Report - CCOV212- ASSIGNMENT-1: Concrete Mix Design and Testing

Group Members
229424791 Chirigo Mildred

227814673 Gune Tinashe

228326583 Khosa Happiness

229377203 Mokoena Dimakatso

229557805 Mzimela Nomkhosi

229580432 Shearer Asanda

229526691 Zimunya Gloria

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Table of Contents

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Introduction
Our team has been tasked with designing a concrete mix for the construction of
precast kerbs, based on the specifications provided. This report outlines the design
and testing of a concrete mix intended for the construction of precast kerbs, as
commissioned by our team, Group 8. This design process requires careful selection of
materials and proportions to ensure that the final concrete meets the necessary
structural and durability standards.

Concrete Mix Design:

Step 1:
The first step in creating concrete that meets necessary specifications is the Mix
Design. For this project, the design will incorporate a blend of cement (Type 32.5N),
sand and stone according to the following requirements:

Cement: Type 32.5N, Dc of 3.14.

Sand: A blend of 60% natural sand (Sand A) and 40% crushed sand (Sand B), Ds of
2.70 and a fineness modulus (FM) of 2.4 and of Average quality

Stone: Aggregate size of 20mm, Da of 2.70, and a compacted bulk density (CBD) of
1500kg/m³.

The aim is to achieve a characteristic strength of 35 MPa at 28 days, with good

control of the concrete mixture. The target consistency for this concrete is a 75mm
slump, achievable through moderate vibration during placement.

Trial Mix and Slump Test

Step 2:
Once the mix proportions are calculated, a trial mix will be conducted to evaluate the
workability and consistency of the freshly mixed concrete. A slump test will be
performed to ensure that the concrete achieves the desired consistency of 75mm,
ensuring it is neither too stiff nor too fluid for the required application .

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Cube Casting and Crushing
Step 3:
Following the successful trial mix, sufficient concrete will be produced to cast four (4)
concrete cubes. These cubes will be tested for compressive strength at specific
intervals. Two cubes will be crushed on either day 7 and day 14, or day 14 and day
21, depending on the lab schedule. The results will then be plotted on a graph to
track the strength development over time and forecast the compressive strength at
28 days.

Analysis of Results
Final Step:
Our approach includes conducting a slump test to determine the consistency of
the freshly mixed concrete. Following this, we will produce sufficient concrete
to cast four cubes for compressive strength testing. The cubes will be crushed
at specified intervals (either on days 7 and 14 or days 14 and 21) to evaluate
the concrete's strength progression, with results graphically represented to
forecast the compressive strength at 28 days.
In the subsequent sections, we will detail our methodology, present our test
results, and provide commentary on the performance of both the fresh and
hardened concrete, thereby offering a comprehensive assessment of the mix's
suitability for precast kerb production.

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  We need to crush a set of two cubes either on day 7 and 14 or day 14 and 21.

Dates: Day 7 – 11 October, Thursday

Day 14 – 18 October, Thursday

Day 21 – 25 October, Thursday

Concrete mix design and Trial mix for Precast Kerbs

Objectives

1. Achieve specified compressive and tensile strength requirements for precast

kerbs.
2. Ensure concrete workability (prevent segregation and bleeding)
3. To ensure durability of the concrete (ability to withstand environmental
conditions)
4. To ensure uniformity in properties of the concrete (consistency)

Apparatus

 Trowels and spades

 Casting moulds
 Graduated cylinders (for water measurements)
 Measuring containers (for cement, aggregate)
 Weighing scale
 Pan concrete mixer (small cement mixer)
 Steel float (the tool we used to smooth and level the surface of the fresh concrete)
 Scoop

Trial Mix Calculations

Step 1: Adjust strength based on degree of control

1. 35 MPa + 8.2 = 43.2 MPa

Step 2: Estimate the water requirement based on the sand type and quality

Quality: Average

Sand A: Natural sand Sand B: Crushed

sand

210 x 60/100 = 126 l/m3 215 x 40/100 = 86

l/m3

= 212 l/m3

Step 3: Determine the Cement content

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Cement Content = water content / Water: Cement ratio

= 212 / 0.5217

= 406,36 kg/m3

Step 4: Determine the Stone content

S = CBD (K – 0.1 FM) K=1

S = 1500 (1 – 0.1 x 2,4)

S = 1140 kg/m3

Step 5: Determine the Sand content

212 1140 406 ,36 x
1= + + +
1 x 1000 2.7 x 1000 3.14 x 1000 2.7 x 1000
x
1=0.763636235+
2.7 x 1000
x
0.236363765=
2.7 x 1000

X =638.1821656kg/m3

Materials For 1m3 For 10L

3
Water (L) 212 l/m 2,12 litres
Cement (kg) 406,36 kg/m3 4,0636 kg
Stone (kg) 1140 kg/m3 11,40 kg
Sand (kg) 638,18 kg/m3 6,3818 kg

Blend ratio

Natural Sand = 3,83 kg (60%) Crusher sand = 2,55 kg (40%)

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Trial mix design methodology and
calculations

Trial mix design process followed We used a trial mix technique that
required both solo and group work. Based on the specified parameters,
each team member independently calculated the concrete mix design in
the beginning. We got together as a group after each person finished their
individual set of calculations to compare outcomes, discuss discrepancies,
and decide on the best mix design. We were able to improve our mix and
strike the ideal ratio of workability, efficiency, and strength thanks to this
cooperative procedure.

 Step 1: Mix Design specifications

Establishing the prerequisites for the mix design, which comprised

the following:
A 28-day compressive strength requirement (35MPa) is known as
**Characteristic Strength.
- Workability: The necessary droop for normal workability.
- Durability Considerations: Air entrainment and other durability
parameters, such as the proper water-to-cement ratio, were
determined with the assistance of exposure circumstances.
- Other Factors: Cement kinds, aggregate sizes, and possible
admixture use based on structural and environmental requirements.

 Step 2: Independent Calculations

The calculations were carried out independently by each team

member utilising the subsequent procedure:

1. Ratio of Water to Cement (w/c)**

Each team member chose a reasonable water-cement ratio, for the
necessary strength of 35MPa, based on the goal strength and
durability requirements.

2. Content of Water**
Using pertinent rules the water content was calculated based on the
target workability

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  3. Content of Cement
4. Content Aggregates.

Step 3: Optimal Mix Selection and Group Collaboration**

Once each of us had finished our separate computations, we got together

as a team to:
1. **Compare Results**: We went over and contrasted the outcomes of
every team member, emphasising variations in the amounts of aggregate,
cement content, and water-to-cement ratio.
2. **Evaluate Differences** : We talked about the assumptions and design
decisions that went into each one, paying particular attention to how
those decisions affected the material's strength, workability, and
efficiency.
3. **Select the Optimal Mix**: Taking into account variables like: - Desired
strength, we selected the mix design that was the most balanced.
- Workability, as the calculated slump indicated.
- Effective material use, striking a balance between price and
performance.

We were able to improve the trial mix through this cooperative process,
making sure it satisfied all practical and technical needs.

---

Lab Trial Mix methodology and

pictures

Once we agreed on the optimal mix design, we

proceeded with the lab trial

 Material weighing

We weighed out the correct quantities of cement, fine and coarse

aggregate and water.

 Concrete mixing
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 In a laboratory mixer, the dry ingredients (cement, fine and coarse
aggregates) were first combined

Water was added gradually while mixing until a

uniform consistency was achieved.

Discussion and conclusion

The concrete mix design and trial mix process is a critical component of
any construction project, influencing the durability, strength, and overall
performance of the concrete used. In our case, we aimed for a target
compressive strength of 30 MPa at 28 days, which necessitated a
thorough approach to mix design.

1. **Mix Design's Significance**: A blueprint for

attaining desired material attributes while taking
workability, durability, and cost into account is
provided by the mix design. The formulation of a mix
that satisfied the strength and performance
requirements required careful consideration of our
specified criteria, which included the water-cement ratio and precise
aggregate sizes.

2. **Individual vs. Collaborative Efforts**: - The first calculations were

made individually, allowing each team member to approach the issue
from a different perspective, which produced a variety of answers and
insights. This phase encouraged thorough research and understanding of
material properties and mix behaviour.
- The subsequent group collaboration was invaluable; by comparing
calculations, discussing assumptions, and evaluating different approaches,
we were able to arrive at a more refined and optimized mix design. This
collaborative review ensured that all aspects, such as potential
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**3.) Trial Mix Results:**: - We successfully mixed the concrete and
carried out the required tests, such as the slump test to determine
workability, during the lab trial. The predicted 55 mm slump fell within our
desired range, proving that the workability and strength of our mix design
were well-balanced. The results of the compressive strength tests at 7, 14,
and 28 days will offer important insights into how well the mix performs.
Examining these outcomes is crucial to verify that the design satisfies the
requirements and to ascertain whether changes are required for
subsequent batches.

The trial mix procedure and concrete mix design showed how crucial a
methodical approach is to get the right material qualities. Through a
combination of individual and group efforts, we were able to meet the
parameters of our project and generate an optimal concrete mix.

4.) Key Takeaways

Teamwork and communication are crucial for seeing possible problems

early and adjust.

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Slump Test
Aim and Objectives
To determine the slump of the freshly mixed concrete in the laboratory and inspect its
cohesiveness and workability.

Apparatus:
 Mould in the form of frustrum cone with a
standard error of +/- 2mm
 Tamping rod, made with steel
 Scoop
 Measuring ruler
 Baseplate
 Trowel

Methodology and
Pictures
 Firstly, ensure that the interior surface of the mould is clean and dump
 Place the mould on the baseplate ensuring that it is free from vibration
 Place your feet on the two-foot restraints to prevent the mould from displacing while
placing /pouring or tamping the concrete mix

 Pour the concrete mix into the mould in intervals of 3 scoops or a third of the height
of the mould

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 Tamp the concrete mix layer by the layer with 25 strokes using the tamping rod,
ensure that the strokes are uniformly distributed over the cross section of the layer
and the strokes penetrate into the underlying layer. While tamping the last layer,
ensure excess concrete is maintained above the top of the mould. If required, add
more concrete while tamping.

 After tamping the last layer, carefully remove the excess concrete and level the top of
the mould using a trowel.

 Clean off the concrete that may have leaked or spilled onto the baseplate.
 Carefully demould the concrete by slowly and carefully raising the mould vertically,
this may take an estimated time of 5 to 10 seconds

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  Immediately after deforming, measure the slump of the concrete. Which is the
difference between the height of the mould and the height of the demoulded
concrete.
 Inspect the shape of the demoulded concrete.
 If the specimen collapses or lateral shearing of concrete occurs, consider the test
unacceptable and repeat on a fresh sample of concrete. If, during two consecutive
tests, collapsing or lateral shearing of the test specimen occurs, the concrete lacks
the necessary plasticity and cohesiveness for the slump test to be applicable.
 Else tamp the comer of the baseplate with a tampering rod in intervals of 2 seconds
to inspect cohesiveness of the concrete

Results and Conclusion

The slump of the concrete was measured to be 55mm and we inspected that it was a true
slump. We further discovered that the concrete was very cohesive and workable as it did not
just collapse while we were continuously ponding on the baseplate. Hence the concrete mix
passed the slump test.

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Concrete Cube Making and Crushing
Aim and Objectives
To produce concrete cubes for comprehensive strength testing and evaluate
the compressive strength at different curing periods.

Apparatus:
 Cube moulds
 Tamping rod
 Steel float
 Scoop
 Curing tanks
 Compressive testing machine
 Concrete mixer

Methodology and Pictures

1. Cube making:
 Fill the moulds with concrete in layers while tamping each
layer with 25 blows maximum.
 Smoothen the top surface using a steel float while making
sure all corners of the mould are filled with concrete and cover
the moulds for concrete curing.

2. Cube Crushing:
 Remove the cubes from the moulds after the curing period.
 Test the cubes using the compression testing machine.
 Record the compressive strength values.

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Cube Making: Comments on Appearance (SANS:5682)

Freshly Mixed Concrete Cube

• Colour – dark-grey colour due to the wet cement. Aggregates were

slightly darked due to the water as well as the pigment of cement.

• Consistency – Aggregates slightly visible as we worked the concrete

mix. The concrete mix appeared to be cohesive with no evidence of
segregation or bleeding.

• Texture – Glossy, which showed that the concrete mixture had sufficient
moisture content. Indicating a god level of hydration.

• Air Bubbles – A few air bubbles were present in the concrete mix.

Dried and Cured Concrete Cube

• Colour – a light-greyish colour was observed. The colour light-grey was

uniformly consistent throughout the surface of the cubes.

• Shape and Dimensions - the cube maintained its intended dimensions

(100mm x 100mm x 100mm) with sharp edges and corners, reflecting the
precision of the casting mould.

• Surface Finish – smooth and uniform with a few very tiny voids. No
cracks present.

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