Lab Manual PRC-1-1 - 240401 - 120249

NAME:
REGISTRATION NO:
PREFACE
This manual has been prepared keeping in view the basic requirements of concrete technology. This
is to be used up to the beginner’s level in concrete materials study. This manual contains the basic
theoretical information extracted from books, the apparatus required for an experiment, the procedure
and calculation of the experiments. Various books and research papers have been consulted while
preparing this manual. If some errors are found then kindly inform the author.
A.Ahmed, Z.A.Siddiqi, A.U.Qazi

Table of contents
Job No. 1 .................................................................................................................................................... 1

Job No. 2 .................................................................................................................................................. 13
Job No. 3 .................................................................................................................................................. 17
Job No. 4 .................................................................................................................................................. 21
Job No. 5 .................................................................................................................................................. 24
Job No. 6 .................................................................................................................................................. 35
Job No. 7 .................................................................................................................................................. 38
Job No. 8 .................................................................................................................................................. 44
Job No. 9 .................................................................................................................................................. 78
Job No. 10 ............................................................................................................................................. 103
Job No. 11 ............................................................................................................................................. 108
Job No. 12 ............................................................................................................................................. 112
Job No. 13 ............................................................................................................................................. 119
Job No. 14 ............................................................................................................................................. 125
Job No. 15 ............................................................................................................................................. 131
Plain and Reinforced Concrete – 1 Job No. 1
1 JOB NO. 1
INTRODUCTION TO CONCRETE:
Concrete is the most commonly used construction material these days. This is a plastic material
that possesses transit properties (properties that change with time) i.e. strength, hardness,
ductility, fluidity etc.
1.1 Definition:
Concrete is a mixture of coarse aggregate, fine aggregate/fillers, cement and water
Being more specific,
Concrete is a transient material comprised of coarse aggregates, matrix and ITZ (Interfacial
transition zone)
Let us discuss the individual items,
a. Coarse Aggregates:
Coarse aggregates constitute the largest portion of the concrete. The main purpose of coarse
aggregates is to provide strength. In normal strength concrete compressive strength is mainly
contributed by the coarse aggregates.
These are the particles retained on sieve # 4 (with an opening of 5mm). There is no set upper
limit on the size of particles but usually an upper limit of 50mm (2in) is considered.
b. Matrix
In simple words we can say that matrix is a mixture of all constituents of concrete other than
the coarse aggregates. This contains the binding material, fillers, water, admixtures and
additives etc. Each of these have been explained below,
i. Binding Material:
This is the component that holds primarily the coarse aggregate particles together. All
the particles in concrete are held together by this component. The function of binding
material can be defined as it provides confinement to coarse and fine aggregate
particles.
In case of concrete confinement is of utmost importance. It can be understood by the

following example,
If we place coarse aggregate particles in a mold (form work) and test that in a
machine, it will provide some strength. But if the aggregates are tried to be tested
without the mold, it would be very difficult to hold them at their location. Before the
machine can apply the load the coarse aggregate particles will drop down. Hence, for
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testing coarse aggregates these should be put in some mold. The mold provides
confinement to the aggregates.
The most commonly used binding material in concrete is Portland cement (ordinary
cement) and the resulting concrete is called, ordinary Portland cement (OPC)
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)
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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 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.
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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.
1.2 Proportioning of concrete materials:
Proportioning of different materials is very important to achieve a material with desired

strength and properties. For example a concrete with less amount of coarse aggregate particles
will provide less strength. Similarly a concrete with less amount of matrix will not be able to
move in the form work and settle properly.
Knowing the properties of each of the constituents of concrete, the amount of all components is
decided. The process is call concrete mix design covered in experiment number 7.
1.3 Hydration of cement:
Hydration process is the one in which cement reacts with water to form a paste known as
calcium hydrate silicate gel responsible for providing the binding property.
The hydration process begins as soon as the water is added to cement. The main components of
cement and their role in hydration has been briefly explained below,
a. C3S : 4.07(CaO)-7.6(SiO2)-6.72(Al2O3 )-1.43(Fe2O3)-2.85(SO3)

b. C2S : 2.87(SiO2)-0.754(3CaO.SiO 2)
c. C3A : 2.65(Al2O3)-1.69(Fe2O 3)
d. C4AF : 3.04 (Fe2O3)
Note:
(a & b) Ca & Si reacts first & start the hydration process
(c & d) Reacts to give hydration & give final setting time

1.4 Workability of concrete:
This can be defined as,

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Glanville, et al. (1947),
The amount of work needed to produce full compaction
ACI, 1990
That property of freshly mixed concrete or mortar which determines the ease and homogeneity
with which it can be mixed, placed, consolidated and finished.
ASTM, 1993
That property determining the effort required to manipulate a freshly mixed quantity of
concrete with minimum loss of homogeneity.
a. Measurement of Workability:
Workability can be by different techniques such as,
i. Slump Test.
ii. Compacting Factor Test.
iii. VB Test.
iv. Flow Table Test.
v. Slump Flow Test.
vi. Degree of compactability test.
These tests have been briefly explained below along with the supporting figures and calculation
methods.
i. Slump test.
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Concrete is filled in a cone with proper compaction. The cone is removed and the drop
in height of concrete is noted down.
For further explanation go to experiment number 8
Fig from Concrete Properties by John Newman
ii. Compacting factor test.
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Concrete is filled in the first bucket out of the two or three in series. The concrete is
allowed to drop from the first bucket to second and then to the mold. This is called
partially compacted concrete. The weight of concrete in this partially compacted state
is compared with the fully compacted weight in form of a ratio called compacting
factor value.
For further explanation go to experiment number 9
iii. VB test.
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In this test the concrete is place in a mold with a plate at the top. Vibrations are
provided until the concrete gets fully settled. The time is noted down.
iv. Flow table test.
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The concrete is placed on a table by using a cone. Then top surface of table is lifted
and dropped for specific number of times and the spread of concrete is noted down.
v. Slump flow test.
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In this test the concrete slump test is performed but instead of determining the drop in
height, spread of concrete is measured.
vi. Degree of compactability test.
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In this test concrete is filled in a mold which is provided vibrations for a specific time.
Then the drop in height of concrete is noted down.
The workability is lost due to the following reasons,

vii. Mix water being absorbed by the aggregate if this not in a saturated state before
mixing
 Evaporation of the mix water
 Early hydration reactions (but this should not be confused with cement setting)
 Interactions between admixtures (particularly plasticizers and superplasticizers) and
the cementitious constituents of the mix.
1.5 Placing and Finishing concrete:
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By placing and finishing we mean how to put concrete in the mold and how to get the final
shape and finish. The basic process is that concrete is poured in the form work by concrete
pump of buckets. Then it is consolidated (vibrations are provided by external or internal
vibraters i.e. vibrating table & pokers/niddle vibraters)
There are a few things to be considered while working with concrete,
 The concrete should be discharged as close as possible to its final position, preferably
straight into the formwork
 A substantial free-fall distance will encourage segregation and should therefore be
avoided
 With deep pours, the rate of placing should be such that the layer of concrete below that
being placed should not have set; this will ensure full continuity between layers, and avoid
cold joints and planes of weakness in the hardened concrete
 Once the concrete is in place, vibration, either internal or external, should be applied to
mold the concrete around embedments e.g. reinforcement, and to eliminate pockets of
entrapped air, but the vibration should not be used to move the concrete into place
 High-workability mixes should not be over vibrated – this may cause segregation.
1.6 Curing of concrete:
As we know that water is added for workability and hydration. So if water is not available for
hydration, strength will be compromised. We also studied that water is lost (loss of workability)
is due to water absorption and evaporation. This loss of water is to be compensated by either
adding extra amount of water or preventing the already present amount of water from
evaporating. This process is called curing.
Different techniques used in curing are,
 Adding extra water by spraying and covering the concrete by gunny bags etc.
 By allowing water to stand on the roofs
 By covering concrete by polythene sheets in order to prevent water from escaping by
evaporation.
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2 JOB NO. 2
Standard Test Method for The Determination of the Normal Consistency of the Hydraulic
Cement.
Code: ASTM C 187-04
2.1 Scope and Significance:
It is used to find out the percentage of water at which the standard consistency is achieved. This
known amount of water is then used in making the cement paste for other tests like;
i. Initial setting time

ii. Final setting time
iii. Soundness test
2.2 Apparatus:
 Weighing Balance
 VICAT Apparatus (contains)
 Plunger with end of 10mm diameter and 50mm length
 Conical ring with lower diameter of 70mm, upper diameter of 60mm and 40mm
height.
 Glass graduates (200mL or 250mL capacity)
 Scraper
 Spatula
 Glass plate trowel
2.3 Related theory:
a. Consistency
The thickness or the viscosity of the cement paste is called consistency.
b. Cement paste
The viscous mass obtained by mixing cement with water is known as cement paste.
c. Standard paste
It is the cement paste for which the 10mm diameter plunger in a standard VICAT test penetrates
by around 10mm.
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d. Standard/Normal consistency
It is the thickness or the viscosity of the standard paste and is expressed as the percentage of
weight of water.
e. VICAT apparatus
The Vicat apparatus consists of a frame A (Fig.) bearing

a movable rod B, weighing 300 g, one end C, the plunger
end, being 10 mm in diameter for a distance of at least 50
mm, and the other end have a removable needle D, 1 mm
in diameter and 50 mm in length. The rod B is reversible,
and can be held in any desired position by a set screw E,
and has an adjustable indicator F, which moves over a scale
(graduated in millimeters) attached to the frame A. The
paste is held in a rigid conical ring G, resting on a plane
non-absorptive square base plate H, about 100 mm on each
side.
The rod B is made of stainless steel having a
hardness of not less than 35 HRC, and shall be straight
with the plunger end which is perpendicular to the rod axis.
The ring is made of a non-corroding, nonabsorbent
material, and have an inside diameter of 70 mm at the base
and 60 mm at the top, and a height of 40 mm. In addition to the above, the Vicat apparatus shall
conform to the following requirements:
Weight of moveable rod = 300±5 gm
Diameter of the plunger end of the rod = 10±0.05 mm
Diameter of the needle = 1±0.05 mm

Inside diameter of the ring at the bottom = 70±3 mm
Inside diameter of the ring at the top = 60±3 mm
Height of the ring = 40±3 mm
2.4 Test specifications:
a. Temperature & humidity
The temperature of the air in the vicinity should be between 20-27.5 °C. The temperature of the
mixing water should be 23±2 °C.
The relative humidity of the laboratory should not be less than 50%.
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b. Amount of cement
Amount of cement required for the test according to various specifications are mentioned below.
ASTM = 650gm
c. Mixing time
The cement paste must be properly mixed and placed in the test specimen within a maximum time
of 4±1/4 min from the instant when cement and water were initially brought in contact.
2.5 Procedure:
Mix 650gm of cement with a measured quantity of water and make a cement paste as per the
standard procedure. Put the cement paste in the ring of the vicat apparatus and remove the excess
paste with the help of a trowel. Center the paste confined in the ring, resting on the plate, under
the rod B and bring the plunger end C of in contact with the surface of the paste, and tighten the
set-screw E. Then set the movable indicator F to the upper zero mark of the scale, or take an
initial reading, and release the rod immediately. This must not exceed 30 seconds after completion
of mixing. The apparatus shall be free of all vibrations during the test.
The paste of normal consistency is achieved when the rod settles to a point such that it is 10mm
from the top surface in 30 seconds after being released. Make trial pastes with varying percentages
of water until the normal consistency is obtained. Make each trial with fresh cement.
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2.6 Observations & Calculations:
Type of cement: _______________
Source of cement: _______________
Manufacturer of cement: _______________
Sampling Person: _______________
Quantity of cement (W1) gm: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Observation No 1 2 3 4
Weight of water added (W 2) gm
Penetration of plunger (mm)
% water by weight = W 2 /W1 × 100
2.7 Comments:
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3 JOB NO. 3
Standard Test Method for The Determination of the Initial and Final Setting Time of the
Hydraulic Cement By VICAT Needle Apparatus.
Code: ASTM C 191-04b
3.1 Scope & significance:
This test method is used to determine the time of setting of the hydraulic cement by Vicat needle
apparatus.
The knowledge of the setting time of the cement is always helpful in deciding the time duration
to mix, transport, place and compact the concrete effectively.
We always prefer a larger initial setting time so that we can mix, transport and place the concrete
easily. According to ASTM specifications, the initial setting time shall not be less than 45 minutes and
not more than 375 minutes.
A smaller value of the final setting time is always preferred in order to avoid large expenditures
on the formwork. According to most of the specifications, the final setting time shall not be greater
than 10hrs and shall not be less than ( 90 + 1.2 × (initial setting time) ) min.
i.e. ( 90 + 1.2 × (initial setting time) ) min < final setting time < 10hrs
3.2 Apparatus:
 Vicat apparatus
 Needle of 1mm2 cross-section and 50mm length (for
initial setting time)
 Flat trowel
 Reference Masses and Devices for Determining Mass
 Spatula
 Graduated cylinders
3.3 Related theory:
a. Setting
In the setting process very little chemical reaction takes place. It only includes the shape
acquisition due to evaporation of water. During the setting process the cement remains in the fluid or
the semi-fluid state and there is very little or no gain in strength. Finer the cement particles more will
be the hydration and therefore it will lead to quick settlement.
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b. Hardening
Hardening is the rate of gain of strength due to the chemical reaction. It also refers to the
strength of the concrete after a specified interval of time.
c. Initial setting time
The time elapsed between the initial contact of cement and water and the time when a 1mm 2
cross-section needle gives a penetration of 25mm in a standard Vicat apparatus is known as initial
setting time of that particular cement paste.
d. Final setting time
It is the time elapsed between the initial contact of cement and water and the time when the
needle does not show considerable penetration.
According to specifications;
Maximum final setting time = 10hrs
Minimum final setting time = [90 + 1.2 (initial setting time)] min
a. Needle sizes
1- For Initial Setting Time and Final Setting Time
1mm x 1mm cross-section (1mm2 cross section required)
50mm length
b. Mixing water
Potable water is satisfactory for the routine tests.
c. Temperature & humidity
The temperature of the air in the vicinity should be between 23±3 °C. The temperature of the
mixing water should be 23±2 °C.
The relative humidity of the laboratory should not be less than 50%.
d. Amount of cement
Amount of cement required for the test according to various specifications are mentioned below.
ASTM = 650gm
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3.5 Procedure:
Prepare a cement paste of standard consistency and put it in the ring of the Vicat apparatus
within the allowable time of 4±1/4 min. Clear and level any extra paste by means of a trowel.
1- Initial Setting Time
Determine the penetration of the 1-mm needle at the start. If a penetration reading of 10mm is
obtained then note down the time as the initial setting time otherwise keep checking the penetration
reading after every 15min thereafter until a penetration reading of 25 mm is obtained which will be
the initial setting time of the cement.
Make each penetration test at least ¼ inches away from any previous penetration and at least
25 mm away from the inner side of the mold.
2- Final Setting Time
Keep on performing the same experiment until there is no

considerable penetration shown by the needle. Note down the time as
final setting time.
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Type of cement: _______________
Observation In minutes In Hours
Initial setting time
Final setting time
3.7 Comments:
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4 JOB NO. 4
Determination of The COMPRESSIVE STRENGTH of HYDRAULIC CEMENT

MORTARS.
Code: ASTM C-109
The following covers only that portion of ASTM Designation: C 109 that is required to determine
the compressive strength of 50-mm (2-in.) portland cement mortar cubes.
4.2 Apparatus:
 Two-kg scale accurate to 0.1 gram

 Six 50 mm (2 in.) cube molds
 Hard rubber tampers 13 × 25 mm (1/2 × 1 in.) cross section and 12 to 15 cm (5 to 6 in.) in
height
 Small steel trowels
 500 grams of portland cement
 1375 grams of Ottawa Sand
 242 cc of water
4.3 Procedure:
A. Preparation of Mortar:
i. Weigh (300) gm of cement and Prepare the corresponding weights of standard sand and
water.
ii. Place the dry paddle and the dry bowl in the mixing position in the mixer. Then introduce
the materials for a batch into the bowl and mix in the following manner:
 Place all the mixing water in the bowl.
 Add the cement to the water, then start the mixer and mix at the low speed (140 ± 5
r/ min) for (30 s).
 Add the entire quantity of sand slowly over a (30 s) period, while mixing at slow
speed.
 Stop the mixer, change to medium speed (285 +10 r/min) and mix for 30 s.
 Stop the mixer and let the mortar stand for 1.5 min. During the first (15 s) of this
interval, quickly scrape down into the batch any mortar that may have collected on
the side of the bowl.
 Finish by mixing for (1min) at medium speed.
B. Molding Test Specimens:

i. Thinly cover the interior faces of the specimen molds with oil.
ii. Start molding the specimens within a total time of not more than 2.5 min after
completion of mixing.
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iii. Place a layer of mortar about 25 mm (half the depth of the mold) in all the cube
specimens.
iv. Tamp the mortar in each cube 32 times (4x8), about 4 rounds, each round to be at right
angles to the other.
v. The tamping pressure shall be just sufficient to insure uniform filling of the molds.
vi. The 4 rounds of taming shall be completed in one cube before going to the next.
vii. When the tamping of the first layer in all cubes is completed, fill the molds with the
remaining mortar and tamp as specified for the first layer.
viii. Cut off the mortar to a plane surface with a straight edge.
ix. Keep the molds in a moist room for 20-24 hours then open them and keep the specimens
in a water basin for a week.
C. Testing Specimens:
i. After 7 days (+ 3 hours), take the specimens out of the basin, dry them with a clean cloth,
put them one after the other in the testing machine.
ii. The cubes must be put on one side, using extra steel plates up and down the specimen.
iii. Start loading in a speed of 1.4 kN /sec or (350 kg /cm2 ) in a minute
iv. When failure, record load and the compressive strength.
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Type of cement: _______________
Cube No. Load (kN) Compressive Strength (MPa)
1
2
3
4
5
6
4.5 Comments:
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5 JOB NO. 5
Determination of the Fineness Modulus of The Coarse And Fine Aggregate From Different
Sources.
Code: ASTM C-316-05, for coarse materials (i.e. > 15μm)
ASTM C-117-05, for fine materials (i.e. < 15μm)
This test method is used to determine the fineness modulus of the given fine grained specimen.
The information obtained from fineness modulus is helpful in the following ways;
1- Fineness modulus tells us directly whether the material is well-graded or gap-graded.

2- Fineness modulus gives us an overall idea whether the material is fine or coarse.
3- It also indicates the surface area of the particles.
1
Surface Area 
Fineness Modulus
Lower the surface area of the aggregate, the required amount of fresh cement paste to
cover the aggregate particles will be less and thus less water is required.
4- Larger value of FM is preferred for fine aggregates. For a good fine aggregate, the FM
should be between 2.3 and 3.1 (ASTM Range for fine aggregates).
5.2 Apparatus:
 Standard set of sieves

 Sieve shaker
 Aggregate samples
5.3 Related theory:
a. Fineness modulus
It is the cumulative percentage retained on standard sieve 150μm and above divided by 100.
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.
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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 μm
(micron).
1 mm = 1000 μm (micron)
Notes:
i- 5 mm is the dividing line between coarse and fine aggregate.

ii- 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. Coarse Aggregates:
Standard Non-Standard
75mm (3 ”)
63mm
50mm
37.5mm (1½ ”)
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)
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B. Fine Aggregates:
ASTM Sieves British Standard Sieves

(mm) (inches)
4.75mm 3/16 (#4)
2.36mm 3/32 (#8)
1.18mm 3/64 (#16)
600μm 3/128 (#30)
300μm 1/88 (#50)
150μm 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/m 2 of
sieving area.
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)
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f. ASTM grading requirements for fine aggregates
Percentage Passing
Sieve Size
Minimum Maximum
9.5mm 100 100
4.75mm 95 100
2.36mm 80 100
1.18mm 50 85
600μm 25 60
300μm 10 30
150μm 2 10
g. ASTM grading requirements for coarse aggregates
Percentage Passing
Sieve Size
37.5mm Down 19.0mm Down 12.5mm Down
(mm)
Minimum Maximum Minimum Maximum Minimum Maximum
50 100 100 - - - -
37.5 95 100 - - - -
25 - - 100 100 - -
19 35 70 90 100 100 100
12.5 - - - - 90 100
9.5 10 30 20 55 40 70
4.75 0 5 0 10 0 15
2.38 - - 0 5 0 5
5.4 Procedure:
Take 2 kg of the oven-dried sample. The sample should be perfectly dry because if there is some
moisture content present then the particles will stick together and will not
pass through the sieves.
Temperature of the oven = 110±5 °C
Place the set of standard and non-standard sieves one above

another with the smallest aperture opening at the bottom. The pan is
placed at the bottom-most position. This experiment can be performed
manually or with the aid of a machine called “sieve shaker”.
The manual method should be performed in a proper sequence which

is as follows;
i- forward and backward motion

ii- left and right motion Mechanical Sieve
Shaker
iii- clockwise (CW) and counter-clockwise (CCW) motion
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iv- Frequent jolting.

Time elapsed for the sieving process is 3-5 minutes.
Weigh the mass retained on each sieve and calculate the percentage passing through each sieve.
Then the FM can be calculated by using the relation;
FM 
 (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;
i- Only sum up the values of standard sieves and do not include the values of the
non-standard sieves.
ii- Only add the sieves of 150μm and above sizes.
iii- If any standard sieve is missing, we may use the value of next higher sieve.
iv- Adding extra sieves does not change the result of FM.
Page | 28
Source of sample: _______________
Fine Aggregate
Sieve # Sieve # Wt. Retained %age Wt. Commulative

(grams) Retained Wt. Retaind
75 mm (3") 75 mm (3")
37.5mm(1.5") 37.5mm(1.5")
19mm (3/4") 19mm (3/4")
9.5mm (3/8 ") 9.5mm (3/8 ")
4 4.75mm(3/16")
8 2.63mm
(3/32")
16 1.18mm
30 600 μm
50 300 μm
100 150 μm
pan pan
Sum
Sum of commulativ e %age weight retained on sieve # 100

Fineness Modulus  
100
Page | 29
Source of sample: _______________
Coarse Aggregate
Sieve # Sieve # Wt. Retained %age Wt. Commulative

(grams) Retained Wt. Retaind
75 mm (3") 75 mm (3")
37.5mm(1.5") 37.5mm(1.5")
19mm (3/4") 19mm (3/4")
9.5mm (3/8 ") 9.5mm (3/8 ")
4 4.75mm(3/16")
8 2.63mm
(3/32")
16 1.18mm
30 600 μm
50 300 μm
100 150 μm
pan pan
Sum
Sum of commulativ e %age weight retained on sieve # 100

Fineness Modulus  
100
Page | 30
Gradation Curve of Fine Aggregate
Page | 31
Gradation Curve of Coarse Aggregate

Page | 32
5.6 Comments:
Page | 33
Page | 34
6 JOB NO. 6
Standard Test Method for The Determination of Bulk Density (i.e. Unit Weight and the
Voids in Aggregates)
Code: ASTM C-29/C-29M
This test method is used to determine the bulk density of the given fine grained specimen.
During the concrete mix design, when the aggregate is to be batched by volume or by weight,
then it becomes necessary to know the mass of the aggregates that will fill the container of unit
volume. If we know the bulk density of the aggregate material then we can easily determine the mass
required to fill a unit volume container.
Bulk density also indicates the percentage of voids present in the aggregate material. This
percentage of voids affects the grading of the aggregates which is important in high strength
concrete.
Bulk density also indicates the compactive effort required to compact the concrete.
6.2 Apparatus: Temping End
 Balance
d=225mm d=16mm
 Temping rod
600mm
 Measuring Cylinder
V 278mm
 Shovel or Scoop =
0
.
Measuring Cylinder Temping Rod
0
6.3 Related theory: 1
4
2
a. Bulk density m
3
It is the mass of the unit volume of bulk aggregate material.
The term volume includes the volume of the individual particles and the volume of the voids
between the particles.
Bulk density is used in weight and volume batching.
b. Voids
It is the space between the individual particles in a unit volume of the aggregate mass and is not
occupied by the solid mineral matter.
Voids within the particles, either permeable or impermeable are not included in the voids for the
determination of bulk density by this method.
Page | 35
c. Absolute density
It is the mass per unit volume of the individual particles only.
d. Facts about bulk density
Bulk density depends upon how densely the aggregate is packed. It also depends upon the size,
distribution and shape of the particles. If the particles are of the same size, then it can be packed to a
limited extent but when the smaller particles are added, the voids get filled with them and thus the
bulk density increases.
For a coarse aggregate, a higher bulk density means that there are few voids which are to be filled
by the fine aggregate and cement. Thus bulk density also depends upon the degree of packing.
6.4 Procedure:
Note down the dimensions and empty weight of the measuring container and compute its
volume. For the determination of the loose bulk density, fill the container with the aggregate material
by means of a shovel and level its top surface. Weigh the container filled with the aggregate and note
down its reading. Then the loose bulk density of the aggregate material can be computed by using the
relation;
(Weight of container  Loose aggregate)  (Weight of empty container )

Loose Bulk Density ( M loose) 
Volume of the container
Now for the determination of the compacted bulk

density, the only difference is in filling the container. In this
case, the container is filled in three equal layers. Fill the
container about one-third full and level the surface with the
fingers. Rod the layer of the aggregate with 25 strokes of the
temping rod evenly distributed over the surface. Next fill the
container two-third full and again rod it with 25 strokes of the
temping rod. Finally, fill the container to overflowing and rod
again in the manner previously mentioned.
Now level the top surface and weigh the container. Calculate the compacted bulk density by
using the relation;
(Weight of container  Compacted aggregate)  (Weight of empty container )

Compacted Bulk Density ( M comp ) 
Volume of the container
Page | 36
Wt. of
Wt. of Wt. of Volume of Bulk
Sample State cylinder +
cylinder aggregate cylinder Density
aggregate
(kg) (kg) (kg) (m3) (kg/m3)
Coarse Compacted
Aggregate Loose
Fine Compacted
Aggregate Loose
6.6 Comments:
Page | 37
7 JOB NO. 7
Standard Test Method for The Determination of Relative Density (Specific Gravity) And
Water Absorption of Different Aggregates.
Code: ASTM C-127/128
In this test method we determine the relative density (i.e. specific gravity) and the water
absorption of the coarse aggregates.
The information obtained from specific gravity is helpful in the following ways;
1- The knowledge of the specific gravity is important for the concrete technologist to
determine the properties of concrete made from such aggregates.
2- It is used for the calculation of the volume occupied by the aggregates in various
mixtures.
3- The pores at the surface of the particles affect the bond between the aggregate and the
cement paste and thus influence the concrete strength.
4- Normally it is assumed that at the time of setting of concrete, the aggregate is in the
saturated and surface dry condition. If the aggregate is to be batched in the dry condition,
then it is assumed that sufficient amount of water will be absorbed from the mix to bring
the aggregate in the saturated condition. If an additional amount of water is not added as
a cover for the absorbed water, the loss of workability is resulted.
Limitation
The limitation of the test is that, it cannot be used for the light weight aggregates.
7.2 Apparatus:
 Balance
 Sample container
 Water tank
 Sieves
 Oven
7.3 Related theory:
a. Aggregates
Aggregates may be classified as;
i- Coarse Aggregates
ii- Fine Aggregates
Page | 38
b. Coarse aggregates
Any material which is retained on ASTM sieve 4.75mm is known as coarse aggregate.
c. Fine aggregates
Any material which is passing ASTM sieve 4.75mm is known as fine aggregate.
d. Types of crush available in Pakistan
i. SARGODHA CRUSH
Sargodha crush possess the following properties;
 Greener in color
 High strength
 Usually elongated particles
ii. MARGHALLA CRUSH
Marghalla crush possess the following properties;
 Grayish in color
 Low in strength
iii. SAKHI SARWAR CRUSH
Sakhi Sarwar crush possess the following properties;
 Whitish in color
e. Absorption
It is the increase in the mass of the aggregate due to the penetration of water into the pores of
the particles during a prescribed period of time.
The term absorption does not include the amount of water adhering to the surface of the
particles. Water absorption is expressed as percentage of the dry mass.
f. Saturated surface dry (s.s.d.) condition
It is the condition related with the aggregate particles in which the permeable pores of the
aggregate particles are filled with water but without free water on the surface of the particles.
g. Oven dry density
It is the mass of the oven dried aggregate per unit volume of the aggregate particles.
The term volume includes the volume of the permeable and the impermeable pores and does not
include the volume of the voids between the particles.
Page | 39
h. Saturated surface dry (s.s.d) density
It is the mass of the saturated surface dry aggregate per unit volume of the aggregate particles.
The term volume includes the volume of the permeable and the impermeable pores which are
filled with water and does not include the volume of the voids between the particles.
i. Apparent density
It is the mass per unit volume of the impermeable portion of the aggregate particles.
OR
It is the mass per unit volume of the solid portion of the particles excluding the voids.
j. Specific gravity/relative density
It is the ratio of the density of the aggregate material to the density of the gas free distilled water
at a standard temperature (i.e. 4 o C).
The relative density is a dimensionless quantity and is expressed as oven dried, saturated surface
dry and apparent
k. Oven dried specific gravity
It is the ratio of the oven dried density of the aggregate to the density of the gas free distilled
water at a standard temperature (i.e. 4 oC).
l. Saturated surface dry specific gravity
It is the ratio of the saturated surface dry density of the aggregate to the density of the gas free
distilled water at a standard temperature (i.e. 4 oC).
m. Apparent specific gravity
It is the ratio of the apparent density of the aggregate to the density of the gas free distilled water
at a standard temperature (i.e. 4 o C).
7.4 Procedure:
A. Coarse Aggregate
i. Select by quartering or use of a sample splitter approximately 5 kg of aggregate. Reject all
material passing a 4.75mm sieve.
ii. Thoroughly wash the sample to remove all dust or other coatings from the particles.
iii. Dry the sample to a constant weight at a temperature of 100 to 110°C (212 to 230°F). Cool
at room temperature for about 15 min. and then immerse in water at room temperature for
approximately 30 min.
iv. Remove sample from water and wipe the particles until all surface films are removed. Weigh
the sample in this saturated surface dry condition to the nearest 0.5 g.
Page | 40
v. Immediately after weighing, place the sample in a wire basket, suspend in water, and obtain
the buoyant weight.
vi. Dry the sample to a constant weight at a temperature of 100 to 110°C (212° to 230°F), cool
in room temperature for at least 30 min. and weigh.
vii. Computations;
B. Fine Aggregate
i. Obtain by sample splitting or quartering 3000 grams of aggregate, including equal quantities
of all fractions.
ii. Dry to a constant weight at a temperature of 100 to 110°C (212 to 230°F).
iii. Allow to cool and cover with water for about 30 min.
iv. Remove excess water and spread on a flat surface. Expose to a gentle moving flame until
test sample approaches a free-flowing condition.
v. Place a portion of the fine aggregate sample loosely into the mold. Tamp lightly 25 times
and lift the mold vertically. If surface moisture is present, the fine aggregate will maintain its
molded shape. Continue drying and testing until upon removal of the mold, the aggregate
slumps slightly. This indicates that the saturated, surface-dry condition has been reached.
vi. Immediately introduce into the pycnometer 500.0 g of the fine aggregate. Fill the
pycnometer almost to capacity and eliminate the air bubbles by agitation. Add water until
the bottom of the meniscus is at the 500 cc line, etched on the pycnometer. Determine the
total weight of the flask, including the sample, and the water.
vii. Carefully remove the fine aggregate and dry to a constant weight of 100 to 110°C (212 to
230°F) and cool for at least 30 min. and weigh.
Page | 41
viii. Computations;
Page | 42
Coarse Aggregates — ASTM Designation: C 127

Passing on ________ Sieve Sample 1 Sample 2 Sample 3 Sample 4
Retained on ________ Sieve
(A) Wt. oven-dry sample (g)
(B) Wt. SSD sample (g)
(C) Wt. saturated sample in water (g)
Bulk specific gravity
Apparent specific gravity
Effective specific gravity
Absorption (%)
Average values:
Bulk sp. gravity = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; Apparent sp. gravity = _ _ _ _ _ _ _ _ _ _ _ _ _
Effective sp. gravity = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; Absorption = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Fine Aggregates — ASTM Designation: C 128

Sample 1 Sample 2 Sample 3 Sample 4
(A) Wt. oven-dry sample (g)
(B) Wt. pycnometer + water to calibration mark
(g)
(C) Pycnometer + water + sample to calibration
mark (g)
Bulk specific gravity
Apparent specific gravity
Effective specific gravity
Absorption (%)
Average values:
Bulk sp. gravity = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; Apparent sp. gravity = _ _ _ _ _ _ _ _ _ _ _ _ _
Effective sp. gravity = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; Absorption = _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
7.6 Comments:
Page | 43
8 JOB NO. 8
Determination of The Aggregate Impact Value of Different Coarse Aggregate Samples.
The aggregate impact value gives a relative measure of the toughness or the resistance of
aggregate sudden shock or impact is not proportional to the resistance to a slowly applied compressive
load.
8.2 Apparatus:
 Coarse aggregate from various sources

 Impact testing machine
 Spanner
 Balance
The test sample shall consist of aggregates the whole of which passes through ½ inch (12.7mm)
sieve and is retained on a 3/8 inch (9.51mm) sieve. The aggregate comprising the test sample shall be
dried in an oven for a period of four hours at a temperature of 100-110 C and cooled.
The measure (cup) shall be filled about one-third full with the aggregate and gives 25 blows of tamping
rod. A further similar quantity of aggregate shall be added and a further 25 blows of tamping rod should
be given to the second layer and on the last layer 25 tamping rod blows should again be given and the
surplus aggregate struck off using the tamping rod as a straight-edge. The net weight of aggregate in the
measure shall be determined to the nearest gram (weight A) and this weight shall be used for the
duplicate test on the same material.
8.4 Procedure:
The impact machine shall test without wedging or packing upon the level plate, block or floor, so
that it is rigid and hammer guide columns are vertical.
The cup shall be fixed firmly in position on the base of the machine and the whole of the test sample
placed in it and compacted by 25 strokes of the tamping rod.
The hammer shall be raised until its lower face is 15 in (381mm) above from the upper surface of
the aggregate in the cup, and allowed to fall freely on the aggregate. The test sample shall be subjected to
a total 15 such blows each being delivered at an interval of not less than one second.
The crushed aggregate shall then be removed from the cup and the whole of it sieved on No. 7 (2.83mm)
sieve until no further significant amount passes in one minute. The fraction passing the sieve shall be
weighted to an accuracy of 0.1 gram (weight B). Te fraction retained on the sieve shall also be weighed
(weight C), and if the total weight B + C is less than the initial weight (weight A) by more than 1 gm the
result shall be discarded and a fresh test made. Two tests shall be made.
Page | 44
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 2.83mm sieve
Page | 45
A = Total Wt. of the Sample

B = Fraction passing 2.83mm sieve after crushing
C = Fraction retained on 2.83mm sieve after crushing
B
Aggregate Impact Value =  100.
A
Sample Sample Type A B C Impact Value

No. (gm) (gm) (gm) (%)
1
2
3
4
5
6
8.6 Comments:
Page | 46
9 JOB NO. 9
Preparing A Concrete-Mix And Casting Various Samples Required For Different Tests.
Code: ACI 211.1 – 91
This purpose of this experiment is to simulate the actual formation of concrete mix, its design
and production. In this experiment certain number of samples will be prepared which will then be tested
for the verification of concrete mix design process.
9.2 Apparatus:
 Concrete Mixer
 Materials
o Cement
o Sand/Fine Aggregate
o Crush/Coarse Aggregate
o Water
 Molds for samples to be prepared
o Cylinders 300mm x 150mm Ø(10+2), compressive strength & split cylinder test
o Cylinders 150mm x 150mm Ø (2), double punch test
o Cubes 150mm (10), compressive strength
o Beams 76mm x 153mm x 1370mm (4), study of flexure behavior
9.3 Plain Cement Concrete:
PCC consists of three basic ingredients: aggregate, water and portland cement. According to the
Portland Cement Association (PCA, 1988):
"The objective in designing concrete mixtures is to determine the most economical and
practical combination of readily available materials to produce a concrete that will satisfy the
performance requirements under particular conditions of use."
PCC mix design has evolved chiefly through experience and well-documented empirical
relationships. Normally, the mix design procedure involves two basic steps:
i. Mix proportioning. This step uses the desired PCC properties as inputs then determines
the required materials and proportions based on a combination of empirical relationships
and local experience. There are many different PCC proportioning methods of varying
complexity that work reasonably well.
ii. Mix testing. Trial mixes are then evaluated and characterized by subjecting them to
several laboratory tests. Although these characterizations are not comprehensive, they can
give the mix designer a good understanding of how a particular mix will perform in the
field during construction and under subsequent traffic loading.
Page | 47
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 | 48
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. 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:
 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 water-cement
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 water-cement 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.
ii. 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
Page | 49
shrinkage. Chiefly, the amount of moisture and the rate of its use/loss will affect
shrinkage 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:
 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:
 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
Page | 50
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).
 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-air-entrained PCC
of the same slump and maximum aggregate size (PCA, 1988).
 Cement properties. Portland cements with higher amounts of C 3S 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.
Page | 51
iii. Mix proportioning. A PCC mixture can be proportioned using experience or a generic
procedure (such as ACI 211.1).
iv. Testing. Run laboratory tests on properly prepared samples to determine key mixture
characteristics. It is important to understand that these tests are not comprehensive nor are
they exact reproductions of actual field conditions.
The selected PCC mixture should be the one that, based on test results, best satisfies the mix
design objectives.
9.4 Concrete Mix Design:
The American Concrete Institute (ACI) mix design method is but one of many basic concrete mix
design methods available today. This section summarizes the ACI absolute volume method
because it is widely accepted in the U.S. and continually updated by the ACI. Keep in mind that
this summary and most methods designated as "mix design" methods are really just mixture
proportioning methods. Mix design includes trial mixture proportioning (covered here) plus
performance tests.
This section is a general outline of the ACI proportioning method with specific emphasis on PCC
for pavements. It emphasizes general concepts and rationale over specific procedures. Typical
procedures are available in the following documents:
 The American Concrete Institute's (ACI) Standard Practice for Selecting Proportions for
Normal, Heavyweight, and Mass Concrete (ACI 211.1-91) as found in their ACI Manual of
Concrete Practice 2000, Part 1: Materials and General Properties of Concrete.
 The Portland Cement Association's (PCA) Design and Control of Concrete Mixtures, 14th
edition (2002) or any earlier edition.
The standard ACI mix design procedure can be divided up into 8 basic steps:
a. Choice of slump
b. Maximum aggregate size selection
c. Mixing water and air content selection
d. Water-cement ratio
e. Cement content
f. Coarse aggregate content
g. Fine aggregate content
h. Adjustments for aggregate moisture
Page | 52
a. Slump
The choice of slump is actually a choice of mix workability. Workability can be described as a
combination of several different, but related, PCC properties related to its rheology:
 Ease of mixing
 Ease of placing
 Ease of compaction
 Ease of finishing
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)
Type of Construction Slump

(mm) (inches)
Reinforced foundation walls 25 - 75 1-3
and footings
Plain footings, caissons and 25 - 75 1-3
substructure walls
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 low as 1 as low as 0 as low as 0
as high as 175 as high as 7 as high as 125 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 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).
Page | 53
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 air-entrained 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 Requirements

for Different Slumps and Maximum Aggregate Sizes (adapted from ACI, 2000)
Mixing Water Quantity in kg/m3 (lb/yd3) for the listed Nominal Maximum Aggregate
Size
9.5 mm 12.5 mm 19 mm 25 mm 37.5 mm 50 mm 75 mm 100 mm
Slump
(0.375 in) (0.5 in.) (0.75 in.) (1 in.) (1.5 in.) (2 in.) (3 in.) (4 in.)
Non-Air-Entrained PCC
25-50 (1 - 2) 207 199 190 179 166 154 130 113

(350) (335) (315) (300) (275) (260) (220) (190)
75-100 (3 - 4) 228 216 205 193 181 169 145 124

(385) (365) (340) (325) (300) (285) (245) (210)
150-175 (6 - 7) 243 228 216 202 190 178 160

-
(410) (385) (360) (340) (315) (300) (270)
Typical entrapped air
3 2.5 2 1.5 1 0.5 0.3 0.2
(percent)
Air-Entrained PCC
25-50 (1 - 2) 181 175 168 160 148 142 122 107
(305) (295) (280) (270) (250) (240) (205) (180)
75-100 (3 - 4) 202 193 184 175 165 157 133 119

(340) (325) (305) (295) (275) (265) (225) (200)
150-175 (6 - 7) 216 205 197 184 174 166 154
-
(365) (345) (325) (310) (290) (280) (260)
Recommended Air Content (percent)
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
Severe Exposure 7.5 7.0 6.0 6.0 5.5 5.0 4.5 4.0
Page | 54
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 water-
cementitious 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 Ratio and Compressive Strength Relationship

(after ACI, 2000)
28-Day Compressive Water-cement ratio by weight

Strength in MPa Non-Air-
Air-Entrained
(psi) Entrained
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
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 ).
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 more stiff and less
Page | 55
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 of PCC

for Different Fine aggregate Fineness Moduli for Pavement PCC (after ACI, 2000)
Nominal Maximum Fine Aggregate Fineness Modulus

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:
Volume of fine aggregate = Unit volume (1 m 3 or yd3) – (Volume of mixing water + Volume of air
+ Volume of portland cement + Volume of coarse aggregate)
h. Adjustments for Aggregate Moisture
Unlike HMA, PCC batching does not require dried aggregate. Therefore, aggregate moisture
content must be accounted for. Aggregate moisture affects the following parameters:
Aggregate weights. Aggregate volumes are calculated based on oven dry unit weights, but
aggregate is typically batched based on actual weight. Therefore, any moisture in the aggregate
will increase its weight and stockpiled aggregates almost always contain some moisture. Without
correcting for this, the batched aggregate volumes will be incorrect.
Amount of mixing water. If the batched aggregate is anything but saturated surface dry it will
absorb water (if oven dry or air dry) or give up water (if wet) to the cement paste. This causes a
net change in the amount of water available in the mix and must be compensated for by adjusting
the amount of mixing water added.
Page | 56
9.5 Concrete Mix Design and Material Calculation Example:
i. Required Data:
fc' = 30 Mpa
Concrete type = Non air entrained
Maximum aggregate size = 20 mm
Slump required = 30-80 mm
Fineness Modulus of Fine aggregate = 2.82
Bulk density of coarse aggregate = 1555 kg/m3
Bulk density of fine aggregate = 1070.16 kg/m3
Specific gravity of cement = 3.15
Specific gravity of coarse aggregate = 2.6
Specific gravity of fine aggregate = 2.63
Water absorption of coarse aggregate = 0.9 %
Water absorption of fine aggregate = 1.2 %
ii. Calculations:
a. Calculation for target strength:
Fcr' = 38.3
b. Selection of type of cement:
Use ordinary Portland Cement

c. Durability check:
Use ordinary Portland Cement

d. Relative water content:
Water content = 92 %
e. Water amount: 2
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

Page | 57
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: 421.053
Coarse Agg.: 960.99
Fine Agg.: 769.856
Water: 202
m. Concrete Mix:
Cement Fine Agg. Coarse Agg.

421.053 769.856 960.99
1 1.83 2.28
W/C = 0.53
Concrete weight = 2353.9 kg/m3
Page | 58
Calculation of materials required
Volume of Total Weight

Size
Sample Quantity Concrete of Concrete
(mm)
(m3) (kgs)
Beam 4 75 × 150 × 1350
Cylinder 12 150Ø × 300
Cylinder 2 150Ø × 150
Cube 10 150 × 150 × 150
Total concrete required = _ _ _ _ _ _ _ _ kg

Allowance for wastage (10%) = _ _ _ _ _ _ _ _ kg
Maximum capacity of the mixer = _ _ _ _ _ _ _ _ kg
Number of batches =________
Quantity required per batch = _ _ _ _ _ _ _ _ kg
Weight of the concrete constituents:
1. Cement = _ _ _ _ _ _ _ _ kg
2. Fine Aggregate = _ _ _ _ _ _ _ _ kg
3. Coarse Aggregate = _ _ _ _ _ _ _ _ kg
4. Water = _ _ _ _ _ _ _ _ kg
9.7 Comments:
Page | 59
10 JOB NO. 10
Standard Test Method for The Slump Of Hydraulic Cement Concrete.
Code: ASTM C-143/C-143 M-03
This test method is used in lab and in field for finding out the slump (decrease i n the height of
concrete when we lift up the mould). This test is used extensively in site works all over the world.
The slump test does not measure the workability of concrete directly but it co-relates the workability
with some physical measurement.
The main significance of this test is as follows;
1- This test method is used to determine the slump of plastic hydraulic cement concrete.
Slump<15mm (Non-Plastic)
Slump>15 (Plastic)
2- This test method is applicable to plastic concrete having coarse aggregate upto 37.5mm in
size. If the coarse aggregate is larger than the 37.5mm then this test method is not applicable.
3- This test method is not applicable to non-plastic and non-cohesive concrete (due to larger
amount of water presence).
10.2 Apparatus:
1- Metal mould, thickness is 1.15mm, it is in cone form with the base 200mm diameter and 300mm
height with the top diameter 100mm. the top and base of cylindrical mould is open and parallel
to each other. The mould is provided with foot pieces and handles.
2- Temping rod, 16mm diameter and 600mm in length having temping ends.
10.3 Related theory:
a. Slump
The decrease in the height of concrete when the mould of standard dimensions is lifted.
b. Types of slump
There are three types of slump.
1- True Slump
2- Shear Slump
3- Collapse slump
Page | 60
Slump
160mm
 We discard the collapse slump due to the very high value of slump
 Shear slump occurs due to the lack of cohesion in mix.
 We often use the term 100% compaction but actually in 100% compaction we have
percentage of air voids less than 3% by volume of concrete.
c. Relation between workability and slump
Workability Compacting Factor Slump (mm)

Very Low 0.78 0-25
Low 0.85 25-50
Medium 0.92 50-100
High 0.95 100-175
Note: More is the slump value more will be the workability.
10.4 Procedure:
The mold is placed on a flat moist non-absorb surface with the smaller opening at the top. It is then
held firmly in place during filling of concrete by the operator standing on two foot pieces. The mould
is filled to a depth of 70mm and 2/3 of volume fills to a depth of 160mm. Each layer is given 25
strokes with the help of temping rod uniformly distributed over the cross-section of each layer. Rod
the 2nd and 3rd layer throughout its depth so that strokes just penetrates into the under lying layer.
After the top layer is rodded strike off the surface of the concrete by means of rolling motion of
temping rod.
Complete the entire test with an elapsed time of 2.5minutes. After filling, the cone is slowly lifted
and the unsupported concrete slumps. The decrease in the height of concrete is called slump.
It is measured with the nearest 5mm. at the beginning of every test, before lifting the mould the
area immediately around the base of the cone should be cleaned off of concrete which may be
dropped accidentally.
Page | 61
Slump Value = _ _ _ _ _ _ _ _ inches, _ _ _ _ _ _ _ _ mm
10.6 Comments:
Page | 62
11 JOB NO. 11
To Perform The Compacting Factor Test.
This test also gives the workability of concrete indirectly. This test is appropriate for concrete
with the maximum aggregate size of 40mm.
11.2 Apparatus:
250
Apparatus consists of two mm
hoppers each in the shape of

275
frustum of a cone and one Upper
Hopper mm
cylinder.
125
The hoppers have hinge door at mm Same
Lower dimensions
the bottom and all the surfaces are
Hopper
polished to reduce friction.
200
mm
Cylinder
150mm
dia
300mm
high
11.3 Related theory:
a. Compacting factor
The degree of compaction is also called the compacting factor and is measured with the help of
density ratio that is the ratio of density actually achieved in the test to the density of same concrete
when it is fully compacted.
Its maximum answer is 1 but practically it is lesser than 1.
b. RELATION BETWEEN WORKABILITY AND COMPACTING FACTOR
Workability Compacting Factor Slump(mm)
Very Low 0.78 0-25

Low 0.85 25-50
Medium 0.92 50-100
High 0.95 100-175
Note: More is the compacting factor more will be the workability.
Page | 63
11.4 Procedure:
First the concrete is placed gently at the upper hopper so that no work is done on concrete to
produce compaction. The bottom door of the upper hopper is then released and the concrete falls
into the lower hopper. The bottom door of the lower hopper is then released and the concrete falls
into the cylinder. Excess concrete is then removed from the cylinder.
The density of concrete in now calculated and this density divided by the density of fully
compacted concrete is known as compacting factor.
More is the compacting factor more will be the workability.
Page | 64
W
Partially Compacted Density   PC    kg m 3
V
W
Fully Compacted Density   FC    kg m 3
V
 PC
Compactive Factor   
 FC
11.6 Comments:
Page | 65
12 JOB NO. 12
Test Method for The Compressive Strength of Cylindrical & Cubical Concrete Specimens.
Code: ASTM C 39 (Only for cylinders)
The purpose is to determine the compressive strength of cylindrical specimens, either molded or
drilled cores. The method is limited to concrete having a density of at least 800 kg/m3 (50 lb/ft3 ).
The 28-day compressive strength (f’c) of molded cylinders is normally used in design.
12.2 Apparatus:
 Universal Testing Machine

 Cylindrical Concrete Specimens
 Cubical Concrete Specimens
12.3 Procedure:
i. Preparation of cylindrical specimens.

 Prepare and cure the specimens in accordance with ASTM Designation: C 192.
 Perform air content, slump, and penetration tests on the fresh concrete prior to casting
the specimens in accordance with ASTM Designations: C 143, C 231, and C 360.
 Fill the cylinders with three lifts of freshly mixed concrete, tamping each lift 25 times with
the tamping rod. Also tap each lift lightly with a mallet 10 to 15 times.
 Strike off the excess concrete with the tamping rod and finish to a smooth surface with a
steel trowel.
 It is recommended that specimens be prepared and tested in groups of three.
ii. Curing of the concrete specimens.
 Allow the specimens to set for about 24 hours at normal room temperature, with the top
surface covered to prevent loss of moisture.
 Strip the mold from the specimens and place in the curing facility until ready for testing.
iii. Compression testing procedure.
 Remove the specimen from the curing facility just prior to testing. Specimens shall be
tested while still in a moist condition.
 Measure the diameter of the specimen, determined at right angles to each other about
mid-height of the specimen. Average the two values to the nearest 0.25 mm (0.01 in.).
 Center the capped specimens in the testing machine and load them.
 Load to failure.
 Record the ultimate load, the angle of fracture, and any other pertinent aspects of failure
such as voids.
Use the same procedure for testing cubes.
Page | 66
Load Area Strength Avg. Strength

Mix Proportion
Date of Casting
Age
w/c Ratio
Sample Weight
Type
No. (kg) (ton) (lb.) (in2) (psi) (psi) (Mpa)

(days)
7
Cube
14
21
28
7
Cylinder
14
21
28
Page | 67
Curve showing rate of gain of strength (Strength Vs Days) of both cyliners and cubes
Page | 68
12.5 Comments:
Page | 69
13 JOB NO. 13
Test Method for The Flexural Strength of Concrete Using Simple Beam With Third-Point
Loading.
Code: ASTM C 78 - 02
 This test method is used to determine the flexural strength of specimens prepared and cured in
accordance with the specifications. Results are calculated and reported as the modulus of
rupture.
 The strength determined will vary where there are differences in specimen size, preparation,
moisture condition, curing, or where the beam has been molded or swayed 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.
 The modulus of rupture is also used as an indirect measure of the tensile strength of concrete.
13.2 Apparatus:
 Universal Testing Machine

 Supporting Beam and Roller/hinge supports
 Third point loading arrangement
13.3 Procedure:
i. Preparation: Make the specimens in accordance with the concrete batch procedure. Test the
concrete for slump and air content. Fill the beam forms with three lifts of concrete, tamping each
lift 25 times with the 16 mm (5/8 in.) tamping rod or fill the form in one lift and consolidate the
concrete with a mechanical vibrating table. Be careful not to over vibrate since that would cause
segregation.
ii. Curing: Allow the specimens to remain in the steel forms with the top properly covered for
about 24 hours at normal room temperature. Strip the forms and place the specimens in the
curing facility until ready for testing.
iii. Testing: Remove the specimens from the curing facility and mark the beam where it will be in
contact with the supports and at the opposite side where it will be in contact with the third-point
loading. Remember that none of these contact points should be on the top or hand -finished
surface of the specimen. In other words, the beam should be tested 90° to its casting position.
iv. Record the ultimate load, the exact location of fracture, and the type of failure.
Page | 70
Beams Cross Sections:
Four beams are casted of size 75mm × 150mm × 1350mm

The reinforcement detailing is shown below.
Singly Reinforced Singly reinforced

2#10 bars 2 #10 & 2 #6 bars
#6 @ 65mm C/C
stirrups
#2
Singly Over Reinforced Doubly Reinforced beam

2#19 & 2#10 bars 2#13 & 2#10 bars
#6 @ 65mm C/C stirrups #6 @ 65mm C/C stirrups
#2 #2
Page | 71
Load Theoretical Load Practical Percentage

No. Type of beam
(kN) (kN) Difference
1
2
3
4
Explain the mode of failure for each beam in the space below,
___________________________________________ ___________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
_________________________________________________ _____
______________________________________________________
13.5 Comments:
Page | 72
14 JOB NO. 14
Standard Test Method for The Determination of the Splitting Tensile Strength
of Cylindrical Concrete Specimen.
Code: ASTM C 496/C 496 M-04
This test method is used for the determination of splitting tensile strength of cylindrical concrete
specimen.
Splitting tensile strength is helpful for the following purposes;
1- Splitting tensile strength is generally greater than the direct tensile strength and lower
than the flexural strength (modulus of rupture).
2- Splitting tensile strength is used in the design of structural light weight concrete
members to evaluate the shear resistance provided by concrete and to determine the
development length of the reinforcement.
2P
T
ld
where,
T = Splitting tensile strength (to be reported in 0.05 MPa multiples)
P = Applied load
l = length of the specimen (mm)
d = Diameter of the specimen (mm)
14.2 Apparatus:
 Testing Machine
 Supplementary Bearing Bar Or Plates (If the diameter or the largest dimension of the upper bearing face or
the lower bearing block is less than the length of the cylinder to be
tested, a supplementary bearing bar or plate of machined steel shall
be used. The bar or plate shall be manner that the load will be applied
over the specimen.)
 Bearing Strips (Two bearing strips of nominal 1 /8 in [3.2 mm] thick plywood, free
of imperfections, approximately 1 in. [25 mm] wide, and of a length
equal to, or slightly longer than, that of the specimen shall be
provided for each specimen. The bearing strips shall be placed
between the specimen and both the upper and lower bearing blocks
of the testing machine or between the specimen and supplemental
bars or plates, when used (see 5.2). Bearing strips shall not be reused.)
Page | 73
a. Size of the specimen
The specimen is a cylinder of 150mm diameter and 300mm height.
Determine the diameter to the nearest 0.25mm by averaging the three diameters. Determine the
length to the nearest 2mm by averaging at least two lengths.
b. Size of bearing strips
According to ASTM specifications, the bearing strips should be 3.2mm thick and 25mm wide.
There is no restriction on their length.
c. Rate of loading
The rate of loading should be such that a stress of 0.7 – 1.4 MPa/min is produced.
14.4 Procedure:
This test method consists of applying a

diametrical force along the length of a cylindrical
concrete at a rate that is within a prescribed range
until failure. This loading induces tensile stresses
on the plane containing the applied load and
relatively high compressive stresses in the area
immediately around the applied load.
Although we are applying a compressive

load but due to Poisson’s effect, tension is
produced and the specimen fails in tension. Tensile
failure occurs rather than compressive failure
because the areas of load application are in a state of tri axial compression, thereby allowing them to
withstand much higher compressive stresses than would be indicated by a uniaxial compressive
strength test result.
Page | 74
Thin, plywood bearing strips are used to distribute the load applied along the length of the
cylinder.
The maximum load sustained by the specimen is divided by appropriate geometrical factors
to obtain the splitting tensile strength.
14.5 Calculations
Calculate the splitting tensile strength of the specimen as follows:
2P
T=
ld
where:
T = splitting tensile strength, (Psi or MPa),
P = maximum applied load indicated by the testing machine, (lbf or N),
l = length, (in. or mm), and
d = diameter, (in. or mm).
Page | 75
Dia of Length of Splitting Tensile

Max. Applied Load Mean
Sr.# Specimen Specimen Strength
(Tons) (N) (mm) (mm) (MPa) (MPa)
1
2
3
4
5
6
14.7 Comments:
Page | 76
15 JOB NO. 15
Determination of The Tensile Strength of Concrete by Double Punch Test.

(Non-Standard Test)
15.1 Apparatus:
 Testing Machine
 Testing Samples
 Punches (2 in number, to be placed at the top and bottom of the sample)
a. Size of the specimen
The specimen is a cylinder of 150mm diameter and 150mm height.
15.3 Procedure:
It is an indirect method in which we determine the tensile strength of concrete based on the
theory of perfect plasticity.
In this test a concrete cylinder is placed vertically between the loading platens of the machine and
is compressed by two steel punches placed parallel to the top and bottom end surfaces.
The sample splits across many vertical diametrical planes radiating from central axis.
Samples should be placed under wet conditions for 24 hours and later on in a curing tank for
28 days.
Page | 77
15.4 Calculation
The tensile strength can be computed as;
ft = Q / [π (1.2 b H - a2)]
Where,
Q = Crushing Load
Page | 78
Max. applied load b a H Mean

Specimen
(Tons) (N) (mm) (mm) (mm) (MPa)
1
2
3
4
5
6
15.6 Comments:
Page | 79

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NAME:

A.Ahmed, Z.A.Siddiqi, A.U.Qazi

Job No. 1 .................................................................................................................................................... 1

Concrete is a mixture of coarse aggregate, fine aggregate/fillers, cement and water

Being more specific,

Let us discuss the individual items,

In case of concrete confinement is of utmost importance. It can be understood by the

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)

Workability and hydration processes have been explained later.

Some common types of admixtures are,

a. Water Reducing Admixtures (plasticizers and super plasticizers):

d. Corrosion inhibiting admixtures:

Corrosion inhibiting admixtures are added to avoid the corrosion of steel.

c. Interfacial transition zone:

1.2 Proportioning of concrete materials:

Proportioning of different materials is very important to achieve a material with desired

1.3 Hydration of cement:

a. C3S : 4.07(CaO)-7.6(SiO2)-6.72(Al2O3 )-1.43(Fe2O3)-2.85(SO3)

(a & b) Ca & Si reacts first & start the hydration process

(c & d) Reacts to give hydration & give final setting time

This can be defined as,

Glanville, et al. (1947),

The amount of work needed to produce full compaction

Workability can be by different techniques such as,

Fig from Concrete Properties by John Newman

ii. Compacting factor test.

Fig from Concrete Properties by John Newman

Fig from Concrete Properties by John Newman

iv. Flow table test.

Fig from Concrete Properties by John Newman

v. Slump flow test.

Fig from Concrete Properties by John Newman

vi. Degree of compactability test.

Fig from Concrete Properties by John Newman

The workability is lost due to the following reasons,

1.5 Placing and Finishing concrete:

There are a few things to be considered while working with concrete,

1.6 Curing of concrete:

Different techniques used in curing are,

Code: ASTM C 187-04

2.1 Scope and Significance:

i. Initial setting time

2.3 Related theory:

The thickness or the viscosity of the cement paste is called consistency.

The Vicat apparatus consists of a frame A (Fig.) bearing

Diameter of the needle = 1±0.05 mm

Height of the ring = 40±3 mm

2.4 Test specifications:

a. Temperature & humidity

2.6 Observations & Calculations:

Type of cement: _______________

Source of cement: _______________

Manufacturer of cement: _______________

Sampling Person: _______________

Quantity of cement (W1) gm: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Weight of water added (W 2) gm

Penetration of plunger (mm)

% water by weight = W 2 /W1 × 100