UNIVERSITI TEKNOLOGI PETRONAS

CIVIL ENGINEERING PROGRAMME

BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

MIX DESIGN PROCESS

5 Flow chart of procedures

The manner in which this method links the various factors involved in the process
of designing a mix is shown as a flow chart in Figure 2. Also a suitable mix design
form for recording the values derived is shown in Table 1*. It will be seen from
the flow chart that initial information is divided into two categories:
● Specified variables, the values of which are usually nominated in specifications,
and
● Additional information, which is normally available to the producer of the
concrete.

This initial information is used in conjunction with reference data, which appear in
the form of figures or tables in this publication, to evaluate a number of ‘derived
values’ which are also subdivided into two categories:
● The mix parameters, several of which form an intermediate step to the
derivation of the second category, and
● The final unit proportions, which are defined in terms of mass of materials
required to produce one cubic meter of compacted concrete, expressed to the
nearest 5 kg.

In order to clarify the sequence of operation, and for ease of reference, the flow
process is divided into five stages. Each of these stages deals with a particular
aspect of the design and ends with an important parameter or final unit
proportions.

Stage 1 : Deals with strength leading to the free-water/ cement ratio

Stage 2 : Deals with workability leading to the free-water content
Stage 3 : Combines the results of Stages 1 and 2 to give the cement content
Stage 4 : Deals with the determination of the total aggregate content
Stage 5 ; Deals with the selection of the fine and coarse aggregate contents

The mix design form shown in Table 1 is sub-divided into the same five stages
and the separate item numbers correspond with the relevant boxes of the flow
chart in Figure 2

Open
1
5.1 Selection of target water/cement ratio (Stage 1)
If previous information concerning the variability of strength tests comprises
fewer than 20 results, the standard deviation to be adopted should be that obtained
from line A in Figure 3. If previous information is available consisting of 20 or
more results, the standard deviation of such results may be used provided that this
value is not less than the appropriate value obtained from line B. The margin can
then be derived from calculation C1:

M = k × s …C1

Where ,
M = the margin (Item 1.3)
k = a value appropriate to the ‘percentage defectives’ permitted below the
characteristic strength (see 4.4)
s = the standard deviation.

Instead of working from the standard deviation and obtaining the margin through
calculation C1, the margin itself may be specified direct. Hence Item 1.3 may be a
derived value or an optional specified value as indicated in Figure 2. Calculation
C2 determines the target mean strength (expressed to two significant figures):

fm = fc + M …C2

Where ,
fm = the target mean strength
fc = the specified characteristic strength
M = the margin

Next, a value is obtained from Table 2 for the strength of a mix made with a free-
water/cement ratio of 0.5 according to the specified age, the strength class of the
cement and the aggregate to be used. This strength value is then plotted on Figure
4 and a curve is drawn from this point and parallel to the printed curves until it
intercepts a horizontal line passing through the ordinate representing the target
mean strength. The corresponding value for the free-water/cement ratio can then
be read from the abscissa. This should be compared with any maximum free-
water/cement ratio that may be specified and the lower of these two values used.

5.2 Selection of free-water content (Stage 2)

Stage 2 consists simply of determining the free-water content from Table 3
depending upon the type and maximum size of the aggregate to give a concrete of
the specified slump or Vebe time.

Open
2
5.3 Determination of cement content (Stage 3)
The cement content is determined from calculation C3:

Cement content = free-water content …C3

free-water / cement ratio

The resulting value should be checked against any maximum or minimum

value that may be specified. If the calculated cement content from C3 is below a
specified minimum, this minimum value must be adopted and a modified free-
water/cement ratio calculated which will be less than that determined in Stage 1.
This will result in a concrete that has a mean strength somewhat higher than the
target mean strength. Alternatively, the free water/cement ratio from Stage 1 is
used resulting in a higher free-water content and increased workability. On the
other hand, if the design method indicates a cement content that is higher than a
specified maximum then it is probable that the specification cannot be met
simultaneously on strength and workability requirements with the selected
materials. Consideration should then be given to changing the type or strength
class, or both, of cement, the type and maximum size of aggregate or the level of
workability of the concrete, or to the use of a water-reducing admixture.

Table2:ApproximateCompressiveStrength(N/mm2)ofConcreteMixesMadewithaFree-
Water/CementRatio0.5
Type Compressive Strengths (N/mm2)
Type
ofCoarseA Age( days)
ofCeme 3 7 28 91
nt ggregate
Ordinary
Portland Uncrushed 22 30 42 49
(OPC) or
Sulphate
Resisting Crushed 27 36 49 56
Portland

RapidHarden Uncrushed 29 37 48 54
ingPortland
(SRPC)
(RHPC)
Crushed
34 43 55 61

1 N/mm2 = 1MN/m2=1 MPa

Open
3
 Table3:ApproximateFree-
WaterContents(kg/m3)requiredtoGiveVariousLevelsofWorkability
Slump (mm) 0-10 10-30 30-60 60-180
Vebe Time(s) >12 6-12 3-6 0-3
MaximumSiz Type
eAggregate ofAggregat
(mm) e
Uncrushed 150 180 205 225
10 Crushed 180 205 230 250
Uncrushed 135 160 180 195
20 Crushed 170 190 210 225
Uncrushed 115 140 160 175
40 Crushed 155 175 190 205
Note:When coarseand fineaggregate ofdifferenttypes areused,the free-
watercontentis estimated by the expression

2/3 Wf + 1/3 Wc

Where ,
Wf = free-watercontent appropriate to type of fine aggregateand

Wc = free-water content appropriate totype ofcoarse aggregate

On the other hand, if the design method indicates a cement content that is
higher than a specified maximum then it is probable that the specification cannot
be met simultaneously on strength and workability requirements with the selected
materials. Consideration should then be given to changing the type or strength
class, or both, of cement, the type and maximum size of aggregate or the level of
workability of the concrete, or to the use of a water-reducing admixture.

5.4 Determination of total aggregate content (Stage 4)

Stage 4 requires an estimate of the density of the fully compacted concrete
which is obtained from Figure 5 depending upon the free-water content and the
relative density* of the combined aggregate in the saturated surface-dry condition
(SSD). If no information is available regarding the relative density of the
aggregate, an approximation can be made by assuming a value of 2.6 for
uncrushed aggregate and 2.7 for crushed aggregate. From this estimated density of
the concrete the total aggregate content is determined from calculation C4:

Total aggregate content = D - C -W …C4

(saturated and surface-dry)

Where ,
D = the wet density of concrete (kg/m3)
C = the cement content (kg/m3)
W = the free-water content (kg/m3)
Open
4
5.5 Selection of fine and coarse aggregate contents (Stage 5)
Stage 5 involves deciding how much of the total aggregate should consist of
materials smaller than 5 mm, ie the sand or fine aggregate content. Figure 6 shows
recommended values for the proportion of fine aggregate depending on the
maximum size of aggregate, the workability level, the grading of the fine
aggregate (defined by its percentage passing a 600 µm sieve) and the free-
water/cement ratio. The best proportion of fines to use in a given mix will depend
on the shape of the particular aggregate, the actual grading of shape of the
particular aggregate, the actual grading of the fine aggregate and the use to which
the concrete is to be put. However, adoption of a proportion obtained from Figure
6 will generally give a satisfactory concrete in the first trial mix which can then be
adjusted as required for the exact conditions prevailing.

The final calculation, C5, to determine the fine and coarse aggregate
contents, is made using the proportion of fine aggregate obtained from Figure 6
and the total aggregate content derived in Stage 4:

Fine aggregate content =

Total aggregate content × proportion of fines
…C5
Coarse aggregate content =
Total aggregate content - fine aggregate content

The coarse aggregate content itself can be subdivided if single sized 10, 20
and 40 mm materials are to be combined. Again, the best proportions will depend
on aggregate shape and concrete usage but the following ratios are suggested as a
general guide:

1:2 for combination of 10 and 20 mm material

1:1.5:3 for combination of 10, 20 and 40 mm material

Open
5
 Table1: Concretemixdesignform
StageItem Referenceor
Value
calculation

1 1.1 Characteristicstrength Specified N/mm2at

daysProportiondefective
percent
1.2 Standarddeviation( ) Fig3 N/mm2ornodata N/mm2
1.3 Margin(kx ) C1 (k= ) x = N/mm2
1.4 Targetmeanstrength C2 + = N/mm2

1.5 Cementtype Specified OPC/SRP/RHPC

1.6 Aggregatetype:coarseA
ggregatetype:fine
1.7 free-water/cementratio Table2,Fig4
Usethelowervalue
1.8 Maximumfree-water/cementratioSpecified

2 2.1 SlumporV-B Specified Slump mmorV-B s

2.2 Maximumaggregatesize Specified mm
2.3 Free-watercontent Table3 kg/m3

3 3.1 Cementcontent C3  = kg/m3

3.2 Maximumcementcontent Specified kg/m3
3.3 Minimumcementcontent Specified kg/m3-UseifgreaterthanItem3.1and
calculateItem3.4
3.4 Modifiedfree-water/cementratio

4 4.1 Relativedensityofaggregate(SSD) known/assumed

4.2 Concretedensity Fig5 kg/m3
4.3 Totalaggregatecontent C4 - - = kg/m3

BS882 Zone
Fig6 percent
x = kg/m3
C5
- = kg/m3

Quantities Cement Water Fineaggregate Coarseaggregate

(kg) (kgorl) (kg) (kg)

perm3(tonearest5kg)
pertrialmixof m3

Iteminitalicsareoptionallimitingvaluesthatmaybespecified(seeSection7)1N/mm2
=1MN/m=1MPa(seefootnoteonpage8)
OPC=ordinaryPortlandcement;SPRC=sulphate-resistingPortlandcement;RHPC=rapid-
hardeningPortlandcementRelativedensity=specificgravity(seefootnoteonpage15)
SSD=basedonasaturatedsurface-drybasis

Open
6
Open
7
Figure 6: Recommended proportions of fine aggregate according to percentage
passing a 600 µm sieve.

Open
8
Open
9
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

MIXING AND SAMPLING FRESH CONCRETE

1.0 OBJECTIVE
Mixing and sampling fresh concrete in the laboratory (as recommended by
BS 1881: Part 125:1986)

2.0 APPARATUS
A non-porous timber or metal platform, a pair of shovels, a steel hand scoop,
measuring cylinder and a small concrete mixer (if machine mix)

3.0 PROCEDURE
a) Weight the quantities of cement, sand and course aggregate to make 1:2:4
concrete mix at water ratio 0.6

b) Hand mixing
i. Mix cement and sand first until uniform on the non-porous platform
ii. Pour course aggregate and mix thoroughly until uniform
iii. Form a hole in the middle and add water in the hole. Mix thoroughly for
3 minutes or until the mixture appears uniform in color

c) Machine Mixing
i. Wet the mixer
ii. Pour aggregate and mix for 25 second
iii. Add half of water and mix for 1 minute and leave for 8 minutes
iv. Add cement and mix for 1 minute
v. Stop the machine and do hand mixing to ensure homogeneity
vi. Pour out the concrete onto the non-porous surface

Open
10
4.0 PRECAUTIONS
a) The room temperature should be approximately 25-27°C.
b) Make sure that fine and aggregate are dry. If they are wet find the content of
the aggregates to determine the quality of water required.

Open
11
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

SLUMP TEST -TEST FOR WORKABILITY

1.0 OBJECTIVE
To measure the workability of a sample from a batch of fresh concrete of a
given mix (as recommended by BS 1881: Part 102:1983)

2.0 THEORY
The measurement of the workability of fresh concrete is important in
assessing the practicality of compacting the mix and also in maintaining
consistency throughout the job.

3.0 APPARATUS
Truncated conical mould 100mm in diameter at the top, 200mm at bottom
and 300mm high, with a steel tamping rod (16mm diameter & 600mm long),
rounded at one end, a scoop, a steel ruler and a steel trowel.

4.0 PROCEDURE
a. Clean the inside mould and place it on a hard, flat and nonabsorbent
surface.
b. Take a representative sample (about 15kg) from a fresh concrete mix.
c. Fill the mould in four layers of concrete of approximately equal depth
(each layer is about 75mm). Each layer is rodded 25 times with the
rounded end of steel rod. Make sure each rodding passes through the high
of each layer.
d. After the top layer has been rodded, the surface of the concrete is struck
off with a trowel to level up with the top of the mould.
e. Clean away any spillage of the concrete around the base of the mould.
f. Carefully and slow lift the mould vertically from the concrete. Invert the
mould and place it next to the moulded concrete. The concrete will slump.
g. Place the rod across the top of the mould.

Open
12
 h. The slump is the different between the height of the slumped concrete and
the mould. Using the steel ruler,, measure the slump from the top of the
concrete to the underside of the rod.
i. Record the slump to the nearest 5mm.

5.0 PRECAUTION
a. The test should be done 6 minutes after water is added to dry concrete mix
(as recommended by BS 1881-Part 102, 1983).
b. During filling the mould must be firmly pressed against its base.
c. The rodding should be applied uniformly through the entire area of the
concrete.
d. The bottom layer should be rodded throughout its dept.
e. Vibration from nearly machine might increase the subsidence.
f. If the specimen collapses off laterally, repeat the test with another sample
of the same batch of concrete.
g. If, in repeat test, the specimen should again collapse or shear, record the
slump.

FIGURE 1:A Slump Cone

Open
13
 FIGURE 2: Measure of Slump

Type of slump

TABLE 1: Slump Test Apparatus & Their Remarks

INDEX APPARATUS REMARKS

1 Slump Cone Heavy Gauge sheet steel, 4” top
diameter, 8” bottom diameter, 12”
height
2 Inspection Scale Machine steel, 0-10 cm slump
measurement, 1 cm increment
3 Base Plate Steel sheet, carrying handle, 600mm
x 600mm x 5mm
4 Scoop Cast Aluminum
5 Trowel Pointed Type
6 Brush Steel wire
7 Tamping Rod Machine Steel, galvanized 16mm
diameter, 600 mm length

Open
14
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

COMPACTING FACTOR TEST- TEST FOR WORKABILITY

1. OBJECTIVE
To measure the workability of a sample from a batch of fresh concrete
(as recommended by BS 1881: Part 103:1983)

2. THEORY
A concrete mix should be workable enough so that it would be compacted
well. Goodcompaction is necessary in order to expel air voids in a fresh
concrete mix. The presence ofvoids in concrete greatly reduces its strength.
Five per cent of voids can results in a drop ofstrength of more than
10per cent.

The compacting factor is defined as the ratio of the weight or partially

compacted concrete to the weight of fully compacted concrete and is normally
stated to the nearest second decimal place.

Compacting factor = mass of partially compacted concrete

mass of fully compacted concrete

3 APPARATUS
The compacting factor test consist of two conical hoppers and a cylindrical
container mounted vertically above one another (the size of apparatus is as
describe in BS 1881: Part 103 (1983),a hand scoop, a steel trowel and a 16mm
diameter and 600mm long tampingrod.

Open
15
4 PROCEDURE

a. Clean the apparatus from any superfluous moisture.

b. Weight the empty cylinder and record down the mass in gram.
c. Fasten the hopper trap door with the catches. Fix the cylinder on the base of
the apparatus. Cover the cylinder top with two steel trowels.
d. Gently fill the top hopper with concrete sample by using a hand scoop until
full. Do not level off or tamp or compact.
e. Open the trap door of the top hopper, allowing the concrete to fall into the
second hopper. Make sure that no concrete sticks in the top hopper.
f. Remove steel trowel from the top cylinder, release trap door of the lower
hopper, allowing the concrete to fall into the cylinder.
g. Level the top of the cylinder and remove spillage from outside the cylinder.
h. Weigh the cylinder with the partially compacted concrete. Record down the
mass in gram.
i. Take out the concrete from the cylinder. Refill the cylinder with the same
concrete in layer approximately 50mm deep.
j. Compact each layer by using a tamping rod for 35strokes (a mechanical
vibrator can also be used)
k. Level off the top, clean away spillage and weigh the mould with fully
compacted concrete. Note the mass in gram.

5 PRECAUTIONS

a. Test should be carried out on a level surface or ground.

b. The hopper and cylinder must be thoroughly clean and dry.
c. If concrete sticks within the hoppers, push the concrete gently by using a
tamping rod
d. The outside of the cylinder must be wiped clean before weighing.
e. The test can be carried out within a period of 2hours from addition of water
to the mix.

Open
16
 FIGURE 1:Compacting Factor Testing Apparatus

Open
17
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

VEE BEE CONSISTOMETER TEST

1. OBJECTIVE
The method of the test covers the procedures for measuring indirectly the
workability of concrete and also for determining in consistency of very dry
mixes. Covered by BS 1881: Part 104 1983.

2. APPARATUS
Vibrating table, a metal pot, a sheet metal cone and standard iron rod.

3. PROCEDURE
a. Placing the slump cone inside the sheet metal cylindrical pot of the
consistometer.
b. Turn the attached glass disc to the swivel arm and place on the top of the
concrete in the pot.
c. Switch on the electric vibrator and simultaneously start a stop watch.
d. The time of vibrator is taken till conical shape disappear and the concrete
assumes cylindrical shape.

FIGURE 1:VEE-BEE CONSISTOMETER

Open
18
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

MAKING AND CURING CUBES AND TEST BEAMS

1. OBJECTIVE
To cast and cure test cubes and test beams of 150mm standard sizes of a
given mix (as recommended by BS 1881: Part 111:1983).

2. APPARATUS
150mm x 150mm x 150mm internal size of steel mould for the test cubes,
150mm x 750mm steel moulds for the test beams, a 300mm long steel
tamping bar with a rimming face 25mm square and a steel trowel.

3. PROCEDURE
a. Brush the inner faces of moulds with oil and tighten the screws.
b. Fill the mould with concrete sample in layers of 50mm deep
approximately.
c. Tamp each layer with the square face steel tamping bar 25times for
test cube and 175 times for test beam. Make sure each tamping passes
through of each layer.
d. After the top layer has been tamped, the surface of the concrete is
struck off level with the top off the mould with a trowel.
e. Using a nail mark the top surface of the concrete test cube to indicate
number and date of casting.
f. Cover the moulds with polythene sheet or damp cloth to prevent
evaporation and keep in the curing room for 24hours.
g. After 24hours the concrete specimen should be removed from the
moulds and stored in the curing tank until they are to be tested at a
temperature of 20+ 5 C.
h. Preferred ages for test are 7days and 28days.
i. At least 2 specimen are made for each mix.

Open
19
4. PRECAUTIONS
a. The fresh concrete samples should be tested for workability before
casting.
b. Test specimen should be made as soon as possible after concrete is
mixed.
c. The specimen in the mould should not be moved within the first few
hours after casting as this may lead to segregation and excessive bleeding
of the concrete.
d. If there is no curing room, place the specimen in the mould in the
laboratory which will be free from vibration.

Open
20
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

COMPRESSIVE STRENGTH TEST CUBES – TEST FOR STRENGTH

1. OBJECTIVE
To determine the compressive strength (crushing strength) of concrete
according to BS 1881: Part 116:1983.

2. THEORY
One of the most important properties of concrete is its strength in
compression. The strength in compression has a definite relationship with all
other properties of concrete. The other properties are improved with the
improvement in compressive strength.
The compressive strength is taken as the maximum compressive load it can
be carry per unit area. Compressive strength tests for concrete with
maximum size of aggregate up to 40mm are usually conducted on 150mm
cubes.

3. APPARATUS
Compression Testing Machine (it complies with the requirement of BS
1610).
4. PROCEDURE
a. Remove the specimen from curing tank and wipe surface water and
grit off the specimen.
b. Weight each specimen to the nearest kg.
c. Clean the top and lower platens of the testing machine. Carefully
center the cube on the lower platen and ensure that the load will be
applied to two opposite cast faces of the cube.

Open
21
 d. Without shock, apply and increase the load continuously at a nominal
rate within the range 0.2N/mm2s to 0.4 N/mm2 until no greater load
can be sustained. Record the maximum load applied to the cube.
e. Note the type of failure and appearance of cracks.
f. Calculate the compressive strength of each cube by dividing the
maximum load by the cross sectional area. Express the results to the
nearest 0.5 N/mm2.

PROJECT/GROUP : LOCATION :

DESCRIPTION : DATE TEST : W/C :

CONCRETE : SLUMP TEST: Job No :

COMPRESSIVE STRENGTH RESULT

Marking Date Age Dimension Weight Weight/Vol Fail Strength

Cast Days (mm) (kg) kg/m3 load N/mm2
(KN) crushing

Open
22
Tested by …………………………. Checked by …………………………

Date …………………………. Date ………………………...

Remarks:

………………………………………………………………………………………………………

……………………………………………………………………………………………………....

………………………………………………………………………………………………………

Open
23
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

REBOUND HAMMER TEST (SURFACE HARDNESS TEST)

1. OBJECTIVE
Rebound Hammer test is basically a surface hardness which provide
information on thequality of the surface layer (about 20mm deep) of the
concrete only. It is unlikely that 95% confidence limits on the estimation of
the in-situ strength of concrete will be better than + 25%under ideal
conditions. Reference Standard: BS 1881 Pt 202 1986.

2. APPARATUS
Rebound Hammer, Testing anvil and Carborundum stone.

3. PROCEDURE
a. By lightly pressing on the head of the impact plunger, the plunger is
released and will slide out of the housing by itself.
b. The plunger is pressed against the spot of the concrete surface to be
tested. Just before it disappears completely in the housing the hammer
is released. Release must be effected by slowly increasing the pressure
on the housing. At the moment of impact the hammer must be held
exactly at right angle to the surface. Do not touch the push button
c. After the impact hammer mass rebounds by a certain amount which is
indicated on the display. The reading on the display gives the rebound
value in N/mm2
d. By simply removing the hammer from the spot tested, it is reset for a
further test and at the same time the indication is cancelled.

Open
24
 FIGURE 1 :Rebound Hammer

Open
25
Open
26
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

ULTRASONIC PULSE VELOCITY TEST (UPV)

1. OBJECTIVE
The UPV test is designed to study the quality of the concrete in existing
structures. It can also can be used to determine the dynamic modulus of
elasticity, dynamic Poisson’s ratio, homogenity, estimated compression
strength, depth of crack, thickness of damaged layers and density of concrete.
Fire damaged structures can also be assessed using this nondestructive testing
technique.Test done using the UPV test technique conforms to BS1881: Part
201:1986 “Non-Destructive” methods of test for concrete measurement of the
velocity of ultrasonic pulses in concrete.

2. APPARATUS
A pulse of longitudinal vibrations is generated by an electro-acoustical
transducer (transmitter) and received by a similar receiver which is placed on
the opposite side of the concrete member under test. The time taken (transmit
time) for the pulse of vibration to travel between the transmitter and receiver
when divided by the transmit time t gives the pulse velocity, V = L/t.

Open
27
FIGURE1:Schematic Diagram

3. PROCEDURE
a. Labeled the faces of the concrete cube with A,B,C,D,E and F
b. Make sure that A and B are place on the opposite faces.
c. The same rule applies to C,D,E and F
d. Use of a coupling gel between the transducer and the concrete cubes
or structures.
e. The transmitting and receiving transducers are placed on opposite
surfaces of the concrete cube.
f. Push the transmitting and receiving transducers as strong as possible.
g. Take the lowest reading measured by UPV device

4. METHOD
The equipment (PUNDIT) used to determine the Ultrasonic Pulse Velocity
in
concrete consists of a transducer, receiver and the Main Control Unit.
Different arrangements to determine ultrasonic pulse velocities are possible
when testing concrete members for quality. Depth of cracks in test members
can be determined by placing the transducers across the crack as shown in
figure below.

Open
28
Direct Transmission Semi-Direct Transmission

Indirect Transmission Measuring Crack Depth

FIGURE 2:Determine Ultrasonic Pulse Velocities

Open
29
Open
30
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

SIEVE ANALYSIS OF FINE & COARSE AGGREGATES

1. OBJECTIVE
This test method cover the determinations of the particle size distribution of
fine and coarse aggregates by sieving. A weighed sample of dry aggregate is
separated through a series of sieves of progressively smaller openings for
determination of particle size distribution.Covered by BS812: Part 103:1985

2.APPARATUS
Scale (or balance) – 0.1g accuracy for fine sieve analysis, 0.5g accuracy for
coarse sieve analysis, Sieves, Mechanical Sieve Shaker,
Drying Oven (110 +/- 5C).

3.PROCEDURE
a. Dry sample to constant weight at a temperature of 110 +/- 5C (230 +/-
9F).
b. Select suitable sieve size to obtain the required information as specified.
The following sieves are applicable with reference to ASTM C33:

Open
31
 Coarse Aggregate (in) Fine Aggregate (in)
1.5 No. 4
1 No. 8
¾ No. 16
½ No. 30
3/8 No. 50
No. 4 No. 100
No. 8 No. 200
No. 16 Pan
Pan

TABLE 2: Size of Sieve Stack for Coarse & Fine Aggregate

c. Nest the sieves in order of decreasing size of opening from the top to
bottom. Place the pan below the bottom sieve. Place the sample on the
top sieve. Place lid over top sieve.
d. Agitate the sieves by hand or by mechanical apparatus for a sufficient
period such that not more than 1% by weight of the residue on any
individual sieve will pass that sieve during 1 minute of additional hand
sieving. Ten minutes of original sieving will usually accomplish this
criteria.
e. Determine the weight of material retained on each sieve. The total
retained weights should closely match the original weight of the sample
(within 0.3%).
4. CALCULATIONS
a. Calculate percentages passing and total percentage retained to nearest
0.1% of the initial dry weight of the sample.
b. Calculate the fine ness modulus as follow:

Fine Aggregate:
F.M = {∑ (Cumulative % Retained on # 4, 8, 16, 30, 50, and 100 sieves)}/100

Coarse Aggregate:
F.M = {∑ (Cumulative % Retained on 1-1/2, ¾, 3/8, Nos. 4, 8, 16, 30, 50, and 100
sieves)}/100

Open
32
Open
33
Open
34
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

AGGREGATE IMPACT VALUE TEST (AIV)

1. OBJECTIVE
The method of the test covers the procedures for determining the aggregate
impact value of course aggregate. The ‘Aggregate Impact Value gives a
relative measure of the resistance of an aggregate to sudden shock or impact,
which in some aggregates differs from its resistance to a slow compressive
load.

2. APPARATUS
Aggregate impact testing machine consist of a circular base over which 2
vertical guidesstand. The hammer which is provided with a locking
arrangement can be raised to fall freely down the vertical guides. The height
of fall can be adjusted through 300mm + 5mm. Supplied complete with a
metal measure 75mm dia x 50mm deep and tamping rod 230mm long and
10mm dia.

3. PREPARATION OF TEST SAMPLE

a. The test sample shall consist of aggregate the whole of which passes a
12.5mm standard sieve and is retained on a 10mm standard sieve. The
aggregate comprising the test sample shall be dried in an oven for a
period of 4 hours at a temperature of 100C – 110C and cooled.

b. The cylindrical steel measure shall be filled about 1/3 rd full with the
aggregate and tamped with 25 strokes of the rounded end of tamping
rod. A further similar quantity of aggregate shall be added and a further
tamping of 25 strokes given. The measure shall finally be filled to over
flowing, tamped 25 times and the surplus aggregate struck off, using the
tamping rod as a straight edge. The net weight of the aggregate in the
measure shall determined to the nearest gram (Call it weight A) and this

Open
35
 weight of a aggregate shall be used for the duplicate test on the same
material.

4. PROCEDURE
a. The impact machine shall rest without wedging or packing upon the level
plate, block or floor, so that it is rigid and the hammer guide column are
vertical.
b. The cup shall be fixed firmly in position on the base of the machine and
the whole of the test sample placed in it and compacted by a single
taping of 25 strokes of the tamping rod.
c. The hammer shall be raised until its lower face to 380mm above the
upper surface of the aggregate in the cup and allow to fall freely on to the
aggregate. The test sample shall be subjected to a total of 15 such blows
each being delivered at an interval of not less than 1 second.
d. The crushed aggregate shall then be removed from the cup and the whole
of it sieved on the 2.36mm standard sieve until no further significant
amount passes in 1 minute. The fraction passing the sieve shall be
weighted to an accuracy of 0.1g (call it weight B). The fraction retained
on the sieve also be weighted (call it weight C) and it the total weight
(B+C) is less than the initial weight (weight A) by more than 1 gram, the
result shall be discarded a fresh test made. Two tests shall be made.

5. CALCULATION
The ratio of the weight of fines formed to the total sample weight in each test
shall be expressed as a percentage, the result being recorded to the first
decimal place.

B
Aggregate Impact Value= x 100
A

The mean of the two result shall be reported to the nearest whole
number asthe aggregate impact value of the tested material

Open
36
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

SILT TEST
1. OBJECTIVE
This test method covers the determination of the drag particle contained in a
sand sample.

2. APPARATUS
Measuring Cylinder of 250ml, salt water, and sand sample.

3. PROCEDURE
a. Take 50ml of salt water using measuring cylinder of 250ml.
b. Add a sample of sand in the cylinder until water level reach 100ml. Then
add salt water till the water level is 150ml.
c. Close the top of measuring cylinder with hand and shake the content for a
while. Then, let the mixture dissolve for 3 hours.
d. After 3 hours, measure the height of dregs and sand level. Measure the dregs
obtain using the given formula:

Height of Dregs
Dregs obtain = x 100%
Height of sand

Open
37
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

BLAINE AIR PERMEABILITY

1. OBJECTIVE
This test method cover the determination of the fineness of hydraulic cement,
using the Blaine air permeability apparatus, in term of the specific surface
expressed as total surface area in square meters per kilogram of cement. The
Blaine apparatus draw a defined volume of air through a prepared bed of
cement defined porosity. Covered by BS: 4359 Part ɪɪ.

2. APPARATUS
Blaine air permeability apparatus – Consists of a manometer, a stainless steel
permeability cell, a perforated metal disk, and a stainless steel plunger.

Balance – 0.001g resolution.

Timer – 0.5 s resolution.

3. PROCEDURE
a. Place approximately 4 oz of cement in a small covered jar or tin container.
Shake vigorously for 2 minutes to fluff the cement and break up lumps and
agglomerates. Allow the covered container to stand for 2 minutes, then
remove the cover and stir gently to homogenize the sample.
b. Weigh out the cement to nearest 0.001g. the weight of sample shall be
determined as follow: W= ρV(1-n).
c. Where ρ is the density of the cement (3.15g/cm³), n is a standard porosity of
the bed (0.5) and V is the total volume of the cement bed determined by
calibration (see ASTM for calibration procedure using NIST SRM No.
114). Prior calibration has established that is volume is : V= 1.8372 cm³.
d. Gently seat the perforated metal dick in the permeability cell on the ledge at
the bottom of the cell using a rod having a diameter slightly smaller than

Open
38
 that of the cell. Place a filter paper on the metal disk and press the edges
down with the same rod.
e. Place the cement in the cell on top of the first filter paper. Tap the side of
the cell lightly in order to level the bed of cement. Place a second filter
paper on this bed of cement.
f. Compress the cement with the plunger until the plunger collar contacts the
top of the cell. Slowly withdraw the plunger a short distance, rotate the
plunger 90°, and compress the cement a second time until the collar contact
the top of the cell. Slowly remove the plunger. Note that fresh filter papers
must be used for each determination.
g. Attach the permeability cell to the manometer tube (use a little stopcock
grease to ensure an airtight connection).
h. Slowly evacuate the air in the right arm of the manometer using the pressure
bulb until the liquid reaches the top mark, and close the manometer valve.
The liquid will start to slowly lower because of airflow through the cement
sample into the manometer.
i. Start the timer when the bottom of the meniscus of the liquid reaches the
third mark (next to the bottom mark). Record this time, T, to the nearest 1
second.

4. CALCULATION
a.Calculate the specific surface values in accordance with the following
equation:
Ss T
S=
Ts

Where T is the measured time interval of the manometer drop for the test
sample, Ss is the specific surface area of the standard reference material
(NIST SRM #114), and Ts is the measured time interval of the
manometer drop for SRM. This equation is valid for cement test
performed at the same temperature as the standard reference test, and at
the same porosity (n = 0.5). Prior calibration has established that these
SRM value are as follows:

Ss = 377.4m²/kg, and
Ts = 92.2 s

Open
39
FIGURE 1 : The Blaine Air Permeability Apparatus

Open
40
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

NORMAL CONSISTENCY OF HYDRAULIC CEMENT -VICAT

APPARATUS

1. OBJECTIVE
To determine the normal consistency of hydraulic cement to ensure that the
cement is of the desired quality and that it conforms to the requirements of
the relevant standards. This test method is intended to be used to determine
the amount of water required to prepare hydraulic cement pastes for testing.

2. APPARATUS
a. Balance – Sensitive to 0.1 percent of the weight of the sample being
tested.
b. Glass Graduate 200 - ml capacity, for measuring mixing water.
c. Vicat Apparatus -The vicat apparatus, consist of a frame item A,
bearing a movable rod itemB weighing about
300grams, one end item C the plunger end, being
10mmin diameter for a distance of at least 50mm,
and the other end having a removable needle D,
1mm in diameter and 50mm in length.
- Rod B is reversible and can be held in any desired
position by a setscrew E, and has an adjustable
indicator F, which moves over a scalethat is
graduated in millimeters and is attached to fram A.
- Rod B is made of stainless steel having a hardness
of not less than 3 HRC, and is straight with the
plunger end which is perpendicular to the rod axis.

Open
41
3. PROCEDURE
a. Measure out 500g. of fresh cement, and add an accurately measured
amount of water (for first trial use 150ml, adjust with further testing).
b. Thoroughly mix the cement and water together taking as little time as
possible producing the approximate shape of a ball with glove hands.
c. Then toss six times through a free path of about 6 inches from one hand
to other so as toproduce a nearly spherical mass that may be easily
inserted into the vicat ring with minimum amount of additional
manipulation.
d. Press the ball, resting in the palm of one hand, into the larger end of the
conical ring G, heldin the other hand, completely filling the ring with
paste. Remove the excess at the larger end by a single movement of
palm of the hand. Place the ring on its larger end on the baseplate H,
andslice off the excess paste at the smaller end at the top of the ring by
the singleoblique stroke of a sharp – edge trowel held at a light angle
with the top of the ring, and smooth the top, if necessary, with a few
light touches of the pointed end of the trowel.
e. During these operations of cutting and smoothing, take care not to
compress the paste.

4. CONSISTENCY DETERMINATION

a. Center the paste confined in the ring, resting on the plate, under the rod B,
which is the plunger end C, which shall be brought in contact with the
surface of the paste, followed by the tightening of the set-screw E.
b. Next set the movable indicator F to the upper zero mark of the scale, or
take an initial reading, and release the rod immediately. This must not
exceed 30 seconds after completion of mixing. The apparatus shall be free
of all vibrations during the test.
c. Make trial pastes with varying percentages of water until the normal
consistency is obtained. Make each trial with fresh cement.
d. Repeat the entire procedure four to five times, each time using the fresh
cement, and the corrected amount of water so that normal consistency may
be attained. The cement paste is of normal consistency when the rod
settles to a point 10 ≤ 1 mm below the original surface in 30 seconds after
being released.
e. Calculate the amount the water required for normal water consistency to
the nearest 0.1 percent and report to the nearest 0.5 percent of weight of

Open
42
 the dry cement. If normal consistency is not attained in five trials, plot
experiment data obtained specifically, penetration verses volume of water
used, one such example is shown on the enclosed graph below. From the
graph constructed interpolate to obtain what volume of water would give
the 10mm required penetration. Note do not copy or use the graph shown,
it is only presented for information only.

FIGURE 1 : VICAT APPARATUS

Open
43
 UNIVERSITI TEKNOLOGI PETRONAS
CIVIL ENGINEERING PROGRAMME
BANDAR SERI ISKANDAR
31750 TRONOH
PERAK DARUL RIDZUAAN

LE CHATELIER (SOUNDNESS TEST)

1. OBJECTIVE
The main purpose of the soundness test is to assess the possible risk of the
late expansion due to hydration of uncombined calcium oxide and
magnesium oxide. For this purpose report the mean difference C-A.

2. APPARATUS
Le Chatelier Apparatus, Water Bath.

3. PROCEDURE
a. Carry out the simultaneously on two specimens from the same batch of
cement paste.
b. Prepare a cement paste of standard consistence. Place a lightly oil Le
Chatelier mould on the lightly oiled base plate and fill it immediately
without undue compaction or vibration using only the hands and straight
edged implement, if desired to level the top surface. During filling
prevent the split in the mould from accidentally opening e.g. by gentle
pressure with the fingers of by typing or by use of a suitable rubber band.
c. Cover the mould with the lightly oiled cover plate, add the additional
mass, if necessary. Maintain it for (24±0.5) h at (20±1) C and not less
than 98% relative humidity.
d. At the end of the (24±0.5) h period measure the distance (A) between the
indicators points to the nearest 0.5mm.
e. Then heat the mould gradually to boiling during (30±5) min and maintain
the water bath at boiling temperature for 3hours ± 5min.
f. At the end of the boiling period the distance (B) between the indicator
points maybe measured to nearest 0.5mm.

Open
44
 g. Allow the mould to cool to (20 ± 2) C. Measure the distance (C) between
the indicator points to nearest 0.5mm.
h. For each specimen, record the measurement A and C and calculate the
difference C – A to nearest 0.5mm.

FIGURE 1 : LE CHATELIER APPARATUS

Open
45