Mastering Yield Stress Evolution and Formwork Friction for Smart Dynamic Casting
Abstract
:1. Introduction
2. Materials and Methods
2.1. Materials
2.1.1. Self-Compacting Concrete
- a set accelerator: SikaRapid C-100 (reportedly based on Ca(NO3)2·4H2O [21]). These mixes are noted S_C.
- a combination of aluminium sulfate solution (produced in house by dissolving Al2(SO4)3·18H2O in water to obtain 260 g/L concentration) and a superplasticizer (BASF MasterGlenium ACE 30). These mixes are noted S_A.
2.1.2. UHPFRC
2.2. Methods
2.2.1. Slump Tests
2.2.2. Penetration Tests
2.2.3. Calorimetry
2.2.4. Friction Tests
- It was first accelerated as a whole and then cast in the box all at once.
- It was gradually placed using 12 smaller batches, each accelerated separately prior to placing. This procedure was done so as to raise the level of concrete by 1.8 cm every 3 min, which mimics formwork filling during the slip-forming process.
3. Part 1: Mastering the Yield Stress Evolution
3.1. Results
3.1.1. Spread Flow
3.1.2. Penetration Tests
3.1.3. Calorimetry
3.2. Discussion
3.2.1. Initial Yield Stress after Accelerator Addition
3.2.2. Penetration Resistance/Strength Evolution
3.2.3. Cement Hydration
4. Part 2: Friction Tests
4.1. Results
4.2. Discussion
5. Part 3: A Theoretical Model for the SDC Process Window
5.1. Reformulating the Process Window with the SDC Number’
5.2. Practical Considerations
6. Conclusions
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
Appendix A
Base Mix | Mix for Uniform Acceleration | Mix for Adapted Acceleration | t | d1 | d2 | h | τ0 (Pa) |
---|---|---|---|---|---|---|---|
(hh:mm) | (cm) | (cm) | (cm) | ||||
S | 16.2 | 16.5 | 2.1 | 128 | |||
S_C_1 | S_C_1 | 01:00 | 26 | 25.6 | 13 | ||
S_C_1 | 03:15 | 23.5 | 24.5 | 19 | |||
S_C_1 | 05:05 | 21.8 | 22.2 | 29 | |||
S_C_3 | 03:10 | 26.4 | 26.9 | 11 | |||
S_C_5 | 05:00 | 29.6 | 30.1 | 6.3 | |||
S_A* | 01:05 | 13.2 | 12.8 | 3.8 | 403 | ||
S_A_1 | S_A_1 | 01:00 | 24.2 | 23.9 | 19 | ||
S_A_1 | 03:05 | 19.7 | 20.3 | 47 | |||
S_A_1 | 05:05 | 19.1 | 19.7 | 54 | |||
S_A_3 | 03:00 | 24.3 | 24.4 | 17 | |||
S_A_5 | 05:00 | 25.3 | 25 | 15 | |||
U | 21.2 | 21.7 | 31 | ||||
U_A_1 | U_A_1 | 01:00 | 34.7 | 35.7 | 2.6 | ||
U_A_1 | 03:05 | 33.5 | 35.2 | 3 | |||
U_A_1 | 05:05 | 30 | 30.7 | 5.5 | |||
U_A_3 | 03:00 | 33.4 | 36.7 | 2.7 | |||
U_A_5 | 05:00 | 32.5 | 34.1 | 3.5 |
Mix | Peak/Plateau |
---|---|
S_C_1 | 3.57 |
S_A_1 | 3.74 |
U_A_1 | 4.77 |
S_C_1 gradual | 3.04 |
S_A_1 gradual | 2.27 |
U_A_1 gradual | 2.18 |
rhy (m) | H (m) | β (-) | αFr (-) | Τ0 Lower Limit (-) SDC | Τ0 Upper Limit (-) SDC/(2*SDC+1) | ||||
---|---|---|---|---|---|---|---|---|---|
Start-Up | Slipping | Start-Up | Slipping | Start-Up | Slipping | ||||
Folded Structures | |||||||||
S_C_1 | 0.025 | 0.3 | 2.9 | 0.2 | 0.1 | 1.8 | 6.3 | 0.4 | 0.5 |
S_A_1 | 0.025 | 0.3 | 1.5 | 0.1 | 0.0 | 3.8 | 14.0 | 0.4 | 0.5 |
U_A_1 | 0.025 | 0.3 | 2.5 | 0.1 | 0.0 | 2.7 | 10.5 | 0.4 | 0.5 |
S_C_1 gradual | 0.025 | 0.3 | 2.9 | 0.1 | 0.0 | 4.0 | 10.4 | 0.4 | 0.5 |
S_A_1 gradual | 0.025 | 0.3 | 1.6 | 0.1 | 0.0 | 4.0 | 8.3 | 0.4 | 0.5 |
U_A_1 gradual | 0.025 | 0.3 | 2.4 | 0.1 | 0.0 | 4.4 | 8.7 | 0.4 | 0.5 |
Mullions | |||||||||
S_C_1 | 0.075 | 0.4 | 2.9 | 0.2 | 0.1 | 3.9 | 14.2 | 0.4 | 0.5 |
S_A_1 | 0.075 | 0.4 | 1.5 | 0.1 | 0.0 | 8.4 | 31.4 | 0.5 | 0.5 |
U_A_1 | 0.075 | 0.4 | 2.5 | 0.1 | 0.0 | 6.2 | 23.5 | 0.5 | 0.5 |
S_C_1 gradual | 0.075 | 0.4 | 2.9 | 0.1 | 0.0 | 9.0 | 23.4 | 0.5 | 0.5 |
S_A_1 gradual | 0.075 | 0.4 | 1.6 | 0.1 | 0.0 | 9.1 | 18.6 | 0.5 | 0.5 |
U_A_1 gradual | 0.075 | 0.4 | 2.4 | 0.1 | 0.0 | 10.0 | 19.5 | 0.5 | 0.5 |
Columns | |||||||||
S_C_1 | 0.106 | 0.4 | 2.9 | 0.2 | 0.1 | 5.6 | 20.1 | 0.5 | 0.5 |
S_A_1 | 0.106 | 0.4 | 1.5 | 0.1 | 0.0 | 11.9 | 44.4 | 0.5 | 0.5 |
U_A_1 | 0.106 | 0.4 | 2.5 | 0.1 | 0.0 | 8.7 | 33.3 | 0.5 | 0.5 |
S_C_1 gradual | 0.106 | 0.4 | 2.9 | 0.1 | 0.0 | 12.7 | 33.1 | 0.5 | 0.5 |
S_A_1 gradual | 0.106 | 0.4 | 1.6 | 0.1 | 0.0 | 12.9 | 26.3 | 0.5 | 0.5 |
U_A_1 gradual | 0.106 | 0.4 | 2.4 | 0.1 | 0.0 | 14.1 | 27.6 | 0.5 | 0.5 |
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Retarded Mix [kg/m3] | Mix S | Mix U |
---|---|---|
Sand (0–4 mm) | 1367.60 | |
Quartz sand (0.125–0.5 mm) | 616.40 | |
Glass fibres (Fibre Technologies AR2500H103) | 7.35 | |
Cement (CEM I 52.5R or N) | 615.06 (R) | 547.50 (N) |
Silica fume (BASF Masterlife SF100) | 32.37 | 191.60 |
Limestone 5–15 µm d50% (OMYA Betocarb-HP) | 183.10 | |
Limestone 3 µm d50% (OMYA Betoflow-D) | 419.10 | |
Water | 247.19 | 192.20 |
Superplasticizer (BASF MasterGlenium ACE-30) | 1.55 | 6.00 |
Sucrose (Sigma Aldrich 99.5% purity D(+)) | 0.68 | 1.33 |
Ca(NO3)2 (SigmaAldrich) | 0.03 | |
w/b (-) | 0.38 | 0.26 |
Accelerator (g/lretarded concrete) | Mix S_C | Mix S_A | Mix U_A | |||||||
---|---|---|---|---|---|---|---|---|---|---|
S_C_1 | S_C_3 | S_C_5 | S_A * | S_A_1 | S_A_3 | S_A_5 | U_A_1 | U_A_3 | U_A_5 | |
Sika Rapid C100 | 15.38 | 20.00 | 24.60 | |||||||
Al2(SO4)3·18H2O | 9.23 | 9.23 | 9.23 | 9.23 | 13.69 | 12.59 | 11.50 | |||
Water | 31.95 | 31.95 | 32.20 | 32.44 | 75.48 | 71.85 | 68.21 | |||
Superplasticizer * | 1.85 | 2.20 | 2.55 | |||||||
w/b acc. (-) | 0.39 | 0.40 | 0.40 | 0.43 | 0.43 | 0.43 | 0.43 | 0.36 | 0.36 | 0.35 |
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Szabo, A.; Reiter, L.; Lloret-Fritschi, E.; Gramazio, F.; Kohler, M.; Flatt, R.J. Mastering Yield Stress Evolution and Formwork Friction for Smart Dynamic Casting. Materials 2020, 13, 2084. https://doi.org/10.3390/ma13092084
Szabo A, Reiter L, Lloret-Fritschi E, Gramazio F, Kohler M, Flatt RJ. Mastering Yield Stress Evolution and Formwork Friction for Smart Dynamic Casting. Materials. 2020; 13(9):2084. https://doi.org/10.3390/ma13092084
Chicago/Turabian StyleSzabo, Anna, Lex Reiter, Ena Lloret-Fritschi, Fabio Gramazio, Matthias Kohler, and Robert J. Flatt. 2020. "Mastering Yield Stress Evolution and Formwork Friction for Smart Dynamic Casting" Materials 13, no. 9: 2084. https://doi.org/10.3390/ma13092084