Belgian Building Research Institute

Lightweight Self-Compacting Concrete (L-SCC):

Systematic approach and case study

5th International RILEM Symposium on Self-Compacting Concrete (SCC2007)

3-5 september 2007, Ghent

Cauberg Niki, BBRI

Kestemont Xavier, Argex
Belgian Building
Research Institute
http://www.bbri.be
Introduction
Introduction

Mix Design/Materials
• Why lightweight SCC?
Knop 2
Test Results
z Reduction in dead load
Case Study z Transport weight
Conclusion

• Objectives research
z Mix design method for precast plants
z Flexibility:
• basic materials

• compressive strength and density

Density classes (D-class) Requested compressive strength class

(LC-class)
D 1.6 LC 25/28
(1400 < oven-dry density < 1600 kg/m³) LC 30/33
LC 35/38
D 1.8 LC 30/33
(1600 < oven dry density < 1800 kg/m³) LC 35/38
LC 40/44
D 2.0 LC 45/50
(1800 < oven dry density < 2000 kg/m³) LC 50/55

Lightweight SCC - SCC 2007, 3-5 september 2/10

Belgian Building
Research Institute
http://www.bbri.be
Mix Design & Materials
Introduction
• Approach (Brouwers)
Mix Design/Materials
z Chinese Method ≈ Modified Andersen and
Andreassen gradings
Knop 2
Test Results

Case Study
z No fixed ratios paste/sand/gravel
Conclusion
Sand
Compressive
= 40% strength
Cement

Mortar Filler
Powder Water demand , larger relative flow
=50%
+
SCC Water/Adm
Aggr.
= 100% = 100

Gravel Mix type D1.6

Water/Adm 80
Modified A&A
Air Fuller
60
PSD [%]

40

20

0
0.01 0.1 1 10 100 1000 10000
Particle size [µm]

Lightweight SCC - SCC 2007, 3-5 september 3/10

Belgian Building
Research Institute
http://www.bbri.be
Mix Design & Materials
Introduction

Mix Design/Materials
• Approach (Brouwers)
Knop 2
Test Results
z No fixed ratios paste/sand/gravel
Case Study z Less cement/filler, more (fine) sand
Conclusion z Input PSD: optimal packing, robust mixtures,
good rheology, more sand, cheaper
100
CEM I 52.5 R
Limestone filler
80 Sand 0/2
Sand 0/5
Lightweight sand (Argex AR 0/4 650)
60 Lightweight aggregate (Argex AM 4/8 650)
PSD [%]

Lightweight aggregate (Argex AM 4/8 750)

40

20

0
0.01 0.1 1 10 100 1000 10000
Particle Size [µm]

Lightweight SCC - SCC 2007, 3-5 september 4/10

Belgian Building
Research Institute
http://www.bbri.be
Mix Design & Materials
Introduction

Mix Design/Materials
• Lightweight aggregates
Knop 2
Test Results
z expanded clay, porous, cellular structure
Case Study z 0/4 mm (650) and 4/8 mm (650 or 750)
Conclusion z water absorption!
-> prewetting

30
12.0%

25
10.0%

Water absorption after 5' [%]

Waterabsorption [%]

20
8.0%

15
6.0%

10

5
4.0%

2.0%
3
0 0.0%
5 30 3600 0.0% 5.0% 10.0% 15.0% 20.0% 25.0%
Time [minutes] Initial humidity of the Lightweight Aggregates, before testing [%]

Lightweight SCC - SCC 2007, 3-5 september 5/10

Belgian Building
Research Institute
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Mix Design & Materials
Introduction

Mix Design/Materials
• Typical mix design
Knop 2
Test Results
z 3 classes
Case Study Mixture design [kg/m³] LD 1.6 D 1.8 D 2.0
Conclusion LC 30/33 LC 35/38 LC 45/50
Cement (CEM 1 (52.5 R LA) 330 350 350
Limestone filler 260 172 172
Sand 0/2 164 140 78
Sand 0/5 0 648 886
Lightweight aggr. 0/4 650 524 0 0
Lightweight aggr. 4/8 650 220 450 0
Lightweight aggr. 4/8 750 0 0 360
Water 159 170 170
SP 4.3 4.1 4.2
VMA 2.3 2.3 3.7
Theoretical density [kg/m³] 1773 1934 2023
W/C [-] 0.50 0.50 0.50
W/P [-] 0.27 0.32 0.32

SP and VMA dosage:

• stability of the mixture (water variations)
• inhibits floating of the lightweight aggregates (« inverse segregation »)
• surface finish
Lightweight SCC - SCC 2007, 3-5 september 6/10
Belgian Building
Research Institute
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Test Results
Introduction

Mix Design/Materials
• Typical test results
Knop 2
Test Results
z 3 classes
Characteristics fresh concrete LD 1.6 D 1.8 D 2.0
Case Study
Slump flow [mm] 655 730 690 ~ Target value
Conclusion T50 mm [s] 4 5 3
Funnel time [s] 15 25 10 ~> Wide range
J-Ring (slump flow) [mm] 675 640 700
with blocking step (h1/h2) 6 10 4
L-Box (ratio)* 0.86 0.70 0.80
Air-ratio [%] 2.0 3.0 1.6
Fresh density [kg/m³] 1766 1834 2070
Characteristics hardened concrete
f_cm_cube 1d [N/mm³] - 32 -
f_cm_cube 7d [N/mm³] 37 - 54
f_cm_cube 28d [N/mm³] 42 46 62
f_ck_cube 28d [N/mm²] 40 39 56
Resulting LC-class LC 30/33 LC 35/38 LC 45/50
Oven-dry density 28d [kg/m³] 1544 1780 1817
E-modulus [N/mm²] 19350 23000 27100

~ Eurocode 2

Shrinkage: 300 to 400 µm/m at 2 months, measurements ongoing

Lightweight SCC - SCC 2007, 3-5 september 7/10
Belgian Building
Research Institute
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Test Results
Introduction

Mix Design/Materials
• Theory -> empirical curves
100.0
Knop 2 D21
Test Results
D 1.6
D42
D43
Case Study 80.0
A&A D44

0.23 < q < 0.5 D45

D46
Conclusion 60.0 D47
D48

PSD [%]
D49
D50
40.0
D51
D52
D56
20.0 D57
D58
D59
0.0 D60
0.01 0.1 1 10 100 1000 10000 D61
100
D62
Upper limit -20.0
A&A1
A&A2
80 Basic curve D 1.6 Particle size [µm] A&A3

Lower limit
PSD [%]

60

40

20

0
0.01 0.1 1 10 100 1000 10000

Particle size [mm]

Lightweight SCC - SCC 2007, 3-5 september 8/10

Belgian Building
Research Institute
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Case study: first industrial tests
Introduction

Mix Design/Materials

Knop 2
• Large-scale tests (precast plant)
Test Results
z housing elements (120·700·15 mm³)
Case Study
Mixture design [kg/m³]
Conclusion Cement 354
Limestone 225
W/C [-] 0.59
Characteristics fresh concrete
Slump flow [mm] 675
Funnel time [s] 13
Fresh density [kg/m³] 2059
Characteristics hardened concrete
f_cm_cube 28d [N/mm³] 51
Oven-dry density 28d [kg/m³] 1800

Lightweight SCC - SCC 2007, 3-5 september 9/10

Belgian Building
Research Institute
http://www.bbri.be
Conclusions
Introduction

Mix Design/Materials
• Mix design method
Knop 2
Test Results z Chinese method, modifications by Brouwers
Case Study and empirical adaptations
Conclusion Including effect of PSD’s
z Optimal packing, robust mixtures

• Resulting mixtures
z Slump flow 700 – 750, funnel time 5 – 25 s
z Density range, oven-dry: 1400 – 2000 kg/m³
z Compressive strenght: LC 20/22 – LC 50/55

• Implementation in precast plants: more

industrial tests are planned

• Surface finish: some work to be done

Lightweight SCC - SCC 2007, 3-5 september 10/10

Belgian Building Research Institute

Thank you very much for your attention!

Questions?

Niki.Cauberg@bbri.be
Xavier.Kestemont@argex.be

www.bbri.be
Belgian Building Research Institute
Belgian Building Research Institute