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The paper addresses numerical modelling of fresh self-compacting concrete. In the previous studies, a numerical tool for casting prediction is built based on the assumption that fresh concrete behaves as a yield-stress fluid and treating zones with rebars as porous media. The present contribution discusses the determination of material parameters, which are required as an input for numerical simulations of casting processes.
In the last decades, numerical simulations of fresh concrete flow have gained importance in concrete industry. They showed a potential to become a tool for prediction of concrete casting and to help engineers to avoid expensive mistakes on site. A promising field for application of numerical modelling is casting of Self-Compacting Concrete (SCC), since the main area of application of SCC are complex and highly-reinforced building elements. Simulations of fresh concrete flow involve complex mathematical models and time-consuming computations. In case of casting simulations, the simulation time is additionally significantly increased because each reinforcement bar occurring in succession has to be considered one by one. This is particularly problematic in case of SCC casting, since this type of concrete is typically used for heavily-reinforced structural members. With the aim to decrease simulation time and to come closer to a practical simulation tool, we proposed an innovative modelling approach that models a zone with arrays of the reinforcement bars as a porous medium (PM). By defining characteristic parameters of the PM, its influence on the flow can be defined. This approach simplifies the geometry to be modelled and significantly decreases the computational time. The present contribution provides a brief description the proposed numerical model and of the conducted validation studies. The applicability of the model on fresh concrete is verified through the comparison between experimental measurements and numerical simulations.
This thesis addresses numerical simulations of self-compacting concrete (SCC) castings and suggests a novel modelling approach that treats reinforcement zones in a formwork as porous media.
As a relatively new field in concrete technology, numerical simulations of fresh concrete flow can be a promising aid to optimise casting processes and to avoid on-site casting incidents by predicting the flow behaviour of concrete during the casting process. The simulations of fresh concrete flow generally involve complex mathematical modelling and time-consuming computations. In case of a casting prediction, the simulation time is additionally significantly increased because each reinforcement bar occurring in succession has to be considered one by one. This is particularly problematic when simulating SCC casting, since this type of concrete is typically used for heavily reinforced structural members. However, the wide use of numerical tools for casting prediction in practice is possible only if the tools are user-friendly and simulations are time-saving.
In order to shorten simulation time and to come closer to a practical tool for casting prediction, instead to model steel bars one by one, this thesis suggests to model zones with arrays of steel bars as porous media. Consequently, one models the flow of SCC through a reinforcement zone as a free-surface flow of a non-Newtonian fluid, propagating through the medium. By defining characteristic parameters of the porous medium, the influence on the flow and the changed (apparent) behaviour of concrete in the porous matrix can be predicted. This enables modelling of any reinforcement network as a porous zone and thus significantly simplifies and fastens simulations of reinforced components’ castings.
Within the thesis, a computational model for SCC flow through reinforced sections was developed. This model couples a fluid dynamics model for fresh concrete and the macroscopic approach for the influence of the porous medium (formed by the rebars) on the flow. The model is implemented into a Computational Fluid Dynamics software and validated on numerical and experimental studies, among which is a large-scale laboratory casting of a highly reinforced beam. The apparent rheology of concrete within the arrays of steel bars is studied and a methodology to determine unknown input parameters for the porous medium is suggested. Normative tables defining characteristic porous medium parameters as a function of the topology of the rebar zone for different reinforcement cases are generated. Finally, the major contribution of this work is the resulting numerical package, consisting of the numerical solver and the parameter library. The thesis concludes on the ability of the porous medium analogy technique to reliably predict the concrete casting behaviour, while being significantly easier to use and far less time consuming than existing tools.