Optimization of casting process parameters for homogeneous aggregate distribution in self-compacting concrete: A feasibility study

The use of self-compacting concrete (SCC) as a construction material has been getting more attention from the industry. Its application area varies from standard structural elements in bridges and skyscrapers to modern architecture having geometrical challenges. However, heterogeneities induced during the casting process may lead to variations of local mechanical properties and hence to a potential decrease in load carrying capacity of the structure. This paper presents a methodology for optimization of SCC casting aiming at having a homogeneous aggregate distribution; a beam has been used as geometric example. The aggregate distribution is predicted by a numerical flow model coupled with a user defined volume fraction subroutine. The process parameters in casting with SCC in general are horizontal and vertical positions, movement, as well as the size of the inlet, and the duration of the filling etc., however since this work is the initial feasibility study in this field, only three process parameters are considered. Despite the reduction in the number of process parameters, the complexity involved in the considered casting process results in a non trivial optimal design set.