ICAR Rheometer

Eric Koehler
W.R. Grace & Co.
eric.koehler@grace.com
2
Outline
What is Rheology?
Definition
Measurement
ICAR Rheometer
Description
Operation
Applications
Mixture proportioning
SCC
Production control
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
Concrete exhibits different rheology when at rest than when flowing.
7
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.
8
Rheology Measurement: Typical Geometry
Rheometers continuously shear concrete through rotational
movement.
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
9
Concrete Rheometers
Tattersall Two-Point Rheometer IBB Rheometer ICAR Rheometer
BML Viscometer BTRHEOM Rheometer
10
ICAR Rheometer
Portable concrete rheometer
Laboratory
Jobsite
Appropriate for moderately and
highly flowable concrete
Measures slumps greater than 75
mm
Especially well-suited for self-
consolidating concrete
Flexible interface allows
measurement of Bingham
parameters, thixotropy, and
other protocols set by user
11
ICAR Rheometer: Operation
Apply Rotation,
Measure Torque
Fluid
Outer
Cylinder
Inner Cylinder
Top View Side View
Based on wide-gap, coaxial
cylinders design
Vane acts as inner cylinder
Compact size
Prevents slip
Outer wall also has vertical
strips to prevent slip
Vane is immersed in concrete
and rotated at different speeds
Computer software operates
test and computes results
Single test complete in 60
seconds
Vane can be replaced with any
other type of impeller

H: 5 in (125 mm)
D: 5 in (125 mm)
12
ICAR Rheometer: Portability
Rheometer Weight: 13 lb (6 kg)
[with accessories: 40 lb (18 kg)]
16 (400 mm)
4.25
(110 mm)
Bucket size depends on aggregate size.
1 (25 mm) aggregate shown
13
Software Interface
All operations managed through single screen.
Flow Curve
Stress Growth
settings
start
real time
data
calculated
results
settings
start
real time
data
calculated
results
All data
automatically
written to text
and Excel file
14
Aggregate Size
Vane is constant size for
all aggregate sizes
Height: 5 in. (125 mm)
Diameter: 5 in. (125 mm)
Outer container is
selected based on
aggregate size
Horizontal and vertical
gaps should be at least 4x
the maximum aggregate
size
Larger container can be
always be used, but
smaller container should
never be used.
15
Stress Growth Test
Stress growth test consists
of the following:
Rotate vane at low, constant
speed
Measure gradual increase in
torque
Identify maximum torque and
convert to stress, which is
equal to static yield stress
Note: reduction in torque after
peak value is associated with
further yielding of material and
is not typically analyzed further
Material is previously at rest
for pre-determined period to
detect effect of thixotropy
Vane speed is typically 0.01
to 0.05 rps
16
Flow Curve Test
Flow curve test measures
shear stress at different
shear rates
Raw torque vs. rotation
speed data are converted to
fundamental units of shear
stress and shear rate
Can also be used to measure
thixotropy
Software Inputs
Test Units
17
Rheometer Test File
All settings and results are
written automatically to a
summary text file.
Raw data (instantaneous
torque and rotation speed) can
optionally be written to a file
for Excel
18
Thixotropy Testing: Flow Curve or Stress Growth
Flow Curve Test
Place concrete in container and allow to rest
for pre-determined time (to allow thixotropic
build-up)
Run flow curve with speeds in ascending
order (low to high), exclude breakdown
period
Immediately run second curve with speeds in
descending order (high to low), include
breakdown period at high speed to assure
full breakdown of thixotropy
Area between up and down curves is
indicative of thixotropy
Stress Growth Test
Place concrete in container and allow to rest
for pre-determined time (to allow thixotropic
build-up)
Run stress growth test, which measures the
static yield stress
The difference between the static yield stress
and dynamic yield stress (flow flow curve) is
indicative of thixotropy
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
19
Applications: Mixture Proportioning
Both the mixture proportions and the admixture can adjusted to
tailor the rheology to the application.

Precast vs. ready mix
SCC vs. conventional concrete
Formwork pressure
Pumpability
Segregation resistance
Mixing
Stickiness and Cohesion
Form surface finish
Finishability
20
Applications: Mixture Proportioning
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
21
Applications: 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.
22
Applications: SCC Rheology
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.
23
Applications: SCC Rheology
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
Elapsed Time (Minutes)
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
Elapsed Time (Minutes)
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
Elapsed Time (Minutes)
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
.

24
Applications: Production Control
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
25
Applications: 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)

26
Applications: Formwork Pressure Case Study
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)
Cell 14 (Hyd.Pres. 63.5 kPa)
Cell 15 (Hyd.Pres. 91.1 kPa)
Cell 16 (Hyd.Pres. 98.7 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
)
Cell 13 (Hyd.Pres. 36.1 kPa)
Cell 14 (Hyd.Pres. 63.5 kPa)
Cell 15 (Hyd.Pres. 91.1 kPa)
Cell 16 (Hyd.Pres. 98.7 kPa)
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.
27
Applications: 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.
28
Applications: 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.
29
Applications: 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
30
Applications: Pumpability Case Study
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
Reference: Koehler, E.P., and Brooks, W., Neuwald, A., and
Mogan, E.. (2009). Applications of Rheology Measurements to
Enable and Ensure Concrete Performance NRMCA Concrete
Technology Forum, Cincinnati, OH.
31
Applications: Pumpability Case Study
Duke Energy Building, Charlotte, NC
32
Applications: Pumpability Case Study

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
Duke Energy Building, Charlotte, NC
33
Conclusions
Rheology is the scientific description of workability.
The ICAR rheometer enables portable rheology measurements in
the lab and field.
Measures concrete greater than 75 mm slump
Measures yield stress, plastic viscosity, and thixotropy
Rheology was shown to provide insights into the following
applications:
Mixture proportioning
SCC
Production control
Formwork pressure
Segregation resistance
Pumpability

34


Thank You.

Questions?