The Art and Science of Batching for

Self-Compacting Concrete
Batching for Self-Consolidating Concrete (SCC) is a discipline that blends
science with meticulous practice. It elevates the concrete production
process from a commodity operation to a high-precision manufacturing
activity. The four pillars—rigorous material management, optimized
batching sequence, relentless quality control, and advanced plant
technology—are interdependent. A weakness in one pillar compromises
the entire system.

The future of SCC batching lies in greater automation and data

integration. The vision of a plant that can self-monitor and self-correct its
output in real-time is within reach. However, even with the most advanced
technology, the human element remains vital. Skilled, knowledgeable
personnel who understand the rheological principles of SCC are essential
to oversee the process, interpret data, and manage exceptions.
Ultimately, the successful batching of SCC is a testament to the concrete
industry's capacity for innovation and precision, delivering a material that
enables safer, faster, and more durable construction.

The successful production of Self-Consolidating Concrete (SCC) is a

testament to the principle that the whole is greater than the sum of its
parts. While its exceptional properties—filling ability, passing ability, and
segregation resistance—are defined by its mix design, the realization of
these properties is entirely dependent on the precision and control
exercised during the batching process. Batching for SCC is not a simple
scaling-up of conventional concrete procedures; it is a highly refined
operation that demands an intimate understanding of material science,
rheology, and process engineering.

The Link Between Design and Reality

Self-Consolidating Concrete represents the pinnacle of fluid concrete

technology. Its defining characteristic is its ability to achieve complete
compaction under its own weight, a property that eliminates the
variability and potential defects introduced by mechanical vibration. This
unique rheology is engineered through a carefully balanced combination
of constituents: a reduced coarse aggregate content, an increased volume
of fine powder (cement and supplementary cementitious materials), and a
sophisticated blend of chemical admixtures, primarily high-range water-
reducers (HRWR) and often viscosity-modifying admixtures (VMA).

The batching process is the crucible where this engineered design

becomes a physical reality. It involves the precise measurement and
combination of these constituents in a central mixing plant, typically a
ready-mix concrete facility. For conventional concrete, batching
tolerances are relatively forgiving; slight variations in water content or
aggregate moisture can often be compensated for during mixing and
placement. For SCC, this margin for error is dramatically reduced. The
delicate equilibrium between fluidity and stability is highly sensitive to
changes in the water-to-powder ratio, the dosage of chemical admixtures,
and the physical characteristics of the aggregates.

Raw Material Management and Characterization

The consistency of the final SCC product is directly proportional to the
consistency of its raw materials. Variability is the enemy of robust SCC
production. A rigorous approach to material sourcing, storage, and testing
is non-negotiable.

[Link] Materials: Cement and SCMs

The powder component is the backbone of the SCC matrix, providing the
fines necessary for cohesion and lubrication. Consistency in cement
composition and fineness is critical. Changes in the C 3A content or
sulphate balance of the cement can significantly alter its compatibility
with HRWR admixtures, leading to unpredictable water demand and slump
flow loss.

Supplementary Cementitious Materials (SCMs) are integral to most SCC

mixes. Fly ash is prized for its spherical particle morphology, which
provides a "ball-bearing" effect that enhances fluidity. The key quality
indicators are fineness, loss on ignition (LOI), and uniformity. High LOI
(indicating unburned carbon) is particularly detrimental as carbon
particles are porous and can absorb admixtures, especially HRWR and air-
entraining agents (AEAs), making dosage control difficult. Each delivery of
fly ash must be tested for consistency.

Slag typically provides a cohesive, smooth rheology. Its glass content and
fineness are the primary quality controls.

Silica Fume is used in smaller percentages to dramatically increase

cohesion and stability. Its extreme fineness means it must be stored in
sealed containers to prevent moisture absorption and handled carefully to
avoid dust issues. It can clump, requiring specialized dispersion
techniques during batching.

Cementitious materials must be stored in separate, moisture-proof silos.

Cross-contamination between silos, or moisture ingress, can have
catastrophic effects on the performance of the powder.

2. Aggregates

The aggregate selection and grading are more critical in SCC than in any
other concrete type.
The content of Coarse Aggregate is typically limited to 28-35% of the total
volume of the concrete (compared to 40-50% in conventional concrete).
This reduction is essential to reduce the internal friction that inhibits flow,
especially through reinforcement. The maximum size is usually limited to
20mm or even 16mm for highly congested elements. The aggregate must
be cubical and rounded rather than flaky or elongated, as irregular shapes
increase viscosity and reduce passing ability. Consistent grading is vital;
significant variation can alter the water demand and the packing density
of the mix.

Sand (Fine Aggregate) constitutes a larger proportion of the aggregate in

SCC. It is the primary component that contributes to the stability of the
mix, preventing the coarse aggregate from settling. The fineness modulus
and grading curve must be tightly controlled. A well-graded sand that fills
the voids between the coarse aggregate particles is ideal. A sand that is
too fine can lead to high water demand, while a sand that is too coarse
can reduce stability and lead to segregation. The moisture content of sand
is the single most variable factor in batching and must be monitored with
extreme diligence.

3. Water
While seemingly straightforward, water is the most potent component in
the mix. A variation of just 1% in the total water content can drastically
alter the rheology of SCC. The water used must be potable and free from
impurities, oils, or chlorides that could affect setting, strength, or
corrosion of reinforcement.

4. Chemical Admixtures
These are the "magic ingredients" that make SCC possible.

High-Range Water-Reducers (HRWR) / Superplasticizers: These

are polycarboxylate ether (PCE)-based polymers in modern SCC. They
work by dispersing the cement particles, releasing trapped water, and
allowing the mix to flow at low water-cement ratios. The compatibility
between the specific PCE admixture and the cement/SCM combination
is paramount. This compatibility must be established through rigorous
testing before a mix is approved for production. Admixtures must be
stored within a specified temperature range to prevent degradation or
crystallization.

 Viscosity-Modifying Admixtures (VMAs): These are used to

increase the plastic viscosity and cohesion of the paste, thereby
enhancing segregation resistance. They are essential when the
paste volume or fines content is borderline for stability, or when the
concrete must be pumped over long distances or placed
underwater. VMAs are typically water-soluble polymers that create a
weak, thixotropic gel structure in the water.

3. Pillar II: The Batching Sequence and Mixing Regime

The order in which materials are added to the mixer has a profound
impact on the efficiency of mixing and the final rheology of the SCC. The
goal is to achieve a perfectly homogeneous mixture with the admixtures
fully dispersed.

3.1. The Critical Importance of Mixing Energy and Time

SCC requires more mixing energy and a longer mixing time than
conventional concrete. The fine powders and admixtures need time to
become fully integrated and effective. Under-mixing is a common cause of
poor SCC performance. Pan or tilting drum mixers are generally preferred
over truck mixers for the initial batching because they provide more
intense and consistent mixing action. However, truck mixing is common,
and protocols must be adjusted accordingly.

3.2. Standard Batching Sequence (for a Central Mix Plant)

A well-established sequence maximizes efficiency and homogeneity.

1. Addition of Coarse Aggregate and a Portion of Mixing Water:

Introducing a portion of the water first helps to coat the aggregate
and reduce the potential for "balling" of the powder materials. It
also begins to clean the mixer drum.
2. Addition of Fine Aggregate (Sand): The sand is added next.
3. Addition of Cementitious Materials (Cement and SCMs): The
powders are added while the mixer is running. This sequence allows
the aggregates to be pre-wetted, which reduces the tendency for
the fine powders to form clumps upon contact with water.
4. Initial Mixing Cycle (30-60 seconds): The materials are mixed
until a uniform, dry-looking mix is achieved.
5. Addition of the Majority of the HRWR with the Remaining
Water: The HRWR is typically diluted in the remaining batch water.
This solution is then added gradually to the mixer. A gradual
addition allows for better control over the final fluidity and prevents
an overshoot of the target slump flow.
6. Final Mixing Cycle (90-120 seconds minimum): The batch is
mixed for a sufficient time to ensure complete dispersion of the
admixture and a homogeneous mixture. The mixing time should be
consistent from batch to batch.
7. Addition of VMA (if required): VMAs are often added last, as a
final adjustment to the viscosity. They can be pre-diluted in water
and added slowly while the mixer is turning.
8. Rest Period and Final Mixing: After the initial mixing, a rest
period of 1-2 minutes can be beneficial. This allows the admixtures
to fully react and any entrapped air to escape. A final mixing of 30-
60 seconds then ensures uniformity before discharge.

3.3. The "Two-Stage" Mixing Method

For particularly sensitive mixes or when using problematic materials like
high-LOI fly ash, a two-stage mixing method can be superior:
  Stage 1: The powders (cement, SCMs) are mixed with the full
amount of water and a portion of the HRWR for a few minutes. This
ensures the powders are fully wetted and the admixture is properly
adsorbed.
 Stage 2: The aggregates are added, along with the remainder of
the HRWR, and mixing continues to full homogeneity.
This method can improve the efficiency of the HRWR and lead to a
more predictable and stable rheology.

3.4. Truck Mixer Batching

When SCC is batched directly into a truck mixer, the sequence must be
adjusted to account for less efficient mixing. The drum speed must be
maintained at the maximum mixing speed (usually 12-18 RPM) for a
longer duration. A typical sequence is: 1) 80% of water, 2) aggregates, 3)
cementitious materials, 4) mix for 70-100 revolutions, 5) remaining water
with HRWR, 6) mix for a further 50-70 revolutions. The total mixing time
and revolution count must be carefully documented and controlled.

4. Pillar III: Quality Control, Testing, and Rheology

Adjustment

Even with perfect materials and sequence, every batch of SCC must be
verified and potentially adjusted before it leaves the plant. This is the core
of quality assurance.

4.1. The Principle of "Robustness"

A robust SCC mix is one that can tolerate minor variations in material
properties (e.g., a 1% change in sand moisture) or ambient temperature
without a significant change in performance. The mix designer's goal is to
create a robust mix. The batcher's goal is to verify the robustness of each
batch.

4.2. The Slump Flow Test: The Primary QC Tool

The slump flow test is the simplest and most rapid test for assessing the
filling ability (yield stress) of SCC. Immediately after mixing, a sample of
concrete is placed in a standard slump cone on a non-absorbent base
plate. The cone is lifted, and the concrete flows outward.

 Target Value: The final diameter of the concrete spread (the

"slump flow") is measured. Typical targets range from 600mm to
750mm, depending on the application.
 T500 Time: The time it takes for the concrete to reach a 500mm
diameter is also recorded. This is an indirect indicator of the plastic
viscosity. A short T500 time (e.g., 2-3 seconds) indicates low
viscosity (very fluid), while a longer time (e.g., 5-7 seconds)
indicates higher viscosity (more cohesive).

4.3. The Adjustment Protocol: "Tempering"

If the slump flow is outside the specified range, adjustments must be
made. The controlled addition of water and HRWR to correct the
consistency is known as "tempering." This process must be done with
extreme care to avoid compromising the water-cement ratio and thus the
strength and durability.

 Standard Tempering Procedure:

1. Measure: Perform the slump flow test. If the flow is too low
(e.g., 550mm vs. a target of 650mm), calculate the required
adjustment.
2. Calculate: A pre-established "recipe" is used. This is typically
a combination of water and HRWR. For example, the mix
design may specify that to increase the slump flow by 50mm,
one should add 1.0 kg/m³ of water along with a corresponding
amount of HRWR (e.g., 0.1 kg/m³) to maintain the w/cm ratio.
Adding water alone is strictly prohibited as it increases
the w/cm ratio, dilutes the paste, and destroys stability.
3. Add and Mix: The calculated amounts of water and HRWR
are added to the mixer. The mixer drum is then turned at
mixing speed for a minimum of 30 revolutions (or 2-3
minutes) to ensure full incorporation.
4. Re-test: The slump flow test is repeated to verify the
adjustment was correct. This process may need to be iterated.

This protocol highlights why accurate moisture probes on aggregate bins

are essential. If the initial batching water is adjusted correctly for the
aggregate moisture, the need for tempering is minimized.

4.4. Additional QC Tests at the Plant

While slump flow is the primary go/no-go test, other tests can be
performed for more critical applications:

 J-Ring or L-Box: These can be used to check passing ability if there

are concerns about blockage.
 Sieve Stability Test or V-Funnel: These provide a quick
assessment of segregation resistance.

A sample should also be taken for casting compressive strength test

cylinders.

5. Pillar IV: Advanced Batching Plant Technology and

Automation

Modern batching plants are increasingly automated, which is a significant

advantage for SCC production. Technology reduces human error and
enhances consistency.

5.1. Automated Moisture Probes

These are arguably the most important technological advancement for
SCC batching. Microwave-based or capacitance-based probes are installed
in the sand and coarse aggregate bins. They continuously measure the
moisture content of the aggregates and send this data to the batching
computer. The computer then automatically deducts the equivalent
amount of "free water" from the total batch water to be added. This real-
time adjustment ensures the total water content is kept constant, which is
the single most important factor in achieving batch-to-batch consistency.

5.2. Sophisticated Batching Software

Modern batching software does more than just open and close gates. It:

 Stores hundreds of mix designs.

 Integrates with moisture probes for automatic water adjustment.
 Controls the batching sequence and mixing time with precision.
 Records every action, creating a complete batch ticket that includes
the actual weights of all materials, moisture readings, and mixing
times. This data is invaluable for traceability and troubleshooting.

5.3. Admixture Dispensing Systems

Advanced plants have dedicated, calibrated pumps and meters for each
liquid admixture. This allows for far more precise dosing than simple
weigh batchers. Some systems can even inject admixtures incrementally
during the mixing process based on pre-programmed sequences.

5.4. The Future: In-Line Rheometers and Closed-Loop Control

The next frontier in SCC batching is real-time rheology control. Prototype
systems exist that feature an "in-line rheometer"—a device installed in the
discharge chute of the mixer that can continuously measure the yield
stress and viscosity of the concrete as it flows out.

 Concept: The rheometer provides instant feedback to the batching

computer.
 Closed-Loop Control: If the rheology deviates from the target, the
computer can automatically calculate and inject the required
corrective dose of water and HRWR (or VMA) back into the mixer,
then re-mix. This would create a fully "adaptive" SCC that is
guaranteed to be within specification upon discharge, representing
the ultimate in quality control.

6. Case Study: Batching SCC for a High-Rise Core Wall

Project: Construction of a 50-story building with a densely reinforced

central core.
Challenge: The SCC must have a slump flow of 680±20mm with a T500
time of 3-5 seconds to ensure it can flow through the reinforcement
without blocking or segregating. Batch-to-batch consistency is critical for
continuous pumping and placement.

Batching Protocol:
1. Pre-Production Trial Batches: A week before the pour, three trial
batches are produced at the plant using the exact materials to be
used on site. The mix is optimized, and the tempering recipe
(water+HRWR per 50mm of slump flow change) is finalized.
2. Day of Pour:
o Pre-Check: The plant manager verifies that the same lots of
cement, fly ash, and admixtures are available. Aggregate
stockpiles are checked for consistency.
o Batching: The automated sequence begins. Moisture probes
report a sand moisture content of 5.2%. The computer
automatically reduces the batch water by the corresponding
amount.
o Initial QC Test: The first batch is discharged into the truck.
The plant technician performs a slump flow test: result is
660mm with a T500 of 4 seconds. It is slightly stiff.
o Tempering: Using the pre-established recipe, the technician
calculates the required addition: 2.0 kg/m³ of water and 0.2
kg/m³ of HRWR. The additives are introduced, the drum mixes
for 30 revolutions, and a re-test shows 680mm with a T500 of
3.5 seconds—perfect.
o Continuous Monitoring: Every third truck is tested
throughout the 8-hour pour. Because of the moisture probes
and controlled batching, all subsequent batches are within
specification without need for adjustment. The data from each
batch is logged.
3. Outcome: The SCC places perfectly, completely filling the complex
formwork with no vibration. The resulting concrete is homogeneous
and of high quality, with excellent strength results from the test
cylinders.