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
Mortar, Grout
Paste,

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

Todays Presentation: Based on ACI 238 Report

Compiled from literature search

T
Tests
t have
h
varying
i degrees
d
off industry
i d t
adoption
New tests continue to being developed

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 and finished (ACI)
consolidated,
(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,
ability finishability
finishability, pumpability
pumpability,
passing ability, segregation resistance,
etc.
Test Methods for Workability and Rheology of Fresh Concrete
3

Categorization of Test Methods

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

value
l ((such
h as di
distance
t
or titime)) th
thatt iis specific
ifi tto th
the ttestt method
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 reportt uses categorization
t
i ti
scheme
h
proposed
d by
b NIST
CATEGORY

DEFINITION

EXAMPLES

Confined Flow

The material flows under its own weight or

under applied pressure through a narrow orifice
orifice.

Compaction Factor

Free Flow

The material either flows under its own weight,

without any confinement, or an object
penetrates the material by gravitational settling.

Slump Test

Vibration

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.

Vebe Test

Rotational
Rheometers

The material is sheared between two surfaces,

one or both of which are rotating.

Parallel plate, coaxial

cylinders, impeller rheometers

Tests for Very High

Yield Stress
Concrete*

The material is subjected to relative higher

forces than in other tests due to its stiff
consistency (no slump).

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 reportt uses categorization
t
i ti
scheme
h
proposed
d by
b NIST

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
Standardized
St d di d as ASTM C 143
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
Yield
Yi ld stress
t
iis calculated
l l t d as a ffunction
ti off d
density
it and
d slump
l
flflow
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
P
Remolding
R
ldi T
Testt
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

Applicable
A li bl tto ffullll range off slumps
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
t t with
ith disk
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)
), determined byy calculation or
Absolute units ((shear stress vs. shear rate),
calibration

slope = H

intercept = G

Speed (rps)
( ps)

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

Shearr Stress, (Pa)

To
orque (Nm
m)

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

The Bingham Model

= 0 + &

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

Shear Rate,, & (1/s)

( )

Test Methods for Workability and Rheology of Fresh Concrete

20

Concrete Rheology: Non-Steady State

Flow Curve Test
Concrete exhibits different rheology
when at rest than when flowing.
Static Yield Stress
minimum shear stress to initiate flow from
rest

Shear Stres
S
ss (Pa)

concrete sheared at various rates

area between up and down
curves due to thixotropy

slope = plastic viscosity

Dynamic Yield Stress

minimum shear stress to maintain flow after
breakdown of thixotropic structure

intercept =
dynamic
yield stress

Plastic Viscosity

Shear Rate (1/s)

Stress Growth Test

change in shear stress per change in shear

rate, above yield stress
Thixotropy
reversible, time-dependent reduction in
viscosity in material subject to shear

Torque (Nm)

concrete sheared at constant

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

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

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

BTRHEOM Rheometer

IBB Rheometer
Rh
t

BML Viscometer

ICAR Rheometer
Rh
t

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
mixer, speed of
probe varies due to planetary motion,
enabling calculation of rheological
parameters

control
unit
slump display (in.)

Sl
Slump: Measurements
M
t off hydraulic
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
u be o
of cyc
cycles.
es
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
V Funnel Test

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

 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

Sh
hear Stresss, (Pa)

Tests for Self-Consolidating Concrete (SCC)

Conventional
Concrete

Similar plastic
viscosity
i
it
Near zero
yield stress

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 ttests
t are available
il bl to
t measure the
th three
th
SCC properties
ti iindependently.
d
d tl
Filling Ability

Passing Ability

Segregation Resistance

Slump Flow
ASTM C 1611

J-Ring
ASTM C 1621

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
i d
index

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)

Column filled with

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

Test Methods for Workability and Rheology of Fresh Concrete

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
t on each
h side
id off b
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
l
cone, concrete
t is
i allowed
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
S
Stability
S
Test
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

Tests for paste, mortar, and
grout are frequently
adaptations of tests for
concrete

Mini-Slump
Mini
Slump Test

Flow Cone Test

Mini-slump or mini-flow tests

Flow cone or marsh cone
Rotational rheometers

Other tests include:

Lombardi p
plate test

L b di Pl
Lombardi
Plate
t T
Testt

Turning tube viscometer

Vicat needle test
Wuerpel test

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