CONCRETE LABORATORY

REPORT

Ruqaya Aljabery – H00234387

Civil Engineering (BEng) – year 2
Civil Engineering Materials – D28MA
Submission Due Date: April 20, 2017
Submit to Dr. Olisanwendu Ogwuda

2017
HERIOT WATT UNIVERSITY
DIAC
 Contents
1. Introduction ........................................................................................................................ 2
2. Theory................................................................................................................................. 2
2.1 Concrete ........................................................................................................................... 2
2.2 Advantages of Concrete .............................................................................................. 2
2.3 Hydration of cement ......................................................................................................... 3
3. Procedure ............................................................................................................................... 3
3.1 Materials ........................................................................................................................... 3
3.2 Apparatus ......................................................................................................................... 4
3.3 Mix Design ....................................................................................................................... 6
3.4 Experimental Procedure and Method of Test ................................................................... 7
4. Results .................................................................................................................................... 8
4.1 Sample Calculations (Density & Strength) .................................................................... 10
4.2 Strength Percentage Error .............................................................................................. 10
5. Discussion ............................................................................................................................ 11
5.1 Concrete workability and slump test .............................................................................. 11
5.2 Concrete Curing and Hydration ..................................................................................... 12
5.3 Concrete Strength ........................................................................................................... 12
6. Conclusion ........................................................................................................................... 12
7. References ............................................................................................................................ 13

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 1. Introduction

This report revolves about the process of making and testing 6 (150mm) concrete cubes in the
laboratory in accordance with a mixing ratio of 1:1:2 with water-cement (w/c) ratio of 0.4 and
targeted strength of 50 MPa.
The aim of the laboratory is to understand the composition, constituents of concrete, understand
the mix proportions and test both fresh and hardened concrete. In addition to understanding the
behavior (failure) of a concrete cube under compression, analyzing and discussing data
obtained. As well as helping the students to gain experience of the process of casting concrete
and working in a laboratory environment.

2. Theory
2.1 Concrete

Concrete is ‘a composite material that consists essentially of a binding medium, such as a

mixture of Portland Cement and water, within which are embedded particles or fragments of
aggregate, usually a combination of fine and coarse aggregate.’1 ‘When aggregate is mixed
together with dry Portland cement and water, the mixture forms a fluid slurry that is easily
poured and molded into shape. The cement reacts chemically with the water and other
ingredients to form a hard matrix that binds the materials together into a durable stone-like
material that has many uses.’2 Some chemical admixtures can be added to improve the
material’s properties and its behavior. Since the concrete is weak in tension, it can be poured
into moulds with reinforcement bars to increase its tensile strength.

2.2 Advantages of Concrete

Concrete is a widely-used construction material due to its unique properties. The quality and/
or properties of the concrete are dependent on the proportion of the ingredients, the way of
mixing, curing and placing them. Concrete has many advantages, e.g. it can be casted into
any shape, and when it is hardened it becomes a load bearing element. It is a non-combustible
material so it can withstand high temperatures. In addition to its durability and requirement of
low maintenance compared to other construction materials.
To identify the strength of a concrete cube at the failure load; the following formula can be
used.
𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝐿𝑜𝑎𝑑
𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ = 𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑆𝑡𝑟𝑒𝑠𝑠 =
𝐴𝑟𝑒𝑎

1
C. Meyer, “Concrete”, McGraw-Hill Encyclopedia of Science & Technology, 10th Ed., Vol. 4, pp 599-604,
2007.
2
Zongjin Li; Advanced concrete technology; 2011

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After applying a load on a specimen, its dimensions will be affected, and can be calculated
using the following formula.

𝐶ℎ𝑎𝑛𝑔𝑒 𝑖𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑁𝑒𝑤 𝑙𝑒𝑛𝑔𝑡ℎ − 𝑂𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ

𝑆𝑡𝑟𝑎𝑖𝑛 = =
𝑂𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ 𝑂𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ

2.3 Hydration of cement

Hydration of cement is the process when water reacts with cement to form a strong/ hard bond
and as a result, it starts to gain strength. Hydration of cement starts with the dissolution of
cement into water, where it releases ions. Early hydration might happen, within few minutes
of mixing, due to the hydration of tricalcium aluminate (C3A) which provides little strength
after 7 days. C3A and C2S are responsible for strength development.
All reactions are written below;
 2C3S + 4H = C3S2H3 + 3Ca(OH)2 (calcium silicate hydrate + calcium hydroxide)
FAST
 2C2S + 4H = C3S2H3 + Ca(OH)2 (calcium silicate hydrate + calcium hydroxide)
SLOW
 C3A + 6H = C3AH6 (calcium aluminate hydrate)

3. Procedure
3.1 Materials

The materials that have been used in this mix are:

 Ordinary Portland cement (OPC), (CEM I): grey in color and has been used as a binder
in the concrete mix;

 coarse aggregate: is the result of natural disintegration and crushed stones. In this mix,
it has been used in a saturated surface dry condition, where water will neither enter nor
leave the cement paste. Aggregates’ sizes of 20 mm and 10 mm in the ratio of 2:1
respectively have been used;

 fine aggregate (sand) and;

 water: is the key of life. It controls the properties of both fresh and hardened concrete,
i.e. it increases the workability in the concrete’s mixture, however, it reduces its
compressive strength when hardened, since the strength is inversely proportional to
w/c ratio. Because of that, the amount of water in concrete must be controlled and
limited.

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 All ingredients are shown in the figures below, and the materials’ proportions are stated in
section 3.3. mix design.

Figure 1: CEM I Figure 2: Coarse Aggregates

Figure 3: Fine Aggregates Figure 4: Water

3.2 Apparatus

 Scales have been used to weigh the dry materials and concrete cubes. See figure 1.
 Graduated cylinder has been used to measure water volume, as shown in figure 2.
 MP2 grease has been used to coat the 6 moulds before curing the concrete mix into
them.
 Concrete pan mixer has been used to mix both dry and wet mixes. See figure 3.
 Slump cone, shown in figure 4, has been used to measure the slump, which identifies
the workability of the mix.
 Vibrating table has been used to get rid of excess air (air bubbles) from the concrete
specimens. See figure 5.
 A ruler has been used to record the concrete cubes’ dimensions and slump value.
 Concrete compression machine, which is shown in figure 6, has been used to test
concrete’s strength.

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Figure 5: Scale Figure 6: Graduated Cylinder

Figure 7: MP2 Grease Figure 8: Concrete Pan Mixer

Figure 9: Slump Cone Figure 10: Compression Machine

Figure 11: Vibrating Table

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 3.3 Mix Design

The concrete mix has been prepared according to the mass ratio of 1:1:2 (cement : fine
aggregate : coarse aggregate) with w/c of 0.4. The mass of each material has been calculated
below.

Assumptions:
 Density of cement (CEM I) = 3150 kg/m3
 Density of fine and coarse aggregates = 2600 kg/m3
 Density of water = 1000 kg/m3
 No. of cubes = 6
 Dimensions of each cube = 150 mm×150 mm×150 mm
 Sum of concrete cubes’ volume = mix’s volume

𝑀𝑎𝑠𝑠
𝑉𝑜𝑙𝑢𝑚𝑒 =
𝐷𝑒𝑛𝑠𝑖𝑡𝑦
𝑥 𝑥 2𝑥 0.4𝑥
+ + + = 0.153 × 6
3150 2600 2600 1000

Where 𝑥 = mass of cement (CEM I), (kg)

 𝑥=10.82 kg
After adding 20% of the ingredients;
 𝑥= 10.82 + (0.20×10.82) = 12.98 kg ≈ 13 kg
Coarse aggregate (20 mm to 10 mm ratio is 2:1 respectively):
 From the calculations above, coarse aggregate’s total mass is 26 kg. So, 20 mm
aggregate and 10 mm aggregate is 2/3 and 1/3 of the coarse aggregate’s total mass
respectively.

Ingredients’ masses are presented in table 1.

Table 1: Ingredients’ Masses

Ingredient CEM I Fine aggregate 20 mm aggregate 10 mm aggregate Water

Mass (kg) 13 13 17.33 8.67 5.2

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 3.4 Experimental Procedure and Method of Test

3.4.1 Fresh Concrete

The experimental procedure has been started with weighing the ingredients. All dry ingredients
have been added together and mixed by a concrete pan mixer, which is shown in figure 8, for
30 seconds. 20% of water have been added to the mix and mixed for another 30 seconds. The
mixture has been mixed for 2 minutes while gradually adding water. When the desirable
consistency has been reached, the mixture has been mixed for further 1 minute. After that, the
mixture has been poured into the concrete slump cone until 1/3 full to conduct the slump test.
The concrete layer has been tamped by a tamping rod 25 times evenly. Another layer of
concrete has been poured into the concrete slump cone until 2/3 full and tamped 25 times. The
cone has been filled completely and tamped 25 times. The cone has been removed, and the
difference between the heights, i.e. original height and the height after slumping, of the mixture
has been measured by a ruler. The slump value should be between 50-155 mm. The first slump
value was zero, so 1 L of water has been added to the mixture to increase its workability. After
that, the mixture has been mixed again by the concrete pan mixer and the slump test took place
again. The workability of the mixture had to be increased, so 0.5 L more of water has been
added to the mixture and the previous procedure has been done. All slump values are presented
in table 2.
The concrete mix has been used to cast six concrete cubes. First, the 6 cubic moulds have been
prepared by cleaning and tightening them. In addition to that, the inner surface of the 6 moulds
have been coated with MP2 grease, to prevent the friction between concrete mix and moulds’
surface. The concrete mixture has been poured into the 6 moulds. Each mould has been put on
the vibrating table for 1 minute to even the top layer and get rid of excess air (air bubbles) and
becomes fully compacted, i.e. achieving the maximum density. The moulds have been
demoulded after 24 hours, then, they have been immersed in water in the curing tank. Three of
them have been tested after 7 days, and three of them after 28 days.

3.4.2 Hardened Concrete

After 7 days, 3 cubes have been taken out from the curing tank. The dimensions of each cube
and the weight have been recorded before the destructive test of concrete takes place. The
destructive test was done by concrete compression machine, which applies a gradually
compressive load until failure. The concrete cube specimen has been put inside the machine.
Two of the smooth surfaces of the cube have been adjusted to be in the center and against the
loading platens. Then, the machine started to compress the concrete cube until it has been
cracked. The maximum compressive load and maximum pressure, at failure, have been
recorded. This test has been done to the other two cubes.
After 28 days, the remaining 3 cubes have been taken out from the curing tank, same procedure
and test have been done.

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 Table 2: Slump Values

Slump test no. Slump value (mm)

1 14
2 42.5
3 55

4. Results

The 6 cubes have been compressed by compression machine, one by one, until they have started
to crack. Tables 3 and 4 show all the information that are related to the concrete cubes.

Table 3: Experiment Results

Slump, 7-Day test results 28-Day test results

Group Density &
w/c ratio Cube 1 Cube 2 Cube 3 Cube 1 Cube 2 Cube 3

Slump (mm) mass (g) mass (g) = mass (g) mass (g) mass (g) mass (g) =
= 55 = 7640 7793.5 =7867.5 =7897 =7737 7845

Group 3 Density Density Density Density Density Density Density

(kg/m3) (kg/m3) (kg/m3) = (kg/m3) = (kg/m3) = (kg/m3) = (kg/m3) =
(Mix 3) = 2263.7 2309.18 2331.11 2339.85 2292.44 2324.44
1:1:2 mix
Failure Failure Failure Failure Failure Failure
New w/c load load (kN) load (kN) load (kN) load (kN) load (kN)
ratio* = 0.5 (kN) = = 643.3 = 659.0 = 767.6 = 736 = 639
647.3

*New w/c ratio:

 Water amount added = 1.5 L = 1.5 kg
1.5 + 5.2
𝑁𝑒𝑤 𝑤⁄𝑐 𝑅𝑎𝑡𝑖𝑜 = = 0.5
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Table 4: Strength Values

Slump (mm) 7-Day test results 28-Day test results

Group & w/c
ratio Cube 1 Cube 2 Cube 3 Cube 1 Cube 2 Cube 3

Group 3 Slump (mm) Strength Strength= Strength= Strength= Strength= Strength=

= 55 = 28.768 28.59 29.28 MPa 34.11 32.71 28.4 MPa
(Mix 3) & w/c = 0.5 MPa MPa MPa MPa
1:1:2 mix

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Load vs time curve, which is shown in figure 12, has been obtained from the compression
machine when cube 1 has been tested after 7 days.

Figure 12: Load vs Time Curve

After compressing the concrete cubes, they have been taken out of the machine. Figures 13 and
14 below show cube’s 1 cracks after the 7-days test and its core.

Figure 13: Cracks Figure 14: Core

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The stress-strain curve couldn’t be obtained from
compression machine. Figure 15 shows a general stress-
strain curve for a brittle material, i.e. concrete.
 From points 1 to 2 the elastic range takes place,
where the material can return to its original shape
and there is a linear relationship between stress and
strain.

 Point 4 is the fracture point where the failure load

takes place, e.g. for cube 1 (7-days test), the failure
load is 28.77 MPa.
Figure 15: Stress vs Strain Curve (Team
Urban Siege [online])

4.1 Sample Calculations (Density & Strength)

 Density (Cube 1), (7-Days test);

𝑀𝑎𝑠𝑠 7.64
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = = = 2263.7 𝑘𝑔/𝑚3
𝑉𝑜𝑙𝑢𝑚𝑒 0.153

 Strength (Cube 1), (7-Days test);

𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝐿𝑜𝑎𝑑 647.3 × 103

𝐹𝑎𝑖𝑙𝑢𝑟𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ = = = 28.768 𝑀𝑃𝑎
𝐴𝑟𝑒𝑎 1502

 Average strength (7-days test);

28.76 + 28.59 + 29.28

𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ𝑎𝑣𝑔 = = 28.87 𝑀𝑃𝑎
3

 Average strength (28-days test);

34.11 + 32.71 + 28.4

𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ𝑎𝑣𝑔 = = 31.74 𝑀𝑃𝑎
3

4.2 Strength Percentage Error

The percentage error in the experimental strength is calculated below;

𝐸𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 𝑉𝑎𝑙𝑢𝑒 − 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑉𝑎𝑙𝑢𝑒

𝐸𝑟𝑟𝑜𝑟 % =
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑉𝑎𝑙𝑢𝑒

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Where the theoretical value = standard strength = 50 MPa
7-days test;
 Cube 1=
28.768 − 50
× 100 = −42.464 %
50

 Cube 2 = - 42.82 %
 Cube 3 = - 41.44 %

28-days test;
 Cube 1 = - 31.78 %
 Cube 2 = - 34.58 %
 Cube 3 = - 43.2 %

5. Discussion

5.1 Concrete workability and slump test

Concrete workability is defined by American Concrete Institute (ACI) as ‘that property of

freshly mixed concrete which determines the ease and homogeneity with which it can be
mixed, placed, consolidated and finished’3
Higher slump value means higher workability. In this experiment, slump test has been
conducted three times, since the desired slump values, i.e. 50-150 mm, have not been
obtained from the first test. Many factors can affect the concrete workability, like;
 shape of aggregates: flaky, elongated and angular aggregates reduce the workability
as compared to rounded aggregates. Since angular aggregates have been used in this
experiment, the workability has been reduced. However, the strength has been
increased.

 grading of aggregates: good grading results in less voids, hence, more cohesive/
lubricant concrete mixture.

 w/c ratio: higher w/c ratio results in higher workability.

3
ACI Standard 116R-90 (ACI 1990b)

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 5.2 Concrete Curing and Hydration

Curing is known as the process of controlling/ providing moisture in concrete and time to
achieve the required/ desired concrete properties. In this experiment, 3 specimens have been
cured in water for 7 days, and 3 specimens for 28 days. By comparing the compressive test
results, the compressive strength for the 28-days specimens is higher. So, concrete strength is
directly proportional to age (i.e. time of curing).

5.3 Concrete Strength

The standard strength of mix 3 (1:1:2) is 50 MPa, however, the average strength of the cubes
after 7 days is 28.87 MPa while after 28 days is 31.74 MPa. The discrepancy between strength
values, i.e. standard and obtained strength values, is due to the addition of more water. Since
more water has been added while mixing the fresh concrete to increase its workability, the w/c
ratio increases and the strength decreases. Inaccuracy while weighing the materials, the quality
of the cement that has been used and the existence of air into the concrete cubes can affect the
overall strength as well. Moreover, the laboratory’s temperature plays a role in curing of
concrete, hence its strength.

6. Conclusion

Concrete is a highly heterogeneous material, mainly consisted of cement, aggregates, water

and sometimes admixtures that can improve concrete properties or change its behavior. The
concrete mixture can gain strength within few minutes of mixing. Generally, there is a
proportional relationship between strength and age (minutes, days etc.)
The experiment has been started by weighing the required ingredients and preparing the
moulds. All the materials have been mixed then cured, using the appropriate equipment and
machines. The strength of the concrete specimens has been tested, however, the standard
strength value has not been met by the concrete strength value obtained. That discrepancy is
due to some factors that have affected concrete mixture, e.g. w/c ratio, quality of cement,
properties of aggregates, surrounding temperature and inaccuracy while weighing the
ingredients.

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 7. References

1. Team Urban Siege, Medieval Destruction in the Modern Era. 2006. Material
Properties. [ONLINE] Available at: http://teamurbansiege.com/designing-
trebuchets/material-properties.html. [Accessed 19 April 2017].

2. CivilBlog.Org. What Are the Factors Affecting Workability of Concrete? [online]

Available at: http://civilblog.org/2014/04/04/what-are-the-factors-affecting-
workability-of-concrete/ [Accessed 19 April 2017].

3. Civil Engineering Materials, D28MA. Concrete Laboratory Handouts. January 2017.

4. American Concrete Institute (ACI) Standard 116R-90 (ACI 1990b)

5. C. Meyer, “Concrete”, McGraw-Hill Encyclopedia of Science & Technology, 10th

Ed., Vol. 4, pp 599-604, 2007.

6. Zongjin Li; Advanced concrete technology; 2011.

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