Material and Concrete Technology Laboratory Manual Content Laboratory 1 - Tests on Fresh Concrete 1 Mixing of fresh concrete P.2 2 Slump test PS 3. Density of fresh concrete P.4 4 — Making of test cubes, beams and cylinders PS 5 Curing of test specimens BG Laboratory 2 —Tests on Steel reinforcement Bar 6 Tensile test on steel reinforcement bar a7 Laboratory 3 — Tests on Hardened Concrete 7 Density of hardened concrete Pll 8 Schmidt rebound hammer P.12 9 — Cube compression test P.13 10 Tensile splitting strength BS 11. Flexural strength P.16ection 1__Mixing Concret I Apparatus Balance of capacity 100 kg and readable to 0.1 kg Mixing pan and shovels Buckets Scoops fe » » & Trowels Il Procedure 1. Use the following mix proportion to prepare a batch of fresh concrete: Cement 8.8kg 20mm agg. 17.6 kg Water 4.4kg 10 mmagg. 8.8 kg Fineagg. 13.2 kg 2. Weight correct amount of aggregate and cement. Mix them in dry thoroughly. 3. Weight correct amount of water, add it into the mixture and mix them thoroughly. 4, Determine the workability of the fresh concrete by slump test (according to the procedure in section 2). 5. Determine the density of the fresh concrete (according to the procedure in section 3). Make one test cube (according to the procedure in section 4). Add 0.8 kg of water more into the mixture and mix them thoroughly again. Determine the slump of the concrete. ye NS Make one test cube, one test cylinder and on test beam (according to the procedure in section 4), P.2See ion2 SI mp Tes I Apparatus 1, Slump cone and base plate 2. Tamping rod 3. Measuring rule Slump Apparatus (Source: ELE) Il Procedure 1. Hold the cone firmly on the base plate, then fill the cone by 3 equal layers of fresh concrete. 2. Tamp each layer by 25 times with a tamping rod. Be sure to penetrate to the previous layer when tamping. 3. Clean away concrete spillage with a sawing and rolling motion of the tamping rod. 4, Lift the cone slowly and steadily in five to ten seconds. 5. If the slumped concrete shear or collapse, the test must be restarted from the first step. If true slump is achieved, continue to the next step. 6. Invert the cone and stand it beside the slumped concrete. 7. Lay the tamping rod across the cone and above the slumped concrete. 8. Record the height different between the underside of the rod and the top of the slumped concrete to the nearest 5 mm. Ii] Form of slump P3 (Source: CS1)sity of Fresh Concrete Section 3. De 1 Apparatus Cylindrical container with a Perspex cover IL Procedure 1. Weight the cylinder with the Perspex cover (m)). 2. Fill the cylinder with water and slide the Perspex cover on top of the rim. Make sure that no air bubble is trapped inside. 3. Wipe the outside of the cylinder with a dry cloth to remove surface water. 4. Weight the cylinder with its content and the Perspex cover (m,).. 5. Empty the cylinder and clean it thoroughly. 6. Fill the cylinder with concrete in six approximately equal layers. Each layer shall be compacted with a compacting bar of not less than 30 strokes, 7. Level the top of the cylinder with a steel float. 8. Clean the outside of the cylinder with a damp cloth. 9, Weight the cylinder with its content and Perspex cover (ms). Ml Calculation Density of the fresh concrete = Tm xp, (report in ke/m*) m-mi Where p,, = 1000 kg/m? BaSection 4 Mal f test cubes, beams and cylindes I Apparatus 1. Cube moulds, cylinder moulds and beam moulds 2. Compacting bar 3. Scoop Il Procedure 1. Clean the mould and properly tighten the bolts. 2. Evenly apply a thin film of mould oil on the inside surface of the mould. 3. Fill the mould with fresh concrete to a thickness of about 50 mm. 4. Use a compacting bar to compact the concrete. Refer to the table below for the minimum of strokes. 5. Repeat step 3 and step 4 until the mould is full. 6. Level the top with a trowel. 7. Cover the mould with a plastic sheet or Perspex cover. ‘Type of specimen Minimum number of strokes per each layer 100 mm cube 25 150 mm cube 35 100 mm @ cylinder 150 mm @ cylinder 100 mm beam 150 mm beam ‘Concrete Moulds and Test Specimens (Source: ELE) BSSection 5 Curing of Concrete Specimen] I Apparatus Curing Tank II Procedure 1. Conerete specimen shall be demoulded in 16 to 24 hours after casting. 2. Mark on the specimen with a sign pen to identify the specimen. 3. Immerse the specimen into a curing tank. The water in the curing shall be kept 273°C, Curing Tank (Source: ELE) P6Section 6 Tensile Test on Steel Bar| I Apparatus 1. Balance of capacity 20 kg and readable to 0.1 2. Stee! measuring rule of 1 m in length ba Universal testing machine & Extensometer (gauge length = 100 mm) I Specimen 1. Plain round steel bar or grade 250 2. Deformed high tensile steel bar or grade 460 IML Procedure 1. Weight the test specimen (m) into the nearest 0.1 g. 2. Measure the length of the test specimen (L) to the nearest 1 mm. 3. Lightly inscribe gauge marks on the specimen throughout the length at intervals of 5/3 d, where d is the nominal diameter of the test specimen. Grip the specimen firmly in the universal testing machine. 5. Record the gauge length of the extensometer and fix it onto the specimen. 6. Adjust the digital readout and the x-y recorder to zero point. 7. Apply the load steadily such that the rate of loading does not exceed 10 N/mm? per second until the yield stress is reached. 8. Hold the applied load; remove the extensometer from the specimen. 9. Resume applying the load for the subsequent determination of the tensile strength until failure occurs. 10. Record the maximum load attained (F,,). 11. Remove the fractured specimen from the machine. BTIv . Fit the broken parts of the specimen in proper contact. Identify those four consecutive gauge marks which have the fracture lying between the middle two marks. Measure the distance spanning the four consecutive gauge marks (L,) to the nearest 1 mm. Calculation Calculate the mass per unit length (M) M= 7 (report in kg/m) Where mis the mass of the specimen, Lis the length of the specimen. Check if the mass per unit length complies with Table 2 & Table 3. Calculate the effective cross-section area (A) M A (report in mm?) Pp Where p.=7850 kg/m? or 0.00785 g/mm? Determine the Young’s Module (E) On the graph, draw a straight line with overlap most with the curve within the limit of proportionality. AF = Astress A (report in kKN/mm?) Astrain Astrain Where AP is the applied force (can be obtained from the plotted curve). Ais the effective cross-sectional area of the specimen. Astrain can be obtained from the plotted curve. P8Determine the yield point load (YL) The yield point load is show from the graph plotted which correspond to 0.33% total strain for grade 250 steel and 0.43% for grade 460 steel. (report in kN) Calculate the yield stress (YS) YS= A (report in N/mm’) Check if the yield stress is not less than steel grade. Calculate the tensile strength (TS) ts- Fe (report in N/mm’) A Calculate the percentage elongation (c) = x 100% (report in %) Where L, is the distance of four consecutive gauge marks which have the fracture lying between the middle two marks L, is the original distance of four consecutive gauge marks. Check if the elongation complies with Table 7. PO‘Table 2. Cross-sectional area and mass Nominal size | Crosssectional | Mase per metre run mm mm? ke et 28.3 0.222 8 50.3 0.395 10 785 0.616 12 113.1 o.gse 16 201.1 1.879 20 3142 2.466 25 490.8 3.354 32 804.2 6.313 40 1256.6 9.864 50° 1963.5 15.413 These are non pr ‘Table 3. Tolerance on mass Nominal size | Tolerance on mass per metre run mm % 6 29 Band10 | +65 12 and over | 2.4.5 Table 7. Tensile properties Grade | Spocitied characteristic Minimum elongation ‘on gauge length strength (cv) 5d* N/mm? % 250 | 250 22 460 | 460 12 *d is the nominal size of the test piece. P.OSection 7 Dei ity yf Hardened Conerete I Apparatus 1. Caliper 2. Balance with stirrup hung beneath and immersed in water. IL Test specimen Conerete cube of 150 x 150 x 150 mm? II Procedure 1. Measure the three dimensions (1), 1; and 1) of the cube with the caliper. Weight the stirrup immersed in water or set the balance reading zero. Place the conerete on the stirrup and fully immersed it in water. Fey Record the apparent mass of the specimen with correction for the apparent mass of the empty stirrup (my). 5. Wipe the specimen to remove the surface water and weight it in air (m,). 6. Perform the test once for each test specimen. IV_ Calculation Density determined by water displacement _ | Density determine by dimension Vo=hxhxls vy ms Density = 7 Where p,, = 1000 kg/m? Density = a (Report in kg/m’) PlSection 8 Schmidt Rebound Hammer] I Apparatus 1. Compression machine 2. Schmidt rebound hammer IL Test specimen Concrete cube of 150 x 150 x 150 (mm) III Procedure 1. Clean the surface of the cube with a towel. 2. Draw lines on two opposite faces (not the trowelled face) of the cube such that each face is subdivided into nine equal squares. 3. Carefully place the cube in the compression machine such that: + The trowelled face is vertical, + The faces with lines drawn are vertical and accessible from the front or rear of the compression machine. 4. Apply loading of 158 — 225 kN to hold the cube. 5. For each face, test with the Schmidt rebound hammer on the centre of each square and record the rebound number. IV_ Calculation 1. Convert the rebound numbers to , compressive strength from the “ chart on the right. cf 3 2. Discard the highest and the Pe lowest value and then take iz | average for the remaining values, 8 wig aoe &Section 9 Compressive strength of Concretel I BYE Apparatus Compression machine Cube checking jig. Caliper Balance of capacity 20 kg and readable to 0.1 g. Feller gauges Procedure Identify and remove the cube specimen from curing tank. Wipe off excess water from specimen surfaces with a piece of cloth. Record the date of the specimen cast. Record the cube if it is having an edge broken for 20mm or more in any direction. Place the cube in cube checking jig with the trowelled surface upwards. Check the contract between the cube and the jib with the feeler gauges. Turn the cube through 90° and repeat the check. Measure the length (1,), width (1;) and height (I) between the three pairs of opposing faces of the cube with a caliper. Weigh the cube. Place the cube on the centre of the lower platen with the trowelled surface of the cube vertical. . Apply the test load steadily so that the stress is increased at a rate within the range of 0.2 N/mm? per second to 0.4 N/mm? per second until no greater load can be sustained. . Record the maximum load applied (F) to the cube specimen.13. Remove the cube specimen from the test machine. Examine and record the mode of failure of the specimen. II Calculation Compressive strength = wa xh (Report in N/mm’) IV_ Failure patterns of cubes | De Wi Note. Alou exposed fee ae cracked approxnaey equally, generaly with litle damage to faces in contact with the platens. Satisfactory Failures Note. T = tensile crack Unsatisfactory Failures (Source: CS1)Section 10 Tensile splitting stren; I Apparatus 1. Compression testing machine 2. Jig for splitting strength test 3. Packing strips 4. Loading pieces IL Test specimen 1. Concrete cylinder of 1506 x 300 (mm) (Source: ELE) i Procedure 1. Place the test specimen in the centering jig with packing strips and loading pieces. 2. Place the jig in the compression machine carefully so that the spacemen is located centrally. 3. Applied the load steadily and without shock such that the stress is increased at a rate within the range of 0.02 MPa/s to 0.04 MPals. 4. Record the maximum load attained (F). IV_ Calculation The Tensile Splitting Strength f, is given by the equation: fa= at (report in N/mm’) where Fis the maximum load L__ is the average measured length D_ isthe average measured diameter ‘Gource: €S1) PASection 11 Flexural Strength) I Apparatus Flexural loading device Il Test specimen Concrete beam of 500 x 100 x 100 (mm) IIL Procedure (Source: ELE) 1. Carefully place the specimen in the flexural loading device such that: «the trowelled face is vertical, ¢ — the specimen is in the centre of the loading device, and the longitudinal axis of the specimen is at right angle to the rollers. 2. Applied the load steadily and without shock such that the stress is increased at a rate within the range of 0.03 MPa/s to 0.06 MPa/s. 3. Record the maximum load attained. (Failures outside the middle one-third of the distance between the supporting rollers shall render the test invalid.) IV_ Calculation The Flexural Strength f.ris given by the equation: Sec= = (Report in Nimm’) L LB is the spacing of the lower rollers or the flexural laginedgyice F is the maximum load 4, & d, are the width and depth of the specimen respectively P16