Standard method for making and curing

cubes made from pre-bagged grouts and

polymer modified mortars
General

Cube size

The method described below is based on practical

experience of making and curing mortar and grout cubes in
the laboratory and on site. Degussa offers the methods
stated in good faith and endeavours to ensure that any
advice given is accurate, however, the method, although
using ASTM C-109 and C-942 as a guideline, should not be
construed as relating to any International standard.

Detailed below are some of the various cube sizes found in

grout and repair specifications used world-wide.

The method statement relates to Degussa products only.

Other materials falling into the above categories may be
mixed successfully using this method, but Degussa cannot
be held responsible for failures caused by not following
manufacturers recommendations or stated procedures.

BS 1881
BS 4551
BS 4550
BS 6319
ASTM C-109

The basic philosophy behind testing should be to assess the

material quality following a standard procedure. The results
of these tests should, initially, be used to determine the
suitability of the product for use, and later to check the
consistency of the supply. Tests may also be carried out to
check the quality of the product being used in a critical area.
This type of testing, however, should be more a check on
the mixing quality rather than the product itself.
The manufacture and testing of cubes made from grout or
polymer modified cementitious mortars can pose many
problems to the Engineer. The materials are based on
cement, and yet there may be conflicting requirements as to
how to do the 3 'C's (cast, cure and crush). Maybe,
because the material is cementitious in nature, and all
technicians and Engineers know BS 1881, it is often easy to
treat these types of product as "concrete". However, this
does not take into account the type of products or the
product's reaction to different curing regimes. With so many
Standards, different cube sizes and various curing methods,
it is possible for the Engineer to become confused.
This guideline hopes to cover some of these points and set
out what is believed to be a reasonable method, easily
reproduced on site or in the laboratory, and able to provide
consistent results.

100mm
100 or 70.7mm
100 or 70.7mm
40mm
50mm

Cube size used is to an extent irrelevant. The main points

to consider are:
I.

Philosophy

Methods for testing concrete

Methods for testing mortars
Methods for testing cement
Methods for testing resin
compositions
Compressive strength of
grouts

The correct type and quality of testing equipment must

be specified and maintained at a fit for use level.
(Planeness, levelness, quality of internal surfaces,
cleanliness etc.)

II. The testing should be comparative throughout. Cubes of

40, 50 and 70mm will give similar results however, there
may be a big difference between 50 and 100mm cubes,
which could amount to 4 - 5 N/mm.
III. The testing should be carried out by trained personnel
and procedures should be followed strictly and under
supervision.
Curing regimes should be used to check the potential
strength of the product. Regimes designed to simulate "site
conditions", e.g. cubes stripped at 1 day and allowed to air
dry until test, will result in lower strengths. These should not
be compared to data sheet values, which have been
determined using maximum curing regimes. Cube strengths
are directly related to the manufacturing technique (given all
other values equal) and to the curing regime employed. Full
immersion curing may be suitable for some products and
detrimental for others. The curing method specified allows
for full curing without over-wetting or over-drying of the
sample. Small cubes are more prone to rapid drying out
due to their size /volume ratio. For high strength materials,
e.g. grouts, once that water has escaped no amount of
immersion in water will recover the lost strength. Full curing
is particularly important over the first 3 days.
The one aspect not able to be covered by this method is
temperature of cure. All standards specify a curing
temperature. In a static laboratory this is usually available,
but may be impossible to achieve in a site laboratory.
Curing tanks stored outside and not temperature controlled
may suffer from solar gain in the day and rapid cooling at

night. Temperatures and standard temperatures vary from

region to region.
The general rule which should be followed, where ever
possible, is to maintain the temperature within the range of:
20 1C for temperate climates
27 1C for tropical and sub-tropical climates.

Normal weight grout and repair

mortar cubes (Density > 1900
kg/m)
Due to the density of the products, curing in the traditional
way, (full immersion in water) does not pose any problems.
However, often curing tanks on site are not maintained and
the cubes need to be transported from site to a testing
house. This is also an area where ill treatment of cubes can
occur.

Light weight repair mortars

(Density <1900 kg/m)
The strengths of these types of product are greatly
influenced by the curing regime. Insufficient curing will show
low strengths due to rapid de-hydration of the specimen.
Conversely, total immersion in water can also show a loss in
strength. The full reasons for this are unclear at the present
time but one theory has it that, because the porosity is
slightly higher, the pores fill with water and the water exerts
an internal hydrostatic force during the crushing process,
which weakens the material.
By employing the method stated below, cubes manufactured
on site can be assured full cure without the need to take
from tanks and risk dehydration during transport or, over
soaking.
IV. The method of tamping the material into the moulds is
also important. Grout cubes need only light tapping of
the mould to release any entrapped air. Lightweight
repair mortars need careful handling to ensure full
compaction.

Summary

Making and curing cubes made

from cementitious grouts and
normal weight / light weight
repair mortars
General
The method described below, if carried out by trained staff,
should ensure consistency of manufacture and hence
consistency of results.

Equipment
Cube moulds
The size to be used should not exceed 70mm and certainly
not be more than 100mm for grout products. Only one size
of cube should be used. Combinations of mould sizes will
give inconsistent cube strengths.
The cube moulds should be precision moulds, specifically
designed as cube moulds, made from metal with matched
parts marked with unique numbers or characters on the
opposite sides of the top flange to facilitate correct
assembly.
The internal faces of the moulds shall be machined. All
angles will be at right angles (90) to adjacent faces. The
depth of the mould and the distance between either pair of
opposite internal faces based on the average of four
measurements should be the nominal size 0.15mm.
The joint between the mould sections and the bottom plate
should be watertight. The mould's internal and external
surfaces and joints should be kept clean from build up of
cement and loose rust by wire brushing, or other suitable
technique, and lightly oiled with a proprietary mould release
agent.
Note: Mould oil should not be allowed to pool in the mould
and any excess oil should removed prior to use. The correct
application can be checked by wiping a dry finger across the
mould surface. If the mould oil is ridged either side of the
finger mark an excess of oil is present. If the finger is still oil
free then insufficient oil is on the surface. New moulds
should have the travelling grease removed before use.

Normal site testing should only be carried out to check the

consistency of supply using some or all of the tests
employed to confirm initial acceptance, unless other testing
regimes have been agreed.

All fasteners should be tightened using the correct tools

such that the mould sections are rigid and will not loosen
under compaction or movement. Avoid over tightening that
can distort the sections.

Only trained technicians should be used for the preparation

and testing of materials, as without doubt, the majority of
product failures come from poor curing and testing
technique.

Where the cubes are made from products that have partial
or complete expansion or are to be restrained in application,
the moulds shall be provided with a covering plate which
shall be firmly fixed ensure that the top of the grout is not
allowed to expand freely.

Curing should be properly employed to ensure cementitious

materials gain their full potential strength. Any other
technique is open to variation unless fully controlled and
monitored.

Cleaning equipment
Wire brush
Rags or similar cleaning materials
25mm paintbrush
Mould release oil
Dust pan and brush
Spanners or hexagonal screw keys
Scrapers
Rubber hammer
Screwdriver

Scoop a quantity of the mortar or grout and half fill each of

the moulds to be cast. Ensure that a representative sample
is taken. This is particularly important for grout products.

Tamping bar
A normal concrete tamping bar (25mm square) is too heavy
and not suitable. A hard wood, or hard rubber or plastic rod
of cross- section approximately - of the nominal
dimensions of the mould should be used. The rod should be
150 - 200mm in length. (If wood is used the wood should be
prepared by saturating in a light mineral oil. This prevents
water from being absorbed during tamping. Note: remove
all excess oil before use.)

Repeat the process, slightly overfilling the mould. Strike off

level with the trowel using a sawing motion. When all
sections of the mould are filled immediately attach the top
plate and tighten it down. Cover the whole with a plastic
sheet. Alternatively the moulds can be sealed inside a
plastic bag.

Steel float for levelling

Absorbent cloth or heavy duty tissue to wrap the cubes
after stripping
Heavy gauge polythene bags and 50mm wide plastic
packing tape
Permanent marker pens and self adhesive labels
Small scoop for filling

Procedure
Prepare an area to manufacture and store the cubes. The
area should be dry and the cubes should be made on a flat,
solid base free from vibration and the effects of weather.
The area should be shaded and if possible inside an
enclosed room.
Ensure that the moulds are clean and ready for use, and all
equipment required to complete the task is at hand. (i.e.
rags, plastic bags, heavy duty cloth etc.)
Follow the mixing method outlined in the appropriate
technical datasheet to mix the material. Use only full bags
of product.
On completion of mixing make the cubes immediately. Do
not wait until the pour is complete and then cast the moulds.
It is recommended to make at least 2 cubes for each age of
test and curing regime. Recommended standard ages for
test are 1,3, 7 and 28 days although other ages can be cast
at the Engineer's discretion, provided sufficient moulds are
available.

Compact in the following manner for:

Grouts
Using the rubber hammer, tap the four corner of each
section of the mould until no air bubbles are seen to rise and
the grout is level. The corners should be completely filled.
The more fluid the product, the less taps are required.

Repair mortars
Using the square section tamper, rod with firm even
pressure over the entire surface of the mould 25 times. Do
not strike through the mortar as this can have the effect of
leaving holes behind after filling the second layer. At the
end of the tamping, lift and drop the mould through 10mm 5
times. This will ensure that any bubbles are forced out.
Repeat the process, again slightly overfilling the mould.
Strike off level with the top surface of the mould.
Immediately fit the top restraining plate and cover the whole
with a plastic sheet. Alternatively the moulds can be sealed
inside a plastic bag.
Clearly mark the moulds with the identification assigned to
that batch of cubes.
After 24 hours carefully strip the cubes from the moulds.
Set the mould sections aside in groups for easy cleaning
and re-assembly. Examine the cubes for any defects.
Reject any that do not look normal (e.g. have an excess of
surface voids or are not complete) and inform the
Laboratory Supervisor or Engineer. Mark on the surface of
each cube with the permanent marker, its' full identification
and the age for test. Do not scratch details onto the cube.
Immediately wrap each set of cubes in the heavy duty tissue
or absorbent cloth pre - soaked in water and seal inside the
polythene bag. Fold over the open end and seal it with
packing tape, such that a water tight and air tight seal is
formed. Repeat the identification marks on a self-adhesive
label for sticking on the polythene bag. Store the bag
containing the cubes carefully ,ensuring that it has no
punctures and cannot be punctured, away from sunlight or
other operations until ready for testing.

Grout and normal weight cubes may alternatively be stored

directly in water until ready for test. Follow the identification
procedures as above prior to immersion. Ensure the
marking medium is water proof. It is recommended that if
the cubes need to be transported to a testing house, they
are wrapped as described above for the journey.
Clean up
Carefully clean the mould sections with the wire brush and
lightly oil the sections before re-assembly. Ensure all joints
and internal faces are clean and there are no steps between
pieces. Ensure all fasteners are tightened correctly and the
corresponding matching sections are in their proper position.
Stack the moulds in a covered area away from the influence
of weather, dirt and other operations. Periodically check the
internal faces and joints dimensions for excessive wear. Do
not join non-matched sections,

Reporting
For each set of cubes made the following minimum
information should be available.
Name of product and manufacturer.
Manufacturer's batch identification.
Appearance of the powder (e.g. free flowing, lump free
etc.)
Quantity of mixing water per bag of product used for
mixing. (and temperatures where required)
Cube identification marks and number made for each
age of test. (These must be unique to each set of cubes)
Time of casting the cubes.
Temperature at time of manufacture.
Temperature and conditions under which the cubes were
stored.
Address of testing house.
Comment on appearance of cubes at stripping.
Position reference where product was used and quantity
represented by the cube test.
Name, signature and position of the person making the
cubes.
Name, signature and position of the Supervisor.

For reference cubes should be crushed within the following

time limits after casting.
1 day
3 days
7 days
28 days

23.5 - 24.5 hours

71.0 - 73.0 hours
7 days 3 hours
28 days 4 hours

The cubes should be crushed in accordance with BS 1881,

Part 116 ASTM C109 or DIN standards using a compression
test machine with ranges suitable for the maximum strength
and cube size of the material under test.
Reporting
Cube identification and age of test.
Cube dimensions in three directions to the nearest
0.5mm.
Cube weight.
Density (either from cube weight or weight in air and
water).
Crushing load in kN.
Compressive strength in N/mm.
Type of failure observed.
Name, position and signature of technician carrying out
the testing.
Name, position and signature of Supervisor.
11/94 Degussa-UAE revised 08/95

Cube crushing
The cubes should be transported to the testing house if this
is not at the site of the cube manufacture, at least 1 day
prior to the crushing time. Grout cubes and normal weight
mortar cubes should be stripped from the paper and plastic
wrapping and stored in water until ready for crushing.

Degussa Construction Chemicals UAE LLC

P.O. Box 37127, Dubai, UAE
Tel: +971 4 8851000

Fax: +971 4 8851002

www.degussa-cc.ae

e-mail: [email protected]

Whilst any information contained herein is true, accurate and

represents our best knowledge and experience, no warranty is given or
implied with any recommendations made by us, our representatives or
distributors, as the conditions of use and the competence of any labour
involved in the application are beyond our control.

Certificate No.
963680

As all Degussa technical datasheets are updated on a regular basis it is the user's responsibility to obtain the most recent issue.

Certificate No.
945787

Certificate No.
772556