Numerical Reliability Study Based on Rheological Input for Bingham Paste Pumping Using a Finite Volume Approach in OpenFOAM

Rheological quantification is important in many industries, the concrete industry in particular, e.g., pumping, form filling, etc. Instead of performing expensive and time-consuming experiments, numerical simulations are a powerful means in view of rheological assessment. However, due to the unclear numerical reliability and the uncertainty of rheological input data, it is important for the construction industry to assess the numerical outcome. To reduce the numerical domain of cementitious suspensions, we assessed the numerical finite volume simulations of Bingham paste pumping flows in OpenFOAM. We analysed the numerical reliability, first, irrespective of its rheological input by comparison with the literature and theory, and second, dependent on a certain rheological quantification by comparison with pumping experiments. Irrespective of the rheological input, the numerical results were significantly accurate. Dependent on the rheological input, a numerical mismatch, however, existed. Errors below 1% can be expected for proposed numerical rules of thumb: a bi-viscous regularisation, with pressure numbers higher than 5/4. To improve bias due to uncertain rheology, a rheological configuration close to the engineer’s aimed application should be used. However, important phenomena should not be overlooked. Further assessment for lubrication flows, in, e.g., concrete pumping, is still necessary to address concerns of reliability and stability.

Rheological Properties of Cement Paste with Nano-Fe3O4 under Magnetic Field: Flow Curve and Nanoparticle Agglomeration

Understanding the influence of magnetic fields on the rheological behavior of flowing cement paste is of great importance to achieve active rheology control during concrete pumping. In this study, the rheological properties of cementitious paste with water-to-cement (w/c) ratio of 0.4 and nano-Fe3O4 content of 3% are first measured under magnetic field. Experimental results show that the shear stress of the cementitious paste under an external magnetic field of 0.5 T is lower than that obtained without magnetic field. After the rheological test, obvious nanoparticle agglomeration and bleeding are observed on the interface between the cementitious paste and the upper rotating plate, and results indicate that this behavior is induced by the high magnetic field strength and high-rate shearing. Subsequently, the hypothesis about the underlying mechanisms of nanoparticles migration in cementitious paste is illustrated. The distribution of the nanoparticles in the cementitious paste between parallel plates is examined by the magnetic properties of the powder as determined by a vibrating sample magnetometer. It is revealed that the magnetization of cementitious powders at different sections and layers provides a solid verification of the hypothesis.

Insights in thixotropic concrete pumping by a Poiseuille flow extension

Thixotropy is a reversible time-dependent phenomenon in fluids, in which an internal structure grows due to flocculation and breaks down under shear action. Numerous fluids are thixotropic, e.g. concretes and cementitious suspensions. Pumping of concrete is an important application. Since current approaches omit thixotropic effects, we aim to develop a simple theoretical model to evaluate or understand the significance of thixotropy on the concrete pumping behaviour. We therefore extended Poiseuille flow for thixotropic concretes and reformulated it in a dimensionless form to gain insights. After a validation, the results and significance are elaborated and concluded.Results showed that for increasing thixotropy and decreasing flow rates, the plug radius, wall shear rate and pumping pressure loss increase. Even though all thixotropy mechanisms may not be covered, a simple model is delivered to interpret or predict the effect of thixotropy on the pumping behaviour of cementitious suspensions. The dimensionless formulations via the Bingham number Bn and related discharge diagrams are sufficiently elegant for computational implementation and very insightful to distinguish a thixotropic flow regime. The model could be extended for more complicated thixotropies, irreversible time-dependent effects or even other pumping related phenomena.

Estimation of Lubrication Layer Thickness and Composition through Reverse Engineering of Interface Rheometry Tests

During concrete pumping, a lubrication layer is formed near the pipe wall. Extensive research has been performed on measuring and modeling the properties of this layer and using these values to predict pumping pressures. However, there are numerous discussions in the literature about the composition and thickness of this layer: can it be considered mortar, a micromortar, or is it cement paste? In this paper, possible solutions for the thickness and composition of the lubrication layer are derived from interface rheometry tests. It is assumed that the lubrication layer is composed of one or more concentric layers of paste or micromortar. To accomplish this determination, the rheological properties of the composing paste, mortars with different maximum particle sizes and concrete need to be known. Challenges arising from using different rheometers and from the sensitivity of the paste rheology to shearing are addressed in this contribution. The results show that, mathematically, a single layer of homogeneous paste or mortar with different maximum particle sizes can be responsible for the formation of the lubrication layer. Physically, however, the composing material should contain sand particles to some extent, as particle migration is proportional to the size squared. If the literature results from pumping are applicable to the results obtained in this paper, it seems that the lubrication layer is composed of a mortar with a maximum particle size of around 1 to 2 mm.