999452702 - 01/2013 en-GB

The Formwork Experts.

Self-Compacting Concrete (SCC)

Doka Knowledge Transfer
For internal use only!

94527-800

Introduction
tion Introduc-

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

by Doka Industrie GmbH, A-3300 Amstetten

2| 999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Introduction

Contents
4 6 7 8 10 12 15 16 17 19 General Concrete raw materials Concrete composition Uses of SCC: Production and transport Forming SCC structures System formwork or design formwork Cost efficiency and sustainability of SCC Practical examples Annex

999452702 - 01/2013

|3

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

General
The problems involved in compacting concrete in structures of complex geometry can be considerable, but self-compacting concrete (SCC) often proves a solution. Compacting as such is unnecessary, because SCC is honey-like and flowable in consistency. There is no need for vibrators. This in turn means less worker exposure to noise and vibration and the corresponding improvement in conditions on site or in the prefabricating plant. Self-compacting concrete de-aerates and self-levels under the influence of gravity. Even though the mixture is highly flowable, the aggregate does not settle (the concrete evinces no propensity to segregate). Consequently, self-compacting concrete ensures a high degree of homogeneity, minimum voids and uniform compressive strength. The low water/binder ratio, moreover, means that the formwork can be stripped out all the sooner. Range of uses for SCC: Structural elements with closely spaced reinforcing bars. Concrete structures with architecturally modelled surfaces. Slim structural elements/elements inclined off-vertical. Structural elements with many openings.

Production
The production of SCC requires specialised plant and a well-trained, skilled workforce. The manufacturer has to take the following points into account: The mixing plant must meter the ingredients as accurately as possible. The moisture content of the sand has to be measured continuously. The moisture content of coarse aggregate also has to be known. Residual water can be used only under certain preconditions, because excess solids entrained in the water can have a detrimental effect. Residual water is water from cleaning of the mixing plant, working concrete residue, washing water from aggregate, ... All traces of rinsing water must be removed from the mixing drum, the transport vehicles and the pumps.

The concreting process

The following points are important with regard to the concreting process as such: Continuous work without long breaks. Check that the formwork is leaktight and check the bracing before and during the concreting process. Rod the poured mix to prevent the formation of voids caused by air bubbles getting trapped near the top of the wall. Avoid lengthy breaks in concreting, because they can cause the crazing effect that mars the top of the concrete. If the formwork is closed all round, provide a sufficient number of windows and de-aerating ports. The timing for pouring the concrete has to be agreed with the concrete supplier. Surface quality improves if the concrete is poured slowly. Use the right release agent and apply it thinly.

History of SCC
Self Compacting Concrete (SCC) was developed in
the late nineteen-eighties in Japan and has been used in Europe since the mid-nineties. In Austria, SCC was used for the first time in large quantities on the Millennium Tower build in Vienna. In May 2005 the European standards for SCC were published in English. The English version was translated into German in 2006. On the Austrian national level, the use of SCC has been regulated since 2002 by the technical bulletin entitled "Selbstverdichtender Beton" (Self-Compacting Concrete). The latest issue is dated March 30, 2009 and can be obtained through www.concreteaustria.com.

4|

999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Technical parameters
Properties of the fresh concrete: Flowability (viscosity) Stoppage tendency Self-levelling capability Self de-aeration Strength of microstructure Properties of hardened concrete: Compressive strength Flexural strength (modulus of elasticity) Durability Shrinkage and creep

Principle
The high proportion of meal (meal grain size maximum is 0.125 mm) combines with water and plasticiser to form a highly viscous suspension (grout). All coarser aggregate floats in this suspension and there is no tendency to segregate. The meal consists of the following materials: Cement Hard-coal fly ash Silica dust Slowly reactive stone powder Broadly speaking it makes little difference which material is used, as long as the interaction with the plasticiser produces the necessary flowability properties. In the production process the flowability and flow properties of SCC are adjusted so as to permit adequate flow and optimum flow rate of the concrete.

999452702 - 01/2013

|5

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Concrete raw materials

Cement and additives
In principle, all cements are suitable for use in the production of SCC. The following are the most commonly used cements: Portland composite cement Portland cement Portland limestone cement Portland shale cement Portland slag cement High-strength concretes, shorter times to stripping out and pourability at low ambient temperatures are achieved with the following kinds of cement: Portland composite cement Portland silica dust cement Portland cement Portland shale cement The following are commonly used as additives (for high cement-grout content): Hard-coal fly ash: Reduces the water-to-cement ratio of the concrete (? = 2250 kg/m3). Slowly reactive quartz or limestone powder (? = 2700 kg/m3).

Aggregate
Rounded or crushed aggregate is used for SCC. Rounded aggregate means a lower voids content, so less cement grout is needed. The advantage of crushed aggregate derives from the larger surface area for a given weight. This improves float in the concrete mix. Sieve size is generally a maximum of 16 mm in order to facilitate passage between closely spaced reinforcing bars. Aggregates for SCC
100

80

Sieve pass [%] by mass

60 A C

40

20

B
94527-820

Water
Water from any public drinking water supply is suitable for the production of self-compacting concrete. Recycling water is not used, on account of the possibility of detrimental effects on the properties of the concrete. On account of the effects on flowability, it is very important for the mix to match the target water content.

0,063

0,125

0,25

0,5

5,6

16

22

32

Sieve mesh [mm] A Absolute limits B Proven compositions for ordinary concrete C Optimum range for SCC

Chemical admixtures
Chemical admixtures
Polycarboxylate-based plasticisers are used to make SCC extremely flowable. Using a plasticiser means that the water content can be reduced. Flowability is influenced as well. Adding a stabiliser further reduces the tendency of the SCC to segregate (bleeding, sinking of the coarse aggregate). The right plasticiser for the cement has to be selected by advance tests.

Other slowly reactive additives

Some additives are essential for the production of SCC, but some other substances can be used as additives as well: Pigments to colourise the concrete structures. Steel fibres as structural reinforcement. Polyethylene fibres to increase fire resistance. Polypropylene fibres (PP fibres) to reduce plastic shrinkage.

6|

999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Concrete composition
In some cases concrete concepts and concrete recipes vary significantly from country to country. A broad distinction is drawn between the following types of concrete: Meal type: Less prone to production fluctuations than the stabiliser type. Stabiliser type: Combination type: Closer to the stabiliser type. Meal content of SCC types:
SCC type Meal type Stabiliser type Meal content [kg/m3] 550 - 650 350 - 500 Depends on Combination type quantity of stabiliser Proportion of additives Low High Medium

Comparison between ordinary concrete and SCC

Ordinary concrete SCC

94527-821

94527-822

Cement grout: 280 l/m3 Aggregate: 720 l/m3 Largest grain size: 32 mm The spaces are filled with cement, additives and water (cement grout).

Cement grout: 365 l/m3 Aggregate: 635 l/m3 Largest grain size: 16 mm Cement-grout content is about 65 to 100 l in excess of the quantity necessary to fill the spaces. It is this excess that makes the concrete flowable.

999452702 - 01/2013

|7

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Uses of SCC:
The window for working SCC is the area in which the special concrete evinces optimum fresh-concrete properties. With many concrete recipes this area is very small. It depends on the relationship between freshconcrete consistency (measured as slump flow) and viscosity (measured as outflow time from V-funnel). Workability window for SCC, concrete-meal type The energy in the SCC causes it to slump and spread. When movement ceases the diameter of the puddled concrete should be between 600 and 800 mm. Coarse aggregate should be evenly distributed and there should be no segregated fines around the edge.

85

a b
C A D
94527-824

Slump flow [cm]

80 75 70 65 60 55 5 10 15 B
94527-801

a ... Slump flow b ... at least 800 mm

See the "Easily Compacted Concrete" User Information tile, and in particular the section entitled "What is easily compacted concrete?"
25

20

Outflow time, V-funnel [sec.] A Sedimentation B No self-compaction C Formation of airhole voids D Target area

Obstacle ring (J-ring)

The SCC flows through the gaps between the reinforcing bars. This is a test to ascertain the tendency of the mix to form stoppages. The diameter of the metal ring is 300 mm. The bars, 16 to 18 mm in diameter, are evenly spaced. Uniform flow and an even grain skeleton inside and outside the ring are indicative of goodquality SCC. Obstacle ring (J-ring)

65 to 75 cm slump flow and 10 to 20 seconds outflow time are considered normal as limit values. Both these indices have to be checked in recipe development and also as part of in-process quality monitoring, in order to ensure that the high requirements are satisfied. Working the concrete outside this window leads to the loss of the self-compacting and de-aerating properties and can result in segregation in the SCC mix.

Testing fresh concrete

Slump flow
1) Place a slump cone on a clean plate of adequate size (min. 800 x 800 mm). Dimensions of slump cone
a
94527-802

Number of bars of the obstacle ring

Largest grain size 8 or 11,4 mm 16 or 22 mm 32 mm Number of bars 22 16 10

c
94527-823

a ... 100 mm b ... 300 mm c ... 200 mm

2) Fill the slump cone with SCC. 3) Lift the slump cone off the plate.

8|

999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

V-funnel
1) Fill the funnel brim-full with concrete. 2) Open the cap at the bottom. 3) Measure how long it takes the funnel to empty. The outflow time for self-compacting concrete should be between 8 and 14 seconds. V-funnel

U-box test
This test provides a means of gauging the concrete's self-levelling capability and its tendency to form stoppages. The U-box consists of two chambers interconnected by an opening in which reinforcing bars are set as obstructions. 1) Before pouring in the concrete, close the gate to seal the outlet from chamber 1. 2) Pour the concrete into chamber 1. 3) Open the gate. The concrete envelopes the reinforcing bars, passes through into chamber 2 and rises in this chamber.
b b

B 1 1

h1

2
94527-803 94527-826

94527-827

L-box test
Dimensions of L-box
b
c

a ... 680 mm b ... 120 mm c ... 340 mm A Reinforcement B Gate

h2 ... Target: at least 300 mm

Kajima box test

a
A B

The Kajima box is used to assess the degree of concrete fill and the de-aeration capability. A Perspex container with reinforcing-bar obstacles is filled with concrete through a filling aperture until the concrete touches the top lay of rebar.
A

h1

d e

a ... 600 mm b ... 200 mm c ... 100 mm d ... 600 mm e ... 700 mm f ... 150 mm h2/h1 ... greater than 0.80 A Gate B Reinforcement

h2

94527-825

h1

94527-828

F [%] = (h1 + h2 / 2 h2) 100 A 1. Reinforcing bar

1) Fill the vertical side of the L-box with SCC. 2) Pull the gate right to left to open. The SCC must envelope 3 reinforcing bars before it reaches the far end of the horizontal leg. Measured flow time must be between 3 and 7 seconds. In addition, the height of the concrete at the near end (h1) and the far end (h2) can also be measured. Quotient h2/h1 should be greater than 0.80.

Criteria for assessment: Height h1. Degree of fill F, target: F min. 90 %. Visual assessment of the extent to which the fresh concrete envelopes the reinforcing bars. There should be no cavities between the SCC and the rods.

999452702 - 01/2013

h2

h2

|9

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Production and transport

Production
SCC is produced in all conventional concrete mixing plants. See also the section entitled "Equipment for the production of CIP concrete and precastings" in the "Construction-engineering equipment (for precastings and CIP concrete)" UI. The moisture content of the aggregate needs strict monitoring, because the permissible range of fluctuation is narrow. Moisture sensors in the silo enable the recipe to be adapted automatically to suit. Mixing time is generally 120 seconds.

Transport
Because it is so flowable, SCC is transported only in truck mixers. The mixer's drum remains in constant movement all the way to site. A cap is fitted if the truck has to negotiate steep gradients. Truck mixer (6 m3)

94504-801

Truck mixer (15 m3)

94504-802

The concrete has to be agitated at maximum speed for about 2 minutes immediately prior to discharge. Corrections on site are possible if delays occur or the consistency of the mix is stiffer. Post-mix addition of plasticisers calls for uniform distribution and strict compliance with the specified minimum mixing time.

10 |

999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

999452702 - 01/2013

| 11

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Forming SCC structures

As long as the wall heights remain within the normal range (maximum 3.00 metres high), the requirements for wall formwork are the same for both ordinary concrete and SCC. When conventional heavy framed formwork is used no special measures are needed for pouring SCC up to heights of 3.50 m. Effects on the formwork when SCC is used: Higher fresh-concrete pressure. Lift and the danger of bleeding, even at constricted openings (flowability of the concrete). The surface structure of the formwork sheeting is clearly imaged on the finished concrete. No inherent strength (produced by stiffening of the concrete) in the the freshly concreted structural elements. The method of concrete placement and the resultant design features of the formwork system must be detailed in consultation between the construction contractor, concrete supply and formwork manufacturer. Filling from above

94527-805

Hydrostatic pressure
A

Placement of the SCC

SCC is very easy to pour and the process is generally a one-man operation. Conventional techniques such as crane bucket, pump or chute of the truck mixer are all used for placing the concrete. On account of the risk of mix segregation, drop height has to be restricted to 1.00 to 2.00 metres. The rate of concreting influences the time for de-aeration of the SCC and ultimately the quality of the finished product. A distinction is made between 2 types: Filling from above Pumping in from below The SCC should be introduced into the formwork at only one point. This permits unimpeded flow, enabling the concrete to fill the formwork by itself and de-aerate. It is important to note, however, that flow in the horizontal direction is subject to restriction. The risk of dynamic segregation increases with distance of flow (empirical rule of thumb: maximum distance of flow is 12.00 to 15.00 metres) and increasing confinement on account of the density of the reinforcement.

94503-810

a ... Height of concrete filling A Top of concrete B Hydrostatic pressure

Filling from above

When the concrete is poured in this way the fresh-concrete pressure is controlled by the concreting rate. High concreting rates (with SCC) lead to hydrostatic freshconcrete pressures. While the wall is still being poured the bottom lays have not yet reached the end of setting (concrete is still soft). The formwork pressure has to be reduced in order to prevent damage to the formwork system. This entails a thorough knowledge of the concrete's properties so that suitable testing can be undertaken and the appropriate conditions for placement of the concrete kept constant. As a basic rule, moreover, the formwork has to be dimensioned for the full permissible formwork pressure (the norm is 24 kN/m).

12 |

999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Pumping in from below

max. wet-concrete pressure [kN/m2]

F E C

100 75 B 50 25 0 0 0,5 1 1,5 2 2,5 3 A

4 3 2 1 0 3,5

Pumping in from below

rate of rise v [m/h]

See the "Doka Knowledge Transfer" Lotus Notes tile and the detailed information on "Easily Compacted Concrete" for more graphs.

94527-806

Pressure of fresh concrete

Time of 5 hours to end of setting tE
max. fresh-concrete pressure [kN/m2]
150 125 100 H 75 50 25 0 0 1 2 3 4 5 6 7 G F E
94511-806

D C B A

4 3 2 1 0

placing rate v [m/h] A B C D E F G H Consistency class F1 Consistency class F2 Consistency class F3 Consistency class F4 ECC, consistency class F5 ECC, consistency class F6 SCC Hydrostatic to tE

999452702 - 01/2013

hydrostatic head hs [m]

hydrostatic head hs [m] | 13

When this method of placement is used the fresh concrete is in constant movement. The hydrostatic concrete pressure has to be used in all calculations. In order to avoid damage it is common practice to monitor concrete pressure with pressure sensors and adapt the concreting rate accordingly.

Time of 15 hours to end of initial setting tE

150 125 G
94511-809

6 5

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Lift and bleeding

It is important to ensure that the formwork is leak
tight, on account of the flowability of SCC. Always use the full concrete pressure for calculations involving horizontal and inclined faces. Use stronger fixings to secure cavity formers in the formwork. The formwork has to be held down (anchored to the ground) to ensure that it does not lift. The holes for the ties, all small openings, the upstand and vertical working joints all have to be well sealed to prevent bleeds.

Imaging of the surface structure

SCC requires formwork sheeting with a high-quality surface. Broadly speaking, all formwork sheets except oriented-strand board (OSB) are suitable for SCC. The interplay of concrete, release agent and formwork sheet should always be tested beforehand, and this is particularly so in the case of fair-faced concrete.

Inherent strength
A freshly concreted SCC wall has no inherent strength, due to the high rate of rise and the composition of the mix. Consequently, adequate bracings and fixings must be provided.

Concrete pressure on formwork surfaces

A A
94503-823 94503-823

94503-814

See the "Doka Knowledge Transfer" Lotus Notes tile and the detailed information on "Structural Analysis: Design loads"

14 |

999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

System formwork or design formwork

The use of formwork systems.
Permissible fresh-concrete pressures Pmax vary for system formwork; the range is from 40 to 90 kN/m2. Permissible concreting heights for Doka system formwork
Formwork system (all panel widths) Steel framed formwork Aluminium framed formwork System beam formwork Circular formwork Per. anchor forces 15.0 AUSTRIA, CH: 120 kN 3.30 m 2.70 m 3.25 m 3.30 m

Higher pressures can be dealt with by reducing panel size/width (therefore more formwork ties per m2). Permissible concreting heights when smaller framed panels are used
Max. panel width 135 cm 90 cm 60 cm 45 cm 30 cm 90 cm 75 cm 60 cm 45 cm 30 cm Steel framed formwork Per. anchor pull 120 kN 150 kN 3.30 m 3.30 m 3.80 m 4.05 m 5.60 m 5.70 m 7.00 m 7.50 m 11.00 m 11.40 m 2.70 m 3.00 m 3.30 m 4.40 m 6.30 m

The use of design formwork

There is a technical upper limit of about 240 kN/m or 10 m concreting height for design beam formwork. The formwork is adapted to fresh-concrete pressure by varying the number of beams and the beam spacing.

Aluminium framed formwork

See Technical Circular No. 678 (year 2005), "Selecting formwork for self-compacting or highly flowable concrete".

999452702 - 01/2013

| 15

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Cost efficiency and sustainability of SCC

Cost efficiency
Better strength development than ordinary concrete
Compressive cube strength [N/mm2]
70 60 50 40 30 20 10 0
94527-829

Sustainability
The sustainability of concrete is defined by the following points: Ecological aspect Sociological aspect Economic aspect Sustainability refers to the entire life cycle of a build.

A B C

Ecological sustainability
The figures for energy consumption and the resultant emissions are calculated from production through use all the way to final disposal. The following categories are factored into the considerations: Energy Greenhouse effect Ozone formation Eutrophication Acidification Human toxicity Ecotoxicity

10

15

20

25

30

[days] A SCC C40/50 B SCC C35/45 C Ordinary concrete C25/30

Economic advantages of SCC

Walls (crane) Ordinary conSCC crete 4 2 10 20 Slabs (pump) Ordinary conSCC crete 8 4 25 30

Manpower Performance [m3/h]

Social sustainability
Social sustainability is influenced by the occurrence of accidents and long-term illnesses. The placement of vibratory-compacted concrete, let us say, is associated with certain health and safety risks such as "fall from working platform", for example. Man-hours worked per cubic metre of concrete poured is often used as a comparative variable for social sustainability.

Practical example: Building with 170 residential units

Comparison of construction time Days per level Walls per day Construction time, carcass Ordinary concrete 9 days 85 m 4.5 months SCC 7 days 110 m 3.5 months

Practical example: School building for 800 pupils

Comparison of conOrdinary concrete struction time Planned construction time with ordinary 8 months concrete Actual build with SCC SCC

Economic sustainability
Comparing sums invested over the entire life cycle of the structure yields a unit of measure for economic assessment. The following cost generators are factored into the equations: Material costs of the concrete Construction costs Life cycle costs Indirect costs

6.5 months

Result in practice
Empirical experience shows that vis--vis ordinary concrete, on a scale of sustainability SCC ranks equivalent to or better than ordinary concrete. The potential for shorter construction times, a reduction in human resource outlay and more degrees of freedom in geometrical design all favour the use of SCC. The greater freedom in geometrical design can be translated into optimised construction processes and scheduling. Without vibratory compactors the site generates less noise. The production costs vis--vis those for ordinary concrete are countered by the advantages in the placement process.
16 | 999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Practical examples
Lakeside pool, Caldaro, South Tyrol Phaeno Science Center, Wolfsburg

94527-809

94527-813

94527-810

94527-814

94527-811

94527-815

94527-812

94527-816

999452702 - 01/2013

| 17

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Wiental collector, Vienna

94527-831

94527-817

Mercedes-Benz museum, Stuttgart

Innsbruck main station, Tyrol

94527-818

94527-819

94527-830

18 |

999452702 - 01/2013

Doka Knowledge Transfer Self-Compacting Concrete (SCC)

Annex
Online: www.beton.org www.wikipedia.org www.doka.com Literature: Experts forum, concrete 2007, "Self-Compacting Concrete SCC" "Selbstverdichtender Beton - nderung der Oberflchengte von Mikrotbbingen durch Betonzusammensetzung und textile Schalungsauflagen" (Selfcompacting concrete - change of surface quality of microtubbings by concrete composition and textile formwork coverings", degree dissertation submitted by Alexander Schroer, 2001 "Selbstverdichtender Beton" (Self-compacting concrete), Holcim (Switzerland) AG, 1st edition 2005 "Die Generation SCC" (The SCC generation), Holcim (Switzerland) AG "Rheodynamic fr selbstverdichtenden Beton" (Rheodynamics for self-compacting concrete), BASF Construction Chemicals Austria GmbH

999452702 - 01/2013

| 19

Doka Knowledge Transfer

Doka Knowledge Transfer offers Doka employees the opportunity of acquiring knowledge about various aspects of building construction and civil engineering. The subjects covered by Doka Knowledge Transfer are many and varied. They extend from "Construction terms" through "Methods of ceiling/floor deck construction" to "Concrete-core activation". Researched in depth and written accordingly, the individual articles are subsequently revised and extended on a rolling basis so as to reflect the state of the art.

Doka GmbH | Josef Umdasch Platz 1 | 3300 Amstetten | Austria | T +43 7472 605-0 | F +43 7472 66430 | oesterreich@doka.com | www.doka.com

999452702 - 01/2013