CI3906Ferraris PDF
CI3906Ferraris PDF
CI3906Ferraris PDF
Role of Rheology in
Achieving Successful
Concrete Performance
Properties must be balanced to manage segregation, surface finish, pumping
pressure, or formwork pressure
by Chiara F. Ferraris, Peter Billberg, Raissa Ferron, Dimitri Feys, Jiong Hu, Shiho Kawashima, Eric Koehler, Mohammed
Sonebi, Jussara Tanesi, and Nathan Tregger
T
his article provides a basic introduction to concrete Measurement Tools and Procedures
rheology, as well as some insight into how rheology Tools and devices
can be applicable to concrete construction. The fresh Rotational shear rheometers are standard equipment used
state performance of concrete is not only important for proper to characterize the rheological properties of fluids. Such
concrete placement and finishing but also for its hardened equipment is commonly used in asphalt binder testing
state properties. Yet, the most commonly used workability test laboratories (state, federal agencies, and producers); for
methods are based on empirical methodologies, such as slump example, refer to ASTM D717513 and AASHTO T 315.14
tests. Even self-consolidating concrete (SCC), which is These devices apply continuous shear to the sample through
governed by the property of flowing under its own weight,1 is rotational movement at controlled torque or speed. Rheometers
typically classified based on the results of empirical tests such for concrete must be specifically designed due to the large
as slump flow, V-funnel, L-box, and J-ring tests. To improve particle size of the aggregates. Most geometrical configurations
quality control and performance of concrete, workability for concrete rheometers are based on coaxial cylinders shown
measurements based on fundamental principles instead of in Fig. 2(a). The coaxial cylinder geometry consists of an
empirical tests are pertinent. inner cylinder (a bob) inserted into an outer cylinder (a cup).
Rheology is the science that seeks to characterize the flow Various geometries can be used for the bob, including but not
and deformation of materials using fundamental principles of limited to a solid cylinder,16 vane,17 and a double spiral.18 The
stresses and shear rates. Similar to how the hardened state vane and double-spiral geometries can be used in place of the
mechanical properties of concrete are characterized by inner cylinder of a coaxial cylinder rheometer to prevent
stresses and strains, rheology provides the user a way to slippage.19 Another commonly used rheometer geometry for
objectively and quantitatively assess the fresh state properties concrete is the parallel plate, as shown in Fig. 2(b).20,21 The
of concrete by relating the shear stresses and shear rates.2 surfaces of the coaxial cylinder and parallel plate should be
Furthermore, rheology is a science that can be applied to textured or roughened to prevent slippage between the
various cement-based systems, including but not limited to concrete and rheometer surface.21 Concrete rheometers have
grouts, SCC, fiber-reinforced concrete, and traditionally been used on various types of concrete classes (for example,
vibrated concrete. SCC and fiber-reinforced concrete), but are not well-suited for
This introduction to concrete rheology begins with a listing stiff concretes (for example, zero-inch slump concrete).
of basic terminology (refer to the textbox), and is followed by Although rotational concrete rheometers have been
explanations of typical measuring instruments and testing successfully used to measure concrete rheology, a series of
procedures used to determine rheological properties. The tests has shown that results from different rheometers do not
concepts of rheology are then further applied to five different agree with each other in absolute terms, caused by differences
practical applications: mixture design and quality control, in experimental techniques and instruments.22-24 Nevertheless,
segregation, pumping, formwork pressure, and surface finish. these results have been shown to rank different mixtures in a
τ (Pa or psi)
Rheology—the science of flow and deformation of matter.2
For fluids, relationships can be described by plotting the shear 0τ = τ + μγ
stress versus the shear rate.
Bingham model—a linear approximation of the shear
* * Δτ
*
**
stress-shear rate relationship of a material or fluid (Fig. 1),
Δγ
described by two material parameters: yield stress and plastic
Shear stress,
viscosity. Most cement-based materials can be described as μ = plastic viscosity
Bingham materials that follow this model. The Bingham yield
= Δτ
stress, or dynamic yield stress, of cement-based materials is Δγ
related to the slump or slump flow.
3,4 5
τ0 = yield stress
Yield stress—the stress required to initiate material flow.
Typically, two types of yield stresses are considered:
•• Static yield stress—the stress required to transition Shear rate, γ (1/s)
from a solid-like to a liquid-like behavior (going from
rest to flow)—that is, starting from a static state and Fig. 1: Representation of Bingham model. The stars represent
going to a dynamic state. As most cementitious experimentally determined data points that are approximated
using a straight line
materials exhibit thixotropy, the static yield stress
increases over time6,7; and
•• Dynamic yield stress—typically taken as the apparent stress where the material transitions from a liquid-like behavior
to a solid-like behavior (going from flow to rest). The dynamic yield stress is an extrapolated value based on the flow
curve (shear stress versus shear rate) and is often based on measurements performed on the “down” flow curve (the
shear stress-shear rate curve obtained from measurements in which the shear rate is decreased from a high shear rate
to a low shear rate; shown in Fig. 1).
Viscosity—a measure of a material’s resistance to flow after flow is initiated. The higher the viscosity, the higher the
material’s resistance to flow. This term is generally used to describe materials that show liquid-like behavior and it provides a
way to fundamentally quantify the “measure of the resistance of a fluid to deform under shear stress.”8
•• Plastic viscosity—the slope of the shear stress-shear rate relationship as described by the Bingham model (Fig. 1).
Thixotropy—the reversible material stiffening with time of the material at rest, and its ability to refluidize when
sheared.9,10 Per definition, thixotropy has a physical nature due to particle agglomeration11,12 and it is not the same as stiffening
due to hydration, which is chemical in nature. Cement-based materials are more complicated than ideal Bingham materials
because the rheological properties of cement-based materials will also vary with time.
Applied rotation
and measured
torque Applied rotation
Bob and measured
torque
Outer Top
cylinder plate
Fluid Fluid
Bottom
plate
(fixed)
(a) (b)
Fig. 2: Typical rheometer configurations: (a) coaxial cylinders; and (b) parallel plates (adapted from Reference 15)
Yield stress, Pa
pumping is by enlarging the pipe diameter. Increasing the pipe Low viscosity:
diameter from 4 to 5 in. (100 to 125 mm) can roughly Risk for High yield stress:
decrease pumping pressure by a factor of two.50 Decreasing segregation, Low filling ability
the flow rate and/or viscosity of the concrete are other especially for Low surface quality
alternatives to reduce pumping pressure. For conventional high free fall Consolidation recommended
concrete, decreasing the yield stress (increasing the slump) and sudden
change in
can also reduce pressure.44 casting
It should be noted, however, that the actual flow behavior 100 direction
in pipes is more complex. The reader is referred to recent, Low yield stress: Zone III
extensive studies on the characterization of the lubrication High filling ability
layer for more information.49,51 0 Good surface quality
0 10 60
Formwork pressure Plastic viscosity, Pa·s
In placing conventional concrete within formwork (and in Fig. 6: Influence of rheological properties on surface finish of SCC
general), vibration is required to achieve proper consolidation. cast in L-shaped elements (adapted from Reference 60)
As the vibration is applied, yield stress is lowered, allowing
consolidation to occur. When the vibration is removed, the
high thixotropic nature of normal concrete restores the high surface finish of concrete or mortar (for example, NF P 18-503,55
yield stress. Although the high yield stress of conventional AMA Hus 9856 or BS 8110-1,57 and CIB No. 2458).
concrete is responsible for requiring vibration, the high yield Surface finish is affected by a variety of parameters,
stress combined with high thixotropy is advantageous because including mixture proportions, setting time, formwork
it also results in low formwork pressure.12 surfaces, type of release agent, casting technique, placement
SCC is a highly flowable concrete. However, an SCC speed and temperature, yield stress, and plastic viscosity.59
mixture must be capable of handling high flow while Figure 6 shows three zones defined by ranges of yield stress
providing adequate segregation resistance. Because of its high and plastic viscosity of SCC, illustrating that the fresh
flowability, SCC does not require any external vibration to concrete behavior and surface finish are affected in different
consolidate it; thus, faster casting rates can be achieved during ways. If the plastic viscosity of the mixture is too low (Zone I),
construction. However, its low yield stress can result in high there can be an elevated risk for segregation during casting,
formwork pressure.12 Underestimating the pressure can lead to especially in placements with large free-fall height and/or
deformed formwork with malformed structures or, in the changes in the direction of concrete flow during casting.
worst case, a formwork collapse. Overestimating the pressure Segregation can affect the surface finish, as it can result in
is an economical issue due to the high share of formwork cost regions with very high or very low paste content. However, if
to overall cost of concrete construction.52 Besides the balance the yield stress of the mixture is too high (Zone II), the
between formwork strength and cost, use of SCC in areas mixture can stabilize large entrapped air bubbles, preventing
where formwork pressure is a concern requires careful them from leaving the system. In a non-SCC mixture, such
attention to thixotropy. In other words, as the SCC rests in the issues can be alleviated by additional consolidation using
form, yield stress and viscosity increase, reducing the amount vibration. This will temporarily lower the yield stress, thus
of vertical pressure that is translated horizontally to the enabling unwanted air bubbles to rise. The necessary
formwork. The faster this rate of increase in rheological consolidation energy is dependent on the yield stress and
properties occurs, the lower the formwork pressure. plastic viscosity of the mixture. However, because SCC
Increasing thixotropy from a mixture design perspective mixtures do not warrant vibration, it is important to ensure
has been the focus of much recent research. Some ways to that the balance between viscosity and yield stress is such that
enhance thixotropy include the use of chemical admixtures the mixture is in Zone III, as this will enable large entrapped
(such as VMAs), SCMs (such as silica fume), and reducing air bubbles to rise to the surface. While mixtures in Zone III
w/cm.11,13,53,54 will generally have good surface quality, it should be noted
that bubbles will rise slowly in mixtures with very high
Quality of surface finish viscosity or in mixtures that exhibit high thixotropy (the static
The quality of the surface finish of concrete is linked to a yield stress increases rapidly when the concrete is at rest).
project’s aesthetic requirements. Primary aesthetic issues A low yield stress with a balanced viscosity can be
include the homogeneity of the color (or tint), roughness of achieved through the use of SCMs or chemical admixtures
the surface, reproduction of formwork details, and the (for example, water reducers), decreasing w/cm, or increasing
presence and size of bug holes. Several standards define the the paste volume.61
Yield stress
increased
Yield stress
high significantly
low low increased
(a)
Viscosity (c)
Viscosity
bugholes
Thixotropy
segregation good ± hydrostatic reduced