LABORATORY REPORT NO.

CE 121: Construction Materials

CONCRETE MIX DESIGN

& MAKING AND CURING
TEST SPECIMENS
ANGEL U. GACUTAN
2007-16069
BS Civil Engineering

Submitted to:
ABSTRACT: Engr. Christian R. Orozco
This experiment deals with the selection of appropriate ingredients and
determining their relative quantities to generate economical concrete
with certain minimum properties, notable workability, strength, and
durability. In this test, based on a specified target compressive
strength, we have computed the different proportions of gravel, sand,
cement, and water using the 9-Step Mix Proportioning Procedure. In
accordance with the ASTM standards, these materials were mixed and
placed in 4” by 8” cylindrical molds. The concrete is then cured for a
span of 7, 14, and 28 days before testing its maximum compressive
strength. From our gathered data, after 28 days, we were able to
achieve our target designed strength of 2500 psi.

SIGNIFICANCE AND USE:

The results of the standard cured cylinders are used for acceptance
testing for specified strengths, verifying the mixture proportions for
strength, and quality control by the concrete producer. It is a major
importance that the specimens are made and cured following the
ASTM standard procedures. Low strength test results due to
procedures not in accordance with the standards can cause undue
concern, cost, and delay to the project. The strength results could also
be used for determining the time at which the structure is permitted to
be put into service and evaluating the adequacy of curing and
protecting concrete in structure.

STANDARD REFERENCE:
 ASTM C192/C192M–02: Standard Practice for Making and Curing
Test Specimens in the Laboratory
 ACI 211.1-91: Standard Practice for Selecting Proportions for
Normal, Heavyweight, and Mass Concrete
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I. OBJECTIVES
This laboratory experiment is done:
 To be able to make concrete cylinders that will resist a given specified compressive
strength of 2500 psi
 To fully understand the 9-Step Mixing Proportioning Procedure to determine the relative
quantities of cement, water, sand and gravel
 To generate economical concrete with certain minimum properties, notable workability,
strength, and durability.
 For the students to appreciate the materials used in the real structures and provide
understanding on how aggregates are utilized and tested.

II. EXPERIMENTAL PROCEDURE

A. MATERIALS AND EQUIPMENT USED
 Cylindrical Molds. Molds for specimens or fastenings thereto in contact with the
concrete shall be made of steel, cast iron, or other nonabsorbent material, nonreactive
with the concrete to be used. The dimensions of the molds used in this experiment have a
diameter of 4 inches (101.6 mm) and a height of 8 inches (203.2 mm).
 Digital Balance. A balance or scale accurate for determining the mass of batches of
materials and concrete shall be accurate within 0.3 % of the test load at any point within
the range of use.
 Concrete Mixer. A power-driven concrete mixer shall be a revolving drum, tilting
mixer, or suitable revolving pan or revolving-paddle mixer capable of thoroughly mixing
batches of the prescribed sizes at the required slump.
 Grease or Oil. Must be applied on the inner surface/wall of the molds in order to prevent
the concrete mixture to stick or cling into it.
 Hammer or Mallet. A mallet with a rubber or rawhide head weighing 1.25 ± 0.50 lb (0.6
± 0.20 kg) shall be used. It will serve as external vibrators.
 Oven. It must be of sufficient size, capable of maintaining a uniform temperature of 110
± 5 °C (230 ± 9 °F). It is used for the preparation and drying of the samples.
 Mixing Tools. Tools and items such as shovels, pails, trowels, wood float, blunted
trowels, straightedge, feeler gage, scoops, rulers, rubber gloves, and metal mixing bowls
shall be provided.

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 Sieves. With sieve openings of 4.75 mm (Sieve No. 4) and 19.0 mm (Sieve No. ¾).
 Sampling and Mixing Pan. The pan shall be flat bottom and of heavy-gage metal,
watertight, of convenient depth, and of sufficient capacity to allow easy mixing by shovel
or trowel of the entire batch.
 Slump Apparatus. The apparatus for measurement of slump shall conform to the
requirements of ASTM Test Method C143/C143M.
 Tamping Rods. A round, straight steel rod, 16 mm (5/8 inches) in diameter and
approximately 600 mm (24 inches) in length, having the tamping end, or both ends,
rounded to a hemispherical tip.
 Water Tank or Curing Box. It must have provisions to maintain required curing
environment during the initial curing period.
 Concrete Raw Materials. The constituents needed to mix concrete are as follows:
 Cement. The cement powder, when mixed with water, forms a paste. This paste acts
like glue and holds or bonds the aggregates together.
 Coarse Aggregates. Crushed rock, gravel or screenings.
 Fine Aggregates. Fine and coarse sands and crusher fines.
 Water. It must be clean, fresh and free from any dirt, unwanted chemicals or rubbish
that may affect concrete.

B. METHODOLOGY
PREPARATION OF CONCRETE MATERIALS
1. The total volume of the concrete mixture that is required to fill the six 4” x 8” cylindrical
molds is computed.
2. The equivalent mass proportions (in kilograms) of gravel, sand, cement and water
required to achieve the given compressive strength of 2500 psi is also calculated.
3. Sufficient amount of the aggregates (i.e. sand and gravel) must be prepared. The gravel
sample must pass through Sieve No. ¾ and retain in Sieve No. 4. And must be
thoroughly washed and cleaned to remove unnecessary materials or particles.
4. Both the fine and coarse aggregate samples are oven dried.
5. Sufficient amount of cement must also be prepared.

CONCRETE MIXING
1. The concrete mixer is washed and cleaned.
2. The gravel is put first into the mixer. The mixer is allowed to spin for about 1-2 minutes.

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3. The sand is placed next into the mixer. Let the mixer to spin for another 1-2 minutes. If
there is some sand that adheres to the surface of the mixer, removed them.
4. The cement is then added to the mixture. The mixer is allowed to spin while adding small
amount of water for at least every after 2 minutes, until all the water has been added.
5. While mixing, grease or oil is applied to the inside surface of the cylindrical molds to
avoid the concrete from adhering.
6. The slump test is performed to check if the concrete mix is workable enough. Once the
concrete mix passed the slump test, the mixture is then poured into the cylindrical molds.
7. The first layer of the mixture is poured in until 1/3 of the height of cylinder. The mixture
is then compacted using the tamping rod for 25 blows while the side of the cylinder is
pounded using a rubber hammer in order to remove air bubbles that may have been
trapped on the mixed concrete. The same procedure is performed until the last layer.
8. Step no. 7 is then repeated and applied to the other remaining molds.
9. Once all the molds are filled with the mixture, let the moulded concrete be stored
overnight for casting/hardening.
10. After 24 hours, the specimens are removed from their cylindrical molds and immersed
them in water tub outside the laboratory until the day of testing (at 7, 14, and 28 days
underwater curing)
11. After seven days, the specimens are air-dried and capped them using heated/melted
sulphur powder and have their compressive strength be tested.
12. Process no. 12 is then repeated after fourteen and twenty eight days.

SLUMP TEST
1. The concrete mix is placed about 1/3 of the height of the mold. Using the tamping rod,
the mixture is compacted for 25 blows.
2. Another layer of concrete is added, this time 2/3 of the height of the mold. Another 25
blows of rod is again applied on the layer as well. The same step is performed until the
last layer.
3. The mold is removed vertically. This will allow the concrete to collapse.
4. The mold is placed side by side with the concrete and the difference of the height of the
slump and the mold must be measured.
5. The range of the slump should be from 1” to 2”. If the slump exceeds the range, adjust
the concrete mixture components as necessary and perform the slump test again.

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C. DATA ANALYSIS
9-STEP MIX PROPORTIONING PROCEDURE
The 9-step mix proportioning[1] procedure is used as an aid for calculating the proportion of
cement, water, gravel, and sand required for the total volume and mass of concrete to be placed
in six 4” x 8” cylindrical concretes to achieve the given compressive stress of 2500 psi.

1. Choice of Slump. It is the stiffest consistency that can be placed and compacted without
segregation. The various slump range is shown in the following table.

Table 1. Recommended values of slump for various type of construction (ACI 211.1)

RANGE OF SLUMP
TYPE OF CONSTRUCTION
mm in
Reinforced foundation walls and footings 20 - 80 1-3
Plain footings, caissons, and substructure walls 20 - 80 1-3
Beams and reinforced walls 20 - 100 1-4
Building columns 20 - 100 1-4
Pavements and Slabs 20 - 80 1-3
Mass Concrete 20 - 80 1-2

2. Choice of Maximum Aggregate Size (MAS)

3. Estimate of Water and Air Content. Water content depends on workability requirements.

Table 2. Approximate Requirements for Mixing Water and Air Content for Different
Workability and Nominal Maximum Sizes of Aggregates (ACI 211.1)
WORKABILITY OF Water content, kg/m3 (lb/yd3) of concrete for indicated max. aggregate size
CONCRETE 10 mm 12.5 mm 20 mm 25 mm 40 mm 50 mm 70 mm 150 mm
Non-air entrained concrete
Slump:
30-50 mm 205 200(335) 185(315) 180(300) 160(275) 155(260) 145(220) 125(190)
80-100 mm 225 215(365) 200(340) 195(325) 175(300) 170(285) 160(245) 140(210)
150-180 mm 240 230(385) 210(360) 205(340) 185(315) 180(300) 170(270) -
Approximate entrapped
3 2.5 2 1.5 1 0.5 0.3 0.2
air content, %:
Air entrained concrete
Slump:
30-50 mm 180 175(295) 165(280) 160(270) 145(250) 140(240) 135(205) 120(180)
80-100 mm 200 190(325) 180(305) 175(295) 155(265) 155(265) 150(225) 135(200)
150-180 mm 215 205(345) 190(325) 185(310) 165(280) 165(280) 160(260) -
Recommended average total air content,%:
Mild exposure 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0
Moderate exposure 6.0 5.5 5.0 4.5 4.5 4.0 3.5 3.0
Extreme exposure 7.5 7.0 6.50 6.0 5.5 5.0 4.5 4.0

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4. Selection of W/C Ratio. The water to cement ratio (W/C) is the weight of the water divided
by the weight of cement. To determine the effective W/C ratio of the concrete, we must first
calculate the value of its average compressive strength.

TABLE 3. Required Increase in Strength

Specified Comp. Strength Req’d. Increase in Strength
f’c (MPa) f’c (psi) (MPa) (psi)
< 21 < 3000 7 1000
21 to 35 3000 to 5000 8.5 1200
35 or more > 5000 10.0 1400

(Equation 1)

Where:
= average compressive strength
= specified compressive strength
= required increase in strength

Table 4. Relationship between W/C ratio & Average Compressive Strength (ACI 211.1)

AVERAGE COMPRESSIVE EFFECTIVE W/C RATIO

STRENGTH (28-days) (by mass)
MPa Psi Non-air entrained Air-entrained
45 - 0.38 -
- 6000 0.41 -
40 - 0.43 -
35 5000 0.48 0.40
30 - 0.55 0.46
- 4000 0.57 0.48
25 - 0.62 0.53
- 3000 0.68 0.61
20 - 0.70 0.61
15 - 0.80 0.71
- 200 0.82 0.74

5. Cement Content Calculation. It is governed by mixing water requirement and W/C ratio.

(Equation 2)

Where:
= cement content, lb/yd3
= water content, lb/yd3
= effective water-cement ratio

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6. Gravel Content Calculation. It is the dry bulk volume of coarse aggregate per unit volume
of concrete. To calculate for the gravel content, we must first determine the following
parameters:

 Volume Fraction. It depends on the nominal maximum aggregate size and the fineness
modulus of the fine aggregates (i.e. sand) derived from the previous laboratory reports.

Table 5. Dry bulk volume of coarse aggregate per unit volume of concrete (ACI 211.1)

MAXIMUM SIZE OF Dry Bulk Volume of Rodded Coarse Aggregate per unit
AGGREGATE Volume of Concrete for FM of Sand
mm in 2.40 2.60 2.80 3.00
10 3/8 0.50 0.48 0.46 0.44
12.5 ½ 0.59 0.57 0.55 0.53
20 ¾ 0.66 0.64 0.62 0.60
25 1 0.71 0.69 0.67 0.65
40 1½ 0.75 0.73 0.71 0.69
50 2 0.78 0.76 0.74 0.72
70 3 0.82 0.80 0.78 0.76
150 6 0.87 0.85 0.83 0.81

 Dry-Rodded Volume of Gravel. Product of the derived volume fraction and the mix
proportioning of concrete per cubic yard which is equivalent to 27 ft3.

The gravel content is simply the product of its computed dry-rodded volume to its dry-rodded
unit weight which is equivalent to 102.47 lb/ft3.

7. Sand Content Calculation. Since the water content, cement content, gravel content, and air
content have already been calculated, we can now get the volume of each to obtain the
amount of sand required for the concrete mix by using the Absolute Volume Method.

In the Absolute Volume Method, the values of the materials’ bulk densities are needed.

TABLE 6. Bulk Density of the Concrete Constituent

Material kg/m3 lb/ft3
Water 1000.00 62.40
Cement 3139.65 196.00
Gravel 2691.13 168.00
Sand 2595.02 162.00

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8. Adjustment for Aggregate Moisture Correction

9. Trial Batch Adjustments.

DETERMINATION OF AVERAGE COMPRESSIVE STRENGTH

(Equation 3)

III. DATA AND RESULTS

TABLE 7. Dimensions of the Cylinder Molds

Diameter, inches 4.00

Height, inches 8.00
Surface Area, in2 12.56637
in3 yard3
Volume
100.53096 0.00215

Note: The calculated surface area is the area of the upper/lower face of the concrete cylinders where the
compressive uniaxial load is directly applied.

TABLE 8. Required Compressive Strength

Design Compressive psi Mpa
Strength, f'c 2500 17.24

9 STEP MIX PROPORTIONING PROCEDURE:

1. CHOICE OF SLUMP
The design will be used for mass concrete (in the form of cylinders), non-air entrained concrete.
Thus, base from Table 1, the target range of slump is equivalent to 1 - 2 inches.

2. CHOICE OF MAXIMUM AGGREGATE SIZE

During the preparation of the materials, all the aggregate samples that retained on Sieve #4 (with
diameter of 19.00 mm) were discarded. Thus, the Nominal MAS of the constituents is
approximately equivalent to 20.00 mm.

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3. ESTIMATE WATER CONTENT

From Table 2, for a slump range of approximately 30-50 mm, a nominal MAS of 20 mm, and
non-air entrained concrete the Water Content is 315 lb/yd3.

4. WATER-CEMENT RATIO
To calculate for the W/C ratio of the concrete mixture, we must first determine the value of the
average compressive strength. The required compressive strength of the concrete mixture is 2500
psi. Thus, for a specified compressive strength of less than 3000 psi, based from Table 3, the
required increase in strength is 1000 psi. Using Equation 1, the average compressive strength,
, is:

Knowing the value of , compute for the effective W/C ratio. From Table 4, the corresponding
W/C ratio for the 3000 psi and 4000 psi are:

TABLE 9. Relationship between W/C Ratio and Average Compressive Strength

Average Compressive Effective W/C Ratio
Strength (psi) (by mass)
3000 0.68
4000 0.57

By interpolation, let x = W/C ratio for 3500 psi

Solving for x, the effective W/C ratio (by mass) for 3500 psi is equivalent to 0.625.

5. CEMENT CONTENT CALCULATION

Given the water to cement ratio of 0.625, we can now compute for the amount of cement
required for the concrete mix, using Equation 2.

Cement Content = 504 lb/yd3

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6. GRAVEL CONTENT CALCULATION

Volume Fraction. Knowing that the nominal MAS is 20.00 mm and an FM value of 2.227 (i.e.
derived from the previous laboratory reports), based on Table 5, the volume fraction is
equivalent to 0.677.

Dry-Rodded Volume of Gravel.

Weight of gravel:

Gravel Content = 1873.13 lb/yd3

7. SAND CONTENT CALCULATION

Knowing the specified bulk density of each material (see Table 6), by Absolute Volume Method,
their estimated volumes are as follows:

TABLE 10. Absolute Volume Method

Computed Bulk Density,
Material Volume, ft3
Content, lb lb/ft3
Water 315.00 62.40 5.04808
Cement 504.00 196.00 2.57143
Gravel 1873.13 168.00 11.14958
TOTAL 18.76909

Sand Content = 1333.41 lb/yd3

8. MOISTURE CORRECTION
Moisture correction is neglected since the materials we have used for the concrete mixing are
oven-dried beforehand.

9. TRIAL BATCH ADJUSTMENTS COMPUTATION FOR 1 yd3

We apply ratio and proportions from the total volume of the total cylindrical forms used in the
laboratory. Note that the computed values are just approximation.

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Knowing that the volume of the cylinder mold is equivalent to 0.00215 yd3 (see Table 7), the
different weights of each mix proportion are as follows:

For us to easily measure the proportion of each material, we converted the computed weight
from pounds (lbs) to kilograms (kg).

TABLE 11. Total Weight of Materials needed for the Concrete Mix
Per Batch Total (7 samples)
Component
Weight (lb) Mass (kg) Weight (lb) Mass (kg)
Water 0.679 0.308 4.751 2.155
Cement 1.086 0.493 7.602 3.448
Gravel 4.036 1.831 28.253 12.815
Sand 2.873 1.303 20.112 9.123
TOTAL 8.674 3.934 60.718 27.541

The following tables show the result of the compressive test performed on each of the 4” x 8”
concrete cylinders per testing day.

Note: Knowing the surface area of the upper/lower face of the concrete cylinder (see Table 7),
the readings of the various compressive uniaxial loads shown in Tables 12, 13, and 14 are
computed using Equation 3.

TABLE 12. Results of the Compressive Uniaxial Load Test for the 7th day
7th Day Test Readings, lb Strength, psi
Trial 1 26100 2076.97201
Trial 2 24100 1917.81706
Average 1997.39454

TABLE 13. Results of the Compressive Uniaxial Load Test for the 14th day
14th Day Test Readings, lb Strength, psi
Trial 1 28000 2228.16920
Trial 2 30000 2387.32415
Average 2307.74667

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TABLE 14. Results of the Compressive Uniaxial Load Test for the 28th day
28th Day Test Readings, lb Strength, psi
Trial 1 31500 2506.69035
Trial 2 33500 2665.84530
Average 2586.26783

Table 15. Summary of the Average Compressive Strength per Testing Day
Testing Day Compressive Strength, psi
th
7 1997.39
14th 2307.75
28th 2586.27

Proximity to the Desired Compressive Strength of 2500 psi:

7th Day Testing:
| |

14th Day Testing:

| |

28th Day Testing:

| |

Figure 1. Compressive Strength per Testing Day

2700

2600
Compressive Strength, psi

2500 2586.26783

2400

2300
2307.74667
2200

2100

2000
1997.39454
1900
5 10 15 20 25 30
Length of Initial Curing Period, day

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IV. DISCUSSION

Most commonly, the compressive strength of concrete is measured to ensure that the
concrete delivered to a project meets the requirements of the job specification and for quality
control. For testing the compressive strength of concrete, cylindrical test specimens (i.e. in this
laboratory experiment, cylindrical molds of size 4” x 8” were used) are cast and stored in the
field until the concrete hardens in accordance with the requirements of the ASTM standards.

Based on the results of the test presented in Table 15, we were able to achieve the
specified designed strength of 2500 psi after 28th day. This positive result is due to several
factors. First are the right relative proportions of the concrete materials we have computed in
accordance with the ACI procedure. Second is that the slump that we obtained during the slump
test is low, which is approximately 1 ¾ inches. Since the slump is within the range, that is 1” to
2”, we no longer repeat the mixture. The requirement for the concrete mix to be successful is to
have a minimum height of slump.

Furthermore, as shown in Table 15, after 7 and 14 days of initial curing, we failed to
reach the desired compressive strength of 2500 psi with a proximity percentage of 20.10 % and
7.69 %, respectively. But during our 28th day of testing, we have finally reached a compressive
strength value which is 3.45 % higher than our target compressive strength. As presented in
Figure 1, as time passes by, concrete cylinders become harder and stronger to resist higher
amount of compressive uniaxial load. From here, we may infer that the longer the concrete is
cured, the closer it will be to its best possible strength and durability.

POSSIBLE SOURCES OF ERRORS: In this experiment, even though we achieved the

desired compressive strength of 2500 psi after the 28th day testing, there could be nominal errors
occurred during our concrete preparation. The possible sources of errors are listed below for
recommendation and further improvement of conducting the experiment:

 During the first slump test, slump was not formed. Due to this, additional amount of
water was added from the computed value. We must take into consideration that adding
more water to a mix gives a weaker hardened concrete.[2]

 Before testing, we have air-dried and made a bit of wiping on the surface of the sample.
According to the ASTM standards, “Relatively small amounts of drying of the surface of
flexural strength specimens will induce tensile stresses in the extreme fibers that will

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markedly reduce the indicated flexural strength.”

 The cylinders may not be consolidated enough and rodding may not be evenly distributed
throughout each layer. In addition, the sides of the mold was not sufficiently tapped with
the mallet in order to close any insertion holes formed while rodding. Thus, there could
still be voids inside the cylinders.

 After we have stored overnight the molded concrete for casting and removed them from
the cylindrical mold, we have observed that there are still air bubbles trapped in the
concrete mix.

 During the initial curing, we were not able to observe and control the required
temperature range of the water tank. Direct sunlight or extreme weather may affect the
curing process. For a specified strength of less than 6000 psi (40 MPa), cylinders must be
placed in a controlled environment where the temperature is maintained in the range of
16 - 27⁰C (60 - 80 ⁰F).[3]

V. SUMMARY AND CONCLUSION

Concrete is obtained by mixing cement, fine aggregate, coarse aggregate and water in
required proportions. The mixture when placed in forms and allowed to cure becomes hard like
stone. The hardening is caused by chemical action between water and the cement due to which
concrete grows stronger as time passes by.

The 9-step mix proportioning procedure is a big help in determining the required amount
of raw materials in doing concrete. Procedures in computing for the proportions of materials for
making a concrete mix should be cautiously done. These amounts of materials being computed,
as well as their physical properties, are important factors that affect the concrete’s durability and
strength to resist a certain load. Other factors include the method of compaction and certain
controls during placing, compaction, and curing. This laboratory experiment is important in
order to prevent failure or damage of a structure made to sustain a specific load.

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VI. LABORATORY SUGGESTIONS

SUGGESTIONS REASONS
Availability of all needed utensils or materials which are in good
Better laboratory conditions is needed in this experiment for better results. For
example, the concrete mixer used is not adequate enough to
materials and
properly mix all the materials. In addition, the weighing scales we
equipment. used may present inaccuracy especially the digital balance since it
is sensitive even to very small movements.

For example, there is no enough space in the oven where we could

Additional laboratory place and oven-dry all our aggregates, since many other groups
have already occupied the limited space of the oven. There is also
equipment. inadequate number of molds and only one concrete mixer is used
by all the CE 121 groups.

In our first computations of concrete mix proportioning, we have

Perform a trial mix
before mixing all of the
materials.
failed to satisfy our slump test. There is too much amount of gravel
content relative to its sand content. So we have no choice but to
repeat all of our computations. It is highly advisable to perform a
trial mix in order to determine whether the computed mix
proportions will produce a minimum value for the slump. If not,
we have to repeat the computations to adjust the mixture.

The physical arrangement of the laboratory environment creates an

Sufficient working
space and orderly
environment.
impact to the productivity of the students. Furthermore, since
several groups perform the experiment in the same day, there is a
limited working space. A better and well-arrange laboratory space
will enhance the enthusiasm and work efficiency of the students.

OTHER REFERENCES:
 [1]
Lecture Notes on CE 121: Construction Materials “CONCRETE: 4.0. MIX DESIGN” by Dr.
Nathaniel B. Diola (July, 2011)
 [2]
“Concrete Basics: A Guide to Concrete Practice” by Cement Concrete and Aggregates, Australia
(August, 2004 )
 [3]
“Concrete in Practice: What, Why and How?” by National Ready Mixed Concrete Association
(NRMCA) 2001
 AASHTO T23: Method of Making and Curing Concrete Test Specimens in the Field
 ASTM C143/C143M: Standard Method of Test for Slump of Portland Cement Concrete
 ASTM C702-98: Standard Practice for Reducing Samples of Aggregate to Testing Size
 ASTM D75/D75M-09: Practice for Sampling Aggregates

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