Computational fluid dynamics analysis of single-point rheological tests for assessing cementitious material workability

This study validates OpenFOAM as a tool for simulating single-point rheological tests used to assess the workability of cementitious materials. Three tests – L -box, mini-slump, and Marsh cone – were modeled using OpenFOAM with Herschel–Bulkley constitutive model and compared against independent reference cases. Numerical results were validated by matching computed fluid-air interfaces with literature wavefront-propagation data. OpenFOAM consistently captured transient non-Newtonian flow behavior in these tests. A key limitation was identified: the Herschel–Bulkley model cannot predict complete flow stoppage because it lacks hardening, preventing direct determination of final spreads. This was mitigated by using empirical correlations and tracking velocity magnitudes approaching negligible values to estimate effective spreads. The validated framework enables inverse parameter estimation from field measurements, allowing inference of rheological properties when rheometers are unavailable or samples scarce. This approach broadens access to quantitative rheology in constrained contexts while maintaining scientific rigor and supporting advances in material design, digital fabrication, and computational quality control. • OpenFOAM validated as a reliable tool for transient non-Newtonian flow analysis in cementitious materials. • CFD-based inverse analysis enables rheological property inference from single-point tests without specialized equipment. • Herschel-Bulkley model limitations identified but circumvented through empirical correlation alignment for applications.