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CONCRETE TESTING

In this manual we will cover 2 main types of concrete testing. Namely: 1. The Slump Test The slump test shows the WORKABILITY of the concrete. Workability measures how easy the concrete is to place, handle and compact. 2. The Cube Test The cube test measures concrete strength in its hardened state. Testing should always be done very carefully and in relation to the specified Company and SABS procedures. Failure to abide by the testing procedures may lead to the incorrect results being obtained and recorded. Incorrect test results can be costly for the Company, this is why it is very IMPORTANT that you ALWAYS follow the CORRECT procedure when testing concrete. Concrete Sampling: The first step is to take a test sample from the middle of the mixer truck. We take 2 samples from the mixer truck. The one is used for Slumps and the other second is used for making cubes. The sample should be representative (all the same) of the concrete supplied. The sample is taken for 2 reasons: 1. 2. Method: For the purpose of accepting or rejecting the load: For routine quality checks:

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Slump Test: The slump test is done to make sure a concrete mix is workable. The measured slump must be within a set range or tolerance from the target slump. Tools Required: 1. Standard Slump Cone (100mm top diameter X 200mm bottom diameter X 300 mm high) 2. Small Scoop 3. Bullet Nose Rod (600mm long X 16mm diameter) 4. Ruler 5. Slump Plate (500mm X 500m)

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Slump Test Method: 1. Clean the cone. Dampen with water and place it on the slump plate. The slump plate MUST be clean, firm, level and non-absorbent. 2. 3. Collect a sample (see page 2 of this manual) Stand firmly on the foot pieces of the cone. (Why? So that it does not move and disturb the results of the test).

Fill 1/3 of the cone with the sample. Compact the concrete by rodding 25 times.

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Definition of Rodding:Means to push a steel rod in and out of the concrete to compact it into the slump cone. Always rod in a definite pattern, working from the outside into the middle. Do not touch the base plate when tamping. 4. Now fill to 2/3 and again rod 25 times, just into the top of the first layer.

5.

Fill to overflowing, rodding again this time just into the top of the second layer. Top up the cone till it overflows.

6.

Level off the surface with the steel rod using a rolling action. Clean any concrete from around the base and top of the cone, push own on the handles and step off the foot pieces.

7.

Carefully lift the cone straight up making sure not to move the sample.

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8.

Turn the cone upside down and place the rod across the up-turned cone

9.

Take several measurements and report the average distance to the top of the sample. Measure from the highest point to the underside of the rod. (A is correct)

10.

If the sample fails by being outside the tolerance (ie: slump is too high or too low), another must be taken. If this also fails then the remainder of the batch should be rejected. Plant Assistants must report the results of slump test to the Batcher at the Plant. This information must be recorded on the cube making sheet.

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Cube Making: Concrete cubes are made to check that the strength of the concrete is above the minimum strength, which has been specified. Making, curing and testing cubes should be carried out in the correct manner. Even small changes from the standard procedures will usually lead to compressive strength results, which are lower than the true strength of the concrete. Example: For each 1% of air entrapped in the cube there will be 4% to 5% loss of strength. Equipment Required: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Moulds for making test cubes 4 in a set Spanners Scoop Steel float or trowel Tamping Rod Vibrating hammer or vibrating table Cleaning rags A bucket or barrow for transporting the samples Polythene sheeting Curing tank Thermometer Square Release oil Wire brush Labels

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Cube Making Procedure: 1. Ensure that the cube moulds are cleaned, properly assembled (bolted firmly together and held down on the base plate) and square, coated with a thin layer of mould release oil. (Be sure NOT to apply too much release oil) Place the moulds on a flat surface.

2. Taking a representative sample from the Readymix Truck, place this concrete in the cube moulds in layers of 50mm. Sizes of Cube Moulds:

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150mm Concrete Cubes: Fill the mould in 3 layers of equal depth and tamp each layer at least 45 times uniformly over the surface of the concrete with the steel-tamping rod. The tamping rod must NOT strike the bottom of the mould forcibly and must NOT penetrate (touch) the previous layers by more than about 10mm. When compacting dry or stony concrete, it may be necessary to tamp each layer more than the above number of times to ensure full compaction.

100mm Concrete Cubes: Fill the mould in 2 layers of equal depth and tamp each layer at least 20 times uniformly over the surface of the concrete with the steel-tamping rod. The tamping rod must NOT strike the bottom of the mould forcibly and must NOT penetrate (touch) the previous layers by more than about 10mm. When compacting dry or stony concrete, it may be necessary to tamp each layer more than the above number of times to ensure full compaction.

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3.

When the final layer has been tamped, level the surface and smooth it off using a float or trowel.

For a valid test, 3 cubes are needed for testing at any age. We test cubes at 7 and 28 days (as is normal), 4 cubes must be made from the batch. Label the cubes. The absorbent paper label must be placed on the top surface of the cube. It must have the date of casting, cube number, delivery note number on it. Cover the set of cube moulds. Strip the cube moulds first thing the next morning and place it in a curing tank at a temperature of 22C to 25C. The cubes must be COMPLETELY COVERED in water. Remove the cubes from the curing tank just before the testing takes place. Do not allow the cubes to dry out at any time.

IMPORTANT - Special Mixes: For very dry concrete notify the Technical Department.

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6. Crush the cubes at the required age eg: 3, 7 or 28 days. Cubes must be crushed by an approved Laboratory. If cubes have to be transported to the testing Laboratory then place them on a rubber mat, cover them with a damp sack and make sure they cannot be thrown around. Cube Crushing:

The test cubes are placed in a cube crushing machine as shown above. A certain pressure is applied to cube and the strength measured when the cube crushes. NOTE: If the cubes have not been compacted properly or are not square the whole exercise will be a waste of time, as the correct strength will NOT be obtained. (The Technician in the Lab will demonstrate the procedure) Pictures of cubes: 1. Perfect Cube (View at Laboratory) 2. Out of square cube: (View at Laboratory) 3. Badly made cube: (View at Laboratory)

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