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Materials Lab
Materials Lab
Laboratory Manual
LABORATORY EXERCISE 1
Specific gravity of cement
I. Introduction
The specific gravity of cement is used in the design and control of concrete
mixture. Its value is needed in the calculation of the proportions of cement
and other materials that make up the concrete mix such as sand (fine
aggregate), gravel (coarse aggregate), water and admixtures. Specific
gravity is also an index for the quality of cement.
II. Objective
Cement
kerosene
Le Chatelier’s flask (Figure 1.1)
Balance with 0.1g accuracy
1. Weigh a clean and dry Le Chatelier Flask with its stopper. Record the
weight as W1.
5. Add more kerosene until the level reaches the graduated mark.
6. Wipe-dry the outside of the flask then weigh. Record the weight as W3.
8. Refill the flask with kerosene until the graduated mark. Wipe-dry the
outside of flask then weigh. Record the weight as W4.
V. Calculations
W2 − W1
SG = Eq. 1.1
ሺW2 − W1ሻ − ሺW3 − W4ሻSG୩ୣ୰୭ୱୣ୬ୣ
Where:
W1 = weight of empty flask
W2 = weight of flask + cement
W3 = weight of flask + cement +kerosene
W4 = Weight of flask + kerosene
SGkerosene = 0.79
Table 1.1. Data sheet for computation of SG of cement
SG of kerosene
SG of cement
Average SG of cement
LABORATORY EXERCISE 2
Specific gravity and absorption of coarse aggregates
I. Introduction
The specific gravity (SG) of a solid is the ratio of the mass in air to the
mass of the water having the same volume as the solid. The SG of coarse
aggregates can be used as a index whether an aggregate is suitable for
use in a concrete mix. Low SG usually indicate porous and absorptive
aggregates while high SG often indicate strong and non-absorptive
aggregates.
II. Objective
Electronic
Balance
Specific
Gravity
Frame
Bucket
Figure 2.2 Apparatus for suspending the bucket in water from the center of the
balance
IV. Procedures
3. After the 24 hour soaking period, remove the aggregates from the water
then roll them in large absorbent cloth until all visible water film is
removed. The sample should appear damp without surface sheen. This is
the saturated-surface-dry (SSD) condition of the aggregates.
5. Place the SSD coarse aggregates in the wire mesh basket then determine
its weight in water. Record the weight as W2.
W1
SG = Eq. 2.1
W1 − W2
Where:
W1 = weight of SSD coarse aggregates in air
W2 = weight of SSD coarse aggregates in water
2. Put the sample in an oven then dry for a period of 24 hours at 100oC.
3. Determine the weight of the dried sample. Record the weight as W3.
W1 − W3
% absorption = x100 Eq. 2.2
W3
Where:
W3 = weight of oven dried coarse aggregates
Weight of SSD
coarse aggregates
in water (W2)
SG of SSD coarse
aggregate
Average SG of 3
samples
Weight of dried
aggregates (W3)
% absorption of
coarse aggregate
Average %
absorption of 3
samples
LABORATORY EXERCISE 3
Specific gravity and absorption of fine aggregates
I. Introduction
In this laboratory exercise, the cone test procedure will be used to prepare
the fine aggregates in SSD condition. The specific gravity and absorption
of SSD fine aggregates can therefore be determined experimentally.
II. Objective
1. Decant excess water with care to avoid loss of contents. Spread the
sample on a flat surface. This effectively exposes the aggregates’ surface
area to the air. Stir the sample frequently to attain uniform drying until the
fine aggregates attain a free-flowing condition.
2. Place a portion of the partially dried fine aggregate into the metal sand
cone mold. The mold should be firmly held in place on a smooth surface
with its large end at the bottom.
3. Lightly tamp the surface of the fine aggregates 25 times. Lift the mold
vertically. If surface moisture is still present, the fine aggregate will retain
the molded shape. If this happens, continue drying the fine aggregates
with constant stirring.
4. Repeat steps 2 and 3 until the tamped fine aggregates slumps slightly
upon removal of the mold. At this point, the fine aggregate has reached
the SSD condition.
5. Put 500g of the SSD fine aggregates in the pycnometer and fill
approximately 90% of its volume with water. Agitate the pycnometer to
remove the air bubbles then bring the water level in the pycnometer to its
calibrated capacity.
6. Weigh the pycnometer with the sample and water. Record the weight as
W1.
7. Remove the fine aggregates from the pycnometer and set aside. Clean the
pycnometer using a wash bottle then let it dry.
8. Fill the pycnometer with water up to its calibrated capacity then weigh.
Record the weight as W2.
500
ܵ= ܩ Eq. 3.1
ܹ2 + 500 − ܹ1
Where:
W1= weight of pycnometer with sample and water to the calibration mark
W2= weight of pycnometer filled with water to its calibrated mark
10. Repeat steps 5 to 9 to obtain the SG of two more samples of SSD fine
aggregates then complete Table 3.1.
B. Determination of water absorption of fine aggregates
2. Put the pan with sample in an oven then dry for a period of 24 hours at
100oC.
3. Determine the weight of the dried sample. Record the weight as W3.
500 − W3
% absorption = x100 Eq. 3.2
W3
Where:
W3 = weight of oven dried coarse aggregates
Weight of
pycnometer filled
with water (W2)
SG of SSD fine
aggregate sample
Average SG of 3
samples of SSD
fine aggregate
Table 3.2. Data for % absorption of coarse aggregates
% absorption of
fine aggregate
Average %
absorption of 3
samples of fine
aggregates
LABORATORY EXERCISE 4
Fineness modulus of fine aggregates
I. Introduction
II. Objective
IV. Procedure
8. Compute the fineness modulus (FM) of the fine aggregate by adding the
cumulative percentages of the sample retained, in descending order, from
the No. 4 sieve through the No. 100 sieve. Divide the sum of the
percentages to get FM.
I. Introduction
The test for surface moisture of fine aggregates is used as a field test to
determine the amount of surface moisture in fine aggregates by
displacement in water. In the field, particularly in a batching plant, this test
provides a convenient procedure on the determination of moisture content
of fine aggregate if the value of specific gravity is known but there is no
facility for drying (oven).
The moisture content that can be determined from this test can be used in
the adjustment of the weights of the fine and coarse aggregates and also
the water content to be used in the mix design of concrete. The accuracy
of the moisture content found from this test will heavily depend on the
accuracy of specific gravity of the fine aggregate in saturated-surface-dry
(SSD) condition.
II. Objective
IV. Procedure
2. Fill the flask to the mark with water and determine the weight in grams.
Record this weight as W1.
3. Remove 50% of the water from the flask then put the sample aggregates
as illustrated in Figure 5.1
Figure 5.1 Illustration of putting sample fine aggregates in a flask (Bowles, 1986)
5. Fill the remaining portion of the flask with water until the calibrated mark.
6. Weigh the flask with the sample and water. Record the weight as W2.
Where:
Wg= weight of water displaced by the sample
W1 = weight of flask filled to the mark with water
W2 = weight of flask + sample + water
Vୱ − Vୢ
% = ݁ݎݑݐݏ݅݉ ݂݁ܿܽݎݑݏ ݔ100 Eq. 5.2
Wୱୟ୫୮୪ୣ − W
Where:
Vd= weight of the sample divided by the specific gravity of the fine
aggregate in SSD condition.
Note: Since 1g of water = 1mL, the volume of the sample Vs is numerically
equal to Wg.
Weight of flask +
sample + water
(W2)
Weight of water
displaced by the
sample (Wg)
Volume of the
sample (Vs)
Weight of the
sample divided by
the specific gravity
of the fine
aggregate in SSD
condition (Vd)
% surface moisture
Average % surface
moisture
LABORATORY EXERCISE 6
Mix Design of Concrete
I. Introduction
II. Objective
To design a concrete mix using the absolute volume method (ACI 211)
Cement
Fine Aggregate
Coarse Aggregate
Water
Concrete Mixer
Trowel
Balance
Bucket
IV. Procedure
3. Choose the maximum aggregate size (MAS). The MAS should be less
than the following items:
4. Estimate the water and air content using Table 6.2. Water content
depends on the workability requirement,
5. Select the water-cement ratio (W/C) using Table 6.3 or Table 6.4. The
W/C requirement to produce a given compressive strength can be
determined by carrying out tests or by using previously established
relations (for mixes made with similar ingredients). Selection of W/C
should also satisfy the durability requirement. In cases where pozzolans
are to be used, the W/(cement + pozzolan) should be considered instead
of W/C.
7. Estimate the content of coarse aggregates (G) using Table 6.5. The dry
bulk volume of coarse aggregate per unit volume of concrete depends on
the fineness modulus of the fine aggregate and on the MAS.
10. Write the mix design data in Table 6.6 then weigh the quantities needed
for the mix.
12. Add all the coarse aggregate and the fine aggregate,
13. Start the mixer and mix for one minute then stop the mixer.
14. Add the cement and mix for one minute. Stop then add the mixing water.
15. Mix all ingredients for 3 minutes. Stop and make a 3 minute stop. Resume
mixing then stop after 2 minutes. The rest and restart period will avoid a
false set. False set is the phenomenon wherein concrete tends to stiffen
minutes after pouring, then loosening up later. Deposit the concrete in a
clean and damp container.
Table 6.1. Recommended values of slump for various type of construction as given by ACI 211.1-81
Range of Slump
Type of Construction
mm in
Reinforced foundation walls and footings 20-80 1-3
Plain footings, caissons and substructure walls 20-80 1-3
Beams and Reinforced walls 20-100 1-4
Building columns 20-100 1-4
Pavements and Slabs 20-80 1-3
Mass Concrete 20-80 1-2
Table 6.2. Approximate requirements for mixing water and air content for different
workabilities and nominal maximum sizes of aggregates according to ACI 211.1-81
Water content, kg/m3 (lb/yd3) of concrete for indicated max. aggregate size
Workability of concrete
10mm 12.5mm 20mm 25mm 40mm 50mm 70mm 150mm
Non-air entrained concrete
Slump:
30-50mm 205(350) 200(335) 185(315) 180(300) 160(275) 155(260) 145(220) 125(190)
80-100mm 225(385) 215(365) 200(340) 195(325) 175(300) 170(285) 160(245) 140(210)
150-180mm 240(410) 230(385) 210(360) 205(340) 185(315) 180(300) 170(270) -
Approx. entrapped air
content 3 2.5 2 1.5 1 0.5 0.3 0.2
Air-entrained concrete
Slump:
30-50mm 180(305) 175(295) 165(280) 160(270) 145(250) 140(240) 135(205) 120(180)
80-100mm 200(340) 190(325 180(305) 175(295) 155(265) 155(265) 150(225) 135(200)
150-180mm 215(365) 205(345 190(325) 185(310) 165(280) 165(280) 160(260) -
Recommended ave. total air content, %
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Extreme exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0
Table 6.3. Relationship between W/C ratio and average Compressive Strength of
Concrete according to ACI 211.1-81
Average
Compressive Effective W/C Ratio (by mass)
Strength at 28 days
Mpa Psi Non-air-entrained Air entrained
45 - 0.38 -
- 6000 0.41 -
40 - 0.43 -
35 5000 0.48 0.4
30 - 0.55 0.46
- 4000 0.57 0.48
25 - 0.62 0.53
- 3000 0.68 0.59
20 - 0.70 0.61
15 - 0.80 0.71
- 2000 0.82 0.74
Table 6.4. Requirements of ACI 318-83 for concrete exposed to sulphate attack
Water- Normal
soluble weight
(SO4 ) in Sulphate (SO4) aggregate Lightweight
Sulphate
water in water Type of Cement content aggregate
Exposure
Min. compressive
Max free W/C
% by mass ppm strength in Mpa
ratio
(psi)
Negligible 0.0-0.1 0-150 - -
Modified(TypeII), Portland-
Moderate pozzolan (Type IP(MS)),
0.1-0.2 150-1500 0.5 26(3750)
(seawater) Portland blast-furnace (Type
IS(MS))
Severe 0.2-2.0 1500-10000 Sulphate-resisting Portland 0.45 29(4250)
Sulphate resisting Portland
Very
over 2.0 over 10000 (Type V) plus pozzolan (fly ash 0.45 29(4250)
severe
or other suitable mat'l)
Table 6.5. Dry bulk volume of coarse aggregate per unit volume of concrete as
given by ACI 211.1-81
Material Properties
Bulk Specific Gravity of cement
Bulk Specific Gravity of fine aggregates
Bulk Specific Gravity of coarse aggregate
Fineness Modulus of fine aggregate
Dry rodded Unit weight of coarse aggregate
Initial Values
Mix Item Unit Calculation Mix proportion
Water per cu. m of concrete
Estimated Air
Water-cement ratio
Cement per cu. m concrete
Volume of coarse aggregates per cu. m
concrete
Coarse aggregate per cu. m concrete
I. Introduction
II. Objective
Concrete Mix
Slump Cone Mold, in the shape of a truncated cone with a base 8-in in
diameter, top 4-in in diameter, and a height of 12 in. (Figure 7.1)
Container for weighing materials
Tamping rod (5/8 in diameter, 24 in long)
Mixing pan
Two large trowels
Ruler
2. Hold the mold firmly in place by the handles (to be done by two students)
or by standing on the foot pieces (one student).
3. Fill the mold with freshly mixed concrete one-third full by volume and rod
the layer 25 times (Figure 1.2). Distribute rodding evenly over the entire
cross-section of the sample.
Figure 7.2 Filling the slump cone one-third full by volume and rodding (Mehta, 2001)
4. Fill the cone two-third full by volume. Rod this layer 25 times with rod
penetrating into, but not through the first layer. Distribute rodding evenly
over the entire cross-section of the sample.
5. Fill the cone to overflowing. Rod this layer 25 times with rod penetrating
into, but not through the second layer. Distribute rodding evenly over the
entire cross-section of the sample.
6. Remove the excess concrete from the top of the cone, using a forward
sawing movement of the trowel or tamping rod. Excess concrete around
the base of the mold should also be cleared away, taking care not to jar
the cone mold in any way.
7. Immediately after striking off the excess concrete, remove the mold. Lift it
slowly (taking about 10 sec), steadily upward. Place the cone alongside
the formed concrete mass and lay the tamping rod across the cone so that
it extends over the concrete mass. The entire procedure from filling the
cone mold to its removal should be completed within 2½ minutes. Avoid
jarring the base on which mold and form are resting.
8. With the ruler, measure the slump – the distance from top of the cone
mold (from the bottom of the extended tamping rod) to the average height
of the concrete mass (Figure 7.3).
9. Qualify the type of slump made using Figure 7.4 as a guide. Record the
slump and the type of slump in Table 7.1.
I. Introduction
II. Objective
Concrete Mix
Platform scale
Unit weight container (Figure 8.1)
Mallet
Tamping rod
Trowel
20-Liter
10-Liter
capacity
capacity
2. The inside of the container should be dampened and then filled with three
layers of concrete. Each layer should be added one at a time with the third
layer overfilling the container. Using the damping rod, each layer should be
compacted in 25 strokes. To be able to penetrate the underlying layer only,
the second and the third layers of concrete should be rodded. After rodding
each layer, use the mallet to tap the outside of the container briskly. The
container should be slightly overfilled after the third layer.
3. Smooth the top of the container with a trowel and strike off any excess
concrete. Smooth the top of the concrete again, this time using the cover
plate. The container must be just level full. After that, the cover plate should
be removed and the any excess concrete should be wiped off on the outside
of the container.
4. The filled unit weight container must then be weighed. Record the weight as
W2.
5. Use Eq. 8.1 to compute for the unit weight of the concrete
ܹ2 − ܹ1
ߛ = Eq. 8.1
ܸ௧
Where:
γf = unit weight of concrete (Kg/m3)
W1= weight of container
W2=weight of container + fresh concrete
6. Perform the procedure for different concrete mixes and complete Table 8.1.
Table 8.1. Data on unit of concrete
Weight of container
+ fresh concrete
(W2)
unit weight of
concrete (γf)
LABORATORY EXERCISE 9
Compressive strength test of concrete
I. Introduction
In the U.S. the standard specimen for testing the compressive strength of
concrete is a 150mm x 300mm (6” x 12”) cylinder, samples of which are
shown in Figure 9.1. The compressive strength is measured by a uniaxial
compressive test (Figure 9.2) wherein the load is progressively increased
causing the specimen to fail within 2 to 3 minutes.
Samples of
hardened
concrete
cylinders
Concrete
cylinder
Loading
table
II. Objective
IV. Procedure
2. Provide sulfur mortar or neoprene pads on both ends of the cylinder. This
provides a uniform load distribution when testing.
4. Center the concrete cylinder in the universal testing machine and load it to
complete failure. The loading rate on a hydraulic machine should be
maintained in a range of 20 to 50 psi/s (0.15 to 0.35 MPa/s) during the
latter half of the loading phase. The type of break should be recorded
(Select from Figure 9.3). A common break pattern is a conical fracture.
D) Shear E) Columnar
6. Record the date when the concrete was formed, the test date, maximum
load applied, compressive strength, type of fracture, and any defects in
cylinders or caps then complete Table 9.1.
Table 9.1 Data on compressive strength of concrete cylinders
Concrete
specimen
1 2 3
Number
Age at test
(days) 3 7 28 3 7 28 3 7 28
Diameter
(mm)
Area (mm2)
Load at
failure (N)
Compressive
strength
(MPa)
LABORATORY EXERCISE 10
Split tensile strength test of concrete
I. Introduction
The split tensile strength test of concrete uses cylinders of the same size
as used in the compressive strength test. The cylinders are placed lying
down on two platens of the compression machine. The concrete cylinder is
thus subjected to compression load along two axial lines which are
diametrically opposite. The compressive stress produces a transverse
tensile stress which is uniform along the vertical diameter.
The split tensile test is an indirect tension test. There is a direct tension
test for concrete but the method is rather more difficult to conduct if not
practically impossible. Thus, the split tension test becomes the preferable
tension test for concrete specimens.
II. Objective
IV. Procedure
3. Place the specimen between the crosshead and the loading table. The
position of the specimen is shown in Figure 10.1.
Adjustable crosshead
150x300mm concrete
cylindrical specimen
Loading table
Figure 10.1 Loading position for splitting tension strength test of concrete
4. Apply the load gradually by controlling the load control knob, making sure
that any impact or shock is prevented.
2ܲ Eq. 10.1
ߪ௧ =
ߨ݀ܮ
Where:
P = maximum load (N)
d = average diameter (mm)
L = average length (mm)
σt = splitting tensile strength (MPa)
Concrete
specimen
1 2 3
Number
Age at test
(days) 3 7 28 3 7 28 3 7 28
Diameter
(mm)
Length (mm)
Maximum
Load (N)
Splitting
tensile
strength
(MPa)
LABORATORY EXERCISE 11
Flexural strength test of concrete
I. Introduction
The flexural strength determined using this test will vary depending on
several factors such as specimen size, preparation, moisture condition,
curing, or where the beam has been molded or sawed to size. The results
of this test method may be used to determine compliance with
specifications or as a basis for proportioning, mixing and placement
operations. It is used in testing concrete for the construction of slabs and
pavements.
II. Objective
IV. Procedure
1. Place fresh concrete in bottom half of the flexure mold. Rod with rounded
end of 5/8” rod 62 strokes, distributing the strokes uniformly over the
surface and depth of concrete. To ensure minimum voids, also tap the
sides of the mold lightly..
2. Fill the remaining volume of the mold with fresh concrete. Tamp 62
penetrating the bottom layer but not hitting the bottom. Tap the sides of the
molds to prevent formation of voids due to trapped air.
3. Strike off the surface of the concrete and make a smooth finish at the
surface using a trowel.
4. Set aside the molded specimen for 24 hours. After 24 hours, remove the
hardened specimen from the beam mold then place in a curing tank.
5. Setup the Universal testing machine for center point bending test then
position the beam specimen as shown in Figure 11.1.
LOAD
Adjustable crosshead
Beam specimen
Loading table
3ܲܮ
ߪ = Eq. 11.1
2ܾ݀ଶ
Where:
P = maximum load (N)
d = depth of beam section (mm)
b = width of beam section (mm)
L = Length of beam (mm)
σf = flexural strength (MPa)
Table 11.1 Data on flexural strength of concrete beam specimens
Concrete
specimen
1 2 3
Number
Age at test
(days) 3 7 28 3 7 28 3 7 28
Width of
beam section
(mm)
Depth of
beam section
(mm)
Maximum
Load (N)
Flexural
strength
(MPa)