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A preliminary concrete mix design for SCC with marble powders
Construction and Building Materials 23 (2009) 1201–1210
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A preliminary concrete mix design for SCC with marble powders Kürsßat Esat Alyamaç, Ragip Ince * Firat University, Engineering Faculty, Civil Engineering Department, 23279 Elazig, Turkey
a r t i c l e
i n f o
Article history: Received 27 September 2007 Received in revised form 15 August 2008 Accepted 16 August 2008 Available online 24 September 2008 Keywords: Self-compacting concrete Marble powder Waste Strength
a b s t r a c t The marble has been commonly used as a building material since ancient times. Disposal of the waste materials of the marble industry, consisting of very fine powders, is one of the environmental problems worldwide today. However, these waste materials can be successfully and economically utilized to improve some properties of fresh and hardened self-compacting concrete (SCC). The aim of this study is to find some relationship between properties of the fresh SCC and the hardened SCC containing marble powder. For this purpose, the mix design approach based on monogram developed by Monteiro and co-workers for normal vibrated concrete was adapted to SCC mixes. In order to obtain this monogram, a series of SCC mixes with different water/cement ratios and water/powder ratios were prepared. Several tests such as slump-flow, T500 time, L-box, V-funnel and sieve segregation resistance were applied for fresh concrete and tests such as compressive strength and split-tension strength at 7, 28 and 90 days were performed for hardened concrete. In conclusion, the mix design method based on monogram can be suggested for preliminary design in SCC. Ó 2008 Elsevier Ltd. All rights reserved.
1. Introduction All natural stones that industrially can be processed as cut to size, polished, used for decorative purposes and economically valuable are called as marble. USA, Belgium, France, Spain, Sweden, Italy, Egypt, Portugal and Greece are among the countries with considerable marble reserve [1]. Turkey has the 40% of total marble reserve in the world. 7,000,000 tons of marble have been produced in Turkey annually and 75% of these production have been processed in nearly 5000 processing plants. It can be apparently seen that the waste materials of these plants reach millions of tons. Stocking of these waste materials is impossible. In marble quarries, the stones are being cut as blocks via different methods (Fig. 1a). These blocks are being moved to processing plants. In these plants, the blocks with 15–20 tons weight are being cut to size as decorative tiles and being polished. During the cutting process, the dust of the marble and water mixes together and become waste marble mud. The material that become dry mud after being refined within the refinement facilities are too big for stocking and becoming harmful for the environment day by day (Fig. 1b). During the cutting process 20–30% of the marble block become dust. These type solid waste materials should be inactivated properly without polluting the environment. The most suitable inactivating method nowadays is recycling. Recycling provides with some advantages such as protecting the natural resources, energy saving, * Corresponding author. Tel.: +90 424 2370000x5402; fax: +90 424 2415526. E-mail address: rince@firat.edu.tr (R. Ince). 0950-0618/$ - see front matter Ó 2008 Elsevier Ltd. All rights reserved. doi:10.1016/j.conbuildmat.2008.08.012
contributing to economy, decreasing the waste materials and investing for the future [2]. The self-compacting concrete technology has a big potential for this type solid waste materials. Self-compacting concrete (SCC) is a special very liquid concrete type that can settle in to the heavily reinforced, narrow and deep sections by its own weight, and can consolidate itself without necessitating internal or external vibration, and while providing with these features can keep its cohesion (stability) without leading segregation and bleeding. This concrete type developed in Japan in 1980s with the progressions in the concrete technologies has become widespread in all over the world. Especially the developments in the superplasticizer technology have contributed considerably to formation and progression of the self-compacting concrete [3,4]. Different from the classical concrete design, the self-compacting concrete needs the superplasticizers, viscosity increasing addition and inert or pozzolanic mineral additions in big quantity all together or partly. New experiment techniques, design methods and ergo standards relating the selection of these materials and usage of them in proper ratios in concrete design is being developed [5–10]. The expected performance criteria for the self-compacting concrete are self-compacting when it is fresh, high early age strength that can stand for the early negative effects and durability to the all external effects in hardened situation. Numerous experimental tests on SCC revealed that the SCC mixes containing inert fine powders such as limestone and chalk have good fresh properties, excellent surface finish and hardening strength higher than expected such as compressive strength and
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splitting tensile strength same as the pozzolanic fine powders such as fly ash, blast-furnace slag and silica fume. This is mainly due to improved particle packing and water retention of the fresh mixes and chemical reactions involving cement hydrates and calcium carbonate [8]. This paper presents a study combining the properties of fresh SCC and hardened SCC in one graph. For this purpose, the mix design method based on monogram devised by Monteiro and coworkers [11] for ordinary concrete was modified to SCC mixes.
This method has based on three laws: the Abrams’ law [12], Lyse’s law [13] and Molinari’s law [14]. In the experimental program of the study, a series of SCC mixes with different water-tocement and water-to-powder ratios were prepared by using three type marble powder: cherry (Rosso Levanto), gold and white. Then, several tests such as slump-flow, T500 time test, L-box, Vfunnel and sieve segregation resistance were applied for fresh concrete and tests such as compressive strength and split-tension strength at 7, 28 and 90 days were performed for hardened concrete cube specimens. Consequently, a monogram was developed using the data obtained from 47 experimental programs for preliminary design in SCC. 2. Concrete mix design monogram There are many methods for concrete mix design with reference to compressive strength. Since it is combining the properties of fresh and hardened cementitious material in one graph, the mix design method proposed by Monteiro and co-workers [11] is highly useful for preliminary design. Fig. 2 illustrates a typical mix design monogram for constant water/cement ratio. This monogram utilizes the three relationships below:
Fig. 1. (a) A marble quarry and (b) marble powder waste.
Fig. 3. Gradation curves of granular materials.
Fig. 2. Mix design monogram for a given water/cement ratio [11].
K.E. Alyamaç, R. Ince / Construction and Building Materials 23 (2009) 1201–1210
2.1. Abrams’ law
fc ¼
One of the most important parameters influencing the behavior of the concrete is water–cement ratio (w/c) used in a concrete mix. Basically, concrete made with high w/c ratios will have low properties such as low compression strength and low tension strength. Considering the compressive strength, this relation was first obtained by Abrams [12] in 1918 and has common use all over the world. The so-called Abrams’ law is expressed as
Table 1 Physical and chemical properties of marble powders used Properties
Cherry
Gold
White
Specific gravity Specific surface area (cm2/g) CaO (%) SiO2 (%) Fe2O3 (%) MgO (%)
2.71 3924 40.45 28.35 9.70 16.25
2.71 5106 49.53 1.25 0.32 0.40
2.71 4372 54.55 0.14 0.32 4.17
K1 w=c
K2
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ð1Þ
where fc is the compressive strength at fixed age and w/c is by weight. K1 and K2 in Eq. (1) are the empirical constants which depend usually on curing, test conditions, test age and cement properties [15,16]. 2.2. Lyse’s law This law essentially gives a relationship between water content and maximum aggregate size for a specific workability value (slump) [13]. It is well known that the cement requirement in concrete decreases with increasing maximum aggregate size. On the other hand, for a particular water/cement ratio, the compressive strength of concrete tends to increase with increasing aggregate cement ratio. Consequently, the following linear relationship between water–cement ratio (w/c) and aggregate-cement ratio by weight (m) can be written as:
m ¼ K 3 ðw=cÞ þ K 4
Fig. 4. SEM of cherry marble powder.
Fig. 5. SEM of gold marble powder.
ð2Þ
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in which K3 and K4 are the empirical constants which depend on the workability properties of cementitious materials. 2.3. Molinari’s law It is necessary to develop a relationship between aggregate/cement ratio (m) and cement content (C) in order to complete the monogram in Fig. 2 [14]. Molinari has proposed the following inversely proportional relationship;
C¼
1000 K5m þ K6
ð3Þ
where K5 and K6 are the material constants.
segregation is to remain homogeneity of concrete without separating of grout from the mix. Although several methods have been used for self-compacting concrete in order to characterize the fresh state of the resulting concrete, there is no single test that can adequately measure for workability properties. On the other hand, there is no unique standard test method measuring the workability properties of SCC. In this study, the standard test methods used according to EFNARC [9] are given: 3.2.1. Slump-flow and T500 time test This test method, based on the traditional slump test, is utilized to determine the flowability and flow rate of SCC. The test equipments are one slump cone and one flow table, as shown in Fig. 7.
3. Experimental studies 3.1. Materials According to EN 197-1, CEM I 42.5 N was used in all mixes. Its specific gravity, specific surface area by Blain, and 28 days compressive strength were 3.1, 3393 cm2/g and 49.2 MPa respectively. The maximum aggregate size was 16 mm. The maximum sand grain size was 4 mm. Mineralogically, the aggregate consisted of river. The gradation curves of the granular materials are shown in Fig. 3. The aggregate and sand were air-dried prior to mixing. The superplasticizer ViscoCrete-3075 was used in order to produce SCC for all mixes. Three types of marble powder were utilized to obtain SCC mixes. Their physical and chemical properties are given in Table 1. Typical SEM photographs are illustrated at 5000 and 10,000 magnifications for each types of marble powder in Figs. 4–6. As shown in the Figs. 4–6, these marble powders have angular shapes with a rough surface texture unlike the fly ash particles that have spherical shape. On the other hand, cherry and white marble powders seem to be coarser than the gold marble powder. This can be also seen from the specific surface area values of these marble powders in Table 1. 3.2. Test equipment Self-consolidation characteristics are related to the workability properties: filling ability, passing ability and, the resistance to segregation. Filling ability is the capability of completely filling all spaces without vibration. Passing ability is the aptitude to flow through reinforcement bars without any blocking. Resistance to
Fig. 6. SEM of white marble powder.
Fig. 7. Test equipments according to EFNARC [9].
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The slump cone is filled with concrete and then lifted vertically. Two characteristic values are measured; time for the concrete
diameter to reach 500 mm (T500) and the final mean diameter of concrete (dm).
Table 2 Classes according to fresh SCC properties expressed by different test methods [9]
3.2.2. V-funnel test The test is utilized to determine filling ability and viscosity SCC. The test equipment is a V-shaped funnel, as detailed Fig. 7. The V-funnel is filled with concrete and then its gate opened. Time for the concrete to flow out of the funnel (tv) determined.
Slump-flow (flow test)
Viscosity (flow test)
Viscosity (Vfunnel test)
Passing ability (L-box test)
Segregation resistance (Sieve test)
Class
dm (cm)
Class
T500 (s)
Class
tv (s)
Class
PA
Class
SR (%)
SF1 SF2 SF3
55–65 66–75 76–85
VS1 VS2
62 >2
VF1 VF2
68 9–25
PA1 PA2
P0.8a P0.8b
SR1 SR2
620 615
a b
With 2 rebars. With 3 rebars.
of in is is
3.2.3. L-box test The test is utilized to determine flowability and passing ability of SCC. The test equipment is an L-shaped box, as detailed in Fig. 7. The vertical compartment of L-box is filled with concrete and then
Table 3 Experimental results: SCC mixes with cherry marble powders C (kg/m3)
Mix
C1C C2Ca C3Ca C4C C5Ca C6Ca C7Ca C8C C9C C10C C11Ca C12Ca C13Ca C14Ca C15Ca C16C C17Ca C18C C19Ca C20Ca C21C C22Ca C23Ca C24Ca C25Ca C26C C27Ca C28Ca C29Ca C30Ca C31Ca C32Ca C33Ca C34Ca C35Ca C36Ca C37Ca C38Ca C39C C40Ca C41Ca C42Ca C43Ca C44C C45C C46Ca C47Ca C48Ca C49C C50Ca C51Ca C52Ca C53C C54C a b
300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 350 350 350 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 450 450 500 500 500 500 500 500 500
P (kg/m3)
100 100 100 100 100 100 100 100 200 200 200 200 200 200 200 250 250 250 250 250 250 250 250 250 250 500 50 150 200 0 0 0 50 100 100 100 100 150 150 150 150 150 150 150 400 50 100 0 50 50 50 50 50 300
w/c
0.55 0.55 0.55 0.60 0.60 0.63 0.67 0.70 0.58 0.58 0.60 0.63 0.63 0.67 0.70 0.57 0.60 0.63 0.63 0.63 0.67 0.67 0.67 0.70 0.70 0.70 0.60 0.60 0.60 0.45 0.48 0.50 0.51 0.45 0.48 0.53 0.55 0.45 0.50 0.50 0.50 0.53 0.55 0.58 0.53 0.44 0.44 0.42 0.36 0.38 0.40 0.42 0.44 0.42
sp (%)
1 2 3 1 2 2 2 2 1 2 2 2 3 2 2 2 2 1 2 3 1 2 3 2 3 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 3 2 2 2 2 2 2 2 2 2 2 2 2 2
G (kg/m3)
722 722 722 706 706 696 685 675 672 672 667 657 657 646 636 658 648 637 637 637 627 627 627 616 616 519 677 638 619 711 701 690 667 672 662 641 630 653 632 632 632 621 611 600 524 654 634 646 658 647 637 626 616 529
S (kg/m3)
1095 1095 1095 1071 1071 1055 1039 1023 1020 1020 1012 996 996 980 964 999 983 967 967 967 951 951 951 935 935 787 1027 968 938 1079 1063 1047 1013 1020 1004 972 956 990 958 958 958 942 926 910 795 992 962 979 998 982 966 950 934 802
These mixes are provided with the properties of SCC. The values in bracket indicate slump values of fresh concrete.
dmb (cm)
30 57 58 43 60 66 68 71 [2] 51 62 68 69 71 73 50 58 [2] 65 66 [4] 66 68 69 71 [20] 63 66 62 62 67 68 66 55 58 69 73 58 44 66 71 68 72 76 51 67 70 70 52 68 71 73 77 56
T500 (s)
– 2.92 2.45 – 2.38 2.34 2.22 1.8 – 3 3.2 2.9 2.5 2.7 2.4 5.4 4 – 3.6 3 – 3.4 2.9 3.2 2.7 – 2.2 2.9 3.3 2.75 2.1 1.5 1.8 2.69 2.3 1.8 1.1 3.7 – 3.1 2.2 2.8 2.2 1.7 6.6 2.4 3.1 1.13 4.47 2.03 1.56 1.37 0.8 5.6
tv (s)
– 4.1 3.5 – 3.4 3.1 2.7 2.3 – – 6.1 5.5 5.2 4.7 4.4 – 7 – 6.4 6.2 – 5.7 5.4 5.3 5.2 – 3.6 4.2 4.9 5.4 5.1 4.5 5 6.5 6.1 4.9 4.2 5.3 – 4.1 3.9 3.6 3.3 2.7 – 5.9 6.4 3.5 – 4.6 4.3 3.9 3.3 –
PA
– 0.89 0.91 – 0.95 0.96 0.98 0.99 – – 0.91 0.94 0.93 0.96 0.97 – 0.89 – 0.91 0.92 – 0.94 0.94 0.97 0.97 – 0.96 0.93 0.92 0.92 0.95 0.97 0.94 0.88 0.91 0.97 0.99 0.88 – 0.93 0.94 0.94 0.96 0.99 – 0.95 0.93 0.96 – 0.93 0.96 0.97 0.99 –
SR (%)
– 1 1 – 7 12 16 33 – – 4 7 7 9 13 – 2 – 4 5 – 7 7 10 16 – 8 5 4 9 12 14 11 8 12 14 17 2 – 4 5 9 14 23 – 13 10 14 11 13 16 18 27 –
fc (MPa)
ft (MPa)
7d
28d
90d
7d
28d
90d
25.8 30.7 22.2 25.8 28.9 27.6 26.2 23.1 29.3 28.4 29.3 28.0 28.0 26.7 25.3 24.0 25.3 23.6 24.4 25.8 24.0 24.4 23.6 23.1 21.8 18.2 27.6 29.3 25.3 38.7 34.7 33.8 35.1 42.7 40.9 36.9 30.7 42.7 29.3 41.3 39.1 38.2 37.3 32.0 20.9 39.6 42.2 43.6 54.7 52.0 50.7 46.7 39.1 31.6
35.6 39.1 29.3 33.3 37.8 36.4 34.2 31.6 40.0 38.2 40.9 38.7 37.8 37.3 34.7 35.6 37.8 34.7 37.3 37.3 35.6 35.6 35.1 33.8 32.0 25.3 38.7 40.9 36.4 55.6 52.0 49.3 50.2 53.8 50.7 46.2 39.6 57.3 40.0 54.2 52.0 51.1 48.9 42.7 30.7 52.4 55.1 57.8 67.1 65.3 62.2 60.0 49.8 44.4
38.7 41.8 32.9 36.0 41.3 39.6 36.9 33.8 45.8 42.7 44.9 41.8 41.3 40.4 38.2 37.3 39.1 36.4 39.6 39.1 37.8 38.2 36.4 35.6 33.8 26.7 41.3 43.6 39.1 61.8 60.0 54.7 56.0 64.4 63.1 56.9 43.6 65.8 45.8 61.3 58.7 57.8 52.9 45.8 33.3 61.8 64.4 67.1 73.8 71.1 67.6 64.4 53.3 48.4
2.19 2.63 1.90 2.19 2.41 2.34 2.27 1.98 2.48 2.45 2.45 2.37 2.37 2.23 2.19 2.01 2.16 2.05 2.09 2.16 2.05 2.09 1.98 2.01 1.90 1.57 2.30 2.48 2.16 3.26 2.91 2.80 2.91 3.57 3.40 3.12 2.55 3.54 2.45 3.44 3.30 3.16 3.12 2.63 1.76 3.23 3.47 3.64 4.47 4.30 4.13 3.85 3.19 2.63
2.94 3.19 2.45 2.80 3.12 3.05 2.87 2.63 3.33 3.16 3.33 3.16 3.16 3.09 2.91 2.94 3.16 2.87 3.09 3.05 2.94 2.98 2.91 2.84 2.70 2.12 3.16 3.37 3.01 4.47 4.23 4.06 4.06 4.37 4.13 3.82 3.23 4.64 3.26 4.40 4.26 4.20 3.95 3.50 2.52 4.20 4.43 4.64 5.38 5.28 5.01 4.88 4.09 3.61
3.19 3.47 2.70 3.01 3.44 3.26 3.01 2.87 3.71 3.54 3.75 3.50 3.37 3.33 3.19 3.12 3.23 2.98 3.33 3.30 3.19 3.12 3.01 2.94 2.80 2.30 3.44 3.54 3.19 5.01 4.81 4.40 4.60 5.25 5.08 4.60 3.61 5.31 3.82 5.01 4.71 4.67 4.30 3.75 2.84 5.05 5.15 5.42 5.88 5.65 5.48 5.15 4.30 3.95
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the sliding gate is lifted. The concrete flows through the steel bars into the horizontal part. The distances H1 and H2 are measured when the concrete is stopped. The value of passing ability PA = H2/H1 is calculated. 3.2.4. Sieve segregation resistance test This is utilized to determine resistance of SCC to segregation. The test equipment is the sieve with diameter frame = 500 mm and sieve size = 5 mm. After placing 4.8 ± 0.2 kg concrete sample into the sieve, the fresh SCC is allowed to stand for 2 min on the sieve. The segregated portion (SR) is calculated as the proportion of the sample passing through the sieve. The slump-flow test is quick while the sieve segregation resistance test is slow. On the other hand, these tests can be performed by single operator. There is good correlation between the sieve segregation resistance test and the behavior in full scale structures. Moreover the slump-flow test has good correlation with L-box test. V-funnel and L-box tests are good indicator of viscosity [17]. In Table 2, the classifications recommended by EFNARC [9] are given for the properties of fresh SCC obtained from different test methods. 3.3. Mix details and test procedure Experimental studies have revealed that the properties of a fresh SCC are particularly influenced by two material parameters: water–cement ratio (w/c) and water–powder ratio (w/p) [8–10]. Several mix design methods have been proposed at academic milieu and institutions for SCC [4–6,8–10]. Not only the properties of fresh concrete but also the properties of hardened concrete are hereby considered in order to find a general expression of the SCC mix design. Totally seventy-three series of mix proportions, of which five series were the references mixes, were tested concerning two essential material parameters (w/c and w/p) in different combinations and for three different marble powder types. The cement contents varied from 300 kg/m3 to 500 kg/m3 whereas the powder
contents varied between 0 and 400 kg/m3 and the water/cement ratios varied from 0.36 to 0.70. The superplasticizer was used in different proportions as 1%, 2% and 3% of the cement content, except for references mixes. All specimens in each series were cast from the same batch of concrete. The experimental results for SCC mixes with cherry powders and for SCC mixes with white and gold powders are given in Table 3 and Table 4, respectively. The reference mixes are presented in Table 5. The first column in Table 3 and 4 gives the mix numbers, namely C1 to C54 for SCC trial mixes and REF1 to REF5 for reference mixes. The letters following the mix numbers in the trial mixes in the first column are depicting the marble powder types used in the batches; C for Cherry, W for White and G for Gold. The mixture proportions are listed on the columns of Tables 3 and 4 from second to seventh, where C, P, w/c, sp, G and S indicate cement content, powder content, water/cement ratio, percent of superplasticizer by weight of cement, aggregate content and sand content, respectively. The properties of fresh concrete prepared according to the procedure proposed by EFNARC committee procedure are shown in columns of Tables 3 and 4 from eighth to twelfth. According to the criterias in Table 2, 53 of the 67 total SCC trial mixes are provided with the properties of SCC. These mixes are represented with an asterisk in Table 3. Besides, all of the SCC mixes containing gold and white marble powders are provided with the properties of SCC in Table 4. None of the trial mixes containing 1% superplasticizer were illustrated the properties of self-compatibility, as shown in Table 3. To determine mechanical properties of hardened concrete, compressive strength and split-tension strength tests were applied at 7, 28 and 90 days. The test specimens were used as 150 mm cubes. Specimens in each series were cast in plastic moulds. Specimens were removed from the mold after 1 day and subsequently, the ones with test age of 7 days were cured at 7 days and the ones with test age of 28 and 90 days were cured at 28 days in a moist room of 95% relative humidity and temperature of about 23 °C. All the specimens were tested in a testing machine with the capacity of
Table 4 Experimental results: SCC mixes with white and gold marble powders Mix
C (kg/m3)
P (kg/m3)
w/c
sp (%)
G (kg/m3)
S (kg/m3)
dm (cm)
T500 (s)
tv (s)
PA
SR (%)
fc (MPa) 7d
28d
90d
7d
28d
90d
C7W C7G C12W C12G C24W C24G C35W C35G C38W C38G C43W C43G C50W C50G
300 300 300 300 300 300 400 400 400 400 400 400 500 500
100 100 200 200 250 250 100 100 150 150 150 150 50 50
0.67 0.67 0.63 0.63 0.70 0.70 0.48 0.48 0.45 0.45 0.55 0.55 0.38 0.38
2 2 2 2 2 2 2 2 2 2 2 2 2 2
685 685 657 657 616 616 662 662 653 653 611 611 647 647
1039 1039 996 996 935 935 1004 1004 990 990 926 926 982 982
66 68 65 67 67 68 56 57 55 58 72 69 65 68
2.4 2.3 3.2 3 3.7 3.4 2.5 2.3 3.4 3.7 2.6 2.3 2.6 2.2
3 2.8 5.9 5.7 5.7 5.4 6.4 6.3 5.6 5.4 3.6 3.3 5 4.7
0.93 0.96 0.91 0.94 0.93 0.96 0.93 0.91 0.87 0.88 0.93 0.95 0.9 0.92
12 15 5 6 7 9 9 11 1 1 12 13 12 13
25.7 25.2 27.8 27.2 22.8 22.6 40.7 40.5 42.7 42.4 36.8 36.4 51.5 50.9
34.0 33.7 38.5 38.4 33.5 33.0 50.4 50.3 57.0 56.9 48.3 47.9 64.5 63.9
36.5 36.3 41.4 41.3 35.4 35.1 62.7 62.1 65.4 65.2 52.4 52.2 70.3 69.8
2.21 2.09 2.21 2.21 1.83 1.83 3.10 3.10 3.47 3.22 3.10 2.97 4.08 3.96
2.72 2.60 2.97 2.85 2.85 2.72 3.96 3.83 4.44 4.32 3.83 3.83 4.92 4.92
2.97 2.72 3.34 3.10 2.97 2.72 4.80 4.68 5.16 4.92 4.20 4.08 5.40 5.16
ft (MPa)
Table 5 Experimental results: reference mixes Mix
C (kg/m3)
w/c
G (kg/m3)
S (kg/m3)
Slump (cm)
REF1 REF2 REF3 REF4 REF5
300 350 400 450 500
0.65 0.60 0.53 0.47 0.42
729 697 680 663 646
1106 1057 1031 1005 979
15 13 9 5 2
fc (MPa)
ft (MPa)
7d
28d
90d
7d
28d
90d
20.4 23.1 27.1 29.8 37.8
30.2 33.3 37.3 43.1 48.9
32.4 36.4 39.1 46.7 54.7
1.76 1.94 2.23 2.48 3.16
2.52 2.73 3.01 3.50 3.99
2.73 3.05 3.30 3.82 4.37
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2000 kN. The specimens were loaded monotonically until failure and care was taken to apply a constant loading rate. Typically, it took about 5 min (±30 s) to reach the maximum load for each specimen. The compressive strength, fc and the split-tension strength, ft at 7, 28, and 90 days of the specimens are given in the last six columns of Table 3–5. The values of strength in these tables were obtained from mean of at least two test results. 4. Experimental results The compressive strength and the split-tension strength measured, as shown in Table 3, are slightly lower for SCC mixes containing 3% superplasticizer than for the ones containing 2% superplasticizer. For this reason, the values of the mixes only containing 2% superplasticizer (a total of 47 series) were utilized in the analysis of mix design. Three powder types should have different water requirements because they have different specific surface areas. Nevertheless the flow values of the concretes obtained from these powder types are almost identical in the same water-to-cement ratio, same cement content, and same powder content, as illustrated in Fig. 8. This means that the effect of the powder type can be negligible for the practical aims. Fig. 9 shows the compressive strength at 28 days against the water/cement ratio, for the considered 47 SCC mixes and 5 references mixes. In the same figure, the best-fit curves expressed by an exponential function are also given. This revealed that SCC mixes containing marble powder pointed out a higher strength at a given water/cement ratio than the traditionally concrete mix. Furthermore, the mean strength of SCC mixes with marble powder
Fig. 8. Comparison of flow values of SCC with different marble powder.
Fig. 9. Comparison of SCC mixes with reference mixes.
1207
was 25% higher than the references concrete. A similar conclusion was observed by Zhu and Gibbs [8] for SCC mixes containing limestone and chalk powders. 5. Analysis of test results Fig. 10 illustrates typical volume proportions of the ordinary concrete and of the self-compacting concrete comparatively [10]. As shown, both the aggregate content (fine + coarse) and the water-to-powder ratio of SCC are smaller than that of traditional vibrated concrete. The powder contribution consists of cement and inert or pozzolanic additions in SCC. In the present work, marble powder is used as additional material while it is assumed as the mineral filler material in fine aggregate in the ordinary concrete. Moreover, the properties of fresh SCC are, as already mentioned above, particularly influenced by the two material parameters: water–cement ratio and water–powder ratio. Nevertheless, the water/powder ratio is not used directly since it is possible to produce SCC mixes without powder. Deducting from the above discussion, a relationship between powder/cement ratio and cement content should be constituted. Consequently, the Molinari’s law (Eq. (3)), which is used for estimating the cement content in the normal concrete, can be modified to the following form for SCC mix:
C¼
1000 K5m þ K6n þ K7
ð4Þ
where n is the powder cement ratio by weight and, K5, K6 and K7 are the material constants. The constants in Eq. (4) can be determined from the multiple linear regression made on Y = K5X1 + K6X2 + K7 with Y = 1000/C, X1 = m and X2 = n. Fig. 11 shows the individual test data and the modified Molinari’s law calculated via Eq. (4) for different ratios of powder/cement in the aggregate/cement ratio versus cement content plane. It is derived from Fig. 11 that the considered test results are very close to the modified Molinari’s law because the determination coefficient R2 = 0.988. The Lyse’s law in the mix design based on monogram proposed by Monteiro et al. [11] uses the slump test for workability of concrete. Similarly, the slump-flow test, which is commonly proposed for determining the workability properties of fresh SCC such as flowability and flow rate at academic milieu and institutions for SCC, was utilized in this study. The flow values in Table 3 and 4 varied from 55 to 75 for the considered 47 data. According to EFNARC, these are classified as: (1) SF1 (55–65 mm) and (2) SF2 (66– 75 mm). Fig. 11 illustrates the individual test data and Lyse’s law calculated via Eq. (2) for two different slump-flow classes in the aggregate/cement ratio versus water/cement ratio plane. The correlation coefficients of Eq. (2) are r = 0.833 for flow 55–65 mm (SF1) and r = 0.911 for 66–75 mm (SF2). Abrams’ law (Eq. (1)) has been applied to some properties of concrete such as the compressive strength, Young’s modulus and
Fig. 10. Comparison of mix proportioning between SCC and ordinary mix.
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Fig. 11. Mix design monogram for SCC mixes with marble powder.
fracture energy [11]. In the present research, this law was also applied to the split-tension strength of concrete. The constants in Eq. (1) can be calculated as K 1 ¼ a and K 2 ¼ expðbÞ from the exponential regression made on Y ¼ a ebX with Y = fc, X = w/c. The results of analysis based on Abrams’ law for the compressive strength (fc) and the split-tension strength (ft) of the specimens at 7, 28 and 90 days are given in Fig. 11. In Fig. 11, the equations’ correlation coefficients, at 7, 28 and 90 days, are respectively 0.965, 0.974 and 0.966 for the compressive strength and, 0.959, 0.964 and 0.958 for the split-tension strength. 6. Comparison with the previous studies In the previous investigations, the effects of water/cement ratios, water/powder ratios, the powder type (inert or pozzolanic), the volume fraction of the solids in the mix, and the content of viscosity modifier agents on the properties of fresh and hardened SCC were evaluated. However, general relationships between properties of the fresh SCC and the hardened SCC containing inert/pozzolanic powder have not been proposed. In this study, the mix design approach based on monogram developed by Monteiro and coworkers [11] for vibrated concrete was adapted to SCC mixes. In order to investigate how well the monogram proposed in this study would simulate the behavior of SCC with different types of
powders available in the literature, the study by Zhu and Gibbs [8] has been simulated. The mixes in their study were designed for water/cement ratios: 0.42 and 0.57 with crushed coarse aggregate of maximum size of 20 mm. In addition, CEM I 42.5 Portland cement with a Blaine specific surface area of 3850 cm2/g, three types of limestone powder and two types of chalk powder were utilized as filler in their SCC mixes. Corresponding to the investigated series of w/c values, values of slump-flow were ranging from 60 to 65 cm. The compressive cube strength tests were performed at 7, 28 and 90 days and splitting cylindrical tests at 28 days. Since the compressive cube strengths at 7 and 90 days are not reported clearly in Ref [8], these mixes (SCC1 and SCC2) and only their average 28day strength values are summarized in Table 6 according to w/c values. Consequently, it is found that the contributions to strength gains were significantly greater for the limestone powder than for the chalk powder. Besides, the diversity in the mean strength values are owing to usage of five different powders in Table 6. Table 6 and Fig. 12 give results of the experiments and the approach based on the presented monogram, comparatively. It is noted that only the SF1 slump-flow class and the strength properties at 28 days are taken into consideration in Fig. 12 different from Fig. 11. Although test data obtained from different laboratory for SCC with different powder types were utilizing in the comparison, Fig. 12 shows that Eq. (2) and Eq. (4) agree with previous test re-
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Agg. (kg/m3)
Cement (kg/m3)
Powder (kg/m3)
SCC1 SCC2
1670 1685
300 405
240 135
Experimental
Predicted
a/c
w/c
fc (MPa)
ft (MPa)
a/c
w/c
fc (MPa)
ft (MPa)
5.57 4.16
0.57 0.42
44–52 67–74
3.2–4.7 4.6–5.9
5.30 3.94
0.60 0.43
41 58
3.3 4.6
Fig. 12. Comparison of developed mix design monagram with study by Zhu and Gibbs [8].
sults quite well. Consequently, the modified Molinari’s Law (Eq. (4)) developed in this study seems to be useful for determining the contribution of powder/cement ratio on the properties of fresh SCC. Nevertheless, experimental results of the study by Zhu and Gibbs have greater strength values than results of the monogram presented in this study. This is mainly due to the strength is influenced by not only water/cement ratio and aggregate/cement ratio but also properties of aggregate particles such as grading, surface texture, shape, strength, stiffness and maximum size [18]. However, if the further researches will be performed, more reliable findings can be proposed. 7. Conclusions From the findings of these experimental and statistical investigations for self-compacting concrete mix design based on mono-
gram proposed by Monteiro and co-workers, the following conclusions can be extracted: 1. Although the marble have been commonly used as a building material since ancient times, disposal of the waste materials of the marble industry is one of the major problems for the environmental concerns all over the world. However, this study emphasizes that these waste materials can be successfully and economically utilized as additional inert filler material in SCC technology. 2. The presented monogram is highly useful since its ability to combine the properties of fresh SCC such as flowability and properties of hardened SCC such as compressive strength and split-tension strength at 7, 28 and 90 days in one graph. 3. The results obtained from the comparison of the modified Molinari’s Law (Eq. (4)) developed in this study and the previous tests depicts that such a relationship seems to be useful
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for determining the contribution of powder/cement ratio on the properties of fresh SCC. 4. This monogram designed for two slump-flow classes: (1) SF1 (55–65 mm) which is suitable for unreinforced/slightly reinforced concrete structures and concretes cast by a pomp injection system, (2) SF2 (66–75 mm) which is appropriate for many applications such as columns. In addition, the monogram allows performing mixes of SCC with different powder to cement ratios. Consequently, this also gives opportunity to obtain economic mix design.
[4]
[5]
[6] [7]
[8]
Acknowledgements The authors would like to acknowledge the Scientific Research Projects Administration Unit of Firat University (Project No: FUBAP-1370) for the financial support. References
[9] [10] [11] [12] [13] [14]
[1] Onargan T, Köse H, Deliormanlı AH. Marble. 4th ed. Union of Chambers of Turkish Engineers and Architects (UCTEA), Chamber of Mining Engineers of Turkey; 2006. p. 1–5 [in Turkish]. [2] Kaseva ME, Gupta SK. Recycling-an environmentally friendly and income generating activity-towards sustainable solid wastes management, case studyDar es Salaam City, Tanzania. Resour Conserv Recycl 1996;17(4):299–309. [3] Okamura H, Ozawa K, Maekawa K, Tangtermsinikul S. High-performance concrete mechanism of super-fluidized concrete. EIT-JSCE-AIT joint seminar on
[15] [16] [17]
[18]
solution to urban infrastructure problems through civil engineering technology, Bangkok; 1992. p. 16. Ozawa K, Maekawa K, Kunishima M, Okamura H. High-performance concrete based on the durability of concrete structures. In: Proceedings of the second East Asia Pacific conference on structural engineering and construction; 1989. Ghezal A, Khayat KH. Optimizing self-consolidating concrete with limestone filler by using statistical factorial design methods. ACI Mater J 2002;99(3):264–72. Su N, Hsu K, Chai H. A simple mix design method for self-compacting concrete. Cem Concr Res 2001;31:1799–807. Bui V, Montgomery D, Hinczak I, Turner K. Rapid testing method for segregation resistance of self-compacting concrete. Cem Concr Res 2002;32:1489–96. Zhu W, Gibbs JC. Use of different limestone and chalk powders in selfcompacting concrete. Cem Concr Res 2005;35:1457–62. EFNARC. European guidelines for self-compacting concrete: specification, production and use; 2005. p. 68. Okamura H, Ouchi M. Self-compacting concrete. J Adv Concr Tech 2003;1(1):5–15. Monteiro PJM, Helene PRL, Kang SH. Designing concrete mixtures for strength, elastic modulus and fracture energy. Mater Struct 1993;26:443–52. Abrams DA. Design of concrete mixtures. Lewis Institute Bulletin 1918:1. Lyse I. Test on consistence and strength of concrete having constant water content. ASTM Proc 1932;32(1):629–36. Helene PRL. Contribuiçao ao estudo do controle e dosagem dos concretos de cimento Portland. PhD Thesis. Sao Paulo University; 1987. Mindess SS, Young JF. Concrete. UK: Prentice-Hall International; 1981. Ince R, Alyamaç KE. Determination of fracture parameters of concrete based on water–cement ratio. Indian J Eng Mater Sci 2008;15:14–22. Bartos PJM. Testing-SCC: towards new European standards for fresh SCC. In: Proceedings of the first international symposium on design, performance and use of self-consolidating concrete, China; 2005. Neville AM. Properties of concrete. 4th ed. London: Longman; 1995.
Contents lists available at ScienceDirect
Construction and Building Materials journal homepage: www.elsevier.com/locate/conbuildmat
A preliminary concrete mix design for SCC with marble powders Kürsßat Esat Alyamaç, Ragip Ince * Firat University, Engineering Faculty, Civil Engineering Department, 23279 Elazig, Turkey
a r t i c l e
i n f o
Article history: Received 27 September 2007 Received in revised form 15 August 2008 Accepted 16 August 2008 Available online 24 September 2008 Keywords: Self-compacting concrete Marble powder Waste Strength
a b s t r a c t The marble has been commonly used as a building material since ancient times. Disposal of the waste materials of the marble industry, consisting of very fine powders, is one of the environmental problems worldwide today. However, these waste materials can be successfully and economically utilized to improve some properties of fresh and hardened self-compacting concrete (SCC). The aim of this study is to find some relationship between properties of the fresh SCC and the hardened SCC containing marble powder. For this purpose, the mix design approach based on monogram developed by Monteiro and co-workers for normal vibrated concrete was adapted to SCC mixes. In order to obtain this monogram, a series of SCC mixes with different water/cement ratios and water/powder ratios were prepared. Several tests such as slump-flow, T500 time, L-box, V-funnel and sieve segregation resistance were applied for fresh concrete and tests such as compressive strength and split-tension strength at 7, 28 and 90 days were performed for hardened concrete. In conclusion, the mix design method based on monogram can be suggested for preliminary design in SCC. Ó 2008 Elsevier Ltd. All rights reserved.
1. Introduction All natural stones that industrially can be processed as cut to size, polished, used for decorative purposes and economically valuable are called as marble. USA, Belgium, France, Spain, Sweden, Italy, Egypt, Portugal and Greece are among the countries with considerable marble reserve [1]. Turkey has the 40% of total marble reserve in the world. 7,000,000 tons of marble have been produced in Turkey annually and 75% of these production have been processed in nearly 5000 processing plants. It can be apparently seen that the waste materials of these plants reach millions of tons. Stocking of these waste materials is impossible. In marble quarries, the stones are being cut as blocks via different methods (Fig. 1a). These blocks are being moved to processing plants. In these plants, the blocks with 15–20 tons weight are being cut to size as decorative tiles and being polished. During the cutting process, the dust of the marble and water mixes together and become waste marble mud. The material that become dry mud after being refined within the refinement facilities are too big for stocking and becoming harmful for the environment day by day (Fig. 1b). During the cutting process 20–30% of the marble block become dust. These type solid waste materials should be inactivated properly without polluting the environment. The most suitable inactivating method nowadays is recycling. Recycling provides with some advantages such as protecting the natural resources, energy saving, * Corresponding author. Tel.: +90 424 2370000x5402; fax: +90 424 2415526. E-mail address: rince@firat.edu.tr (R. Ince). 0950-0618/$ - see front matter Ó 2008 Elsevier Ltd. All rights reserved. doi:10.1016/j.conbuildmat.2008.08.012
contributing to economy, decreasing the waste materials and investing for the future [2]. The self-compacting concrete technology has a big potential for this type solid waste materials. Self-compacting concrete (SCC) is a special very liquid concrete type that can settle in to the heavily reinforced, narrow and deep sections by its own weight, and can consolidate itself without necessitating internal or external vibration, and while providing with these features can keep its cohesion (stability) without leading segregation and bleeding. This concrete type developed in Japan in 1980s with the progressions in the concrete technologies has become widespread in all over the world. Especially the developments in the superplasticizer technology have contributed considerably to formation and progression of the self-compacting concrete [3,4]. Different from the classical concrete design, the self-compacting concrete needs the superplasticizers, viscosity increasing addition and inert or pozzolanic mineral additions in big quantity all together or partly. New experiment techniques, design methods and ergo standards relating the selection of these materials and usage of them in proper ratios in concrete design is being developed [5–10]. The expected performance criteria for the self-compacting concrete are self-compacting when it is fresh, high early age strength that can stand for the early negative effects and durability to the all external effects in hardened situation. Numerous experimental tests on SCC revealed that the SCC mixes containing inert fine powders such as limestone and chalk have good fresh properties, excellent surface finish and hardening strength higher than expected such as compressive strength and
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splitting tensile strength same as the pozzolanic fine powders such as fly ash, blast-furnace slag and silica fume. This is mainly due to improved particle packing and water retention of the fresh mixes and chemical reactions involving cement hydrates and calcium carbonate [8]. This paper presents a study combining the properties of fresh SCC and hardened SCC in one graph. For this purpose, the mix design method based on monogram devised by Monteiro and coworkers [11] for ordinary concrete was modified to SCC mixes.
This method has based on three laws: the Abrams’ law [12], Lyse’s law [13] and Molinari’s law [14]. In the experimental program of the study, a series of SCC mixes with different water-tocement and water-to-powder ratios were prepared by using three type marble powder: cherry (Rosso Levanto), gold and white. Then, several tests such as slump-flow, T500 time test, L-box, Vfunnel and sieve segregation resistance were applied for fresh concrete and tests such as compressive strength and split-tension strength at 7, 28 and 90 days were performed for hardened concrete cube specimens. Consequently, a monogram was developed using the data obtained from 47 experimental programs for preliminary design in SCC. 2. Concrete mix design monogram There are many methods for concrete mix design with reference to compressive strength. Since it is combining the properties of fresh and hardened cementitious material in one graph, the mix design method proposed by Monteiro and co-workers [11] is highly useful for preliminary design. Fig. 2 illustrates a typical mix design monogram for constant water/cement ratio. This monogram utilizes the three relationships below:
Fig. 1. (a) A marble quarry and (b) marble powder waste.
Fig. 3. Gradation curves of granular materials.
Fig. 2. Mix design monogram for a given water/cement ratio [11].
K.E. Alyamaç, R. Ince / Construction and Building Materials 23 (2009) 1201–1210
2.1. Abrams’ law
fc ¼
One of the most important parameters influencing the behavior of the concrete is water–cement ratio (w/c) used in a concrete mix. Basically, concrete made with high w/c ratios will have low properties such as low compression strength and low tension strength. Considering the compressive strength, this relation was first obtained by Abrams [12] in 1918 and has common use all over the world. The so-called Abrams’ law is expressed as
Table 1 Physical and chemical properties of marble powders used Properties
Cherry
Gold
White
Specific gravity Specific surface area (cm2/g) CaO (%) SiO2 (%) Fe2O3 (%) MgO (%)
2.71 3924 40.45 28.35 9.70 16.25
2.71 5106 49.53 1.25 0.32 0.40
2.71 4372 54.55 0.14 0.32 4.17
K1 w=c
K2
1203
ð1Þ
where fc is the compressive strength at fixed age and w/c is by weight. K1 and K2 in Eq. (1) are the empirical constants which depend usually on curing, test conditions, test age and cement properties [15,16]. 2.2. Lyse’s law This law essentially gives a relationship between water content and maximum aggregate size for a specific workability value (slump) [13]. It is well known that the cement requirement in concrete decreases with increasing maximum aggregate size. On the other hand, for a particular water/cement ratio, the compressive strength of concrete tends to increase with increasing aggregate cement ratio. Consequently, the following linear relationship between water–cement ratio (w/c) and aggregate-cement ratio by weight (m) can be written as:
m ¼ K 3 ðw=cÞ þ K 4
Fig. 4. SEM of cherry marble powder.
Fig. 5. SEM of gold marble powder.
ð2Þ
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in which K3 and K4 are the empirical constants which depend on the workability properties of cementitious materials. 2.3. Molinari’s law It is necessary to develop a relationship between aggregate/cement ratio (m) and cement content (C) in order to complete the monogram in Fig. 2 [14]. Molinari has proposed the following inversely proportional relationship;
C¼
1000 K5m þ K6
ð3Þ
where K5 and K6 are the material constants.
segregation is to remain homogeneity of concrete without separating of grout from the mix. Although several methods have been used for self-compacting concrete in order to characterize the fresh state of the resulting concrete, there is no single test that can adequately measure for workability properties. On the other hand, there is no unique standard test method measuring the workability properties of SCC. In this study, the standard test methods used according to EFNARC [9] are given: 3.2.1. Slump-flow and T500 time test This test method, based on the traditional slump test, is utilized to determine the flowability and flow rate of SCC. The test equipments are one slump cone and one flow table, as shown in Fig. 7.
3. Experimental studies 3.1. Materials According to EN 197-1, CEM I 42.5 N was used in all mixes. Its specific gravity, specific surface area by Blain, and 28 days compressive strength were 3.1, 3393 cm2/g and 49.2 MPa respectively. The maximum aggregate size was 16 mm. The maximum sand grain size was 4 mm. Mineralogically, the aggregate consisted of river. The gradation curves of the granular materials are shown in Fig. 3. The aggregate and sand were air-dried prior to mixing. The superplasticizer ViscoCrete-3075 was used in order to produce SCC for all mixes. Three types of marble powder were utilized to obtain SCC mixes. Their physical and chemical properties are given in Table 1. Typical SEM photographs are illustrated at 5000 and 10,000 magnifications for each types of marble powder in Figs. 4–6. As shown in the Figs. 4–6, these marble powders have angular shapes with a rough surface texture unlike the fly ash particles that have spherical shape. On the other hand, cherry and white marble powders seem to be coarser than the gold marble powder. This can be also seen from the specific surface area values of these marble powders in Table 1. 3.2. Test equipment Self-consolidation characteristics are related to the workability properties: filling ability, passing ability and, the resistance to segregation. Filling ability is the capability of completely filling all spaces without vibration. Passing ability is the aptitude to flow through reinforcement bars without any blocking. Resistance to
Fig. 6. SEM of white marble powder.
Fig. 7. Test equipments according to EFNARC [9].
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The slump cone is filled with concrete and then lifted vertically. Two characteristic values are measured; time for the concrete
diameter to reach 500 mm (T500) and the final mean diameter of concrete (dm).
Table 2 Classes according to fresh SCC properties expressed by different test methods [9]
3.2.2. V-funnel test The test is utilized to determine filling ability and viscosity SCC. The test equipment is a V-shaped funnel, as detailed Fig. 7. The V-funnel is filled with concrete and then its gate opened. Time for the concrete to flow out of the funnel (tv) determined.
Slump-flow (flow test)
Viscosity (flow test)
Viscosity (Vfunnel test)
Passing ability (L-box test)
Segregation resistance (Sieve test)
Class
dm (cm)
Class
T500 (s)
Class
tv (s)
Class
PA
Class
SR (%)
SF1 SF2 SF3
55–65 66–75 76–85
VS1 VS2
62 >2
VF1 VF2
68 9–25
PA1 PA2
P0.8a P0.8b
SR1 SR2
620 615
a b
With 2 rebars. With 3 rebars.
of in is is
3.2.3. L-box test The test is utilized to determine flowability and passing ability of SCC. The test equipment is an L-shaped box, as detailed in Fig. 7. The vertical compartment of L-box is filled with concrete and then
Table 3 Experimental results: SCC mixes with cherry marble powders C (kg/m3)
Mix
C1C C2Ca C3Ca C4C C5Ca C6Ca C7Ca C8C C9C C10C C11Ca C12Ca C13Ca C14Ca C15Ca C16C C17Ca C18C C19Ca C20Ca C21C C22Ca C23Ca C24Ca C25Ca C26C C27Ca C28Ca C29Ca C30Ca C31Ca C32Ca C33Ca C34Ca C35Ca C36Ca C37Ca C38Ca C39C C40Ca C41Ca C42Ca C43Ca C44C C45C C46Ca C47Ca C48Ca C49C C50Ca C51Ca C52Ca C53C C54C a b
300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 350 350 350 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 450 450 500 500 500 500 500 500 500
P (kg/m3)
100 100 100 100 100 100 100 100 200 200 200 200 200 200 200 250 250 250 250 250 250 250 250 250 250 500 50 150 200 0 0 0 50 100 100 100 100 150 150 150 150 150 150 150 400 50 100 0 50 50 50 50 50 300
w/c
0.55 0.55 0.55 0.60 0.60 0.63 0.67 0.70 0.58 0.58 0.60 0.63 0.63 0.67 0.70 0.57 0.60 0.63 0.63 0.63 0.67 0.67 0.67 0.70 0.70 0.70 0.60 0.60 0.60 0.45 0.48 0.50 0.51 0.45 0.48 0.53 0.55 0.45 0.50 0.50 0.50 0.53 0.55 0.58 0.53 0.44 0.44 0.42 0.36 0.38 0.40 0.42 0.44 0.42
sp (%)
1 2 3 1 2 2 2 2 1 2 2 2 3 2 2 2 2 1 2 3 1 2 3 2 3 2 2 2 2 2 2 2 2 2 2 2 2 2 1 2 3 2 2 2 2 2 2 2 2 2 2 2 2 2
G (kg/m3)
722 722 722 706 706 696 685 675 672 672 667 657 657 646 636 658 648 637 637 637 627 627 627 616 616 519 677 638 619 711 701 690 667 672 662 641 630 653 632 632 632 621 611 600 524 654 634 646 658 647 637 626 616 529
S (kg/m3)
1095 1095 1095 1071 1071 1055 1039 1023 1020 1020 1012 996 996 980 964 999 983 967 967 967 951 951 951 935 935 787 1027 968 938 1079 1063 1047 1013 1020 1004 972 956 990 958 958 958 942 926 910 795 992 962 979 998 982 966 950 934 802
These mixes are provided with the properties of SCC. The values in bracket indicate slump values of fresh concrete.
dmb (cm)
30 57 58 43 60 66 68 71 [2] 51 62 68 69 71 73 50 58 [2] 65 66 [4] 66 68 69 71 [20] 63 66 62 62 67 68 66 55 58 69 73 58 44 66 71 68 72 76 51 67 70 70 52 68 71 73 77 56
T500 (s)
– 2.92 2.45 – 2.38 2.34 2.22 1.8 – 3 3.2 2.9 2.5 2.7 2.4 5.4 4 – 3.6 3 – 3.4 2.9 3.2 2.7 – 2.2 2.9 3.3 2.75 2.1 1.5 1.8 2.69 2.3 1.8 1.1 3.7 – 3.1 2.2 2.8 2.2 1.7 6.6 2.4 3.1 1.13 4.47 2.03 1.56 1.37 0.8 5.6
tv (s)
– 4.1 3.5 – 3.4 3.1 2.7 2.3 – – 6.1 5.5 5.2 4.7 4.4 – 7 – 6.4 6.2 – 5.7 5.4 5.3 5.2 – 3.6 4.2 4.9 5.4 5.1 4.5 5 6.5 6.1 4.9 4.2 5.3 – 4.1 3.9 3.6 3.3 2.7 – 5.9 6.4 3.5 – 4.6 4.3 3.9 3.3 –
PA
– 0.89 0.91 – 0.95 0.96 0.98 0.99 – – 0.91 0.94 0.93 0.96 0.97 – 0.89 – 0.91 0.92 – 0.94 0.94 0.97 0.97 – 0.96 0.93 0.92 0.92 0.95 0.97 0.94 0.88 0.91 0.97 0.99 0.88 – 0.93 0.94 0.94 0.96 0.99 – 0.95 0.93 0.96 – 0.93 0.96 0.97 0.99 –
SR (%)
– 1 1 – 7 12 16 33 – – 4 7 7 9 13 – 2 – 4 5 – 7 7 10 16 – 8 5 4 9 12 14 11 8 12 14 17 2 – 4 5 9 14 23 – 13 10 14 11 13 16 18 27 –
fc (MPa)
ft (MPa)
7d
28d
90d
7d
28d
90d
25.8 30.7 22.2 25.8 28.9 27.6 26.2 23.1 29.3 28.4 29.3 28.0 28.0 26.7 25.3 24.0 25.3 23.6 24.4 25.8 24.0 24.4 23.6 23.1 21.8 18.2 27.6 29.3 25.3 38.7 34.7 33.8 35.1 42.7 40.9 36.9 30.7 42.7 29.3 41.3 39.1 38.2 37.3 32.0 20.9 39.6 42.2 43.6 54.7 52.0 50.7 46.7 39.1 31.6
35.6 39.1 29.3 33.3 37.8 36.4 34.2 31.6 40.0 38.2 40.9 38.7 37.8 37.3 34.7 35.6 37.8 34.7 37.3 37.3 35.6 35.6 35.1 33.8 32.0 25.3 38.7 40.9 36.4 55.6 52.0 49.3 50.2 53.8 50.7 46.2 39.6 57.3 40.0 54.2 52.0 51.1 48.9 42.7 30.7 52.4 55.1 57.8 67.1 65.3 62.2 60.0 49.8 44.4
38.7 41.8 32.9 36.0 41.3 39.6 36.9 33.8 45.8 42.7 44.9 41.8 41.3 40.4 38.2 37.3 39.1 36.4 39.6 39.1 37.8 38.2 36.4 35.6 33.8 26.7 41.3 43.6 39.1 61.8 60.0 54.7 56.0 64.4 63.1 56.9 43.6 65.8 45.8 61.3 58.7 57.8 52.9 45.8 33.3 61.8 64.4 67.1 73.8 71.1 67.6 64.4 53.3 48.4
2.19 2.63 1.90 2.19 2.41 2.34 2.27 1.98 2.48 2.45 2.45 2.37 2.37 2.23 2.19 2.01 2.16 2.05 2.09 2.16 2.05 2.09 1.98 2.01 1.90 1.57 2.30 2.48 2.16 3.26 2.91 2.80 2.91 3.57 3.40 3.12 2.55 3.54 2.45 3.44 3.30 3.16 3.12 2.63 1.76 3.23 3.47 3.64 4.47 4.30 4.13 3.85 3.19 2.63
2.94 3.19 2.45 2.80 3.12 3.05 2.87 2.63 3.33 3.16 3.33 3.16 3.16 3.09 2.91 2.94 3.16 2.87 3.09 3.05 2.94 2.98 2.91 2.84 2.70 2.12 3.16 3.37 3.01 4.47 4.23 4.06 4.06 4.37 4.13 3.82 3.23 4.64 3.26 4.40 4.26 4.20 3.95 3.50 2.52 4.20 4.43 4.64 5.38 5.28 5.01 4.88 4.09 3.61
3.19 3.47 2.70 3.01 3.44 3.26 3.01 2.87 3.71 3.54 3.75 3.50 3.37 3.33 3.19 3.12 3.23 2.98 3.33 3.30 3.19 3.12 3.01 2.94 2.80 2.30 3.44 3.54 3.19 5.01 4.81 4.40 4.60 5.25 5.08 4.60 3.61 5.31 3.82 5.01 4.71 4.67 4.30 3.75 2.84 5.05 5.15 5.42 5.88 5.65 5.48 5.15 4.30 3.95
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the sliding gate is lifted. The concrete flows through the steel bars into the horizontal part. The distances H1 and H2 are measured when the concrete is stopped. The value of passing ability PA = H2/H1 is calculated. 3.2.4. Sieve segregation resistance test This is utilized to determine resistance of SCC to segregation. The test equipment is the sieve with diameter frame = 500 mm and sieve size = 5 mm. After placing 4.8 ± 0.2 kg concrete sample into the sieve, the fresh SCC is allowed to stand for 2 min on the sieve. The segregated portion (SR) is calculated as the proportion of the sample passing through the sieve. The slump-flow test is quick while the sieve segregation resistance test is slow. On the other hand, these tests can be performed by single operator. There is good correlation between the sieve segregation resistance test and the behavior in full scale structures. Moreover the slump-flow test has good correlation with L-box test. V-funnel and L-box tests are good indicator of viscosity [17]. In Table 2, the classifications recommended by EFNARC [9] are given for the properties of fresh SCC obtained from different test methods. 3.3. Mix details and test procedure Experimental studies have revealed that the properties of a fresh SCC are particularly influenced by two material parameters: water–cement ratio (w/c) and water–powder ratio (w/p) [8–10]. Several mix design methods have been proposed at academic milieu and institutions for SCC [4–6,8–10]. Not only the properties of fresh concrete but also the properties of hardened concrete are hereby considered in order to find a general expression of the SCC mix design. Totally seventy-three series of mix proportions, of which five series were the references mixes, were tested concerning two essential material parameters (w/c and w/p) in different combinations and for three different marble powder types. The cement contents varied from 300 kg/m3 to 500 kg/m3 whereas the powder
contents varied between 0 and 400 kg/m3 and the water/cement ratios varied from 0.36 to 0.70. The superplasticizer was used in different proportions as 1%, 2% and 3% of the cement content, except for references mixes. All specimens in each series were cast from the same batch of concrete. The experimental results for SCC mixes with cherry powders and for SCC mixes with white and gold powders are given in Table 3 and Table 4, respectively. The reference mixes are presented in Table 5. The first column in Table 3 and 4 gives the mix numbers, namely C1 to C54 for SCC trial mixes and REF1 to REF5 for reference mixes. The letters following the mix numbers in the trial mixes in the first column are depicting the marble powder types used in the batches; C for Cherry, W for White and G for Gold. The mixture proportions are listed on the columns of Tables 3 and 4 from second to seventh, where C, P, w/c, sp, G and S indicate cement content, powder content, water/cement ratio, percent of superplasticizer by weight of cement, aggregate content and sand content, respectively. The properties of fresh concrete prepared according to the procedure proposed by EFNARC committee procedure are shown in columns of Tables 3 and 4 from eighth to twelfth. According to the criterias in Table 2, 53 of the 67 total SCC trial mixes are provided with the properties of SCC. These mixes are represented with an asterisk in Table 3. Besides, all of the SCC mixes containing gold and white marble powders are provided with the properties of SCC in Table 4. None of the trial mixes containing 1% superplasticizer were illustrated the properties of self-compatibility, as shown in Table 3. To determine mechanical properties of hardened concrete, compressive strength and split-tension strength tests were applied at 7, 28 and 90 days. The test specimens were used as 150 mm cubes. Specimens in each series were cast in plastic moulds. Specimens were removed from the mold after 1 day and subsequently, the ones with test age of 7 days were cured at 7 days and the ones with test age of 28 and 90 days were cured at 28 days in a moist room of 95% relative humidity and temperature of about 23 °C. All the specimens were tested in a testing machine with the capacity of
Table 4 Experimental results: SCC mixes with white and gold marble powders Mix
C (kg/m3)
P (kg/m3)
w/c
sp (%)
G (kg/m3)
S (kg/m3)
dm (cm)
T500 (s)
tv (s)
PA
SR (%)
fc (MPa) 7d
28d
90d
7d
28d
90d
C7W C7G C12W C12G C24W C24G C35W C35G C38W C38G C43W C43G C50W C50G
300 300 300 300 300 300 400 400 400 400 400 400 500 500
100 100 200 200 250 250 100 100 150 150 150 150 50 50
0.67 0.67 0.63 0.63 0.70 0.70 0.48 0.48 0.45 0.45 0.55 0.55 0.38 0.38
2 2 2 2 2 2 2 2 2 2 2 2 2 2
685 685 657 657 616 616 662 662 653 653 611 611 647 647
1039 1039 996 996 935 935 1004 1004 990 990 926 926 982 982
66 68 65 67 67 68 56 57 55 58 72 69 65 68
2.4 2.3 3.2 3 3.7 3.4 2.5 2.3 3.4 3.7 2.6 2.3 2.6 2.2
3 2.8 5.9 5.7 5.7 5.4 6.4 6.3 5.6 5.4 3.6 3.3 5 4.7
0.93 0.96 0.91 0.94 0.93 0.96 0.93 0.91 0.87 0.88 0.93 0.95 0.9 0.92
12 15 5 6 7 9 9 11 1 1 12 13 12 13
25.7 25.2 27.8 27.2 22.8 22.6 40.7 40.5 42.7 42.4 36.8 36.4 51.5 50.9
34.0 33.7 38.5 38.4 33.5 33.0 50.4 50.3 57.0 56.9 48.3 47.9 64.5 63.9
36.5 36.3 41.4 41.3 35.4 35.1 62.7 62.1 65.4 65.2 52.4 52.2 70.3 69.8
2.21 2.09 2.21 2.21 1.83 1.83 3.10 3.10 3.47 3.22 3.10 2.97 4.08 3.96
2.72 2.60 2.97 2.85 2.85 2.72 3.96 3.83 4.44 4.32 3.83 3.83 4.92 4.92
2.97 2.72 3.34 3.10 2.97 2.72 4.80 4.68 5.16 4.92 4.20 4.08 5.40 5.16
ft (MPa)
Table 5 Experimental results: reference mixes Mix
C (kg/m3)
w/c
G (kg/m3)
S (kg/m3)
Slump (cm)
REF1 REF2 REF3 REF4 REF5
300 350 400 450 500
0.65 0.60 0.53 0.47 0.42
729 697 680 663 646
1106 1057 1031 1005 979
15 13 9 5 2
fc (MPa)
ft (MPa)
7d
28d
90d
7d
28d
90d
20.4 23.1 27.1 29.8 37.8
30.2 33.3 37.3 43.1 48.9
32.4 36.4 39.1 46.7 54.7
1.76 1.94 2.23 2.48 3.16
2.52 2.73 3.01 3.50 3.99
2.73 3.05 3.30 3.82 4.37
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2000 kN. The specimens were loaded monotonically until failure and care was taken to apply a constant loading rate. Typically, it took about 5 min (±30 s) to reach the maximum load for each specimen. The compressive strength, fc and the split-tension strength, ft at 7, 28, and 90 days of the specimens are given in the last six columns of Table 3–5. The values of strength in these tables were obtained from mean of at least two test results. 4. Experimental results The compressive strength and the split-tension strength measured, as shown in Table 3, are slightly lower for SCC mixes containing 3% superplasticizer than for the ones containing 2% superplasticizer. For this reason, the values of the mixes only containing 2% superplasticizer (a total of 47 series) were utilized in the analysis of mix design. Three powder types should have different water requirements because they have different specific surface areas. Nevertheless the flow values of the concretes obtained from these powder types are almost identical in the same water-to-cement ratio, same cement content, and same powder content, as illustrated in Fig. 8. This means that the effect of the powder type can be negligible for the practical aims. Fig. 9 shows the compressive strength at 28 days against the water/cement ratio, for the considered 47 SCC mixes and 5 references mixes. In the same figure, the best-fit curves expressed by an exponential function are also given. This revealed that SCC mixes containing marble powder pointed out a higher strength at a given water/cement ratio than the traditionally concrete mix. Furthermore, the mean strength of SCC mixes with marble powder
Fig. 8. Comparison of flow values of SCC with different marble powder.
Fig. 9. Comparison of SCC mixes with reference mixes.
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was 25% higher than the references concrete. A similar conclusion was observed by Zhu and Gibbs [8] for SCC mixes containing limestone and chalk powders. 5. Analysis of test results Fig. 10 illustrates typical volume proportions of the ordinary concrete and of the self-compacting concrete comparatively [10]. As shown, both the aggregate content (fine + coarse) and the water-to-powder ratio of SCC are smaller than that of traditional vibrated concrete. The powder contribution consists of cement and inert or pozzolanic additions in SCC. In the present work, marble powder is used as additional material while it is assumed as the mineral filler material in fine aggregate in the ordinary concrete. Moreover, the properties of fresh SCC are, as already mentioned above, particularly influenced by the two material parameters: water–cement ratio and water–powder ratio. Nevertheless, the water/powder ratio is not used directly since it is possible to produce SCC mixes without powder. Deducting from the above discussion, a relationship between powder/cement ratio and cement content should be constituted. Consequently, the Molinari’s law (Eq. (3)), which is used for estimating the cement content in the normal concrete, can be modified to the following form for SCC mix:
C¼
1000 K5m þ K6n þ K7
ð4Þ
where n is the powder cement ratio by weight and, K5, K6 and K7 are the material constants. The constants in Eq. (4) can be determined from the multiple linear regression made on Y = K5X1 + K6X2 + K7 with Y = 1000/C, X1 = m and X2 = n. Fig. 11 shows the individual test data and the modified Molinari’s law calculated via Eq. (4) for different ratios of powder/cement in the aggregate/cement ratio versus cement content plane. It is derived from Fig. 11 that the considered test results are very close to the modified Molinari’s law because the determination coefficient R2 = 0.988. The Lyse’s law in the mix design based on monogram proposed by Monteiro et al. [11] uses the slump test for workability of concrete. Similarly, the slump-flow test, which is commonly proposed for determining the workability properties of fresh SCC such as flowability and flow rate at academic milieu and institutions for SCC, was utilized in this study. The flow values in Table 3 and 4 varied from 55 to 75 for the considered 47 data. According to EFNARC, these are classified as: (1) SF1 (55–65 mm) and (2) SF2 (66– 75 mm). Fig. 11 illustrates the individual test data and Lyse’s law calculated via Eq. (2) for two different slump-flow classes in the aggregate/cement ratio versus water/cement ratio plane. The correlation coefficients of Eq. (2) are r = 0.833 for flow 55–65 mm (SF1) and r = 0.911 for 66–75 mm (SF2). Abrams’ law (Eq. (1)) has been applied to some properties of concrete such as the compressive strength, Young’s modulus and
Fig. 10. Comparison of mix proportioning between SCC and ordinary mix.
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Fig. 11. Mix design monogram for SCC mixes with marble powder.
fracture energy [11]. In the present research, this law was also applied to the split-tension strength of concrete. The constants in Eq. (1) can be calculated as K 1 ¼ a and K 2 ¼ expðbÞ from the exponential regression made on Y ¼ a ebX with Y = fc, X = w/c. The results of analysis based on Abrams’ law for the compressive strength (fc) and the split-tension strength (ft) of the specimens at 7, 28 and 90 days are given in Fig. 11. In Fig. 11, the equations’ correlation coefficients, at 7, 28 and 90 days, are respectively 0.965, 0.974 and 0.966 for the compressive strength and, 0.959, 0.964 and 0.958 for the split-tension strength. 6. Comparison with the previous studies In the previous investigations, the effects of water/cement ratios, water/powder ratios, the powder type (inert or pozzolanic), the volume fraction of the solids in the mix, and the content of viscosity modifier agents on the properties of fresh and hardened SCC were evaluated. However, general relationships between properties of the fresh SCC and the hardened SCC containing inert/pozzolanic powder have not been proposed. In this study, the mix design approach based on monogram developed by Monteiro and coworkers [11] for vibrated concrete was adapted to SCC mixes. In order to investigate how well the monogram proposed in this study would simulate the behavior of SCC with different types of
powders available in the literature, the study by Zhu and Gibbs [8] has been simulated. The mixes in their study were designed for water/cement ratios: 0.42 and 0.57 with crushed coarse aggregate of maximum size of 20 mm. In addition, CEM I 42.5 Portland cement with a Blaine specific surface area of 3850 cm2/g, three types of limestone powder and two types of chalk powder were utilized as filler in their SCC mixes. Corresponding to the investigated series of w/c values, values of slump-flow were ranging from 60 to 65 cm. The compressive cube strength tests were performed at 7, 28 and 90 days and splitting cylindrical tests at 28 days. Since the compressive cube strengths at 7 and 90 days are not reported clearly in Ref [8], these mixes (SCC1 and SCC2) and only their average 28day strength values are summarized in Table 6 according to w/c values. Consequently, it is found that the contributions to strength gains were significantly greater for the limestone powder than for the chalk powder. Besides, the diversity in the mean strength values are owing to usage of five different powders in Table 6. Table 6 and Fig. 12 give results of the experiments and the approach based on the presented monogram, comparatively. It is noted that only the SF1 slump-flow class and the strength properties at 28 days are taken into consideration in Fig. 12 different from Fig. 11. Although test data obtained from different laboratory for SCC with different powder types were utilizing in the comparison, Fig. 12 shows that Eq. (2) and Eq. (4) agree with previous test re-
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K.E. Alyamaç, R. Ince / Construction and Building Materials 23 (2009) 1201–1210 Table 6 Comparison design based on the monogram and the study of Zhu and Gibbs [8] Mix
Agg. (kg/m3)
Cement (kg/m3)
Powder (kg/m3)
SCC1 SCC2
1670 1685
300 405
240 135
Experimental
Predicted
a/c
w/c
fc (MPa)
ft (MPa)
a/c
w/c
fc (MPa)
ft (MPa)
5.57 4.16
0.57 0.42
44–52 67–74
3.2–4.7 4.6–5.9
5.30 3.94
0.60 0.43
41 58
3.3 4.6
Fig. 12. Comparison of developed mix design monagram with study by Zhu and Gibbs [8].
sults quite well. Consequently, the modified Molinari’s Law (Eq. (4)) developed in this study seems to be useful for determining the contribution of powder/cement ratio on the properties of fresh SCC. Nevertheless, experimental results of the study by Zhu and Gibbs have greater strength values than results of the monogram presented in this study. This is mainly due to the strength is influenced by not only water/cement ratio and aggregate/cement ratio but also properties of aggregate particles such as grading, surface texture, shape, strength, stiffness and maximum size [18]. However, if the further researches will be performed, more reliable findings can be proposed. 7. Conclusions From the findings of these experimental and statistical investigations for self-compacting concrete mix design based on mono-
gram proposed by Monteiro and co-workers, the following conclusions can be extracted: 1. Although the marble have been commonly used as a building material since ancient times, disposal of the waste materials of the marble industry is one of the major problems for the environmental concerns all over the world. However, this study emphasizes that these waste materials can be successfully and economically utilized as additional inert filler material in SCC technology. 2. The presented monogram is highly useful since its ability to combine the properties of fresh SCC such as flowability and properties of hardened SCC such as compressive strength and split-tension strength at 7, 28 and 90 days in one graph. 3. The results obtained from the comparison of the modified Molinari’s Law (Eq. (4)) developed in this study and the previous tests depicts that such a relationship seems to be useful
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for determining the contribution of powder/cement ratio on the properties of fresh SCC. 4. This monogram designed for two slump-flow classes: (1) SF1 (55–65 mm) which is suitable for unreinforced/slightly reinforced concrete structures and concretes cast by a pomp injection system, (2) SF2 (66–75 mm) which is appropriate for many applications such as columns. In addition, the monogram allows performing mixes of SCC with different powder to cement ratios. Consequently, this also gives opportunity to obtain economic mix design.
[4]
[5]
[6] [7]
[8]
Acknowledgements The authors would like to acknowledge the Scientific Research Projects Administration Unit of Firat University (Project No: FUBAP-1370) for the financial support. References
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