Slump Flow | Same Mix Design | Different Rheology
w/c = 0.35 w/c = 0.35
250
30 PC 068
PC 059
Dynamic Yield Stress (Pa)

200
Slump Flow (inches)
25 PC 915
Reference: Jeknavorian, A., Koehler, E.P., Geary, D., Malone, J. (2008).
“Concrete Rheology with High-Range Water-Reducers with Extended
20
150
Slump Flow Retention” Proceedings of SCC 2008, Chicago, Illinois.
15
100
10
PC 068
PC 059 50
5
PC 915
0 0
0 30 60 90 120 0 30 60 90 120
Elapsed Time (Minutes) Elapsed Time (Minutes)
w/c = 0.35
120 0.45
PC 068 PC 068
0.40 PC 059
100 PC 059
PC 915 0.35 PC 915

Thixotropy (Nm/s)
80 0.30
0.25
60
0.20
40 0.15
0.10
20
0.05
0 0.00
0
Tenth 30
CANMET/ACI 60
International 90
Conference on120 0
Recent Advances in Concrete 30
Technology and60Sustainability
90 Issues 120
Elapsed Time (Minutes) Elapsed Time (Minutes) 19
SCC: Design
Concrete can be modeled as a concentration suspension. These model can
be used to design mixture proportions.
=solid volume concentration =viscosity of suspension

=Huggins coefficient
=viscosity of suspending medium
=intrinsic viscosity
ICAR Mixture Proportioning Procedure

Factors Sub-Factors
• Based on concrete as concentrated Maximum Size
suspension of aggregates in paste Aggregates Grading
• Includes equation for calculating Shape
required paste volume. Filling Ability
Paste Volume Passing Ability
Reference: Koehler, E.P., Fowler, D.W. Robustness
(2007). “ICAR Mixture Proportioning Water
Procedure for SCC” International Center for
Paste Composition Powder
Aggregates Research, Austin, TX.
Air
20
SCC: Management
 The workability box is an effective
way to ensure production Example
consistency
50
Low Flow
Definition: Zone of rheology
45 Good
associated with acceptable workability Requires Vibration
Segregation
(self-flow and segregation resistance) 40

 Mixture proportions affect 35
rheology; therefore, controlling 30

rheology is an effective way to 25
Good
control mixture proportions
20
 Workability boxes are mixture- 15
specific Segregation
10
• SCC encompasses a wide range of
5
materials and rheology
0
• Rheology appropriate for one set of 0 50 100 150
materials may be inappropriate for
Yield Stress (Pa)
another set of materials
• Larger workability box corresponds to
greater robustness
21
SCC Case Studies
 Formwork pressure
 Segregation resistance
 Pumpability
22
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)
23
600 0.8 40
Thixotropic Breakdown Area (Nm/s)

Mix 1 (Base) Mix 1 (Base)
Peterborough Trial 2 - July 12, 2006
0.7 35
Dynamic Yield Stress (Pa)
500 Mix 2 (Increased Mix 2 (Increased Concrete temperature 20C

CA) CA)
Mix 3 (Lower w/cm,
0.6 30
Mix 3 (Lower w/cm,
Different Admix) Different Admix)
400 0.5 25
Lateral Pressure (kPa)

0.4 20
300
0.3
15
200 0.2 Cell 13 (Hyd.Pres. 36.1 kPa)
10 Cell 14 (Hyd.Pres. 63.5 kPa)
0.1 Cell 15 (Hyd.Pres. 91.1 kPa)
100 5
0 Cell 16 (Hyd.Pres. 98.7 kPa)
0
0 -0.1
11.0 11.5 12.0 12.5 13.0
0 20 40 60 80 100 120 0 20 40 60 80 100 120 -5
Time (Hour + Decimal)
Time from Placement, Minutes Time from Placement, Minutes -10
100
Peterborough Trial 3 - Sept 20, 2006,
Concrete temperature 21C
Mix 1 and 2: Fast increase in yield stress and thixotropy – low 80 Cell 13 (Hyd.Pres. 36.1 kPa)
formwork pressure Cell 14 (Hyd.Pres. 63.5 kPa)
Cell 15 (Hyd.Pres. 91.1 kPa)
Mix 3: Slow increase in yield stress and thixotropy – high formwork
Lateral Pressure (kPa)

60
Cell 16 (Hyd.Pres. 98.7 kPa)
pressure
40
Results confirm that high static yield stress 20
reduces formwork pressure.

0
10.0 10.5 11.0 11.5 12.0 12.5 13.0
Time (Hour + Decimal)
-20
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
24
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
25
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
Gravitational Force
-Aggregate density
-Aggregate size Equations relating descent of sphere to rheology
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”, Journal
 0  (0.09533) g  sphere   fluid R
of Fluid Mech., 158, 219-244.
Jossic, L., and Magnin, A. (2001). “Drag and

Stability of Objects in a Yield Stress Fluid,”  0  (0.124) g  sphere   fluid R
Buoyancy + Resisting Force AIChE Journal, 47(12). 2666-2672.
-Paste rheology Saak, A.W., Jennings, H.M., and Shah, S.P.

g  sphere   fluid R
(2001). “New Methodology for Designing Self- 4
-Paste density Compacting Concrete,” ACI Materials Journal, 0 
3
-Aggregate morphology 98(6), 429-439.
-Neighboring aggregates (lattice Reference: Koehler, E.P., and Fowler, D.W. (2008). “Static and Dynamic
effect) Yield Stress Measurements of SCC” Proceedings of SCC 2008, Chicago, IL.
26
SCC Case Study: Segregation Resistance
50 0.20
Plastic Viscosity, 0 min. (Pa.s)
Column Seg<10% Column Seg<10%

45
Thixotropyy, 0 min. (Nm/s)

Column Seg>10% Column Seg>10%
40 0.15
35
30 0.10
25
20 0.05
15
10 0.00
5
0 -0.05
0 20 40 60 80 100 0 20 40 60 80 100
Dynamic Yield Stress, 0 min. (Pa) Dynamic Yield Stress, 0 min. (Pa)
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.
27
SCC Case Study: Pumpability
 Concrete moves through a

pump line as a “plug”
surrounded by a sheared sheared
region at the walls. region
• Higher viscosity increases plug flow flow

pumping pressure, reduces flow region
rate
• Unstable mixes may cause
blocking
shear stress = yield stress
 Pumping concrete in high-rise
buildings presents unique
challenges
Buckingham-Reiner Equation
• High strength mixes often have
low w/cm, resulting in high
concrete viscosity PR  4  0  1  0  
4
4
Q 1       
• Blockage can result in significant 8L  3   w  3   w  
jobsite delays  
Q  flow rate P  pressure
R  tube radius L  tube length
 w  shear stress at wall
28
 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 106 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
29
Duke Energy Building, Charlotte, NC
30
Duke Energy Building, Charlotte, NC
 VMA and/or other changes in

mixture proportions were shown to
increase pumpability by reducing
5.0
#1: baseline concrete viscosity.
#4: Increase paste vol
4.5
#4: +VMA
#5: Increase w/cm
 Role of VMA in reducing viscosity:
4.0
#5: +VMA
3.5 #6: Change agg • VMA results in shear-thinning behavior

#6: +VMA

Torque (Nm)
Increased viscosity (thickens) concrete at rest

3.0
and at low shear rates: beneficial for reduced
2.5 formwork pressure and increased segregation
resistance
2.0
 Decreased viscosity (thins) at high shear rates:
1.5 beneficial for improved pumpability
1.0 • Reduced pump stroke time confirmed

0.5
in field mix with VMA
0.0
0.00 0.10 0.20
Tenth CANMET/ACI International 0.30
Conference on Recent Advances in Concrete Technology and Sustainability Issues
31
Rotation Speed (rps)
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
32

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Use of Rheology to Design, Specify, and

Manage Self-Consolidating Concrete

Tenth CANMET/ACI International Conference on Recent Advances in

Shear Stress (Pa)

Static Yield Stress

Dynamic Yield Stress

Thixotropy is especially critical in highly flowable concretes.

• Proportioning concrete for

Change in yield stress from mixing through delivery and placement

Static Yield Stress of

Concrete is partially Time from Mixing

Typical Rheometer Geometry Configurations

BTRHEOM Rheometer BML Viscometer

Vane Geometry Example Test Protocols

Shear Stress,  (Pa)

 Each property should be evaluated independently

Test requirements vary between lab and field.

Slump flow vs. yield stress for single

• Precast vs. ready mix

Aggregate grading (optimize)  

Reference: Koehler, E.P., Fowler, D.W. (2007). “ICAR Mixture Proportioning

Dynamic Yield Stress (Pa)

PC 915 0.35 PC 915

=solid volume concentration =viscosity of suspension

ICAR Mixture Proportioning Procedure

Plastic Viscosity (Pa.s)

rheology; therefore, controlling 30

 Formwork pressure is related to

Thixotropic Breakdown Area (Nm/s)

500 Mix 2 (Increased Mix 2 (Increased Concrete temperature 20C

Lateral Pressure (kPa)

Lateral Pressure (kPa)

Results confirm that high static yield stress 20

reduces formwork pressure.

Jossic, L., and Magnin, A. (2001). “Drag and

-Paste rheology Saak, A.W., Jennings, H.M., and Shah, S.P.

Column Seg<10% Column Seg<10%

Thixotropyy, 0 min. (Nm/s)

Segregation resistance increased with:

 Concrete moves through a

• Higher viscosity increases plug flow flow

 To meet compressive strength and elastic

Duke Energy Building, Charlotte, NC

 VMA and/or other changes in

3.5 #6: Change agg • VMA results in shear-thinning behavior

Increased viscosity (thickens) concrete at rest

1.0 • Reduced pump stroke time confirmed

 Rheology can be optimized to ensure concrete performance.

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