ICAR Rheometer

Eric Koehler
W.R. Grace & Co.
[Link]@[Link]
Outline
 What is Rheology?
• Definition
• Measurement

 ICAR Rheometer
• Description
• Operation

 Applications
• Mixture proportioning
• SCC
• Production control
• Formwork pressure
• Segregation resistance
• Pumpability

2
 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 Results
Bingham model, which is a function of:
• Yield stress: the minimum stress to initiate Flow Curve

 
Shear Stress,  (Pa)
or maintain flow (related to slump)
The Bingham Model
• Plastic viscosity: the resistance to flow once    0  
yield stress is exceeded (related to
stickiness) slope = plastic viscosity ()
 Concrete rheology provides many
insights into concrete workability.
intercept = yield stress (0)
• Slump and slump flow are a function of
concrete rheology.
   (1/s)
Shear Rate,

3
Workability and Rheology
 Workability: “The ease with which ACI 238.1R-08 report describes 69
[concrete] can be mixed, placed, workability and rheology tests.
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

4
Concrete Flow Curves (Constitutive Models)
 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.

   0  a b
   0  
  0  a0 
b
a b
  
  0  a0 
b
a b

5
Concrete Rheology: Non-Steady State

Concrete exhibits different rheology when at rest than when flowing.

6
 Concrete Rheology: Non-Steady State
Flow Curve Test
concrete sheared at various rates

Shear Stress (Pa)

Concrete exhibits different rheology area between up and down
curves due to thixotropy
when at rest than when flowing.

Static Yield Stress

minimum shear stress to initiate flow from
rest slope = plastic viscosity

Dynamic Yield Stress

intercept =
minimum shear stress to maintain flow after dynamic Shear Rate (1/s)
breakdown of thixotropic structure yield stress
Stress Growth Test
Plastic Viscosity concrete sheared at constant, low rate

change in shear stress per change in shear maximum stress from rest
rate, above yield stress = static yield stress

Torque (Nm)
Thixotropy
reversible, time-dependent reduction in
viscosity in material subject to shear

Thixotropy is especially critical in highly flowable concretes.

Time (s)
7
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)
Typical Rheometer Geometry Configurations
Coaxial Cylinders Parallel Plate Impeller

8
 Concrete Rheometers
Tattersall Two-Point Rheometer IBB Rheometer ICAR Rheometer

BTRHEOM Rheometer BML Viscometer

9
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

10
ICAR Rheometer: Operation

 Based on wide-gap, coaxial Apply Rotation,

cylinders design Measure Torque
Inner Cylinder
 Vane acts as inner cylinder
• Compact size Outer
Cylinder
• Prevents slip
Fluid
 Outer wall also has vertical
strips to prevent slip
Side View Top View
 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)

11
 ICAR Rheometer: Portability

Rheometer Weight: 13 lb (6 kg)

[with accessories: 40 lb (18 kg)]

4.25”
(110 mm)

16” (400 mm)

Bucket size depends on aggregate size.

1” (25 mm) aggregate shown

12
 Software Interface
All operations managed through single screen.

All data
automatically
written to text
and Excel file

Stress Growth Flow Curve

settings settings
start start

real time
data real time
data

calculated
results calculated
results

13
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.

14
 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
15
 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

16
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

17
Thixotropy Testing: Flow Curve or Stress Growth
Flow Curve Test
 Flow Curve Test concrete sheared at various rates
• Place concrete in container and allow to rest

Shear Stress (Pa)

area between up and down
for pre-determined time (to allow thixotropic curves due to thixotropy
build-up)
• Run flow curve with speeds in ascending
order (low to high), exclude breakdown
period
• Immediately run second curve with speeds in slope = plastic viscosity
descending order (high to low), include
breakdown period at high speed to assure
intercept =
full breakdown of thixotropy Shear Rate (1/s)
dynamic
• Area between up and down curves is yield stress
indicative of thixotropy
Stress Growth Test
concrete sheared at constant, low rate
 Stress Growth Test maximum stress from rest
• Place concrete in container and allow to rest = static yield stress

Torque (Nm)
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
Time (s)
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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

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 Applications: Mixture Proportioning
Effects of Materials and Mixture Proportions on Rheology

Yield Plastic
Stress Viscosity
Aggregate max. size (increase)  
Plastic Viscosity (Pa.s)

Aggregate grading (optimize)  

Aggregate angularity  
Silica Fume Aggregate shape (equidimensional)  
HRWR
Paste volume (increase)  
Water/powder (increase)  
AEA
Fly ash  
Slag  
Water Silica fume (low %)  
Silica fume (high %)  
Yield Stress (Pa) VMA  
HRWR  
AEA  

Reference: Koehler, E.P., Fowler, D.W. (2007). “ICAR Mixture Proportioning

Procedure for SCC” International Center for Aggregates Research, Austin, TX.

20
 Applications: SCC Rheology
Conventional
 SCC is designed to flow under its own

 
Concrete

Shear Stress,  (Pa)

mass, resist segregation, and meet 
other requirements (e.g. mechanical
properties, durability, formwork 0 Similar plastic
pressure, pump pressure)
viscosity
 Compared to conventional concrete, Near zero
SCC exhibits: yield stress SCC
• Significantly lower yield stress (near zero): 
allows concrete to flow under its own mass
0
• Similar plastic viscosity: ensures
segregation resistance
 Plastic viscosity must not be too high    (1/s)
Shear Rate,
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

Yield stress is the main difference between SCC and conventional concrete.

21
 Applications: SCC Rheology
Empirical workability tests are a function of rheology.
Rheology provides greater insight into workability.

Slump flow vs. yield stress for single

T20 vs. plastic viscosity
mixture proportion, variable HRWR

10
2
9 R = 0.90

8
7
6

T20 (s)
5
4
3
2
1
0
0 30 60 90 120
Plastic Viscosity (Pa.s)
Reference: Koehler, E.P., Fowler, D.W. (2008). “Comparison of Workability Test
Methods for Self-Consolidating Concrete” Submitted to Journal of ASTM International.

22
 Applications: SCC Rheology
3 Different HRWRs | Same Slump Flow | Same Mix Design | Different Rheology
w/c = 0.35 w/c = 0.35
250
30 PC 068
PC 059

Dynamic Yield Stress (Pa)

200
Slump Flow (inches)

25 PC 915
Reference: Jeknavorian, A., Koehler, E.P., Geary, D., Malone, J. (2008).
“Concrete Rheology with High-Range Water-Reducers with Extended

20
150
Slump Flow Retention” Proceedings of SCC 2008, Chicago, Illinois.

15
100
10
PC 068
PC 059 50
5
PC 915

0 0
0 30 60 90 120 0 30 60 90 120
Elapsed Time (Minutes) Elapsed Time (Minutes)
w/c = 0.35
120 0.45
PC 068 PC 068
0.40 PC 059
100 PC 059
Plastic Viscosity (Pa.s)

PC 915 0.35 PC 915

Thixotropy (Nm/s)
80 0.30

0.25
60
0.20

40 0.15

0.10
20
0.05

0 0.00
0 30 60 90 120 0 30 60 90 120
Elapsed Time (Minutes) Elapsed Time (Minutes) 23
 Applications: Production Control
 The workability box is an effective
way to ensure production Example
consistency
50
Low Flow
Definition: Zone of rheology
45 Good
associated with acceptable workability Requires Vibration
Segregation
(self-flow and segregation resistance) 40

Plastic Viscosity (Pa.s)

 Mixture proportions affect 35

rheology; therefore, controlling 30

rheology is an effective way to 25
Good
control mixture proportions
20
 Workability boxes are mixture- 15
specific Segregation
10
• SCC encompasses a wide range of
5
materials and rheology
0
• Rheology appropriate for one set of 0 50 100 150
materials may be inappropriate for
Yield Stress (Pa)
another set of materials
• Larger workability box corresponds to
greater robustness

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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)

25
 Applications: Formwork Pressure – Case Study
600 0.8 40

Thixotropic Breakdown Area (Nm/s)

Mix 1 (Base) Mix 1 (Base)
Peterborough Trial 2 - July 12, 2006
0.7 35
Dynamic Yield Stress (Pa)

500 Mix 2 (Increased Mix 2 (Increased Concrete temperature 20C

CA) CA)
Mix 3 (Lower w/cm,
0.6 30
Mix 3 (Lower w/cm,
Different Admix) Different Admix)
400 0.5 25

Lateral Pressure (kPa)

0.4 20
300
0.3
15
200 0.2 Cell 13 ([Link]. 36.1 kPa)
10 Cell 14 ([Link]. 63.5 kPa)
0.1 Cell 15 ([Link]. 91.1 kPa)
100 5
0 Cell 16 ([Link]. 98.7 kPa)
0
0 -0.1
11.0 11.5 12.0 12.5 13.0
0 20 40 60 80 100 120 0 20 40 60 80 100 120 -5
Time (Hour + Decimal)
Time from Placement, Minutes Time from Placement, Minutes -10
100
Peterborough Trial 3 - Sept 20, 2006,
Concrete temperature 21C
Mix 1 and 2: Fast increase in yield stress and thixotropy – low 80 Cell 13 ([Link]. 36.1 kPa)
formwork pressure Cell 14 ([Link]. 63.5 kPa)
Cell 15 ([Link]. 91.1 kPa)
Mix 3: Slow increase in yield stress and thixotropy – high formwork

Lateral Pressure (kPa)

60
Cell 16 ([Link]. 98.7 kPa)
pressure
40

Results confirm that high static yield stress 20

reduces formwork pressure.

0
10.0 10.5 11.0 11.5 12.0 12.5 13.0
Time (Hour + Decimal)
-20

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

26
 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

Gravitational Force
-Aggregate density
-Aggregate size Equations relating descent of sphere to rheology
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”, Journal
 0  (0.09533) g  sphere   fluid R
of Fluid Mech., 158, 219-244.

Jossic, L., and Magnin, A. (2001). “Drag and

Stability of Objects in a Yield Stress Fluid,”  0  (0.124) g  sphere   fluid R
Buoyancy + Resisting Force AIChE Journal, 47(12). 2666-2672.

-Paste rheology Saak, A.W., Jennings, H.M., and Shah, S.P.

g  sphere   fluid R
(2001). “New Methodology for Designing Self- 4
-Paste density Compacting Concrete,” ACI Materials Journal, 0 
3
-Aggregate morphology 98(6), 429-439.

-Neighboring aggregates (lattice Reference: Koehler, E.P., and Fowler, D.W. (2008). “Static and Dynamic
effect) Yield Stress Measurements of SCC” Proceedings of SCC 2008, Chicago, IL.

27
 Applications: Segregation Resistance

50 0.20
Plastic Viscosity, 0 min. (Pa.s)

Column Seg<10% Column Seg<10%

45

Thixotropyy, 0 min. (Nm/s)

Column Seg>10% Column Seg>10%
40 0.15

35
30 0.10
25
20 0.05
15
10 0.00
5
0 -0.05
0 20 40 60 80 100 0 20 40 60 80 100
Dynamic Yield Stress, 0 min. (Pa) Dynamic Yield Stress, 0 min. (Pa)

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.

28
Applications: Pumpability

 Concrete moves through a

pump line as a “plug”
surrounded by a sheared sheared
region at the walls. region

• Higher viscosity increases plug flow flow

pumping pressure, reduces flow region
rate
• Unstable mixes may cause
blocking
shear stress = yield stress
 Pumping concrete in high-rise
buildings presents unique
challenges
Buckingham-Reiner Equation
• High strength mixes often have
low w/cm, resulting in high
concrete viscosity PR  4  0  1  0  
4
4

Q 1       
• Blockage can result in significant 8L  3   w  3   w  
jobsite delays  
Q  flow rate P  pressure
R  tube radius L  tube length
 w  shear stress at wall

29
 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 106 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 Reference: Koehler, E.P., and Brooks, W., Neuwald, A., and
• High pump pressure Mogan, E.. (2009). “Applications of Rheology Measurements to
Enable and Ensure Concrete Performance” NRMCA Concrete
Technology Forum, Cincinnati, OH.

30
Applications: Pumpability – Case Study
Duke Energy Building, Charlotte, NC

31
 Applications: Pumpability – Case Study

Duke Energy Building, Charlotte, NC

 VMA and/or other changes in

mixture proportions were shown to
increase pumpability by reducing
5.0
#1: baseline concrete viscosity.
#4: Increase paste vol
4.5
#4: +VMA
#5: Increase w/cm
 Role of VMA in reducing viscosity:
4.0
#5: +VMA

3.5 #6: Change agg • VMA results in shear-thinning behavior

#6: +VMA

Torque (Nm)

Increased viscosity (thickens) concrete at rest

3.0
and at low shear rates: beneficial for reduced
2.5 formwork pressure and increased segregation
resistance
2.0
 Decreased viscosity (thins) at high shear rates:
1.5 beneficial for improved pumpability

1.0 • Reduced pump stroke time confirmed

0.5
in field mix with VMA

0.0
0.00 0.10 0.20 0.30
32
Rotation Speed (rps)
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

33
Thank You.

Questions?

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