Comprehensive Laboratory Report No.

1 INTRODUCTION TO CONSTRUCTION MATERIALS

AND TESTING Activity A:

Familiarization of the Construction Materials and Testing Laboratory; and its Apparatus and
Equipment

Objective:

To let the students become acquainted with the Material Testing Laboratory, the equipment
available, and the course requirement

Preparatory Reading:

ASTM E 380 (Appendices A, B, and C

INTRODUCTION:

The course of Construction Materials and Testing is a vital subject in Civil

Engineering although it doesn’t require much computations. Getting to know the basic and
the more advanced characteristics and properties of the materials used in construction will
help students analyze the principles lying behind the design of structures.
Construction Materials Testing (CMT) is the testing of materials used to build new
projects, add to existing projects, or amend existing construction projects. The services
involved in a comprehensive CMT process greatly depends on the project, the land, and the
scope of services. Various agencies offer certification for specific CMT knowledge, such as
DOT, ACI, the EPA, and more.

Since it is critical for the viability and safety of a construction project. CMT can reveal
any number of issues related to construction quality. It can highlight future risks, help
classify a building site, and assist with engineering decisions. Without CMT, engineers and
builders may not know if the quality of the construction meets the requirements.

Construction Materials Testing is also a regulatory requirement for most large-scale

projects. Specifications and regulatory overseers vary from state to state, but a few of the
most-cited oversight organizations include ASTM, FAA, USACE, and AASHTO. To stay
compliant, project managers must work with qualified, licensed CMT professionals before
starting work.

BODY:

1. REBOUND HAMMER

- The rebound hammer is also called as Schmidt hammer that consist of a

spring controlled mass that slides on a plunger within a tubular housing.
When the plunger of rebound hammer is pressed against the surface of
concrete, a spring controlled mass with a constant energy is made to hit
concrete surface to rebound back. The extent of rebound, which is a measure
of surface hardness, is measured on a graduated scale. This measured value
is designated as Rebound Number (rebound index). A concrete with low
strength and low stiffness will absorb more energy to yield in a lower
rebound value.
OBJECTIVES:

1. To determine the compressive strength of the concrete by relating the rebound index
and the compressive strength
2. To assess the uniformity of the concrete
3. To assess the quality of the concrete based on the standard specifications
4. To relate one concrete element with other in terms of quality

PRINCIPLES:

Rebound hammer test method is based on the principle that the rebound of an
elastic mass depends on the hardness of the concrete surface against which the mass
strikes. The operation of the rebound hammer is shown in figure-1. When the plunger of
rebound hammer is pressed against the concrete surface, the spring controlled mass in the
hammer rebounds. The amount of rebound of the mass depends on the hardness of
concrete surface. Thus, the hardness of concrete and rebound hammer reading can be
correlated with compressive strength of concrete. The rebound value is read off along a
graduated scale and is designated as the rebound number or rebound index.
The compressive strength can be read directly from the graph provided on the body of the
hammer.

PROCEDURE:

Procedure for rebound hammer test on concrete structure starts with calibration of
the rebound hammer. For this, the rebound hammer is tested against the test anvil made of
steel having Brinell hardness number of about 5000 N/mm2. After the rebound hammer is
tested for accuracy on the test anvil, the rebound hammer is held at right angles to the
surface of the concrete structure for taking the readings. The test thus can be conducted
horizontally on vertical surface and vertically upwards or downwards on horizontal surfaces
as shown in figure below If the rebound hammer is held at intermediate angle, the rebound
number will be different for the same concrete.
 2. CONCRETE SLUMP CONES
- Slump Cones measure the workability of a fresh concrete mix in accordance
with applicable ASTM and AASHTO standards. The slump cone test is
performed for acceptance purposes, to record mixture characteristics, or as
an indirect method of determining the water/cement ratio.
- The cones are constructed of rust-resistant spun steel or high-density plastic.
The cones meet inch (4x8x12) or metric (100x200x300) dimensional
requirements for holding the compacted concrete layers.
- The slump cone test can be carried out in the lab or field. Slump base plates
are available and can be used interchangeably with steel or plastic cones.
- Steel Slump Cones are available in inch or metric units. The slump cones
meet ASTM criteria for top diameter, bottom diameter, and height indicated
within the standards.
- Plastic Slump Cones are made from lightweight, easy to clean, durable
high-density plastic. They meet ASTM inch or metric dimensional
requirements.
-

3. UNIVERSAL TESTING MACHINE

- A Universal testing machine (UTM) is used to test the mechanical properties
(tension, compression etc.) of a given test specimen by exerting tensile,
compressive or transverse stresses. The machine has been named so
because of the wide range of tests it can perform over different kind of
materials. Different tests like peel test, flexural test, tension test, bend test,
friction test, spring test etc. can be performed with the help of UTM.

FUNCTIONS:

The main functions of UTM are to test the mechanical properties of materials. The standard

tests performed by UTM are:

1. Tensile Test
2. Compression Test
3. Adhesion Tests
4. Pull-Out Tests
5. Bending Test
6. Hysteresis Test
 4.

VICAT APPARATUS
- a device for determining the normal consistency and time of setting of
portland cements that consists of a rod weighing 300 grams, having a
needle in each end, and supported in a frame with a graduated scale to
measure the distance to which the needle penetrates the cement
- Vicat apparatus is a penetration device used in testing of hydraulic cements
and similar materials to determine their normal or standard consistency. It is
also used to determine the initial setting time and final setting time of
hydraulic cements and similar materials.

PARTS:

1. Needles

Needle for Initial Setting Time: The needle is having a cross sectional area of 1mm².
The end of the needle is flat.
Needle for Final Setting Time: The needle is circular and is having a cross sectional area
of 1mm². The needle is fitted with a metal attachment. The end of needle projects beyond
the cutting edge of the hollowed out metal attachment.

2. Plunger for Standard Consistency

Plunger is made of polished brass with a projection at the upper end for insertion into the
movable rod. The lower end is flat.
3. Movable Rod
Movable rod carries an indicator which moves over a graduated scale attached to the frame
(certain models have an additional attachment of dash pot, which facilitates lowering of
movable rod slowly).
4. Graduated Scale
Graduated scale is 40 mm in length and the shortest division of scale is 1 mm.
5. Vicat Mould
Single mould: The Vicat mould is in the foam of a frustum of a cone having an internal
diameter of 60 ± 0.5 mm at the top, 70 ± 0.5 mm at the bottom and height 40 ± 0.5 mm.
Split type Vicat mould: The split type Vicat mould is used as an alternative to single
mould. This mould consist of a split ring having an internal diameter 80 ± 0.1mm and a
height 40 ± 0.5mm. A non-porous base plate is provided. The split mould is provided with a
suitable clamping ring.

5. METER STICK
- A meterstick or yardstick is either a straightedge or foldable ruler used
to measure length, and is especially common in the construction industry.
They are often made of wood or plastic, and often have metal or plastic joints
so that they can be folded together. Normal length of a meterstick made for
the international market is either one or two meters, while a yardstick made
for the U.S. market is typically one yard (3 feet or 0.9144 meters) long.

6. HYDROMETER
- A hydrometer or hydroscope is a device that measures the
relative densities of two liquids. They are typically calibrated to measure
the specific gravity of a liquid. In addition to specific gravity, other scales may
be used, such as API gravity for petroleum, Plato scale for brewing, Baume
scale for chemistry, and Brix scale for wineries and fruit juices. The invention
of the instrument is credited to Hypatia of Alexandria in the latter part of the
4th century or early 5th century.

COMPOSTION AND USES:

There are several different types of hydrometers, but the most common version is a
closed glass tube with a weighted bulb at one end and a scale going up the side. Mercury
used to be used to weight the bulb, but newer versions may use lead shot instead, which is
much less hazardous in case the instrument breaks.

A sample of liquid to be tested is poured into a sufficiently tall container. The

hydrometer is lowered into the liquid until it floats and the point where the liquid touches
the scale on the stem is noted. Hydrometers are calibrated for various uses, so they tend to
be specific for the application (e.g., measuring fat content of milk or proof of alcoholic
spirits).
7. PRESSURE GAUGE
- A pressure gauge is a method of measuring fluid, gas, water, or steam
intensity in a pressure powered machine to ensure there are no leaks or
pressure changes that would affect the performance of the system. Pressure
systems are designed to operate within a specific pressure range. Any
deviation from the acceptable norms can seriously affect the workings of the
system
- Pressure gauges have been used for more than a hundred years and have
been constantly evolving to fit the needs of new applications. The
implementation and use of pressure gauges has made them a necessity as
more and more pressure systems become operational.

8. VIBRATORS
 - Vibrating is a critical step on many concrete construction projects. When
concrete is poured, it might have hundreds or even thousands of air bubbles,
which can substantially weaken the concrete structure. Concrete vibrators
eliminate air bubbles by vigorously shaking the freshly poured concrete. Using
a concrete vibrator during a pour is not only recommended but, in many cases,
it is also a building code requirement.

HOW IT WORKS:

Concrete vibrators come in different forms and can be electric or air-driven.

Applications for concrete vibration can be grouped into three basic categories:

 Formwork vibration: Formwork vibration is commonly used in precast concrete

construction and involves mounting the vibrators to the outsides of the concrete forms. For
larger pours, the external form vibrators are often spaced 6 feet apart.
 Surface vibration: With surface vibration, large vibrators (sometimes called "jumpers") are
directed manually onto the surface of the poured concrete. This method is limited to slab
depth of about 6 inches or less, but it provides a smooth surface that is especially desirable
when appearance is important.
 Internal vibration: Internal concrete vibrators are the most common type used. Many can
be handled by a single operator. The process is relatively simple: The worker quickly jams a
probe-like internal vibrator down into the wet concrete, then slowly withdraws it

9. HYDRAULIC JACK
- A hydraulic jack is a device that is used to lift heavy loads by applying a force
via a hydraulic cylinder. Hydraulic jacks lift loads using the force created by
the pressure in the cylinder chamber.

HOW IT WORKS:

A hydraulic jack creates pressure by moving oil through two cylinders via a pump
plunger. The pump plunger is drawn back, which opens the suction valve and draws oil into
the pump chamber. As the plunger is pushed down, the oil is transported through an
external discharge valve and into the cylinder chamber. The suction valve then closes,
resulting in pressure being built up within the
chamber; causing the piston in the chamber
to rise and lift your heavy object. This
process can be repeated many times,
allowing your load to be lifted higher, and
higher.
 10. CONCERTE MIXER
- Traditionally, concrete mixtures
were prepared manually which
consumed a lot of time as well
as lacked precision. With
growing demand and advances
in technology, now, concrete
mixture, even in small scale
applications, is prepared using
concrete mixers. Concrete
mixers are devices capable of
preparing concrete mixtures of
varying strength precisely as well as quickly. Some concrete mixers are even
capable of dispensing the concrete mixture directly on the location of the
construction. Depending on the requirement of the application, concrete
mixers of various sizes and types are available. Portable concrete mixers can
be used in small and medium-sized applications whereas for large scale
applications concrete batching plants can also be built at the construction site

CATEGORIES:

1. Batch Mixer
As the name suggests, this type of mixer produces concrete one batch at a time. Batch
mixers either have a drum or a pan, consisting of blades, which when rotated prepares the
concrete mix. The speed of rotation, angle of the blades and in some cases the angle of
inclination of the drum can be controlled. These are the most commonly used concrete
mixers and are highly preferable to be used in small and medium-sized construction sites.

2. Continuous Mixer
These concrete mixers work without any interruption and keep producing concrete
continuously as long as work is going on. They are fed raw materials continuously and the
concrete is discharged and collected by construction workers as soon as the mix is ready.
Continuous mixer systems are generally set up in the construction site itself. They have a
separate feeder unit for the intake of constituent materials, a mixer unit for mixing concrete
and a dischararge mechanism for dispensing the concrete mix. These mixers are deployed
while constructing very large structures such as bridges, tunnels for roads, dams, etc.

Standards and Codes which are widely used in the world or are references for other codes
include:
 1. ASTM International
2. Canadian Standard Association (CSA)
3. European Standard (EN Eurocodes)
4. British Standards (BS)
5. Indian Standards (IS)

1. ASTM INTERNATIONAL
- It is the largest source of standards in the world for materials, goods,
services and systems. ASTM internatinal also publishes documents on
sampling and testing methods for health, safety and performance aspects of
materials, effects of physical and biological agents and chemicals, and safety
guidelines.

Construction
ASTM international standards
material

ASTM D2216, ASTM D4318, ASTM C136, ASTM D5268, ASTM D6913,
Soil ASTM D2974, ASTM D422, ASTM D2434, ASTM D1140, ASTM D7263,
ASTM D5918, ASTM D698, ASTM D854, and ASTM D1557

ASTM C88, ASTM C295, ASTM C127, ASTM D5312, ASTM C128, ASTM
Aggregate
D5313, ASTM C29, ASTM D4992, ASTM D5821, ASTM D4791, ASTM
and Rock
D3967, ASTM C131, ASTM D7012, and ASTM C535

Concrete and
ASTM C617, ASTM C1231, ASTM C39, ASTM C78
Masonry

ASTM D6926, ASTM D2726, ASTM D6307, ASTM D5444, and ASTM
Asphalt
D2041

2. CANADIAN STANDARD ASSOCIATION (CSA)

- The CSA is a standard organization which develops standards in Canada. It
publishes standards in print and electronic form and provides training and
advisory services. All materials used in construction of buildings and other
structures in Canada is manufactured to meet the requirements of the CSA
standards.

Construction
CSA standards
materials

Cement CSA A3001, CSA A3002, CSA A3003, CSA A3004, and CSA A3005

Concrete CSA A23.1, CSA A23.2, CSA A23.4, and CSA S806

CSA A165.1, CSA A165.2, CSA A165.3, CSA A179, CSA A370, and CSA
Masonry
A371

3. EUROPEAN STANDARD (EN Eurocodes)

 - Test standards are part of the comprehensive system of European standards
relating to construction. They are intended to be used for the determination
of material and product properties required for the design of buildings and
other civil engineering structures with the EN Eurocodes. In particular, test
standards related to the EN Eurocodes comprise testing for materials, e.g.
concrete, masonry, timber and metallic materials, non-destructive test
methods as well as fire tests. BS EN is abbreviation for official English version
of European standards
-
Construction materials European Standards (EN)

BS EN 12390-4:2000, BS EN 12390-
concrete 5:2000, BS EN 12390-6:2000, BS EN 1170-
4:1998

BS EN 1052-1:1999, BS EN 846-5:2000, BS
masonry
EN 846-6:2000

timber EN 594, EN 1075, EN 1380

metallic materials BS EN 10002-1:2001

Plywood BS EN 1072:1995

BS EN 12372:1999, BS EN 14617-15:2005,
Stone
BS EN 14580, BS EN 14617-2:2004,

Aggregate BS 812-2:1995

4. BRITISH STANDARDS (BS)

- British Standard publications, which are produced by the British Standard
Institute, are technical specifications that give recommendations on a wide
range of building and construction matters including materials, testing, health
and safety, access and regulations and many more. They are essential
reference for architects, developers, building owners, site managers, building
contractors, structural engineers and materials specifiers.

Construction
British Standards
materials

Concrete BS 1881-119:1983, BS 1881-121:1983, BS 1881-127:1990

resin and
BS 6319-10:1987, BS 6319-11:1993, BS 6319-2:1983, BS
polymer/cement
6319-3:1990, BS 6319-6:1984, BS 6319-7:198,
compositions

Mortar BS EN 1015-11:1999, BS EN 1015-12:2000,

5. INDIAN STANDARDS
- Indian Standards are large number of documents that published by Bureau of
Indian Standard (BIS) and involves almost all aspects of civil engineering.
The BIS has developed a set of guidelines in order to guarantee the quality
 standards of the deferent types of construction materials. These are classified
into two broad categories namely; Building Materials including Paints and Civil
Engineering Design and Construction. These standards contain guidelines for
testing cement, concrete, concrete admixtures, additives, soil, rock, steel, and
aluminum.

Construction material Indian standards

Cement IS 650 – 1991, IS 14032 – 1988,

Coarse / Fine Aggregate IS 2386 (Part I To VIII) 1963

Bricks IS 3495 (Parts I TO iv) 1976

soil IS: 2720 (Part. XIII) 1986, IS:2720 (Part.30) 1980

CONCLUSION:

Materials Testing is performed for a variety of reasons and can provide a wealth of
information about the tested materials, prototypes or product samples. The data collected
during testing and the final test results can be very useful to engineers, designers,
production managers and others. Many products are used in critical applications where a
failure could result in extensive damage or injury. Some examples are manufactured
fasteners and parts that have a vital role in maintaining the safety of aircraft, bridges,
vehicles, nuclear reactors, military equipment and medical implants. In addition, many
jurisdictions have adopted legislation restricting the use of hazardous materials.
In cases like these, governments and regulatory bodies set compliance requirements that
must be met by manufacturers. Companies must adhere to these standards, which generally
specify test procedures, to prove compliance.
The quality of a material going into a manufactured product is as important as the
reliability of the production process. Materials testing helps us to understand and quantify
whether a specific material or treatment is suitable for a particular application.
With the wide variety of materials and treatments available in the marketplace, testing can
help narrow down the choices to the most appropriate selection for the intended use. As
mentioned before, for many industry applications, testing is performed to certify material to
a given standard or specification, or to verify that it meets other stringent criteria before it is
put into use.
Not only is testing commonly relied on for material selection and choosing a reliable
supplier, it is frequently used as a verification process to be sure that material received from
a new supplier is what was ordered. Material Testing may include methods that yield
information about the structure or mechanical properties of the material. It may also make
sense to verify the composition or elemental content of the material with an instrumental or
classical wet chemical analysis technique.
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