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MATERIALS TESTING AND QUALITY CONTROL SEMINAR for Philippine Rural Development Program January 12 – 16, 2015 BY ENG’R. ABNER GEORGE S. LOMIBAO THE UNIVERSAL CONSTRUCTION MATERIALS INSPECTION AND LABORATORY
POZZOLANIC PHILS, INC.
PORTLAND CEMENT CONCRETE
HISTORY OF CONCRETE ROMAN EMPIRE- Finely divided volcanic materials were blended with crudely slaked lime commonly called the “Pozzolanic Cement”) 1824- Joseph Aspdin discovered a powder in the Isle of Portland, England 20th Century- Portland Cement Concrete
PORTLAND CEMENT CONCRETE IS A COMPOSITE MATERIAL WHICH CONSIST ESSENTIALLY OF A BINDING MEDIUM WITHIN WHICH ARE EMBEDDED PARTICLES OR FRAGMENTS OF AGGREGATES
PORTLAND CEMENT CONCRETE INGREDIENTS PORTLAND CEMENT WATER AGGREGATES • COARSE AGGREGATES • FINE AGGREGATES
MINERAL ADMIXTURES CHEMICAL ADMIXTURES
Properties of Concrete Workability - the ease in which it can be placed, compacted, and finished. Consistency - to flow with respect to its state of fluidity. Plasticity is a degree of consistency. Uniformity - the ingredients are properly and uniformly distributed throughout the mass. Strength - to sustain loads imposed upon without failure.
Properties of Concrete Durability - to resist weathering action, chemical attack, abrasion, and other conditions to which it is subjected in service. Water-tightness or Impermeability – to resist the flow of water through its mass.
TESTING CONCRETE –TEST FOR FRESHLY MIXED CONCRETE 1. 2. 3. 4.
SLUMP TEST (ASTM C-172/143) UNIT WEIGHT (ASTM C-138) TIME OF SETTING (ASTM C-191) AIR CONTENT DETERMINATION (ASTM C-231)
THE CONCRETE SLUMP TEST-POINT OF NO RETURN SMALL MISTAKES CAUSE BIG TROUBLES -Poor sampling -Neglecting to dampen the cone -Improper rodding -Unstable base
-Wrong type of rod
THE CONCRETE SLUMP TEST-POINT OF NO RETURN • FILLING THE CONE
• RODDING • REMOVING THE CONE • MEASURING TNHE SLUMP
UNIT WEIGHT The weight per unit volume of concrete
Unit Weight =
Weight of Concrete Volume of Bucket
SETTING TIME Concrete sets in two stages: Initial Setting = Sieved Mortar reached a penetration resistance of 3.5 Mpa (500psi) Final Setting = Penetration resistance of 28Mpa (4000 psi)
AIR CONTENT Entrapped or Accidental Air in Concrete
Air Content can be determine using Air Content Apparatus
TESTING CONCRETE –TEST FOR HARDENED CONCRETE 1. 2. 3. 4. 5.
COMPRESSIVE STRENGTH TEST (ASTM C-39) FLEXURAL STRENGTH TEST (ASTM C-78) REBOUND HAMMER TEST (ASTM C-805) CORE TEST (ASTM C-42) LOAD TEST (ACI-318)
TESTING CONCRETE THE RIGHT WAY TO MAKE STRENGTH CYLINDERS (ASTM C-31/C-192) TAKE PROPER SAMPLES USE STANDARDS MOLDS FILL CYLINDER AND ROD CAREFULLY PROTECT CYLINDERS
TESTING CONCRETE COMPRESSIVE STRENGTH CYLINDERS (ASTM C-39) CAPPING OF CYLINDERS CS = P/A
TESTING CONCRETE Required Specification (ACI 318/DPWH) Strength level of Concrete shall be considered satisfactory if both of the following requirements are met: Average of all sets of three consecutive strength test results equal or exceed the specified Strength, fc´. No individual strength test result is deficient by more than 15% of the specified Strength, fc´.
TESTING CONCRETE - HOW TO MAKE FLEXURE BEAM SPECIMEN IN THE FIELD (ASTM C-31/C-192) SAMPLING MOLD ABOUT THE MOLD MOLDING PROCEDURES CURING
TESTING CONCRETE - FLEXURAL STRENGTH OF BEAM SPECIMEN (ASTM C-78) THIRD POINT LOADING FS = PL/bd² CENTER POINT LOADING FS = 3PL/2bd²
TESTING CONCRETE Required Specification (ACI 318/DPWH) Strength level of Concrete shall be considered satisfactory if both of the following requirements are met: Average of all sets of three consecutive strength test results equal or exceed the specified Strength, fc´. No individual strength test result is deficient by more than 15% of the specified Strength, fc´.
Rebound Hammer Test Report Design Strength is 3000 psi @ 28 days
A
B
C
D
E
F
G
SPOT NO
STRUCTURE TESTED
POSITION OF HAMMER
AVERAGE REBOUND NUMBER
ANVIL CORRECTION FACTOR
CORRECTED REBOUND NUMBER
EQUIVALENT COMPRESSIVE STRENGTH, PSI
1
Slab
DOWNWARD
26.00
1.025
27.00
3016
2
Slab
DOWNWARD
28.00
1.025
29.00
3548
3
Slab
DOWNWARD
27.00
1.025
28.00
3194
4
Slab
DOWNWARD
26.00
1.025
27.00
3016
Concrete Core Test (ASTM C42) Design Strength is 3000 psi @ 28 days ACTUAL LOCATION OF CORE
DIAMETE R
(mm)
LENGTH (mm) BEFOR E
AFTER
L/D
CAPPING
STRENGT H
CROSS
COMPRES SIVE
COMPRESSVE
CORRECTED
CORREC TION
SECTION AL
LOAD
STRENGTH
COMPRESSI VE
FACTOR
AREA, mm²
(KN)
Mpa
PSI
STRENGTH (Mpa) Psi
G-Rhyme JB 1
95.0
150.0
156.0
1.610
0.969
7088
60.0
8.5
1233
1194
G-Rhyme JB 2
95.0
150.0
156.0
1.626
0.970
7088
59.6
8.4
1218
1181
G-Rhyme JB 3
95.0
150.0
156.0
1.605
0.968
7088
43.7
6.2
899
870
Concrete Core Test (ASTM C42) Design Strength is 3000 psi @ 28 days CORE SAMPLE
ACTUAL LOCATION OF CORE
ID
DIAMET ER
(mm)
LENGTH (mm) BEFOR E
AFTE R
L/D
CAPPING
STRENGT H
CROSS
CORRECTI ON
SECTION AL
FACTOR
AREA, mm²
COMPRE SSIVE
(N)
COMPRES SVE
CORRECTE D
STRENGT H
COMPRESS IVE
(Mpa) Psi
STRENGTH (Mpa) Psi
C-1
Damaged
138
1.47
0.960
6940
175.5
25.3 (3669)
3522
C-2
Damaged 74.0
140
1.89
0.990
4301
30.7
7.1 (1030)
1020
74.0
115
1.55
0.964
4301
54.7
12.7 (1842)
1776
C-6
74.0
90
1.22
0.923
4301
31.1
7.2 (1044)
964
C-7
74.0
100
1.35
0.942
4301
56.6
13.2 (1914)
1803
C-8
74.0
155
2.09
1.000
4301
31.9
7.4 (1073)
1073
C-10
74.0
142
1.92
0.994
4301
17.4
4 .0 (577)
577
C-11
74.0
84
1.14
0.904
4301
29.3
6.8 (986)
891
C-12
74.0
71
1.00
0.870
4301
40.8
9.5 (1378)
1199
C-13
74.0
97
1.31
0.940
4301
61.8
14.4 (2088)
1963
C-4 C-5
With rebar
Concrete Core Test (ASTM C42) Design Strength is 3000 psi @ 28 days
CORE
SAMPL E
ACTUAL
LOCATION OF CORE
ID
DIAMET ER
(mm)
LENGTH (mm)
BEFOR E
AFTE R
L/D
CAPPING
STRENGTH
CROSS
CORRECTI ON
SECTION AL
FACTOR
AREA, mm²
COMPRE SSIVE
(N)
COMPRE SSVE
CORRECTED
STRENGT H
COMPRESSI VE
(Mpa) Psi
STRENGTH (Mpa) Psi
C-1
S - 3 CF CPI
99.0
99.0
1.00
0.870
7698
238700
31.0
(26.97) 3911
C-2
S - 3 CF CPI
99.0
147.0
1.50
0.960
7543
153900
20.4
(19.584) 2840
Concrete Core Test (ASTM C42) Required Specification (ACI 318) Concrete in an area represented by Core tests shall be considered structurally adequate if the average of three (3) Cores is equal or more than 85% of fc´ (Design or required Strength) and if no single Core is less than 75% of fc´ (Design or required Strength).
Load Test (ACI 318) Load Test of flexural members Structure must be 56 days old Loading shall be total load as per the Structural Engineer Initial Deflection reading after 24 hours Final Deflection reading 24 hours after the removal of the test load Visual Inspection of the structure
FACTORS AFFECTING THE STRENGTH CONCRETE
CURING CONDITIONS
AGE
CHARACTERISTICS OF THE CEMENT
QUANTITY OF THE CEMENT
QUANTITY OF THE MIXING WATER
FACTORS AFFECTING THE STRENGTH CONCRETE CHARACTERISTICS OF THE AGGREGATES TIME OF MIXING CONDITIONS OF TEST o o o
METHOD OF TAKING SAMPLE METHOD OF MAKING SPECIMEN CURING OF SPECIMEN
FACTORS AFFECTING THE STRENGTH CONCRETE o o o o o o
SIZE AND SHAPE OF THE TEST SPECIMEN IRREGULARITIES IN THE TEST SPECIMEN MOISTURE CONTENT OF THE TEST SPECIMEN CAPPING OF TEST SPECIMEN TYPE OF BEARING BLOCK RATE OF APPLICATION OF LOAD
AIR ENTRAINMENT
HOW TO AVOID ERRATIC RESULTS
Always use accepted standards 8 Steps to reliability 1. Sampling 2. Rodding 3. Strike off 4. Job Curing 5. Transportation to the laboratory 6. Laboratory moist room curing 7. Capping 8. Compression Testing
HOW TO AVOID ERRATIC RESULTS
Improper cure is fatal Rectify mistakes before they happen Avoid poor test practices.
Principal Sources of Variations in Strengths Test Results Variations in properties of concrete
Discrepancies in testing methods
Changes in water-cement ratio Poor control of water Excessive variation of moisture in aggregates Retempering
Improper sampling
Variations in water requirement Aggregate grading, absorption, particle shape Cement and admixture properties Delivery time and temperature
Variations due to fabrication techniques Cylinder molding Poor quality molds Handling and curing of newly made cylinders
Variations in characteristics and proportions of ingredients Aggregates Cement Pozzolans (Mineral Additives) Chemical admixtures
Changes in curing Temperature variation Variable moisture Delays in bringing cylinders to the laboratory
Variations in batching, mixing, transporting, placing, and compaction Variations in temperature and curing
Poor testing procedures Care of cylinders Transportation and capping Improper placement in testing machine Testing machine platens out of specification Incorrect speed of testing
POZZOLANIC PHILS, INC.
PORTLAND CEMENT CONCRETE
HISTORY OF CONCRETE ROMAN EMPIRE- Finely divided volcanic materials were blended with crudely slaked lime commonly called the “Pozzolanic Cement”) 1824- Joseph Aspdin discovered a powder in the Isle of Portland, England 20th Century- Portland Cement Concrete
PORTLAND CEMENT CONCRETE IS A COMPOSITE MATERIAL WHICH CONSIST ESSENTIALLY OF A BINDING MEDIUM WITHIN WHICH ARE EMBEDDED PARTICLES OR FRAGMENTS OF AGGREGATES
PORTLAND CEMENT CONCRETE INGREDIENTS PORTLAND CEMENT WATER AGGREGATES • COARSE AGGREGATES • FINE AGGREGATES
MINERAL ADMIXTURES CHEMICAL ADMIXTURES
Properties of Concrete Workability - the ease in which it can be placed, compacted, and finished. Consistency - to flow with respect to its state of fluidity. Plasticity is a degree of consistency. Uniformity - the ingredients are properly and uniformly distributed throughout the mass. Strength - to sustain loads imposed upon without failure.
Properties of Concrete Durability - to resist weathering action, chemical attack, abrasion, and other conditions to which it is subjected in service. Water-tightness or Impermeability – to resist the flow of water through its mass.
TESTING CONCRETE –TEST FOR FRESHLY MIXED CONCRETE 1. 2. 3. 4.
SLUMP TEST (ASTM C-172/143) UNIT WEIGHT (ASTM C-138) TIME OF SETTING (ASTM C-191) AIR CONTENT DETERMINATION (ASTM C-231)
THE CONCRETE SLUMP TEST-POINT OF NO RETURN SMALL MISTAKES CAUSE BIG TROUBLES -Poor sampling -Neglecting to dampen the cone -Improper rodding -Unstable base
-Wrong type of rod
THE CONCRETE SLUMP TEST-POINT OF NO RETURN • FILLING THE CONE
• RODDING • REMOVING THE CONE • MEASURING TNHE SLUMP
UNIT WEIGHT The weight per unit volume of concrete
Unit Weight =
Weight of Concrete Volume of Bucket
SETTING TIME Concrete sets in two stages: Initial Setting = Sieved Mortar reached a penetration resistance of 3.5 Mpa (500psi) Final Setting = Penetration resistance of 28Mpa (4000 psi)
AIR CONTENT Entrapped or Accidental Air in Concrete
Air Content can be determine using Air Content Apparatus
TESTING CONCRETE –TEST FOR HARDENED CONCRETE 1. 2. 3. 4. 5.
COMPRESSIVE STRENGTH TEST (ASTM C-39) FLEXURAL STRENGTH TEST (ASTM C-78) REBOUND HAMMER TEST (ASTM C-805) CORE TEST (ASTM C-42) LOAD TEST (ACI-318)
TESTING CONCRETE THE RIGHT WAY TO MAKE STRENGTH CYLINDERS (ASTM C-31/C-192) TAKE PROPER SAMPLES USE STANDARDS MOLDS FILL CYLINDER AND ROD CAREFULLY PROTECT CYLINDERS
TESTING CONCRETE COMPRESSIVE STRENGTH CYLINDERS (ASTM C-39) CAPPING OF CYLINDERS CS = P/A
TESTING CONCRETE Required Specification (ACI 318/DPWH) Strength level of Concrete shall be considered satisfactory if both of the following requirements are met: Average of all sets of three consecutive strength test results equal or exceed the specified Strength, fc´. No individual strength test result is deficient by more than 15% of the specified Strength, fc´.
TESTING CONCRETE - HOW TO MAKE FLEXURE BEAM SPECIMEN IN THE FIELD (ASTM C-31/C-192) SAMPLING MOLD ABOUT THE MOLD MOLDING PROCEDURES CURING
TESTING CONCRETE - FLEXURAL STRENGTH OF BEAM SPECIMEN (ASTM C-78) THIRD POINT LOADING FS = PL/bd² CENTER POINT LOADING FS = 3PL/2bd²
TESTING CONCRETE Required Specification (ACI 318/DPWH) Strength level of Concrete shall be considered satisfactory if both of the following requirements are met: Average of all sets of three consecutive strength test results equal or exceed the specified Strength, fc´. No individual strength test result is deficient by more than 15% of the specified Strength, fc´.
Rebound Hammer Test Report Design Strength is 3000 psi @ 28 days
A
B
C
D
E
F
G
SPOT NO
STRUCTURE TESTED
POSITION OF HAMMER
AVERAGE REBOUND NUMBER
ANVIL CORRECTION FACTOR
CORRECTED REBOUND NUMBER
EQUIVALENT COMPRESSIVE STRENGTH, PSI
1
Slab
DOWNWARD
26.00
1.025
27.00
3016
2
Slab
DOWNWARD
28.00
1.025
29.00
3548
3
Slab
DOWNWARD
27.00
1.025
28.00
3194
4
Slab
DOWNWARD
26.00
1.025
27.00
3016
Concrete Core Test (ASTM C42) Design Strength is 3000 psi @ 28 days ACTUAL LOCATION OF CORE
DIAMETE R
(mm)
LENGTH (mm) BEFOR E
AFTER
L/D
CAPPING
STRENGT H
CROSS
COMPRES SIVE
COMPRESSVE
CORRECTED
CORREC TION
SECTION AL
LOAD
STRENGTH
COMPRESSI VE
FACTOR
AREA, mm²
(KN)
Mpa
PSI
STRENGTH (Mpa) Psi
G-Rhyme JB 1
95.0
150.0
156.0
1.610
0.969
7088
60.0
8.5
1233
1194
G-Rhyme JB 2
95.0
150.0
156.0
1.626
0.970
7088
59.6
8.4
1218
1181
G-Rhyme JB 3
95.0
150.0
156.0
1.605
0.968
7088
43.7
6.2
899
870
Concrete Core Test (ASTM C42) Design Strength is 3000 psi @ 28 days CORE SAMPLE
ACTUAL LOCATION OF CORE
ID
DIAMET ER
(mm)
LENGTH (mm) BEFOR E
AFTE R
L/D
CAPPING
STRENGT H
CROSS
CORRECTI ON
SECTION AL
FACTOR
AREA, mm²
COMPRE SSIVE
(N)
COMPRES SVE
CORRECTE D
STRENGT H
COMPRESS IVE
(Mpa) Psi
STRENGTH (Mpa) Psi
C-1
Damaged
138
1.47
0.960
6940
175.5
25.3 (3669)
3522
C-2
Damaged 74.0
140
1.89
0.990
4301
30.7
7.1 (1030)
1020
74.0
115
1.55
0.964
4301
54.7
12.7 (1842)
1776
C-6
74.0
90
1.22
0.923
4301
31.1
7.2 (1044)
964
C-7
74.0
100
1.35
0.942
4301
56.6
13.2 (1914)
1803
C-8
74.0
155
2.09
1.000
4301
31.9
7.4 (1073)
1073
C-10
74.0
142
1.92
0.994
4301
17.4
4 .0 (577)
577
C-11
74.0
84
1.14
0.904
4301
29.3
6.8 (986)
891
C-12
74.0
71
1.00
0.870
4301
40.8
9.5 (1378)
1199
C-13
74.0
97
1.31
0.940
4301
61.8
14.4 (2088)
1963
C-4 C-5
With rebar
Concrete Core Test (ASTM C42) Design Strength is 3000 psi @ 28 days
CORE
SAMPL E
ACTUAL
LOCATION OF CORE
ID
DIAMET ER
(mm)
LENGTH (mm)
BEFOR E
AFTE R
L/D
CAPPING
STRENGTH
CROSS
CORRECTI ON
SECTION AL
FACTOR
AREA, mm²
COMPRE SSIVE
(N)
COMPRE SSVE
CORRECTED
STRENGT H
COMPRESSI VE
(Mpa) Psi
STRENGTH (Mpa) Psi
C-1
S - 3 CF CPI
99.0
99.0
1.00
0.870
7698
238700
31.0
(26.97) 3911
C-2
S - 3 CF CPI
99.0
147.0
1.50
0.960
7543
153900
20.4
(19.584) 2840
Concrete Core Test (ASTM C42) Required Specification (ACI 318) Concrete in an area represented by Core tests shall be considered structurally adequate if the average of three (3) Cores is equal or more than 85% of fc´ (Design or required Strength) and if no single Core is less than 75% of fc´ (Design or required Strength).
Load Test (ACI 318) Load Test of flexural members Structure must be 56 days old Loading shall be total load as per the Structural Engineer Initial Deflection reading after 24 hours Final Deflection reading 24 hours after the removal of the test load Visual Inspection of the structure
FACTORS AFFECTING THE STRENGTH CONCRETE
CURING CONDITIONS
AGE
CHARACTERISTICS OF THE CEMENT
QUANTITY OF THE CEMENT
QUANTITY OF THE MIXING WATER
FACTORS AFFECTING THE STRENGTH CONCRETE CHARACTERISTICS OF THE AGGREGATES TIME OF MIXING CONDITIONS OF TEST o o o
METHOD OF TAKING SAMPLE METHOD OF MAKING SPECIMEN CURING OF SPECIMEN
FACTORS AFFECTING THE STRENGTH CONCRETE o o o o o o
SIZE AND SHAPE OF THE TEST SPECIMEN IRREGULARITIES IN THE TEST SPECIMEN MOISTURE CONTENT OF THE TEST SPECIMEN CAPPING OF TEST SPECIMEN TYPE OF BEARING BLOCK RATE OF APPLICATION OF LOAD
AIR ENTRAINMENT
HOW TO AVOID ERRATIC RESULTS
Always use accepted standards 8 Steps to reliability 1. Sampling 2. Rodding 3. Strike off 4. Job Curing 5. Transportation to the laboratory 6. Laboratory moist room curing 7. Capping 8. Compression Testing
HOW TO AVOID ERRATIC RESULTS
Improper cure is fatal Rectify mistakes before they happen Avoid poor test practices.
Principal Sources of Variations in Strengths Test Results Variations in properties of concrete
Discrepancies in testing methods
Changes in water-cement ratio Poor control of water Excessive variation of moisture in aggregates Retempering
Improper sampling
Variations in water requirement Aggregate grading, absorption, particle shape Cement and admixture properties Delivery time and temperature
Variations due to fabrication techniques Cylinder molding Poor quality molds Handling and curing of newly made cylinders
Variations in characteristics and proportions of ingredients Aggregates Cement Pozzolans (Mineral Additives) Chemical admixtures
Changes in curing Temperature variation Variable moisture Delays in bringing cylinders to the laboratory
Variations in batching, mixing, transporting, placing, and compaction Variations in temperature and curing
Poor testing procedures Care of cylinders Transportation and capping Improper placement in testing machine Testing machine platens out of specification Incorrect speed of testing
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