design a self-compacting concrete (scc) … a self-compacting concrete (scc... · design a...

DESIGN A SELF-COMPACTING CONCRETE (SCC) USING LOCAL MATERIALS - STUDY ON WORKABILITY AND COMPRESSIVE

STRENGTH

A project Paper Submitted To Faculty of Engineering, University Malaysia Sarawak

In Partial Fulfillment for The Degree of Bachelor of Engineering (Hons) Civil Engineering

2000

Dedicate To My Beloved Parent & Brothers and Sisters

H. Achong Lulut & Jara Asun Desmond, Anna, Pauline & Nyadang

11

ACKNOWLEDGEMENT

First of all, I would like to express gratitude and appreciation to my supervisor, Mr.

Mohammad Ibrahim Safawi Bin Mohammad Zain for his guidance, concern,

knowledge and idea which I manage to do this project smoothly. To my partner,

Abdul Razi Bin Kassim, thanks for your co-operation in this project. Thanks to lab

assistants for their immaculate helping this project done especially to Tuan Hj.

Affandi and Puan Rosidah. The deepest appreciation to Stigang Resources Sdn. Bhd.

and Premier Structure PTE LTD for giving us free sample of quarry dust and

chemical admixture respectively that we use in this project. Not forgetting to my

friend, 5-induk hajik who gives me support and courage especially to Aaa, Mac, Jess,

Pauline and Agnes. Stay cool and always be hajik !

Lastly to my mum and dad, my brothers and sisters who are always beside me in

wherever I am and whatever I do. I love you all.

Ill

ABSTRACT

Self-Compacting Concrete (SCC) is new type of concrete first developed in Japan in

1988. SCC refer to concrete that can be compacted into every corner of formwork,

purely by its own weight and without the need for vibrating compaction. SCC can

also flow between reinforcement bar without tendency blockage of coarse aggregate.

Besides that introduced SCC as construction material not only satisfied the

workability and strength requirement but also will develop new rational construction

system. For examples, the elimination of vibration process and reduction in labor cost,

creating working environment free from noise pollution and other better aspects of

construction method. Therefore the main objectives of this project are to design self-

compacting concrete using local material and to study on workability and

compressive strength of designed SCC. This project will view detail information

about SCC and process involved in producing SCC based on the experiment that has

been done in the laboratory.

iv

ABSTRAK

Self-Compacting Concrele (S('() merupakan prototaip konkrit Yang perluma

dimujukun di Jepun puda luhun 1988. S('(' merujuk kepudu konkrit yang belch

dipadatkan keseluruh sudul kotak acuan menggunakun dgya berat konkril itu sendiri

lanpa huntuun mesin gegaran S('(' juga belch mengalir di untara halang hesi dimunu

hatu kelikir lidak cenderung untuk tersekal. Selain itu, penggunuan SCC sehagui

bahan binuaz2 bukan suhuju memenuhi ciri-ciri tahup husuh konkrit dun kekuulun

dayu padalan konkrit malahan mewujudkan sistem pemhinaan rasional yang huru.

('ontohnvu, penghapusun proses pemadatan oleh mesin gegaran clan pengurungun

gUji pekerja, mewujudkan kawasan pembinuan yang hehas duripadu pencemaran

bun vi . sertu kueduh pemhinuun yang lehih efektif Oleh itu, ohjektif utumu projek ini

adalah untuk merekahentuk S('(' dengan menggunakan hahan hinaan iempulun dun

seterusnya mempe/ujari ciri-ciri S( '( ' padu tahup hasah clan kekuutan duvu pudulun

konkrit ketika keras. Yrcyek ini akan memaparkan maklumut lerperinci lentung S('('

dun proses yang te/ihut dulum menghusilkun S('(' herdasurkun kepudu ck. sperimen

yang telah dilaksanakan dulum makmul.

V

CONTENT

Declaration

Dedication

Acknowledgment

Abstract

Abstrak

Content

List of Tables

List of Figures

List of Symbols

i

ii

Ill

IV

V

vtu

ix

xi

xv

vi

1.0 Chapter 1: Introduction

1.1 Overview 1.1.1 Concrete 1.1.2 Self-Compacting Concrete (SCC) 1.1.3 Reason for the Development of SCC

1.2 SEC Historical Background 1.3 Objectives 1.4 Project Description 1.5 Chapter Summary

2.0 Chapter 2: Literature Review

2.1 Concrete Components 2.2 Type of Concrete 2.3 Self-compacting Concrete (SCC)

2.3.1 SCC Component 2.3.2 SCC Properties 2.3.3 Obtaining High Performance Concrete 2.3.4 Achieve High Compactability 2.3.5 Proportional Mix Design of SCC 2.3.6 SCC Classification 2.3.7 Proposed Standard Test of SCC

2.4 Workability Definition 2.5 Factor Affecting Workability 2.6 Review on SCC Experiment

2.6.1 Common Workability Test 2.6.2 Result

2.6.2.1 SCC Applied in Sandwich Composite Structure in Japan

2.6.2.2 SCC Experiment in Korea 2.6.2.3 SCC Experiment in Netherlands

3.0 Chapter 3: Experimental Works

3.1 Introduction 3.2 Design Mix Proportion of SCC 3.3 Preparation of Material 3.4 Mixing SCC 3.5 Workability Test

3.5.1 Slump-Flow Test 3.5.2 Box-type Test 3.5.3 L-shaped Test

1 1 2 ý

4 5 6 7

9 16 16

17 19 22 23 24 25 26

29 30 31

31 31

31 32 33

34 36 37 41 42

43 44 45

vii

3.6 Curing Process 47 3.7 Hardened Test: Compressive Strength Test 48 3.8 Trial Mix 49

3.8.1 Trial Mix Proportion 3.8.2 Result and Discussion

3.9 Experimental Work

4.0 Chapter 4: Result and Data Analysis

4.1 Introduction 4.2 Result

4.2.1 Sieve Analysis for Fine Aggregate 4.2.2 Observation and Description

49 50

53

55 56

56 57

4.2.2.1 Mixing Stage 57 4.2.2.2 Fresh Stage: Workability 60

4.2.2.2.1 Slump Flow and Segregation 60 4.2.2.2.2 Self-Compatibility 64 4.2.2.2.3 Flowability 65

4.2.2.3 Placing, Curing and Demoulding Stage 66 4.2.2.4 Hardened Stage: Surface Texture and

Aggregate Distribution 68

4.3 Data Analysis 71

4.3.1 Data Summary 71 4.3.2 Analysis on Workability 73 4.3.2 Analysis on Compressive Strength 77

4.4 Analysis Summary

5.0 Chapter 5: Conclusion

5.1 Project Objective Achievement 5.2 Conclusion 5.3 Recommendation

BIBLIOGRAPHY

APPENDIX A: Project Schedule

APPENDIX B: Experimental Result

82

84 85 86

87

88

89

Vlll

LIST OF TABLES

Table 1.1: Chronological of Development SCC 4

Table 2.1: Constituents of Cement Involve in Hydration 10

Table 2.2: Type of Aggregate 12

Table 2.3: Classification of Compressive Strength Concrete 16

Table 2.4: Example of Superplasticizer 19

Table 2.5: Performance of SCC 21

Table 2.6: Consistency Test Procedures Standardised in Various Countries 31

Table 2.7: Result of Experiment 31

Table 2.8: Result Experiment in Korea 32

Table 2.9: Characteristic of Powder Material 32

Table 2.10: Characteristic of Superplasticizer 32

Table 2.11: Result Experiment in Netherlands 33

Table 3.1: Mix proportion of SCC in kg/m3 37

Table 3.2: Specified Mix Proportion of SCC for Trial Mix 49

Table 3.3: Result of Trial Mix 52

Table 3.4: Specified Mix Proportion of SCC in Kilogram (kg) 53

Table 4.1: Sieve Analysis for Fine Aggregate 56

Table 4.2: Summarize Experimental Result 71

Table 4.3: Analysis Summary 81

ix

LIST OF FIGURES

Figure 1.1: Rational Construction System Achieved by Making Full Performance of SCC 3

Figure 1.2: General Stages of Producing SCC 6

Figure 2.1: Main Components of Concrete 9

Figure 2.2: Formula for Determine Fineness Modulus (FM) 14

Figure 2.3: Effect Water Cement Ratio to Compressive Strength 15

Figure 2.4: SCC Components 17

Figure 2.5: Properties of SCC 19

Figure 2.6: Method to Obtain High Performance Concrete 22

Figure 2.7: Proportional Mix Method 24

Figure 2.8: Classification of SCC 25

Figure 2.9: Proposed Standard Test of SCC 26

Figure 2.10: Concept of Acceptance Test on Site 28

Figure 3.1: Concrete Mould of 150x150x150 mm 35

Figure 3.2: A Rational Mix Design Method for Self-Compacting Concrete 36

Figure 3.3: Main components of SCC 37

Figure 3.4: Quarry Dust from Stigang Resource Sdn. Bhd. 38

Figure 3.5: Coarse Aggregate (Gravel) 39

Figure 3.6: Fine Aggregate (sand) 39

Figure 3.7: Sieve Analysis Apparatus 39

Figure 3.8: Forced Pan Mixer 41

Figure 3.9: Slump Flow Test Apparatus 43

XI

Table B 1: Experimental Result for SCC I

Table B2: Experimental Result for SCC 2









Table B 11: Box-type Test Result

89

89

89

90

90

90

90

91

91

91

91

X

Figure 3.10: Dimension of Slump Flow Apparatus

Figure 3.11: Dimension Box-type test

Figure 3.12: Box-type Test

Figure 3.13: L-shaped Apparatus

Figure 3.14: Dimension of L-shaped Test

Figure 3.15: Curing Tank

Figure 3.16: Compressive Strength Test Machine

Figure 3.17: Material For Trial Mix

Figure 3.18: Slump Test for Trial Mix

Figure 3.19: Trial Mix after 24 hours Placing

Figure 3.20: Trial Mix (TM) After 7 days Curing

Figure 3.21: Compressive Strength Test for TM3

Figure 3.22: TM 3 after Compressive Test

Figure 4.1: Particle Size Distribution Analysis of Sand

Figure 4.2: SCC 5 Before Added Mighty 21 Using Forced Pan Mixer

Figure 4.3: SCC 5 After Added Mighty 21 Forced Pan Mixer

Figure 4.4: SCC 10 Before Added Mighty 21 using Hand Mixing

Figure 4.5: SCC 10 After Added Mighty 21 using Hand Mixing

43

44

44

45

46

47

48

49

50

50

51

51

51

56

57

57

58

58

Figure 4.6: Remix SCC 7 in the Tray 59

Xll

Figure 4.7: SCC 3- 640 x 620 mm

Figure 4.8: SCC 3 at T50 Value

Figure 4.9: SCC 5- 530 x 520 mm

Figure 4.10: SCC 6- 520x510mm

Figure 4.11: $CC 7- 430 x 430 mm

Figure 4.12: SCC 8- 400 x 390 mm

Figure 4.13: SCC 9- 400 x 400 mm

Figure 4.14: SCC 10-380x 380 mm

Figure 4.15: SCC 2- 40 mm

Figure 4.16: SCC 4- 20 mm

Figure 4.17: Self-Compactability of SCC 3 Evaluated Using Box-typed Test

Figure 4.18: Self-Compactability of SCC 5 Evaluated Using Box-typed Test

Figure 4.19: Evaluated Fioiwabiiity of SCC 6 Using L-shaped

Test

Figure 4.20: SCC 6 Flowing Through Reinforcement Bars of L-Shaped Apparatus

Figure 4.21: Remix SCC 3 in Tray

Figure 4.22: placing SCC 3 into Mould

Figure 4.23: Placing SCC 4 and SCC 5 into Mould

Figure 4.24: Remove the SCC 2 Cube from Mould

Figure 4.25: SCC 6 After 24 hours Casting

Figure 4.26: Ready for Strength Test SCC 3, SCC 5-1 and SCC 5-2

Figure 4.27: Ready for Compressive Strength Test

60

60

60

61

61

61

62

62

63

63

64

64

65

65

66

66

67

67

68

68

69

Figure 4.28: Surface Texture of SCC 69

xrn l

Figure 4.29: SCC 5 at age 28 days After Strength Test 70

Figure 4.30: SCC 8,9& 10 After Compressive Strength Test 70

Figure 4.31: Coarse Aggregate Distribution in SCC 5 at age 14 days 70

Figure 4.32: Slump Flow of SCC 2 and SCC 4 73

Figure 4.33: Slump Flow of SCC 2, SCC 3 and SCC 5 74

Figure 4.34: Slump Flow of SCC 5, SCC 6 and SCC 7 75

Figure 4.35: plump Flow of SCC 8, SCC 9 and SCC 10 76

Figure 4.36: Average Compressive Strength for SCC 1 76

Figure 4.37: Compressive Strength for SCC 2 and SCC 4 After 28 day Curing 77

Figure 4.38: Compressive Strength for SCC 3 with 5% Mighty 21 78

Figure 4.39: Compressive Strength with Different Quantity of Mighty 21 78

Figure 4.40: Increment of Compressive Strength 79


Figure 4.42: Average Compressive Strength for SCC 7 and SCC 8 After 28 day Curing 80


X1V

LIST OF SYMBOLS

C- Cement (OPC)

Cube ref. - Cube reference

D- Diameter

d- Day

f cu - Compressive Strength in N/mm2

FM - Fineness Modulus

H- Filing Height of box-type test

G- Coarse aggregate

G max - Maximum size of coarse aggregate

M21 - Mighty 21

QD - Quarry Dust

R,; - Relative funnel speed

S- Fine aggregate (sand)

S/a - Coarse aggregate to concrete ratio

SCC - Self-Compacting Concrete

SP - Superplasticizer

s- Second

TM - Trial Mix

T50 - Time in second taken to reach slump flow of 50 cm

W- Water

W/C - Water cement ratio

W/P - Water powder ratio

p- Density in kg/m2

+- Varied parameter

- Fixed parameter

xv

CHAPTER I

INTRODUCTION

1.1 Overview

1.1.1 Concrete

These days, apart from steel, concrete is the most common and widely used as

structural material in construction field. Concrete defined as a composite material

made up of composed granular material (the aggregate or filler) embedded in a hard

matrix of material (cement or binder) and water that fills the space between the

aggregate particles and glues them together. There are many types of concrete with

different material used and mix design. Therefore the definitions of concrete itself not

specific to one definition but become more broadly depended on various type

materials use in concrete constituent itself.

In mix design, good concrete must economical and fulfill the requirements include:

" Fresh state: satisfactory the workability, compacted, cohesive enough to be

transported, and place in the formwork without segregation

" Hardened state: satisfactory compressive strength, tensile strength, durability,

density, permeability and other properties.

I

1.1.2 Self-Compacting Concrete (SCC)

To fulfill all these requirements, the research to develop new type concrete become a

major interest in most country. In Japan, researchers were successful developed a new

type of concrete named Self-Compacting Concrete (SCC). This new concrete not only

satisfied the two basic requirements of concrete, but also create the new properties of

concrete that is very workable, flowable and self-compacting.

From definition, SCC is a type of concrete that can be compacted into every corner of

formwork, purely by means of its own weight and without the need for vibrating

compaction. SCC classified in High Performance Concrete which define as follow-

" Fresh: self-compactable and flowable

" Early age: Avoidance from initial defects

" Hardened: protection against external factor ýx'

1.1.3 Reason for the Development of SCC

The main factors for the development of SCC are to achieve high durable, flowable,

workable and, self-compacting of concrete and to solve the weakness properties of

concrete as we know the concrete is a brittle material with low tensile strength,

volume stability, low ductility and low strength to weight ratio.

Normal concrete usually needs vibration. The vibrations cause noise that not only

leads to stress on construction site but also effect the surrounding neighborhood.

Apart from that, it has harmful physical impact on worker such deafness and `white

finger'. Moreover vibration is time consuming. When the casting is on critical path of

1)

the construction process it can produce delay and increase the cost. However, SCC is

different because it is more homogeneous concrete in the construction for example

variation due to consolidation with vibrator during placing. Adopt SCC means less

variation in production of concrete for example less deviation in strength.

The other advantage using SCC is improved the surface quality of concrete. It also no

refinishing before painting or paper hanging of the walls. Applied SCC means reduce

damage on the surface of the construction such as visual effects. Last but not least,

cost will decrease as manpower reduces during placement of fresh concrete.

Self-Compacting Concrete

No Vibration

Less Restriction to design

Resistance to Segregation

Less Restriction to Particle

v New Type of

Structure

Rational Combination

of Concrete andSteel

Rational Construction System

Figure 1.1: Rational Construction System Achieved by

Making Full Perwrmunce of S('(' ýý'

As shown in Figure 1.1, in future, researchers believe by implementing this new type

of concrete will satisfies all the construction requirements.

3

1.2 SCC Historical Background

Problem of the durability of concrete structures was a major topic of interest in Japan

beginning in 1983. This situation is seen as a major problem facing by Japanese

society. Sufficient compaction by skilled workers is required in order to realize

durable concrete structures. However, the gradual reduction of the number of skilled

workers in Japan's construction industry has led to a similar reduction in the quality of

construction work. Therefore the development of self-compacting concrete would be

necessary in order to guarantee durable concrete structures in the future. Table 1.1

shows the chronological of development SCC:

Year Event Place

March 1986

August 1989

January

i r I i ý I ý

1989

July 1989

Proposal for developing self-compacting concrete (SCC) by Okamura

Completion of a prototype by Okamura

A presentation by Okamura at the second East-Asia

and Pacific Structural Engineering and Construction (EASEL-2)

An open experiment

May 1992 Presentation on SCC by Ozawa at i

ý--ä International Conference

Japan ý-------- ---

CANMET & ACI I

i

I Istanbul

-1 I ý I I I

ý----- -_i j September A text book on self-compacting HPC in Japanese

I99-3

November ACI Workshop on High Performance 1994 -n_I -I

---

-I sponsorea oy rroi. raue Lia January RILEM Committee found SCC

1997 August Proceedings of International

1yyx Compacting Concrete

i I i

Japan

Bangkok Concrete

Workshop on _- ---

Self- Kochi University of Technology, Tosa-

yamada, Kochi,

1 uhle 1.1: Chronological o/*Uevelopment S( X'

Japan

Japan

in Chaing-Mai

I University of Tokyo,

i

4

Beside Japanese researcher, almost the same time, Aitcin et al. "K) aslo defined "High

Performance Concrete" as concrete with high durability due to low water cement

ratio. However, this types of concrete differ from SCC because of the difference

contrived to make the concrete self-compactable.

The use of self-compacting concrete in actual structures has been gradually increasing

over the last few years. The applications of SCC are:

" Used in the construction of the two anchorage of the Akashi-Kaiyo bridge

" Used for wall of a large LNG tank of Osaka Gas Company

" Applied to sandwich composite structure

" Widely use in concrete product such box culvert, precast retaining wall, segment

for shield tunnel, precast concrete girder and other concrete block.

1.3 Objectives

The main objectives of this project are:

1. To design Self-Compacting Concrete (SCC) based on the current mix

proportion using local material.

II. To study the fresh property such as workability of the SCC.

Ill. To investigate the hardened property such as compressive strength of SCC.

5

1.4 Project Description

Design mix-proportion Scc

ý

Trial Mix

Experiment work

T Data Analysis

Self-Compacting Concrete (SCC)

Mixing

w Workability Test

Placing, Curing Removing

Compressive Strength Test

' Figure 1.2: General Stakes of Producing SC C

Our project is classified as an experimental project. The description of the project is

summarized as shown in Figure 1.2. First of all, the project begins with design a mix-

proportion of SCC. The design of SCC will be based on Okamura and Ozawa method

We also use the mix proportion suggested by Premier Structure PTE Ltd., one

company from Singapore that provide us free sample chemical admixture, Mighty 21

for our project.

After design, we proceed the trial mix for SCC. This trial mix is very important in

order to ensure the relevant mix proportion of SCC. However, during trial mix the

additive not available because of delivery problem. Therefore we have proceeded the

trial mix without additive.

6

Then, our project continued with experimental works. First step for experimental

work is material preparation and followed by mixing. Just after mixing, we test for

three type of workability test namely slump-flow test, box-type test and L-shaped test.

The next process is placing in concrete mould. After one day, concrete cubes removed

from mould and then proceed with curing process. Compressive strength test applied

the sample at age 7,14 and 28 days.

Data analysis is the entire process of converting raw data into meaningful information

for analyst. Experimental data present in convenient form using graphical method

such as bar chart. This information will reduce to major finding and ultimate finding

will yield to conclusions and recommendations of project. If the experimental work

satisfied all the experiment and fulfils the criteria SCC, this project considered as

succeeded in designing and producing a new type of concrete using local material

known as SCC.

1.5 Chapter Summary

This thesis is divided into six chapters. Chapter one will elaborate on self-compacting

concrete in general such as definition, historical background, and reason of

development SCC. Besides that, the objectives and project description are explained

in this chapter. The literature review mostly on concrete and SCC widely described in

chapter two.

Experimental work is described in chapter three. This chapter will elaborate on how

this project done, the design and the experiments involved. Trial mix experiment also

7

discussed here. Data analysis of the project is discussed in chapter four. All the raw

data from experimental work will illustrate and convert into graphs and tables in this

chapter.

Finally the project conclusion will be in chapter five. This chapter will conclude how

far the achievement of the project, future works recommendation if it required and

conclusion.

8

CHAPTER 2

LITERATURE REVIEW

2.1 Concrete. Components

Concrete define as composite material composed of granular material (the aggregate

or filler) embedded in a hard matrix of material (cement or binder) and water that fills

the space between the aggregate particles and glues them together. (" In hydraulic

cement concrete, the binder is formed from a mixture of hydraulic cement and water.

Concrete

ý

Cement

" Portland Cement

" Rapid Hardening Portland Cement

" Calcium aluminate cement

"Enoxv resin

Aggregate

" Natural sources: sand, gravel, crushed stone

" Synthetic: expanded clay and shale, blast- furnace slag, Fly ash

Water Potable water or drinking water pH between 6.0 to 8.0

Figure 2.1: Main Components o/ ('oncrele

9

design a self-compacting concrete (scc) … a self-compacting concrete (scc... · design a...

Documents