SCHOOL OF CIVIL AND ENVIRONMENTAL ENGINEERING FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY UNIVERSITY OF TECHNOLOGY, SYDNEY

SPRING SEMESTER 2013 SUBJECT 48352 CONSTRUCTION MATERIALS LABORATORY TESTING HANDBOOK TESTING OF CONSTRUCTION MATERIALS

L ABORATORY I NSTRUCTIONS FOR THE E XPERIMENTAL T ESTING OF M ETALS , A GGREGATES AND C ONCRETE

P REPARED B Y : D R K. V ESSALAS (L ECTURER )

Page 1 of 41

TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. Student instructions Introduction Tensile testing of metals Laboratory report one marking scheme Testing of aggregates for concrete Laboratory report two marking scheme Testing of fresh and hardened concrete Laboratory report three marking scheme 2 5 6 12 13 21 22 41

48352/S2013/LR1/LR2/LR3/KV

Page 2 of 41

STUDENT INSTRUCTIONS
General Instructions
1. Students must print out the laboratory handbook available on UTS Online and bring it with them to each laboratory session. It is also advisable to bring along a calculator and camera to each session to take photos for enhancing the quality of the laboratory reports. 2. Students are responsible for recording all necessary experimental data covered during the laboratory sessions and, where applicable, obtain uploaded experimental data available from UTS Online. 3. Students must remain in their allocated group for laboratory session 3 unless prior permission has been granted from the subject coordinator for students to change to another group. 4. 5. Students should find out where the locations of the laboratory sessions are in advance. Students should read the laboratory handbook in advance of the laboratory session. It helps to know the details of the experiment before entering the laboratory session. 6. Students should be punctual in attending the 3 laboratory sessions on time. The most important part of the laboratory session is often the introduction. Missing this part by a few minutes could lead to confusion for the remainder of the laboratory session. 7. Students should ask questions if in any doubt during the laboratory session to understand the reasons behind undertaking the experiment. It is often best to ask questions during the laboratory session and not a few days before the report is due.

Important Instructions
a) Compulsory attendance is required for the full duration of laboratory session 3 that is, the laboratory session dealing with the fresh and hardened testing of concrete. b) Students need to attend their designated laboratory class session during tutorial week. A student group list comprised of 8 laboratory sessions scheduled to take place during tutorial week will be made available on UTS Online. Students need to check the list and contact the subject coordinator in advance, if a clash arises with another subject activity and students are unable to attend their designated session. c) Failure to attend laboratory session 3 and record attendance details on the laboratory quiz given at the end of the session will result in instant disqualification of the laboratory report being marked.

48352/S2013/LR1/LR2/LR3/KV

Page 3 of 41

d) Students should ensure to wear fully enclosed shoes and appropriate clothing to the concrete testing laboratory session or entry may be denied. Failure to comply with this requirement will result in instant disqualification of the laboratory report being marked. e) Students should notify the subject coordinator in advance, or at the first available opportunity, when they are physically unable to attend laboratory session 3 due to a legitimate certified UTS approved reason. If the subject coordinator is contacted in advance, it may be possible for the student to attend another scheduled laboratory session in place of their missed session. f) Bonus marks are given based on a students compulsory attendance at laboratory session 3 and undertaking the laboratory quiz. The mark received for the quiz will be taken as a bonus mark and added to the total assessment. g) Laboratory reports are a team effort and must not be copied and/or plagiarised. Plagiarism is treated very seriously and can result in: 1) Failure of the assessment task 2) Failure in the subject, or 3) Exclusion from the university The following website links provide guidance on the definition and consequences of plagiarism and academic misconduct: http://www.gsu.uts.edu.au/rules/16-2.html http://www.gsu.uts.edu.au/rules/s5-2.html http://www.uts.edu.au/teachlearn/avoidingplagiarism/what/index.html h) Follow instructions and marking guidelines given in the laboratory handbook when writing up the 3 laboratory reports. All laboratory reports must be submitted by 12:00 pm on their due date listed in the teaching schedule. Actual submission requires the laboratory report being physically placed in Kirk Vessalas mailbox 28, which is located up the staircase on the left when entering level 5 of building 2 from level 5 of building 1. i) A student is required to fill out an online special consideration application form to be considered for any special review of awarded marks if they are absent from laboratory session 3. Failure to comply with this UTS rule will mean that a students case for special consideration will not be considered nor will it be reviewed separately. More information on how to fill out a special consideration application form can be found at the following website link: http://www.sau.uts.edu.au/assessment/consideration/online.html

48352/S2013/LR1/LR2/LR3/KV

Page 4 of 41

j)

Students are expected to work in teams of minimum 2 persons or maximum 3 persons when writing up laboratory reports 1 and 2. In addition, students are expected to work in teams of minimum 2 persons or maximum 5 persons when writing up laboratory report 3. It is the responsibility of the student to find a suitable partner or partners in advance before their laboratory report is due. If for any reason students are having trouble with team members contributing to the write up of laboratory reports, please contact the subject coordinator via email in advance of the due date to arrange for alternate arrangements of submission.

k)

Assessment of each laboratory report will be based on a 10-point scale as follows: 10 Excellent report 8 7 6 5 3 0 Very good report Good report Average report Just acceptable Unsatisfactory performance Unacceptable performance

l)

Late reports will incur a penalty. For each day the report is late, a deduction of 0.5 marks will apply up to 7 days. Any reports handed in 8 days and thereafter will result in 0 marks issued.

Laboratory Room Locations

Metals testing laboratory (CB02.04.29) Aggregates testing laboratory (CB02.04.29) Concrete testing laboratory (CB02.01.116)

Student Signature
I have read and acknowledged all instructions stated above: Student name: Student number: Student signature: Date:

48352/S2013/LR1/LR2/LR3/KV

Page 5 of 41

1. INTRODUCTION
1. Objectives of Materials Testing
Practically, all branches of engineering, especially those dealing with structures and machines, are intimately connected with materials. The properties of materials must be determined by tests using accepted or relevant standard test methods. An understanding of the following testing areas is required for studying the properties of materials: a) Testing technique b) Physical principles involved in the testing apparatus and procedure c) e) Theory of measurements Interpretation of results d) Variability of materials

Principal materials used in civil engineering applications include steel, aluminium, concrete, bituminous mixes, timber, masonry materials (including clay products), and plastics. The principal requirements of construction materials in structures and in service are strength, rigidity, and durability. These requirements largely define the properties of materials and, hence, broadly determine the nature of tests carried out on such materials. The testing of materials may be performed according to one or more of the following three objectives: a) To supply routine information on the quality of a product for commercial or control testing b) To develop or enhance known materials or to further develop new materials for materials research and development work c) To obtain physical constants or derive empirical relationships for adopting an accurate measure of scientific measurements

2. Standard Specifications for Materials Testing

A notable development over the last few decades, particularly in regards to materials testing, has been the preparation and use of standard specifications. A standard specification used for materials testing is the result of an agreement between those concerned in a particular field and involves acceptance for use by participating agencies. A standard is a published and referenced document, which sets out specifications and procedures designed to ensure that a material, product, method, or service is fit for purpose and, in application, consistently performs the way it was designated. Standards Australia has developed several specification requirements and methods for testing construction materials for their physical, chemical, and engineering properties. It is essential for engineers and testing personnel to follow Australian Standard (AS) procedures in all respects, if the results of testing are to be accepted by industry. In this laboratory-testing handbook, the testing of metals, aggregates and concrete will be performed in accordance with relevant AS testing standards. This will give an opportunity for civil engineering students to familiarise themselves with these testing methods while carrying out measurements, recording, interpreting and reporting of the results.

48352/S2013/LR1/LR2/LR3/KV

Page 6 of 41

S CHOOL F ACULTY

OF

C IVIL

AND

E NVIRONMENTAL E NGINEERING
AND I NFORMATION

OF

E NGINEERING
OF

T ECHNOLOGY

U NIVERSITY

T ECHNOLOGY , S YDNEY

Subject 48352 Construction Materials Spring Semester 2013

TEN SI LE T E ST I N G OF ME T A L S

MARK

Student Names: (1) .. (2) .. Student Nos: (1) .. (2) ..

Date of Submission: ..

48352/S2013/LR1/LR2/LR3/KV

Page 7 of 41

2. TESTING OF METALS IN DIRECT TENSION (AS 1391)

1. Objective
To determine the engineering properties of metals and compare the ductile and brittle behaviour of metals in direct tension.

2. Metals tested
(1) Mild Steel (black mild steel that has been annealed) (2) Cast Iron

3. Test performed
Direct uniaxial tensile test.

4. Equipment
Universal testing machine (Shimadzu RH30) 30 tonne (300 kN) set to 60 kN range Instron extensometer 50.00 mm gauge length LVDT RPD LDC 2000 (that is, a 100 mm linear variable differential/displacement transducer/transformer) P3500 strain amp (Biolab/Davidson) DT605 data taker (data logger 10 channel and 1 sample per 1 second) Laptop computer (any computer with a serial port)

5. Relevant information
As a rule of thumb, the original gauge length of a metal specimen may be taken as: 5 x diameter (to be exact: 5.65 x [area]0.5). Remember this equation, as the original gauge length may not be given in an examination question. Students may need to calculate out this value from the cross-sectional area. Percent (%) elongation is calculated from the gauge length taken before test and after fracture of the test specimen by placing the broken sections together (first measure of ductility). Percent (%) reduction in area is calculated from the diameter taken before test and after fracture of the test specimen at the failed cross-section (second measure of ductility). The extensometer is set to 50.00 mm and, thus, 0.2% proof stress would be taken at 0.1 mm. The extensometer is sensitive. It must be withdrawn from the specimen before fracture to avoid damage (approximately 1.0 mm maximum travel is allowed). The extensometer readings are used to calculate strain and for plotting the stress-strain curve to determine various mechanical properties. The LVDT is attached to the cross head on the machine. It is used to produce a crosshead travel (CHT) graph from the data. It will show the elastic limit load (beginning of plastic deformation), maximum load, and load at fracture and provide an overview of the material performance. This graph cannot be used for determining % elongation or 0.2% proof stress (due to slippage and movement of the machine and jaws).

48352/S2013/LR1/LR2/LR3/KV

Page 8 of 41

The maximum load will be given (load at fracture can be obtained from the CHT graph). Students will be given raw data and will be expected to produce graphs (spreadsheet). Data will be uploaded on UTS Online over the next day or so. Please ask questions if in any doubt. All tensile tests are carried out at room temperature (normally 23C). The universal testing machines are calibrated using National Association of Testing Authorities, Australia (NATA) registered equipment to grade A requirements and are within 1% of their rated value per range. The Shimadzu RH30 is set on the 60 kN range and the display is set to 60 kN full-scale range. The output from all equipment is in volts.

6. Testing procedure
Refer to AS 1391 Metallic materials tensile testing at ambient temperatures specification and test method standard for more information. The metal test specimens are to be tested under uniaxial tension at room temperature.

7. Properties to be determined
a) Proportionality Limit (in MPa) for the 2 metals b) Yield strength for mild steel c) e) f) Proof strength, plastic elongation Rp0.2 for cast iron Percentage elongation for the 2 metals Percentage area reduction for the 2 metals d) Proof strength, total elongation Rt0.5 for cast iron

g) Young's Modulus of Elasticity (E to the nearest 5 GPa) for the 2 metals h) Elastic resilience = (proportional limit)2 / (2 x E) for the 2 metals (MJ/m3) i) Modulus of Toughness for cast iron only (MJ/m3)

48352/S2013/LR1/LR2/LR3/KV

Page 9 of 41

8. Test Records

Measurement Original diameter (mm) Final diameter (mm) at fracture location Original gauge length (mm) Final gauge length (mm) Maximum load (kN) Fracture load (kN) Proportional limit load (kN) Lower yield load (kN)

Mild Steel

Cast Iron

Note: Measure the diameter and length using a suitable measuring instrument and express the mean value (that is, average of 3 readings)

SKETCH THE FRACTURE PATTERNS OF THE TEST PIECES

MILD STEEL

CAST IRON

48352/S2013/LR1/LR2/LR3/KV

Page 10 of 41

9. Determination of metal properties

a) Plot the load versus extension diagram for the 2 metal specimens and determine the yield load, maximum load and fracture load b) Plot the engineering stress-strain relationship for both metal specimens from the load-extension data provided using excel software c) Use the stress-strain plots to determine: (a) modulus of elasticity for the 2 metals; (b) both the upper and lower yield strengths for mild steel; and, (c) proof strength (R p0.2) for cast iron d) Determine the ductility of the 2 metals (that is, both % elongation and % reduction in area)

10. The joint group report must include the following

a) A brief description of the test method, including any digital photographs b) Sketches describing the fracture pattern of the 2 metal specimens (digital photographs may be included). For example This metal specimen was observed to have a ductile mode of failure from the large amount of necking observed before fracture. The significant reduction in cross-sectional area experienced at the fracture zone after failure indicates a metal exhibiting a high amount of ductility. A cup and cone fracture was also evident due to a significant reduction in cross-sectional area just before fracture. c) e) f) h) i) j) k) Plot the load-extension graph for the 2 metal specimens Determine the tabulated mechanical properties showing a typical sample calculation for each property Summarise the mechanical properties of the 2 metals Discuss and compare the properties between the 2 metals tested with respect to their significance in civil engineering applications Comment on the test methods used, the accuracy of the measurements taken and general reflections gathered from undertaking this experiment Conclusions References

d) Establish the engineering stress-strain relationship for the 2 metal specimens

g) Discuss and compare the mechanical properties and behaviour observed between the 2 metals tested

48352/S2013/LR1/LR2/LR3/KV

Page 11 of 41

SUMMARY OF METAL PROPERTIES

Property Density (kg/m3) Proportional Limit (MPa) Tensile strength (MPa) Fracture stress (MPa) Upper Yield Strength (MPa) Lower Yield Strength (MPa) Proof Strength R p0.2(MPa) Proof Strength R t0.5(MPa) Percent Elongation Percent Area Reduction Experimental Young's Modulus (GPa) Expected Young's Modulus (GPa)* % Error in Youngs Modulus Elastic Resilience (MJ/m3) Modulus of Toughness (MJ/m3) 200 120 Black Mild Steel 7850 Cast Iron 7150

48352/S2013/LR1/LR2/LR3/KV

Page 12 of 41

GROUP REPORT ONE REQUIREMENTS AND MARKING SCHEME

Results and Discussion Section Requirements
Group reports will be assessed on the following criteria: a) b) c) d) e) f) Presentation of results Analysis of results Comparison of results in tabulated and/or graphical form Comprehensive discussion of results including discussion of errors and applied engineering examples Conclusions References

Typed reports are required Reports are due 2 weeks after completing the laboratory testing exercise

Report Marking Scheme

Laboratory report no.: Date of submission: Part 1 2 3 4 5 Section Introductions, objectives and methods Test results, sketches and sample calculations Graphs and tabulated summaries Discussions and conclusions References, presentation format and style Deductions Total marks Marking Criteria Very good performance = 2/2 marks Acceptable performance = 1/2 marks Unacceptable performance = 0/2 marks /10 Mark /2 /2 /2 /2 /2

General Comments

48352/S2013/LR1/LR2/LR3/KV

Page 13 of 41

S CHOOL F ACULTY

OF

C IVIL

AND

E NVIRONMENTAL E NGINEERING
AND I NFORMATION

OF

E NGINEERING
OF

T ECHNOLOGY

U NIVERSITY

T ECHNOLOGY , S YDNEY

Subject 48352 Construction Materials Spring Semester 2013

TESTING OF AGGREGATES FOR CONCRETE

MARK

Student Names: (1) .. (2) .. Student Nos: (1) .. (2) ..

Date of Submission: ..

48352/S2013/LR1/LR2/LR3/KV

Page 14 of 41

3.1. SAMPLING OF AGGREGATES FOR TESTING (AS 1141)

1.1. Sampling of aggregates - General
Quality control tests are routinely carried out on representative samples of aggregates to ensure that any variation in quality is within specification limits. The need for representative samples cannot be overemphasized. Test results may misrepresent chemical and physical characteristics of the aggregates. Sampling operations, therefore, must be conducted by such test methods to ensure that the samples obtained are as far as possible representative of the given batch available. The basic-unit of sampling is called the sample increment, which is defined as a portion of material taken directly from the conveyor, bin, truck, or stockpile. Sample increments should be taken in sets of five and should be approximately the same size. A bulk sample comprises of five sample increments that are mixed thoroughly to give a uniform bulk sample. The bulk sample may be subdivided into smaller fractions to produce a sample of appropriate size for further testing. Division into smaller factions may be carried out to produce the test portion for use in a particular test. A refereed sample is a portion that is reserved for testing in the event a dispute arises with the test results obtained.

1.2. Sample size and sampling frequency

Testing standards for materials (in this case aggregates) specifies the sample size required for the test as well as the sampling method and sampling frequency. Therefore, for actual testing on site or during production, it is essential to follow the recommendation from standards to assess the quality and property of the materials tested.

1.3. Sample Reduction

When the amount of material has been reduced, it is essential that the representative nature of the sample be maintained. Suitable methods for sample division are by coning and quartering or by the use of a sample divider.

48352/S2013/LR1/LR2/LR3/KV

Page 15 of 41

3.2. TESTING FOR COMPACTED BULK DENSITY (AS 1141.4)

2.1. Significance
The dry density test provides a simple indicator of the variability of properties of aggregates in terms of particle shape and particle size. It can be quickly performed and easily carried out in the field. A low bulk density value for a particular aggregate may indicate a change in aggregate shape or grading, and in turn a change in concrete properties such as porosity, strength, and durability. Furthermore, a change in bulk density should prompt the user to carry out additional tests for proper characterisation of the aggregate.

2.2. Objectives
a) To determine the compacted bulk density of a sample of fine, coarse and mixed aggregate b) To determine the void content of a sample of fine, coarse and mixed aggregate c) To determine the optimum fine aggregate content to produce minimum void content, hence, maximum bulk density

2.3. Apparatus
An electronic balance Metal cylinder Metal scoop Tamping steel rod Water

2.4. Theory
Equations: Bulk density (Db) = aggregate weight (w) / aggregate bulk volume (vb) Particle density (Dp) = aggregate weight (w) / aggregate solid volume (vs) Db / Dp = vs / vb Void content (%) = 100 [vb vs] / vb Void content (%) = 100 [1 vs/vb] Void content (%) = 100 [1 Db / Dp]

48352/S2013/LR1/LR2/LR3/KV

Page 16 of 41

2.5. Test Procedure

a) Record the mass of the empty cylinder (w1) to the nearest gram b) Note down the moisture condition of the aggregate (e. g., air-dry, wet or damp) c) e) f) Check the aggregate to see if it is fully mixed and if necessary remix Compact the aggregate by using the tamping rod with 25 strokes without striking the bottom plate of the cylinder Scoop more aggregate into the cylinder to two-thirds of its height g) Compact the aggregate with another 25 strokes using the tamping rod h) Fill the cylinder with the remaining aggregate overflowing the top and level the surface with the tamping rod i) j) When compacting the aggregate with the tamping rod, ensure each stroke penetrates the previous layer Strike off the surface of the aggregate level with the rim using the tamping rod d) Place the cylinder on a horizontal flat surface. Fill the cylinder with aggregate to one-third of its height

k) Record the mass of the cylinder + aggregate (w2) to the nearest gram

2.6. Determination of Compacted Bulk Density and Void Content

a) Calculate the volume of the cylinder (litres) from the diameter (d) and depth (h) or using the water method (for improved accuracy) b) Calculate the compacted bulk density (CBD) of the aggregate using the following equation: CBD (kg/m3) = 1,000 x aggregate mass (kg) / cylinder volume (litres) CBD (kg/m3) = 1000 (w2 w1) / v c) Determine the theoretical void content of the aggregate assuming the particle density of normal weight aggregate used in this experiment is 2,600 kg/m3

2.7. Records
Tray Identity No. A B C D E F Fine Agg. Content (%) 0 20 40 60 80 100 Agg. Identity Type Coarse Mixed Mixed Mixed Mixed Fine Cylinder Volume [v] (m3) Cyl. Wt [w1] (kg) Cyl. + Agg. Wt [w2] (kg) Void Content (%)

CBD (kg/m3)

48352/S2013/LR1/LR2/LR3/KV

Page 17 of 41

2.8. Calculations and Discussion

Show typical calculations for calculating void content and bulk density Copy the results provided by the other groups

a) Plot the relationship between compacted bulk density and fine aggregate content (use straight lines to join the points) b) Plot the relationship between void content (%) and fine aggregate content (use straight lines to join the points) Using the above plots, determine the optimum fine aggregate content required to obtain minimum void content as well as maximum bulk density a) Discuss factors that influence the optimum fine aggregate content b) Discuss the reasons for blending fine and coarse aggregates for use in concrete mixes

2.9. Conclusions 2.10. References

48352/S2013/LR1/LR2/LR3/KV

Page 18 of 41

3.3

SIEVE ANALYSIS FINE AND COARSE AGGREGATES (AS 1141.11.1)

3.1. Significance
The particle size distribution of aggregates is of significance to most civil engineering applications utilising aggregates. Examples of the use of well-graded aggregates in construction materials include Portland cement concrete, bituminous concrete and unbound road base material. Other applications include single-sized aggregate filter beds, open graded concrete and bituminous mixes.

3.2. Objectives
To determine the particle size distribution of a sample of fine aggregate and a sample of coarse aggregate by sieving using a set of standard-sized sieves consisting of the following sizes: 37.5 mm 19.0 mm 9.5 mm 4.75 mm 2.36 mm 1.18 mm 600 m 300 m 150 m

3.3. Testing Apparatus

Electronic balance Set of AS compliant sieves

3.4. Test Procedure

a) Oven-dry the aggregate at 105C to constant mass. b) Stack the sieves in order of aperture size with the smallest aperture size at the bottom. Fit the pan at the very bottom of the sieve stack. c) e) Take a representative sample of aggregate of suitable mass. Hold the stack of sieves by the base and lid and shake it to-and-fro at about 100 strokes per minute turning through one-sixth of a turn about every 25 strokes. Continue until no more aggregate passes through the sieves. f) Weigh the aggregate that has been retained on the sieve. within the base pan. h) Tabulate the mass of aggregate retained on each sieve. g) Remove sieves from the stack one by one, weighing each retained fraction including the portion contained d) Transfer the weighed aggregate into the top sieve and fit the lid.

48352/S2013/LR1/LR2/LR3/KV

Page 19 of 41

i)

Calculate the percent total mass, which has been retained on each sieve, the cumulative percent retained and the cumulative percent passing. Record these results in the table provided.

3.5. Test Records Table 1: Sieve Analysis Results Coarse aggregate

AS 1141 Sieve Size 37.5 mm 19.0 mm 9.5 mm 4.75 mm Pan Total Wt retained on sieve (g) Wt retained % total mass Cumulative % retained Cumulative % passing

Table 2: Sieve Analysis Results Fine Aggregate

AS 1141 Sieve Size Wt retained on

48352/S2013/LR1/LR2/LR3/KV

Page 20 of 41

3.6. Discussion of Results

a) Comment on the shape of the grading curves (continuous graded or gap graded) b) Discuss the importance of aggregate grading on concrete properties c) Comment on the accuracy of the plots

3.7. Conclusions 3.8. References

48352/S2013/LR1/LR2/LR3/KV

Page 21 of 41

GROUP REPORT TWO REQUIREMENTS AND MARKING SCHEME

Results and Discussion Section Requirements
Group reports will be assessed on the following criteria: a) b) c) d) e) f) Presentation of results Analysis of results Comparison of results in tabulated and/or graphical form Comprehensive discussion of results including discussion of errors and applied engineering examples Conclusions References

Typed reports are required Reports are due 2 weeks after completing the laboratory testing exercise

Report Marking Scheme

Laboratory report no.: Date of submission: Part 1 2 3 4 5 Section Introductions, objectives and methods Test results, tables and calculations Graphs Discussions and conclusions References, presentation format and style Deductions Total marks Marking Criteria Very good performance = 2/2 marks Acceptable performance = 1/2 marks Unacceptable performance = 0/2 marks /10 Mark /2 /2 /2 /2 /2

General Comments

48352/S2013/LR1/LR2/LR3/KV

Page 22 of 41

S CHOOL F ACULTY

OF

C IVIL

AND

E NVIRONMENTAL E NGINEERING
AND I NFORMATION

OF

E NGINEERING
OF

T ECHNOLOGY

U NIVERSITY

T ECHNOLOGY , S YDNEY

Subject 48352 Construction Materials Spring Semester 2013

TESTING OF FRESH AND HARDENED CONCRETE

MARK

Student Names: (1) .. (2) .. Student Nos: (1) .. (2) ..

Date of Submission: ..

48352/S2013/LR1/LR2/LR3/KV

Page 23 of 41

4. MIXING AND TESTING OF CONCRETE (AS 1012)

1. INTRODUCTION
Concrete is the most commonly used construction material for building civil engineering infrastructure. The quality of concrete specified for an application varies significantly since the performance requirement will change with different loading modes, different construction methods, different component materials, and different service conditions. The use of a suitable concrete mix, having the specified properties in both fresh and hardened state, is essential to achieve durable concrete construction. Standard tests on both fresh and hardened concrete are undertaken to ensure that an appropriate quality of concrete is used in construction. The purpose of the concrete laboratory session is to achieve the following objectives: a) To introduce standard testing procedures following AS 1012 b) To gain experience in batching, mixing, moulding and curing of concrete specimens c) To test the fresh and hardened properties of concrete incorporating different water-to-cement ratio (w/c) d) To report, analyse and discuss the test results obtained for four (4) concrete mixes (mixes A, B, C and D)

2. PREPARATION OF MATERIALS
a) All raw materials, including water, should be brought to room temperature (anywhere between 20C to 26C) before beginning operations b) As a basis for the batch masses, a decision should be made as to the moisture condition in which the aggregates are to be used in the concrete The most common moisture conditions are field moisture condition and saturated surface dry (SSD). Prior to batching, each aggregate used should be of uniform moisture condition, determined to 0.1 % accuracy by oven drying to constant mass. Oven temperatures should be in the range of 105C to 110C. c) If added, admixtures should be prepared in accordance with the suppliers recommendations

3. MEASUREMENT OF MATERIALS
a) All raw materials used in a batch should be measured by mass or volume as appropriate to an accuracy of 0.2 % for cement and water; 0.2 % for aggregate; and, if added, 0.5 % for admixtures b) Where liquid admixtures are added, the total volume of solution used should also be included in the calculated amount of mixing water to be added

48352/S2013/LR1/LR2/LR3/KV

Page 24 of 41

4. MIXING CONCRETE
a) The batch size used should exceed that required for test purposes and moulding of all test specimens for fresh and hardened tests by at least 10 % b) Where a pan type mixer is used and concrete is transferred directly to the moulds, the inside of the pan should be moistened and the pan cleaned out between batches c) Where admixtures are used, care should be taken to ensure these additives are uniformly distributed throughout the concrete. Where applicable, admixtures should be added following the suppliers specifications. Each admixture should be added separately. Admixtures may be added at other times where specific effects of additions are being assessed. Water-soluble admixtures should be dissolved in part of the balance of the mixing water to be added. Any such solutions should be counted as part of the mixing water. d) Unless otherwise specified, the following tolerances on the nominated slump, measured in accordance with AS 1012.3, should apply:

e)

The procedure for hand loading is as follows: i) ii) Charge the mixer with the coarse aggregate, then the fine aggregate, before adding a sufficient quantity of the mixing water to wet the aggregate Operate the mixer for 30 seconds and stop addition of fly ash), all components should be added to the mixer together. To prevent loss of powdered cementitious materials, cover the cement with some of the aggregate in the mixer prior to commencing mixing. iii) Add the cement. Where the cementitious material comprises more than one component (such as the

48352/S2013/LR1/LR2/LR3/KV

Page 25 of 41

iv) Commence mixing as set out in Figure 1. Any variation to the procedure specified in Figure 1 should be recorded.

48352/S2013/LR1/LR2/LR3/KV

Page 26 of 41

5. SAMPLING OF FRESHLY-MIXED CONCRETE

a) The trial batch prepared should be regarded as the sample for all subsequent tests. Where pan mixers not fitted with discharging gates are used, the fresh concrete should be sampled directly from the pan. b) Where other types of mixers are used, the fresh concrete should be discharged onto a smooth clean damp non-absorbent surface, briefly remixed with a shovel or scoop, and heaped together to ensure uniformity c) Where a delay is anticipated between the completion of mixing and commencement of testing, the sample should be covered to prevent evaporation

6. USE OF FRESHLY-MIXED CONCRETE

a) Any tests required in accordance with AS 1012 should be completed within the following time limits after the completion of mixing: i) ii) 5 minutes for the determination of consistency 10 minutes for other tests on freshly-mixed concrete, including determination of air content and mass per unit volume b) The preparation of specimens should be completed within the following time limits after completion of mixing: i) ii) 30 minutes for the determination of setting time 10 minutes for the determination of bleeding

iii) 20 minutes for the determination of hardened concrete properties iv) 30 minutes for the determination of drying shrinkage c) Unless noticeable loss of mixing water has occurred, concrete used to test consistency and mass per unit volume of concrete (except when the mass per unit volume was determined during a test for air content) may be remixed into the composite sample. The period of remixing should be 30 seconds. The remixing should be done after all other samples for tests on freshly mixed concrete have been taken and prior to making specimens for tests on hardened concrete.

7. TESTING OF FRESH CONCRETE

7.1. Objective To measure the workability (by measurement of slump) and unit weight (wet density) of freshly mixed concrete using AS 1012. 7.2. Background During concrete construction, uniformity and compaction of freshly mixed concrete is required to fill formwork properly. When mixed concrete lacks uniformity, difficulties are experienced with compacting and filling formwork on a construction site. These difficulties will result in a significant reduction to the strength, stiffness, and durability of the concrete. The single term workability is used to define the rheology of the freshly mixed concrete. Workability is critical when pumping freshly mixed concrete to fill formwork.

48352/S2013/LR1/LR2/LR3/KV

Page 27 of 41

The workability of concrete required differs from a construction site to the next and depends on several factors such as the reinforcement details, the compaction method used, the member size and shape, and method of transporting the concrete to fill the formwork. Four (4) standard test methods, specified by the Australian Standards (AS) 1012.3, are used to measure the workability of concrete. They are the slump test, the compacting factor test, the Vebe test, and the compactibility index test. The slump and compacting factor tests are more suitable for measuring the workability of concretes requiring a medium level of workability, whereas the Vebe test is suitable for measuring concretes requiring a low and very low level of workability. The compactibility index test is recommended only for concrete mixes having a slump below 10 mm. For this laboratory session, the compacting factor, Vebe test, and compactibility index test will not be performed; however, the use of such testing equipment will be briefly demonstrated. 7.3. Slump Test (AS 1012.3.1) Scope This AS test method sets out the method for determining the workability of concrete by measurement of slump when the nominal size of aggregate does not exceed 40 mm. Principle a) This method describes the procedures of filling a slump cone (frustum) with fresh concrete in three equal layers and rodding each layer 25 times and then removing the slump cone vertically upwards away from the concrete b) The vertical subsidence of the concrete that occurs, when the slump cone is raised, is termed the slump of the concrete c) The slump will not vary between individual batches produced if the characteristics and proportions of ingredients used to make the concrete do not vary from batch to batch Apparatus Standard slump cone (measuring 200 mm bottom diameter, 100 mm top diameter and 300 mm height) Cone funnel Steel rod (measuring 600 mm long and 16 mm diameter) Scoop Graduated ruler

Procedure a) Dampen the slump cone, funnel, tamping rod and area of level concrete floor with water in preparation for the test

48352/S2013/LR1/LR2/LR3/KV

Page 28 of 41

b) Assemble the slump cone on the prepared spot on the concrete floor and place both feet firmly on the footplates. Ensure that the cone is seated flat on the floor. The cone should be held rigid by the feet of the tester throughout the entire duration of the rodding procedure. Any slight movement of the cone will invalidate the test result and the test will have to be repeated. c) Obtain a representative sample of concrete from the mixing pan tamping rod. During the filling and rodding sequence of the top layer, sufficient concrete should be placed in the funnel to ensure an excess of concrete is available above the top of the slump cone at all times throughout the rodding procedure. e) f) After the top layer has been rodded, the surface of the concrete should be struck off level with the top of the cone ensuring that throughout the operation the slump cone is firmly seated on the floor The slump cone should now be raised slowly and carefully in a vertical direction, allowing the concrete to subside. The raising of the slump cone should be completed in 3 + 1 seconds g) Observe and record the shape of the slump obtained. Identify the slump as one of four types: i) Zero slump d) Fill the cone in three (3) equal height layers, rodding each layer 25 times with the rounded end of the

ii) True slump iii) Shear slump iv) Collapse slump h) If the slump obtained is a shear slump, then repeat the test with another part of the sample Note: An indication of the cohesiveness and workability of the concrete can be obtained if after slump measurement the side of the test specimen is tapped gently with the tamping rod. Well-proportioned concrete, which has an appreciable slump, will gradually slump further. Badly proportioned concrete is likely to fall apart. Measurement of Slump a) The slump of the concrete should be determined immediately by measuring the difference between the height of the slump cone and the average height from three (3) measurements taken across the top surface of the concrete b) The whole operation from the start of filling the cone to the removal of the cone should be completed within 2.5 minutes c) Slump should be recorded to the nearest 5 mm for slumps measuring 100 mm and less and to the nearest 10 mm for the slumps measuring greater than 100 mm 7.4. Mass Per Unit Volume of Freshly Mixed Concrete (AS 1012.5) Scope This AS test method sets out the method for determining mass per unit volume of freshly mixed concrete that is in its plastic state.

48352/S2013/LR1/LR2/LR3/KV

Page 29 of 41

Apparatus A metal cylinder with a diameter-to-height ratio of 0.75-1.25 and a capacity of not less than 5 L for concrete containing aggregates of nominal size not exceeding 40 mm Weighing balance A mallet A flat glass cover plate External vibrator

Consolidation External Vibrating Table (Procedure) a) Measure the volume of the cylinder by filling it with water (v). Convert the volume of the cylinder from litres to m3 b) Dampen the internal sides, and base of the cylinder and the underneath of the glass plate with water and weigh the empty cylinder plus glass plate (m1) in kg c) e) Obtain a representative sample of concrete from mixing Compact each layer on a vibrating table only long enough to achieve full compaction. Avoid over vibration. While the concrete is being consolidated on the vibrating table, securely hold the cylinder in place to prevent it from moving. f) Strike off the excess concrete and finish off the surface level using the flat glass cover plate to ensure that the concrete precisely fills the measure g) Weigh the cylinder plus concrete plus glass plate (m2) in kg h) Calculate the mass of compacted concrete (mc = m2 m1) in kg i) Calculate the mass per unit volume of concrete (MPV) using the expression: MPV (kg/m3) = mc (kg) / v (m3) 7.5. Making of Concrete Specimens for Strength Tests (AS 1012.8.1) Scope This section sets out the method for making and curing of compression and indirect tensile test specimens of concrete sampled in the laboratory or in the field. Shape and Diameter of Test Specimens a) The specimens used for both compressive and indirect tensile strength tests are 100 mm diameter by 200 mm height. AS 1012 recommends the use of 150 mm diameter by 300 mm height cylinders for indirect tensile strength testing of concrete mixes containing a maximum aggregate size of 40 mm. In addition, AS 1012 also specifies the use of 150 mm diameter by 300 mm height cylinders for compressive strength testing of concrete mixes containing an aggregate size between 21 mm and 40 mm. b) 100 mm cubes are used by some international standards such as British Standards d) Fill the cylinder in two equal layers with the scoop

48352/S2013/LR1/LR2/LR3/KV

Page 30 of 41

Moulding Specimens a) Check whether the moulds are properly clamped and clean. Thinly coat the inside surface of the steel moulds and steel base-plates with mould oil. b) Take the sample of concrete and place the concrete in the mould in approximately two (2) equal layers using a scoop. Compact the concrete without causing segregation. c) Strike off and smooth the concrete surface using a moistened wooden float the concrete test specimens. Make sure the mould caps and plastic sheets are not touching the concrete surface. Curing of test specimens a) Leave the moulded test specimens in the laboratory to cure for 24 hours b) Remove the test specimens from the moulds after an initial curing period of 24 hours c) e) Identify the specimens with the date of moulding and weigh the specimens Store three cylinders in laboratory ambient conditions (air-storage) d) Store all specimens, except for three cylinders, in a water tank maintained at 23 2 oC d) Cover the moulded specimens with a plastic sheet or mould caps to avoid moisture loss and drying out of

Capping of test specimens a) Where capping is required, the specimens should be tested using either: i) ii) Moulded capping; or Restrained natural rubber capping system

b) Moulded caps should be as thin as practicable and not more than 6 mm in thickness. Only one layer of capping material should be used on each surface requiring capping, but small depressions may be filled prior to capping. c) Moulded capping materials should consist of one of the following five types: i) ii) Filled sulphur mixtures Portland cement mortar

iii) High-alumina cement mortar iv) Cement pastes v) Special gypsum plasters

48352/S2013/LR1/LR2/LR3/KV

Page 31 of 41

PART A: TESTING OF FRESH CONCRETE

1. Objectives
a) To batch and mix concrete using specified amounts of concrete making materials b) To determine the workability and unit weight of freshly mixed concrete c) To investigate the influence of increasing the w/c on the fresh properties of concrete d) To mould a number of test specimens for determining hardened concrete properties

2. Test Procedures
The following tests on fresh concrete should be carried out and results recorded: Slump Mass per unit volume of concrete

3. Batch Weights (kg)

Material Cement Fine sand* Coarse sand* 10 mm coarse aggregate* 20 mm coarse aggregate* Mixing water Mixing water/cement ratio Free water**/cement ratio * Aggregates have been batched from laboratory bins in air-dried storage conditions. This means that the aggregates batched are not in saturated surface dry (SSD) condition. ** Calculate the free water using the given moisture contents and absorption capacities of the four (4) aggregates. Given: Moisture Content (MC) and Absorption Capacity (AC) of the aggregates 1. 2. 3. 4. Fine sand Coarse sand 10 mm coarse aggregate 20 mm coarse aggregate 0.6% MC 0.5% MC 0.3% MC 0.2% MC 1.6% AC 1.5% AC 1.0% AC 0.9% AC Sp. Gr. 3.15 2.60 2.60 2.65 2.65 1.00 Mix A 16.0 10.0 10.0 25.0 25.0 6.4 0.40 Mix B 16.0 10.0 10.0 25.0 25.0 7.2 0.45 Mix C 16.0 10.0 10.0 25.0 25.0 8.0 0.50 Mix D 16.0 10.0 10.0 25.0 25.0 8.8 0.55

48352/S2013/LR1/LR2/LR3/KV

Page 32 of 41

4.

Test Records
Measurement Cylinder diameter (mm) Cylinder height (mm) Volume of cylinder (v) (m3) Wt. of empty cylinder (mo) Wt. of cylinder with concrete (m1) Wt. of compacted concrete (mc = m1 mo) Slump of concrete to nearest 5 mm MPV (mc/v) to nearest 10 kg/m3 Mix A Mix B Mix C Mix D

Notes: Conduct the slump test immediately after mixing the concrete

5. Observations
a) Sketch the slump pattern observed (digital photography is allowed) b) Note the type of slump: No / True / Shear / Collapse (circle the correct type) c) Note if the slump is stable: Yes / No (circle yes or no) d) Is the phenomenon of bleeding observed after moulding of the fresh concrete?

6. Standard Test Specimens Moulding and Curing Operations (4 Mixes)

9 x 100 mm diameter by 200 mm height cylinders (1 to 9) (6 cylinders for water-curing and 3 cylinders for air-storage) 3 x 100 mm cubes (water-curing) (10 to 12) 1 x 100 mm diameter by 200 mm height uncompacted cylinder (water-curing) (13)

7. 28 Day Tests Required (4 Mixes)

a) Compressive cylinder strength = 3 x water-cured (nos. 1 to 3) b) Compressive cylinder strength = 3 x air-stored (nos. 4 to 6) c) e) f) Indirect tensile strength = 3 x water-cured (nos. 7 to 9) Compressive cube strength = 3 x water-cured (nos. 10 to 12) Uncompacted compressive cylinder strength = 1 x water-cured (no. 13) d) Ultrasonic pulse velocity (non-destructive)= 3 x water-cured (nos. 10 to 12)

48352/S2013/LR1/LR2/LR3/KV

Page 33 of 41

8. Calculations and Plots

Determine the cement content, aggregate content, and free water content for all four (4) mixes and show a typical sample calculation. Group Unit weight of concrete (kg/m3) Cement content (kg/m3) Aggregate content (kg/m3) Free water content (kg/m3) Plot the relationship between slump and free water content Plot the relationship between unit weight and free water content Mix A Mix B Mix C Mix D

9. Discussion
Using the above relationships, discuss the influence of water content on the workability and unit weight of the concrete.

48352/S2013/LR1/LR2/LR3/KV

Page 34 of 41

P A R T B : TESTING OF HARDENED CONCRETE

1. Objectives
a) To determine the compressive and indirect tensile strengths of hardened concrete b) To examine the effects of curing condition on strength development of concrete c) e) To examine the influence of specimen shape (geometry) on compressive strength To examine the effect of increasing w/c on compressive and indirect tensile strengths of concrete d) To examine the effect of compaction on compressive strength

2. Procedure (AS 1012)

2.1. Compressive strength (AS 1012.9)

In this test, standard cylinders and cubes will be subjected to uniaxial compressive loading with the load applied at a standard stress rate of 20 MPa/min up to failure. The maximum applied load is recorded for determining compressive strength.

When testing a cylinder, a capping material is required on the top rough surface of the cylinder to achieve a plane surface for uniform loading Load is applied to a planar surface when testing a cube, as no capping is required The compressive strength of concrete (fc) is calculated using the expression: fc (MPa) = maximum load (N) / load bearing area (mm2) Cylinder load bearing area = x (r2), where r is the cylinder radius Cube load bearing area = d x d, where d is the cube length, depth or height

2.2. Indirect Tensile Strength (AS 1012.10)

In this test, a standard cylinder is placed on its side (that is, perpendicular) and subjected to compressive loading with the load applied as a standard stress rate of 1.5 MPa/min along its length. The cylinder splits in indirect tension along a diagonal direction due to induced tension resulting from Poisson's effect. It is necessary to use bearing strips (5 mm thick, plywood strips) between each cylinder and testing machine platens to avoid localised crushing.

The indirect tensile strength of concrete (fst) is calculated using the expression: fst (MPa) = 2000 x maximum load (kN) / x l (mm) x d (mm) l = length of cylinder (in mm) d = diameter of cylinder (in mm)

48352/S2013/LR1/LR2/LR3/KV

Page 35 of 41

3. Test Results
3.1. Compressive Strength Cylinders (Water cured for 28 days) Diameter (mm) Height (mm) Weight (g) Max. load (kN) fc.28 (MPa)

Specimen No. A1.1 A1.2 A1.3 B1.1 B1.2 B1.3 C1.1 C1.2 C1.3 D1.1 D1.2 D1.3

fcm.28 (MPa)

Note: Express the strength to 3 significant numbers Observations Draw typical failure patterns of the concrete cylinders in compression

48352/S2013/LR1/LR2/LR3/KV

Page 36 of 41

3.2. Compressive Strength Cylinders (Air stored for 28 days) Diameter (mm) Height (mm) Weight (g) Max. load (kN) fc.28 (MPa)

Specimen No. A1.4 A1.5 A1.6 B1.4 B1.5 B1.6 C1.4 C1.5 C1.6 D1.4 D1.5 D1.6

fcm.28 (MPa)

Note: Express the strength to 3 significant numbers Observations Draw typical failure patterns of the concrete cylinders in compression

48352/S2013/LR1/LR2/LR3/KV

Page 37 of 41

3.3. Indirect Tensile Strength Cylinders (Water cured for 28 days) Diameter (mm) Weight (g) Max. load (kN) fst.28 (MPa)

Specimen No. A1.7 A1.8 A1.9 B1.7 B1.8 B1.9 C1.7 C1.8 C1.9 D1.7 D1.8 D1.9

Length (mm)

fstm.28 (MPa)

Note: Express the strength to 3 significant numbers Observations and Remarks Is failure observed through the aggregates or the aggregate-cement paste bond (comment on this observation)?

48352/S2013/LR1/LR2/LR3/KV

Page 38 of 41

3.4. Ultrasonic Pulse Velocity Cubes (Water cured for 28 days)

Specimen No. A1.10 B1.10 C1.10 D1.10

Path length (mm)

Elapsed time (sec)

Pulse velocity (km/s)

Cylinder strength (MPa)

3.5. Compressive Strength Cubes (Water cured for 28 days) Depth (mm) Weight (g) Max. load (kN) fc.28 (MPa)

Specimen No. A1.10 A1.11 A1.12 B1.10 B1.11 B1.12 C1.10 C1.11 C1.12 D1.10 D1.11 D1.12

Width (mm)

fcm.28 (MPa)

Note: Express the strength to 3 significant numbers Observations Draw typical failure patterns of the concrete cubes in compression

48352/S2013/LR1/LR2/LR3/KV

Page 39 of 41

4. Calculations
a) Determine the unit weight of the hardened concrete b) Determine the mean compressive cylinder strength c) e) Determine the mean indirect tensile strength Determine the mean cube strength d) Calculate the ultrasonic pulse velocity (3 significant numbers)

5. Presentation of Test Results

Material Cement content (kg/m3) Free water content (kg/m3) Free water/cement ratio Hardened unit weight (kg/m3) Cylinder strength (MPa) Indirect tensile strength (MPa) Ultrasonic pulse velocity (km/s) Cube strength (MPa) Plot the following graphical relationships and discuss these relationships a) b) c) d) e) f) g) h) i) Cylinder compressive strength versus free w/c [water-cured] Cylinder compressive strength versus free w/c [air-stored] Cylinder compressive strength [water-cured] to cylinder compressive strength [air-stored] ratio versus cylinder strength [water-cured] Cylinder indirect tensile strength versus free w/c [water-cured] Cylinder indirect tensile strength versus cylinder compressive strength [water-cured] Cylinder indirect tensile strength to cylinder compressive strength ratio versus cylinder compressive strength [water-cured] Cylinder compressive strength versus ultrasonic pulse velocity [water-cured] Cube compressive strength versus free w/c [water-cured] Cylinder compressive strength versus cube compressive strength [water-cured] include the theoretical relationship cylinder compressive strength = 0.80 x cube compressive strength Mix A Mix B Mix C Mix D

48352/S2013/LR1/LR2/LR3/KV

Page 40 of 41

6. Discussion of Test Results

Using your results, discuss the following characteristics: a) b) c) d) e) f) g) Effects of free water content on the fresh properties (workability and unit weight of concrete) Effects of free w/c on the hardened properties (compressive strength and indirect tensile strength) Effects of curing condition on the compressive strength Relationship between compressive strength and ultrasonic pulse velocity Effect of specimen shape on compressive strength Discuss possible errors that may have occurred during these tests Discuss your reflection on the importance of the laboratory session etc

7. Additional Instructions
a) b) c) d) e) f) g) Include sample calculations Use Excel to plot relationships (ensure to select the appropriate scales) All results for the 4 mixes (A, B, C and D) should be used in writing up this report Use the trend line function in Excel to plot the fitting relationships. The discussion is the most important part of the report and, therefore, should have more focus by being detailed and descriptive Ensure to include references (beyond my lecture notes and Wikipedia) Submit your combined fresh and hardened concrete report before the due date

Please do not submit instructions and procedures listed in the laboratory handbook. Students should briefly write down the procedures used and present the results and your own analysis of results, discussion, and conclusions.

8. Conclusions
List the conclusions obtained from your analysis of the results and discussion. Both qualitative and quantitative statements are required in your conclusions.

9. References
References should be made to textbooks and notes used in your discussion

Importance Announcement
This is a laboratory report is worth 10% of your final assessment Three or more students must combine to write up the report Any copied report will not be marked Signed declarations by all students in the same group must be included on the cover page of the report

48352/S2013/LR1/LR2/LR3/KV

Page 41 of 41

GROUP REPORT THREE REQUIREMENTS AND MARKING SCHEME

Results and Discussion Section Requirements
Group reports will be assessed on the following criteria: a) b) c) d) e) f) Presentation of results Analysis of results Comparison of results in tabulated and/or graphical form Comprehensive discussion of results including discussion of errors and applied engineering examples Conclusions References

Typed reports are required Reports are due 3 weeks after completing the laboratory testing exercise

Report Marking Scheme

Laboratory report no.: Date of submission: Part 1 2 3 4 5 Section Introductions, objectives and methods Test results, tables and calculations Graphs and illustrations Discussions and conclusions References, presentation format and style Deductions Total marks Marking Criteria Very good performance = 2/2 marks Acceptable performance = 1/2 marks Unacceptable performance = 0/2 marks /10 Mark /2 /2 /2 /2 /2

General Comments

48352/S2013/LR1/LR2/LR3/KV