Concrete Repair, Rehabilitation and Retrofitting II Alexander et al (eds)

2009 Taylor & Francis Group, London, ISBN 978-0-415-46850-3

159
Durability requirements in self-compacting concrete mix design
A. Ioani & J. Domsa
Technical University of Cluj-Napoca, Cluj-Napoca, Romania
C. Mircea & H. Szilagyi
National Institute for Research in Construction (INCERC), Cluj-Napoca Branch, Romania
ABSTRACT: The paper presents results furnished by a national research program developed at the Technical
University of Cluj-Napoca in cooperation with specialists from INCERC Cluj-Napoca Branch, in order to
implement self-compacting concrete in the Romanian precast concrete industry. Mixes for C50/60, C40/50
and C30/37 strength classes with cement CEM I 52.5R, cement and silica fume or cement and limestone filler
have been designed and tested, and properties in fresh and hardened state have been evaluated. Mix constituents
(sand, gravel) are materials currently in use in a local precast concrete plant and admixtures (HRWR) and addi-
tions (silica fume) are provided by Sika Romania Ltd. Mixture proportions and parameters such as cement type,
cement content, w/c ratio and concrete strength class are discussed with respect to the limit values specified in
the Romanian Standard SR EN 206-1: 2006, for durability reasons.
1 INTRODUCTION
Starting from 1983, the problem of durability for
concrete structures has been a major issue in J apan.
Making durable structures involves appropriate and
sufficient mechanical compaction by skilled work-
ers. The lack of such skilled workers in J apan led to
a significant reduction in the quality of construction
works. The solution proposed by H. Okamura in 1986,
focused on the achievement of durable concrete struc-
tures independent of the classic mechanical vibration
process, by means of a concrete which can be com-
pacted by its own weight, without vibration devices
(Okamura & Ouchi 2003). Practically, the potential
hazard of human errors is reduced by the use of SCC,
errors which can generate incorrect and non-uniform
vibration. The result is a homogenous concrete struc-
ture with improved durability and quality. The high
quality of demoulded surfaces decisively contrib-
utes to increase in durability, too. Nowadays SCC
has become a very attractive material for designers,
clients, contractors or precasters due to its benefits:
more innovative design of elements, more complex
shapes, faster construction, improved durability,
reduced formwork, placement, finishing costs, less
manpower and a shorter production cycle.
Recently, Ramsburg et al. (2003), Schindler et al.
(2007) discussed the durability aspects of SCC designed
for precast applications, and their experimental set of
data (permeability, shrinkage, scaling resistance, air
void content and freeze-thaw) confirmed a very good
response of SCC to durability requirements. Similar
results have been reported by Persson (2002), after an
extensive and complex experimental program on SCC
properties.
The paper presents results obtained at The Tech-
nical University of Cluj-Napoca, Romania, in the
design of SCC mixes for the precast/prestressed con-
crete industry. Performances in the fresh and hard-
ened state of SCC are presented. The paper shows that
typical SCC compositions for the precast/prestressed
applications satisfy the requirements for durability
regarding to different exposure classes (X0, XC, XD,
XS, XA and XM) and the limit values of the concrete
composition and concrete properties specified in the
National Annex of the Romanian Standard SR EN
206-1: 2006 for durability reasons.
2 MIXTURE PROPORTIONING
PARTICULARITIES
2.1 Objectives
The research program was established in coopera-
tion with specialists from ASA CONS Romania Ltd.,
the largest precast concrete plant from Transylvania,
Romania.
160
At this plant, currently the production structure of
conventional (vibrate) concrete is:
20% prestressed elements of C50/60 concrete
strength class;
40% prestressed elements of C40/50 concrete
strength class;
40% R/C precast elements of C30/37 strength
class.
Thereby, the research program has focused on
designing and testing SCC with these specified
strength classes.
Similar to the case of conventional vibrated con-
crete, the primary specification for the hardened SCC
is to meet the exposure class (EN 206-1) and the
characteristic compressive strength at 28 days. When
SCC is used in precast applications, and particularly
for prestressed members, the dominant requirement
is a high early strength of concrete which enables
the workers to demould, to prestress or to move the
elements within a short production cycle (EFNARC
2005).
For prestressed applications, precasters required a
cube compressive strength at transfer (24 to 36 hours)
higher than 49 MPa for C50/60 mixes, and 42 MPa
for C40/50 mixes. Durability aspects of the designed
SCC mixes are discussed in Section 4. At the same
time, in the SCC mix design, a balance between the
previously defined requirements in the hardened state
and the necessary properties in the fresh state (flow-
ability, viscosity, passing ability and stability) should
be achieved.
Taking into account the characteristics of concrete
members cast in the factory (shape, size, reinforce-
ment, etc.), the following requirements for the fresh
SCC were established:
Slump-Flow class SF2, where 660 < SF < 750 mm;
Viscosity class VF2, where 9 < VF < 25 s;
Passing ability class PL2, where PL 0.8 with 3
rebars;
Segregation resistance class SR2, where SR < 15%.
2.2 Ranges of variation
In a recent study, Domone (2006) analysed 68 differ-
ent SCC mixes and showed that mixture proportions
vary widely, so that there is not a unique solution
for any given application. However, the study shows
some distinctive variation ranges of the main con-
stituents. In Table 1, these ranges are compared with
typical ranges of SCC constituents recommended by
EFNARC (2005).
The research report ICAR 108-2F (2007) shows
that, in general, the SCC mixture when compared
to conventional vibrated concrete, is characterized
by: lower coarse aggregate contents, increased paste
volume, higher powder contents, low water/powder
ratios, high HRWRA (high range water reducing
admixtures) dosages and the use of VMA (viscosity
modifying admixture) in some cases.
2.3 Mixture proportioning guidelines
In the frame of the research program developed at
The Technical University of Cluj-Napoca, the authors
proposed a mixture proportioning procedure, aiming
to fulfil the SCC requirements in fresh and hardened
state.
The procedure is based on the following principles
(Ioani & Szilagyi 2008):
Maximise the total aggregate volume in order to
obtain less paste. The largest possible volume of
aggregate is advantageous with regard to stiff-
ness, permeability, creep and drying shrinkage and
finally, improves durability; shrinkage is a paste
property and the aggregate is the most impor-
tant restraint on the change in volume within the
paste;
Reduce the powder content as much as possible
and use the possible lowest water/powder ratio.
Less powder also means savings in the most
expensive constituents (cement, silica fume, filler)
and contributes to reductions of shrinkage; in the
same time, a low water content is recommended to
increase the strength and durability of the concrete
and to mitigate high drying shrinkage (Ozyildirim &
Lane 2003);
Select the optimal sand/aggregate ratio (S/Agg)
which leads to a minimum volume of voids. This
is achieved by using more sand and less gravel
(S/Agg = 0.50.55), as it appears in the works of Su
et al. (2001) and Brouwers & Radix (2005); a lower
coarse aggregate content (270-300 l) improves the
paste rheology and gives the best results in the
filling height of the U-box type test (Okamura &
Ouchi 2003), as it is shown in Figure 1;
Table 1. Typical range of variation for SCC constituents.
Constituents Domone (2006) EFNARC (2005)
Powder (kg) 445505 380600
Paste (l) 300420 300380
Water (l) 150210
Coarse aggregate (l) 280380 270360
Fine aggregate 3854% of 4855% of
(sand) mortar volume total aggregate
Max. Agg. Size (mm) 1620 mm 1220 mm
Cement type in general, all cement
non-Portland conf. EN 197-1
161
Select the proportions between the aggregate ingre-
dients in order to maintain the aggregate grading
curve in the recommended range (Fig. 2). Such
range proposed by Ioani & Szilagyi (2008) covers
all important grading curves proposed for SCC in
the technical literature: Fuller n = 0.4 curve, modi-
fied Andreasen & Andersen curve (D
max
= 16 mm,
q = 0.25) preferred in the works of Brouwers &
Radix (2005), Grace recommendation regarding
the upper and lower limits for a blended gradation
(Grace TB-1503), 0.45-power curve presented in
the report ICAR 108-1 (2007); such curves repre-
sent grading with high packing densities and they
are favourable in SCC mixes;
Determine the cement amount in order to reach the
required compressive strength and to satisfy the
limit values prescribed for the selected exposure
(durability) classes in the European Standard EN
206-1: 2000 or in the Romanian Standard SR EN
206-1: 2006; durability requirements determine
limits for certain parameters of the concrete mixes,
such as: type of cement, w/c values, cement dos-
ages, concrete strength classes).
3 EXPERIMENTAL PROGRAM
3.1 Materials
The mix design procedure was successfully tested on
more than 50 mixes for the precast concrete industry.
It involves four stages and 12 steps and is extensively
presented in a previous work (Ioani & Szilagyi 2008).
In the laboratory tests only local materials or materi-
als currently in use at the precast unit plant have been
selected: Portland cement CEM I 52.5R, limestone
filler, sand (04 mm) and river coarse aggregate
(48 mm, 816 mm).
Three different types of concrete were cast: SCC
made only with cement (as powder), SCC made with
cement and limestone filler, and SCC made with
cement and silica fume.
The key material for any type of SCC is repre-
sented by the admixture. In the experimental program
a HRWR admixture of the polycarboxilic ether type
produced by Sika under the brand name Sika Visco-
Crete-20 Gold, was used. The selected pozzolanic
addition (SikaFume-HR/-TU) was compatible with
the Sika ViscoCrete-20 Gold admixture.
3.2 Selected mixtures and results
Representative SCC mix compositions are presented
in Table 2, where C50/60 and C40/50 mixes have been
designed for prestressed applications and C30/37 mix
for R/C precast elements.
The principal characteristics in fresh and hardened
state are shown in Table 3.
Regarding the compressive strength, all mixes have
a good evolution in time. Using the cube compressive
strength at 28 days (Table 3), the concrete character-
istic strength is evaluated and the results revealed that
mixes meet the strength requirements corresponding
to the designed concrete strength classes.
At one day, the compressive strength is slightly
inferior with respect to the target strength required at
transfer (f
cm1
= 45 < 49 MPa at transfer for C50/60,
and f
cm1
= 40 < 42 MPa at transfer for C40/50 mixes)
and consequently, the prestress transfer should be
done at 3236 hours.
Mix SCC-50 designed for the concrete strength
class C30/37 could be classified after the results as
Figure 1. Influence of coarse aggregate content on self-
compactibility (Okamura & Ouchi 2003).
Figure 2. Aggregate grading ranges for SCC (Ioani &
Szilagyi 2008).
162
SCC sensitivity to small changes in material char-
acteristics (sand fineness, changes in moisture content
of the materials or in aggregate gradation, etc.), has
been observed during the tests. The major variation in
the composition during production at the plant comes
for normal changes in the moisture content of the
sand and the coarse aggregate (ENC 179 VMA/2006).
A well designed and robust SCC can accept a 5 to
10 l/m
3
change in water content without falling out-
side the specified classes of performance when fresh
(EFNARC 2005). For this reason the water sensitiv-
ity (tolerance) of mixes has been established. The
mix SCC 46representative for the strength class
C30/37can accept a water tolerance of (4.5 l) to
(+8 l); in this range which is within the control capa-
bilities of the concrete producer, small changes in
the slump flow (15 mm to +20 mm), in T
500
values
(1.5 s) and strength (4%) are recorded (Table 4).
4 DURABILITY REQUIREMENTS
4.1 Exposure classes
The Romanian Standards SR EN 206-1: 2006 shows,
in correspondence with EN 206-1: 2000 that dura-
bility design is realised by defining the exposure
classes (X) in relation to environmental conditions
and mechanical actions. These actions have been
associated to certain measures regarding the concrete
composition, minimum concrete cover, crack width,
etc., and also to provisions regarding the execution,
quality control, inspections, verifications or special
measures (use of stainless steel, coatings, cathodic
protection).
The exposure classes can be divided in exposure
classes with risk on concrete or/and on reinforcement
steel, as in Table 5.
Exposure classes related to environmental condi-
tions and informative examples where these classes
may occur are presented in EN 206-1, Table 4.1.
C35/45, having comparable performances in fresh
and hardened state with SCC-mix C, developed by
Brouwers & Radix (2005).
The slump-flow test shows a good total spread
value (670 to 680 mm), a V-funnel time in the range
of 9 to 12 sec and a very good passing ability meas-
ured by L-box with passing ratios between 0.80 and
0.87 (Table 3). With respect to these experimental
results, the mixes meet the requirements in fresh state
of the specified classes: SF2, VF2, LP2 and SR2.
The properties in fresh state are stable in time,
small variations being recorded in terms of slump-
flow (SF), V-funnel time and passing ability (PL).
For mix SCC -18 the following variation is
reported:
at 15 minutes: SF = 680 mm, VF = 9.2 s, PL = 0.87;
at 40 minutes: SF = 665 mm, VF = 13 s, PL = 0.83.
Table 4. Water sensitivity of mix SCC-46.
SCC mix index 48 49 46 47*
Water (l/m
3
) 185.5 185.5 190 198
Slump-flow (mm) 715 705 720 740
T
500
Slump-flow (s) 5 5 3.5 2.5
V-funnel time (s) 17.5 19.5 11 10
Cube compressive
strength (MPa) at
1 day
7 days
28 days
37.1
46.0
55.3
37.0
47.1
58.2
35.8
48.6
56.2
33.6
43.3
54.0
* VMA of 2.45 kg/m
3
is added to avoid the bleeding and
segregation tendency.
Table 2. SCC mix compositions.
Strength classes
C50/60 C40/50 C30/37
Mix index SCC 18 19" 31' 50
Cement (kg) 510 481 410 350
Limestone filler (kg) 95 155
SikaFume (kg) 25
Sand 04 mm (kg) 920 920 920 920
Gravel 48 mm (kg) 230 230 230 230
Gravel 816 mm (kg) 493 493 493 493
Water (l) 199 202 192 190
water/cement 0.39 0.38 0.47 0.54
water/powder 0.39 0.40 0.38 0.37
Sand/Agg 0.56 0.56 0.56 0.56
V
agg
(l) 620 620 620 620
V
paste
(l) 380 380 380 380
ViscoCrete 20 Gold (kg) 6.12 6.32 6.5 5.5
% of powder 1.20 1.25 1.30 1.58
Table 3. Test results on fresh and hardened state.
Strength classes
C50/60 C40/50 C30/37
Mix index SCC 18 19" 31' 50
Slump-flow (mm) 680 635 683 670
T
500
Slump-flow (s) 3 3.5 3.5 3
V-funnel time (s) 9.2 10.5 11 12.0
L-box passing ratio 0.87 0.82 0.80 0.80
Segregation resistance (%) 6.0 5.2 7.2 4.75
Cube compressive strength
(MPa) at 1 day 44.0 45.2 40.3 34.0
7 days 53.5 58.8 49.6 43.6
28 days 64.4 66.6 55.8 52.8
163
For each exposure class (X), the National Annex of
SR EN 2061: 2006Annex F gives recommendations
for the selection of limit values for the concrete com-
position and concrete properties function of the speci-
fied exposure class. These limit values are established
considering a service life of 50 years, compositions
with CEM I 32.5 and aggregates ha-ving a maximum
size in the range of 20 to 32 mm (Tables 67).
4.2 Exposure classes vs. SCC for prestressed
applications
SCC mixes for prestressed applications are charac-
terized by low water/cement ratios, high dosages of
cement and high concrete strength classes, (Table 2):
Water/cement ratios: 0.39 0.38 0.47;
Cement content: 510 481 410 kg/m
3
;
Concrete strength classes: C50/60 C40/50.
Table 7. Limit values for the concrete composition and concrete properties for XF, XA and XM exposure classes.
Freeze/Thaw attack Chemical attack Mechanical attack
Parameter XF1 XF2 XF3 XF4 XA1 XA2 XA3 XM1 XM2 XM3
Max. w/c 0.50 0.55 0.50 0.55 0.50 0.50 0.55 0.50 0.45 0.55 0.55 0.45 0.45
Min. strength
class
C25/30 C25/30 C35/45 C25/30 C35/45 C30/37 C25/30 C35/45 C35/45 C30/37 C30/37 C35/45 C35/45
Min. cement
(kg/m
3
) 300 300 320 300 320 340 300 320 360 300 300 320 320
Min. air
content (%) a
*
a
*
a
*

Suppl.
conditions
Aggregate with freeze/thaw resistance
(SR EN 12620: 2003)
s
**
Sulfate resist-
ing cement
t
***

*
The minimum air content will be established depending on the maximum size of aggregates; for D
max
= 16 mm, a > 5.5%.
**
For exposures in marine zones, sea water resisting cement must be used.
***
Concrete surface treatment is recommended (e.g. vacuum dewatering).
Table 5. Exposure classes (SR EN 206-1: 2006).
Exposure classes Observations
X0 No risk of corrosion or
attack
On concrete and
reinforcement steel
XF Freeze/Thaw attack XF1,
XF2, XF3, XF4
XA Chemical attack XA1,
XA2, XA3
Exposure classes
with risk on concrete
XM Mechanical actions XM1,
XM2, XM3
XC Corrosion induced by
carbonation XC1, XC2,
XC3, XC4
XD Corrosion induced by
chlorides XD1, XD2,
XD3
Exposure classes with
risk on reinforce
ment steel
XS Corrosion induced by
chlorides from sea
water XS1, XS2, XS3
Table 6. Limit values for the concrete composition and concrete properties for X0, XC, XS, and XD exposure classes.
Corrosion induced by chlorides
No risk Corrosion induced by carbonation from sea from other sources
Parameter X0 XC1 XC2 XC3 XC4 XS1 XS2 XS3 XD1 XD2 XD3
Max. w/c 0.65 0.60 0.60 0.50 0.55 0.50 0.45 0.55 0.50 0.45
Min. strength
class C12/15 C16/20 C16/20 C20/25 C25/30 C30/37 C35/45 C35/45 C30/37 C35/45 C35/45
Min. cement
(kg/m
3
) 260 260 280 300 300
*
320
**
320
**
300 320
*
320*

Min. air
content (%)
Suppl.
conditions
*
Cements resisting to airborne sea salt must be used.
**
Sea water resisting cement must be used.
164
The most restrictive value for water/cement ratio
(Tables 67) is w/c = 0.45, and is required only by
certain exposure classes (XS3, XD3, XA3, XM2,
XM3); consequently, all SCC compositions satisfy
the limit values given in Tables 67 with respect to
the magnitude of water/cement ratio, with the follow-
ing specifications:
For elements exposed to corrosion induced by chlo-
rides from sea XS3 (parts of massive structures in
tidal, splash and spray zones) or from other sources
XD3 (parts of bridges exposed to spray containing
chlorides, pavements, car park slabs), and for ele-
ments placed in highly aggressive chemical envi-
ronments XA3 (soil and ground water), when the
maximum accepted value for w/c is 0.45, only SCC
mixes of C50/60 strength class having lower w/c
ratios (0.380.39) are recommended.
The cement content in the proposed mixes var-
ies from 510 to 410 kg/m
3
; these values are greater
than the most restrictive limit (360 kg/m
3
) and con-
sequently all SCC compositions satisfy the limit val-
ues given in Tables 67 with respect to the minimum
cement content.
Typical concrete strength classes for prestressed
applications are C50/60 and C40/50; these classes
are greater than the highest strength class (C35/45)
required by Tables 67. Consequently, all SCC com-
positions satisfy the limit values given in Tables
67 with respect to the concrete strength class
parameter.
Accordingly to SR EN 206-1: 2006National
Annex F.3.3the cement type used in all SCC mixes
(CEM I 52.5R) is accepted for all exposure classes
and it was primarily selected in precast/prestressed
applications for its capacity to produce concrete with
high early strength.
It can be concluded that the proposed mixes for
prestressed application satisfy entirely the recom-
mended limit values given in Tables 67 and conse-
quently they are suitable for all exposure classes.
In addition, for the particular situations revealed in
Tables 67, special measures should be taken:
For elements exposed to the chloride attack, spe-
cial type of cement resistant to the sea water action
should be used;
For elements exposed to freeze/thaw attack in the
XF4-exposure class, supplementary air entrain-
ing admixture should be used in order to reach an
air content greater than 5.5% (for SCC made with
aggregate having a maximum size of 16 mm); SCC
mixtures with 5 to 7% air content are currently
reported in literature (Ramsburg et al. 2003, Zia
et al. 2005, Schindler et al. 2007);
For elements exposed to chemical attack XA2,
XA3 (acid or sulfate) the use of sulfate resisting
cement are highly recommended (CEM II/B-S,
CEM III/A). ACI 201.2R-01 shows that some
pozzolans and GGBF slag used either in blended
cement or added separately to the concrete in
mixer, increase the life expectancy of concrete in
sulfate exposure, considerably. In very severe sul-
fate attack conditions even Type V cement (sulfate
resisting) in combination with pozzolan or GGBF
slag is recommended. Because SCC mixes are cur-
rently made with moderate to high amounts of poz-
zolanic or latent hydraulic powders additions, SCC
is particularly indicated for elements exposed to
chemical attack.
4.3 Exposure classes vs. SCC for R/C precast
applications
SCC mixtures developed in the research program for
R/C precast elements are characterized by a moderate
water/cement ratios (w/c = 0.54), moderate dosages
of cement (350 kg/m
3
) and a concrete strength class
C30/37 (Table 2).
Having these characteristics, mix SCC-50 meets
the durability requirements corresponding to the fol-
lowing exposure classes (Table 67):
XC1, XC2 and XC3, elements subjected to risk of
corrosion induced by carbonation;
XS1 and XD1, elements subjected to risk of corro-
sion induced by chlorides from sea water or from
other sources;
XF2 and XF3, elements exposed to freeze/thaw
attack when air entraining admixtures are used in
compositions to produce air content in concrete
greater than 5.5%;
XA1, concrete subjected to slightly aggressive
chemical environment (soils and ground water);
XM1, concrete subjected to mechanical attack
(abrasion) which produces a moderate wear on
industrial floors, slabs and platforms due to pneu-
matic wheel vehicular traffic.
The proposed mixture (SCC50) for R/C precast
elements does not meet the requirements of certain
exposure classes (XC4, XS2, XS3, XD2, XD3, XF1,
XF4, XA2, XA3, XM2 and XM3) with respect to the
water/cement parameter.
5 CONCLUSIONS
The results obtained in the experimental program
confirm the possibility to produce with local mate-
rials, SCC with remarkable properties in fresh state
and hardened state and an impeccable surface after
removal from the mould (Fig. 3).
165
The proposed mixes for prestressed application
(C50/60 and C40/50 strength classes) satisfy entirely
the limit values specified in the National Annex SR
EN 206-1: 2006 for concrete composition and con-
crete properties for whole exposure classes.
SCC mix designed for C30/37 strength class, satis-
fies only partially the demands of exposure classes,
future tests will be need to obtain SCC having lower
water/cement ratios.
ACKNOWLEDGEMENTS
The authors wish to express their thanks to the Sika
Romania Ltd, for the partial financial support of this
study and for providing admixtures and additions for
the experimental program.
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