THEORY OF DESIGN AND STRUCTURES

SEMESTER – 4

BARC 404

RIYA YOGESH PATIL

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ACADEMIC YEAR 2020-2021

VIVA SCHOOL OF ARCHITECTURE

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MATERIAL TESTING OF CONCRETE, COURSE AGGREGATE AND

MANGLORE TILES:-

CONCRETE

COURSE AGGREGATE

MANGLORE TILES

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WRITE A REPORT ON MATERIAL TESTING OF THE FOLLOWING:

1. COARSE AGGREGATES:- (A) FINENESS MODULUS:

WHAT IS FINENESS MODULUS OF COARSE AGGREGATES?
 Fineness modulus of coarse aggregates represents the average size of the particles in the
coarse aggregate by an index number. It is calculated by performing sieve analysis with
standard sieves.
 The cumulative percentage retained on each sieve is added and subtracted by 100 gives the
value of fine aggregate. Higher the aggregate size higher the Fineness modulus hence
fineness modulus of coarse aggregate is higher than fine aggregate.
 Coarse aggregate means the aggregate which is retained on 4.75mm sieve when it is sieved
through 4.75mm. To find fineness modulus of coarse aggregate we need sieve sizes of
80mm, 40mm, 20mm, 10mm, 4.75mm, 2.36mm, 1.18mm, 0.6mm, 0.3mm and 0.15mm.
 Fineness modulus is the number at which the average size of particle is known when we
counted from lower order sieve size to higher order sieve. So, in the calculation of coarse
aggregate we need all sizes of sieves.

Fineness Modulus of Coarse Aggregates

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`
Sieve Analysis

SAMPLE PREPARATION:
1. Take a sample of coarse aggregate in pan and placed it in dry oven at a temperature of 100
–110oC.
2. After drying take the sample weight to nearest gram.

TEST PROCEDURE FOR FINENESS MODULUS OF COARSE AGGREGATES:

1. Arrange the sieves in descending order and put the arrangement on mechanical shaker.
2. It is suggested that, to know the exact value of fineness modulus for coarse aggregate,
mechanical shaker will give better value than hand shaking because of more no. of sieves
and heavy size particles.
3. After proper sieving, record the sample weights retained on each sieve and find out the
cumulative weight of retained particles as well as cumulative % retained on each sieve.
4. Finally add all cumulative percentage values and divide the result with 100. Then we get the
value of fineness modulus.

EXAMPLE FOR FINENESS MODULUS CALCULATION

Let us say dry weight of coarse aggregate = 5000g
Values after sieve analysis are

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Therefore, fineness modulus of coarse aggregates = sum (cumulative % retained) / 100 =

(717/100) = 7.17
Fineness modulus of 7.17 means, the average size of particle of given coarse aggregate sample
is in between 7th and 8th sieves, that is between 10mm to 20mm.

LIMITS OF FINENESS MODULUS:

Fineness modulus of coarse aggregate varies from 5.5 to 8.0. And for all in aggregates or
combined aggregates fineness modulus varies from 3.5 to 6.5. Range of fineness modulus for
aggregate of different maximum sized aggregates is given below.

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1. COARSE AGGREGATES:- (B) CRUSHING TEST:

CONCEPT AND SIGNIFICANCE OF THE AGGREGATE CRUSHING VALUE TEST:
 The ‘aggregate crushing value test ` gives a relative measure of the resistance of an
aggregate to crushing under a gradually applied compressive load.
 Aggregate crushing value is defined as the percentage by weight of the crushed (or finer)
material obtained when the test aggregates are subjected to a specified load under
standardized conditions, and the strength of the aggregate used in road construction is
expressed by numerical index.
 Aggregates with lower crushing value show a lower crushed fraction under load and would
give a longer service life to the road and hence a more economical performance.
 If we used a weaker would get crushed under traffic loads, would produce smaller pieces
not coated with a binder, and these would be easily displaced or loosened out resulting in
loss of the surface/layer.
 Due to this reason, the aggregates used in road construction must be strong enough to
withstand crushing under roller and traffic.

“Aggregate Crushing value is a relative resistance of aggregates to crushing under gradually

applied compressive load”.

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OBJECTIVES OF CRUSHING TEST:

1. To determine the crushing value of aggregate for road aggregates;
2. To determine the suitability of aggregates for use in different types of road pavements.
APPARATUS:
1. A steel cylinder 15 cm diameter with plunger and base plate.
2. A straight metal tamping rod 16mm diameter and 45 to 60cm long rounded at one end.
3. A balance of capacity 3 kg readable and accurate to one gram.
4. IS sieves of sizes 12.5mm, 10mm and 2.36mm
5. A compression testing machine.
6. Cylindrical metal measure of sufficient rigidity to retain its from under rough usage and of
11.5cm diameter and 18cm height.
7. Dial gauge

Aggregate crushing value test apparatus components

Aggregate crushing value test appparatus, the thickness of cylinder wall may be 1.6 cm.

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SAMPLING AND PROCEDURE:

1. The aggregate sample: The material for the standard test consists of aggregates sized 10.0
mm to 12.5 mm. The aggregates must be in a surface dry condition before testing. The
aggregates may be dried by heating at 100 oC – 110 o C for not more than 4 hours and
cooled to room temperature before testing, if necessary.
2. Sieve the material through 12.5 mm and 10 mm IS sieves. The aggregates passing through a
12.5 mm sieve and retained on a 10.0 mm sieve comprise the test material.
3. Take about 3.25 kg of this material.
4. Aggregates should be poured to fill about just more than 1/3 rd depth of the measuring
cylinder.
5. The material is compacted by giving 25 gentle blows with the rounded end of the tamping
rod.
6. Two more layers are added in a similar manner, such that the cylinder is full.
7. Remove the excess material with a straight edge. Now, this amount of quantity contained in
the measuring cylinder is the amount of aggregates that will be used to prepare the test
specimen.
8. Empty the cylinder and weight the aggregates, accurate up to 1 gm.
9. Transfer the whole of this weighted quantity to the test mould by filling it in three layers in
the same manner as for cylindrical measure. The total depth of the sample is then about 10
cms and the surface a little below the top of mould.
10. The surface is leveled and place the plunger over it so that it rests horizontally on the
surface of the aggregates.
11. Then place this assembly on the pedestal of the compression testing machine.
12. The load is applied at a uniform rate of 4 tonnes.
13. Release the load
14. Take the aggregate out of the cylinder and sieve them through a 2.36 mm IS sieve. Weight
this fraction passing through it to an accuracy of 0.1 gm. This fraction is a quantity of the
loss of material due to crushing.

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15. Note down the observations in the proforma then compute the aggregate crushing value.
The mean of two observations, rounded to the nearest whole number is reported as the
“Aggregate crushing Value”.

CALCULATION OF AGGREGATE CRUSHING VALUE:

The ratio of weight of fines formed to the weight of total sample in each test shall be expressed
as a percentage, the result being recorded to the first decimal place.
Aggregate crushing value = (W2 x 100) / (W1-W)
W2 =Weight of fraction passing through the appropriate sieve
W1-W =Weight of surface dry sample.

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AGGREGATE CRUSHING VALUES FOR ROADS AND PAVEMENT CONSTRUCTION:

The table below shows limits of aggregate crushing value for different types of road
construction:

PRECAUTIONS:
1. The plunger should be placed centrally and rest directly on the aggregates. Care should be
taken that it does not touch the walls of the cylinder so as to ensure that the entire load is
transferred onto the aggregates.
2. In the operation of sieving the aggregates through 2.36 mm sieve and weighting care should
be taken to avoid loss of fines. The sum of weights of fractions retained, and passing the
sieve should not differ from the original weight of the specimen by more than 1 gm.
3. The tamping should be done properly by gently dropping the tamping rod and not by
hammering action.
4. And the tamping should be uniform over the surface of the aggregates taking care that the
tamping rod does not strike against the walls of the mould.

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2. CONCRETE: (A) COMPRESSIVE STRENGTH:

WHAT IS THE COMPRESSIVE STRENGTH?
Compressive strength is the capacity of material or structure to resist or withstand under
compression. The Compressive strength of a material is determined by the ability of the
material to resist failure in the form cracks and fissure.
In this test, the push force applied on the both faces of concrete specimen and the maximum
compression that concrete bears without failure is noted.

Concrete testing helps us to majorly focus on the Compressive strength of concrete because it
helps us to quantify the ability of concrete to resists Compressive stresses among structures
where-as other stresses such as axial stresses and tensile stresses are catered by reinforcement
and other means.
In technical point of view,
Compressive Strength of concrete is defined as the Characteristic strength of 150mm size
concrete cubes @28 days.
COMPRESSIVE STRENGTH OF CONCRETE AND ITS IMPORTANCE:-
 As we all know that concrete is a mixture of sand, cement, and aggregate. The strength of
the concrete depends upon many factors like individual compressive strength of its
constituents (Cement, Sand, aggregate), quality of materials used, air entrainment mix
proportions, water-cement ratio, curing methods and temperature effects.
 Compressive strength gives an idea of the overall strength and above-mentioned factors.
Through conducting this test, one can easily judge the concrete strength psi and quality of
concrete produced.

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FACTORS AFFECTING COMPRESSIVE STRENGTH OF CONCRETE:-

1. Coarse aggregate
2. Air-entrainment
3. Water/Cement ratio
WHY DO WE TEST CONCRETE FOR 7 DAYS, 14 DAYS & 28 DAYS?
 Concrete gains maximum strength at 28days. Since in construction sector great amount of
capital is at stake, so instead of checking strength at 28 days we can check strength in terms
of concrete strength psi at 7 and 14 days to predict the target strength of construction
work.
 From the below table it is clear that, Concrete gains 16 % of its strength within 24 hrs,
whereas concrete gains 65% of the target strength by the time of 7 days of its casting.
 Till 14 days concrete shows 90% of the target strength and thereafter the gain in strength
slows down and it takes 28days to achieve 99% of strength.
 We cant judge the strength of concrete until it becomes stable. And we also won’t wait for
28 days to judge the concrete whether it suitable for construction or not to keep it
balanced, concrete is tested at various intervals.
COMPRESSIVE STRENGTH TESTING OF CONCRETE:-
The test is carried out using 150mm concrete cubes on a Universal testing machine or
compressive testing machine.
APPARATUS:
Compression test machine, moulds, mixer, trowel, tamping rod (steel bar 16 mm diameter and 60 cm
long) As per IS: 516-1959 Compressive testing machine (2000Kn),15cm×15cm×15cm steel cube molds or
Cylinder having Dia 15cm and length 30cm are used.

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SAMPLE PREPARATION
Samples are taken from the concrete patches used in site or prepared with the same mixture as
used in the field.

SPECIMEN SIZE:
 3 cylinders [15 cm x 30 cm] or 3 cubes [15 cm x 15cm x 15 cm]
 Minimum three specimens should be tested at each selected age. The Average of three
specimens gives the strength of concrete.

CONCRETE MIXING:
 By laboratory batch mixer, or
 By hand: First, mix the cement and fine aggregate until the mixture is thoroughly blended.
 Then, add the coarse aggregate and mix until the coarse aggregate is uniformly distributed.
Finally, add water and mix until the concrete appears to be homogeneous and of the
required consistency.

Pouring Concrete into moulds:

1. Clean the moulds properly and finish it with oil so that concrete will not stick into the mould
and make latter cleaning difficult.
2. Put concrete in the moulds layer by by layer. Each layer is around 5 cm thick. Each layer is
compacted with a tamping rod [35 stroke]
3. Level the top surface with a trowel

CURING:
Test specimens are kept in the moulds and stored in moist air for 24 hours and then, the
specimens are removed from the moulds and submerged in fresh water for the specified curing
period.

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TEST PROCEDURE:
1. Get the specimen out of water after curing time and wipe out excessive water from the
surface.
2. Measure the dimensions of the specimen are that will be subjected to load.
3. Place the specimen in the appropriate location in the test machine. Note the load will be
applied to the face perpendicular to the direction of casting.
4. Align the specimen centrally on the base plate of the machine.
5. Make the movable portion of machine touches the specimen top surface.
6. Apply the load gradually at the rate of 140 kg/cm2/minute until the specimen fails
7. Record the maximum load.

CALCULATION OF COMPRESSIVE STRENGTH:

 Cube size =15 cm x 15 cm x 15 cm
 Area of the specimen subjected to load=150 x 150 = 2250 mm2
 Maximum load at failure at 7 or 28 days = ………. N
 Characteristic compressive strength(f ck) at 7 or 28 days days = Failure Load / Area =
………….. N/mm2
 Average compressive strength of the 3 concrete cubes = [strength of cube 1 + strength of
cube 2 + strength of cube 3] / 3 = ………….N/ mm2 (at 7 or 28 days)

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GUIDANCE:
The following table gives the strength of concrete at different ages as a percentage of the
strength at 28 days in order to accept the test result.

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2. CONCRETE: (B) SLUMP TEST:

Slump test is a laboratory or at site test used to measure the consistency of concrete. Slump
test shows an indication of the uniformity of concrete in different batches. The shape of the
concrete slumps shows the information on the workability and quality of concrete. The
characteristics of concrete with respect to the tendency of segregation can be also judged by
making a few tamping or blows by tapping rod on the base plate. This test continues using since
1922 due to the simplicity of apparatus and simple procedure. The shape of the Slump cone
shows the workability of concrete.
PRINCIPLE OF SLUMP TEST:
The slump value of concrete is just a principle of gravity flow of surface of the concrete cone
that indicates the amount of water added to it, which means how much this concrete mix is in
workable condition.
OBJECTIVES OF SLUMP TEST:
The main objective of the slump test can be listed as follows:
1. To determine the workability of the fresh concrete before it sets .
2. To identify the improperly mixed batch of concrete.
FACTORS WHICH INFLUENCE THE CONCRETE SLUMP TEST:
1. Material properties like chemistry, fineness, particle size distribution, moisture
2. content and temperature of cementitious materials. Size, texture, combined grading,
cleanliness and moisture content of the aggregates,
3. Chemical admixtures dosage, type, combination, interaction, sequence of addition and its
effectiveness,
4. Air content of concrete,
5. Concrete batching, mixing and transporting methods and equipment,
6. Temperature of the concrete,
7. Sampling of concrete, slump-testing technique and the condition of test equipment,
8. The amount of free water in the concrete, and
9. Time since mixing of concrete at the time of testing.

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APPARATUS FOR SLUMP TEST:

Followings apparatus are used in the slump test of concrete:
1. Metallic mould in the shape of a frustum of cone having bottom diameter 20 cm (8 in), top
diameter 10 cm (4 in) and height 30 cm (12in).
2. Steel tamping rod having 16 mm (5/8 in) diameter, 0.6 m (2 ft.) long with bullet end.

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PROCEDURE OF SLUMP TEST:

During Slump test following steps are followed:
1. First of all, the internal surface of the mould is cleaned and free from moisture and free
from other old sets of concrete.
2. Then place the mould on the smooth horizontal, rigid, and non-absorbant surface.
3. The mould is then filled with fresh concrete in four layers with taping each layer 25 times by
taping rod, and level the top surface with a trowel.
4. Then the mould is slowly pulled in vertical and removed from concrete, so as not to disturb
the concrete cone.
5. This free concrete deform all the surface to subside due to the effect of gravity.
6. That subsidence of concrete in the periphery is a SLUMP of concrete.
7. The height difference between the height of subsidence concrete and mould cone in mm is
‘slump value of concrete’.

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PRECAUTION DURING TEST:

1. The internal surface of the mould should be cleaned and free from moisture.
2. The base plate or surface should be free from vibrations or shocking.
3. This test is done just after sampling nearly after 2 minutes.
SHAPE OF CONCRETE SLUMP:
When the metal mould is removed from the concrete cone, the slump takes the following
shapes:
1. TRUE SLUMP – True slump is the only slump that can be measured in the test. The
measurement is taken between the top of the cone and the top of the concrete after the
cone has been removed as shown in figure-1.
2. ZERO SLUMP – Zero slump is the indication of very low water-cement ratio, which results in
dry mixes. These type of concrete is generally used for road construction.
3. COLLAPSED SLUMP – This is an indication that the water-cement ratio is too high, i.e.
concrete mix is too wet or it is a high workability mix, for which a slump test is not
appropriate.
4. SHEAR SLUMP – The shear slump indicates that the result is incomplete, and concrete to be
retested.

FACTORS INFLUENCING SLUMP CONE:

Followings factors influence concrete Slump value:
1. Water –cement ratio of concrete.
2. The quality of coarse and fine aggregates, their shape, moisture content, texture, and
grading.
3. The use of plasticizer, superplasticizer admixture, and the sequence of their mixing.
4. The void ratio of concrete and air content of concrete.
5. The time of the test after mixing of concrete.

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3. MANGLORE TILES: (A) FLEXURAL TEST:

FLEXURE TEST ON MANGLORE TILES:

The most common purpose of a flexure test is to measure flexural strength and flexural
modulus. Flexural strength is defined as the maximum stress at the outermost fiber on either
the compression or tension side of the specimen. Flexural modulus is calculated from the slope
of the stress vs. strain deflection curve. These two values can be used to evaluate the sample
materials ability to withstand flexure or bending forces.

APPARATUS:
 The testing machine consists of an angle iron frame. A double lever system is provided for
applying the load. The lower lever is supported on a ball bearing and carries a counter
balanced weight and a receiving pan.
 The lead shots flow through a supply in to the receiving pan. The pan can be removed by
just taking out a pin for transferring the lead shot to the storage pan. The storage pan is
permanently fixed through the top plate.
 The upper lever is connected to the lower lever by means of straps. The upper lever is held
by an adjustable capstan. The adjustable loading yoke is connected to the upper lever
through the vertical rods passing through the top plate. The loading yoke cross head can be
locked in position after mounting the specimen.
 Three 40 mm diameter rollers are provided. The self-aligning bearing rollers are mounted
on the metal blocks. The guide pins are fixed to the block and the corresponding holes are
drilled on the top plate to adjust the center distance of bearing rollers to 250mm and
270mm for 320mm and 345mm long tiles respectively.
 The third rolling roller, also of 40mm diameter is attached to the loading yoke. The roller
can be adjusted to sit centrally on the specimen while loading.

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FLEXURE TESTING MACHINE

PROCEDURE:
 Tile Specimen
 A total of six tiles shall be tested for dry strength and six tiles should be tested for wet
strength.
 Machine Operation
 Put the counterbalance weight on the screw attached to the lower lever.
 Adjust the loading roller along with the yoke for the specimen thickness. Adjust the
counterweight so that the lower lever is in balance position.
 Keeping the specimen on the loading rollers, start loading the specimen by starting the flow
of the lead shots. For this, operate the shutter lever by pressing it down.
 As soon as the specimen fails the lever strikes hard on the shutter and close the flow of lead
shots.

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RESULTS:
Breaking load due to dry test and breaking load due to wet test are recorded. The transverse
strength can be computed from the following equation:

Where:
• P: breaking load, N
• I: span between supports, mm, see Table 1.
• b: tile width, mm
• t: tile thickness, mm

TABLE 1 DESIGNATED SPAN FOR TILES TO BE TESTED FOR CAN BE COMPUTED FROM THE
FOLLOWING EQUATION: TRANSFER STRENGTH

SIZE OF TILE, MM SPAN, MM

 200x200 150
 250x250 200
 300x300 250
 400x400 300

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