CTC4801 practical manual 2024

CONCRETE TECHNOLOGY (CTC4801)
PRACTICAL MANUAL
UNISA
Compiled according to South African National
Standards
by
Prof Ikotun Bolanle

&
Miss Zakithi Dube
PRACTICAL MANUAL FOR CTC4801
TABLE OF CONTENT
Table of content ……………………………………………………..…………………….. 2
PREFACE ……………………………………………………….…………………………..3
1. MORTAR SAMPLES PREPARATION, FLEXURAL STRENGTH AND

COMPRESSIVE STRENGTH TEST OF MORTAR TO SANS (SOUTH AFRICAN
NATIONAL STANDARD) SANS 50196-1 …………………….……………………..4
2. SIEVE ANALYSIS TEST PROCEDURE FOR UNISA STUDENTS ACCORDING
TO SANS 3001-AG1 ………………………………………………………………..…7
3. BULK DENSITY TEST PROCEDURE FOR UNISA STUDENTS ACCORDING
TO SANS 5845:2006 ………………………………………………………………...10
4. PARTICLE SHAPE TEST PROCEDURE FOR UNISA STUDENTS
ACCORDING TO SANS 5847:2008 and SANS 3001-AG4:2015 …….………... 12
5. BULK RELATIVE DENSITY, APPARENT RELATIVE DENSITY AND WATER
ABSORPTION ACCORDING TO SANS 3001-AG20:2011………….….………..14
6. CONCRETE MIX DESIGN …………………………………………………………. 17
7. SLUMP TEST PROCEDURE FOR UNISA STUDENTS ACCORDING TO SANS
5862-1:2006 …………………………………………………………………………. 21
8. SAMPLE PREPARATION, COMPRESSIVE STRENGTH AND SPLIT TENSILE
TESTS PROCEDURE FOR UNISA STUDENTS ACCORDING TO SANS 5861-
1, 5861-3, 5863:2006 and 6253:2006……………………………………………... 23
REFERENCES……………………………………………………………………………. 26
2
PREFACE
This practical manual is for Concrete Technology Module (CTC4801). The module is
offered at the Department of Civil Engineering, University of South Africa for BEng
Tech (Hons), Structures. This module will assess ECSA graduate attribute 1: Identify,
formulate, analyse and solve complex problems creatively and innovatively. After the
practical session, you are expected to submit a practical report, where each test
performed will be reported.
Use the outline below to complete your practical report.
• Cover page
• Table of content
• Chapter one: Introduction
• Chapter two: Mortar Flexural strength
• Chapter three: Mortar Compressive strength
• Chapter four: Sieve analysis
• Chapter five: Bulk density
• Chapter six: Particle shape
• Chapter seven: Bulk relative density, Apparent relative density and Water
absorption
• Chapter eight: Concrete Mix design
• Chapter nine: Slump test
• Chapter ten: Concrete Compressive strength
• Chapter eleven: Concrete Split tensile strength
• References
The guidelines for each test are explained in the subsequent sessions of this manual.
3
1. MORTAR SAMPLES PREPARATION, FLEXURAL STRENGTH AND

COMPRESSIVE STRENGTH TEST OF MORTAR TO SANS (SOUTH AFRICAN
NATIONAL STANDARD) SANS 50196-1
1.1 AIM AND OBJECTIVES

To determine the flexural and compressive strengths of mortar in the laboratory.
1.2 APPARATUS
• Stainless steel mortar mixer
• Stainless steel mortar mixer frame
• 40 x 40 x 160 mm prism moulds
• Jolting (Vibration) apparatus
• Flexural strength testing machine
• Compressive strength testing machine
• Scoop
• Rubber or plastics scraper
• Curing tanks
• Impervious sheet
• Weighing balance
1.3 PROCEDURES
1.3.1 Batching
Use standard sand, cement that has been thoroughly mixed and potable water. The
standard sand is a natural siliceous sand consisting of rounded particles and has a
silica content of at least 98%. Batch mortar for three test specimens using 450 g of
cement, 1350 g of sand and 225 g of water.
1.3.2 Mixing
Mix the mortar in a laboratory mortar mixer, in such a manner as to avoid loss of
cement and water.
(a) Weigh the materials on the weighing balance
(b) Place the water and the cement in the mixer bowl and record the time water and
cement got in contact as the zero time.
(c) Start the mixer at low speed for 30s, then add sand steadily over the next 30s.
Switch the mixer to high speed and continue to mix for another 30s. Stop the mixer
for 90s, during this period use the rubber or plastic scraper to remove the mortar
adhering to the wall of the mixing bowl into the main mortar at the middle of the
mixing bowl. Continue to mix for the next 60s at high speed to complete the mixing.
1.3.3 Making mortar prisms

(a) Slightly smear the mould with oil before casting the mortar.
4
(b) Scoop the mortar from the mixing bowl and place in into each mould compartment.
(c) Spread the mortar in the mould and vibrate on the vibrating table for 10 seconds.
Add another layer of mortar and vibrate for another 10 seconds.
(d) Strike off the excess mortar and level the mortar.
(d) Place an impervious sheet on the mould and place in a moist air room until its
appropriate time for demoulding.
1.3.4 Curing
(a) Demould the specimens and cure the specimens in water at 200C with a built-in
thermostat to maintain the temperature in the curing tank. Place the specimen on the
gratings and keep them apart to give allowance for the six faces to have access to
water.
(b) Remove the specimen for testing at the appropriate testing time.
1.3.5 Mortar flexural strength test
(a) Use a center-point loading method

(b) Place a 40 x 40 x 160 mm mortar prism in the testing machine with one side face
on the supporting roller and its longitudinal axis normal to the supports.
(c) Apply load vertically by means of the loading roller to the opposite side face of the
prism and increase it smoothly at the rate of 50 ± 10 N/s until failure.
(d) Calculate the flexural strength (Rf) using the equation below or read it off from the
automated equipment.
1 .5 F . L
Rf = b3
where:
Rf is the flexural strength, in Newtons per square millimeter (N/mm2)
b is the side of the square section of the prism, in millimeters (mm)
F is the ultimate load applied to the middle of the prism at fracture, in Newton (N)
L is the distance between the supports, in millimeters (mm)
(e) Record the average results of two samples.

(f)
1.3.5.1 Report deliverable on mortar flexural strength
Use the following outline to complete chapter two: Mortar Flexural strength
• Title, objectives, apparatus and pictures
• Methodology
• Safety precautions
5
• Observations
• Results and calculations
• Discussion
• Conclusion
1.3.6 Mortar compressive strength test

(a) Carry out the compressive strength test on the halves of 40 x 40 x 160 mm
mortar prisms obtained after the flexural strength test.
(b) Centre placed the prism halves laterally to the platens of the testing machine
within ± 0.5 mm and longitudinally such that the end face of the prism overhangs the
auxiliary plates by 10 mm.
(c) Increase the load smoothly at the rate of 2400 ± 200 N/s over the entire load
application until failure.
(d) Calculate the compressive strength (Rc) using the equation below or read it off
from the automated equipment.
Fc
Rc = A
where:
Rc is the compressive strength in N/mm2
Fc is the maximum load at fracture, in N
A is the area of the load bearing plates, in mm2
(e) Record the average results of four samples.
1.3.6.1 Report deliverable on mortar compressive strength

Use the following outline to complete chapter three: Mortar Compressive strength
• Methodology
• Observations
• Discussion
• Conclusion
6
2. SIEVE ANALYSIS TEST PROCEDURE FOR UNISA STUDENTS ACCORDING

TO SANS 3001-AG1

To determine the particle size distribution and to calculate the fineness modulus of fine
aggregates.
2.2 APPARATUS
• Sieves (sizes: 37.5 mm, 28mm, 20mm, 14mm, 10 mm, 7.1 mm, 5 mm, 2 mm,
1 mm, 0.6 mm, 0.3 mm, 0.15 mm, 0.075 mm and pan) starting with the sieve
that has the largest apertures.
• Mallet
• Cleaning brushes
• Weighing balance
• Oven and pans
2.3 PROCEDURES
• Pour the field sample into a riffler pan. Then pour the material through the riffler
by slowly titling the pan so that the material flows in an even stream across its
width. At the same time, move the pan to and fro along the full length of the
riffler to ensure an even flow of the material. Repeat the process with the
contents of one of the pans under the riffler until a sample of the required size
is obtained. Use Table 2.1 as a guide.
Table 2.1: Size of the sample
1 2
Maximum particle size Approximate sample mass
Mm g
75 10 000
50 7 000
37.5 4 000
28 3 000
20 2 500
14 1 500
10 1 000
5 and smaller 500
• Dry a test sample to constant mass at 105 to 110 °C in a well-ventilated oven.

Allow the test sample to cool to room temperature and determine its mass to
an accuracy of 0.1%.
7
• Place the test sample in a suitable container and add enough water to cover
the sample. Agitate thoroughly in the water to loses and dust particles adhering
to the aggregate and also to break down any clay lumps that may exist. Decant
the wash water over the 0.075 mm sieve protected by one or two coarser
sieves. The wash water containing the -0.075 mm material is discarded or
allowed to run away. Continue this washing until the water that passes through
the sieves is clear. Return all the material retained on the sieves to the container
by gentle and careful washing. Dry a test sample to constant mass at 105 to
110 °C in a well-ventilated oven.
• Sieve through the required or specified sieves in order of decreasing size from
to bottom into a pan (sieve sizes: 37.5 mm, 28mm, 20mm, 14mm, 10 mm, 7.1
mm, 5 mm, 2 mm, 1 mm, 0.6 mm, 0.3 mm, 0.15 mm, 0.075 mm and pan).
• Weigh the material retained on each sieve and record the mass to the nearest
0.1g.
2.4 EXAMPLE OF SIEVE ANALYSIS CALCULATIONS FOR CRUSHER SAND

SIEVE
SIZE INDIVIDUAL INDIVIDUAL CUMMALATIVE PERCENTAGE
PERCENTAGE
(mm) MASS PERCENTAGE RETAINED MATERIAL
RETAINED PASSED ROUNDED
RETAINED (g) (%) (%) OFF (%)
10 0 0 0 100
7.10 0 0 0 100
5.00 13.0 2.6 2.6 97
2.00 41.5 8.4 11.0 89
1.00 99.5 20.1 31.1 69
0.60 160.0 32.3 63.4 37
0.30 86.0 17.3 80.7 19
0.15 43.5 8.8 89.5 11
Subtotal 1 443.5 89.5 278.3 -
0.075 30.0 6.0 - 4.5
PAN
After dry 5.0
sieving (mass c) 1.0 - -
PAN
Material
passing
0.075 by 17.5
washing (mass a-b) 3.5 - -
22.5
(mass a-b) +
Subtotal 2 (mass c) 4.5 - -
496.0
Total mass (mass of
of mass sample after
496.0 (g) test) 100 - -
8
TO CALCULATE THE FINENESS MODULUS

FM = (Sum of cum.% retained 5.0 mm to 0.15 mm sieve) / 100
278.3
=
100
= 2.78
2.5 Report deliverable for Sieve analysis

Use the following outline to complete chapter four: Sieve analysis
• Methodology
• Observations
• Discussion
• Conclusion
9
3. BULK DENSITY TEST PROCEDURE FOR UNISA STUDENTS ACCORDING TO

SANS 5845:2006
To determine the compacted and uncompacted densities of aggregates.
3.2 APPARATUS
* 3-litre and 15-litre watertight cylindrical containers
* Metal tamping rod
* Suitable shovel or scoop
* Oven
3.3 PROCEDURES
Dry the test sample (fine/coarse aggregate) to constant mass at a temperature of
105 to 110 °C in an oven. Cool the test sample to room temperature.
3.3.1 For uncompacted bulk density

Use the shovel or scoop to fill the container to overflowing with the thoroughly mixed
dried aggregate.
Note: The aggregate should be discharged from a height not exceeding 50 mm above
the rim of the container. Segregation of the particles of different sizes should as far as
possible be prevented.
Remove the surplus aggregate by rolling the tamping rod across and in contact with
the rim of the container, and remove, by hand, any (coarse) aggregate impeding
progress. In the case of aggregate of particle size 5.0 mm and smaller, level off the
surface, using the tamping rod as a straight-edge. Determine, to the nearest 0.2%, the
mass (m) of the aggregate in the container.
3.3.2 Compacted bulk density (rodding procedure)

Carefully fill the container with three approximately equal layers, the last layer to
overflowing, levelling the surface of the first two layers by hand and rodding each layer
of aggregate with the required number of strokes (20 for fine aggregate and 30 for
coarse aggregate) of the tamping rod evenly distributed over the surface of the layers.
Note 1: When rodding the first layer, do not allow the rod to strike the bottom of the
container forcibly.
Note 2: When rodding the second and third layers, use enough force to cause the
tamping rod to penetrate the previous layer of aggregate.
10
Note 3: Avoid breaking up individual particles of the aggregate.

Level off the surface of the aggregate as described and determine the mass (m) of the
aggregate in the container to the nearest 0.2.
3.4 CALCULATIONS
Calculate the bulk density δ of the aggregate (compacted or uncompacted, as
appropriate), in kilograms per cubic metre, as follows:
𝑚
δ=
𝑣
Where:
m is the mass of the aggregate in the container, in kilograms;
V is the volume of the container, in cubic metres. Report the result to the nearest 10
kg/𝑚3 .
3.5 Report deliverable on Bulk density

Use the following outline to complete chapter five: Bulk density
• Methodology
• Observations
• Discussion
• Conclusion
11
4. PARTICLE SHAPE TEST PROCEDURE FOR UNISA STUDENTS ACCORDING

TO SANS 5847:2008 and SANS 3001-AG4:2015

To determine the flakiness index of coarse aggregate.
4.2 APPARATUS
• Test sieves (sizes: 37.5 mm, 28mm, 20mm, 14mm, 10 mm, 7.1 mm, 5 mm)
starting with the sieve that has the largest apertures.
• Flakiness gauge
• Electronic balance
4.3 PROCEDURES
• Carry out a grading analysis as described in SANS 3001-AG1, separating the
test sample into the relevant fractions
• Weigh each fraction to be gauged to the nearest 1g and record the mass (𝑀𝑆 ),
• Gauge all the particles in each fraction size (using corresponding slot),
contains the material that passes through the appropriate individual slots,
weigh to the nearest 1g and record the masses (𝑀𝑓 ).
• Calculate 𝑀𝑆 , the summation of all the fractions retained (gauged) and 𝑀𝐹 , the
summation of all the fractions passing the slots.
4.4 CALCULATIONS
Calculate the flakiness index of the sample to one decimal place as follows:
𝑀𝐹
𝐹𝐼 = 100
𝑀𝑆
FI is the flakiness index of the sample expressed as a percentage;
𝑀𝐹 is the mass of all the fractions passing the slots, expressed in grams;
𝑀𝑆 is the mass of all the fractions gauged, expressed in grams.
4.5 Report deliverable on Particle shape

Use the following outline to complete chapter six: Particle shape
12

• Methodology
• Observations
• Discussion
• Conclusion
13
5. BULK RELATIVE DENSITY, APPARENT RELATIVE DENSITY AND WATER

ABSORPTION ACCORDING TO SANS 3001-AG20:2011

To determine the following parameters on aggregate particles retained on the 5 mm
sieve:
a) Bulk density;
b) Apparent density; and
c) Water absorption.
5.2 APPARATUS
• 5 mm sieve
• Riffler, with suitable openings larger than the largest particle in the sample, and
at least three pans.
• Weighing balance, fine measurement type that complies with SANS 1649, and
with a capacity of at least 12 kg, and reading to 0.1 g.
• Wire basket, approximately 200 mm in diameter and 200 mm in height,
manufacture from mesh with 1 mm to 3 mm apertures.
• Container, filled with water at temperature of between 24 ℃ and 26 ℃, suitable
for immersing the wire basket containing the test sample.
• Cloth, of chamois leather approximately 750 mm x 750 mm in size.
• Drying oven, that is capable of maintaining a temperature range of between
105 ℃ and 110 ℃, with continuous draft.
• Thermometer, capable of covering the temperature range 0 ℃ to 100 ℃, and
reading to 1℃
5.3 PROCEDURES
• Pour the field sample into a riffler pan. Then pour the material through the riffler
by slowly titling the pan so that the material flows in an even stream across its
width. At the same time, move the pan to and fro along the full length of the
riffler to ensure an even flow of the material. Repeat the process with the
contents of one of the pans under the riffler until a sample of the required size
is obtained.
• Screen the sample on the 5mm sieve. Retain the material that does not pass
that sieve.
• Thoroughly wash the test sample retained on a 5mm sieve so as to remove
dust from the surface of the particle, and soak for 24 h± 1 in water.
14
• Remove the sample from the water, drain off the free water for few seconds
and transfer it to the cloth.
• Roll the material in the cloth until all visible water has been absorbed by the
cloth. The saturated surface-dry condition has been reached when the cloth
has absorbed all visible water, but the surface of the particle still appear damp.
Large particles may be surfaced-dried individually using the cloth.
• Immediately weigh the test sample and record the mass, B, to the nearest 0,1
g. Use Table 5.1 as a guide. Transfer the test sample to the wire basket that
has been tared.
• Completely submerge the wire basket with the test sample in the container of
water at a temperature of between 24 and 26 ℃, taking care that no air bubbles
are entrapped. Weigh the wire basket and test sample in the water and record
the mass, C, to the nearest 0,1 g.
• Remove the sample from the wire basket, allow free water to drain off and then
dry it to a constant mass in the oven at a temperature of between 105 ℃ to 110
℃.
• Determine the mass of the oven-dried test sample, A, to the nearest 0,1 g.
Table 5.1: Size of test sample after quartering
5.4 CALCULATIONS
5.1 Determine the bulk relative density (BD), the apparent density (AD) and the
water absorption of the test sample given in 3.1.1, 3.1.2 and 3.1.3, respectively.
5.4.1 Determine the Bulk Relative Density, using the following equation:
𝐴
BRD = ( )
(𝐵−𝐶)
B = is the mass of the saturated surface-dry test sample, expressed in grams

(g);
C = is the mass of the saturated test sample in water at 25 ℃, expressed in

grams
A = is the mass of the oven dried test sample, expressed in grams (g);
5.4.2 Determine the Apparent Relative Density, using the following equation:
15
𝐴
ARD = ( )
(𝐴−𝐶)
5.4.3 Determine the water absorption as the loss in mass between the saturated
surface-dry and the oven-dry conditions of the oven-dried mass of the test sample, to
one decimal place, using the following equation:
𝐵−𝐴
𝑊𝐴𝐵𝑆 = 100 x ( )
𝐴
where
𝑊𝐴𝐵𝑆 is the water absorption of the test sample, expressed as a percentage (%).
5.5 Report deliverable bulk relative density, apparent relative density and water
absorption
Use the following outline to complete chapter seven: Bulk relative density, Apparent
relative density and Water absorption

• Methodology
• Observations
• Discussion
• Conclusion
16
6 CONCRETE MIX DESIGN

To achieve the required slump and strength of concrete.
6.2 PROCEDURES
Procedures and calculations are done according to the C&CI design method (chapter
11 of Fulton’s concrete technology, 9th edition).
The following steps summarise the procedure to follow when designing a mix using
the C & CI method:
• Specify the concrete strength and stone size.

• Specify the slump.
• Specify the cement type, maximum W/C ratio, and minimum binder content.
• Select the cement type and source.
• Select the stone and sand.
• Select a chemical admixture, if required.
• Characterise the stone (derived from aggregates tests).
• Characterise the sand (derived from aggregates tests).
• Select the W/C ratio.
• Estimate the water requirement, W.
• Calculate the cement content C, using C = W ÷ W/C.
• Calculate the stone content St, using St = CBDSt (K – 0.1FM)
where:
St = mass of stone in 1 m3 of concrete, kg
CBDSt = dry compacted bulk density of stone
FM = fineness modulus of the sand
K = a factor that depends on the nominal size of the stone and the workability
of the concrete.
Note: For workable concrete that needs to be pumped, stone content should be
reduced by 200kg/m3.
• Calculate sand content
17
Using,
cement sand stone water
1m 3 = + + +
( RDx1000) ( RDx1000) ( RDx1000) ( RDx1000)
• Make the trial mix
• Measure slump
• Assess stone content and cohesiveness of concrete
• Approve mix if okay
• Reject mix if not okay
• Modify design if necessary
• Specify mix proportions for manufacture of concrete
6.3 MIX DESIGN CALCULATIONS

Procedures and calculations are done according to the C&CI design method (chapter
11 of Fulton’s concrete technology, 9th edition).
Example of mix design calculation:
Calculate the batch weight required for 20 L of trial mix based on the mix design
tables provided below.
Cement Type CEM1 cement

Relative density (RD) 3.14
Sand Relative density (RD) 2.70
FM 2.3
Quality Average
Given Stone Relative density (RD) 2.7
Size 19.0 mm
Compacted Bulk Density 1550 kg/m3
(CBD)
Plant standard deviation 5.0 MPa
Proportion defective 5%
Specified 28 day compressive strength 30 MPa
18
Consistence 75 mm slump for

Required moderate vibration
Estimated water requirement 210 l/m3
W/C 0.6
Use the Table below to determine K for the calculation.
Approx. Compaction K
slump Nominal maximum size of stone, mm
range, mm 9.5 13.2 19.0 26.5
75 – 150 Hand compaction 0.75 0.84 0.94 1.00
25 – 100 Moderate 0.80 0.90 1.00 1.06
compaction
0 – 25 Heavy vibration 1.00 1.05 1.08 1.10
Note: Calculating the batch mix is the same as the designing of the mix.
Solution
Determine the cement content
Cement content = water content/water:cement ratio
= 210/0.6 =350kg/m3
Determine the stone content (S) = CBD(k – 0.1 FM)
k from table is 1.0
S = 1550(1.0 - 0.1 x 2.3) = 1193.5 kg/m3 (Say 1194 kg/m3)
Determine the sand content

cement sand stone water
1m 3 = + + +
( RDx1000) ( RDx1000) ( RDx1000) ( RDx1000)
19
350 sand 1194 210

1m 3 = + + +
(3.14x1000) (2.7 x1000) (2.7 x1000) (1x1000)
sand
1m3 = 0.1115 + + 0.4422 + 0.21
2700
sand
1 = 0.7637 +
2700
sand
2700
(
= 0.2363  sand = 638.01kg / m 3 say 638kg / m 3 )
Materials For 1m3 For 20 L

Cement (kg) 350 7 (½)
Water (L) 210 4.2 (½)
Sand (kg) 638 12.76 (½)
Stone (kg) 1194 23.88 (½)
6.4 Report deliverable Concrete mix design

Use the following outline to complete chapter eight: Concrete mix design
• Title and objectives
• Methodology
• Parameters and calculations
• Discussion
• Conclusion
20
7 SLUMP TEST PROCEDURE FOR UNISA STUDENTS ACCORDING TO SANS

5862-1:2006

To determine the slump of freshly mixed concrete in the laboratory.
7.2 APPARATUS
Mould in the form of a frustum of a cone (Figure 7.1), with the following nominal
internal dimensions:
a) Diameter of base: 200 mm ± 2 mm;
b) Diameter of top: 100 mm ± 2 mm; and c) Height: 300 mm ± 2 mm
c) Height: 300 mm ± 2 mm
Figure 7.1: Slump test cone
• Tamping rod, made of straight steel, of nominal diameter 16 mm and length

600 mm ± 2 mm, and having at least one hemispherical end
• Scoop
• Measuring ruler
7.3 PROCEDURES
• Ensure that the interior surface of the mould is clean and damp.
• Place the mould on a clean, smooth, horizontal, rigid and non-absorbent
surface that is free from vibration and shock. While the mould is being filled,
21
hold it firmly in place by standing on the foot pieces or by any other suitable
means.
• Fill the mould with concrete in three layers, each layer being approximately one-
third of the height of the mould.
• Tamp each layer with 25 strokes applied with the hemispherical end of the
tamping rod, distributing the strokes uniformly over the cross-section of the
layer and throughout its depth, ensuring that when the second and third layers
are being tamped, the strokes penetrate into the underlying layer.
• While tamping the third layer, ensure that excess concrete is maintained above
the top of the mould, if necessary, by adding more concrete while tamping.
• Strike off the excess concrete, using a sawing and rolling motion of the tamping
rod.
• Clean off any concrete that may have leaked or spilled around the base of the
mould during the tamping.
• Demould the concrete by slowly and carefully raising the mould vertically, taking
5 to 10 s to do this.
• The entire process of moulding and demoulding should be carried out within
150 s.
• Immediately after demoulding, measure the slump of the concrete to the
nearest 5 mm by determining the difference between the height of the mould
and the highest point of the specimen under test. If the specimen collapses or
if lateral shearing of concrete occurs, consider the test invalid and repeat it on
a fresh sample of concrete. If, during two consecutive tests, collapsing or lateral
shearing of the test specimen occurs, the concrete lacks the necessary
plasticity and cohesiveness for the slump test to be applicable.
7.4 Report deliverable on Slump test

Use the following outline to complete chapter nine: Slump test
• Methodology
• Observations
• Discussion
• Conclusion
22
8. SAMPLE PREPARATION, COMPRESSIVE STRENGTH AND SPLIT TENSILE

TESTS PROCEDURE FOR UNISA STUDENTS ACCORDING TO SANS 5861-1,
5861-3, 5863:2006 and 6253:2006

To determine the compressive strength of hardened concrete in the laboratory.
8.2 APPARATUS
• Concrete mixer
• Shovel
• Compressive testing machine
• Cube moulds
• Steel float
• Vibrating table
• Scoop
• Curing tanks
• Impervious sheet
8.3 PROCEDURES
8.3.1 Batching
Use aggregate that has been oven-dried or air-dried, cement that has been thoroughly
mixed and potable water. The aggregate for each batch of concrete may be added
either in separate size fractions or with an all-in grading.
8.3.2 Mixing
Mix the concrete in a laboratory mixer, in such a manner as to avoid loss of water or
other materials.
(a) Load the mixer with approximately half of the coarse aggregate, then with the
cement, then with the fine aggregate, then with the rest of the coarse aggregate, and
always in such a way as to prevent loss of material. Mix the dry materials for not longer
than 30 s, and finally add the water slowly.
(b) Continue the mixing until the concrete is uniform in appearance, but in any case,
for a period of not less than 2 min and not more than 3 min after all the materials have
been loaded in the mixer.
(c) After machine mixing, rework the concrete with a trowel to ensure that any mortar
or fine material sticking to the pan of the mixer is worked into the concrete mass.
23
8.3.3 Making concrete cubes

Moulds should be clean and smeared with release oil. Place the mould on a firm, level
surface. From concrete mixed in the laboratory, prepare at least three specimens for
each test age by filling each of three moulds (already greased) in such a way as to
provide full compaction of the concrete without segregation or excessive laitance, and
then compact using the vibration table. Once the top layer has been compacted, use
the steel float to strike off the surface of the concrete level with the top of the mould.
Ensure that the mould is clamped to the table or held firmly against the hammer when
using a vibrating table.
8.3.4 Curing
Cover the specimens (as marked in their moulds) with an impervious sheet and then
store them in a place that is free from vibration and in an atmosphere with a relative
humidity of at least 90% and at a temperature of 22 to 25 °C for 20 to 24 h after the
time of the addition of water to the dry ingredients. Demould the specimens and
submerge them, until just prior to testing, in potable water that is maintained at a
temperature of 22 to 25 °C. Ensure that specimens do not become dry at any time
before testing.
8.3.5 Compressive strength test

Test each specimen immediately after it has been removed from the water and while
it is still saturated. Remove surface water, grit and projecting fins, and determine the
mass (to an accuracy of at least 1%) of each specimen before testing it. Wipe clean
the bearing surfaces of the platens of the compression testing machine and position a
specimen in the machine such that the load is applied to opposite as-cast faces of the
specimen in the case of cubes (i.e. not to the top and bottom). Specimens should be
centred in the middle of the platens. Apply the compression load without shock and
increase it continuously at a uniform rate of between 0.3 MPa/s ± 0.1 MPa/s until the
specimen fails.
8.3.5.1 Report deliverable on concrete Compressive strength

Use the following outline to complete chapter ten: Concrete compressive strength
• Methodology
• Observations
• Discussion
• Conclusion
24
8.3.6 Split tensile strength test

For split tensile test, you can use either cylindrical specimen or cube specimen. In this
practical, use cube specimen. Place the test specimen in the compression testing
machine with the packing strips carefully positioned along the top and bottom of the
specimen in the plane of Loading. Apply the load to the opposite faces of the as-cast
specimen. Calculate the split tensile strength (F) using the equation below:
2P
F =
 .a 2
where:
F = tensile strength (N/mm2)
P = compressive load at fracture (N)
a= size of cube (mm)
Calculate and record the average results to the nearest 0.05 MPa
8.3.6.1 Report deliverable on concrete Split tensile strength

Use the following outline to complete chapter eleven: Concrete split tensile strength
• Methodology
• Observations
• Discussion
• Conclusion
25
REFERENCES
SANS 50196-1:2006: Methods of testing cement: Part 1- Determination of strength
SANS 3001-AG1: Civil engineering test methods: PartAG1: Particle size analysis of
aggregates
SANS 5845:2006: Bulk densities and voids content of aggregates
SANS 5847:2008: Flakiness index of coarse aggregates
SANS 3001-AG4:2015: Civil engineering test methods: PartAG4: Determination of
flakiness index of coarse aggregate
SANS 3001-AG20:2011: Civil engineering test methods: PartAG20: Determination of
the bulk density, apparent density and water absorption of aggregate particles retained
on the 5 mm sieve for road construction materials
Fulton’s concrete technology 9th edition, Chapter 11: Concrete mix design. Edited by
Gill Owens. ISBN: 978-0-9584779-1-8
SANS 5862-1:2006: Concrete tests – Consistence of freshly mixed concrete – Slump
test
SANS 5861-1:2006: Concrete tests: Part 1- Mixing fresh concrete in the laboratory
SANS 5861-3:2006: Concrete tests: Part 3 – Making and curing of test specimens
SANS 5863:2006: Concrete tests – Compressive strength of hardened concrete
SANS 6253:2006: Concrete tests – Tensile splitting strength of concrete
26

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CONCRETE TECHNOLOGY (CTC4801)

Prof Ikotun Bolanle

Table of content ……………………………………………………..…………………….. 2

1. MORTAR SAMPLES PREPARATION, FLEXURAL STRENGTH AND

1. MORTAR SAMPLES PREPARATION, FLEXURAL STRENGTH AND

1.1 AIM AND OBJECTIVES

1.3.3 Making mortar prisms

1.3.5 Mortar flexural strength test

(a) Use a center-point loading method

(e) Record the average results of two samples.

1.3.5.1 Report deliverable on mortar flexural strength

1.3.6 Mortar compressive strength test

(e) Record the average results of four samples.

1.3.6.1 Report deliverable on mortar compressive strength

2. SIEVE ANALYSIS TEST PROCEDURE FOR UNISA STUDENTS ACCORDING

2.1 AIM AND OBJECTIVES

• Dry a test sample to constant mass at 105 to 110 °C in a well-ventilated oven.

2.4 EXAMPLE OF SIEVE ANALYSIS CALCULATIONS FOR CRUSHER SAND

TO CALCULATE THE FINENESS MODULUS

2.5 Report deliverable for Sieve analysis

3. BULK DENSITY TEST PROCEDURE FOR UNISA STUDENTS ACCORDING TO

3.3.1 For uncompacted bulk density

3.3.2 Compacted bulk density (rodding procedure)

Note 3: Avoid breaking up individual particles of the aggregate.

3.5 Report deliverable on Bulk density

4. PARTICLE SHAPE TEST PROCEDURE FOR UNISA STUDENTS ACCORDING

4.1 AIM AND OBJECTIVES

FI is the flakiness index of the sample expressed as a percentage;

𝑀𝑆 is the mass of all the fractions gauged, expressed in grams.

4.5 Report deliverable on Particle shape

• Title, objectives, apparatus and pictures

5. BULK RELATIVE DENSITY, APPARENT RELATIVE DENSITY AND WATER

5.1 AIM AND OBJECTIVES

Table 5.1: Size of test sample after quartering

B = is the mass of the saturated surface-dry test sample, expressed in grams

C = is the mass of the saturated test sample in water at 25 ℃, expressed in

• Title, objectives, apparatus and pictures

6 CONCRETE MIX DESIGN

• Specify the concrete strength and stone size.

6.3 MIX DESIGN CALCULATIONS

Example of mix design calculation:

Cement Type CEM1 cement

Consistence 75 mm slump for

Use the Table below to determine K for the calculation.

Determine the sand content

350 sand 1194 210

Materials For 1m3 For 20 L

6.4 Report deliverable Concrete mix design

7 SLUMP TEST PROCEDURE FOR UNISA STUDENTS ACCORDING TO SANS

7.1 AIM AND OBJECTIVES

Figure 7.1: Slump test cone

• Tamping rod, made of straight steel, of nominal diameter 16 mm and length

7.4 Report deliverable on Slump test

8. SAMPLE PREPARATION, COMPRESSIVE STRENGTH AND SPLIT TENSILE

8.1 AIM AND OBJECTIVES

8.3.3 Making concrete cubes

8.3.5 Compressive strength test

8.3.5.1 Report deliverable on concrete Compressive strength

8.3.6 Split tensile strength test

8.3.6.1 Report deliverable on concrete Split tensile strength

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