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Properties of Fresh Concrete
Edited by H.-J. Wierig
Fresh concrete is a mixture of water, cement, aggregate and admixture (if any). After mixing, operations such as transporting, placing, compacting and finishing of fresh concrete can all considerably affect the properties of hardened concrete. It is important that the constituent materials remain uniformly distributed within the concrete mass during the various stages of its handling and that full compaction is achieved. When either of these conditions is not satisfied the properties of the resulting hardened concrete, for example, strength and durability, are adversely affected.
The characteristics of fresh concrete which affect full compaction are its consistency, mobility and compactability. In concrete practice these are often collectively known as workability. The ability of concrete to maintain its uniformity is governed by its stability, which depends on its consistency and its cohesiveness. Since the methods employed for conveying, placing and consolidatingd a concrete mix, as well as the nature of the section to be cast, may vary from job to job it follows that the corresponding workability and stability requirements will also vary. The assessment of the suitability of a fresh concrete for a particular job will always to some extent remain a matter of personal judgment.
In spite of its importance, the behaviour of plastic concrete often tends to be overlooked. It is recommended that students should learn to appreciate the significance of the various characteristics of concrete in its plastic state and know how these may alter during operations involved in casting a concrete structure.
13.1 Workability
Workability of concrete has never been precisely defined. For practical purposes it generally implies the ease with which a concrete mix can be handled from the mixer to its finally compacted shape. The three main characteristics of the property are consistency, mobility and compactability. Consistency is a measure of wetness or fluidity. Mobility defines the ease with which a mix can flow into and completely fill the formwork or mould. Compactability is the ease with which a given mix can be fully compacted, all the trapped air being removed. In this context the required workability of a mix depends not only on the characteristics and relative proportions of the constituent materials but also on (1) the methods employed for conveyance and compaction, (2) the size, shape and surface roughness of formwork or moulds and (3) the quantity and spacing of reinforcement.
Another commonly accepted definition of workability is related to the amount of useful internal work necessary to produce full compaction. It should be appreciated that the necessary work again depends on the nature of the section being cast. Measurement of internal work presents many difficulties and several methods have been developed for this purpose but none gives an absolute measure of workability.
The tests commonly used for measuring workability do not measure the individual characteristics (consistency, mobility and compactability) of workability. However, they do provide useful and practical guidance on the workability of a mix. Workability affects the quality of concrete and has a direct bearing on cost so that, for example, an unworkable concrete mix requires more time and labour for full compaction. It is most important that a realistic assessment is made of the workability required for given site conditions before any decision is taken regarding suitable concrete mix proportions.
13.2 Measurement of Workability
Three tests widely used for measuring workability are the slump, compacting factor and V-B consistometer tests (figure 13.1). These are standard tests in the United Kingdom and are described in detail in BS 1881: Part 2. Their use is also recommended in CP 110: Part 1. It is important to note that there is no single relationship between the slump, compacting factor and V-B results for different concretes. In the following sections the salient features of these tests together with their merits and limitations are discussed.
Slump Test
This test was developed by Chapman in the United States in 1913. A 300 mm high concrete cone, prepared under standard conditions (BS 1881: Part 2) is allowed to subside and the slump or reduction in height of the cone is taken to be a measure of workability. The apparatus is inexpensive, portable and robustd and is the simplest of all the methods employed for measuring workability. It is not surprising that, in spite of its several limitations, the slump test has retained its popularity.
Figure 13.1 Apparatus for workability measurement: (a) slump cone, (b) compacting factor and (c) V-B consistometer
The test primarily measures the consistency of plastic concrete and although it is difficult to see any significant relationship between slump and workability as defined previously, it is suitable for detecting changes in workability. For example, an increase in the water content or deficiency in the proportion of fine aggregate results in an increase in slump. Although the test is suitable for quality-control purposes it should be remembered that it is generally considered to be unsuitable for mix design since concretes requiring varying amounts of work for compaction can have similar numerical values of slump. The sensitivity and reliability of the test for detecting variation in mixes of different workabilities is largely dependent on its sensitivity to consistency. The test is not suitable for very dry or wet mixes. For very dry mixes, with zero or near-zero slump, moderate variations in workability do not result in measurable changes in slump. For wet mixes, complete collapse of the concrete produces unreliable values of slump.
Figure 13.2 Three main types of slump
The three types of slump usually observed are true slump, shear slump and collapse slump, as illustrated in figure 13.2. A true slump is observed with cohesive and rich mixes for which the slump is generally sensitive to variations in workability. A collapse slump is usually associated with very wet mixes and is generally indicative of poor quality concrete and most frequently results from segregation of its constituent materials. Shear slump occurs more often in leaner mixes than in rich ones and indicates a lack of cohesion which is generally associated with harsh mixes (low mortar content). whenever a shear slump is obtained the test should be repeated and, if persistent, this fact should be recorded together with test results, because widely different values of slump can be obtained depending on whether the slump is of true or shear form.
The standard slump apparatus is only suitable for concretes in which the maximum aggregate size does not exceed 37.5 mm. It should be noted that the value of slump changes with time after mixing owing to normal hydration processes and evaporation of some of the free water, and it is desirable therefore that tests are performed within a fixed period of time.
Compacting Factor Test
This test, developed in the United Kingdom by Glanville et al. (1947), measures the degree of compaction for a standard amount of work and thus offers a direct and reasonably reliable assessment of the workability of concrete as previously defined. The apparatus is a relatively simple mechanical contrivance (figure 13.1) and is fully described in BS 1881: Part 2. The test requires measurement of the weights of the partially and fully compacted concrete and the ratio of the partially compacted weight to the fully compacted weight, which is always less than 1, is known as the compacting factor. For the normal range of concretes the compacting factor lies between 0.80 and 0.92. The test is particularly useful for drier mixes for which the slump test is not satisfactory. The sensitivity of the compacting factor is reduced outside the normal range of workability and is generally unsatisfactory for compacting factors greater than 0.92.
It should also be appreciated that, strictly speaking, some of the basic assumptions of the test are not correct. The work done to overcome surface friction of the measuring cylinder probably varies with the characteristics of the mix. It has been shown by Cusens (1956) that for concretes with very low workability the actual work required to obtain full compaction depends on the richness of a mix while the compacting factor remains sensibly unaffected. Thus it follows that the generally held belief that concretes with the same compacting factor require the same amount of work for full compaction cannot always be justified. One further point to note is that the procedure for placing concrete in the measuring cylinder bears no resemblance to methods commonly employed on the site. As in the slump test, the measurement of compacting factor must be made within a certain specified period. The standard apparatus is suitable for concrete with a maximum aggregate size of up to 37.5 mm.
V-B Consistometer Test
This test was developed in Sweden by Bhrner (1940) (see figure 13.1). Although generally regarded as a test primarily used in research its potential is now more widely acknowledged in industry and the test is gradually being accepted. In this test (BS 1881: Part 2) the time taken to transform, by means of vibration, a standard cone of concrete to a compacted flat cylindrical mass is recorded. This is known as the V-B time, in seconds, and is stated to the nearest 0.5 s. Unlike the two previous tests, the treatment of concrete in this test is comparable to the method of compacting concrete in practice. Moreover, the test is sensitive to change in consistency, mobility and compactability, and therefore a reasonable correlation between the test results and site assessment of workability can be expected.
The test is suitable for a wide range of mixes and, unlike the slump and compacting factor tests, it is sensitive to variations in workability of very dry and also air-entrained concretes. It is also more sensitive to variation in aggregate characteristics such as shape and surface texture. The reproducibility of results is good. As for other tests its accuracy tends to decrease with increasing maximum size of aggregate; above 19.0 mm the test results become somewhat unreliable. For concretes requiring very little vibration for compaction the V-B time is only about 3 s. Such results are likely to be less reliable than for larger V-B times because of the difficulty in estimating the time of the end point (concrete in contact withd the whole of the underside of the plastic disc). At the other end of the workability range, such as with very dry mixes, the recorded V-B times are likely to be in excess of their true workability since prolonged vibration is required to remove the entrapped air bubbles under the transparent disc. To overcome this difficulty an automatic device which records the vertical settlement of the disc with respect to time can be attached to the apparatus. This recording device can also assist in eliminating human error in judging the end point. The apparatus for the V-B test is more expensive than that for the slump and compacting factor tests, requiring an electric power supply and greater experience in handling; all these factors make it more suitable for the precast concrete industry and ready-mixed concrete plants than for general site use.
13.3 Factors Affecting Workability
Various factors known to influence the workability of a freshly mixed concrete are shown in figure 13.3. From the following discussion it will be apparent that a change in workability associated with the constituent materials is mainly affected by water content and specific surface of cement and aggregate.
Cement and Water
Figure 13.3 Factors affecting workability of fresh conrete
Typical relationships between the cement-water ratio (by volume) and the volume fraction of cement for different workabilities are shown in figure 15.5. The change in workability for a given change in cement-water ratio is greater when the water content is changed than when only the cement content is changed. In general the effect of the cement content is greater for richer mixes. Hughes (1971) has shown that similar linear relationships exist irrespective of the properties of the constituent materials.
For a given mix, the workability of the concrete decreases as the fineness of the cement increases as a result of the increased specific surface, this effect being more marked in rich mixtures. It should also be noted that the finer cements improve the cohesiveness of a mix. With the exception of gypsum, the composition of cement has no apparent effect on workability. Unstable gypsum is responsible for false set, which can impair workability unless prolonged mixing or remixing of the fresh concrete is carried out. Variations in quality of water suitable for making concrete have no significant effect on workability.
Admixtures
The principal admixtures affecting improvement in the workability of concrete are water-reducing and air-entraining agents. The extent of the increase in workability is dependent on the type and amount of admixture used and the general characteristics of the fresh concrete.
Workability admixtures are used to increase workability while the mix proportions are kept constant or to reduce the water content while maintaining constant workability. The former results in a slight reduction in concrete strength.
Air-entraining agents are by far the most commonly used workability admixtures because they also improve both the cohesiveness of the plastic concrete and the frost resistance of the resulting hardened concrete. Two points of practical importance concerning air-entrained concrete are that for a given amount of entrained air, the increase in workability tends to be smaller for concretes containing rounded aggregates or low cement-water ratios (by volume) and, in general, the rate of increase in workability tends to decrease with increasing air content. However, as a guide it may be assumed that every 1 per cent increase in air content will increase the compacting factor by 0.01 and reduce the V-B time by 10 per cent.
Aggregate
For given cement, water and aggregate contents, the workability of concrete is mainly influenced by the total surface area of the aggregate. The surface area is governed by the maximum size, grading and shape of the aggregate. Workability decreases as the specific surface increases, since this requires a greater proportion of cement paste to wet the aggregate particles, thus leaving a smaller amount of paste for lubrication. It follows that, all other conditions being equal, the workability will be increased when the maximum size of aggregate increases, the aggregate particles become rounded or the overall grading becomes coarser. However, the magnitude of this change in workability depends on the mix proportions, the effect of the aggregate being negligible for very rich mixes (aggregate-cement ratios approaching 2). The practical significance of this is that for a given workability and cement-water ratio the amount of aggregate which can be used in a mix varies depending on the shape, maximum size and grading of the aggregate, as shown in figure 13.4 and tables 13.1 and 13.2. The influence of air-entrainment (4.5 per cent) on workability is shown also in figure 13.4.
TABLE 13.1
Effect of maximum size of aggregate of similar grading zone on aggregate-cement ratio of concrete having water-cement ratio of 0.55 by weight, based on McIntosh (1964)
Maximum aggregate size
(mm)
Aggregate-cement ratio (by weight)
Low workability
Medium workability
High workability
Irregular gravel
Crushed rock
Irregular gravel
Crushed rock
Irregular gravel
Crushed rock
9.5
19.0
37.5
5.3
6.2
7.6
4.8
5.5
6.4
4.7
5.4
6.5
4.2
4.7
5.5
4.4
4.9
5.9
3.7
4.4
5.2
TABLE 13.2
Effect of aggregate grading (maximum size 19.0 mm) on aggregate-cement ratio of concrete having medium workability and water-cement ratio of 0.55 by weight, based on McIntosh (1964)
Type of aggregate
Aggregate-cement ratio
Coarse grading
Fine grading
Rounded gravel
Irregular gravel
Crushed rock
7.3
5.5
4.7
6.3
5.1
4.3
Figure 13.4 Effect of aggregate shape on aggregate-cement ratio of concretes for different workabilities, based on Cornelius (1970)
Several methods have been developed for evaluating the shape of aggregate, a subject discussed in chapter 12. Angularity factors together with grading modulus and equivalent mean diameter provide a means of considering the respective effects of shape, size and grading of aggregate (see chapter 15). Since the strength of a fully compacted concrete, for given materials and cement-water ratio, is not dependent on the ratio of coarse to fine aggregate, maximum economy can be obtained by using the coarse aggregate content producing the maximum workability for a given cement content (Hughes, 1960) (see figure 13.5). The use of optimum coarse aggregate content in concrete mix design is described in chapter 15. It should be noted that it is the volume fraction of an aggregate, rather than its weight, which is important.
Figure 13.5 A typical relationship between workability and coarse aggregate content of concrete, based on Hughes (1960)
The effect of surface texture on workability is shown in figure 13.6. It can be seen that aggregates with a smooth texture result in higher workabilities than aggregates with a rough texture. Absorption characteristics of aggregate also affect workability where dry or partially dry aggregates are used. In such a case workability drops, the extent of the reduction being dependent on the aggregate content and its absorption capacity.
Ambient Conditions
Environmental factors that may cause a reduction in workability are temperature, humidity and wind velocityd. For a given concrete, changes in workability are governed by the rate of hydration of the cement and the rate of evaporation of water. Therefore both the time interval from the commencement of mixing to compaction and the conditions of exposure influence the reduction in workability. An increase in the temperature speeds up the rate at which water is used for hydration as well as its loss through evaporation. Likewise wind velocity and humidity influence the workability as they affect the rate of evaporation. It is worth remembering that in practice these factors depend on weather conditions and cannot be controlled.
Figure 13.6 Effect of aggregate surface texture on aggregate-cement ratio of concretes for different workabilities, based on Cornelius (1970)
Time
The time that elapses between mixing of concrete and its final compaction depends on the general conditions of work such as the distance between the mixer and the point of placing, site procedures and general management. The associated reduction in workability is a direct result of loss of free water with time through evaporation, aggregate absorption and initial hydration of the cement. The rate of loss of workability is affected by certain characteristics of the constituent materials, for example, hydration and heat development characteristics of the cement, initial moisture content and porosity of the aggregate, as well as the ambient conditions.
For a given concrete and set of ambient conditions, the rate of loss of workability with time depends on the conditions of handling. Where concrete remains undisturbed after mixing until it is placed, the loss of workability during the first hour can be substantial, the rate of loss of workability decreasing with time as illustrated by curve A in figure 13.7. On the other hand, if it is continuously agitated, as in the case of ready-mixed concrete, the loss of workability is re