CHAPTER 3

Experimental Setup
3.1 General
The primary focus of the study was to evaluate and compare the performance of concrete made
of slag aggregate and brick aggregate. The performance of slag aggregate as coarse aggregate,
the performance of slag aggregate as fine aggregate, and the combined performance of concrete
made of 100% slag and other varying mix types were evaluated in this study. A compressive
study of various codes and regulation were made to find the minimum engineering property
requirements which are to be fulfilled by aggregates for the purpose of using it in concrete
other than wearing surfaces. Various engineering properties of aggregate were evaluated and
was checked with various codes and regulations. Mechanical properties of concrete like
compressive strength, tensile strength and modulus of elasticity were also evaluated. Besides,
to ensure the practical performance of the concrete made of slag aggregate number of four full
scale slabs (10 ft x 12 ft) were also prepared which were subjected to uniform distributed load.
Two of them were made with traditionally used brick aggregate and other two were made with
slag aggregate. Moreover, the performance of mortar made of slag fine aggregate acting as a
thermal barrier was also evaluated along with its behavior and strength parameters if exposed
to fire. On the other hand, the performance of slag coarse aggregate in creating permeable
concrete was also evaluated during the coarse of the study. Finally, the durability performance
against chloride ion ingress in exposure to harsh saline environment was evaluated by means
of tests like rapid chloride migration test and rapid chloride permeability test.

3.2 Engineering Property Tests of Aggregate

3.2.1 Engineering Property Tests of coarse Aggregate
The following test scheme has been designed for the evaluation of engineering properties for
ensuring the suitability of the coarse aggregate to be used in various concrete works:

 Gradation of Aggregate (ASTM C136)

 Specific Gravity (ASTM C127)
 Water Absorption Capacity (ASTM C127)
 Void in Aggregate (ASTM C29)
 Aggregate Impact Value (BS812)
 Aggregate Crushing Value (BS 812)
  Ten Percent Fine Value (BS 812)
 Flakiness Index
 Elongation Index
 Angularity Number
 Los Angles Abrasion Value (ASTM C131)
3.2.2 Description of The Engineering Property Tests
3.2.2.1 Gradation of Aggregate
Gradation has an important effect on the workability and finishing characteristics of fresh
concrete consequently as the properties of hardened concrete.

(a)

(b)
Fig. 3.1: Gradation of aggregate. (a) Standard sieve for coarse aggregate, (b) Standard
sieve for fine aggregate

3.2.2.2 Specific Gravity

Specific gravity is not a measure of quality of aggregate but if there is a variation in specific
gravity than it reflects a change in the porosity of the particle.
 Fig. 3.2: Test for determining specific gravity.

3.2.2.3 Water Absorption Capacity

Absorption of the aggregate has effects on the water-cement ratio and workability of concrete.
It also plays a great role in affecting on the durability of concrete when the concrete is subjected
to harsh environments.

Fig. 3.3: Oven dry test for determining water absorption capacity.
3.2.2.4 Unit Weight
The unit weight of concrete largely depends on the unit weight and specific gravity of
aggregates. It also depends on the amount of air entrained, mix proportion and properties that
determines water content. As aggregate covers the largest portion of concrete, with the increase
of unit weight of aggregate, the unit weight of concrete also rises.

3.2.2.5 Aggregate Impact Value

The aggregate impact value is a measure of resistance to sudden impact or shock, which may
differ from its resistance to gradually applied compressive load. The aggregates should have
sufficient toughness to resist their disintegration due to impact.

Fig. 3.4: Aggregate impact value measuring apparatus.

3.2.2.6 Aggregate Crushing Value

Aggregate crushing value is a numerical index of the strength of the aggregate and it is used in
construction of roads, pavements and concrete

3.2.2.7 Ten Percent Fines Value

Ten percent fines value is a measure of the resistance of aggregate crushing subjected to loading
and it is applicable to both weak and strong aggregate.
 Fig. 3.5: Apparatus for determining Aggregate crushing value and Ten percent fines value.
3.2.2.8 Los Angeles Abrasion Test
Los Angeles abrasion test on aggregates is the measure of aggregate toughness and abrasion
resistance such as crushing, degradation and disintegration.

Fig. 3.6: L.A. abrasion testing equipment.

3.2.2.9 Flakiness
Flaky particles may seriously hamper the performance and strength of aggregate, it is necessary
to know the flakiness index for better understanding of the aggregate type.
 Fig. 3.7: Apparatus for determining Flakiness index.

3.2.2.10 Elongation
Presence of elongated aggregates in a mix disturbs the packing of particles and creates more
space. Elongated particles have high ratio of surface area to volume which reduces the
workability of concrete.

Fig. 3.8: Apparatus for determining Elongation.

3.2.2.11 Angularity Number

Angularity number test gives an idea of how angular the aggregate is. This is based on the
percentage of voids in the aggregate after compaction in a specified manner.

Fig. 3.9: Apparatus for determining Angularity number.

Summary of the various engineering properties of different kinds of aggregates is presented in
Table 3.1 and Table 3.2. Details test report of this tests are presented at Appendix-A.

Table 3.1: Various engineering properties of coarse aggregates

Stone Chips Brick Chips Slag
Test Parameters
(Coarse Aggregate) (Coarse Aggregate) (Coarse Aggregate)
Fineness of Modulus (FM) 6.81 6.28 6.52
Bulk Specific Gravity (OD) 2.63 1.73 2.42
Water Abortion Capacity 0.80% 11.40% 2.70%
Unit Weight (Bulk Density) 1530 kg/m3 1040 kg/m3 1290 kg/m3
Voids in Aggregates
42% 40% 47%
(Compacted by Rodding)
Aggregate Impact Value
32% 37% 44%
(AIV)
Aggregate Crushing Value
24% 36% 44%
(ACV)
Ten Percent Fines Value
160 kN 90 kN 40 kN
(TFV)
Flakiness Index 24% 23% 8%
Elongation Index 38% 28% 19%
Angularity Number 8 8 12
Los Angeles Abrasion
30% 33% 45%
Value (LA)
pH 7.0 6.0 7.2

Table 3.2: Various engineering properties of fine aggregates

Sylhet Sand Slag

Test Parameters
(Fine Aggregate) (Fine Aggregate)

Unit Weight (Bulk Density) 1540 Kg/m3 1630 Kg/m3

Voids in Aggregates
40% 40%
(Compacted by Rodding)
Bulk Specific Gravity (OD) 2.59 2.74
Water Absorption Capacity 1.00% 3.90%
Gradation of Aggregates (FM) 3.07 -
3.3 Materials Used
The concrete used for preparing slabs were made with Ordinary Portland Cement (OPC) and
there was a variation in the aggregate type for the specimens. The detail material configuration
is presented in Table 3.3.

Table 3.3: Material used for test slabs

Slab Coarse
Fine Aggregate Cement Type
Designation Aggregate
Coarse sand
S61 Brick Chips OPC
(Sylhet Sand)
Coarse sand
S62 Brick Chips OPC
(Sylhet Sand)
Slag (Coarse Slag (Fine
S63 OPC
Aggregate) Aggregate)
Slag (Coarse Slag (Fine
S64 OPC
Aggregate) Aggregate)

Table 3.4: Detail description of the cylindrical specimens used for determining mechanical
properties of concretes

Slump
Designations Mix ratio W/C CA FA Cement (mm)

4
A 1 1.5 3 0.4 Slag Slag OPC
20
B 1 1.5 3 0.45 Slag Slag OPC
154
C 1 1.5 3 0.5 Slag Slag OPC
0
D 1 2 4 0.4 Slag Slag OPC
10
E 1 2 4 0.45 Slag Slag OPC
152
F 1 2 4 0.5 Slag Slag OPC
30
G 1 1.5 3 0.4 Slag + Brick Slag OPC
90
H 1 1.5 3 0.45 Slag + Brick Slag OPC
158
I 1 1.5 3 0.5 Slag + Brick Slag OPC
0
J 1 2 4 0.4 Slag + Brick Slag OPC
 10
K 1 2 4 0.45 Slag + Brick Slag OPC
150
L 1 2 4 0.5 Slag + Brick Slag OPC
20
M 1 1.5 3 0.4 Brick Sylhet OPC
160
N 1 1.5 3 0.45 Brick Sylhet OPC
190
O 1 1.5 3 0.5 Brick Sylhet OPC
20
P 1 2 4 0.4 Brick Sylhet OPC
58
Q 1 2 4 0.45 Brick Sylhet OPC
130
R 1 2 4 0.5 Brick Sylhet OPC
100
S 1 1.5 3 0.4 Brick Slag OPC
135
T 1 1.5 3 0.45 Brick Slag OPC
170
U 1 1.5 3 0.5 Brick Slag OPC
90
V 1 2 4 0.4 Brick Slag OPC
135
W 1 2 4 0.45 Brick Slag OPC
150
X 1 2 4 0.5 Brick Slag OPC

3.3.1 Cement
For the construction of all the specimen Ordinary Portland Cement was used. Specification and
composition of cement by the manufacture:
28 days strength: 52.5 N (ASTM C595)
Clinker: 95%
Gypsum: 0-5%
Specific Gravity: 3.15
Unit weight: 197 psf
This product is made in accordance with BDS EN 197-1:2003

The aggregates are shown in Fig. 3.10.

 (a) (b)

(c) (d)
Fig. 3.10: Various type of aggregates. (a) Slag coarse aggregate, (b) Slag fine aggregate, (c)
Brick chips and (d) Coarse sand (Sylhet sand)

3.4 Compressive Strength Test of Cylinder

Compressive strengths of all test samples were measured as suggested by ASTM C39 (2012). Test
procedure is illustrated in Fig. 3.11.

Fig. 3.11: Compressive strength test.

3.5 Tensile Strength Test of Cylinder
Split tensile strength (Tensile Strength) was measured as suggested by ASTM C496 (2017). Details of
the test procedure is described in Fig. 3.12.

3.6 Modulus of Elasticity

Modulus of elasticity was measured as suggested by ASTM C469 (2014). Test procedure is illustrated
in Fig. 3.13.

Fig. 3.12: Tensile strength test Fig.3.13: Modulus of Elasticity Test

3.7 Compressive Strength Test on Mortar

Compressive strength test was determined using standard procedure ASTM C109 and was
represented to nearest 0.1 MPa.

3.8 Flexural Strength Test on Mortar

The test was conducted according to ASTM C348. The test procedure is demonstrated in Fig.
3.14.

(a) (b)
Fig. 3.14: Test procedure for determining flexural strength of cement mortars. (a) Test setup,
(b) Samples after testing
Flexural strength was determined following ASTM C348 and by using Eq. 3.1 and was
represented to nearest 0.1 MPa.

Sf = 0.0028P (3.1)
Where, Sf = Flexural strength (in MPa)
P = Total maximum calibrated load (in N)

3.9 Process of Conducting Open Fire Test on Mortar

Comparison of compressive and flexural strength of four different types of mortar with each of
them having three different water-cement ratios under normal condition (unburnt condition)
and under fire exposure condition were made. Four different types of mortars were made using
locally available induction furnace slag fine aggregate (Slag fine aggregate), river sand, fine
aggregate from burnt clay brick and coarse sand (Sylhet sand). Water-cement ratios of 0.4, 0.5
and 0.6 were used for all of them. Compressive strength tests were conducted on 50 mm cube
specimens following ASTM C109 and flexural strength tests were conducted on 4 cm x 4 cm
x 16 cm prism specimens following ASTM C348 after 28 days of curing. The mortar samples
were burned in open fire for two hours. 72 number of samples were cooled with water after
burning and 72 number of samples were kept in normal atmospheric condition for cooling after
burning. The test was conducted under control temperature. The temperature was continuously
measured with the help of Infrared Thermometer and the temperature was controlled through
continuous supply of wood and kerosene as fuel. The process of burning the mortar samples is
illustrated in Fig. 3.15

Fig. 3.15: Burning of cement mortar samples under controlled temperature.

The temperature development with time is shown in Fig. 3.16.
 Fig. 3.16: Temperature development with time

3.10 Steps for Determining Thermal Conductivity of Mortar

The test was conducted according to the “Less and Chorlton” method. The test procedure is
described below:

i. The mass of the disc A was measured as m (in gram).

ii. The thickness of the sample was measured as D (in centimeter) and the setup was made
as shown in Fig. 3.17 (c).
iii. Steam was passed through the boiler, C and the temperature, ϴ1 and ϴ2 of B and A was
measured with the help of thermometer T1 and T2 respectively at intervals of 5 minutes
until they remain constant that is when the data is repeated at least three consecutive
times.
iv. Supply of steam was then stopped and both B and C are removed. The disc A was being
heated from bottom till its temperature raised about 10o C above the steady temperature,
ϴ 2.
v. The Burner was removed and the disc, A was allowed to loss heat having the sample,
S on it. Temperature was recorded in every 30 second interval with the help of
thermometer, T2 till the temperature fall about 10o C from the steady temperature, ϴ2.
vi. A graph with the time of cooling as abscissa and the temperature of A as ordinate was
drawn. A tangent on the plotted curve on steady temperature, ϴ2 was drawn. And the
slope of the tangent which gives the rate of cooling dϴ/dt at ϴ2 was measured.
After obtaining all the values, the thermal conductivity was determined by using Eq. 3.2
 dϴ
msd
K = dt
(3.2)
α(ϴ1 − ϴ2 )
Where,

K = Thermal conductivity of the specimen (In calories per cm. per sec. per oC)
m = Mass of disc, A (in gram)
S = Specific heat of material, A (in Cal.g-1 oC-1)
d = Thickness of the specimen (in cm)
α = Area of cross-section of specimen (in sq.cm)
= (π/4)*D2
D = Diameter of the specimen (in cm)
ϴ1 = Steady temperature of B (in oC)
ϴ2 = Steady temperature of A (in oC)
dϴ/dt = Rate of cooling

(a) (b)

(c) (d)
Fig. 3.17: Details of the test procedure. (a) Schematic diagram (b) Lees and Chorlton’s
Apparatus, (c) Close view of the setup, (d) Test specimens.
3.11 Steps for Determining Water Infiltration Rate of Permeable Concrete

A total 9 number of 2 ft x 2 ft x 3 inch slabs were prepared with three different water-cement
ratio and three different sizes of aggregates. The details test scheme is presented at table 3.5.

Table 3.5: Test Scheme for various slag aggregate concrete

Designation ID Maximum Aggregate Size Water/Cement
(Inch)
Slab 1 1 0.36
Slab 2 1 0.32
Slab 3 1 0.28
Slab 4 3/4 0.36
Slab 5 3/4 0.32
Slab 6 3/4 0.28
Slab 7 3/8 0.36
Slab 8 3/8 0.32
Slab 9 3/8 0.28

The slabs were made using aggregate-cement ratio of 4:1. Details of the slabs are presented in
Fig. 3.18.

After casting and curing the slabs for 28 days, the slabs were ready for measuring permeability.
The permeability was measured according to ASTM C1701.

Steps for measuring permeability:

1. At first dust and debris from the surface of the slabs were removed using only brush.
2. A 300 mm inner diameter pipe was used for measuring permeability. Two lines were
drawn at 10 mm and 15 mm distance from the edge of the pipe and at the inner surface
of the slabs so that the test could be conducted according to ASTM C1701.
3. The edge was sealed with sealed with putty.
4. Pre-wetting of the surface was done by applying water and the time was measured using
a stop watch from the moment when the water first touched on the slab surface till all
the water from the surface was drained.
5. If the time for pre-wetting was less than 30 sec, then 18 Kg water was used for
permeability test and if the time for pre-wetting was higher than 30 sec then 3.6 Kg
water was used for permeability test.
 6. For permeability test the ASTM C1701 code specified water was applied on the surface
of the slabs. During pouring of water, the water level was kept in between the two lines
drawn inside of the pipe. And the time was measured with the help of a stopwatch from
the moment of water touching the slab surface till all the water from the surface was
drained.
The permeability was measured using the Eq. 3.3

= (3.3)
( ∗ )
Where:
I = Infiltration rate, mm/hr
M = Mass of infiltrated water, kg
D = Inside diameter of infiltration ring, mm
t = Time required for measure amount of water to infiltrate the concrete, s
K = 4583666000 (In SI units)

(a) (b) (C)

(d)
Fig. 3.18: Details of the test procedure. (a) Apparatus Setup, (b) Test process, (c) Close
view of the apparatus and (d) Pervious slabs.
3.12 Steps for Determining Rapid Chloride Permeability Test (RCPT)
This test method covers the determination of the electrical conduction of concrete to provide a
rapid indication of its resistance to the penetration of chloride ions. The entire test setup is
installed according to the specification of ASTM C1202.

After curing for a specific time, concrete cylinder is taken out of the curing pond and a 2 inch
slice is cut out parallel to the top of the core with a concrete cutter saw. This 2 inch thick
specimen is then allowed to surface dry for an hour and the side surfaces of the specimen is
painted with rapid setting coating of paint. After drying and no longer sticky to touch, the
specimen is put into the desiccator of the vacuum saturation apparatus. The desiccator being
completely sealed, the vacuum pump is started and pressure is decreased to around 1 mm Hg
and this vacuum pump is maintained for 3 hours. With the vacuum pump still running sufficient
deaerated water is drained into the container from the separatory funnel to completely cover
the specimen inside. Vacuum pump is again run for an additional hour. Then the pump is turned
off and the specimen is soaked under water for 18 hours.

The specimen is removed from water and after blotting off excess water, the sample has been
inserted between the two halves of the test cell. The cell containing the top surface of the
specimen is filled with 3% NaCl while the other one is filled with 0.3N NaOH solution. A
voltage source of 60 V has been connected with lead wires whose positive end is connected to
the NaOH end. The current reading is recorded every 30 minutes for 6 hours and the total
charge passed is calculated. During the test, it is strictly maintained that the temperature of the
solutions is not allowed to exceed 90o C. A thermometer has been used to check the temperature
of the solution every 30 minutes in this regard.

Fig. 3.19: RCPT setup

3.13 Steps for Determining Rapid Chloride Migration Test (RMT)
After curing for a specific time, concrete cylinder is taken out of the curing pond and a 2 inch
slice is cut out parallel to the top of the core with a concrete cutter saw. This 2 inch thick
specimen is then allowed to surface dry for an hour and the side surfaces of the specimen is
painted with rapid setting coating of paint. After drying and no longer sticky to touch, the
specimen is put into the desiccator of the vacuum saturation apparatus. The desiccator being
completely sealed, the vacuum pump is started and pressure is decreased to around 1 mm Hg.
With the vacuum process still running, the setup for chloride migration test was prepared. After
the 18-hour is elapsed, the cylindrical specimen was placed inside the rubber sleeve and secured
with clamps was placed above the rubber support. The rubber sleeve above the specimen was
filled with 300 ml of 0.3 N NaOH (anolyte) solution. The glass catholytic reservoir was filled
with about 12 liters of 10% NaCl (catholyte) solution. The steel mesh with steel rod (anode)
was placed inside the rubber sleeve immersing it in the anolyte solution.

Fig. 3.20: RMT setup.

Fig. 3.21: Desiccator.

The anode and cathode of the setup were connected to the positive and negative poles of the
power supply, respectively. Once power supply was on, a potential of 30V was set and the
initial current was measured to the nearest 0.001A. Depending on the initial current, potential
was adjusted to a new value and a corresponding new initial current was recorded yet again as
per the data presented in Table3.6. The experiment was carried out for a duration specified in
Table 3.6. At the expiration of test duration, the final current and voltage reading was recorded
and power supply was turned off. For the time frame of test duration, both the initial and final
temperature of the anolyte solution was recorded, using a thermometer.

Table 3.6: Voltage Adjustment and Test Duration Values as per NT BUILD 492 (1999)

Initial Current, I0 for Voltage Adjustment Possible New

Test Duration (hour)
30V (mA) (V) Current, I (mA)
I0<5 60 I<10 96
5≤ I0<10 60 10≤ I<20 48
10≤ I0<15 60 20≤ I<30 24
15≤ I0<20 50 25≤ I<35 24
20≤ I0<30 40 25≤ I<40 24
30≤ I0<40 35 35≤ I<50 24
40≤ I0<60 30 40≤ I<60 24
60≤ I0<90 25 50≤ I<75 24
90≤ I0<120 20 60≤ I<80 24
120≤ I0<180 15 60≤ I<90 24
180≤ I0<360 10 60≤ I<120 24
I0≥360 10 I≥120 6

3.14 Curing
The mortar samples and cylindrical specimens were cured for 28 days inside the pond full of
lime saturated water and the slab specimens were cured using wet gunny bags.
3.15 Slump Test
Workability of fresh concrete is evaluated on the basis of slump value of readily made fresh
concrete. Detail data of the slump values of various batch are provided on table 3.22.

Fig. 3.22: Slump Test.

3.16 Tension Tests of Reinforcing Bars
Tension tests were performed according to ASTM A615/615M to determine the stress-strain
characteristics of the steel reinforcements. The actual load deflection curves for all
reinforcements can be found on Figure 3.23 and Figure 3.24. The failure mode of the
reinforcements was found by subjecting them to a tension test until rupture. Table 3.7 and Table
3.8 shows the bar yield stress, ultimate stress and percent elongation of the steel bars.

Table 3. 7: Steel properties of tested bars

Yield Ultimate Percent
Sample
Bar Type Frog Mark Stress , fy Stress , fu fu/fy Elongation
No.
(ksi) (ksi) (%)
6 mm 60 BSRM. G
1 75.84 79.67 1.05 8
Grade 300
6 mm 60 BSRM. G
2 76.84 82.99 1.08 7
Grade 300
6 mm 60 BSRM. G
3 75.53 82.59 1.09 7
Grade 300
 Fig. 3.23: Load-Deflection curve for 6 mm 60 Grade bar

Table 3.8: Steel properties of tested bars

Yield Ultimate Percent
Sample
Bar Type Frog Mark Stress, fy Stress, fu fu/fy Elongation
No.
(ksi) (ksi) (%)
10 mm 40
1 BSRM. G 300 66.62 91.41 1.37 18
Grade
10 mm 40
2 BSRM. G 300 65.52 91.47 1.40 23
Grade
10 mm 40
3 BSRM. G 300 66.64 91.15 1.37 23
Grade
10 mm 60 BSRM
4 82.75 114.01 1.38 16
Grade ULTIMA 420 D
10 mm 60 BSRM
5 83.18 114.01 1.37 17
Grade ULTIMA 420 D
10 mm 60 BSRM
6 80.74 108.66 1.35 16
Grade ULTIMA 420 D
 Fig. 3.24: Load-Deflection curve for 10 mm 40 Grade and 10 mm 60 Grade bar.

3.17 Fabrication of The Slab Specimens

All the specimens were fabricated at BUET concrete laboratory. Two steel frames were
constructed using I section and slabs were installed on top of them. 1 inch thick mango wood
was used for formwork and plain stainless steel sheets were used for creating bottom smooth
surface. Bamboo propping was used to support the slabs during construction. Further
illustration of the fabrication is shown in Fig. 3.25.

Fig. 3.25: Fabrication of the specimens.

Table 3.9 :Slabs

Spacing of
Slab Coarse Fine Cement Dia. of The
main bars
Designation Aggregate Aggregate Type Main Bars
(inch @c/c)
Coarse sand
S61 Brick Chips OPC 10 mm 8
(Sylhet Sand)
Coarse sand
S62 Brick Chips OPC 6 mm 4
(Sylhet Sand)
Slag (Coarse Slag (Fine
S63 OPC 10 mm 8
Aggregate) Aggregate)
Slag (Coarse Slag (Fine
S64 OPC 6 mm 4
Aggregate) Aggregate)

3.18 Test Process for Applying Uniformly Distributed Load on Slabs

After 28 days curing period, the test was conducted using several weights. So that the slab
became subjected to uniformly distributed load. Steel plates were used to ensure uniform
distribution of load. As the weights were not enough to produce cracking load, further loading
was done by applying sand bags of measured weights until some visible cracks were observed
on the bottom surface of the slab with naked eye. Detail of loading process is shown in Figure
4. Multiple cameras were used for obtaining data and for ensuring safety. The deflection was
measured from the reading obtained from deflectometer. Crack width was measured with the
help of the crack comparator shown in Fig. 3.27.

Fig. 3.26: Loading procedure.

 (a) (b) (c)
Fig. 3.27: Crack comparator. (a) Deflectometer and crack comparator, (b) Close view of the
setup and (c) Crack comparator