LABORATORY MANUAL

ON
CONCRETE STRUCTURES LAB

DEPARTMENT OF CIVIL ENGINEERING

JAYPEE UNIVERSITY OF
ENGINEERING & TECHNOLOGY
A.B. ROAD RAGHOGARH-GUNA (M.P.)-473226 (INDIA)

DEPARTMENT OF CIVIL ENGINEERING, JUET GUNA

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 0
 ADVANCE CONCRETE STRUCTURES LAB
(COURSE CODE: 14M17CE171)

CONTENTS

EXP. NO. NAME OF THE EXPERIMENT PAGE NO

PART-A To be performed upto P-1 Exam ---

--- Instructions for report writing 2–3
(A) Normal consistency of hydraulic cement 4–5
1.
(B) Specific surface area of hydraulic cement by blain’s apparatus 6–8
(A) Soundness test of hydraulic cement by cement autoclave 9 – 11
2.
(B) Compressive strength of hydraulic cement 12 – 13
(A) Los on Ignition (LOI) 14 – 14
3.
(B) Percentage of Silica 15 – 15
(C) Determination of Ferric Oxide , Alumina and Calcium Oxide 16 – 18
(A) Insoluble Residue 19 – 19
4.
(B) Percentage of sulphuric anhydride (SO3) 20 – 20
(A) Specific gravity of cement 21 – 21
5.
(B) Marsh funnel viscosity test 22 – 23
6. Air permeability test on cement mortar 24 – 26
ASSIGNMENT CONCRETE MIX DESIGN OF SPECIFIED GRADE AS PER INDIAN STANDARDS 27 – 30

PART-B To be performed after P-1 & upto P-2 Exam ---

7. Air content in fresh concrete by air entrainment meter 31 – 36
8. Influence of W/C ratio on workability & strength of concrete 37 – 38
Compressive strength of the normal and accelerated cured 39 – 41
9. plain cement concrete
(A) Non Destructive Test of concrete by Rebound Hammer 42 – 43
10.
(B) Non Destructive Test of concrete by UPV (PUNDIT-7) 44 – 46
Bend & re-bend test of different type of steel bars by 47 – 49
11.
Universal Testing Machine (UTM).

12. Durability test of concrete by Rapid Chloride Ion Permeability 50 – 54

(RCPT) Test.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 1
 -- References 55

INSTRUCTIONS FOR LABORATORY REPORT WRITING

A full report is an extensive account of experiment, such as may be required for external
readers. It should be a standalone document and so is likely to include a description of the
apparatus and a summary of the experimental procedure.

A full report is not to exceed 1500 words (excluding Tables and Diagrams). It is to be
organized under the following headings:

OBJECTIVE/OBJECTIVES

EXPERIMENTAL SETUP WITH DIAGRAM

THEORY TO BE USED FOR EXPERIMENT

EXPERIMENTAL METHOD

OBSERVATIONS/DATA COLLECTED

SAMPLE CALCULATIONS

EXPERIMENTAL RESULTS

DISCUSSION/CONCLUSIONS (Including that of errors)

OBJECTIVES

It contains the aim of the experiment and how the author is going to achieve his aim.

EXPERIMENTAL SETUP WITH DIAGRAM

Write every experimental setup and instruments you used with their dimensions. Draw a
neat sketch of experimental setup.

THEORY TO BE USED FOR EXPERIMENT

Write theory behind your experiment briefly.

EXPERIMENTAL METHOD

It should contain a brief description of experimental method, a neat sketch of experimental

setup.

OBSERVATIONS/DATA COLLECTED

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 2
Write down all data collected by you and also attached the signed lab data sheet.
SAMPLE CALCULATIONS
Give the sample calculations.

EXPERIMENTAL RESULTS

Represent experimental results in tabulated form and diagrams.

DISCUSSIONS / CONCLUSIONS

Compare your results with available reported results from standard literature. Give the
reason of departure of your results from reported results.

The conclusions contains a summary (what has been done and what are the main results)
and in addition to that some future prospective.

Note: Failure to submit the report and attend the viva voce will result in a zero mark.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 3
 Experiment No-1(A)
NORMAL CONSISTENCY OF CEMENT
REF: - IS: 4031 (PART-4) 1988 / 1995
OBJECTIVE:
To determine the quantity of water for cement paste for normal consistency
APPARATUS/MATERIAL

1. Vicat apparatus
2. Plunger of 10 mm dia. & 50 mm long, conforming to IS: 5513 - 1976
3. Gauging trowel conforming to IS: 10086 - 1982.
4. Balance
5. Tray
6. Cement sample (OPC or PPC)
7. Measuring flask of capacity 0-100 ml

VICAT APPARATUS WITH SPECIFICATIONS

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 4
Gauging Trowel Steel Tray Measuring Cylinder
THEORY:

The basic aim is to find out the water content required to produce a cement paste of
standard consistency as specified by the IS: 4031 (Part 4) - 1988. The principle is that
standard consistency of cement is that consistency at which the Vicat plunger
penetrates to a point 5 – 7 mm from the bottom of Vicat mould

The percentage of water by weight of cement which produces a consistency which permits
plunger having diameter 10 mm to penetrate up to depth of 5 to 7 mm above the bottom of
mould is called the normal consistency of cement paste.

Temperature and Humidity

The temperature of moulding room, dry materials and water shall be maintained at
27±2°C. The relative humidity of the laboratory shall be 65±5 percent.

PROCEDURE:

1. Take 400 gm of cement sample.

2. Add 25 % of water in dry cement and mix it. The gauging time should not be less
than 3 minutes and not more than 5 minutes. The gauging time is time consumed
from adding of water in dry cement to commencing to fill the mould.
3. After mixing properly, fill the vicat mould with this paste.
4. Level the surface of cement with top of mould.
5. A standard plunger, 10 mm diameter and 50 mm long is attached and brought
down to touch the surface of the paste in the test block.
6. Release the plunger and allow it to penetrate by its own weight and note down the
reading.
7. If the penetration is less than the desired one then make another trial sample by
increasing water content and find the penetration.
8. Repeat the steps until the desired penetration is obtained, i.e. penetration up to 5 to
7 mm. above the bottom is achieved.

OBSERVATIONS:

S. No. Quantity of Quantity of % of water by weight Penetration above

cement water from bottom
1.
2.
3.

RESULT:
Express the amount of water as a percentage by mass of the dry cement to the first place of
decimal.
Normal consistency (N.C.) of cement =……………. %

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 5
Precautions: Write the necessary precautions for this experiment.
Experiment No-1 (B)
SPECIFIC SURFACE AREA OF CEMENT BY BLAIN’S APPARATUS
Reference-IS: 4031 (Part-2)-2004

SCOPE

This test method covers the determination of the fineness of hydraulic cements 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 draws a defined volume
of air through a prepared bed of cement of defined porosity.

APPARATUS

1. Blaine air permeability apparatus with manometer , permeability cell, a perforated

disk and plunger
2. Balance-0.001g resolution.
3. Timer-0.5s resolution

BLAIN’S APPARATUS PERFORATED DISC

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 6
 BALANCE STOP WATCH
MATERIALS
1. Hydraulic cements-3g
2. Filter paper- (type 1 grade B, 12.7 mm dia, .7µm porosity)
3. Manometer liquid(light mineral oil low viscosity, & density such as dibutyle
thalate
4. Standard cement sample.

PROCEDURE
1. The laboratory in which the air permeability test is carried out shall be maintained
at a temperature of 27±2 and a relative humidity not exceeding 65 percent.
2. Weigh out the cement to the nearest 0.001gm. the weight of sample shall be
determined as follows;
W=ρv (1–e)
Where ρ is the density of the cement (3.15g/cm3), e is a standard porosity of the bed
(0.5) and v is the total volume of the cement bed determined by calibration
3. Gently seat the perforated disk in the permeability cell on ledge at the bottom of the
cell using a rod having a diameter slightly smaller than that of the cell. Place the
filter paper on the metal disk and the press the edges down with the rod.
4. 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.
5. Compress the cement with the plunger until the plunger collar contacts the top of
the cell. slowly with draw the plunger a short distance, rotate the plunger 900, and
compress the cement a second time until the collar contacts the top of the cell
slowly remove the plunger , Note that fresh filter papers must be used for each
determination.
6. Attach the permeability cell to the manometer tube(use a little stop cock grease to
ensure an air tight connection)
7. Slowly evacuate the air in the left arm of the manometer using the mouth until the
liquid reaches the top mark, and then close the manometer valve. The liquid will
start to slowly lower because of air flow through the cement sample in to the mano
meter.
8. Start the timer when the bottom of the meniscus of the liquid reaches the second
mark from the top and stop the timer when the bottom of the meniscus the third
mark (next to the bottom mark) Record the time, T, to the nearest 1 second.
CALCULATION
Calculate the specific surface values in accordance with the following equation

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 7
 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 slandered reference material and tS IS the measured time
interval of the manometer drop for the SRM. This equation is valid for cement test is
performed at the same temperature as the standard reference test, and at the same
porosity (e=0.5). The SRM values are as follows;

Ss = 377.4 m2/kg and, Ts = 92.2 second

Report: - The specific surface area to the nearest 1 m2/ kg

Effect of fineness of cement

( 1 ) D u e t o i n c r e a s e d f i n e n e s s , t h e s u r f a c e a r e a o f cement increases and

reaction with water becomes quicker. Therefore the gain of strength also becomes faster
but the ultimate strength remains unaffected. This will be clear by observing the trend of
relation between specific surface and strength as shown in Figure;

Figure: Relation between specific surface and strength

From this figure it is evident that 7 days or 28 days strength may be higher for finer cement
but 1 year strengths almost same even for higher fineness. In fact it will be exactly same if
we compare the ultimate strength at infinity.

(2) Chance of bleeding reduces in the concrete if finer cement is used.

(3) Shrinkage and cracking in the concrete increases with fineness

Minimum value of specific surface area is giving blow:

S. No. Type of Cement Surface Area in (M2/KG)

1. PPC 300 M2/KG

2. OPC,PSC 225 M2/KG
3. 53S 370 M2/KG

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 8
 Experiment No-2 (A)
SOUNDNESS TEST OF CEMENT BY CEMENT AUTOCLAVE
IS: 4031 (Part 3) – 1988-2005

OBJECTIVE

To determine the soundness of a given cement sample by Autoclave method.

APPARATUS REQUIRED

NAME CAPACITY / RANGE / SIZE ACCURACY / LEAST COUNT

Autoclave 1000C (min) 10C

Length comparator IS: 9459 0.02 mm

Measuring cylinder 150 ml 1 ml

Balance 1000 g 1g

Mould 25 x 25 x 282 mm (IS:10086)

CEMENT AUTOCLAVE SHRINKAGE BAR MOULD

THEORY

In the soundness test a specimen of hardened cement paste is boiled for a fixed time so that
any tendency to expand is speeded up and can be detected. Soundness means the ability to
resist volume expansion.
SAMPLE PREPARATION
1. Thinly cover the mould with mineral oil. Then attach the reference points so as to
get an effective length of 250 mm.
2. Take 500 g of cement and mix with sufficient water to give a paste of standard
consistency.
3. After mixing fill the mould in one or two layers by pressing the paste into corners by
thumb. Smoothen the top layer by trowel.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 9
 4. After completion of preparation of the mould, store it in a moist room for a period of
24 hours.

PROCEDURE

1. After 24 ± ½ hrs after moulding, remove the specimen from the moist atmosphere,
measure its length (L1) and place it in the autoclave at room temperature in a rack
so that the four sides of each specimen is exposed to saturated steam vapour during
the entire period of test.
2. To permit air to escape from the autoclave during the early portion of the heating
period left the vent valve open until steam begins to escape.
3. Then close the vent valve and raise the temp of the autoclave at such a rate, so as to
make the gauge pressure of the steam to 2.1 N/mm2 in 1 to 1.5 hrs from the time
heat turned on. This pressure is maintained for 3 hrs.
4. After 3 hrs switch off the autoclave, and let it be cooled at the rate so as to make the
pressure less than 0.1 N/mm2 in one hour and bring it to atmospheric pressure by
opening vent valve.
5. Then remove the specimen from autoclave and place it in water maintained at a
temperature of 90°C. Then cool the water to 27±20C in 15 minutes. Dry the surface
of the specimen and measure its length (L2).

CALCULATION

Soundness of cement = L1-L2

Where,

L1=Length measured after curing for a period of 24 hrs in a moist room.

L2=Length measured after completion of autoclave test.
A contraction (negative expansion) is indicated by prefixing a (–) sign to the percentage
expansion reported.

Note: In the event of cement failing to comply with the specified requirements, a further
test should be made from another portion of the same sample in manner described above,
but after aeration (done by spreading out to a depth of 75 mm at a relative humidity of 50
to 80% for a total period of 7 days).

PRECAUTIONS
1. Length L1 and L2 should be measured accurately
2. The temp of autoclave should be raised and lowered gradually.
3. The automatic control shall be maintained in proper working order at all times
4. The safety valve shall be set so as to relieve the pressure at about 6 to 10 percent
above the maximum of 2.1 MPa specified, that is at about 2.3 MPa
5. The safety valve discharge shall be directed away from the operator.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 10
TECHNICAL DISCUSSIONS

1. Volume expansion in cement mortar or in cement concrete is caused by the

presence of unburnt lime (CaO), dead burnt MgO and also CaSO4.
2. By Autoclave method we only find out presence of unburnt lime (CaO) and magnesia
(MgO).
3. Magnesia content allowed in cement is limited to 6%.
4. Indian standard specification stipulates that cement having a magnesia content of
more than 3% shall be tested for soundness by Autoclave test which is sensitive to
both free magnesia and free lime.
5. No satisfactory test is available for deduction of unsoundness due to an excess of
calcium sulphate. But it can be easily determined by chemical analysis.

STANDARD SPECIFICATIONS
Reference Indian
Type/Name Of cement Standard Expansion, %,( max.)

OPC (33) IS:269-1989 0.8

OPC (43) IS:8112-1989 0.8

OPC (53) IS:12269-1987 0.8

Rapid hardening IS:8041-1990 0.8

Low heat cement IS:12600-1989 0.8

Super sulphated IS:6909-1990 Not specified

Portland pozzolana IS:1489-1991(part 1) 0.8

PSC IS:455-1976 0.8

High alumina cement IS:6452-1976 Not specified

SRC IS:12330-1988 0.8

Masonry cement IS:3466-1988 1.0

IRS-T-40 Railway standards 0.8

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 11
 Experiment No-2(B)
COMPRESSIVE STRENGTH OF CEMENT
Ref - IS: 4031 (Part-6) 1988

AIM
To determine the compressive strength of given cement sample.
APPARATUS

1. Compression testing machine

2. Balance
3. Tray
4. Gauging trowels
5. Cube Mould 7.06 cm size – 3 nos
6. Vibrating Machine

MATERIAL

1. Cement
2. Sand
3. Water

VIBRATION MACHINE CUBE MOULD GAUGING TROWEL

THEORETICAL BACKGROUND:
Compressive strength of cement is the measure of ability of cement mortar specimen to
withstand in compression or we can say that compressive load. It is an important to
determine the strength of cement.

TEMPERATURE AND HUMIDITY:

The temperature of lab molding room, dry materials and water shall be maintained at 27 ±
20 C and relative humidity of the laboratory shall be 65±5 %

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 12
PROCEDURE:
1. Take 200 gm of cement and 600 gm of sand (200 gm each of grade I, II & III,) Place
on a nonporous plate and mix it dry with a trowel for 1minute properly.

2. Take (p/4 +3) % water of the total weight of sand and cement, where ‘p’ is the
percentage of water for normal consistency

3. Mix until the mixture is of uniform colour.

4. The time of mixing shall in any event be not less than 3 min and should be time
taken to obtain a uniform colour exceed 4min, the mixture shall be rejected.
5. The material for each cube will be made separately.

6. Interior surface of the mould be greased with its base plate.

7. Place the assembled mould on the table of the vibrating machine and hold it firmly
in position by mean of a suitable clamp with hopper this shall not be removed until
the completion of the vibrating machine.

8. Test the cubes on compression testing machine for 3 and 7 days & 28 days.

9. Pace rate of C.T.M. will be 35/N/mm2/Minutes or 2.91 kN/second.

OSERVATION & CALCULATION

S. No. Age of Specimen Dimensions Area Load Applied Compressive Strength

(Days) (mm) (mm2) (kN) (N/mm2)
1. 3
2. 3
3. 3
4. 7
5. 7
6. 7

RESULT:
Compressive strength at 3 days = ………………….. MPa
Compressive strength at 7 days = ………………….. MPa

PRECAUTIONS

Write the necessary precautions for this experiment

DISCUSSIONS

Write the discussions according to your result obtained.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 13
 Experiment No-3 (A)
LOSS ON IGNITION (LOI) TEST
Ref: IS: 4032-1985-2005
OBJECTIVE
Determination of loss on ignition in given cement sample
THEORY

The Loss on Ignition Test is designed to measure the amount of moisture or impurities lost
when the sample is ignited under the conditions specified in the individual monograph. The
mass loss can be due to the loss of moisture, carbon, sulfur, and so forth, from the
decomposition or combustion of the residue. LOI in cement is determined to check the level
of adulteration in cement

Hereinafter in the Monographs, such a specification as indicates that when determined by

igniting 1 to 2 g of the sample, accurately weighed, at 900－1000℃ for 1 hour.

PROCEDURE
1. Heat 1.00 g of the sample for 1 hour in a weighed and covered platinum crucible (a
porcelain crucible may also be used) of 20 to 25 ml capacity by placing it in a muffle
furnace at temperature between 900° and 1000°C;
2. Cool and weigh.
3. Check the loss in weight by a second heating for 5 minutes and re-weigh.
4. Record the loss in weight as the loss on ignition and calculate the percentage of loss
on ignition to the nearest 0.1.

CALCULATION

Calculate the percent loss on ignition as below:

Percent loss on ignition = loss in weight × 100

(Weight of crucible with sample before keeping-Wt of crucible with sample after loss on ignition) x 100
Initial weight of sample

RESULT:
LOI = ………………..%
Note: LOI in cement should be less than 5.0 %

SIGNIFICANCE AND USE

LOI refers to the mass loss of a combustion residue whenever it is heated in an air or oxygen
atmosphere to high temperatures. In the cement industry, use of the term LOI normally refers
to a mass loss in a sample heated to 950°C. To combustion engineers, the term LOI normally
refers to mass losses in samples heated to temperatures normally less than 950°C. These test
methods establish a procedure for determining LOI values for combustion residues heated to
750°C or 950°C. LOI values from these test methods can be used by industries that utilize
combustion residues in various processes and products.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 14
 Experiment No-3 (B)
PERCENTAGE OF SILICA
(REF-IS: 4032-1985-2005)

OBJECTIVE
To determine the percentage of silica in given cement sample.
PROCEDURE
1. Transfer 0.5 g of the sample to an evaporating dish, moisten with 10 ml of distilled
water at room temperature to prevent lumping, add 5 to 10 ml of hydrochloric acid,
and digest with the aid of gentle heat and agitation until the sample is completely
dissolved.
2. Dissolution may be aided by light pressure with the flattened end of a glass rod.
Evaporate the solution to dryness on a steam-bath.
3. Without heating the residue any further treat it with 5 to 10 ml of hydrochloric acid
and then with an equal amount of water, or pour at once upon the residue 10 to 20
ml of hydrochloric acid (1 : 1). Then cover the dish and digest for 10 minutes on the
water-bath or hot-plate.
4. Dilute the solution with an equal volume of hot water, immediately filter through an
ashless filter paper (Whatman No. 40 or its equivalent), and wash the separated
silica (SiO2) thoroughly with hot water and reserve the residue.
5. Again evaporate the filtrate to dryness, baking the residue in an oven for one hour at
105 to 110°C. Then treat the residue with 10 to 15 ml of hydrochloric acid (1 : 1)
and heat the solution on water-bath or hot-plate.
6. Dilute the solution with an equal volume of hot water catch and wash the small
amount of silica it contains on another filter paper. Reserve the filtrate and
washings for the determination of combined alumina and ferric oxide.
7. Transfer the papers containing the residues to a weighed platinum crucible. Dry and
ignite the papers, first at a low heat until the carbon of the filter paper is completely
consumed without inflaming, and finally at 1 100 to 1 200°C until the weight
remains constant.
8. Treat the ignited residue thus obtained, which will contain small amounts of
impurities, with 1 to 2 ml of distilled water, about 10 ml of hydrofluoric acid and 2
drops of sulphuric acid and evaporate cautiously to dryness. Finally heat the small
residue at 1 050 to 1 100°C for a minute or two; cool and weigh. The difference
between this weight and the weight of ignited sample represents the amounts of
silica:

Silica Percent = 200 (W1 – W2)

Where,

W1 = weight of silica + (insoluble impurities – residue), and

W2 = weight of impurities

NOTE: 1. For routine analysis, treatment with hydrofluoric acid may be omitted
2. SiO2 in Portland cement should be between 18-24%

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 15
 Experiment No-3 (C)
FERRIC OXIDE, ALUMINA AND CALCIUM OXIDE
Ref: - IS: 4032-1985-2005
OBJECTIVE
To Determine the Ferric Oxide, Alumina and Calcium Oxide in given cement sample.
FERRIC OXIDE
Preparation of EDTA Solution;
Standard EDTA Solution — 0.01 M. Dissolve 3.7224 g of disodium ethylenediamine tetra acetate
dihydrate in 400 ml hot water and make up the volume in one litre flask. Take 10 ml of standard
zinc solution in an Erlenmeyer flask. Add 20 ml buffer solution of pH 10 and warm to 50 to 60°C.
Add 50 mg Eriochrome Black-T indicator and titrate with EDTA till the colour changes from wine
red to clear blue. Note the volume of EDTA used (V). Calculate the molarity of EDTA as follows
0.01 10
Molarity of EDTA =
V
Adjust the molarity to 0.01 M, if required

Preparation of filtrate
1. Evaporate the filtrate to dryness, baking the residue in an oven for one hour at 105 to
110°C. Then treat the residue with 10 to 15 ml of hydrochloric acid (1 : 1) and heat the
solution on water-bath or hot-plate. Dilute the solution with an equal volume of hot water
catch and wash the small amount of silica it contains on another filter paper. Reserve the
filtrate and washings for the determination of combined alumina and ferric oxide.

2. Add 0.5 g of sodium or potassium persulphate to the crucible and heat below red heat until
the small residue of impurities is dissolved in the melt. Cool, dissolve the fused mass in
water, and add it to the filtrate and washings reserved for the determination of the
combined alumina and ferric oxide.

PROCEDURE
1. Mix the filtrates and make up the volume in a 250-ml volumetric flask.
2. Take 25 ml of solution and add dilute ammonium hydroxide (1 : 6) till turbidity
appears.
3. Clear the turbidity with a minimum amount of dilute hydrochloric acid (1 : 10) and
add a few drops in excess to adjust the pH to approximately 1 to 1.5. Shake well.
4. Then add 100 mg of sulphosalicylic acid and titrate with 0.01 M EDTA solution
carefully to a colourless or pale yellow solution.
CALCULATION
Calculate the percentage of Fe2O3 as below: 1 ml of 0.01 M EDTA = 0.7985 mg of Fe2O3
0.7985 V
Iron oxide (Fe2O3) percent =
W
Where,
V = Volume of EDTA used in ml, and
W = Weight of the sample in g.
RESULT:
Iron oxide (Fe2O3) percent = ……………… %

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 16
 ALUMINIUM OXIDE
PROCEDURE: (EDTA METHOD)
1. Take 25 ml of solution reserved and titrate iron at pH approximately 1 to 1.5 with
EDTA using sulphosalicylic acid as indicator .
2. Add 15 ml standard EDTA solution.
3. Add 1 ml of phosphoric acid (1 : 3), 5 ml of sulphuric acid (1 : 3) and one drop of
thymol blue into the titration flask.
4. Add ammonium acetate solution by stirring until the colour changes from red to
yellow.
5. Add 25 ml of ammonium acetate in excess to obtain pH approximately 6.
6. Heat the solution to boiling for one minute and then cool.
7. Add 50 mg of solid xylenol orange indicator and bismuth nitrate solution slowly
with stirring until the colour of the solution changes from yellow to red.
8. Add 2 to 3 ml of bismuth nitrate solution in excess.
9. Titrate with 0.01 M EDTA solution to a sharp yellow end point red colour.

CALCULATION

Calculate the percentage of Al2O3 as below:

V = V1 – V2 – (V3 × E)
Where,

V = Volume of EDTA for alumina in ml,

V1 = Total volume of EDTA used in the titration in ml,
V2 = Volume of EDTA used for iron in ml,
V3 = Total volume of bismuth nitrate solution used in the titration in ml, and
E = Equivalence of 1 ml of bismuth nitrate solution (see Note below )

1 ml of 0.01 M EDTA = 0.5098 mg of Al2O3

0.5098 V
Aluminium oxide (Al2O3) percent =
W

Where, W = Weight of the sample in g.

NOTE — Equivalence of bismuth nitrate solution is obtained as follows:

Transfer 100 ml of bismuth nitrate solution to a 500-ml flask and dilute with about 100 ml distilled
water. Add a few drops of thymol blue solution and ammonium acetrate solution until the colour
changes from red to yellow. Add 50 mg of xylenol orange indicator and titrate with 0.01 M EDTA
solution until the colour changes from red to yellow. The equivalence (ml of EDTA) of 1 ml of
bismuth nitrate solution is calculated as follows:
V4
E
100
Where, V4 = Volume of EDTA solution in ml.
RESULT: Aluminium oxide (Al2O3) percent = ………………….%

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 17
 CALCIUM OXIDE

PROCEDURE: (EDTA METHOD);

1. Take 10 ml of Silica & R2O3 free solution reserved in a 250-ml conical flask.

2. Add 5 ml of 1 : 1 glycerol with constant stirring and 5 ml of diethyl amine.

3. To this add 10 ml of 4N sodium hydroxide solution and shake well to adjust pH to highly
alkaline range of 12 or slightly more.

4. Add approximately 50 ml of distilled water and 50 mg of solid Patton-Reeder’s indicator.

5. Titrate against 0.01 M EDTA solution to a sharp change in colour from wine red to clear blue
(see Note).

CALCULATION

Calculate the percentage of CaO as below:

1 ml of 0.01 M EDTA = 0.5608 mg of CaO

0.05608 25 V
Calcium Oxide (CaO) percent =
W

Where,

V = Volume of EDTA used in ml, and

W = Weight of the sample in g.

NOTE

Manganese interferes with the estimation of CaO in presence of manganese

RESULT

Calcium Oxide (CaO) percent = ………………….%

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 18
 Experiment No-4 (A)
PERCENTAGE OF SULPHURIC ANHYDRIDE
(Ref: - IS: 4032-1985-2005)

OBJECTIVE
Determination of SO3 (sulphuric anhydride) in given cement sample
APPARATUS

1. Hot plate
2. Beaker-250 ml
3. Volumetric Flask
4. Glass rod
5. Whatman filter paper-40 no

THEORY
SO3 in cement sample is determined so as to need bureau of Indian standard specifications.
PROCEDURE

1. To one gram of the sample, add 25 ml of cold water, and while the mixture is stirred
vigorously add 5 ml of hydrochloric acid. If necessary, heat the solution and grind
the material with flattened end of a glass rod until it is evident that the
decomposition of the cement is complete.
2. Dilute the solution to 50 ml and digest for 15 minutes at a temperature just below
boiling.
3. Filter and wash the residue thoroughly with hot water. Set aside the filter paper
with the residue.
4. Dilute the filtrate to 250 ml and heat to boiling. Add slowly drop by drop, 10 ml of
hot barium chloride (100 g/l) solution and continue the boiling until the precipitate
is well formed.
5. Digest the solution on a steam-bath for 4 hours or preferably overnight. Filter the
precipitate through a Whatman No. 42 filter paper or equivalent and wash the
precipitate thoroughly.
6. Place the filter paper and the contents in a weighed platinum or porcelain crucible
and slowly incinerate the paper without inflaming. Then ignite at 800 to 900°C, cool
in a desiccator and weigh the barium sulphate obtained, calculate the sulphuric
anhydride content of the material taken for the test.

CALCULATION
Calculate the percentage of SO3 as, SO3 percent = W x 34.3
Where, W= wt of residue (BaSO4) in g and
34.3 = molecular ratio of SO3 to BaSO4 (0.343) multiplied by 100

RESULT
Percentage of SO3 = …………%

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 19
 Experiment No-4 (B)
INSOLUBLE RESIDUE IN CEMENT
(REF-IS: 4032-1985-2005)

OBJECTIVES:

To determine the insoluble materials in Portland cement.

BACKGROUND:

Insoluble residue is a measure of adulteration of cement, largely coming from impurities in

gypsum and can be found by treating the cement with hydrochloric acid and sodium
hydroxide.

Over the past several years, the Division of Materials has seen an increase in the number of
failures when testing Portland cement for insoluble residue. Insoluble residue is a non
cementing material which is present in Portland cement and excessive amounts of
insoluble residue may indicate contamination or high amounts of siliceous or
argillaceous materials in the cement.

PROCEDURE

1. Digest the filter paper containing the residue set aside under 4A in 30 ml of hot
water and 30 ml of 2N sodium carbonate solution maintaining constant volume, the
solution being held at just below the boiling point for 10 minutes.

2. Filter and wash with dilute hydrochloric acid (1 : 99) and finally with hot water till
the residue is free from chlorides.

3. Ignite the residue in a tared crucible at 900 to 1 000°C, cool in a desiccator and
weigh

RESULT

Insoluble residue/ materials in given cement = ………………%

Note:

Limits for Insoluble Residue in various cement varieties are as follows;

53 Grade OPC : Not more than 4%

43 Grade OPC : Not more than 5%
33 Grade OPC : Not more than 5%

4(100 X )
PPC :– Not more than X
100
Where,

‘X’ is declared percentage of pozzolona

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 20
 Experiment No-5 (A)
SPECIFIC GRAVITY OF CEMENT BY LE-CHATELIER FLASK
REF- IS: 4031 (Part-11) – 1988 -2005
OBJECTIVE
To determine the specific gravity of the cement.
APPARATUS
S. No. Name of Apparatus Specifications
1. Le-Chatelier Flask 250 ml cap., the neck graduated 0-1 ml and 15-24 ml
2. Kerosene Desired kerosene
3. Funnel Glass made, narrow mouth
4. Wash Bottle Plastic made, 250 ml capacity
5. Pipette Glass made, 5 ml capacity
6. Thermometer Glass made, 0-50OC
7. Spatula 150 mm blade length
8. Soft Brush Round type

Funnel

Brush
THEORETICAL BACKGROUND:
Specific gravity of solid particles is defined as the ratio of the mass of a given volume of
solids to the mass of an equal volume of water. The specific gravity depends upon the
mixing the quantity by which it is made. It can detect the adulterating.
PROCEDURE
1. Fill up the flask with kerosene up to the mark below the bulb.
2. Take 64 gram of cement sample.
3. Pour the cement gradually into the flask through the funnel.
4. As the kerosene rise the lowest point of graduation, cement is cautiously poured.
5. Volume of the cement is noted down.
OBSERVATIONS AND CALCULATION:
Weight of cement used, W = 64 gm
Volume of the cement, V = …………………..
Specific Gravity of cement = W/V = ……………..

RESULT: Specific gravity of given cement sample is …………..

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 21
 Experiment No-5 (B)
MARSH FUNNEL VISCOSITY TEST
OBJECTIVE

To determine the viscosity of cement paste/slurry by using the super plasticizers

EQUIPMENT

• Marsh Funnel
• Measuring Cup (graduated)
• Stopwatch
• Thermometer

THEORY

The Marsh funnel is a simple device for measuring viscosity by observing the time it takes
a known volume of liquid to flow from a cone through a short tube. Cones with different
geometries and orifice arrangements are called flow cones, but have the same operating
principle.

Funnel viscosity is the ratio of the speed of the slurry as it passes through the outlet tube
(shear rate) to the force (weight of the slurry) causing the slurry to flow (shear stress).
Funnel viscosity is reported as the seconds required for one quart of slurry to flow
out a full funnel.

PROCEDURE
1. Prepare / collect a fresh cement slurry sample.
2. Hold the funnel erect/vertically with a finger over the outlet tube.
3. Pour the slurry into the funnel through the screen/mesh (to remove any particles
which might block the tube) until the slurry level reaches the bottom of the screen.
4. When the fluid level reaches the mesh, the amount inside is equal to the rated
volume.
5. Quickly remove your finger from the outlet tube, and at the same time start the stop
clock/watch and allow the liquid to run into a measuring container.
6. Record the time in seconds it takes for the quart of slurry to flow from the funnel.
7. Report this value as the Marsh funnel viscosity

PRECAUTION

1. The Marsh funnel should be clean and dry before performing this procedure.
2. Clean and dry the funnel thoroughly after each use
3. Take special care not to bend or flatten the brass outlet tube at the bottom of the
funnel.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 22
OBSERVATION AND CALCULATIONS:

S. No. % of Super Quantity (Q) of Time (t) in second Viscosity (Q/t)

Plasticizer slurry in ml

RESULT

Marsh Funnel Viscosity = ……………………..

Calibration Check

Periodically check the calibration of the Marsh funnel by measuring the viscosity of fresh
water. The Marsh funnel viscosity of one quart of fresh water at 70 ± 5o F (21 ± 3o C) is 26
± 0.5 seconds.

If the funnel is out of calibration, clean it using a pipe cleaner to make sure that nothing is
obstructing the outlet. If the funnel continues to give an incorrect reading for fresh water
after cleaning, then the outlet tube has probably been damaged and the funnel should be
replaced.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 23
 Experiment No-6
AIR PERMEABILITY TEST
(IS: 3085-1965-2002)

OBJECTIVE

To determine the coefficient of permeability.

APPARATUS/EQUIPMENTS

1. Permeability apparatus:- The equipment comprises of the following:

a) Three moulds
b) Three collars
c) Three top plates
d) Three bottom plates
e) One four way connector
f) One pressure chamber fitted with pressure regulator and pressure gauges.
g) Three stand
h) Two blind plugs
i) Compressor

2. Miscellaneous tools – spanners, trays, trowels, balance etc.

3. Materials- pozzolana, cement and sand

SPECIMEN PREPARATION

Clean all the all appliances which are used for mixing. Maintain the temperature of the
water to be used at 27 deg C ± 2 deg C at the time of mixing operation. Take the dry
materials, pozzolana, cement and sand in proportion 0.2 N: 08:5 by weight and blend them
immediately.

Where,

The amount of water for gauging should be equal to that required to give a flow of 105±5 %
with 25 drops in 15 seconds as determined by flow table. The sand to be used in the
penetration of mortar should be natural, rounded siliceous sand with a maximum possible
amount of quartz. The particle size distribution, determined by sieving should be between
the limits given below

IS Sieve Cumulative retained (%)

2.0 mm 0
1.70 mm 5±5
1.0 mm 33±5
500 mic 67±5
150 mic 88±5
78 mic 98±2

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 24
MIXING

The mixing should be done mechanically by means of mixing apparatus. Place the dry
paddle and bowl in the mixing position in the mixer. Then introduce the materials for batch
into the bowl and mix in the following manner:

Place all the mixing water in the bowl. Add the pozzolanic mixture to the water, then start
the mixer and mix at (140±5 rev/min) for 30 seconds. Add the entire quantity of sand
slowly over a period of 30 seconds while mixing at slow speed. Stop the mixer. Change to
285±10 rev/min and mix for 30 seconds. Stop the mixer and let the mortar stand for one
and a half minutes. During the first 15 seconds of this interval, quickly scrap down into the
batch any mortar that may have collected on the side of the bowl with the lid. Finish by
mixing for one minute at 285±10 rev/min.

Clean the mould and apply a thin coating of neat slurry. Place the mould on the base plate
and place the mortar, in two layers, in the mould. Compact each layer with 10 blows of
rammer falling freely through a height of 15±1mm in its tubular guide. During compaction
the guide of the rammer should remain in contact with the wall of the container ring. Move
the rammer through a uniform distance after each blow so as to cover the entire periphery
of the mould. After compaction the top of the specimen should be leveled off with a rod
slowly and firmly over the surface. No trowelling or other type of surface finish should be
allowed.

CURING AND STORAGE

Keep the mould with specimens at a temperature of 27 deg C ± 2ºC in an atmosphere of

atleast 90 % relative humidity for 24 hours. At the end of that period submerge the
specimen in clean fresh water and keep there for 27 days, and take it out just prior to
testing. The water in which the specimens are submerged should be renewed every
seventh day and should be maintained at a temperature of 27 deg C ± 2ºC.

TEST PROCEDURE

1. Assemble the apparatus. Fill the pressure vessel with water and connect it to some
source of compressed air supply. Pour the water into the collar till it is nearly filled.
2. Apply an initial pressure of about 0.5 kgf/cm2 by turning the pressure regulator
handle in clockwise direction and open the valve to the water in the collar and from
time to time take out and weigh the collecting container.
3. Determine the rate of percolation.
4. The rate of percolation will be comparatively high in the initial stages and will then
become stabilized.
5. After this stage the pressure is increased again by 0.5 kgf/cm2 and repeat the
procedure until a final pressure of 2 kgf/cm2 is reached.
6. When a stable flow readings of the percolation should be taken at fixed intervals of
time for eight hours. The test should be carried out at a temperature of 27 deg C ±
2ºC.
7. For each test three specimens should be tested at a time. Calculate the coefficient of
permeability from the formula: K= QS/WATH

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 25
Where,

K = Coefficient of permeability in cm/sec/unit gradient

Q = Quantity of water collected in g.

S = Thickness of the specimen

W = Density of water in g/cm3 normally equal to one.

A = Area of cross section of the specimen in cm2

T = Time of collection in seconds.

H = Net pressure head on the specimens in cm of water

The average of three specimens should be reported as the permeability of the mortar.

If specimens give permeability values differing by more than 15 percent from the average,
these should not be considered, and in such cases, a retest should be made

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 26
 ASSIGNMENT
CONCRETE MIX DESIGN
(REFERENCE: - IS: 10262-2009 & IS: 456-2000/2005)
OBJECTIVE:
Design the concrete mix as per Indian Standards (IS: 10262-2009 & IS-456-2000) for a
required grade of concrete.

THEORETICAL BACKGROUND:
One of the ultimate aims of studying the various properties of the material of concrete is to
enable a concrete technologist to design a concrete mix for a particular strength. mix design
can be defined as the process of selecting suitable ingredients of concrete and determining
their relative proportions with the object of producing concrete of certain minimum
strength and durability as economical as possible. There are different methods for concrete
mix design out of which Indian Standard code recommendation is used here to design the mix.
The compressive strength of hardened concrete which is generally considered to be an index
of its other properties, depends upon many factors, e.g. quality and quantity of cement, water
and aggregates; batching and mixing; placing, compaction and curing.

NOMINAL OR STANDARD MIXES

The Nominal Mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and
may result in under- or over-rich mixes. For this reason, the minimum compressive strength
has been included in many specifications. These mixes are termed standard mixes.
IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M20,
M25, M30, M35 and M40. In this designation the letter M refers to the mix and the number to
the specified 28 days cube strength of mix in N/mm2. The mixes of grades M10, M15, M20
and M25 correspond approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and
(1:1:2) respectively.

MIX PROPORTION DESIGNATIONS

The common method of expressing the proportions of ingredients of a concrete mix is in the
terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of
proportions 1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or
the mix contains one part of cement, two parts of fine aggregate and four parts of coarse
aggregate. The proportions are either by volume or by mass. The water-cement ratio is usually
expressed in mass

FACTORS TO BE CONSIDERED FOR MIX DESIGN

1. The grade designation giving the characteristic strength requirement of

concrete.
2. The type of cement influences the rate of development of compressive strength of
concrete.
3. Maximum nominal size of aggregates to be used in concrete may be as large as
possible within the limits prescribed by IS 456:2000.
4. The cement content is to be limited from shrinkage, cracking and creep.
5. The workability of concrete for satisfactory placing and compaction is related to
the size and shape of section, quantity and spacing of reinforcement and technique
used for transportation, placing and compaction.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 27
1. STIPULATION FOR PROPORTIONING
a) Grade designation: ………………….. Reinforcement Concrete,Table-5 of IS:456, Page-20
Exposure Min grade Min Cement W/C
b) Type of cement: ………………………
Condition of concrete content Ratio
c) Degree of Workability =………………… Mild 20 300 0.55
d) Degree of quality control = ……………… Moderate 25 300 0.50
e) Exposure condition = …………………….. Severe 30 320 0.45
f) Minimum consumption of cement = …. kg/cum V. Severe 35 340 0.45
g) Maximum size of coarse aggregate-……….. mm Extreme 40 360 0.40

2. TEST DATA FOR MATERIALS SUPPLIED/USED

2a) CEMENT

i) Make:
ii) Type :
ii) Specific gravity :

2b) COARSE AGGREGATE

i) Type: 20 mm Graded Crushed stone aggregate

ii) Specific gravity : 2.75
iii)Water absorption : 2.03 %
iv) Fineness Modulus : 7.37

2c) FINE AGGREGATES

i) Type:
ii) Specific gravity :
iii) Grading Zone:
iv) Fineness Modulus :

3. TARGET MEAN STRENGTH (TMS)

TABLE-8 OF IS:456 (PAGE-23)
Grade of Std. Deviation
a) Statistical constant, K 1.65
Concrete (S)
b) Standard deviation, S ……. M-10 3.5
c) Characteristic Strength, fck ……. M-15 3.5
TMS, fck¯ = fck + 1.65 x S M-20 4.0
fck¯ = ….. + 1.65 x ….. M-25 4.0
Thus, TMS, fck¯ ……….. N/mm² M-30 -M-50 5.0

4. SELECTION OF WATER CEMENT (W/C) RATIO

From table 5 of IS: 456, maximum water required for TMS = ………….
Selection of water content: from table 2 of IS: 10262, maximum water content = …………….. liters
Estimated water content for ……………………………….workable concrete

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 28
 Maximum Water Content per cubic meter of
0 Concrete (Reference-Table: 2 of IS: 10262)
For example, 186 186 Nominal Max size Maximum Water
100 S. No of Aggregate in Content in
= 186 Liters (mm) (Kg)

Slump upto 50 mm 186.0 Liters 1 10 208

Slump 50-75 mm 3 % Additional 2 20 186

Slump 75-100 mm 6 % Additional 3 40 165

5. DETERMINATION OF CEMENT CONTENT

Water Cement Ratio (Table-5 of IS:456, Page-20)

Minimum Grade W/c
W/c Ratio= ……………. Exposure Cement
of Concrete Ratio
Maximum Cement Content Mild 20 300 0.55

186 ………….. Moderate 25 300 0.50

0 . 50 =…….…. Kg/m³ Severe 30 320 0.45

Very Severe 35 340 0.45

From table 5 of IS: 456, for ……………… condition minimum cement content = …………….. Kg/ m3

Therefore, ………… Kg/m³ > …………. Kg/ m³ = O.K.

6. PROPORTION OF VOLUME OF COARSE AND FINE AGGREGATE CONTENT

From Table -3 of IS: 10262-2009, Volume of coarse aggregate corresponding to …………. mm size
aggregate and fine aggregate (Zone-……) for water cement ratio of …………….. = ……………………

Therefore, corrected proportion of volume of course aggregate for the w/c ratio of 0.50 = 0.60

1. Volume of Coarse Aggregate …………… …………….

2. Volume of fine Aggregate 1 - …………….. ……………

Table:3,Volume of Coarse Aggregate per Unit Volume of Total Aggregate for Different Zones of
Fine
Aggregate (Clauses 4.4, A-7 and B-7)

Volume of Coarse Aggregate per Unit Volume of Total Aggregate for

Nominal Maximum Different Zones of Fine Aggregate
Size of Aggregate
Zone-IV Zone-III Zone-II Zone-I
10 0.50 0.48 0.46 0.44
20 0.66 0.64 0.62 0.60
40 0.75 0.73 0.71 0.69

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 29
7. MIX CALCULATIONS

A. Volume of Concrete (Total) = 1.000 M³

B. Volume of Cement Mass of Cement 1 = ……… x 1

Sp Gr of cement 1000 = ……… x 1000
= 0.118 M³
C. Volume of water Mass of water 1 = ………. x 1
Sp Gr of Water 1000 = 1 x 1000
= …………. M³

D. Volume of all in aggregates (E) [A-(B + C )] ……………. …………. M³

E. Mass of Coarse Aggregate E x Vca x Gca x 1000 …………… …………. Kg

F. Mass of River Sand (Fine Aggre) E x Vfa x Gfa x 1000 …………… ...……….. Kg

Where,

Vca = Volume of Coarse Agr

Vfa = Volume FA
Gca = Sp Gr of CA
Gfa = Sp Gr of FA

8. MIX PROPORTION FOR TRIAL NUMBERS

MATERIALS Mix Design Ratio-Actual Trial Mix Design Ratio

Cement

Fine Aggregate

Coarse Aggregate

Water

Total weight in Kg

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 30
 Experiment No-7
AIR CONTENT TEST ON FRESH CONCRETE
(Reference-IS: 1199-1959/2004)
OBJECTIVE

To determine the air content in freshly prepared concrete.

INTRODUCTION

Although it is actually the air content within the mortar (cement paste + fine aggregate)
that is of concern, cement paste air content is usually what is measured. This air content
can be measured in several ways, the most common of which is the pressure method.
Using the pressure method, a sample of fresh PCC is placed in a pressure vessel (see Figure
5.47). The remaining volume of the vessel is filled with water and then the vessel is
pressurized. The water level is read once, then the vessel is depressurized and the water
level is read again. Finally, using Boyle's law (The principle that at a constant temperature
the volume of a confined ideal gas varies inversely with its pressure) the difference in
water levels (which corresponds to a volume) is converted into a volume of air.

APPARATUS

MALLET

PRESSURE VESSEL FOR MEASURING AIR CONTENT FOOT PUMP FOR PRESSURE

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 31
Air Entrainment Meter: - The equipment meets the requirements of IS: 1199, IS: 9799 and
ASTM C 231 for determining the air content of freshly mixed concrete by the pressure method.
This method is considered adequate for all ordinary types of concrete and mortar, except for
concrete or mortar made with highly porous aggregates, where the aggregate correction factor
cannot be determined accurately by the technique found satisfactory for usual types of
relatively dense natural aggregate.
a. Measuring Bowl
A flanged metallic bowl, not readily attacked by the cement paste having a diameter
equal to about 1 to 1.25 times the height. The outer rim and upper surface of the flange
as well as the interior surfaces of the bowl are smooth. The bowl is pressure tight and
sufficiently rigid to limit the expansion factor `D` of the apparatus.
b. Conical cover assembly (4)
The flanged metallic cover, not readily attached by the cement paste, as interior
surfaces inclined from the horizontal. The outer rim and lower surface of the flange and
the sloping interior surface are pressure tight and sufficiently rigid to limit the
expansion factor of the assembly. The cover is fitted with a stand pipe (7). The
graduations are for the range 0 – 10% of the air content. The internal diameter of the
stand pipe (7) is so designed that under the normal operating pressure the water
column is lowered sufficiently to measure air contents up to 0.1%. The applied air
pressure is indicated by a pressure gauge (8) connected to the air chamber above the
water column on stand pipe (7). The cover is fitted with air valves (6) for venting air at
the top and a petcock (13) to fill water as required. Clamps (5) are provided for
clamping the cover to the bowl to make a pressure tight seal without entrapping air at
the joint between the flanges of the cover and bowl. A pressure bulb (14) is provided for
applying required pressure to the specimen. A base (1) is provided for keeping the
whole assembly in vertical position.
c. Calibration cylinder (9)
It consists of a cylindrical metallic measure with slots at lower end.
d. Spring (10)
Spring leaf is provided for holding the calibration cylinder in place.
e. Spray tube with funnel (12)
A tube of appropriate diameter with funnel so constructed that when water is added
there is minimum disturbance to the concrete in the measuring bowl.
f. Rubber mallet (11)
It is used for tapping sides of the bowl and conical cover.
g. Measure (2)
For filling the indicator stand pipe with water from the top of the concrete to the zero
mark.
h. Strike-off bar
A strike-off bar is provided for leveling the concrete.
i. Trowel
j. Tamping rod
It is used to consolidate each layer of concrete by rodding.
k. Foot pump
It is used to give the pressure on the concrete

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 32
PROCEDURE
Change in barometric pressure is caused by changes in altitude or by changes of
temperature and humidity and rough handling will affect the calibration of pressure type
apparatus for determination of air content.
Following procedure should be adopted to check the operating pressure.
1. Calibration of calibration cylinder
The weight of water ‘W’ (in grams) required to fill calibration cylinder shall be
accurately determined, using a scale sensitive to 0.5g.
2. Calibration of measuring bowl
The weight of water ‘W’ (in grams) required to fill measuring bowl shall be
determined, using a scale sensitive to 0.1% of the weight of the bowl filled with
water.
A glass plate is placed carefully over the flange of the bowl in such a manner as to
ensure that bowl is completely filled with water. A thin film of cup grease smeared
on the flange of the bowl will make a water tight joint between the glass plate and
the top of the bowl.
3. Determination of constant ‘R’
The constant ‘R’ represents the volume of the calibration cylinder (W) expressed as
percentage of the volume of the measuring bowl (W). ‘R’ is calculated as follows:

150
R= Or, R 100 3.0%
5000
4. Determination of expansion factor ‘D’
The expansion factor ‘D’ for the assembly shall be determined by filling the
apparatus with water only (making certain that all entrapped air has been removed
and the water level is exactly on the zero mark) and applying an air pressure
approximately equal to the operating pressure P , determined by the calibration
test. The amount by which the water column is lowered shall be equivalent
expansion factor ‘D’ for that particular apparatus and pressure. (P=2.96 kg/cm²)
5. Determination of calibration factor ‘K’
The calibration factor ‘K’ is the amount by which the water column shall be
depressed, during the calibration procedure to obtain the gauge pressure required
to make the graduations on the glass tube correspond directly to the percentage of
air introduced in to the measuring bowl by the calibration cylinder when the bowl is
level full of water. The calibration factor ‘K’ is as follows:

(K = 0.98R+D = 0.98 x 3 = 2.94+0.005 = 2.945= 3%)

6. Calibration test to determine operating pressure ‘p’ on pressure gauge

Invert the calibration cylinder and place it at the centre of the dry bottom of the
measuring bowl carefully lower the conical cover over the measuring bowl with
seal. After the cover is clamped in place, carefully adjust the apparatus assembly to
vertical position and add water at room temperature by means of the tube and
funnel, until it rises above the zero mark on the stand pipe. Close the vent and pump
air into the apparatus to the approximate operating pressure. Incline the assembly
about 30º from the vertical and using the bottom of the bowl as a pivot; describe

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 33
 several complete circles with upper end of stand pipe simultaneously tapping the
cover and sides of the bowl lightly to remove any entrapped air in the inner surfaces
of the apparatus and open the vent. Bring the water level exactly to the zero mark by
bleeding water through the petcock in the top of the conical cover. After closing the
vent apply the pressure until the water level has dropped to an amount equivalent
to about 0.1 percent of air more than the value of the calibration factor K. To relive
local restraints lightly tap the sides of the bowl. When the level is exactly at the
value of the calibration factor ‘K’ read the pressure ‘P’ indicated by the gauge and
record it to the nearest 0.01kgf/cm2.

Gradually release the pressure and open the vent to determine whether the water
level returns to zero mark, while lightly tapping the sides of the bowl. Failure of
water level to return indicates loss of air from the calibration cylinder or loss of
water due to leak in the assembly. If the water level fails to return to within 0.05%
of air content of the zero mark and no leakage beyond few drops of water is found.
Some air probably was lost from the calibration cylinder. If the leakage of is more
than a few drops of water, lighten the water leakage joint before repeating the
calibration procedure. Check the indicated pressure reading promptly by bringing
the water level exactly to zero mark, closing the vent, and applying the pressure p,
just determined. Tap the water column should read the value of the calibration
factor K, used in the first pressure application within about 0.05% of air.
(p=0.75 kg/cm²)

7. Determination of Aggregate Correction Factor ‘G’

The aggregate correction factor shall be determined in a combined sample of fine
and coarse aggregates.
The weights of fine and coarse aggregates present in the volume ‘S’ of the sample of
fresh concrete whose air content is to be determined, shall be determined as
follows:

S 0.005
Fs Fb 546 2.78Kg
B 0.98

S 0.005
Cs Cb 1187 6.0Kg
B 0.98
Where,

Fs = weight in kg of fine aggregate in concrete sample under test

S = volume in dm3 of concrete sample (same as the volume of the measuring
bowl of apparatus)
B = volume in dm3 of concrete produced per batch
Fb = total weight in kg of fine aggregate in batch
Cs = weight in kg of coarse aggregate in concrete sample under test
Cb = total weight in kg of coarse aggregate in batch
Mix representative sample of fine aggregate of weight Fs and coarse aggregate of weight Cs
and place in the measuring bowl filled one third full of water. Add the mixed aggregate in
small amounts at a time, until all the aggregate is indicated. Add each scoopful in a manner

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 34
that will entrap as little air as possible and remove accumulations of foam promptly. Tap
the sides of the bowl and lightly rod the upper layer of the aggregate about ten times and
stir after each addition of fine aggregate to eliminate entrapped air. When all of the
aggregate has been [placed in the bowl and inundated for at least 5 minutes, strike off all
foam and excess water and thoroughly clean the flanges of both the bowl and conical cover
so that when the cover is clamped in place, a pressure tight seal is obtained. Complete the
test as described below. The aggregate correction factor G = h1-h2 as determined in the
tests on the aggregate, h1= reading at pressure p and h2 = reading at zero pressure after
release of pressure p.
PROCEDURE FOR DETERMINING AIR CONTENT OF CONCRETE

Place a representative of the concrete in the measuring bowl in three equal layers,
consolidating each layer by rodding the bowl. Vibration may be substituted for rodding and
by tapping the sample when the air content of concrete placed by vibration is to be
determined. When the concrete is to be placed by rodding, consolidate each layer of
concrete by 25 strokes of the tamping rod evenly distributed over the cross section. Follow
the rodding of each layer by tapping the sides of the bowl smartly 10 to 15 times with the
mallet until the cavities left by rodding are leveled out and no large bubbles of the air
appear over the surface of the rodded layer. In rodding the first layer, the rod shall not
forcibly strike the bottom of the bowl. In rodding the second layer and final layer, only
enough force shall be used to cause the rod to penetrate the surface of the previous layer.
Slightly overfill the bowl with the third layer and after rodding or vibration remove the
excess concrete by sliding the strike-off bar across the top flange with a sawing motion
until the bowl is just full to the flange level. Thoroughly clean the flanges of the bowl and off
the conical cover so that when the cover is clamped in place, a pressure tight seal will be
obtained. Assemble the apparatus and add water over the concrete by means of the tubes
until it rises to about half way mark in the stand pipe. Incline the apparatus assembly about
30 degree from vertical and using the bottom of the bowl as a pivot, describes several
complete circle, with the upper and of the column simultaneously tapping of the conical
cover lightly to remove any entrapped air bubbles above the concrete sample. Replace the
apparatus assembly to its vertical [position and fill the water column slightly above zero
mark, while lightly tapping the sides of the bowl. Foam the surface of the water column
may be removed with a syringe of with a spray of alcohol to provide a clear meniscus.

Bring the water level to the zero mark of the stand pipe closing the bend at the top of the
water column. Apply slightly more than the decode test pressure ‘p’ (0.02 kg/cm2 more)
to the concrete by means of hand pump. To relieve local restraint, tap the sides of the
measures smartly, and when the pressure gauge indicated the exhaust test pressure ‘p’ (as
determined in accordance with the calibration test) read the level h1 and record to the
nearest division or half division (0.10-0.05 % air constant) on the graduated stand pipe.
For extremely harsh mixes at may be necessary to tap the bowl vigorously until further
tapping produces no change in the indicated air constant. Gradually release the air
pressure through the vent at the top of the water column and tap the sides of the bowl
lightly or about 1 minute.

Record the water level h2 to the nearest division or half division. The apparent sir content
A1 is equal to h1-h2. Repeat the step specified as above (without adding water to re-
establish the water level at zero mark). The two consecutive determination of apparent air
content should check within 0.2 % of air and shall be average to give the value A1 to be
used in calculating the air content, as given below (p=0.75+0.02=0.752 kg/cm²)

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 35
OBSERVATIONS

APPARENT AIR CONTENT PERCENTAGE BY VOLUME OF CONCRETE (A1)

(Ratio-1 : 1.5 : 3 : 0.5: Cement = 2.0 kg, Sand = 3.0 kg, Aggregate = 6.0 kg and Water = 1.0 lit)

Trail Numbers H1 H2 Difference (H1-H2)

1
2
3
4
5
Average (A1)

AGGREGATES CORRECTION FACTOR, (G) PERCENT BY VOLUME OF CONCRETE

(Fine aggregate: 3.0 kg and Coarse Aggregate: 6.0 kg)

Trail Numbers H1 H2 Difference

1
2
3
4
5
Average (G)

CALCULATIONS

Calculate the air content of the concrete as follows;

A = A1-G

Where,

A = air content, percentage by volume of concrete.

A1 = apparent air content, percentage by volume of concrete
G = aggregate correction factor, percentage by volume of concrete.

RESULT

PRECAUTION

REMARKS

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 36
 Experiment No-8
INFLUENCE OF W/C RATIO ON WORKABILITY & STRENGTH
REF: - IS: 1199-1959/2004
OBJECTIVE

To determine the Influence of W/C Ratio on Workability & Strength

EQUIPMENTS REQUIRED

The apparatus for conducting the slump test is of metallic mould in the form of
frustum of cone having dimension:
Bottom diameter : 20cm
Top diameter : 10cm
Height : 30cm
Thickness of metallic sheet : 1.6mm

Temping rod bullet end – 16 mm dia. and 60 cm long

Concrete mixing equipment

THEORY

The water cement ratio is the ratio of the weight of water to the weight of cement used in
a concrete mix and has an important influence on the quality of concrete produced.

A lower water-cement ratio leads to higher strength and durability, but may make the
mix more difficult to place. Placement difficulties can be resolved by using plasticizers or
super-plasticizers.
The water-cement ratio is one of the most important aspects when it comes to maintaining
the strength of Concrete. The ratio depends on the grade of concrete and the structure size.
We generally prefer a W/C ratio of 0.4 to 0.6, but it can be decreased in case of high grade
concrete, we reduce the amount of water and use plasticizers instead.

W/C ratio affects the workability of concrete and thus should be taken into careful
consideration. Also, if the ratio exceeds the normal value, segregation of concrete occurs
and the coarse aggregate settles at the bottom, thus affecting the strength of concrete
greatly.
Concrete is a water based product. To make the mixture 'workable', easy to place and
consolidate, more water than what is required for the hydration of cement is used. This
extra water is known as 'water of convenience', which will bleed out of the concrete,
leaving behind pores/capillaries.
The simplest way to think about the w/c ratio is to think that the greater the amount of
water in a concrete mix, the more dilute the cement paste will be. This not only affects the
compressive strength, it also affects the tensile and flexural strengths, the porosity, the
shrinkage and the color.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 37
PROCEDURE:
1. Mix the concrete ingredients in the definite proportions of a particular
grade.
2. Oil the interior surface of the mould.
3. Place the mould on a smooth, horizontal, rigid and non-absorbent surface.
4. Mould is then filled with concrete in four layers and each layer is tamped 25
times by the tamping rod.
5. After the top layer has been rodded, the concrete is struck off level with a
trowel and temping rod.
6. The mould is removed from concrete immediately by raising it slowly and
carefully in a vertical direction. This allows the concrete to subside.
7. The difference of the level of mould and the highest point of the subsided
concrete is measured.
8. Cast atleast 3 cubes from the same mix to determine the compressive
strength.

OBSERVATION FOR WORKABILITY

S. Grade of W/c Initial mould Highest point of the Difference of

No. concrete mix Ratio height concrete subsides height
(mm) (mm) (mm)
1 300
2 300
3 300
4 300
5 300

OBSERVATION FOR COMPRESSIVE STRENGTH

S. Water Grade of Date of Date Age of Wt of Area of Load Compressive

No. cement concrete Casting of cube cube cube applied Strength,
Ratio mix testing (days) L= L/A
(W/c) (kg) A=mm2 (kN) N/mm2
1
2
3

RESULT:

Avg. Compressive strength = …………………N/mm2 (MPa), at W/C ratio ……………….

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 38
 Experiment No-9
COMPRESSIVE STRENGTH OF NORMAL & ACCELARATED CURED CONCRETE
(Reference: - IS: 516-1959/2004)

OBJECTIVE:

To determine the 7 & 28 days compressive strength of designed mix concrete for the
required grade.

APPARATUS:

Compressive testing machine (CTM)

Cube Mould size: 150 x 150 x 150 mm
Tamping rod
Trowels
Vibrating table
Trays
Accelerated curing tank

COMPRESSION TESTING MACHINE CUBE MOULD

MATERIALS

1. Cement
2. Fine aggregate (passing from 4.75 mm sieve)
3. Coarse Aggregate-1 (10 - 20 mm size)
4. Coarse Aggregate-2 (4.75 - 10 mm size)
5. Water

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 39
THEORETICAL BACKGROUND:
Concrete is a construction material composed of cement (commonly Portland Cement) as
well as other cementitious materials such as fly ash and slag cement, aggregate (generally a
coarse aggregate such as gravel, limestone, or granite, plus a fine aggregate such as sand),
water, and chemical admixtures.

Nominal mix

Nominal mix means mixing cement, fine aggregates and coarse aggregates based on
volume, e.g. 1:2:4 mix means mixing one volume of cement with two volumes of sand and
four volumes of coarse aggregates. This is normally used when the volume of concrete
work to be done is less.

Design Mix

A Design mix is that mix which uses minimum quantity of components to attain the
designed strength of concrete whereas in a nominal mix attaining the characteristic
compressive strength is the criteria of mix proportioning.

Strength

Strength is probably the most well-known PCC performance parameter. Compressive and
tensile strength are fundamental to any building material in order to properly proportion
and design structural items made from that material. Although PCC is most often known
for its compressive strength, it is typically its tensile strength (or more exactly, its flexural
strength) that governs its use in rigid pavements. However, given the popularity and
relative ease of the compressive test, both tests are typically used in pavement
applications. Strength concepts covered are:

The compressive strength of concrete is the most useful and important properties of
concrete. In most of the structural applications concrete is employed primarily to resist
compressive stresses. Cubes or cylinders are casted and tested for the determinations of
the compressive strength of harden concrete.

PROCEDURE:

1. Calculate and take the proper quantities of cement, coarse aggregate, fine aggregate,
and water required for making 6 cubes of desired grade of concrete.
2. Mix thoroughly to all the materials in a steel tray with gauging trowels.
3. Place the concrete mix in cube and vibrate it. After vibration, level the top surface of
cube by removing excess concrete.
4. Put the cubes at 27 2oC for 24 hrs for final setting.
5. Remove the concrete cubes from the mould and Put 3 cubes in normal water tank at
27 2oC and 3 cubes in accelerated curing tank at 27 2oC of each grade for curing.
6. Put them in compression testing machine after 7 days or 28 days of curing for
testing.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 40
OBSERVATIONS & CALCULATIONS

S. No. Grade of Date of Date of Age of Wt of Area of Load Compressive

concrete Casting testing cube cube cube applied Strength, L/A
mix (days) (kg) A=mm2 L= (kN) N/mm2
Normal Cured Concrete

1.

2.

3.

Accelerated Cured Concrete

1.

2.

3.

RESULT:

Avg. Compressive strength = …………………N/mm2 (MPa)

DISCUSSIONS

Write the discussion according to your result obtained

PRECAUTIONS

Write the necessary precautions

RECOMMENDED VALUES

Grade of Minimum compressive Specified characteristic compressive

Concrete strength N/mm2 at 7 days strength (N/mm2) at 28 days
M-15 10 15
M-20 13.5 20
M-25 17 25
M-30 20 30
M-35 23.5 35
M-40 27 40
M-45 30 45

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 41
 Experiment No-10(A)
NON-DESTRUCTIVE TEST BY REBOUND HAMMER
Ref: 13311 (Part 2) – 1992/2004.

OBJECTIVE

To assess the likely compressive strength of concrete with the help of suitable co-relations
between rebound index and compressive strength,

APPARATUS

Rebound Hammer: It consists of a spring controlled mass that slides on a plunger within a
tubular housing. The impact energy required for rebound hammers for different
applications

REBOUND HAMMER

THEORY

When the plunger of rebound hammer is pressed against the surface of the concrete, the
spring-controlled mass rebounds and the extent of such rebound depends upon the surface
hardness of concrete. The surface hardness and therefore the rebound is taken to be
related to the compressive strength of the concrete. The rebound is read off along a
graduated scale and is designated as the rebound number or rebound index.

PRINCIPLE

The rebound of an elastic mass depends on the hardness of the surface against which its
mass strikes. When the plunger of the rebound hammer is pressed against the surface of
the concrete, the pring-controlled mass rebounds and the extent of such a rebound
depends upon the surface hardness of the concrete. The surface hardness and therefore the
rebound is taken to be related to the compressive strength of the concrete. The rebound
value is read from a graduated scale and is designated as the rebound number or rebound
index. The compressive strength can be read directly from the graph provided on the body
of the hammer.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 42
PROCEDURE

1. Before commencement of a test, the rebound hammer should be tested against the
test anvil, to get reliable results, for which the manufacturer of the rebound hammer
indicates the range of readings on the anvil suitable for different types of rebound
hammer.

2. Apply light pressure on the plunger - it will release it from the locked position and
allow it to extend to the ready position for the test.
3. Press the plunger against the surface of the concrete, keeping the instrument
perpendicular to the test surface.

4. Apply a gradual increase in pressure until the hammer impacts. (Do not touch the
button while depressing the plunger.

5. Press the button after impact, in case it is not convenient to note the rebound
reading in that position.)

6. Take the average of about 15 readings.

Interpretation of Results

The rebound reading on the indicator scale has been calibrated by the manufacturer of the
rebound hammer for horizontal impact, that is, on a vertical surface, to indicate the
compressive strength. When used in any other position, appropriate correction as given by
the manufacturer is to be taken into account

RESULT:
Avg. Compressive Strength = ………….. N/mm2

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 43
 Experiment No-10(B)
NDT BY ULTRASONIC PULSE VELOCITY TEST
(REF:-IS: 13311 (PART-1)-1992/2004)

OBJECTIVE
The measurement of pulse velocity may be used to determine:
1. The homogeneity of the concrete,
2. The presence of voids, cracks or other imperfections,
3. Changes in the concrete which may occur with time (i.e. due to the cement
hydration) or through the action of fire, frost or chemical attack,
4. The quality of the concrete in relation to specified standard requirements, which
generally refer to its strength.

Applications

The pulse velocity method of testing may be applied to the testing of plain, reinforced and
prestressed concrete whether it is precast or cast in situ.

The velocity of ultrasonic pulses travelling in a solid material depends on the density and
elastic properties of that material. The quality of some materials is sometimes related to
their elastic stiffness so that measurement of ultrasonic pulse velocity in such materials can
often be used to indicate their quality as well as to determine their elastic properties.
Materials which can be assessed in this way include, in particular, concrete and timber but
exclude metals.

Homogeneity of the concrete

Measurement of pulse velocities at points on a regular grid on the surface of a concrete

structure provides a reliable method of assessing the homogeneity of the concrete. The size
of the grid chosen will depend on the size of the structure and the amount of variability
encountered. It is useful to plot a diagram of pulse velocity contours from the results
obtained since this gives a clear picture of the extent of variations. It should be appreciated
that the path length can influence the extent of the variations recorded because the pulse
velocity measurements correspond to the average quality of the concrete along the line of
the pulse path and the size of concrete sample tested at each measurement is directly
related to the path length.

Detection of defects

When an ultrasonic pulse travelling through concrete meets a concrete-air interface, there
is a negligible transmission of energy across this interface so that any air-filled crack or
void lying directly between the transducers will obstruct the direct beam of ultrasound
when the void has a projected area larger than the area of the transducer faces. The first
pulse to arrive at the receiving transducer will have been diffracted around the periphery
of the defect and the transit time will be longer than in similar concrete with no defect. It is
sometimes possible to make use of this effect for locating flaws, etc. but it should be
appreciated that small defects often have little or no effect on transmission times.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 44
Detection of large voids or cavities

A large cavity may be detected by measuring the transit times of pulses passing between
the transducers when they are placed in suitable positions so that the cavity lies in the
direct path between them. The size and position of such cavities may be estimated by
assuming that the pulses pass along the shortest path between the transducers and around
the cavity. Such estimates are more reliable if the cavity has a well defined boundary
surrounded by uniformly dense concrete. If the projected area of the cavity is smaller than
the diameter of the transducer the cavity cannot be detected.

Monitoring changes in concrete with time

Changes occurring in the structure of concrete with time caused by either hydration (which
increases strength) or by an aggressive environment such as frost or sulphates, may be
determined by repeated measurements of pulse velocity at different times. Changes in
pulse velocity are indicative of changes in strength and their measurement can be made
over progressive periods of time on the same test piece or concrete product

ESTIMATING THE DEPTH OF A SURFACE CRACK

APPARATUS

The apparatus for ultrasonic pulse velocity measurement shall consist of the following:

1. Electrical pulse generator,

2. Transducer - one pair, Any suitable type of transducer operating within the frequency range of 20 kHz
to 150 kHz
3. Amplifier, and
4. Electronic timing device.

PLACING THE TRANSDUCERS

It is possible to take measurements of pulse velocity by placing the transducers in three
alternative positions:
a) Direct transmission with transducers on opposite faces of the material.
b) Semi-direct transmission with transducers on adjacent faces.
c) Indirect or surface transmission with the transducers on the same faces.
(a) is the most sensitive method as the receiving transducer will receive maximum energy
from the transmitted pulse.
(b) is the next preferred method and (c) should be used only when it is impossible to get to
two faces of the material being tested. The received pulse amplitude, for the same path
length, is only about 1% of that received when using method (a).
PULSE VELOCITY
Having determined the method of transducer placement, make careful measurements of
the path length L. Apply couplant to the faces of the transducers and press hard onto the
material under test. Do not move the transducers while a reading is being taken as this can
generate noise signals and errors in measurements.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 45
The pulse velocity is given by: v = L/T (where T is the transit time)

It is advisable, when using very long cables, to prevent the two cables from coming into
close contact with each other when transit time measurements are being made. If this is
not done, it is possible for the receiver cable to pick up unwanted signals from the
transmitter cable which will result in an incorrect display of transit time. If this happens,
the readings on the display will be unstable.

PROCEDURE:

Method-1

An estimate of the depth of a crack visible at the surface may be obtained by measuring the
transit times across the crack for two different arrangements of the transducers placed
on the surface. One suitable arrangement shown in figure 6a in which the transmitting and
receiving transducers are placed at a distance x on opposite sides of the crack and
equidistance from it. Two values of x are chosen and transit times corresponding to these
are measured: convenient values of x are 150 mm and 300 mm. if these values are used, the
depth of the air filled crack C (in mm) is given below;

4t12 t 22
C 150 2 2
t 2 t1
Where,
T1 is the transit time when x is 150 mm in micro second
T2 is the transit time when x is 300 mm in micro second
Note:
1. The above equation is derived by assuming that the plane of the crack is
perpendicular to the concrete surface and that the concrete in the vicinity of the
crack is of reasonably uniform quality.
2. A check may be made to assess whether or not the crack is lying in a plane
perpendicular to the surface by placing both transducers near to the crack and
moving each in turn

Method-2
In this method the transmitting transducer is placed at a distance of 2.5 y from the center of
the crack and three readings of the transit time taken with the receiving transducer at
distances of y, 2y and 3y from the transmitter in the direction of the crack. The transit
times are plotted against distance in which y is 150 mm. if the projection of the straight
Velocity Criterion for Concrete Quality Grading
S. No. Pulse velocity by cross probing Concrete grading quality
(km/sec)
1 Above 4.5 Excellent
2 3.5 to 4.5 Good
3 3.0 to 3.5 Medium
4 Below 3.0 Doubtful
Note - In case of ‘doubtful’ quality it may be necessary to carry out further tests.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 46
 Experiment No-11
BEND AND REBEND TEST OF STEEL
(REF: BS4449:1997 & IS: 1786-2008)

OBJECTIVE
Bend and re-bend test of steel bars
PURPOSE & FIELD APPLICATION
The purpose of re-bend test is to measure the effect of strain ageing on steel. Strain ageing
has embrittlement effect which takes place after cold deformation by diffusion of nitrogen
in steel. Hence, there is limitation stated in some design codes to restrict the nitrogen
content of steel to 0.012%.
This method applies to all types or grades of non-prestressing reinforcing steel.
SYMBOLS AND DEFINITIONS

Symbol Definition Unit

dn nominal diameter of test piece mm
D diameter of mandrel mm
α angle of bend degree

METHOD OF TESTING
All parts of the test procedure shall be performed at ambient temperature of 23 ± 5 °C,
except when the steel is being aged.
The testing shall be carried out by qualified persons. If computerized testing is used, the
procedure shall be well documented.
TEST PIECE
A test piece of sufficient length is cut or sawn from the bar. If test pieces are taken from
welded fabrics they shall not contain any heat affected zones (HAZ).
PROCEDURE
The test procedure consists of bending, ageing, rebending and inspection in that order.
Bending
The test piece shall be bent over a mandrel with diameter (D) not greater than 10 times dn.
The angle after unloading shall be 90°. The time to complete the bending shall be at least 1
sec.
Note: A recommended series of mandrel diameters are given in appendix.
Artificial ageing

The bent test piece is artificially aged at +100 °C for two hours (2 h) in still air furnace or
half an hour in boiling water followed by free cooling in air, to ambient temperature. As
option a temperature of +250 °C for half an hour (0.5 h) can also be used.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 47
Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 48
Rebending

The bent and aged test piece shall be rebent. The distance between the support rollers shall
allow the rebend to take place within the bent area until the angle after unloading is
reduced to less than 70°

Inspection

After rebending, no fracture, transverse or oblique cracks visible to the naked eye shall
occur on the test piece.

The following mandrel diameters are recommended for the bend testing

Test Piece Mandrel

Diameter Diameter Diameter
mm mm mm
a) b)

6 50 63
8 63 80
10 80 100
12 100 125
16 125 160
20 160 200
25 200 250
32 250 320

a) This series will give a deformation over 5%.

b) This series will give a deformation below 5%.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 49
 Experiment No-12
DURABILTY OF CONCRETE BY RCPT TEST
(REF: AASHTO T277-83 & ASTM C1202)

OBJECTIVE

To measure the electrical current passing through a concrete specimen for a period of standard
6 hours at a standard voltage of 60 VDC.

THEORY

The current (in milliamps) is measured over 6 hours and the ampere-seconds are achieved by
integration of the curve in order to obtain the Coulombs. This is done automatically. The
Coulombs are, according to ASTM C 1202-97, an indication of the concrete’s ability to resist
chloride ion penetration at 60 VDC and 6 hours of testing, and for a specimen with a diameter
of 95 mm (3 ¾”), 50 mm long, as shown in table 1:

Table-1. Chloride ion penetrability based on charge passed (ref.1)

Coulombs Chloride Ion Permeability Typical of

>4000 High High w/c-ratio

4000-2000 Moderate 0.4-0.5 w/c-ratio
2000-1000 Low w/c-ratio < 0.4
1000-100 Very low Latex modif. concrete
<100 Negligible Polymer concrete

APPARATUS

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 50
Specimen

In the laboratory the specimens may be cast in a 100 mm diameter mold, 50 mm high, or
produced by coring. For cored specimens, the CEL-100 Core case coring rig is recommended to
be used. The rig produces accurately the correct 100 mm +/-1 mm core diameter.

Conditioning the specimen

Place the specimen(s) in the vacuum desiccator’s bowl. A maximum of 6 specimens can be
placed in one PR-1069 plastic desiccator and 16 in the PR-1070 glass desiccator. Clean the
edge of the lid and oil it slightly with silicone oil. Make sure stopcock is closed, see fig.2.
Place the lid on the bowl. Connect the hose from the vacuum pump to the valve below the
vacuum gauge and turn on the vacuum pump. Open the valve. Maintain the vacuum for 3
hours. Close the valve adjacent to the gauge. Turn off the vacuum pump.

Attach the supplied hose to the stopcock on the side of the desiccator and place the other
end in the container with the boiled water. Allow the de-aerated water to flow into the
desiccator by opening the stopcock slowly. The water must completely cover the
specimens. No air should be allowed to enter the desiccator.

Close the stopcock, start the vacuum pump and open the valve. Run the vacuum pump for
another hour.

Turn off the vacuum pump and remove the hose from the water container. Open the stopcock
slowly to allow air to enter into the desiccator. When water starts running back through
stopcock, close the stopcock.

Let the specimens soak in the container water for another 18 hours. Remove the lid together
with the moistened specimens. Blot the specimens dry with a cloth.

Fig. 2 illustrates the setup of the vacuum pump, desiccator with stopcock, vacuum gauge and
valve, and the de-aerated water container after the water has filled the desiccator.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 51
Installing gaskets with epoxy between gaskets and specimen

Epoxy between the gaskets and the specimen has to be applied if the concrete surface is rough or not
cylindrical, of if notches are present from saw cutting, or otherwise, if the cell cannot be made
watertight after assembling.

Apply a thin layer of silicone oil to the end faces and inner surfaces of the spacer. Position
the spacer centrally on the specimen for it to rest against the gasket. Govern the other
rubber gasket over the end of the specimen, again with a rotary motion until the gasket is
resting against the spacer. Remove any excess epoxy. Wait 5 minutes and turn the unit
upside down. To avoid water evaporation from the readymade moistened specimen, cover
the specimens with a plastic wrap or sheet and allow the epoxy to harden.

Oil with silicone oil slightly the side faces of the gaskets prior to mounting the gaskets in
the cell.

Place one cell part on the table with the groove upwards. Insert the installed gasket on the
specimen in the groove. Govern the other cell part on the upper gasket on the specimen to a
fully engaged position.

Make sure the black and the red terminal posts of the cell parts points in the same direction
of the cell parts.

Insert the four tightening bolts with washers in the cell holes and turn the cell to a vertical
position. Attach the washers/nuts and tighten opposite bolts/nuts using two 17 mm
wrenches. Finally, tighten the bolts/nuts firmly. The sealed, leak-free and surface-dry cell is
now ready for testing.

NOTICE: Do not tighten the bolts/nuts excessively. This will only damage the cell

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 52
Connecting the cells to the PROOVE’it Microprocessor Power Supply unit

Cell #1 is connected to channel #1 of the power supply unit, cell #2 to channel #2, etc. A
maximum of 8 cells can be tested simultaneously.
It is imperative that each cell is connected only to each channels power supply binding
posts. In other words, red jack to red binding post and black jack to black binding post.
Turning on and running the system
Turn on the microprocessor power supply unit by activating the switch on the back panel.
When switched on, the front panel’s on/off lamp will go from red to yellow after a few
seconds. If it stays red, the voltage supplied to the unit is either not stable or out of range of
the needed voltage supply to the unit (more of than +/- 15 VAC for 115 VAC mains or more
of than +/- 30 VAC for 220 VAC mains). The unit is not able to operate properly in such
cases. A proper line or main voltage has been found to solve the problem
SET-UP
1. Voltage of Channels : 60 V
2. Testing Time : 6 Hours
3. Specimen Diameter : 100 mm
4. Max. Temperature : 90 Deg C

Start Channel: To start the channels select the channel in question with the mouse or
press the Shift F-keys for each chan-nel.
Testing will proceed until the selected duration of time has been reached, the technician
stops the test or if the temperature of the liquid in the measuring cells exceed the
maximum temperature.
To avoid stopping the testing by an accident the channels are locked. Therefore the
channels has to be unlocked if it has to be stopped by the user.
Unlock Channel: The active channels are shown with black letters. To unlock a channel
select the channel in question with the mouse or press the Ctrl + F- keys for each channel.
When a channel is un-locked “Unlocked” will be indicated below the chan-nel number.
The channel test continues but now it can be stopped either for interrupting the test or to
prepare to print the data. After unlocking the channel can be stopped
STOP Channel: To stop a test the channel in question has to be stopped. Once a channel is
stopped it cannot be started again before resetting the chan-nel
When a channel is stopped it is possible to save the data and reset the channel. The data
will be saved in a database in Access
Reset Channel: to save the data from a test and/or reset the channel select the channel in
question. If the channels are not stopped, testing will proceed for the testing time selected
The status of the channels is FIN (finish) and the permeability class for each sample is
shown at the bottom row.
Once the results are saved for a channel the screen shown below will appear with a
confirmation.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 53
Turning off the system

To turn off the PROOVE’it© software make sure all channels are in the OFF-Status. Then
select File in the menu and Quit Program. The green indicator light on the power supply
unit will turn into yellow.

Turn off the power supply. Disconnect the cells from each channel set of binding posts.
Remove the temperature probes.

Report

To print a report with test data the PROOVE’it Report Manager utility is used. It can be
started either from using the REPORT in the menu shown below. Alternatively the
PROOVE’it Report Manager can be started from the folder Programs and then the
subfolder PROOVE’it in the Start-menu.

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 54
 REFERENCES

1. IS: 4031(Part-2, 4, 6 & 11)

2. IS: 4032-1985 /2004
3. IS: 3085-1965/2002
4. IS: 10262-2009
5. IS: 456-2000/2005
6. IS: 1199-1959/2004
7. IS: 516-1959/2004
8. IS: 13311 (Part 2) – 1992/2004
9. IS: 13311 (PART-1)-1992/2004
10. BS: 4449:1997
11. ISO: 10065:1990
12. IS: 1786-2008
13. AASHTO T277-83
14. ASTM C1202

Prepared By: M.L. Rathore (Lab Engineer), Department of Civil Engineering, JUET Guna (M.P.): 55