Registration ame

No.
2008 – CIVIL – / Sec:

LAB MANUAL
PLAIN AND REINFORCED CONCRETE – I
 PREFACE

This manual has been prepared keeping in view the basic requirements of concrete technology. This is
to be used up to the beginner’s level in concrete materials study. Various books and research papers
have been consulted while preparing this manual. If some errors are found then kindly inform the
author on the email address shown below.

This manual contains the basic theoretical information extracted from books, the apparatus required
for an experiment, the procedure and calculation of the experiments.
 TABLE OF CONTENTS

1 Introduction to Concrete:.................................................................................................................1
2 Job No. 2..........................................................................................................................................9
3 Job No. 3........................................................................................................................................12
4 Job No. 4........................................................................................................................................16
5 Job No. 5........................................................................................................................................23
6 Job No. 6........................................................................................................................................27
7 Job No. 7........................................................................................................................................32
8 Job No. 8........................................................................................................................................35
9 Job No. 9........................................................................................................................................48
10 Job No. 10......................................................................................................................................51
11 Job No. 11......................................................................................................................................53
12 Job No. 12......................................................................................................................................60
13 Job No. 13......................................................................................................................................63
 Plain and Reinforced Concrete – 1 Job No. 1

INTRODUCTION TO CONCRETE:
Concrete is the most commonly used construction material these days. This is a plastic material that
possesses transit properties (properties that change with time) i.e. strength, hardness, ductility, fluidity
etc.

1.1 Definition:

Concrete is a mixture of coarse aggregate, fine aggregate/fillers, cement and water

Being more specific,

Concrete is a transient material comprised of coarse aggregates, matrix and ITZ (Interfacial
transition zone)

Let us discuss the individual items,

a. Coarse Aggregates:

Coarse aggregates constitute the largest portion of the concrete. The main purpose of coarse
aggregates is to provide strength. In normal strength concrete compressive strength is mainly
contributed by the coarse aggregates.

These are the particles retained on sieve # 4 (with an opening of 5mm). There is no set upper limit
on the size of particles but usually an upper limit of 50mm (2in) is considered.

b. Matrix

In simple words we can say that matrix is a mixture of all constituents of concrete other than the
coarse aggregates. This contains the binding material, fillers, water, admixtures and additives etc.
Each of these have been explained below,

i. Binding Material:

This is the component that holds primarily the coarse aggregate particles together. All the
particles in concrete are held together by this component. The function of binding material
can be defined as it provides confinement to coarse and fine aggregate particles.

In case of concrete confinement is of utmost importance. It can be understood by the

following example,

If we place coarse aggregate particles in a mold (form work) and test that in a machine, it
will provide some strength. But if the aggregates are tried to be tested without the mold, it
would be very difficult to hold them at their location. Before the machine can apply the
load the coarse aggregate particles will drop down. Hence, for testing coarse aggregates
these should be put in some mold. The mold provides confinement to the aggregates.

The most commonly used binding material in concrete is Portland cement (ordinary
cement) and the resulting concrete is called, ordinary Portland cement (OPC)
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Plain and Reinforced Concrete – 1 Job No. 1

There are different types of cement,

Type-I (Normal strength cement)

Type-II (Moderate sulfate resistant cement)

Type-III (High early strength cement)

Type-IV (Low heat of hydration cement)

Type-V (Sulfate resistant cement)

ii. Fillers:

Fillers are mainly used to fill the gaps between the coarse aggregate particles. These
provide better packing and economize the concrete production by reducing the amount of
cement required.

The most commonly used filler is sand/fine aggregate. In road construction stone dust is
also used. In high strength concrete, where binders and fillers are equally important in
achieving strength as the coarse aggregates, some other types of filler material like quartz
sand is used to fill in the gaps between the fine aggregate particles.

iii. Water:

Water is a very important constituent of concrete. It is provided for two main reasons, first
one is the hydration process and second one is the workability of concrete.

Water is required for the hydration process. It reacts with cement and forms calcium
hydrate silicate gel that provides the binding property. Further it acts as a lubricant
between different particles present in concrete and allows them to move while in fresh
state. This makes it possible to pour concrete in the form work.

Workability and hydration processes have been explained later.

iv. Admixtures:

Admixtures are the ingredients that are used to change properties like workability, flow,
setting time etc.

These are mostly mixed with water and added to concrete at a later stage of mixing (in
high strength concrete these are usually added in the second step to form a paste with
powdered substances)

Some common types of admixtures are,

a. Water Reducing Admixtures (plasticizers and super plasticizers):

These are used for increasing workability with constant amount of water. The
excessive amount of water can render the concrete weak as after the evaporation of
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Plain and Reinforced Concrete – 1 Job No. 1

extra water voids are left behind that cause serious reduction in strength by two
main processes. First one is the direct effect on compressive strength due to
reduction in area of concrete available at a section. Secondly the voids allow the
entrance of harmful chemicals that can either affect the cement or aggregates or
cause corrosion of steel present in form of tensile reinforcement.

b. Retarding admixtures:

Retarding admixtures are used to delay the setting time of cement. This provides
extra time to use concrete especially in those construction projects where concrete
batching plants are installed at a large distance from the site. In such projects
transportation takes a lot of time. Concrete cannot be used after the initial setting
time of cement. So in order to delay this initial setting time of cement retarders are
used.

c. Accelerating Admixtures:

Accelerators are used to reduce the setting time of cement. This type of admixtures
is usually used while concreting in cold regions where the setting of cement occurs
at a slow rate. This may also be used to speed up the construction process in order
to use the same formwork on upper stories or to open a project earlier for public
(e.g. repair or new construction of a bridge)

d. Corrosion inhibiting admixtures:

Corrosion inhibiting admixtures are added to avoid the corrosion of steel.

Corrosion of steel affects the strength of reinforced cement concrete in two ways.
By reducing the area of steel required to resist the applied tensile stresses and by
reducing the grip of concrete over steel that ensures the transfer of tensile stresses
from concrete to steel.

v. Additives:

These are the substances used to increase the strength of concrete. These can be pozzolanic
materials like silica fumes, fly ash or other materials like matakaolin or even powdered
fillers like quartz powder that fill in the gaps between binder particles.

These are usually added in dry state along with the other binding materials like cement.

c. Interfacial transition zone:

This is the boundary zone between the matrix and coarse aggregates. The study of this boundary is
very important especially in high strength concrete where the function of matrix is equally
important as that of coarse aggregates.

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 Plain and Reinforced Concrete – 1 Job No. 1

1.2 Proportioning of concrete materials:

Proportioning of different materials is very important to achieve a material with desired strength
and properties. For example a concrete with less amount of coarse aggregate particles will provide
less strength. Similarly a concrete with less amount of matrix will not be able to move in the form
work and settle properly.

Knowing the properties of each of the constituents of concrete, the amount of all components is
decided. The process is call concrete mix design covered in experiment number 7.

1.3 Hydration of cement:

Hydration process is the one in which cement reacts with water to form a paste known as calcium
hydrate silicate gel responsible for providing the binding property.

The hydration pro ess begins as soon as the water is added to cement. The main components of
cement and their role in hydration has been briefly explained below,

i. C3S : 4.07(CaO)-7.6((SiO2)-6.72((Al2O3)-1.43 (Fe2O3)-2.85(SO3)

ii. C2S : 2.87(SiO2)-0.7 54(3CaO.Si O2)
iii. C3A : 2.6
65(Al2O3)-1 .69(Fe2O3)
iv. C4AF : 33.04 (Fe2O3)

• (i & ii) Ca & Si reacts first & start the hydration process

• (iii & iv) R eacts to givee hydration & give finall setting timee

1.4 Workability of concrete:

This can be defined as,

Glanville, et al. (1947),

The amount of work needed to produce full compaction

ACI, 1990

That property of freshly mixed concrete or mortar which determines the ease and homogeneity with
which it can be mixed, placed, consolidated and finished.

ASTM, 1993

That property determining the effort required to manipulate a freshly mixed quantity of concrete
with minimum loss of homogeneity.

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Plain and Reinforced Concrete – 1 Job No. 1

a. Measurement of Workability:

Workability can be by different techniques such as,

 Slump test.
Concrete is filled in a cone with proper compaction. The cone is removed and the drop in
height of concrete is noted down.
For further explanation go to experiment number 8

Fig from Concrete Properties by John Newman

 Compacting factor test.

Concrete is filled in the first bucket out of the two or three in series. The concrete is
allowed to drop from the first bucket to second and then to the mold. This is called
partially compacted concrete. The weight of concrete in this partially compacted state is
compared with the fully compacted weight in form of a ratio called compacting factor
value.
For further explanation go to exp riment number 9

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Plain and Reinforced Concrete – 1 Job No. 1

Fig from Concrete Properties by John Newman

 VB test.
In this test the concrete is place in a mold with a plate at the top. Vibrations are provided
until the concrete gets fully settled. The time is noted down.

Fig from Concrete Properties by John Newman

 Flow table test.

The concrete is placed on a table by using a cone. Then top surface of table is lifted and
dropped for specific number of times and the spread of concrete is noted down.

Fig from Concrete Properties by John Newman

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Plain and Reinforced Concrete – 1 Job No. 1

 Slump flow test.

In this test the concrete slump test is performed but instead of determining the drop in
height, spread of concrete is measured.

Fig from Concrete Properties by John Newman

 Degree of compactability test.

In this test concrete is filled in a mold which is provided vibrations for a specific time.
Then the drop in height of concrete is noted down.

Fig from Concrete Properties by John Newman

The workability is lost due to the following reasons,

 Mix water being absorbed by the aggregate if this not in a saturated state before mixing
 Evaporation of the mix water
 Early hydration reactions (but this should not be confused with cement setting)

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 Plain and Reinforced Concrete – 1 Job No. 1

 Interactions between admixtures (particularly plasticizers and superplasticizers) and the

cementitious constituents of the mix.

1.5 Placing and Finishing concrete:

By placing and finishing we mean how to put concrete in the mold and how to get the final shape
and finish. The basic process is that concrete is poured in the form work by concrete pump of
buckets. Then it is consolidated (vibrations are provided by external or internal vibraters i.e.
vibrating table & pokers/niddle vibraters)

There are a few things to be considered while working with concrete,

 The concrete should be discharged as close as possible to its final position, preferably straight
into the formwork
 A substantial free-fall distance will encourage segregation and should therefore be avoided
 With deep pours, the rate of placing should be such that the layer of concrete below that being
placed should not have set; this will ensure full continuity between layers, and avoid cold
joints and planes of weakness in the hardened concrete
 Once the concrete is in place, vibration, either internal or external, should be used to mold the
concrete around embedments e.g. reinforcement, and to eliminate pockets of entrapped air, but
the vibration should not be used to move the concrete into place
 High-workability mixes should not be over vibrated – this may cause segregation.

1.6 Curing of concrete:

As we know that water is added for workability and hydration. So if water is not available for
hydration, strength will be compromised. We also studied that water is lost (loss of workability) is
due to water absorption and evaporation. This loss of water is to be compensated by either adding
extra amount of water or preventing the already present amount of water from evaporating. This
process is called curing.

Different techniques used in curing are,

 Adding extra water by spraying and covering the concrete by gunny bags etc.
 By allowing water to stand on the roofs
 By covering concrete by polythene sheets in order to prevent water from escaping by
evaporation.

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 Plain and Reinforced Concrete – 1 Job No. 2

JOB NO. 2

Standard Test Method for the Determination of The Normal Consistency Of The Hydraulic
Cement.

Code: ASTM C 187-04

2.1 Scope and Significance:

It is used to find out the perc ntage of water at which the standard consistency is achieved. This
known amount of water is then used in making the cement paste for the other tests like;

i. Initial setting time

ii. Final setting time

iii. Soundness test

2.2 Apparatus:

 Reference Masses and Devices for Determining Mass

 VICAT Apparatus
 Plunger with 10mm diameter and 50mm length
 Glass graduates (200mL or 250mL capacity)
 Spatula
 Glass plate trowel

2.3 Related theory:

a. Consistency

The thickness or the viscosity of the cement paste is called consistency.

b. Cement paste

The viscous mass obtained by mixing cement with water is known as cement paste.

c. Standard paste

It is the cement paste for which the 10mm diameter plunger in a standard VICAT test penetrates to
such an extent that its distance from the bottom is 5-7mm.

d. Standard/Normal consistency

It is the thickness or the viscosity of the standard paste and is expressed as the percentage of weight
of water.

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 Plain and Reinforced Concrete – 1 Job No. 2

e. Vicat’s apparatus

The Vicat’s apparatus consists of a frame A (Fig.)

bearing a movable rod B, weighing 300 g, one end C, the
plunger end, being 10 mm in diameter for a distance of at
least 50 mm, and the other end have a removable needle D,
1 mm in diameter and 50 mm in length. The rod B is reversible,
and can be held in any desired position by a set screw E,
and has an adjustable indicator F, which moves over a scale
(graduated in millimeters) attached to the frame A. The
paste is held in a rigid conical ring G, resting on a plane
non-absorptive square base plate H, about 100 mm on each
side.
The rod B is made of stainless steel having a
hardness of not less than 35 HRC, and shall be straight with
the plunger end which is perpendicular to the rod axis. The
ring is made of a non-corroding, nonabsorbent material, and have an inside diameter of 70 mm at the
base and 60 mm at the top, and a height of 40 mm. In addition to the above, the Vicat apparatus shall
conform to the following requirements:
Weight of moveable rod = 300±5 gm
Diameter of the plunger end of the rod = 10±0.05 mm
Diameter of the needle = 1±0.05 mm
Inside diameter of the ring at the bottom = 70±3 mm
Inside diameter of the ring at the top = 60±3 mm
Height of the ring = 40±3 mm

2.4 Test specifications:

a. Temperature & humidity

The temperature of the air in the vicinity should be between 20-27.5 °C. The temperature of the
mixing water should be 23±2 °C.

The relative humidity of the laboratory should not be less than 50%.

b. Amount of cement

Amount of cement required for the test according to various specifications are mentioned below.

BS = 500gm

ASTM = 650gm

c. Mixing time

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 Plain and Reinforced Concrete – 1 Job No. 2

The cement paste must be properly mixed and placed in the test specimen within a maximum time of
4±1/4 min from the instant when cement and water were initially brought in contact.

2.5 Procedure:

Mix 650gm of cement with a measured quantity of water and make a cement paste as per the standard
procedure. Put the cement paste in the ring of the vicat apparatus and remove the excess paste with the
help of a trowel. Center the paste confined in the ring, resting on the plate, under the rod B and bring
the plunger end C of in contact with the surface of the paste, and tighten the set-screw E. Then set the
movable indicator F to the upper zero mark of the scale, or take an initial reading, and release the rod
immediately. This must not exceed 30 s after completion of mixing. The apparatus shall be free of all
vibrations during the test.
The paste of normal consistency is achieved when the rod settles to a point such that it is 4-7mm
above the bottom surface in 30 s after being released. Make trial pastes with varying percentages of water
until the normal consistency is obtained. Make each trial with fresh cement.

2.6 Observations and Calculations:

Cement Brand =…………………………………

Trial
Weight of Weight/Volume of Mixing Scale
Sr. # Moisture Temperature
Cement Water Time Reading
Content
(gm) (%) (1gm = 1mL) (°C) (min) (mm)

Achieved Standard Consistency =……………………..%

2.7 Comments:

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 Plain and Reinforced Concrete – 1 Job No. 3

JOB NO. 3

Standard Test Method For The Determination Of The Initial And Final Setting Time Of The
Hydraulic Cement By Vicat Needle Apparatus.

Code: ASTM C 191-04b

3.1 Scope & significance:

This test method is used to determine the time of setting of the hydraulic cement by Vicat needle
apparatus

The knowledge of the setting time of the cement is always helpful in deciding the time duration to
mix, transport, place and compact the concrete effectively.

We always prefer a larger initial setting time so that we can mix, transport and place the concrete
easily. According to ASTM specifications, the initial setting time shall not be less than 30min but in the
field we prefer an initial setting time not less than 45min.

A smaller value of the final setting time is always preferred in order to avoid large expenditures on the
formwork. According to most of the specifications, the final setting time shall not be greater than 10hrs
and shall not be less than ( 90 + 1.2 x (initial setting time) ) min.

i.e. ( 90 + 1.2 x (initial setting time) ) min < final setting time < 10hrs

3.2 Apparatus:

 Vicat apparatus
 Needle of 1mm2 cross-section and 50mm length (for initial setting time)
 Plunger with 1mm smaller needle and 5mm outer diameter (for final setting time)
 Flat trowel
 Reference Masses and Devices for Determining Mass
 Spatula
 Graduated cylinders

3.3 Related theory:

a. Setting

In the setting process very little chemical reaction takes place. It only includes the shape
acquisition due to evaporation of water. During the setting process the cement remains in the fluid or the
semi-fluid state and there is very little or no gain in strength. Finer the cement particles more will be the
hydration and therefore it will lead to quick settlement.

b. Hardening

Hardening is the rate of gain of strength due to the chemical reaction. It also refers to the
strength of the concrete after a specified interval of time.

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 Plain and Reinforced Concrete – 1 Job No. 3

c. Initial setting time

The time elapsed between the initial contact of cement and water and the time when a 1mm2 cross-
section needle gives a reading between 4-7mm from the bottom in a standard Vicat apparatus is known as
initial setting time of that particular cement paste.

d. Final setting time

It is the time elapsed between the initial contact of cement and water and the time when the smaller
needle (1mm2 cross-section and 1mm deep) completely penetrates into the paste and the outer metal
attachment of 5mm diameter does not leave an impression on the cement paste.

According to specifications;

Maximum final setting time = 10hrs

Minimum final setting time = [90 + 1.2 (initial setting time)] min

3.4 Test specifications:

a. Needle sizes

1- For Initial Setting Time

1mm x 1mm cross-section

50mm length

2- For Final Setting Time

1mm2 cross-section and 1mm deep inner needle

5mm diameter outer metal attachment

b. Mixing water

Portable water is satisfactory for the routine tests.

c. Temperature & humidity

The temperature of the air in the vicinity should be between 23±3 °C. The temperature of the mixing
water should be 23±2 °C.

The relative humidity of the laboratory should not be less than 50%.

d. Amount of cement

Amount of cement required for the test according to various specifications are mentioned below.
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 Plain and Reinforced Concrete – 1 Job No. 3

BS = 500gm

ASTM = 650gm

3.5 Procedure:

Prepare a cement paste of standard consistency and put it in the ring of the Vicat apparatus within the
allowable time of 4±1/4 min. Clear and level any extra paste by means of a trowel.

1- Initial Setting Time

Determine the penetration of the 1-mm needle at the start. If a penetration reading of 4-7mm is
obtained then note down the time as the initial setting time otherwise keep checking the penetration
reading after every 10min thereafter until a penetration reading of 4-7 mm is obtained which will be the
initial setting time of the cement.
Make each penetration test at least 5 mm away from any previous penetration and at least 10 mm
away from the inner side of the mold.
2- Final Setting Time

Now fix the final setting time plunger in which the smaller needle has the diameter of 1mm and the
diameter of the outer needle is 5mm. Drop the rod of the Vicat apparatus and note down the time when
the smaller 1mm diameter needle completely penetrates into the paste and the outer needle leaves no
impression on the cement surface.

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 Plain and Reinforced Concrete – 1 Job No. 3

3.6 Observations and Calculations:

Initial setting time =

Final s tting time =

3.7 Comments:

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 Plain and Reinforced Concrete – 1 Job No. 4

JOB NO. 4

Determination of the Fineness Modulus of the Coarse And Fine Aggregate From Different
Sources.

Code: ASTM C-316-05, for coarse materials (i.e. > 15μm)

ASTM C-117-05, for fine materials (i.e. < 15μm)

4.1 Scope & significance:

This test method is used to determine the fineness modulus of the given fine grained specimen.

The information obtained from fineness modulus is helpful in the following ways;

1- Fineness modulus tells us directly whether the material is well-graded or gap-graded.

2- Fineness modulus gives us an overall idea whether the material is fine or coarse.
3- It also indicates the surface area of the particles.
1
Surface Area 
Fineness Modulus

Lower the surface area of the aggregate, the required amount of fresh cement paste to cover
the aggregate particles will be less and thus less water is
required.

4- Larger value of FM is preferred for fine aggregates.

For a good fine aggregate, the FM should be
between 2.3 and 3.1 (ASTM Range for fine
aggregates).

4.2 Apparatus:

 Standard set of sieves

 Sieve shaker
 Sample of the aggregate

4.3 Related theory:

a. Fineness modulus

It is the cumulative percentage retained on standard sieve 150μm and above divided by 100.

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 Plain and Reinforced Concrete – 1 Job No. 4

It is a single factor or an empirical number which we get from the results of sieve analysis. The value
of FM will not change if we add sieves above.

b. Sieve analysis

It is the operation of dividing the aggregate into various fractions, each consisting of particles of same
size.

OR

It is the operation of determining the particle size distribution of the given specimen.

The standard approach is to designate the sieve sizes by nominal aperture sizes in mm or μm
(micron).

1 mm = 1000 μm (micron)

Notes:

i- 5 mm is the dividing line between coarse and fine aggregate.

ii- Well graded coarse aggregates of large size will reduce shrinkage of concrete by 50%.

c. Functions of sieve analysis

Sieve analysis is performed on coarse and fine aggregates in order to check their gradation. This
gradation gives an indirect measure if the workability and average particle size.

d. Set of sieves

The set of sieves used for the process of sieve analysis can be categorized as;

a- Fine Aggregates
ASTM Sieves British Standard Sieves

(mm) (inches)

4.75mm 3/16 (#4)

2.36mm 3/32 (#8)
1.18mm 3/64 (#16)
600μm 3/128 (#30)
300μm 1/88 (#50)
150μm 1/176 (#100)
Pan Pan
Note: For the sieves with openings smaller than 4.75mm, the quantity retained on any sieve
at the completion of sieving shall not exceed 7 kg/m2 of sieving area.

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 Plain and Reinforced Concrete – 1 Job No. 4

b- Coarse Aggregates
Standard Non-Standard

75mm (3 ”)
63mm
50mm
37.5mm (1½ ”)
25mm
19mm (3/4 ”)
9.5mm (3/8 ”)
4.75mm (3/16 ”)
2.36mm (3/32 ”)
Pan
Note: For sieves with openings 4.75mm & larger, the quantity retained in kg shall not
exceed the product of

2.5 x sieve opening (mm) x effective sieving area (mm2)

e. Quality of a good sample

There are some limiting values for every sieve provided by ASTM or BS, we use these limiting values
to get our final answer by the method explained below.

Take the minimum and the maximum values provided by ASTM and plot them on the grading curve.
Now take these minimum and maximum value lines as your reference and if the curve of our own data
lies inside these two lines then the quality of our sample is OK but if your curve lies outside these two
lines of maximum and minimum range then the sample is not according to specifications.

Maximum limit according to specification

Cumulative % Passing

Plot of tested specimen

Minimum limit according to specification

Sieve Size (Log Scale)

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 Plain and Reinforced Concrete – 1 Job No. 4

f. ASTM grading requirements for fine aggregates

Cumulative % Passing
Sieve Size
Minimum Maximum

9.5mm 100 100

4.75mm 95 100

2.36mm 80 100

1.18mm 50 85

600μm 25 60

300μm 10 30

150μm 2 10

4.4 Procedure:

Take 2 kg of the oven-dried sample. The sample should be perfectly dry

because if there is some moisture content present then the particles will stick
together and will not pass through the sieves.

Temperature of the oven = 110±5 °C

Place the set of standard and non-standard sieves one above another
with the smallest aperture opening at the bottom. The pan is placed at the
bottom-most position. This experiment can be performed manually or with
the aid of a machine called “sieve shaker”.

The manual method should be performed in a proper sequence which is

as follows; Mechanical Sieve

i- forward and backward motion

ii- left and right motion
iii- clockwise (CW) and counter-clockwise (CCW) motion
iv- Frequent jolting.
Time elapsed for the sieving process is 3-5 minutes.

Weigh the mass retained on each sieve and calculate the percentage passing through each sieve. Then
the FM can be calculated by using the relation;

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Plain and Reinforced Concrete – 1 Job No. 4

FM 
(Cumulative % Re tained on S tan dard Sieves of 150 m or above)
100

Following points must be kept in mind while calculating the FM;

i- Only sum up the values of standard sieves and do not include the values of the non-
standard sieves.
ii- Only add the sieves of 150μm and above sizes.
iii- If any standard sieve is missing, we may use the value of next higher sieve.
iv- Adding extra sieves does not change the result of FM.

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 Plain and Reinforced Concrete – 1 Job No. 4

4.5 Observations and Calculations:

Sample no. 1:…………………………………………………………..

SIEV MASS % CUMULATIV CUMULATIV

SIEVE # E RETAINE RETAINE E% E%
SIZES D D RETAINED PASSING
(opening
(mm
s per
or (gm) (%) (%) (%)
linear
μm)
inch)
3 75
1½ 37.5
3/4 19
3/8 9.5
3/16 4.75
3/32 2.36
Pan Pan

FM 
(...........................................)  ................
100

Sample no. 2:…………………………………………………………..

SIEV MASS % CUMULATIV CUMULATIV

SIEVE # E RETAINE RETAINE E% E%
SIZES D D RETAINED PASSING
(opening
(mm
s per
or (gm) (%) (%) (%)
linear
μm)
inch)
3 75
1½ 37.5
3/4 19
3/8 9.5
3/16 4.75
3/32 2.36
Pan Pan

FM 
(...........................................)  ................
100
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 Plain and Reinforced Concrete – 1 Job No. 4

Sample no. 3:…………………………………………………………..

SIEV MASS % CUMULATIV CUMULATIV

SIEVE # E RETAINE RETAINE E% E%
SIZES D D RETAINED PASSING
(opening
(mm
s per
or (gm) (%) (%) (%)
linear
μm)
inch)
3 75
1½ 37.5
3/4 19
3/8 9.5
3/16 4.75
3/32 2.36
Pan Pan

FM 
(...........................................)  ................
100

4.6 Comments:

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 Plain and Reinforced Concrete – 1 Job No. 5

JOB NO. 5

Standard Test Method for the Determination of Bulk Density (I.E. Unit Weight and the Voids in
Aggregates).

Code: ASTM C-29/C-29M

5.1 Scope & significance:

This test method is used to determine the bulk density of the given fine grained specimen.

During the concrete mix design, when the aggregate is to be batched by volume or by weight, then it
becomes necessary to know the mass of the aggregates that will fill the container of unit volume. If we
know the bulk density of the aggregate material then we can easily determine the mass required to fill a
unit volume container.

Bulk density also indicates the percentage of voids present in the aggregate material. This
percentage of voids affects the grading of the aggregates which is important in high strength concrete.

Bulk density also indicates the compactive effort required to compact the concrete.

5.2 Apparatus: Tempingg

 Balance
 Temping rod d=225mm d=16
mm
 Measuring Cylinder 600
 Shovel or Scoop
V 27
=

a
Measuring Temping
R d
5.3 Related theory:

a. Bulk density

It is the mass of the unit volume of bulk aggregate material.

The term volume includes the volume of the individual particles and the volume of the voids between
the particles.

Bulk density is used in weight and volume batching.

b. Voids

It is the space between the individual particles in a unit volume of the aggregate mass and is not
occupied by the solid mineral matter.

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 Plain and Reinforced Concrete – 1 Job No. 5

Voids within the particles, either permeable or impermeable are not included in the voids for the
determination of bulk density by this method.

c. Absolute density

It is the mass per unit volume of the individual particles only.

d. Facts about bulk density

Bulk density depends upon how densely the aggregate is packed. It also depends upon the size,
distribution and shape of the particles. If the particles are of the same size, then it can be packed to a
limited extent but when the smaller particles are added, the voids get filled with them and thus the bulk
density increases.

For a coarse aggregate, a higher bulk density means that there are few voids which are to be filled by
the fine aggregate and cement. Thus bulk density also depends upon the degree of packing.

5.4 Procedure:

Note down the dimensions and empty weight of the measuring container and compute its volume.
For the determination of the loose bulk density, fill the container with the aggregate material by means of
a shovel and level its top surface. Weigh the container filled with the aggregate and note down its reading.
Then the loose bulk density of the aggregate material can be computed by using the relation;

(Weight of container  Loose aggregate)  (Weight of empty container)

Loose Bulk Density(M loose ) 
Volume of the container

Now for the determination of the compacted bulk

density, t e only difference is in filling the container. In this
case, the container is filled in three equal layers. Fill the
container about one-third full and level the surface with the
fingers. Rod the layer of the aggregate with 25 strokes of the
temping rod evenly distributed over the surface. Next fill the
container two-third full and again rod it with 25 strokes
of the temping rod. Finally, fill the container to
overflowing and rod again in the manner previously
mentioned.

Now level the top surface and weigh the container. Calculate the compacted bulk density by using
the relation;

(Weight of container  Compacted aggregate)  (Weight of empty container)

Compacted Bulk Density(M comp ) 
Volume of the container

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 Plain and Reinforced Concrete – 1 Job No. 5

5.5 Observations and Calculations:

MEASURING CYLINDER FOR COARSE AGGREGATE

Diameter =……………………… Height =………………………

Volume =………………………

MEASURING CYLINDER FOR FINE AGGREGATE

Diameter =……………………… Height =………………………

Volume =………………………

VOLUME
SAMPLE WEIGHT OF OF WEIGHT OF WEIGHT OF BULK
AGG. +
STATE CONTAINER CONTAINER CONT. AGGREGATE DENSITY
3
(kg) (m ) (kg) (kg) (kg/m3)
COARSE AGGREGATE
LOOSE
COMPACTED
LOOSE
COMPACTED
FINE AGGREGATE
LOOSE
COMPACTED
LOOSE
COMPACTED

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 Plain and Reinforced Concrete – 1 Job No. 5

COMPARISON TABLE:

COMPACTED INCREASE
Sr. LOOSE BULK %
SAMPLE BULK IN BULK
NO. DENSITY INCREASE
DENSITY DENSITY

5.6 Comments:

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 Plain and Reinforced Concrete – 1 Job No. 6

JOB NO. 6
Standard Test Method For The Determination Of Relative Density (I.E. Specific Gravity) And
Water Absorption Of The Coarse Aggregates.

Code: ASTM C-127-04

6.1 Scope & significance:

In this test method we determine the relative density (i.e. specific gravity) and the water absorption of
the coarse aggregates.

The information obtained from specific gravity is helpful in the following ways;

1- The knowledge of the specific gravity is important for the concrete technologist to determine
the properties of concrete made from such aggregates.
2- It is used for the calculation of the volume occupied by the aggregates in various mixtures.
3- The pores at the surface of the particles affect the bond between the aggregate and the cement
paste and thus influence the concrete strength.
4- Normally it is assumed that at the time of setting of concrete, the aggregate is in the saturated
and surface dry condition. If the aggregate is to be batched in the dry condition, then it is
assumed that sufficient amount of water will be absorbed from the mix to bring the aggregate
in the saturated condition. If an additional amount of water is not added as a cover for the
absorbed water, the loss of workability is resulted.
Limitation

The limitation of the test is that, it can not be used for the light weight aggregates.

6.2 Apparatus:

 Balance
 Sample container
 Water tank
 Sieves
 Oven

6.3 Related theory:

a. Aggregates

Aggregates may be classified as;

i- Coarse Aggregates
ii- Fine Aggregates

b. Coarse aggregates

Any material which is retained on BS sieve #4 (ASTM sieve 4.75mm) is known as coarse aggregate.

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Plain and Reinforced Concrete – 1 Job No. 6

c. Fine aggregates

Any material which is passing BS sieve #4 (ASTM sieve 4.75mm) is known as fine aggregate.

d. Types of crush available in Pakistan

1- SARGODHA CRUSH

Sargodha crush possess the following properties;

 Greener in color
 High strength
 Usually elongated particles
2- MARGHALLA CRUSH

Marghalla crush possess the following

properties;

 Grayish in color
 Low in strength
3- SAKHI SARWAR CRUSH

Sakhi Sarwar crush possess the following properties;

 Whitish in color

e. Absorption

It is the increase in the mass of the aggregate due to the penetration of water into the pores of the
particles during a prescribed period of time.

The term absorption does not include the amount of water adhering to the surface of the particles.
Water absorption is expressed as percentage of the dry mass.

f. Saturated surface dry (s.s.d.) condition

It is the condition related with the aggregate particles in which the permeable pores of the aggregate
particles are filled with water but without free water on the surface of the particles.

g. Oven dry density

It is the mass of the oven dried aggregate per unit volume of the aggregate particles.

The term volume includes the volume of the permeable and the impermeable pores and does not
include the volume of the voids between the particles.

h. Saturated surface dry (s.s.d) density

It is the mass of the saturated surface dry aggregate per unit volume of the aggregate particles.

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 Plain and Reinforced Concrete – 1 Job No. 6

The term volume includes the volume of the permeable and the impermeable pores which are filled
with water and does not include the volume of the voids between the particles.

i. Apparent density

It is the mass per unit volume of the impermeable portion of the aggregate particles.

OR

It is the mass per unit volume of the solid portion of the particles excluding the voids.

j. Specific gravity/relative density

It is the ratio of the density of the aggregate material to the density of the gas free distilled water at a
standard temperature (i.e. 4 oC).

The relative density is a dimensionless quantity and is expressed as oven dried, saturated surface dry
and apparent

k. Oven dried specific gravity

It is the ratio of the oven dried density of the aggregate to the density of the gas free distilled water at
a standard temperature (i.e. 4 oC).

l. Saturated surface dry specific gravity

It is the ratio of the saturated surface dry density of the aggregate to the density of the gas free
distilled water at a standard temperature (i.e. 4 oC).

m. Apparent specific gravity

It is the ratio of the apparent density of the aggregate to the density of the gas free distilled water at a
standard temperature (i.e. 4 oC).

6.4 Procedure:

The sample of the aggregate is immersed in water for 24hrs to essentially fill all the pores. Remove the
test sample from the water and roll it in a large absorbent cloth until all visible films of water are
removed. Wipe the larger particles individually. A moving stream of air is permitted to assist in the
drying operation. Take care to avoid evaporation of water from aggregate pores during the surface-
drying operation. Determine the mass of the test sample in the saturated surface-dry condition. Record
this and all subsequent masses to the nearest 0.5 g or 0.05 % of the sample mass, whichever is greater.
In order to calculate the volume of the aggregate, immediately place the saturated-surface-dry test
sample in the sample container and determine its apparent mass in water at 23±2.0 °C. Take care to
remove all entrapped air before determining its mass by shaking the container while immersed. The
difference between the mass in air and the mass when the sample is immersed in water equals the mass
of water displaced by the sample. This mass of water equals the volume of water displaced because

ρwater = mwater x Vwater

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 Plain and Reinforced Concrete – 1 Job No. 6

mwater = Vwater (ρwater=1 gm/cm3)

Vwater = Vaggregate

Dry the test sample in the oven to constant mass at a temperature of 110±5 °C, cool in air at
room temperature 1 o 3 h, or until the aggregate has cooled to a temperature that is comfortable to
handle (approximately 50 °C), and determine the mass in order to calculate the oven specific gravity of
the specimen.

6.5 Observations and Calculations:

TABLE NO. 1: CALCULATION OF SPECIFIC GRAVITY

Volume
Volume Specific
Weight of Volume of
of Gravity
SAMPLE AGG. Wagg of
WATER
AGGREG
=Wagg/V
WATER ATE
+ AGG. agg
Vagg
(gm) (mL) (mL) (mL)

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 Plain and Reinforced Concrete – 1 Job No. 6

TABLE NO. 2: CALCULATION OF WATER ABSORPTION

WATER
WT. OF ABSORPTION
SSD OD
SAMPLE ABSORBED = (SSD WT - OD
WEIGHT WEIGHT
WATER WT) X 100 (SSD
WT)
(GM) (GM) (GM)

6.6 Comments:

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 Plain and Reinforced Concrete – 1 Job No. 7

JOB NO. 7

Determination of The Aggregate Impact Value Of Different Coarse Aggregate Samples.

7.1 Scope & significance:

The aggregate impact value gives a relative measure of the toughness or the resistance of aggregate
sudden shock or impact is not proportional to the resistance to a slowly applied compressive load.

7.2 Apparatus:

 Coarse aggregate from various sources

 Impact testing machine
 Spanner
 Balance

7.3 Test specifications:

The test sample shall consist of aggregates the whole of which passes through ½ in B.S. test sieve and
is retained on a 3/8 in B.S. test sieve. The aggregate comprising the test sample shall be dried in an oven for a
period of four hours at a temperature of 100-110 C and cooled.
The measure (cup) shall be filled about one-third full with the aggregate and gives 25 tamping rod. A further
similar quantity of aggregate shall be added and a further 25 tamping given to the second and tot the last
layer 25 tamping shall again be given and the surplus aggregate struck off using the tamping rod as a straight-
edge. The net weight of aggregate in the measure shall be determined to the nearest gram (weight A) and this
weight shall be used for the duplicate test on the same material.

7.4 Procedure:

The impact machine shall test without wedging or packing upon the level plate, block or floor, so that
it is rigid and hammer guide columns are vertical.
The cup shall be fixed firmly in position on the base of the machine and the whole of the test sample placed
in it and compacted by a single tamping of 25 strokes of the tamping rod.
The hammer shall be raised until its lower face is 15 in. above from the upper surface of the aggregate
in the cup, and allowed to fall freely on the aggregate. The test sample shall be subjected to a total 15 such
blows each being delivered at an interval of not less than one second.
The crushed aggregate shall then be removed from the cup and the whole of it sieved on No. 7 B.S. sieve
until no further significant amount passes in one minute. The fraction passing the sieve shall be weighted to
an accuracy of 0.1 gram (weight B). Te fraction retained on the sieve shall also be weighed (weight C), and if
the total weight B + C is less than the initial weight (weight A) by more than 1 gm the result shall be
discarded and a fresh test made. Two tests shall be made.

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 Plain and Reinforced Concrete – 1 Job No. 8

a. Calculations

The ratio of the weight of fines formed to the total sample weight in each test shall be expressed as a
percentage, the result being recorded to the first decimal place.
B
Aggregate Impact Value =  100.
A
Where, A = weight of oven dried sample

B = weight of fraction passing B.S. sieve No. 7

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 Plain and Reinforced Concrete – 1 Job No. 8

7.5 Observations and Calculations:

A = Total Wt. of the Sample

B = Fraction passing BS sieve #7 after crushing
B
Aggregate Impact Value = × 100
A

Cup Diameter =……………………….. Depth of Cup = ………………………..

Weight of Hammer = ……………………….. Drop Height = ………………………..

WT OF IMPACT
Sr EMPTY WT. OF SAMPLE VALUE
WT. OF SAMPLE + WT OF SAMPLE
# A= (W2-W1) PASSING BS
TYPE OF CRUSH CUP CUP B
N O. 7 S IEVE = ×100
“W 1 ” “W 2 ” A
B
gm gm gm gm %

7.6 Comments:

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 Plain and Reinforced Concrete – 1 Job No. 8

JOB NO. 8

Preparing A Concrete-Mix And Casting Various Samples Required For Different Tests.

Code: ACI 211.1 – 91

8.1 Scope & significance:

This purpose of this experiment is to simulate the actual formation of concrete mix, its design and
production. In this experiment certain number of samples will be prepared which will then be tested for the
verification of concrete mix design process.

8.2 Apparatus:

 Concrete Mixer
 Materials
o Cement
o Sand/Fine Aggregate
o Crush/Coarse Aggregate
o Water
 Molds for samples to be prepared
o Cylinders 300mm x 150mm Ø(10+2), compressive strength & split cylinder test
o Cylinders 150mm x 150mm Ø (2), double punch test
o Cubes 150mm (10), compressive strength
o Beams 76mm x 153mm x 1370mm (4), study of flexure behavior

8.3 Plain Cement Concrete:

PCC consists of three basic ingredients: aggregate, water and portland cement. According to the
Portland Cement Association (PCA, 1988):

"The objective in designing concrete mixtures is to determine the most economical and practical
combination of readily available materials to produce a concrete that will satisfy the performance
requirements under particular conditions of use."

PCC mix design has evolved chiefly through experience and well-documented empirical
relationships. Normally, the mix design procedure involves two basic steps:

i. Mix proportioning. This step uses the desired PCC properties as inputs then determines the
required materials and proportions based on a combination of empirical relationships and local
experience. There are many different PCC proportioning methods of varying complexity that
work reasonably well.
ii. Mix testing. Trial mixes are then evaluated and characterized by subjecting them to several
laboratory tests. Although these characterizations are not comprehensive, they can give the
mix designer a good understanding of how a particular mix will perform in the field during
construction and under subsequent traffic loading.

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 Plain and Reinforced Concrete – 1 Job No. 8

This section covers mix design fundamentals common to all PCC mix design methods. First, two
basic concepts (mix design as a simulation and weight-volume terms and relationships) are discussed
to set a framework for subsequent discussion. Second, the variables that mix design may manipulate
are presented. Third, the fundamental objectives of mix design are presented. Finally, a generic mix
design procedure is presented.

a. Basic Concepts

Before discussing any mix design specifics, it is important to understand a couple of basic mix design
concepts:

 Mix design is a simulation

 Weight-volume terms and relationships

i. Mix Design is a Simulation

First, and foremost, mix design is a laboratory simulation. Mix design is meant to simulate actual
PCC manufacturing, construction and performance. Then, from this simulation we can predict (with
reasonable certainty) what type of mix design is best for the particular application in question and how
it will perform.

Being a simulation, mix design has its limitations. Specifically, there are substantial differences
between laboratory and field conditions. For instance, mix testing is generally done on small samples
that are cured in carefully controlled conditions. These values are then used to draw conclusions
about how a mix will behave under field conditions. Despite such limitations mix design procedures
can provide a cost effective and reasonably accurate simulation that is useful in making mix design
decisions.

ii. Weight-Volume Terms and Relationships

The more accurate mix design methods are volumetric in nature. That is, they seek to combine the
PCC constituents on a volume basis (as opposed to a weight basis). Volume measurements are
usually made indirectly by determining a material's weight and specific gravity and then calculating
its volume. Therefore, mix design involves several key aggregate specific gravity measurements.

b. Variables

PCC is a complex material formed from some very basic ingredients. When used in pavement, this
material has several desired performance characteristics - some of which are in direct conflict with
one another. PCC pavements must resist deformation, crack in a controlled manner, be durable over
time, resist water damage, provide a good tractive surface, and yet be inexpensive, readily made and
easily placed. In order to meet these demands, mix design can manipulate the following variables:

i. Aggregate. Items such as type (source), amount, gradation and size, toughness and abrasion
resistance, durability and soundness, shape and texture as well as cleanliness can be measured,
judged and altered to some degree.

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Plain and Reinforced Concrete – 1 Job No. 8

ii. Portland cement. Items such as type, amount, fineness, soundness, hydration rate and
additives can be measured, judged and altered to some degree.
iii. Water. Typically the volume and cleanliness of water are of concern. Specifically, the volume
of water in relation to the volume of portland cement, called the water-cement ratio, is of
primary concern. Usually expressed as a decimal (e.g., 0.35), the water-cement ratio has a
major effect on PCC strength and durability.
iv. Admixtures. Items added to PCC other than portland cement, water and
aggregate. Admixtures can be added before, during or after mixing and are used to alter basic
PCC properties such as air content, water-cement ratio, workability, set time, bonding ability,
coloring and strength.

c. Objectives

By manipulating the mixture variables of aggregate, portland cement, water and admixtures, mix
design seeks to achieve the following qualities in the final PCC product (Mindess and Young, 1981):

i. Strength. PCC should be strong enough to support expected traffic loading. In pavement
applications, flexural strength is typically more important than compressive strength (although
both are important) since the controlling PCC slab stresses are caused by bending and not
compression. In its most basic sense, strength is related to the degree to which the portland
cement has hydrated. This degree of hydration is, in turn, related to one or more of the
following:
o Water-cement ratio. The strength of PCC is most directly related to its capillary
porosity. The capillary porosity of a properly compacted PCC is determined by its
water-cement ratio (Mindess and Young, 1981). Thus, the water-cement ratio is an
easily measurable PCC property that gives a good estimate of capillary porosity
and thus, strength. The lower the water-cement ratio, the fewer capillary pores and
thus, the higher the strength. Specifications typically include a maximum water-
cement ratio as a strength control measure.

o Entrained air (air voids). At a constant water-cement ratio, as the amount of

entrained air (by volume of the total mixture) increases, the voids-cement ratio
(voids = air + water) decreases. This generally results in a strength
reduction. However, air-entrained PCC can have a lower water-cement ratio than
non-air-entrained PCC and still provide adequate workability. Thus, the strength
reduction associated with a higher air content can be offset by using a lower water-
cement ratio. For moderate-strength concrete (as is used in rigid pavements) each
percentile of entrained air can reduce the compressive strength by about 2 - 6
percent (PCA, 1988).
o Cement properties. Properties of the portland cement such as fineness and
chemical composition can affect strength and the rate of strength gain. Typically,
the type of portland cement is specified in order to control its properties.
ii. Controlled shrinkage cracking. Shrinkage cracking should occur in a controlled
manner. Although construction techniques such as joints and reinforcing steel help control
shrinkage cracking, some mix design elements influence the amount of PCC
shrinkage. Chiefly, the amount of moisture and the rate of its use/loss will affect shrinkage
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Plain and Reinforced Concrete – 1 Job No. 8

and shrinkage cracking. Therefore, factors such as high water-cement ratios and the use of
high early strength portland cement types and admixtures can result in excessive and/or
uncontrolled shrinkage cracking.
iii. Durability. PCC should not suffer excessive damage due to chemical or physical attacks
during its service life. As opposed to HMA durability, which is mainly concerned with aging
effects, PCC durability is mainly concerned with specific chemical and environmental
conditions that can potentially degrade PCC performance. Durability is related to:
o Porosity (water-cement ratio). As the porosity of PCC decreases it becomes more
impermeable. Permeability determines a PCC's susceptibility to any number of
durability problems because it controls the rate and entry of moisture that may
contain aggressive chemicals and the movement of water during heating or freezing
(Mindess and Young, 1981). The water-cement ratio is the single most
determining factor in a PCC's porosity. The higher the water-cement ratio, the
higher the porosity. In order to limit PCC porosity, many agencies specify a
maximum allowable water-cement ratio.

o Entrained Air (Air voids). Related to porosity, entrained air is important in

controlling the effects of freeze-thaw cycles. Upon freezing, water expands by
about 9 percent. Therefore, if the small capillaries within PCC are more than 91
percent filled with water, freezing will cause hydraulic pressures that may rupture
the surrounding PCC. Additionally, freezing water will attract other unfrozen
water through osmosis (PCA, 1988). Entrained air voids act as expansion
chambers for freezing and migrating water and thus, specifying a minimum
entrained air content can minimize freeze-thaw damage.

o Chemical environment. Certain chemicals such as sulfates, acids, bases and

chloride salts are especially damaging to PCC. Mix design can mitigate their
damaging effects through such things as choosing a more resistant cement type.
iv. Skid resistance. PCC placed as a surface course should provide sufficient friction when in
contact with a vehicle's tire. In mix design, low skid resistance is generally related to
aggregate characteristics such as texture, shape, size and resistance to polish. Smooth,
rounded or polish-susceptible aggregates are less skid resistant. Tests for particle shape and
texture can identify problem aggregate sources. These sources can be avoided, or at a
minimum, aggregate with good surface and abrasion characteristics can be blended in to
provide better overall characteristics.
v. Workability. PCC must be capable of being placed, compacted and finished with reasonable
effort. The slump test, a relative measurement of concrete consistency, is the most common
method used to quantify workability. Workability is generally related to one or more of the
following:
o Water content. Water works as a lubricant between the particles within
PCC. Therefore, low water content reduces this lubrication and makes for a less
workable mix. Note that a higher water content is generally good for workability
but generally bad for strength and durability, and may cause segregation and
bleeding. Where necessary, workability should be improved by redesigning the
mix to increase the paste content (water + portland cement) rather than by simply
adding more water or fine material (Mindess and Young, 1981).

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Plain and Reinforced Concrete – 1 Job No. 8

o Aggregate proportion. Large amounts of aggregate in relation to the cement paste

will decrease workability. Essentially, if the aggregate portion is large then the
corresponding water and cement portions must be small. Thus, the same problems
and remedies for "water content" above apply.
o Aggregate texture, shape and size. Flat, elongated or angular particles tend to
interlock rather than slip by one another making placement and compaction more
difficult. Tests for particle shape and texture can identify possible workability
problems.
o Aggregate gradation. Gradations deficient in fines make for less workable
mixes. In general, fine aggregates act as lubricating "ball bearings" in the
mix. Gradation specifications are used to ensure acceptable aggregate gradation.
o Aggregate porosity. Highly porous aggregate will absorb a high amount of water
leaving less available for lubrication. Thus, mix design usually corrects for the
anticipated amount of absorbed water by the aggregate.
o Air content. Air also works as a lubricant between aggregate particles. Therefore,
low air content reduces this lubrication and makes for a less workable mix. A
volume of air-entrained PCC requires less water than an equal volume of non-air-
entrained PCC of the same slump and maximum aggregate size (PCA, 1988).
o Cement properties. Portland cements with higher amounts of C3S and C3A will
hydrate quicker and lose workability faster.

Knowing these objectives, the challenge in mix design is then to develop a relatively simple procedure
with a minimal amount of tests and samples that will produce a mix with all the qualities discussed
above.

d. Basic Procedure

In order to meet the requirements established by the preceding desirable PCC properties, all mix
design processes involve four basic processes:

i. Aggregate selection. No matter the specific method, the overall mix design procedure begins
with evaluation and selection of aggregate and asphalt binder sources. Different authorities
specify different methods of aggregate acceptance. Typically, a battery of aggregate physical
tests is run periodically on each particular aggregate source. Then, for each mix design,
gradation and size requirements are checked. Normally, aggregate from more than one source
is required to meet gradation requirements.
ii. Portland cement selection. Typically, a type and amount of portland cement is selected based
on past experience and empirical relationships with such factors as compressive strength (at a
given age), water-cement ratio and chemical susceptibility.
iii. Mix proportioning. A PCC mixture can be proportioned using experience or a generic
procedure (such as ACI 211.1).

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 Plain and Reinforced Concrete – 1 Job No. 8

iv. Testing. Run laboratory tests on properly prepared samples to determine key mixture
characteristics. It is important to understand that these tests are not comprehensive nor are
they exact reproductions of actual field conditions.

The selected PCC mixture should be the one that, based on test results, best satisfies the mix design
objectives.

8.4 Concrete Mix Design:

The American Concrete Institute (ACI) mix design method is but one of many basic concrete mix
design methods available today. This section summarizes the ACI absolute volume method because it
is widely accepted in the U.S. and continually updated by the ACI. Keep in mind that this summary
and most methods designated as "mix design" methods are really just mixture proportioning
methods. Mix design includes trial mixture proportioning (covered here) plus performance tests.

This section is a general outline of the ACI proportioning method with specific emphasis on PCC for
pavements. It emphasizes general concepts and rationale over specific procedures. Typical
procedures are available in the following documents:

 The American Concrete Institute's (ACI) Standard Practice for Selecting Proportions for
Normal, Heavyweight, and Mass Concrete (ACI 211.1-91) as found in their ACI Manual of
Concrete Practice 2000, Part 1: Materials and General Properties of Concrete.
 The Portland Cement Association's (PCA) Design and Control of Concrete Mixtures, 14th
edition (2002) or any earlier edition.

The standard ACI mix design procedure can be divided up into 8 basic steps:

a. Choice of slump
b. Maximum aggregate size selection
c. Mixing water and air content selection
d. Water-cement ratio
e. Cement content
f. Coarse aggregate content
g. Fine aggregate content

h. Adjustments for aggregate moisture

a. Slump

The choice of slump is actually a choice of mix workability. Workability can be described as a
combination of several different, but related, PCC properties related to its rheology:

 Ease of mixing
 Ease of placing
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Plain and Reinforced Concrete – 1 Job No. 8

 Ease of compaction
 Ease of finishing

Generally, mixes of the stiffest consistency that can still be placed adequately should be used (ACI,
2000). Typically slump is specified, but Table 5.14 shows general slump ranges for specific
applications. Slump specifications are different for fixed form paving and slip form paving. Table
5.15 shows typical and extreme state DOT slump ranges.

Table 5.14: Slump Ranges for Specific Applications (after ACI, 2000)

Slump
Type of Construction
(mm) (inches)
Reinforced foundation walls
25 - 75 1-3
and footings
Plain footings, caissons and
25 - 75 1-3
substructure walls
Beams and reinforced walls 25 - 100 1-4
Building columns 25 - 100 1-4
Pavements and slabs 25 - 75 1-3
Mass concrete 25 - 50 1-2

Table 5.15: Typical State DOT Slump Specifications (data taken from ACPA, 2001)

Fixed Form Slip Form

Specifications
(mm) (inches) (mm) (inches)
Typical 25 - 75 1-3 0 - 75 0-3
as low as as low as as low as as low as
25 1 0 0
Extremes
as high as as high as as high as as high as
175 7 125 5

b. Maximum Aggregate Size

Maximum aggregate size will affect such PCC parameters as amount of cement paste, workability and
strength. In general, ACI recommends that maximum aggregate size be limited to 1/3 of the slab
depth and 3/4 of the minimum clear space between reinforcing bars. Aggregate larger than these
dimensions may be difficult to consolidate and compact resulting in a honeycombed structure or large

Page | 41
Plain and Reinforced Concrete – 1 Job No. 8

air pockets. Pavement PCC maximum aggregate sizes are on the order of 25 mm (1 inch) to 37.5 mm
(1.5 inches) (ACPA, 2001).

c. Mixing Water and Air Content Estimation

Slump is dependent upon nominal maximum aggregate size, particle shape, aggregate gradation, PCC
temperature, the amount of entrained air and certain chemical admixtures. It is not generally affected
by the amount of cementitious material. Therefore, ACI provides a table relating nominal maximum
aggregate size, air entrainment and desired slump to the desired mixing water quantity. Table 5.16 is
a partial reproduction of ACI Table 6.3.3 (keep in mind that pavement PCC is almost always air-
entrained so air-entrained values are most appropriate). Typically, state agencies specify between
about 4 and 8 percent air by total volume (based on data from ACPA, 2001).

Note that the use of water-reducing and/or set-controlling admixtures can substantially reduce the
amount of mixing water required to achieve a given slump.

Table 5.16: Approximate Mixing Water and Air Content Requirements

for Different Slumps and Maximum Aggregate Sizes (adapted from ACI, 2000)

Mixing Water Quantity in kg/m3 (lb/yd3) for the listed Nominal

Maximum Aggregate Size
9.5 12.5 19 25 37.5 50 75 100
mm mm mm mm mm mm mm mm
Slump
(0.375 (0.5 (0.75 (1 (1.5 (2 (3 (4
in.) in.) in.) in.) in.) in.) in.) in.)
Non-Air-Entrained PCC
25 - 50 207 199 190 179 166 154 130 113
(1 - 2) (350) (335) (315) (300) (275) (260) (220) (190)
75 - 100 228 216 205 193 181 169 145 124
(3 - 4) (385) (365) (340) (325) (300) (285) (245) (210)
150 - 175 243 228 216 202 190 178 160
-
(6 - 7) (410) (385) (360) (340) (315) (300) (270)
Typical
entrapped air 3 2.5 2 1.5 1 0.5 0.3 0.2
(percent)
Air-Entrained PCC
25 - 50 181 175 168 160 148 142 122 107
(1 - 2) (305) (295) (280) (270) (250) (240) (205) (180)
75 - 100 202 193 184 175 165 157 133 119
(3 - 4) (340) (325) (305) (295) (275) (265) (225) (200)
150 - 175 216 205 197 184 174 166 154
-
(6 - 7) (365) (345) (325) (310) (290) (280) (260)
Recommended Air Content (percent)
Mild Exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0

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Plain and Reinforced Concrete – 1 Job No. 8

Moderate
6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Exposure
Severe
7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0
Exposure

d. Water-Cement Ratio

The water-cement ratio is a convenient measurement whose value is well correlated with PCC
strength and durability. In general, lower water-cement ratios produce stronger, more durable
PCC. If natural pozzolans are used in the mix (such as fly ash) then the ratio becomes a water-
cementitious material ratio (cementitious material = portland cement + pozzolonic material). The ACI
method bases the water-cement ratio selection on desired compressive strength and then calculates the
required cement content based on the selected water-cement ratio. Table 5.17 is a general estimate of
28-day compressive strength vs. water-cement ratio (or water-cementitious ratio). Values in this table
tend to be conservative (ACI, 2000). Most state DOTs tend to set a maximum water-cement ratio
between 0.40 - 0.50 (based on data from ACPA, 2001).

Table 5.17: Water-Cement Ratio and Compressive Strength Relationship

(after ACI, 2000)

28-Day Water-cement ratio by weight

Compressive
Strength in MPa Non-Air- Air-
(psi) Entrained Entrained

41.4 (6000) 0.41 -

34.5 (5000) 0.48 0.40
27.6 (4000) 0.57 0.48
20.7 (3000) 0.68 0.59
13.8 (2000) 0.82 0.74

e. Cement Content

Cement content is determined by comparing the following two items:

 The calculated amount based on the selected mixing water content and water-cement ratio.
 The specified minimum cement content, if applicable. Most state DOTs specify minimum
cement contents in the range of 300 - 360 kg/m3 (500 - 600 lbs/yd3).

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Plain and Reinforced Concrete – 1 Job No. 8

An older practice used to be to specify the cement content in terms of the number of 94 lb. sacks of
portland cement per cubic yard of PCC. This resulted in specifications such as a "6 sack mix" or a "5
sack mix". While these specifications are quite logical to a small contractor or individual who buys
portland cement in 94 lb. sacks, they do not have much meaning to the typical pavement contractor or
batching plant who buys portland cement in bulk. As such, specifying cement content by the number
of sacks should be avoided.

f. Coarse Aggregate Content

Selection of coarse aggregate content is empirically based on mixture workability. ACI recommends
the percentage (by unit volume) of coarse aggregate based on nominal maximum aggregate size and
fine aggregate fineness modulus. This recommendation is based on empirical relationships to produce
PCC with a degree of workability suitable for usual reinforced construction (ACI, 2000). Since
pavement PCC should, in general, be stiffer and less workable, ACI allows increasing their
recommended values by up to about 10 percent. Table 5.18 shows ACI recommended values.

Table 5.18: Volume of Coarse Aggregate per Unit Volume of PCC

for Different Fine aggregate Fineness Moduli for Pavement PCC (after ACI, 2000)

Nominal Maximum Fine Aggregate Fineness Modulus

Aggregate Size 2.40 2.60 2.80 3.00
9.5 mm (0.375 inches) 0.50 0.48 0.46 0.44
12.5 mm (0.5 inches) 0.59 0.57 0.55 0.53
19 mm (0.75 inches) 0.66 0.64 0.62 0.60
25 mm (1 inches) 0.71 0.69 0.67 0.65
37.5 mm (1.5 inches) 0.75 0.73 0.71 0.69
50 mm (2 inches) 0.78 0.76 0.74 0.72
Notes:

1. These values can be increased by up to about 10 percent for

pavement applications.
2. Coarse aggregate volumes are based on oven-dry-rodded
weights obtained in accordance with ASTM C 29.

g. Fine Aggregate Content

At this point, all other constituent volumes have been specified (water, portland cement, air and coarse
aggregate). Thus, the fine aggregate volume is just the remaining volume:

Unit volume (1 m3 or yd3)

- Volume of mixing water
- Volume of air
- Volume of portland cement
- Volume of coarse aggregate

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 Plain and Reinforced Concrete – 1 Job No. 8

Volume of fine aggregate

h. Adjustments for Aggregate Moisture

Unlike HMA, PCC batching does not require dried aggregate. Therefore, aggregate moisture content
must be accounted for. Aggregate moisture affects the following parameters:

1. Aggregate weights. Aggregate volumes are calculated based on oven dry unit weights, but
aggregate is typically batched based on actual weight. Therefore, any moisture in the
aggregate will increase its weight and stockpiled aggregates almost always contain some
moisture. Without correcting for this, the batched aggregate volumes will be incorrect.

Amount of mixing water. If the batched aggregate is anything but saturated surface dry it will absorb
water (if oven dry or air dry) or give up water (if wet) to the cement paste. This causes a net change in
the amount of water available in the mix and must be compensated for by adjusting the amount of
mixing water added.

8.5 Concrete Mix Design and Material Calculation Example:

i. Required Data:

fc' = 30 Mpa
Concrete type = Non air entrained
Maximum aggregate size = 20 mm
Slump required = 30-80 mm
Fineness Modulus of Fine aggregate = 2.82
Bulk density of coarse aggregate = 1555 kg/m3
Bulk density of fine aggregate = 1070.16 kg/m3
Specific gravity of cement = 3.15
Specific gravity of coarse aggregate = 2.6
Specific gravity of fine aggregate = 2.63
Water absorption of coarse aggregate = 0.9 %
Water absorption of fine aggregate = 1.2 %

ii. Calculations:
a. Calculation for target strength:

Fcr' = 38.3

b. Selection of type of cement:

Use ordinary Portland Cement

c. Durability check:

Use ordinary Portland Cement

d. Relative water content:

Water content = 92 %

e. Water amount:

Page | 45
Plain and Reinforced Concrete – 1 Job No. 8

Water suggested = 200 kg/m3

Air content = 2 %
Water content = 184 kg/m3

f. Calculation of water/cement ratio:

w/c = 0.437

g. Cement content:

Cement content = 421.053 kg/m3

h. Bulk volume of aggregate:

Bulk vol.of agg. = 0.618

i. Weight of coarse aggregate:

Wt. of coarse agg. = 960.99 kg/m3

j. Weight of fine aggregate:

Wt. of fine agg. = 769.856 kg/m3

k. Water after considering water absorption:

Water absorbed by C.A= 8.64891 kg/m3

Water absorbed by F.A= 9.23827 kg/m3
Water content required = 202 kg/m3

l. Weight of ingredients (kgs):

Cement: 421.053
Coarse Agg.: 960.99
Fine Agg.: 769.856
Water: 202

m. Concrete Mix:

Cement Fine Agg. Coarse Agg.

421.053 769.856 960.99
1 1.83 2.28

W/C = 0.53

Concrete weight = 2353.9 kg/m3

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Plain and Reinforced Concrete – 1 Job No. 8

n. Calculation of materials required

Volume of Total Weight

Size
Sample Quantity Concrete of Concrete
(mm)
(m3) (kgs)
Beam 4 76 × 153 × 1370 0.01593 76.5
Cylinder 12 150Ø × 300 0.005301 51
Cylinder 2 150Ø × 150 0.005301 51
Cube 10 150 × 150 × 150 0.003375 32.5

Total concrete required = 160 kg (assumed value)

Allowance for wastage (10%) = 160 × 1.1 = 176 kg
Maximum capacity of the mixer = 125 kg
Number of batches = 176 / 125 = 1.408 = 2 batches
Quantity required per batch = 176 / 2 = 88 kg
Weight of the concrete constituents:
1
1. Cement =  88  17.22 kg  18 kg
1  1.83  2.28
1.83
2. Fine Aggregate =  88  31.52 kg  31.6 kg
1  1.83  2.28
2.28
3. Coarse Aggregate =  88  39.26 kg  39.5 kg
1  1.83  2.28
4. Water = 0.53 × 18 = 9.54 kg ≈ 10 kg (Including allowance for wetting the sides of mixer)

Page | 47
 Plain and Reinforced Concrete – 1 Job No. 10

JOB NO. 9

Standard Test Method for The Slump Of Hydraulic Cement Concrete.

Code: ASTM C-143/C-143 M-03

9.1 Scope & significance:

This test method is used in lab and in field for finding out the slump (decrease in the height of
concrete when we lift up the mould). This test is used extensively in site works all over the world. The
slump test does not measure the workability of concrete directly but it co-relates the workability with
some physical measurement.

The main significance of this test is as follows;

1- This test method is used to determine the slump of plastic hydraulic cement concrete.

Slump<15mm (Non-Plastic)

Slump>15 (Plastic)

2- This test method is applicable to plastic concrete having coarse aggregate upto 37.5mm in size. If
the coarse aggregate is larger than the 37.5mm then this test method is not applicable.

3- This test method is not applicable to non-plastic and non-cohesive concrete (due to larger amount
of water presence).

9.2 Apparatus:

1- Metal mould, thickness is 1.15mm, it is in cone form with the base 200mm diameter and 300mm
height with the top diameter 100mm. the top and base of cylindrical mould is open and parallel to
each other. The mould is provided with foot pieces and handles.
2- Temping rod, 16mm diameter and 600mm in length having temping ends.

9.3 Related theory:

a. Slump

The decrease in the height of concrete when the mould of standard dimensions is lifted.

b. Types of slump

There are three types of slump.

1- True Slump
2- Shear Slump
3- Collapse slump
u
Slump

160mm Page | 48
 Plain and Reinforced Concrete – 1 Job No. 10

 We discard the collapse slump due to the very high value of slump
 Shear slump occurs due to the lack of cohesion in mix.
 We often use the term 100% compaction but actually in 100% compaction we have percentage of
air voids less than 3% by volume of concrete.

c. Relation between workability and slump

Workability Compacting Factor Slump (mm)

Very Low 0.78 0-25

Low 0.85 25-50

Medium 0.92 50-100

High 0.95 100-175

Note: More is the slump value more will be the workability.

9.4 Procedure:

The mold is placed on a flat moist non-absorb surface with the smaller opening at the top. It is then held
firmly in place during filling of concrete by the operator standing on two foot pieces. The mould is filled
to a depth of 70mm and 2/3 of volume fills to a depth of 160mm. Each layer is given 25 strokes with the
help of temping rod uniformly distributed over the cross-section of each layer. Rod the 2nd and 3rd layer
throughout its depth so that strokes just penetrates into the under lying layer. After the top layer is rodded
strike off the surface of the concrete by means of rolling motion of temping rod.

Complete the entire test with an elapsed time of 2.5minutes. After filling, the cone is slowly lifted and
the unsupported concrete slumps. The decrease in the height of concrete is called slump.

It is measured with the nearest 5mm. at the beginning of every test, before lifting the mould the area
immediately around the base of the cone should be cleaned off of concrete which may be dropped
accidentally.

Page | 49
 Plain and Reinforced Concrete – 1 Job No. 10

9.5 Observations and Calculations:

Slump Value = mm

9.6 Comments:

Page | 50
 Plain and Reinforced Concrete – 1 Job No. 10

JOB NO. 10
To Perform The Compacting Factor Test.

10.1 Scope & significance:

This test also gives the workability of concrete indirectly. This test is appropriate for concrete with
the maximum aggregate size of 40mm.

10.2 Apparatus:
250
Apparatus consists of two
hoppers each in the shape of
frustum of a cone and one Upper 275

cylinder.
125
The hoppers have hinge door at Same the
Lower dimensions
bottom and all the surfaces are
polished to reduce friction.
200
Cylinder
150mm
m
dia

10.3 Related theory:

a. Compacting factor

The degree of compaction is also called the compacting factor and is measured with the help of
density ratio that is the ratio of density actually achieved in the test to the density of same concrete when
it is fully compacted.

Its maximum answer is 1 but practically it is lesser than 1.

b. RELATION BETWEEN WORKABILITY AND COMPACTING FACTOR

Workability Compacting Factor Slump(mm)

Very Low 0.78 0-25

Low 0.85 25-50

Medium 0.92 50-100

High 0.95 100-175

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 Plain and Reinforced Concrete – 1 Job No. 10

Note: More is the compacting factor more will be the workability.

10.4 Procedure:

First the concrete is placed gently at the upper hopper so that no work is done on concrete to
produce compaction. The bottom door of the upper hopper is then released and the concrete falls into
the lower hopper. The bottom door of the lower hopper is then released and the concrete falls into the
cylinder. Excess concrete is then removed from the cylinder.

The density of concrete in now calculated and this density divided by the density of fully compacted
concrete is known as compacting factor.

More is the compacting factor more will be the workability.

10.5 Observations and Calculations:

Compacting Factor Value = mm

10.6 Comments:

Page | 52
 Plain and Reinforced Concrete – 1 Job No. 11

JOB NO. 11

Test Method For The Flexural Strength Of Concrete Using Simple Beam With Third-Point
Loading.

Code: ASTM C 78 - 02

11.1 Scope & significance:

 This test method is used to determine the flexural strength of specimens prepared and cured in
accordance with the specifications. Results are calculated and reported as the modulus of rupture.
 The strength determined will vary where there are differences in specimen size, preparation, moisture
condition, curing, or where the beam has been molded or swayed to size.
 The results of this test method may be used to determine compliance with specifications or as a basis
for proportioning, mixing and placement operations. It is used in testing concrete for the construction
of slabs and pavements.
 The modulus of rupture is also used as an indirect measure of the tensile strength of concrete.

11.2 Apparatus:

 Universal Testing Machine

 Supporting Beam and Roller/hinge supports
 Third point loading arrangement

The testing apparatus is shown in the figure above.

11.3 Related Theory:

a. Difficulties in Determining Tensile Strength of Concrete:

There are considerable experimental difficulties in determining the true tensile strength of concrete. In
direct tension test following are the difficulties:

1. When concrete is gripped by the machine it may be crushed due the large stress concentration
at the grip.
2. Concrete samples of different sizes and diameters show large variation in results.
3. If there are some voids in sample the test may show very small strength.
4. If there is some initial misalignment in fixing the sample the results are not accurate.

Page | 53
Plain and Reinforced Concrete – 1 Job No. 11

b. Tests For Tensile Strength of Concrete:

Following tests are used to determine the tensile strength of concrete.

 Split Cylinder Test

 Double Punch Test
 Modulus of Rupture Test

c. Modulus of Rupture:

In a flexural test on a plane concrete specimen, the maximum tensile stress reached at the bottom fiber
of a standard size prism (beam) under predefined loading type is called modulus of rupture.

d. Type/Size of The Specimen for The Test:

The specimen used is a prism, square in cross-section and having a certain length. There are two
standard sizes of the specimen that can be used for specified aggregate sizes.

1- 150 x 150 x 750 (mm)

2- 100 x 100 x 510 (mm)
The size (150 x 150 x750 mm) can be used for all sizes of the aggregate particles.

The size (100 x 100 x 510 mm) can only be used for the aggregate sizes less than 25mm.We are using
this size for our test.

e. Average Value Of MOR (fr):

There are some relationships which relate fr with compressive strength of concrete

fr = 0.69 √ fc’

fc’ and fr are in MPa

ACI code gives formulae for fr

fr = 0.5 √ fc’ (ACI code for Strength Calculation)

fr = 0.625 √ fc’ (ACI code for Deflection Control)

Generally,

Tensile Strength  Compressive Strength

Page | 54
Plain and Reinforced Concrete – 1 Job No. 11

As a rough estimate, we take 8 – 15% of compressive strength as the MOR.

f. Modulus of Rupture of a Prismoidal Beam:

The MOR for the test specimen can be computed by using the relation derived below;

Two point loading

Yd
2
My
fr 
I
where,
3
bd 3 I bd 12  bd 2
I  and s   
12 y d 6
2

M M P 6
 fr    a 2
I s 2 bd
y
3Pa (MPa )
 fr 
bd 2

Page | 55
 Plain and Reinforced Concrete – 1 Job No. 11

11.4 Test specifications:

a. Rate of loading:

The rate of loading should be such that we get a stress of 0.02― 0.10 (MPa/s).

b. Acceptance Criteria of The Specimen:

If proper compaction is not done, then the specimen may fail outside the central portion i.e. near the
ends.

In such a case, if;

i- (a – a’) > 0.05 l → Ignore the specimen and discard the results.

ii- (a – a’) =< 0.05 l → Use the same formula but instead of a, use a’ for the calculation of
MOR.

Where a’= distance from the support center to the crack

a = one-third distance between the supports

l = distance between the supports

The final result should be reported in multiples of 0.1 MPa.

c. Size of the specimen:

The specimen used is a prism of 100 x 100 (mm) square in cross-section and having a length of
510mm.

Thus the dimensions of the specimen are;

100 x 100 x 510 (mm)

d. Type of loading:

Page | 56
 Plain and Reinforced Concrete – 1 Job No. 11

The loading pattern on the beam is called the third-point/two-point loading. The main advantage of
third-point loading is that, the behavior of the beam can be studied under pure bending as there is no
shear at the central portion of the beam. The phenomenon is depicted by the figure below.
P
P P

5 41 5
P P
51

136.6 136.66 136.6

M
B. +
0 0

S. + +
0

No shear iin the central portion.

bending

11.5 Procedure

When using molded specimens, turn the test specimen on its side with respect to its position as
molded and center it on the support blocks. When using sawed specimens, position the specimen so
that the tension face corresponds to the top or bottom of the specimen as has been cut from the parent
material. Center the loading system in relation to the applied force. Bring the load-applying blocks in
contact with the surface of the specimen at the third points and apply a load of between 3 and 6 % of
the estimated ultimate load.

Grind, cap, or use leather shims on the specimen contact surface to eliminate any gap in excess of
0.004 in. (0.10 mm) in width. Gaps in excess of 0.015 in. (0.38 mm) shall be eliminated only by
capping or grinding. Grinding of lateral surfaces should be minimized in as much as grinding may
change the physical characteristics of the specimens. Capping shall be in accordance with the
applicable sections of Practice C 617.
Page | 57
Plain and Reinforced Concrete – 1 Job No. 11

Load the specimen continuously and without shock. The load shall be applied at a constant rate to the
breaking point. Apply the load at a rate that constantly increases the extreme fiber stress between 125
and 175 psi/min (0.86 and 1.21 MPa/min) until rupture occurs. The loading rate is calculated using
the following equation:

a. Calculations:

Case — 1:

If the fracture initiates in the tension surface within the middle third of the span length, calculate
the modulus of rupture as follows:

R = PL/bd2
where:
R = modulus of rupture, psi, or MPa,
P = maximum applied load indicated by the testing machine, lbf, or N,
L = span length, in., or mm,
b = average width of specimen, in., or mm, at the fracture, and
d = average depth of specimen, in., or mm, at the fracture.

Note: The weight of the beam is not included in the above calculation.

Case — 2:

If the fracture occurs in the tension surface outside of the middle third of the span length by not
more than 5 % of the span length, calculate the modulus of rupture as follows:

R = 3Pa`/bd 2
where:
a` = average distance between line of fracture and the nearest support measured on the
tension surface of the beam, (in or mm).

Note: The weight of the beam is not included in the above calculation.

Case — 3:

If the fracture occurs in the tension surface outside of the middle third of the span length by more
than 5 % of the span length, discard the results of the test.

Page | 58
 Plain and Reinforced Concrete – 1 Job No. 11

11.6 Observations & calculations:

Max. Applied
a' a – a' M.O.R Mean
Sr.# Load Acceptance

(kg) (N) (mm) (mm) (MPa) (MPa)

11.7 Comments:

Page | 59
 Plain and Reinforced Concrete – 1 Job No. 12

JOB NO. 12

Standard Test Method For The Determination Of The Splitting Tensile Strength
Of Cylindrical Concrete Specimen.
Code: ASTM C 496/C 496 M-04

12.1 Scope & significance:

This test method is used for the determination of splitting tensile strength of cylindrical concrete
specimen.
Splitting tensile strength is helpful for the following purposes;
1- Splitting tensile strength is generally greater than the direct tensile strength and lower than
the flexural strength (modulus of rupture).
2- Splitting tensile strength is used in the design of structural light weight concrete members
to evaluate the shear resistance provided by concrete and to determine the development
length of the reinforcement.

2P
T
ld

where,
T = Splitting tensile strength (to be reported in 0.05 MPa multiples)
P = Applied load
l = length of the specimen (mm)
d = Diameter of the specimen (mm)

12.2 Apparatus:

 Testing Machine
 Supplementary Bearing Bar Or Plates (If the diameter or the largest dimension of the upper bearing face or the
lower bearing block is less than the length of the cylinder to be tested, a
supplementary bearing bar or plate of machined steel shall be used. The
bar or plate shall be manner that the load will be applied over the
specimen.)
 Bearing Strips (Two bearing strips of nominal 1 /8 in [3.2 mm] thick plywood, free of
imperfections, approximately 1 in. [25 mm] wide, and of a length equal to,
or slightly longer than, that of the specimen shall be provided for each
specimen. The bearing strips shall be placed between the specimen and
both the upper and lower bearing blocks of the testing machine or
between the specimen and supplemental bars or plates, when used (see
5.2). Bearing strips shall not be reused.)

Page | 60
 Plain and Reinforced Concrete – 1 Job No. 12

12.3 Test specifications:

a. Size of the specimen

The specimen is a cylinder of 150mm diameter and 300mm height.

d= 150mm

30

Standard

Determine the diameter to the nearest 0.25mm by averaging the three diameters. Determine the
length to the nearest 2mm by averaging at least two lengths.

b. Size of bearing strips

According to ASTM specifications, the bearing strips should be 3.2mm thick and 25mm wide. There
is no restriction on their length.

c. Rate of loading

The rate of loading should be such that a stress of 0.7 – 1.4

MPa/min is produced.

12.4 Procedure:

This test method consists of applying a diametrical

force along the length of a cylindrical concrete at a rate that is
within a prescribed range until failure. This loading induces
tensile stresses on the plane containing the applied load and
relatively high compressive stresses in the area
immediately around the applied load.

Although we are applying a compressive

load but due to Poisson’s effect, tension is
produced and the specimen fails in tension. Tensile
failure occurs rather than compressive failure
because the areas of load application are in a state
of triaxial compression, thereby allowing them to
withstand much higher compressive stresses than
would be indicated by a uniaxial compressive
strength test result.

Page | 61
 Plain and Reinforced Concrete – 1 Job No. 12

Thin, plywood bearing strips are used to distribute the load applied along the length of the
cylinder.

The maximum load sustained by the specimen is divided by appropriate geometrical factors to
obtain the splitting tensile strength.

12.5 Calculations

Calculate the splitting tensile strength of the specimen as follows:

2P
T=
ld

where:
T = splitting tensile strength, (psi or MPa),
P = maximum applied load indicated by the testing machine, (lbf or N), l
= length, (in. or mm), and
d = diameter, (in. or mm).

12.6 Observations and Calculations:

Length Splitting
Max. Applied Dia of
of Tensile Mean
Sr.# Load Specimen
Specimen Strength
(Tons) (N) (mm) (mm) (MPa) (MPa)

12.7 Comments:

Page | 62
 Plain and Reinforced Concrete – 1 Job No. 13

JOB NO. 13

Determination Of The Tensile Strength Of Concrete By Double Punch Test. (Non-

Standard Test)

13.1 Apparatus:

 Testing Machine
 Testing Samples
 Punches (2 in number, to be placed at the top and bottom of the sample)

13.2 Test specifications:

a. Size of the specimen

The specimen is a cylinder of 150mm diameter and 150mm height.

d= 150mm

15

Specimen

13.3 Procedure:

It is an indirect method in which we determine the tensile strength of concrete based on the
theory of perfect plasticity.
In this test a concrete cylinder is placed vertically between the loading platens of the machine and is
compressed by two steel punches placed parallel to the top and bottom end surfaces.
The sample splits across many vertical diametrical planes radiating from central axis.
Samples should be placed under wet conditions for 24 hours and later on in a curing tank for 28
days.

13.4 Calculation

The tensile strength can be computed as;

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 Plain and Reinforced Concrete – 1 Job No. 13

ft = Q / [Π (1.2bH - a2)]
where,
Q = Crushing Load

13.5 Observations and Calculations:

Length of Splitting
Max. applied Dia of
Specimen Tensile Mean
Specimen load Specimen
Strength
(Tons) (N) (mm) (mm) (MPa) (MPa)

13.6 Comments:

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