PRC 1 Lab Manual

Reegistration
No
o.
20
008 CIVIL
L
N
Name
/ Seec:
LAB MANUA
M
AL
PLAIN
N AND
D REINF
FORCE
ED CON
NCRETE
EI
PREFACE
This manual has been prepared keeping in view the basic requirements of concrete technology. This is
to be used up to the beginners 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
Introduction to Concrete:.................................................................................................................1
Job No. 2..........................................................................................................................................9
Job No. 3........................................................................................................................................12
Job No. 4........................................................................................................................................16
Job No. 5........................................................................................................................................23
Job No. 6........................................................................................................................................27
Job No. 7........................................................................................................................................32
Job No. 8........................................................................................................................................35
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
JJob No. 1
INTROD
DUCTION TO CONCRE
ETE:
Concrete is the most commonly used
u
constru
uction materrial these daays. This is a plastic maaterial that
perties (propeerties that ch
hange with ttime) i.e. streength, hardnness, ductilityy, fluidity
possesses transit prop
etc.
1.1
Definittion:
Concrete is a mixturee of coarse ag
ggregate, fin
ne aggregatee/fillers, cem
ment and watter
Being mo
ore specific,
Concrete is a transient materia
al compriseed of coarsse aggregate
tes, matrix and ITZ (IInterfacial
transition
n zone)
Let us disscuss the ind
dividual item
ms,
a. Coarsse Aggregattes:
Coarse aggregates constitute the largestt portion off the concreete. The maiin purpose of coarse
aggreg
gates is to provide
p
streength. In no
ormal strenggth concrete compressivve strength is mainly
contributed by thee coarse aggrregates.
Thesee are the partticles retaineed on sieve # 4 (with an opening of 55mm). There is no set uupper limit
on thee size of partticles but usu
ually an upper limit of 500mm (2in) is consideredd.
b. Matriix
In sim
mple words we
w can say that
t
matrix is
i a mixture of all consttituents of cooncrete otheer than the
coarsee aggregates. This contaains the bind
ding materiall, fillers, waater, admixtuures and addditives etc.
Each of
o these have been explaained below,,
i.
Binding Material:
M
This is thee componentt that holds primarily
p
thhe coarse agggregate partiicles togetheer. All the
particles in
n concrete arre held togetther by this component. The functioon of bindingg material
can be deffined as it pro
ovides confiinement to c oarse and finne aggregatee particles.
In case off concrete confinement
c
is of utmoost importannce. It can bbe understoood by the
following example,
If we placee coarse agg
gregate partticles in a moold (form woork) and test that in a m
machine, it
will provid
de some streength. But iff the aggregaates are triedd to be testeed without thhe mold, it
would be very difficullt to hold th
hem at their location. B
Before the m
machine can apply the
load the coarse aggreegate particlles will dropp down. Hennce, for testinng coarse agggregates
uld be put in some mold. The mold prrovides conffinement to the aggregaates.
these shou
The most commonly used bindiing materiall in concrette is Portlaand cement (ordinary
cement) an
nd the resulting concretee is called, orrdinary Porttland cementt (OPC)
Page | 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
Page | 2
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.
Page | 3

1.2
JJob No. 1
Proporrtioning of concrete
c
ma
aterials:
Proporttioning of diifferent materials is verry importantt to achieve a material with desiredd strength
and pro
operties. Forr example a concrete witth less amouunt of coarsee aggregate particles wiill provide
less streength. Simillarly a concrrete with less amount off matrix willl not be ablee to move inn the form
work an
nd settle prop
perly.
Knowin
ng the propeerties of eacch of the co
onstituents of concrete, tthe amount of all compponents is
decided
d. The processs is call con
ncrete mix design covereed in experim
ment number 7.
1.3
Hydrattion of cemeent:
Hydratiion process is the one in
n which cem
ment reacts w
with water too form a passte known aas calcium
hydratee silicate gel responsible for providin
ng the bindinng property.
The hydration proccess begins as soon as the
t water iss added to ccement. The main compponents of
cement and their ro
ole in hydratiion has been
n briefly expllained below
w,
i.
ii.
iii.
iv.
1.4
C3S : 4.0
07(CaO)-7.6((SiO2)-6.72((Al2O3)-1.433(Fe2O3)-2.885(SO3)
C2S : 2.8
87(SiO2)-0.754(3CaO.Si O2)
C3A : 2.6
65(Al2O3)-1..69(Fe2O3)
C4AF : 3.04
3 (Fe2O3)
(i & ii) Ca & Si reacts first & start the hydratioon process
(iii & iv) Reacts

R
to givee hydration & give finall setting timee
ability of con
ncrete:
Worka
This can be defined
d as,
947),
Glanvillle, et al. (19
The amount of work needed to prroduce full ccompaction
ACI, 19
990
That prroperty of freeshly mixed concrete or mortar whicch determinees the ease aand homogenneity with
which it can
c be mixed
d, placed, connsolidated aand finished.
ASTM,, 1993
That property
p
dettermining the effort requ
uired to man ipulate a freeshly mixed qquantity of cconcrete
with minim
mum loss of hhomogeneityy.
Page | 4
JJob No. 1
a. Measu
urement of Workabilitty:
Workaability can be
b by differen
nt techniquees such as,
Slump testt.
Concrete is
i filled in a cone with proper
p
comppaction. The cone is rem
moved and thhe drop in
height of concrete
c
is noted
n
down.
For furtheer explanatio
on go to expeeriment num
mber 8
Fig from Concrete

C
Pro
operties by John
J
Newmaan
Compactin
ng factor testt.
Concrete is
i filled in the first buccket out of the two or three in seeries. The cooncrete is
allowed to
o drop from
m the first bucket
b
to seecond and tthen to the mold. This is called
partially compacted
c
concrete. Thee weight of concrete inn this partially compacteed state is
compared with the fu
ully compactted weight in form of a ratio calleed compactiing factor
value.
For furtheer explanatio
on go to expeeriment num
mber 9
Page | 5
JJob No. 1
Fig from Concrete

C
Pro
operties by John
J
Newmaan
VB test.
In this testt the concrette is place in
n a mold wiith a plate att the top. Viibrations aree provided
until the co
oncrete gets fully settled
d. The time iis noted dow
wn.
Fig from Concrete

C
Pro
operties by John
J
Newmaan
Flow tablee test.

The concrrete is placed
d on a table by using a cone. Then top surfacee of table is lifted and
dropped fo
or specific nu
umber of tim
mes and the sspread of cooncrete is notted down.
Fig from Concrete

C
Pro
operties by John
J
Newmaan
Page | 6
JJob No. 1
Slump flow
w test.
In this tesst the concreete slump teest is perforrmed but insstead of dettermining thhe drop in
height, sprread of concrrete is measu
ured.
Fig from Concrete

C
Pro
operties by John
J
Newmaan
Degree of compactabillity test.

In this tesst concrete is filled in a mold whicch is provideed vibrationns for a speccific time.
Then the drop
d
in heigh
ht of concrette is noted doown.
Fig from Concrete

C
Pro
operties by John
J
Newmaan
w
iss lost due to the followin
ng reasons,
The workability
Mix waterr being absorrbed by the aggregate
a
if this not in a saturated sttate before m
mixing
Evaporatio
on of the mix
x water
ons (but this should not bbe confusedd with cemennt setting)
Early hydrration reactio
Page | 7
1.5
JJob No. 1
Interaction
ns between admixtures (particularlyy plasticizerrs and superplasticizerss) and the
cementitio
ous constitueents of the mix.
m
Placing
g and Finish
hing concrette:
By placcing and finiishing we mean
m
how to put concrette in the molld and how to get the fiinal shape
and fin
nish. The baasic process is that conccrete is pouured in the fform work bby concrete pump of
bucketss. Then it is consolidatted (vibratio
ons are proovided by eexternal or iinternal vibraters i.e.
vibratin
ng table & po
okers/niddlee vibraters)
There are
a a few thin
ngs to be con
nsidered while working with concrete,
Th
he concrete should
s
be diischarged as close as poossible to its final positioon, preferablly straight
intto the formw
work
A substantial free-fall
f
disttance will en
ncourage seggregation andd should therrefore be avoided
With
W deep pou
urs, the rate of placing should be succh that the layer of conccrete below tthat being
plaaced should
d not have set;
s this willl ensure ful l continuityy between laayers, and aavoid cold
joiints and plan
nes of weakn
ness in the hardened conncrete
On
nce the conccrete is in place, vibratio
on, either intternal or extternal, shouldd be used too mold the
co
oncrete aroun
nd embedmeents e.g. rein
nforcement, aand to elimiinate pocketss of entrappeed air, but
thee vibration should
s
not bee used to mo
ove the conccrete into plaace
Hiigh-workability mixes sh
hould not bee over vibrateed this maay cause segrregation.
1.6
Curing
g of concretee:
As we know that water
w
is add
ded for worrkability andd hydration. So if water is not avaailable for
hydratio
on, strength will be com
mpromised. We
W also studdied that waater is lost (lloss of workkability) is
due to water
w
absorp
ption and ev
vaporation. This
T loss of water is to be compenssated by eithher adding
extra am
mount of water or prev
venting the already
a
pres ent amount of water froom evaporaating. This
processs is called cu
uring.
Differen
nt techniquees used in cu
uring are,
Adding extrra water by spraying

s
and
d covering thhe concrete bby gunny baggs etc.
By allowing
g water to staand on the ro
oofs
By covering
g concrete by polythen
ne sheets inn order to pprevent watter from esccaping by
evaporation
n.
Page | 8
Job No. 2
JOB NO. 2
Standard
d Test Metthod for thee Determination of Th
he Normal Consistencyy Of The H
Hydraulic
Cement..
Code: AS
STM C 187--04
2.1
Scope and
a Significcance:
It is used to find out
o the perceentage of waater at whicch the standaard consistenncy is achieeved. This
known amount of water
w
is then used in mak
king the cem
ment paste foor the other teests like;
i. Initiall setting timee
ii. Finall setting timee
iii. Soun
ndness test
2.2
Appara
atus:
2.3
Referrence Massess and Devicees for Determ

mining Mass
VICA
AT Apparatuus
Plungger with 10m
mm diameter and 50mm leength
Glasss graduates (2200mL or 2550mL capacitty)
Spatuula
Glasss plate trowell
Related
d theory:
a. Consiistency
The th
hickness or th
he viscosity of
o the cemen
nt paste is callled consistenncy.
b. Cemeent paste
The viiscous mass obtained
o
by mixing
m
cemeent with wateer is known aas cement paste.
c. Stand
dard paste
It is th
he cement paaste for whicch the 10mm
m diameter pplunger in a sstandard VIC
CAT test pen
netrates to
such an exxtent that its distance from
m the bottom
m is 5-7mm.
d. Stand
dard/Norma
al consistenccy
It is th
he thickness or the visco
osity of the sttandard pastte and is exprressed as thee percentage of weight
of water.
Page | 9
Job No. 2
e. Vicats apparatu
us
The Vicats
V
appaaratus consists of a frame A (Figg.)
bearing a movable ro
od B, weighin
ng 300 g, on
ne end C, thhe
plunger en
nd, being 100 mm in diam
meter for a distance of at
least 50 mm,
m and the other end haave a removaable needle D
D,
1 mm in diameter
d
and 50
5 mm in lenggth. The rod B is reversiblle,
and can be
b held in an
ny desired position
p
by a set screw E
E,
and has an
n adjustable indicator F, which movees over a scaale
(graduated
d in millimeeters) attach
hed to the frame
f
A. Thhe
paste is held
h
in a rigiid conical riing G, restin
ng on a planne
non-absorrptive squaree base plate H,
H about 1000 mm on eacch
side.
Th
he rod B is
i made of stainless stteel having a
hardness of
o not less th
han 35 HRC, and shall be straight wi th
the plungeer end which
h is perpendicular to the rod axis. Thhe
ring is maade of a non
n-corroding, nonabsorben
nt material, and have ann inside diam
meter of 70 m
mm at the
base and 60 mm at th
he top, and a height of 40
4 mm. In adddition to thhe above, thee Vicat apparratus shall
conform to
t the follow
wing requirem
ments:
Weight off moveable rod
r
= 30005 gm
Diameter of the plungger end of thee rod = 10

0.05 mm
Diameter of the needle
= 100.05 mm
meter of the ring at the bottom

b
= 70
3 mm
Inside diam
2.4
Inside diam
meter of the ring at the to
op
= 60
3 mm
Height of the ring
= 40
3 mm
pecificationss:
Test sp
a. Temp
perature & humidity
h
The teemperature of
o the air in
n the vicinityy should be between 20-27.5 C. Th
he temperatuure of the
mixing waater should be 232 C.
The reelative humid
dity of the lab
boratory should not be leess than 50%
%.
b. Amou
unt of cemen
nt
Amouunt of cement required fo
or the test acccording to vaarious specifiications are m
mentioned beelow.
BS
= 500gm
ASTM
M = 650gm
c. Mixin
ng time
Page | 10
Job No. 2
The ceement paste must be pro

operly mixed and placed iin the test sppecimen with
hin a maximuum time of
41/4 min from the in
nstant when cement and water were innitially brougght in contacct.
2.5
Proced
dure:
Mix 6550gm of cem
ment with a measured
m
quaantity of wateer and make a cement paaste as per thee standard
proceduree. Put the cem
ment paste in
n the ring off the vicat appparatus andd remove thee excess paste with the
help of a trowel. Centter the paste confined in
n the ring, reesting on thee plate, undeer the rod B and bring
the plungeer end C of in contact with
w the surfaace of the paaste, and tighhten the set-screw E. Th
hen set the
movable indicator
i
F to
t the upper zero mark of
o the scale, or take an iinitial readin
ng, and releasse the rod
immediateely. This muust not exceeed 30 s afterr completionn of mixing. The apparattus shall be free of all
vibrationss during the test.
t
Th
he paste of normal
n
consisstency is ach
hieved when the rod settlles to a pointt such that itt is 4-7mm
above the bottom surfface in 30 s after
a
being reeleased. Makke trial pastess with varyingg percentagees of water
until the normal
n
consistency is obttained. Makee each trial wi
with fresh cem
ment.
2.6
Observ
vations and Calculation
ns:
Cement Brand =
Sr. #
Weight
W
of
Cement
C
(gm)
Trial
Moisture
Content
(%)
Weight/V
Volume of
Wa
ater
Temperatu
ure
Mixxing
Time
S
Scale
Reeading
(1gm = 1mL)
(C)
(m
min)
((mm)
d Standard Co
onsistency =
=
..%
%
Achieved
2.7
Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 11
Jobb No. 3
JOB NO. 3
Standard
d Test Meth
hod For The Determin
nation Of The Initial A
And Final S
Setting Time Of The
Hydrauliic Cement By
B Vicat Neeedle Appara
atus.
Code: AS
STM C 191-0
04b
3.1
Scope & significan

nce:
This test
t method is used to determine
d
thee time of setting of the hydraulic ceement by Vicat needle
apparatus..
The knowledge
k
off the setting time of the cement is allways helpfuul in decidingg the time dduration to
mix, transport, place and compact the concretee effectively.
We alw
ways prefer a larger inittial setting tim
me so that w
we can mix,, transport aand place thee concrete
easily. Acccording to ASTM
A
specifiications, the initial setting
ng time shall not be less than 30min but in the
field we prrefer an initiaal setting tim
me not less than 45min.
A smaaller value off the final settting time is always
a
preferrred in order to avoid largge expendituures on the
formworkk. According to most of the
t specificaations, the finnal setting tim
me shall nott be greater tthan 10hrs
and shall not
n be less th
han ( 90 + 1.22 x (initial seetting time) ) min.
i.e.
3.2
Appara
atus:
3.3
( 90 + 1.2 x (initial setting time) ) minn < final settting time < 10hrs
Vicaat apparatus
Neeedle of 1mm2 cross-sectio
on and 50mm
m length (for initial settingg time)
Plun
nger with 1m
mm smaller needle and 5m
mm outer diaameter (for fiinal setting time)
Flatt trowel
Refe
ference Massees and Devicces for Deterrmining Mas s
Spatula
Graaduated cylinders
Related
d theory:
a. Settin
ng
In
n the settingg process veery little cheemical reacttion takes pplace. It onlly includes the shape
acquisition
n due to evap
poration of water.
w
Duringg the setting process the cement rem
mains in the flluid or the
semi-fluid
d state and th
here is very liittle or no gaain in strengtth. Finer thee cement parrticles more w
will be the
hydration and thereforre it will lead to quick setttlement.
b. Hardeening
Hardening
H
is the rate of gain of streength due too the chemiical reaction.. It also refe
fers to the
strength of
o the concrette after a speecified interval of time.
Page | 12
Jobb No. 3
c. Initial setting tim

me
The tiime elapsed between
b
the initial contaact of cemennt and water and the timee when a 1m
mm2 crosssection neeedle gives a reading betw
ween 4-7mm from the boottom in a staandard Vicat apparatus is known as
initial settiing time of th
hat particularr cement passte.
d. Final setting timee
It is th
he time elapssed between the initial co
ontact of cem
ment and waater and the time when th
he smaller
2
needle (1m
mm cross-seection and 1mm
1
deep) completely ppenetrates innto the pastee and the ouuter metal
attachmen
nt of 5mm diiameter does not leave an
n impression on the cemeent paste.
Accordingg to specificaations;
Maximum finaal setting timee = 10hrs
Minimum finall setting timee = [90 + 1.22 (initial settinng time)] minn
3.4
Test sp
pecificationss:
a. Needlle sizes
1- Fo
or Initial Settting Time
1mm x 1m
mm cross-secttion
50mm lenggth
2- Fo
or Final Settting Time
1mm2 crosss-section and
d 1mm deep inner needlee
5mm diam
meter outer metal
m
attachment
b. Mixin
ng water
Portab
ble water is satisfactory fo
or the routinee tests.
c. Temp
perature & humidity
h
The teemperature of
o the air in the
t vicinity sh
hould be bettween 233 C. The temperature of tthe mixing
water shouuld be 232 C.
The reelative humid
dity of the lab
boratory should not be leess than 50%
%.
d. Amou
unt of cemen
nt
Amouunt of cement required fo
or the test acccording to vaarious specifiications are m
mentioned beelow.
Page | 13

BS
Jobb No. 3
= 500gm
ASTM
M = 650gm
3.5
Proced
dure:
Preparre a cement paste
p
of stan
ndard consisteency and putt it in the rinng of the Vicaat apparatus within the
allowable time of 41/
/4 min. Cleaar and level an
ny extra pastte by means oof a trowel.
1- Initiall Setting Tim
me
Determ
mine the peenetration off the 1-mm needle at thhe start. If a penetration
n reading of 4-7mm is
obtained then note down the tim
me as the initial setting ttime otherwiise keep cheecking the penetration
reading affter every 10m
min thereaftter until a peenetration reaading of 4-7 mm is obtaiined which w
will be the
initial settiing time of the
t cement.
Make each pen
netration testt at least 5 mm
m away from
m any previoous penetration and at leaast 10 mm
away from
m the inner siide of the mo
old.
2- Final Setting Tim
me
Now fix
f the final setting time plunger in which
w
the sm
maller needle has the diam
meter of 1mm
m and the
diameter of
o the outer needle is 5m
mm. Drop thee rod of the Vicat apparaatus and notee down the ttime when
the smalleer 1mm diam
meter needle completely penetrates iinto the pastte and the o
outer needle leaves no
impression
n on the cem
ment surface.
Page | 14

3.6
3.7
Jobb No. 3
Observ
ns:
Initial setting
s
time =
______
________
Final seetting time =
______
________
Comments:
___________
__________
___________
___________
_______________________________________
______
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 15
Joob No. 4
JOB NO. 4
Determin
nation of th
he Finenesss Modulus of the Coaarse And F
Fine Aggreggate From Different
Sources.
STM C-316--05, for coarrse materials (i.e. > 15m
m)
Code: AS
AS
STM C-117--05, for fine materials (i.e. < 15m)
4.1
nce:
Scope & significan
This teest method is used to dettermine the fineness
f
moddulus of the ggiven fine graained specim
men.
The in
nformation obtained
o
from
m fineness modulus is hellpful in the foollowing wayys;
1- Fineness modulus
m
tells us directly whether
w
the m
material is weell-graded orr gap-graded.
2- Fineness modulus
m
givees us an overaall idea whethher the mateerial is fine orr coarse.
3- It also indiicates the surrface area of the particles .
Surrface Area
1
Fineness Modulus
M
Lower the surface areaa of the aggregate, the reequired amouunt of fresh cement pastee to cover
th
he aggregate particles willl be less and
d thus
less water is
required.
4- Larger valuue of FM is preferred
p
forr fine
For a good
d fine aggreggate, the FM
between 2.3 and 3.1 (A
ASTM Range for
aggregates)).
4.2
Appara
atus:
4.3
aggrregates.
shouuld be
fine
Stan
ndard set of sieves
s
Sievve shaker
Sam
mple of the agggregate
Related
d theory:
a. Finen
ness modulu
us
It is th
he cumulativee percentage retained on standard sievve 150m annd above diviided by 100.
Page | 16
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 m
(micron).
1 mm = 1000 m (micron)
Notes:
iii-
5 mm is the dividing line between coarse and fine aggregate.

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)
600m
3/128 (#30)
300m
1/88 (#50)
150m
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.
Page | 17
Job No. 4
b- Coarse Aggregates
Standard
Non-Standard
75mm (3 )
63mm
50mm
37.5mm (1 )
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)
Page | 18
Joob No. 4
f. ASTM
M grading requirement
r
ts for fine ag
ggregates
Cu
umulative % Passing
Sieve Size
4.4
Minimum
Maxximum
9.5m
mm
100
1100
4.75m
mm
95
1100
2.36m
mm
80
1100
1.18m
mm
50
85
600
m
25
60
300
m
10
30
150
m
10
Proced
dure:
Take 2 kg of the oven-dried
o
saample. The sample shouldd be perfectlly dry
because iff there is som
me moisture content
c
preseent then the pparticles willl stick
together and
a will not pass
p through the sieves.
Tem
mperature off the oven = 1105 C
Place the set of
o standard an
nd non-stand
dard sieves oone above annother
with the smallest
s
aperrture openingg at the botttom. The pann is placed aat the
bottom-m
most position. This experiiment can bee performed manually orr with
the aid of a machine caalled sieve shaker.
s
The manual
m
metho
od should bee performed in a proper ssequence whhich is
as follows;
Mechanicaal Sieve
iforward an
nd backward motion
iileft and rigght motion
iiiclockwise (CW)
(
and counter-clockw
wise (CCW) m
motion
ivFrequent jo
olting.
Time elapsed
e
for the sieving prrocess is 3-5 minutes.
Weigh
h the mass reetained on eaach sieve and
d calculate thhe percentagee passing through each siieve. Then
the FM caan be calculatted by using the relation;
Page | 19

FM
Job No. 4
(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;

iiiiiiiv-
Only sum up the values of standard sieves and do not include the values of the nonstandard sieves.
Only add the sieves of 150m and above sizes.
If any standard sieve is missing, we may use the value of next higher sieve.
Adding extra sieves does not change the result of FM.
Page | 20

4.5
Joob No. 4
Observ
ns:
Sample no.
n 1:

..
SIEV
V
SIEVE #
(opening
s per
linear
inch)
3
1
3/4
3/8
3/16
3/32
Pan
F
FM
E
SIZE
ES
(mm
m
or
m))
MASS
RETAINE
E
%
RETAINE
E
D
CU
UMULATIV
E%
RETAINED
CUM
MULATIV
E%
PASSSING
(gm)
(%)
(%)
((%)
CUM
MULATIV
E%
PASSSING
((%)
75
37.5
5
19
9.5
4.75
5
2.36
6
Pan
n
(...........................................) .................
100
Sample no.
n 2:

..
SIEV
V
SIEVE #
(opening
s per
linear
inch)
3
1
3/4
3/8
3/16
3/32
Pan
F
FM
E
SIZE
ES
(mm
m
or
m))
MASS
RETAINE
E
%
RETAINE
E
CU
UMULATIV
E%
RETAINED
(gm)
(%)
(%)
75
37.5
5
19
9.5
4.75
5
2.36
6
Pan
n
(...........................................) .................
100
Page | 21
Joob No. 4
Sample no.
n 3:

..
SIEV
V
SIEVE #
(opening
s per
linear
inch)
3
1
3/4
3/8
3/16
3/32
Pan
F
FM
4.6
E
SIZE
ES
(mm
m
or
m))
MASS
RETAINE
E
%
RETAINE
E
D
CU
UMULATIV
E%
RETAINED
CUM
MULATIV
E%
PASSSING
(gm)
(%)
(%)
((%)
75
37.5
5
19
9.5
4.75
5
2.36
6
Pan
n
(...........................................) .................
100
Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 22
Job No. 5
JOB NO. 5
Standard
d Test Method for the Determinati
D
ion of Bulk Density (I.E
E. Unit Weiight and thee Voids in
Aggregattes).
Code: AS
STM C-29/C-29M
5.1
Scope & significan

nce:
This teest method is used to dettermine the bulk
b density oof the given fine grained specimen.
During the concreete mix desiggn, when the aggregate is to be batcheed by volum
me or by weigght, then it
becomes necessary
n
to know the mass
m of the aggregates
a
thhat will fill thhe container of unit voluume. If we
know the bulk densityy of the aggrregate materiial then we ccan easily dettermine the mass requireed to fill a
me container..
unit volum
Buulk density also indicatees the perceentage of vooids presentt in the agggregate mateerial. This
percentagee of voids afffects the grad
ding of the aggregates
a
whhich is imporrtant in high strength con
ncrete.
Buulk density allso indicates the compacttive effort reqquired to com
mpact the co
oncrete.
5.2
Appara
atus:
Balaance
Tem
mping rod
Meaasuring Cylind
der
Shovvel or Scoop
Tempingg
d=2255mm
600
V
=
27
Meaasuring
5.3
dd=16
m
mm
d theory:
Related
Temping
R d
a. Bulk density
It is th
he mass of th
he unit volum
me of bulk agggregate mateerial.
The teerm volume includes
i
the volume of th
he individuall particles andd the volumee of the voidds between
the particlles.
Bulk density
d
is useed in weight and
a volume batching.
b
b. Voidss
It is the space between the in
ndividual parrticles in a uunit volume of the aggreegate mass aand is not
occupied by
b the solid mineral
m
matter.
Page | 23
Job No. 5
ble or imperrmeable are not includedd in the voidds for the

Voids within the particles, eitther permeab
determinaation of bulk density by th
his method.
c. Absollute density
It is th
he mass per unit
u volume of
o the individ
dual particless only.
d. Facts about bulk
k density
Bulk density
d
depeends upon how
h
densely the aggregaate is packedd. It also deepends upon
n the size,
distributio
on and shapee of the partticles. If the particles aree of the sam
me size, then it can be paacked to a
limited exxtent but wheen the smalleer particles are
a added, thhe voids get ffilled with th
hem and thuus the bulk
density inccreases.
For a coarse aggreegate, a higheer bulk densiity means thaat there are ffew voids wh
hich are to b
be filled by
the fine agggregate and cement. Thuus bulk densiity also depennds upon thee degree of p
packing.
5.4
Proced
dure:
Note down the diimensions an
nd empty weeight of the measuring ccontainer andd compute itts volume.
For the deetermination of the loosee bulk densityy, fill the conntainer with tthe aggregatee material byy means of
a shovel and
a level its top surface. Weigh
W
the co
ontainer filledd with the agggregate and note down itts reading.
Then the loose
l
bulk deensity of the aggregate material can bee computed by using the relation;
Loose Bulk Density

D
( M loosee )
(Weight of
o container Loose aggreegate) (Weigh
ht of empty co
ontainer)
Volume of th
he container
No
ow for the determination
d
n of the com
mpacted
density, th
he only diffeerence is in filling
f
the con
ntainer.
case, the container is filled in three equal layeers. Fill
nd level the surface
container about one-tthird full an
fingers. Ro
od the layer of the aggreggate with 25 strokes
temping rod evenly distributed oveer the surface. Next
container two-third full
f
and agaain rod it with
w
25
of the teemping rod. Finally, filll the contaiiner to
overflowin
ng and rod again in the manner preeviously
mentioned
d.
bulk
In this
the
with the
of
the
fill the
strokes
No
ow level the top surface and
a weigh th
he container. Calculate thhe compactedd bulk densitty by using
the relatio
on;
Compacted
d Bulk Densityy( M comp )
(Weeight of container Compaccted aggregatee) (Weight off empty contaiiner)

Voluume of the con tainer
Page | 24

5.5
Job No. 5
Observ
ns:
MEASURIING CYLINDER FOR COA

ARSE AGGRE
EGATE
Diameter =
Height =
Volume =
=
MEASURIING CYLINDER FOR FINE AGGREGA

ATE
Diameter =
Height =
Volume =
=
VOLUM
ME
SAMPL
LE
WEIGHT OF
OF
STAT
TE
CONTAINER
O
CONTAIN
NER
(kg)
(m )
W EIGHT OF
AGG. +
CONT.
WEIGHT
T OF
BULK
AGGREG
GATE
DENSITY
(kg)
(kg)
((kg/m3)
COAR
RSE AGGREG
GATE
LOOSSE
COMPAC
CTED
LOOSSE
COMPAC
CTED
FIN
NE AGGREGA
ATE
LOOSSE
COMPAC
CTED
LOOSSE
COMPAC
CTED
Page | 25
Job No. 5
E:
COMPARIISON TABLE
Sr.
NO .
5.6
SAMP
PLE
LOOSE BULK
U
DENSITY
Y
C OMPACTED
BULK
DENSITY
INCREASE
ULK
IN BU
DENSIITY
%
IN
NCREASE
Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 26
Jobb No. 6
JOB NO. 6
Standard
d Test Meth
hod For Thee Determina
ation Of Reelative Denssity (I.E. Sp
pecific Gravvity) And
Water Ab
bsorption Of
O The Coarrse Aggrega
ates.
Code: AS
STM C-127-0
04
6.1
Scope & significan

nce:
In thiss test method
d we determiine the relativve density (i..e. specific grravity) and th
he water abso
orption of
the coarsee aggregates.
The in
nformation obtained
o
from
m specific graavity is helpfu
ful in the folloowing ways;
1- The knowlledge of the specific
s
graviity is importaant for the cooncrete techn
nologist to ddetermine
the properties of concrrete made fro
om such aggrregates.
2- It is used for
f the calculaation of the volume
v
occuupied by the aaggregates in
n various mixxtures.
3- The pores at the surfacce of the partticles affect thhe bond betw
ween the agggregate and th
he cement
paste and thus
t
influencce the concrete strength.
4- Normally it
i is assumed that at the tiime of setting
ng of concretee, the aggreggate is in the ssaturated
and surfacee dry condition. If the agggregate is to be batched iin the dry con
ndition, then
n it is
assumed th
hat sufficientt amount of water
w
will be absorbed froom the mix tto bring the aaggregate
in the saturrated conditiion. If an add
ditional amouunt of water is not addedd as a cover fo
for the
absorbed water,
w
the losss of workabiility is resulteed.
Limitatio
on
The lim
mitation of the
t test is thaat, it can not be used for tthe light weigght aggregatees.
6.2
Appara
atus:
6.3
Balaance
Sam
mple container
Watter tank
Sievves
Oveen
Related
d theory:
a. Aggreegates
Aggregates may bee classified ass;
iii-
Coarse Agggregates
Fine Aggreegates
b. Coarsse aggregatees
Any material
m
which
h is retained on BS sieve #4 (ASTM ssieve 4.75mm
m) is known as coarse agggregate.
Page | 27
Jobb No. 6
c. Fine aggregates
a
Any material
m
which
h is passing BS
B sieve #4 (ASTM sievee 4.75mm) is known as fiine aggregatee.
d. Typess of crush av
vailable in Pakistan
P
1- SARGODHA CRUSH
H
Sargodha crush
c
possesss the followin
ng propertiess;
Greener in colo
or
Higgh strength
Usuually elongatted particles
ALLA CRUSH
2- MARGHA
Marghalla crush posssess the following
properrties;
Grayish in colo
or
Low
w in strength
h
3- SAKHI SA
ARWAR CR
RUSH
Sakhi Sarw
war crush posssess the follo
owing properrties;
Wh
hitish in colo
or
e. Absorrption
It is th
he increase in
i the mass of
o the aggreggate due to tthe penetratiion of waterr into the po
ores of the
particles during
d
a presccribed period
d of time.
The teerm absorptiion does nott include thee amount of water adheri
ring to the suurface of thee particles.
Water absorption is exxpressed as percentage
p
off the dry mass.
f. Saturrated surfacce dry (s.s.d..) condition
It is th
he condition related with
h the aggregaate particles iin which thee permeable p
pores of thee aggregate
particles are
a filled with
h water but without
w
free water
w
on the surface of thhe particles.
g. Oven dry density
y
he mass of th
he oven dried
d aggregate per unit volum
me of the agggregate particcles.
It is th
The teerm volume includes thee volume off the permeaable and the impermeablle pores andd does not
include the volume of the voids beetween the paarticles.
h. Saturrated surfacce dry (s.s.d)) density
It is th
he mass of th
he saturated surface
s
dry agggregate per unit volumee of the aggreegate particlees.
Page | 28
Jobb No. 6
The teerm volume includes thee volume of the

t permeabble and the im
mpermeable pores which
h are filled
with waterr and does no
ot include th
he volume of the voids beetween the paarticles.
i. Apparent density
y
It is th
he mass per unit
u volume of
o the imperm
meable portiion of the agggregate partiicles.
OR
It is th
he mass per unit
u volume of
o the solid portion
p
of thhe particles exxcluding the voids.
j. Speciffic gravity/rrelative den
nsity
It is th
he ratio of th
he density off the aggregatte material too the densityy of the gas ffree distilled water at a
standard temperature
t
(i.e.
( 4 oC).
The reelative densitty is a dimen
nsionless quaantity and is expressed ass oven driedd, saturated surface dry
and apparent
k. Oven dried speciific gravity
It is th
he ratio of th
he oven dried
d density of the
t aggregatee to the denssity of the gas free distilleed water at
o
a standard
d temperaturee (i.e. 4 C).
l. Saturrated surfacce dry speciffic gravity
It is the
t ratio of the saturated
d surface drry density off the aggregaate to the ddensity of the gas free
distilled water
w
at a stan
ndard temperrature (i.e. 4 oC).
m. Apparent specific gravity
It is th
he ratio of th
he apparent density
d
of thee aggregate tto the densityy of the gas ffree distilled water at a
o
standard temperature
t
(i.e.
( 4 C).
6.4
Proced
dure:
The saample of the aggregate is immersed in
n water for 244hrs to essenntially fill all tthe pores. Reemove the
test samp
ple from the water and roll it in a large absorbbent cloth uuntil all visib
ble films of water are
removed. Wipe the laarger particlees individuallly. A movinng stream of air is perm
mitted to asssist in the
drying op
peration. Takke care to avvoid evaporation of watter from agggregate porees during the surfacedrying operation. Determine the mass
m of the test
t sample iin the saturaated surface-dry conditio
on. Record
this and alll subsequent masses to the
t nearest 0.5 g or 0.05 % of the sam
mple mass, w
whichever is ggreater.
In
n order to callculate the vo
olume of the aggregate, im
mmediately pplace the satuurated-surfacce-dry test
sample in
n the sample container and
a determin
ne its appareent mass in w
water at 23
2.0 C. Takke care to
remove alll entrapped air before determining its mass byy shaking thhe container while immeersed. The
differencee between the mass in airr and the maass when thee sample is im
mmersed in water equalss the mass
of water displaced
d
by the
t sample. This
T mass off water equalls the volumee of water diisplaced becaause
water
= mwater x Vwater
w
Page | 29
Jobb No. 6
(water=1 gm/cm3)
= Vwater
mwater
w
Vwater
= Vaggregatte
w
Drry the test sample in thee oven to co

onstant masss at a temperrature of 1105 C, coo
ol in air at
room tem
mperature 1 to
t 3 h, or un
ntil the aggrregate has coooled to a teemperature tthat is comffortable to
handle (ap
pproximatelyy 50 C), and
d determine the mass in order to callculate the ovven specific gravity of
the specim
men.
6.5

ns:
Observ
O. 1: CALCU
ULATION OF SPECIFIC GRAVITY
R
TABLE NO
SAMP
PLE
Weigh
ht of
AGG
G.
Waggg
Volume
V
of
WATER
(gm
m)
(mL)
Volume
of
WATER
+ AGG.
(mL)
Volumee
of
AGGREG
G
ATE
Vagg
(mL)
Speccific
Gravvity
=Waggg/V
aggg
Page | 30
Jobb No. 6
O. 2: CALCU
ULATION OF WATER ABS
SORPTION
TABLE NO
WATER
SAMP
PLE
6.6
SSD
WEIGHT
OD
WEIGHT
T
(GM)
(GM)
WT. OF
A BSORBED
WATER
ABSORPTION
N
= (SSD WT - O
OD
WT
T) X 100 (SSD
D
WT)
(GM)
Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 31
JJob No. 7
JOB NO. 7
Determin
nation of Th
he Aggregatte Impact Value Of Diff
fferent Coarrse Aggregaate Samples..
7.1
Scope & significan

nce:
The agggregate imp

pact value givves a relative measure oof the toughnness or the rresistance off aggregate
suudden shock or impact is not proporttional to the resistance
r
to a slowly appplied compreessive load.
7.2
Appara
atus:
7.3
Coarrse aggregatee from variouus sources

Imp
pact testing machine
m
Span
nner
Balaance
Test sp
pecificationss:
The teest sample sh

hall consist of aggregates the whole off which passes through in B.S. testt sieve and
is retained on a 3/8 in B.SS. test sieve. The
T aggregatte comprisingg the test sam
mple shall bee dried in an o
oven for a
peeriod of fourr hours at a temperature of
o 100-110 C
C and cooledd.
T
The measure (cup) shall be
b filled abouut one-third full
f with the aggregate annd gives 25 ttamping rod. A further
siimilar quantity of aggregate shall bee added and a further 255 tamping givven to the seecond and to
ot the last
laayer 25 tampiing shall agaiin be given and
a the surpllus aggregatee struck off uusing the tam
mping rod as a straighteddge. The net weight of agggregate in th
he measure shall
s
be deterrmined to thhe nearest graam (weight A
A) and this
w
weight shall be used for th
he duplicate test
t on the saame material..
7.4
Proced
dure:
The im
mpact machin
ne shall test without
w
wed
dging or packking upon thee level plate, block or floor, so that
it is rigid and hammer
h
guid
de columns are
a vertical.
T
The cup shall be fixed firm
mly in positio
on on the baase of the maachine and thhe whole of the test sam
mple placed
in
n it and comp
pacted by a single tampin
ng of 25 strokkes of the tam
mping rod.
The hammer shall be raised un
ntil its lower face
f is 15 in. above from the upper suurface of thee aggregate
in
n the cup, an
nd allowed to
o fall freely on
o the aggregate. The tesst sample shhall be subjeccted to a totaal 15 such
bllows each beeing delivered
d at an intervval of not lesss than one seecond.
T
The crushed aggregate
a
shall then be removed
r
from
m the cup aand the wholle of it sieveed on No. 7 B.S. sieve
un
ntil no further significantt amount passes in one minute.
m
The fraction passing the sievve shall be w
weighted to
an
n accuracy of 0.1 gram (w
weight B). Tee fraction rettained on thee sieve shall also be weigghed (weight C), and if
th
he total weigght B + C is
i less than the initial weight
w
(weighht A) by moore than 1 ggm the resullt shall be
diiscarded and a fresh test made.
m
Two tests
t
shall be made.
Page | 32
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
Page | 33

7.5
Job No. 8
Observ
ns:
A = Total Wtt. of the Sam

mple
B = Fraction passing
p
BS sieve
s
#7 afteer crushing
Aggreegate Impacct Value =
C
Cup Diameterr
B
100
A
..
Depth
th of Cup =
..
W
Weight of Haammer =
..
Drop Height =
..
Sr
#
TYPE
Y
OF CRUS
SH
EMPPTY
WT. OF
WT. OF
SAMPLE +
CUP
W1
UP
CU
W2
gm
m
7.6
gm
m
WT O
OF
WT OF SAMPLE
A=
= ( W2 - W1 )
gm
SAMPL
LE
PASSING
G BS
NO. 7 SIIEVE
B
gm
IMPACT
VA
ALUE
=
B
100
A
%
Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 34
Job No. 8
JOB NO. 8
Preparing A Concreete-Mix And
d Casting Va
arious Samp
ples Requirred For Diffferent Testss.
CI 211.1 91
1
Code: AC
8.1
Scope & significan

nce:
This purpose
p
of th
his experimeent is to simulate the acttual formatioon of concreete mix, its ddesign and
prroduction. In
n this experim
ment certain
n number of samples willl be preparedd which will then be testted for the
veerification off concrete miix design pro
ocess.
8.2
Appara
atus:
Con
ncrete Mixer
Mateerials
o Cement
o Sand/Fine Aggregate
o Crush/Coaarse Aggregaate
o Water
Molds for samplles to be prep
pared
o Cylinders 300mm
3
x 1500mm (10+2), compresssive strength & split cylin
nder test
o Cylinders 150mm
1
x 1500mm (2), double
d
punchh test
o Cubes 150m
mm (10), com
mpressive strrength
o Beams 76m
mm x 153mm
m x 1370mm (4), study off flexure behaavior
8.3
Plain Cement
C
Con
ncrete:
PCC conssists of threee basic ing
gredients: ag
ggregate, waater and porrtland cemennt. Accordiing to the
Portland Cement
C
Asso
ociation (PC
CA, 1988):
"The objective in designing concrete
c
mix
xtures is to ddetermine thhe most econnomical andd practical
combiination of reeadily availaable materialls to producee a concrete that will saatisfy the perrformance
requirrements undeer particular conditions of
o use."
PCC mix
x design has
h
evolved
d chiefly through exxperience aand well-doocumented empirical
relationsh
hips. Normaally, the mix design procedure involvves two basicc steps:
i.
Mix
M proportio
oning. This step uses th
he desired P
PCC propertiies as inputss then determ
mines the
req
quired materrials and pro
oportions bassed on a com
mbination off empirical rrelationships and local
ex
xperience. There
T
are maany differentt PCC propoortioning meethods of varrying compllexity that
wo
ork reasonab
bly well.
ii.
Mix
M testing. Trial
T
mixes are then evaluated and characterizeed by subjecting them tto several
lab
boratory tests. Althoug
gh these chaaracterizationns are not comprehensivve, they cann give the
miix designer a good understanding of
o how a par
articular mixx will perforrm in the fieeld during
co
onstruction and
a under sub
bsequent traaffic loading..
Page | 35
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.
Page | 36
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.
ii.
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 watercement ratio as a strength control measure.
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 watercement 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).
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.
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
Page | 37
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.
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.
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).
Page | 38
Job No. 8
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.
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.
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.
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.
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-airentrained PCC of the same slump and maximum aggregate size (PCA, 1988).
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).
Page | 39

iv.
Job No. 8
Teesting. Run
n laboratory
y tests on properly
p
preepared sam
mples to dettermine keyy mixture
ch
haracteristicss. It is impo
ortant to understand thaat these testts are not coomprehensivve nor are
theey exact reproductions of
o actual field conditionss.
The seleccted PCC miixture should

d be the onee that, basedd on test resuults, best sattisfies the m
mix design
objectivess.
8.4
Concreete Mix Desiign:

The Ameerican Concrrete Institutee (ACI) mix
x design metthod is but one of manny basic conncrete mix
design meethods availaable today. This section
n summarizes the ACI abbsolute volum
me method bbecause it
is widely accepted in the U.S. an
nd continuallly updated bby the ACI. Keep in miind that this summary
and mostt methods designated as "mix deesign" methhods are reeally just m
mixture propportioning
methods. Mix design
n includes trial mixture proportioning
p
g (covered hhere) plus performance teests.
This sectiion is a geneeral outline of
o the ACI proportioning
p
g method w
with specific emphasis onn PCC for
pavementts. It emph
hasizes gen
neral concep
pts and rattionale over specific procedures. Typical
procedurees are availab
ble in the folllowing docu
uments:
Th
he American
n Concrete Institute's (ACI)
(
Standdard Practicce for Seleccting Proporrtions for
No
ormal, Heav
vyweight, an
nd Mass Con
ncrete (ACII 211.1-91) as found in their ACI M
Manual of
Co
oncrete Pracctice 2000, Part
P 1: Mateerials and Geeneral Propeerties of Conncrete.
Th
he Portland Cement Asssociation's (PCA)
(
Desig
ign and Conntrol of Conncrete Mixtuures, 14th
ed
dition (2002)) or any earliier edition.
The stand
dard ACI mix
x design pro
ocedure can be
b divided uup into 8 basiic steps:
a. Ch
hoice of slum
mp
b. Maximum
M
agg
gregate size selection
c. Mixing
M
water and air conttent selection
n
d. Water-cement
W
t ratio
e. Ceement conten
nt
f. Co
oarse aggreg
gate content
g. Fine aggregatee content
h. Ad
djustments for
f aggregatee moisture
a. Slump
p
The choicce of slump
p is actually
y a choice of
o mix workkability. Woorkability can be descrribed as a
combinatiion of severaal different, but
b related, PCC
P
propertties related tto its rheologgy:
Eaase of mixing
g
Eaase of placin
ng
Page | 40
Ease of compaction
Ease of finishing
Job No. 8
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

and footings
25 - 75
1-3
Plain footings, caissons and

substructure walls
25 - 75
1-3
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)
Specifications
Fixed Form
Slip Form
(mm)
(inches)
(mm)
(inches)
Typical
25 - 75
1-3
0 - 75
0-3
Extremes
as low as
25
as high as
175
as low as
1
as high as
7
as low as
0
as high as
125
as low as
0
as high as
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
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 airentrained 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
for Different Slumps and Maximum Aggregate Sizes (adapted from ACI, 2000)
Requirements
Mixing Water Quantity in kg/m3 (lb/yd3) for the listed Nominal

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

Mild Exposure
4.5
4.0
Page | 42
Job No. 8
Moderate
Exposure
6.0
5.5
5.0
4.5
4.5
4.0
3.5
3.0
Severe
Exposure
7.5
7.0
6.0
6.0
5.5
5.0
4.5
4.0
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 watercementitious 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
(after ACI, 2000)
Ratio
and
Compressive
Strength
28-Day
Compressive
Strength in MPa
(psi)
Water-cement ratio by weight

Non-AirEntrained
AirEntrained
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
Relationship
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).
Page | 43
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
for Different Fine aggregate Fineness Moduli for Pavement PCC (after ACI, 2000)
of
PCC
Fine Aggregate Fineness Modulus
Nominal Maximum
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
Page | 44
Job No. 8
Volum
me of fine agggregate
h. Adjusstments for Aggregate Moisture
Unlike HM
MA, PCC batching doess not requiree dried aggreegate. Thereefore, aggregate moisturre content
must be accounted
a
forr. Aggregate moisture affects
a
the foollowing paraameters:
1. Ag
ggregate weeights. Aggrregate volum
mes are calcculated baseed on oven dry unit weeights, but
ag
ggregate is typically baatched baseed on actuaal weight. Therefore, any moistuure in the
ag
ggregate willl increase its
i weight and
a stockpilled aggregattes almost aalways conttain some
mo
oisture. Witthout correctting for this, the batchedd aggregate vvolumes willl be incorrecct.
Amount of mixing wa
ater. If the batched
b
aggrregate is anyything but saaturated surfface dry it w
will absorb
water (if oven
o
dry or air
a dry) or giive up waterr (if wet) to tthe cement ppaste. This ccauses a net change in
the amoun
nt of water available in
n the mix an
nd must be ccompensatedd for by adjjusting the aamount of
mixing water added.
8.5
Concreete Mix Desiign and Ma

aterial Calcu
ulation Exam
mple:
i..
Requireed Data:
=
fc'
oncrete type
=
Co
Maaximum aggrregate size
=
Slu
ump required
d
=
Fin
neness Modu
ulus of Fine aggregate =
Bu
ulk density of coarse agg
gregate
=
Bu
ulk density of fine aggreg
gate
=
Speecific gravity of cement
=
Speecific gravity of coarse aggregate
a
=
Speecific gravity of fine agg
gregate
=
Waater absorptiion of coarsee aggregate =
Waater absorptiion of fine ag
ggregate =
ii..
30
Mpa
Non aair entrainedd
20
mm
30-800 mm
2.82
1555 kg/m3
1070..16
kgg/m3
3.15
2.6
2.63
0.9
%
1.2
%
Calcula
ations:
a. Calcu
ulation for target streng
gth:
Fcrr' = 38.3
b. Selecttion of type of cement:
Usee ordinary Portland Cem
ment
bility check
k:
c. Durab
Usee ordinary Portland Cem
ment
d. Relatiive water co
ontent:
Waater content = 92 %
e. Waterr amount:
2
Page | 45
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:
Coarse Agg.:
Fine Agg.:
Water:
421.053
960.99
769.856
202
m. Concrete Mix:
Cement
421.053
1
Fine Agg.
769.856
1.83
Coarse Agg.
960.99
2.28
W/C = 0.53
Concrete weight = 2353.9
kg/m3
Page | 46
Job No. 8
n. Calculation of materials required

Sample
Beam
Cylinder
Cylinder
Cube
Quantity
Size
(mm)
4
12
2
10
76 153 1370
150 300
150 150
150 150 150
Volume of
Concrete
(m3)
0.01593
0.005301
0.005301
0.003375
Total Weight
of Concrete
(kgs)
76.5
51
51
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
Joob No. 10
JOB NO. 9
Standard
d Test Method for The Slump Of Hydraulic
H
C
Cement Con
ncrete.
Code: AS
STM C-143/C
C-143 M-03
9.1
Scope & significan

nce:
This test
t method is used in lab
l and in fiield for findding out the slump (decrrease in the height of
concrete when
w
we lift up the mouuld). This tesst is used exttensively in site works alll over the w
world. The
slump test does not measure
m
the workability of concrete directly butt it co-relates the workab
bility with
some physsical measureement.
The main
m significaance of this teest is as follo
ows;
1- Th
his test method is used to
o determine the
t slump off plastic hydraaulic cement concrete.
Slump<15mm (Non-Pllastic)
Slump>15 (Plastic)
2- Th
his test meth
hod is applicaable to plastiic concrete hhaving coarsee aggregate uupto 37.5mm
m in size. If
the co
oarse aggregate is larger th
han the 37.5m
mm then thiss test methodd is not appliicable.
3- Th
his test meth
hod is not app
plicable to no
on-plastic annd non-cohessive concretee (due to larger amount
of watter presence).
9.2
Appara
atus:
1- Metal mould, thickkness is 1.15m
mm, it is in cone
c
form wiith the base 2200mm diam
meter and 3000mm
heightt with the top
p diameter 1000mm. the to
op and base oof cylindricall mould is op
pen and paraallel to
each other.
o
The mould is proviided with foo
ot pieces andd handles.
2- Tempiing rod, 16m
mm diameter and 600mm in length havving tempingg ends.
9.3
d theory:
Related
a. Slump
p
The decrease in the height of concrete
c
when the mouldd of standard dimensions is lifted.
b. Typess of slump
There are three typ
pes of slump.
1- Trrue Slump
2- Sh
hear Slump
3- Co
ollapse slump
p
Slu
ump
160mm
Page | 48
Joob No. 10
We
W discard thee collapse sluump due to th
he very high value of slum
mp
Sh
hear slump occcurs due to the lack of cohesion
c
in m
mix.
We
W often use the
t term 100%
% compactio
on but actuallly in 100% ccompaction w
we have perccentage of
airr voids less th
han 3% by vo
olume of con
ncrete.
n workabilitty and slum

mp
c. Relatiion between
Workability
Compactingg Factor
Sluump (mm)
Very Low
w
0.78
0-25
Low
0.85
25-50
Medium
0.92
50-100
High
0.95
100-175
Note: Mo
ore is the slum
mp value mo
ore will be thee workabilityy.
9.4
Proced
dure:
The mold is placed on
n a flat moistt non-absorb surface withh the smallerr opening at tthe top. It is then held
firmly in place
p
during filling of con
ncrete by thee operator sttanding on tw
wo foot pieces. The mouuld is filled
to a depth
h of 70mm an
nd 2/3 of vo
olume fills to
o a depth of 1160mm. Each layer is givven 25 strokees with the
help of temping rod uniformly
u
disstributed oveer the cross-ssection of eaach layer. Ro
od the 2nd an
nd 3rd layer
throughouut its depth so that strokees just penetrrates into thee under lying layer. After the top layerr is rodded
strike off the
t surface of
o the concrete by means of rolling mootion of tem
mping rod.
Comp
plete the entirre test with an
a elapsed tim
me of 2.5minnutes. After ffilling, the co
one is slowlyy lifted and
the unsupported concrrete slumps. The decreasee in the heighht of concrette is called sluump.
It is measured
m
with
h the nearestt 5mm. at th
he beginning of every testt, before liftiing the moulld the area
immediateely around the base of the cone sh
hould be cleaaned off of concrete wh
hich may bee dropped
accidentally.
Page | 49
9.5
Joob No. 10
Observ
ns:
Slump Value
V
= ___
___________
____ mm
9.6
Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 50
Joob No. 10
10 JOB NO. 10
To Perforrm The Com
mpacting Faactor Test.
100.1 Scope & significan
nce:
Th
his test also gives
g
the worrkability of co
oncrete indirrectly. This teest is approp
priate for con
ncrete with
the maxim
mum aggregatte size of 40m
mm.
100.2 Appara
atus:
250
Apparratus consissts of two

o
hoppers each in the shape off
frustum of a conee and onee
cylinder.
Upper
275
125
The hopp
pers have hiinge door att
bottom and
a
all the surfaces aree
polished to reduce fricction.
S
Same
d
dimensions
Lower
the
200
Cylinder
150mm
m
dia
100.3 Related
d theory:
a. Comp
pacting factor
The degree
d
of compaction is also called the compactting factor aand is measuured with th
he help of
density rattio that is thee ratio of den
nsity actuallyy achieved inn the test to tthe density o
of same conccrete when
it is fully compacted.
c
Itss maximum answer
a
is 1 but
b practicallyy it is lesser thhan 1.
b. RELA
ATION BET
TWEEN WORKABILIITY AND C
COMPACT
TING FACT
TOR
Workability
Compactingg Factor
SSlump(mm)
Very Low
w
0.78
0-25
Low
0.85
25-50
Medium
0.92
50-100
High
0.95
100-175
Page | 51
Joob No. 10
ore is the com

mpacting facttor more willl be the workkability.
Note: Mo
100.4 Proced
dure:
Firrst the concrrete is placed
d gently at the
t upper hoopper so thaat no work iss done on co
oncrete to
produce compaction.
c
The bottom door of thee upper hoppper is then rreleased and the concretee falls into
the lower hopper. Thee bottom do
oor of the low
wer hopper iis then releaased and the concrete fallls into the
cylinder. Excess
E
concrrete is then reemoved from
m the cylinderr.
The density
d
of con
ncrete in now
w calculated and this dennsity divided by the denssity of fully ccompacted
concrete is known as compacting
c
factor.
f
More is the compacting facctor more willl be the worrkability.
100.5 Observ
ns:
__________
_____ mm
Compaccting Factor Value = ___
100.6 Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 52
Joob No. 11
11 JOB NO. 11
Test Metthod For The
T Flexura
al Strength Of Concreete Using S
Simple Beam
m With Th
hird-Point
Loading.
STM C 78 - 02
0
Code: AS
nce:
This test method is

i used to dettermine the flexural
f
strenngth of speciimens preparred and curedd in
accord
dance with th
he specificatiions. Results are calculateed and reporrted as the m
modulus of ruupture.
The sttrength deterrmined will vary
v where th
here are diffeerences in sppecimen size, preparation, moisture
condittion, curing, or where thee beam has been
b
molded or swayed too size.
The reesults of this test method
d may be used
d to determiine compliannce with speccifications orr as a basis
for proportioning,, mixing and placement operations.
o
Itt is used in teesting concreete for the
constrruction of slaabs and paveements.
The modulus
m
of ruupture is also
o used as an indirect
i
meaasure of the ttensile strenggth of concreete.
11.2 Appara
atus:
Univversal Testing Machine

Supp
porting Beam
m and Roller/
/hinge suppo
orts
Thirrd point load
ding arrangem
ment
The testin
ng apparatus is
i shown in the
t figure abo
ove.
d Theory:
11.3 Related
a. Difficculties in Deetermining Tensile
T
Streength of Con
ncrete:
There are considerablle experimen
ntal difficultiies in determ
mining the trrue tensile sttrength of cooncrete. In
direct tenssion test folllowing are th
he difficultiees:
1. When
W
concreete is gripped
d by the macchine it may be crushed ddue the largee stress conccentration
at the grip.
2. Concrete
C
sam
mples of diffeerent sizes an
nd diameter s show largee variation inn results.
3. Iff there are so
ome voids in
n sample the test may shoow very smaall strength.
4. If
I there is some initial misalignment
m
in fixing thee sample thee results are nnot accuratee.
Page | 53
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
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 d2
My
I
where,
fr
bd 3
I
12
and
3
I bd 12 bd 2
s
d
y
6
2
M M P
6
a 2
I
s
2
bd
y
3Pa
fr
( MPa )
bd 2
fr
Page | 55
Joob No. 11
11.4 Test sp
pecificationss:
a. Rate of
o loading:
The raate of loadin
ng should be such that wee get a stresss of 0.02 00.10 (MPa/s)).
b. Accep
ptance Criteeria of The Specimen:
If proper compaction is not donee, then the sp
pecimen mayy fail outsidde the centraal portion i.ee. near the
ends.
In such a case, if;
i- (a a) > 0.05 l Ignore th
he specimen and discard the results.
ii- (a a) =< 0.05 l Use the same formulaa but insteadd of a, use a for the calcculation of
MOR.
Wheree a= distan
nce from the support centter to the craack
a = one-thiird distance between thee supports
l = distancce between th
he supports
The final result should

d be reported
d in multiplees of 0.1 MP
Pa.
c. Size of
o the specim
men:
The speciimen used is
i a prism of
o 100 x 100 (mm) squuare in crosss-section annd having a length of
510mm.
Thus the dimensions
d
of
o the specim
men are;
100
0 x 100 x 51
10 (mm)
d. Type of loading:
Page | 56
Joob No. 11
o the beam is called thee third-poin

nt/two-pointt loading. The main advvantage of
The loading pattern on
third-poin
nt loading is that, the behavior of th
he beam can be studied uunder pure bbending as thhere is no
shear at th
he central po
ortion of the beam. The phenomenon
p
n is depictedd by the figurre below.
P
41
51
136.6
136.66
1 36.6
M
B.
+
0
S.
No shear iin the central pportion.

Thereforee
pure
bbending
11.5 Proced
dure
When usiing molded
d specimens,, turn the teest specimenn on its sidde with respect to its poosition as
molded an
nd center it on the supp
port blocks. When
W
usingg sawed speccimens, position the speecimen so
that the teension face corresponds
c
to the top orr bottom of the specimeen as has beeen cut from tthe parent
material. Center the loading systeem in relatio
on to the appplied force. B
Bring the loaad-applying blocks in
contact with
w the surfaace of the sp
pecimen at th
he third poinnts and applyy a load of bbetween 3 annd 6 % of
the estimaated ultimatee load.
Grind, caap, or use leather shims on the speccimen contaact surface too eliminate any gap in excess of
0.004 in. (0.10 mm) in width. Gaps
G
in exceess of 0.0155 in. (0.38 m
mm) shall bbe eliminatedd only by
capping or
o grinding. Grinding off lateral surffaces shouldd be minimiized in as m
much as grinnding may
change th
he physical characteristics of the specimens. Capping sshall be in accordance with the
applicablee sections off Practice C 617.
Page | 57
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
Joob No. 11
11.6 Observ
vations & ca
alculations:
Sr.#
Max.
M Applieed
Load
(kg)
(N)
a'
(m
mm)
a a'
(m
mm)
Acceeptance
M.O.R
(MPa)
Mean
(MPa))
11.7 Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 59
Joob No. 12
12 JOB NO. 12
Standard
d Test Meethod For The Deterrmination
n Of The Sp
plitting Teensile Streength
Of Cylin
ndrical Co
oncrete Speecimen.
Code: AST
TM C 496/C
C 496 M-04
nce:
This test
t method is used for the determiination of spplitting tensille strength o
of cylindricall concrete
specimen.
Splittin
ng tensile strrength is help
pful for the following
fo
purrposes;
1- Splittin
ng tensile streength is geneerally greaterr than the dirrect tensile sttrength and llower than
the flexuraal strength (m
modulus of ruupture).
2- Splittin
ng tensile strrength is used
d in the desiggn of structuural light weight concretee members
to evaluatee the shear resistance provided
p
by concrete annd to determ
mine the devvelopment
length of th
he reinforcem
ment.
2P
ld
where,
T = Splitting teensile strength
h (to be repoorted in 0.05 MPa multiples)
P = Applied loaad
l = length of th
he specimen (mm)
d = Diameter of
o the specim
men (mm)
122.2 Appara
atus:
Testin
ng Machine
Suppleementary Beaaring Bar Orr Plates (If thee diameter or thhe largest dimension of the uppper bearing faace or the
Bearin
ng Strips
lowerr bearing blockk is less than thee length of the cylinder to be tested, a
suppllementary beari
ring bar or platee of machined steel shall be used. The
bar or
o plate shall bee manner that thhe load will be applied over th
he
specimen.)
(Two
o bearing strips of nominal 1 //8 in [3.2 mm] thick plywoodd, free of
imperfections, approoximately 1 in. [25 mm] wide,, and of a lengtth equal to,
or each
or sligghtly longer th an, that of the specimen shalll be provided fo
specimen. The beariing strips shall be placed betw
ween the specim
men and
both the upper and lower bearing blocks of the testing machinee or
betweeen the specim
men and supplem
mental bars or plates, when ussed (see
5.2). Bearing
B
strips sshall not be reuused.)
Page | 60
Joob No. 12
122.3 Test sp
pecificationss:
a. Size of
o the specim
men
The sp
pecimen is a cylinder of 150mm
1
diam
meter and 3000mm height.
d=
=150mm
30
Standard
mine the diaameter to th

he nearest 0.25mm by aaveraging thee three diam
meters. Determine the
Determ
length to the
t nearest 2mm by averaaging at leastt two lengths.
b. Size of
o bearing sttrips
Accorrding to AST
TM specificattions, the beaaring strips sshould be 3.22mm thick and 25mm wi
wide. There
is no restrriction on theeir length.
c. Rate of
o loading
The raate of loadin
ng should be such that a stress of 0.7
MPa/min is produced.
1.4
122.4 Proced
dure:
Th
his test meth
hod consists of applyingg a diametriccal
force alon
ng the length
h of a cylindrrical concretee at a rate thhat
within a prescribed
p
raange until faiilure. This lo
oading inducces
tensile stresses on the plane contaaining the app
plied load annd
relatively high comprressive stressses in the area
immediateely around th
he applied loaad.
is
Allthough we are applyingg a compressive

load but due to Poissons
P
efffect, tension
n is
n tension. Teensile
produced and the speccimen fails in
failure occcurs ratherr than com
mpressive faailure
because th
he areas of lo
oad applicatiion are in a state
of triaxiall compressio
on, thereby allowing
a
them
m to
withstand much higheer compressive stresses than
would bee indicated by a uniaxxial compressive
strength teest result.
Page | 61
Joob No. 12
Th
hin, plywood
d bearing strrips are used to distribuute the loadd applied alo
ong the lenggth of the
cylinder.
Th
he maximum
m load sustained by the specimen
s
is divided by aappropriate geometrical factors to
obtain thee splitting ten
nsile strength
h.
122.5 Calcula
ations
Caalculate the splitting
s
tensiile strength of
o the specim
men as follow
ws:
T=
2P
ld
wh
here:
T = splitting tensile streength, (psi orr MPa),
P = maximuum applied load indicated
d by the testiting machine, (lbf or N),
l = length, (in.
( or mm), and
d = diameteer, (in. or mm
m).
122.6 Observ
ns:
Srr.#
Max.
M Applied
d
Load
(To
ons)
(N
N)
Dia
D of
Speecimen
Length
of
Specimen
Splittting
Ten
nsile
Stren
ngth
Mean
(m
mm)
(mm)
(MP
Pa)
(MPa)
122.7 Comments:
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
______
___________
__________
___________
___________
_______________________________________
Page | 62
Joob No. 13
13 JOB NO. 13
Determiination Off The Tensile Streng
gth Of Con
ncrete By Double Punch Testt. (NonStandard
d Test)
133.1 Appara
atus:
Testin
ng Machine
Testin
ng Samples
Punch
hes (2 in num
mber, to be pllaced at the top
t and bottoom of the sam
mple)
133.2 Test sp
pecificationss:
a. Size of
o the specim
men
Th
he specimen is a cylinder of 150mm diameter
d
and 150mm heigght.
Q
d=
=150mm
15
Specimen
133.3 Proced
dure:
It is an indirect method in which we determine tthe tensile strength of cconcrete based on the
theory of perfect plastiicity.
In thiss test a conccrete cylinderr is placed veertically betw
ween the loadding platens of the mach
hine and is
compresseed by two steeel punches placed
p
paralleel to the top and bottom end surfacess.
The saample splits across
a
many vertical diam
metrical planees radiating fr
from central aaxis.
days.
Saamples should be placed under wet co

onditions forr 24 hours annd later on iin a curing taank for 28
133.4 Calcula
ation
The teensile strengtth can be com
mputed as;
Page | 63
Joob No. 13
ft = Q / [ (1.2bH
H - a2)]
wh
here,
hing Load
Q = Crush
133.5 Observ
ns:
Sp
pecimen
Max. ap
pplied
load
d
(Tons)
(N)
Dia of
Specimen
Lenggth
of
men
Specim
Sp
plitting
T
Tensile
Sttrength
Mean
(mm)
(mm
m)
(M
MPa)
(MPa)
133.6 Comments:
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Page | 64

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Job No. 2..........................................................................................................................................9

Job No. 3........................................................................................................................................12

Job No. 4........................................................................................................................................16

Job No. 5........................................................................................................................................23

Job No. 6........................................................................................................................................27

Job No. 7........................................................................................................................................32

Job No. 8........................................................................................................................................35

Job No. 9........................................................................................................................................48

10 Job No. 10......................................................................................................................................51

Plain and Reinforced Concrete 1

Plain and Reinforced Concrete 1

There are different types of cement,

Plain and Reinforced Concrete 1

c. Interfacial transition zone:

Plain and Reinforced Concrete 1

(iii & iv) Reacts

Plain and Reinforced Concrete 1

Fig from Concrete

Plain and Reinforced Concrete 1

Fig from Concrete

Fig from Concrete

Flow tablee test.

Fig from Concrete

Plain and Reinforced Concrete 1

Fig from Concrete

Degree of compactabillity test.

Fig from Concrete

Plain and Reinforced Concrete 1

Adding extrra water by spraying

Plain and Reinforced Concrete 1

Referrence Massess and Devicees for Determ

Plain and Reinforced Concrete 1

Diameter of the plungger end of thee rod = 10

meter of the ring at the bottom

Height of the ring

Plain and Reinforced Concrete 1

The ceement paste must be pro

Plain and Reinforced Concrete 1

Scope & significan

Plain and Reinforced Concrete 1

c. Initial setting tim

Plain and Reinforced Concrete 1

Plain and Reinforced Concrete 1

Final seetting time =

Plain and Reinforced Concrete 1

Plain and Reinforced Concrete 1

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

c. Functions of sieve analysis

British Standard Sieves

Plain and Reinforced Concrete 1

e. Quality of a good sample

Plot of tested specimen

Minimum limit according to specification

Sieve Size (Log Scale)

Plain and Reinforced Concrete 1

Plain and Reinforced Concrete 1

(Cumulative % Re tained on S tan dard Sieves of 150 m or above)

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

Plain and Reinforced Concrete 1

Plain and Reinforced Concrete 1

Plain and Reinforced Concrete 1

Scope & significan