1.

Background

2. Executive Summary
 3. Introduction

This specific study was initiated by EDY Precast Technologies to determine the appropriate light
weight concrete material for precast panels which will be used to build fences and other structural
elements. Through laboratory test process we examine concrete mix designs, experimentation and
selection of optimized material for structural design. The test report contains trial mix designs (mix
requirements and mix proportions) and experimental results (compressive strength) of three
concretes to be selected.

The purpose of this study is to investigate how materials behave under a compressive load, the
maximum stress each material can sustain, and the Ultimate Compressive Strength of the materials.
A sample of the material is placed in a testing machine and tested for failure. While this occurs,
notes are taken for values of force and weight. By converting the data to represent stress, the new
values are written for each specimen. The stress of specimens in each mix designs can be used to
determine characteristic Ultimate Compressive Strength for each mix designs (new materials). A
material that is strong and light weight would be chosen for design. It was hypothesized that the mix
design with mix ratio 1:1:4 for cement, sand and pumice (fly ash) respectively is selected material for
the design.
This study was undertaken to investigate the suitability of pumice aggregates in precast
panels productions. The study also presents the results of experimental investigation
studying mix design, strength and density characteristics of pumice concretes.
Theoretical investigations are carried out to determine the strength and deformation
characteristics of ribbed slab.
 4. Mix Designs
4.1. Aggregate selection

For all concretes, the mix design has a huge effect on the properties of the material. Concrete
required four different components: water, cement, coarse aggregate, and a fine aggregate. The
coarse aggregate was the larger one that could have been lime stone, granite, gravel, steel fibres, or
recycled materials, and the fine aggregate was the smaller one that could have been sand, sawdust,
or foams. In this experiment, pumice and gravel(10mm) were used for the coarse aggregate, and
sand and fine pumice were used for the fine aggregate.

As lightweight concrete is suitable for precast concrete structure buildings, abundant lightweight
aggregates are mighty choices. Researches have been conducted worldwide on a large
number of natural and artificial lightweight aggregates to manufacture mortar and
concrete. Natural lightweight aggregates include diatomite, pumice, scoria, sawdust, oil
palm shells, bottom ash, and starch-based aggregates. Artificial aggregates include
expanded shale, slate, perlite, sintered fly ash, bonded fly ash, solidified blast furnace
slug, and vermiculite. Use of natural lightweight aggregates instead of processed
artificial aggregates can significantly reduce the cost of such concretes.
th
Following Italy, Chile, and Ecuador; Ethiopia is the 4  leading producer of pumice and
scoria aggregates in the world. Hence, it is essential to investigate precast panels
properties with the aim of using these locally available low-cost lightweight materials and
thereby minimizing the cost of construction. Therefore, Pumice is the primary aggregate
selected in this study.

4.2. Mould preparation for test cubes

For cube test cubes of 15cm X 15cm X 15cm are used. We had produced 30 moulds;
we have three material types then 10 moulds are prepared for each material types (mix
designs).
If moulds are out of square, the area of the concrete cube is changed, and this will
negatively affect the compressive strength that is obtained from the test. The results
will therefore not be a true representation of the concrete cast on site. Therefore,
 Ensure that all the mould sides are at 90° angles with the base plate
 Ensure that the test moulds are clean.
 Apply a thin layer of release agent or mould oil on the inside of the assembled
mould.
 Place the moulds on a smooth, level surface.
Aggregate quality
Aggregates are inert filler materials for making concrete mixes. They form 60-80
percent volume and 70-85 percent weight of the concrete. The chemical and physical
properties of the aggregates have a great bearing on the structures they form. We can
categorize them as coarse and fine aggregates based on their sizes. The coarse
aggregates on the IS Sieve of 4.75mm are retained (cannot pass). While the fine
aggregates are those that pass 4.75mm sieve. Coarse aggregates we used are pumice
and gravel of size 10mm. In cement concrete, the maximum aggregate size is 40 mm.
The selection of good quality coarse aggregate is essential for the production of
concrete that meets the desired strength and durability requirements. Ideal
construction aggregate should have a rough surface texture and should be clean,
strong, and free from coating and other dirt particles.
In order to select good quality coarse aggregates, we consider the followings
1. Organic substances and dirt coating compromise the strength and durability of
concrete. To insure this, we washed the aggregates.
2. Coarse aggregate should contain various fraction sizes to ensure adequate
compaction of particles, hence resulting in increased density and reduced voids
in concrete.

3. In the majority of concrete works, aggregate sizes of 20 mm or smaller are

used.
4. The shape and texture have a greater on concrete strength. To do bond better
the sands from riverbeds and rough aggregates make excellent aggregate
composition.
 4.3. Water cement ratio
Water cement ratio plays an important role in deciding the quantity of water to be
added to cement so that strength can be achieved and the concrete can be kept
workable.

Water cement ratio gives a comparison of how much water is present per unit
quantity of cement. A lower value indicates higher strength but it is difficult to carry

out concreting operations.

4.3.1. Effective Water Cement Ratio

Aggregates are believed to use up some of the water to achieve saturated and
surface-dry conditions from the water added for hydration. Hence, the net water
available for hydration is the water added minus water absorbed by aggregates. The
effective water cement ratio is calculated using this net water.

Net water available for hydration = water added – water absorbed by aggregates

Effective water cement ratio = net water available/ weight of cement

4.3.2. Strength of Concrete & W/C Ratio

Strength of concrete mainly depends on the strength of cement paste. 

Strength of cement paste can be improved by-

o Increasing cement content

o Decreasing water content
o Decreasing air content
In ordinary construction, not all the air is expelled from the concrete even if full
compaction is exercised on the site. 

At given hydration, the w/c ratio becomes the deciding factor of strength in cement
paste. 

If the water content is high, then the porosity of the cement paste will be increased.
The total volume of voids in gel pores and capillary pores as well as entrapped air will
reduce the strength of concrete. 

With the age of concrete, the degree of hydration increases, therefore strength also
increases.
 4.3.3. Graph between Strength of Concrete vs W/C Ratio

Water Cement Ratio vs

Compressive Strength Graph
As seen above, the graph between the strength of concrete and the w/c ratio is
approximately hyperbolic in shape.

The intermediate values in the graph are difficult to interpolate. Hence, the graph
between strength and cement water ratio is sometimes plotted. 

Cement Water Ratio vs

Compressive Strength Graph
As seen from the above graph, the graph between strength and cement/water
ratio has an approximately linear relation. Thus, it is easier to find the intermediate
relation as the graph is almost a straight line.
 4.3.4. Functions of Water in Concrete

o Water reacts chemically with cement resulting in setting of cement and

ultimately hardening of cement takes place. 
o Water acts as a lubricant for aggregates. Thus, passage of cement through
voids between the aggregates is facilitated imparting workability to concrete.
To carry out the above two processes, the water requirement is about 0.5-0.6 times
the weight of cement.

4.3.5. Water Requirement for Concrete

Minimum water providing reasonable workability should be added to concrete. 

For proper workability, a w/c ratio of about 0.4 to 0.6 is required. As expected,
maximum strength is attained at a w/c ratio of 0.4

As we know, for complete hydration of concrete, 38 % of water by weight of cement

is required. 

Accordingly, we had used water to cement ratio of 0.6 to achieve both strength and
workability which means 0.6kg of water to 1kg of cement or 30liters of water for
50kg(1bag) of cement.

4.3.6. Importance of Water Cement Ratio

Significance of water cement ratio is discussed below:

o Higher water cement ratio leads to cracks in concrete.

o It also causes shrinkage in concrete which then results in micro cracks forming
zones of weakness.
o Excess water may squeeze out of the concrete owing to the weight of
aggregates and cause bleeding of concrete
o Excess water may cause the cement slurry to separate out from the
aggregates causing segregation of concrete
o If w/c ratio is too low, the concrete would not be workable and stiff concrete
may be formed
o Stiff concrete results into honeycombed structure
Thus, w/c ratio is a crucial factor to be taken into consideration. 

4.3.7. Concrete Quality Parameters Governed by W/C ratio

o Strength: Strength increases with decrease in w/c ratio

o Resistance to weathering: As the strength is increased, resistance to
weathering increases with decrease in w/c ratio
 o Durability: Durability increases as resistance to weathering increases with
decrease in w/c ratio
o Bond between two successive concrete layers: Increases with decrease in
w/c ratio
o Bond between concrete and reinforcement: Increases with decrease in w/c
ratio
o Volume changes due to wetting and drying: Decreases with decrease in w/c
ratio

5. Curing and Testing

The chemical interaction between cement and water binds the aggregate. Fresh
concrete will be plastic so that it can be moulded to any desired shape and
compacted to form a dense mass.
Concrete should be placed in a position before it starts losing its plasticity. The time
at which concrete completely lost its plasticity and became hard is called the final
setting time of concrete.

Curing of concrete:
Curing plays a vital role in concrete strength development and durability. After
adding water to the concrete mix (Cement, Sand & Aggregate), the exothermic
reaction (hydration) takes place, which helps the concrete to harden. Hardening of
concrete is not instant and continues for a longer period, which requires more
amount of water for processing hydration. So, the concrete kept moist until the
hydration reaction in concrete completes. This process called the curing of concrete.
or

Curing is the process in which the concrete kept moist to protect it from loss of
moisture due to atmospheric temperature and hydration reaction. So, we kept the
cubes immersed in water as shown in the figure below.
or

Curing is the process of controlling the rate and extent of moisture loss from
concrete during cement hydration.

Purpose of Curing of Concrete: -

The reaction between cement and water is called hydration. It is an exothermic
reaction (the reaction which releases heat).

After adding water to the concrete mix, hydration starts, which makes the concrete
to dry out quickly due to an exothermic reaction which releases heat. To complete
the hydration process, concrete is kept moist to attain the maximum strength of
concrete as soon as possible.

As there are many frequently asked questions about the curing of concrete. Below
are some of them

Procedure for curing of concrete:

Draining water on the concrete surface cures the concrete. Water cooler than 5 0C is not suitable for
curing concrete. As the hydration reaction in concrete expels heat and keep concrete warm, using cold
water less than 50C on concrete may lead to cracking and failing. Alternate drying and wetting on the
concrete surface causes volumetric changes in concrete and ultimately leads to cracking.
The minimum period for curing concrete to attain maximum strength is 28 Days.
Concrete cube test Procedure

 After the Specified curing time remove the specimen from water
and excess water is to be wiped out from the surface.
 Take the dimension to be nearest 0.2 m.
 The bearing surface of the testing machine is to be cleaned.
 The specimen in the machine is to be put in such a manner that
the load should be applied to the opposite sides of the cube cast.
 The specimen should be aligned centrally on the base plate of the
machine.
 The movable portion should be rotated gently with hands so that
it touches the top surface of the specimen.
 Load should be applied gradually without the shock at the rate of
140kg per cm2 per minute continuously till the specimen gets fail.
 Maximum load is to be recorded and unusual features in the type
of failure are noted.
 Note:

1. Minimum 3 specimens should be tested at each selected age.

2. Rejection of those specimens is taken into account whose
strength varies by more than 15% of average strength.
3. An average of 3 specimens gives us the crushing strength of
concrete.
Cube Tests Reports:
1. Identification Marks
2. Date of test
3. Age of Specimen
4. Date of Completion of specimen and curing conditions
5. Showing of Fractured faces of concrete and the type of fracture if
they are not usual
Concrete Compressive Strength at various days:
With age Concrete compressive strength increases. Here is the table to show
the concrete compressive strength at different stages after casting.
                              DAY STRENGTH PERCENT

1 DAY 16%

3 DAYS 40%

7 DAYS 65%

14 DAYS 90 %

28 DAYS 99%

Different Grades of Concrete Compressive strength

at 7 Days and 28 Days:

 Concrete Minimum Compressive strength Specified Characteristics compressive strength

Grade  N/mm2 at 7 days at 28 days in N/mm2

M15 10 15

M20 13.5 20

M25 17 25

M30 20 30

M35 23.5 35

M40 27 40

      

Table vibrator

Teraz vibrator

Mixer

Panel Moulds

Teraz Moulds

Conclusion:
The concrete compressive strength test or cube test represents the quality of
poured concrete on the construction site. If concrete cubes do not acquire the
required strength then poured concrete is repaired by different methods such
as grouting or injection of chemicals to increase the strength of the concrete.
6. Appropriate Material Selection
7. Design Of Concrete Panels
8. Standardizing Panels
9. Production Technique
10. Conclusion
11. Recommendations
12. References
13. Appendix