CHAPTER 3

MATERIALS AND TESTING METHODS

3.1. Materials
In this study, high performance concrete is made up of materials which are
available from construction material markets in our country. They are local cement
(Crown Brand), coarse aggregate from Htone Pho, sand from Ayeyarwaddy river,
class C fly ash (Triple Dragon Brand), superplasticizer (Sikament-520). Firstly, some
physical test of these materials such as fineness, specific gravity, consistency,
absorption and setting time are made.

3.2. Testing of Cement

Before making trial mix, the physical tests of sample cement have been made
by using appropriate methods. In this study, fineness, soundness, specific gravity,
consistency, strength and setting time of cement are tested.

3.2.1. Fineness Test of Cement (Blaine Air Permeability Method)

Fineness refers to the size of cement particles directly affect the hydration,
setting and hardening, shrinkage, strength and heat of hydration. There are several
methods available for the measurement of fineness [Kester 19631]. In this study,
fineness of cement is tested by Blaine air permeability method. From test result, the
fineness of local cement (Crown Brand) is 4356 cm2/gm.

Figure 3.1. Blaine Air Permeability Apparatus

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3.2.2. Specific Gravity of Cement (ASTM C 188)

Specific gravity of cement is determined on the material as received, unless
otherwise specified. The specific gravity of cement is determined by the standard Le
Chatelier flask according to (ASTM C 188) . The purpose of this test is to determine
the density of hydraulic cement in connection with the design of Portland cement
concrete mixtures. The test result of specific gravity of Crown cement is shown with
the following equations.

Weight of cement, W = 64 (g)

Volume of Kerosene + Cement, V1 = 21.2 ml
Volume of Kerosene, V2 = 0.9 ml
W
Density of Cement = V 1 −V 2

64
Density of Cement = 21. 2−0 .9 = 3.15
g/ml
Density of Water = 1g / cc
Density of cement
Specific gravity of Cement = Density of water
3.15
Specific gravity of Cement = = 3.15
1
Therefore, the test result of specific gravity of Crown cement is 3.15.

3.2.3. Normal Consistency Test of Cement (ASTM C-191)

The normal consistency of cement is determined by using Vicat apparatus
according to (ASTM C-191). This test is to determine the water required to achieve
desired plastic state called normal consistency of cement paste. For finding out initial
setting time, final setting time and soundness of cement, normal consistency of
cement is required to know.
Normal consistency of cement paste is defined as that consistency (degree of
wetness) which will permit the Vicat plunger to penetrate the cement paste to a point
10 ± 1 mm from the top of the mold. The standard normal consistency of Portland
cement is within 26-33 percent. According to the test result, normal consistency of
 37

Crown cement is 30%. The test result of normal consistency of Crown cement is
shown in Figure 3.2.

Figure 3.2. Normal Consistency of Cement

3.2.4. Initial and Final Setting Time

The setting time of cement is very important in the construction projects. This
test is to determine the time required for cement paste to harden. The setting time of
cement is determined according to ASTM C-191 (01) and is measured by Vicat
apparatus. Initial setting time is defined as the time of which the needle penetrates
25mm into the cement paste. Final setting time is the time at which the needle does
not sink visibly into the cement paste.
Starting time of supply of water is 9hrs : 30 mins. Time observed of initial
setting time and final setting time are 11 hrs : 20 mins and 12 hr : 40 mins
respectively. Therefore, the initial setting time and final setting time of Crown cement
are 1 hrs: 50 mins and 3 hrs: 10 mins in this study. The standard initial setting is 45
mins in minimum and final setting time is 10 hrs in maximum.

3.2.5. Soundness Test of Cement

The soundness test of cement refers to the stability of the volume
change in the process of setting and hardening. The soundness test if performed
with the help of Le-Chatelier apparatus according to ASTM C 151. If the volume
change is unstable after setting and hardening, the concrete structures will crack. This
 38

test is carried out to detect the presence of uncombined lime in cement. The apparatus
consists of a small brass cylinder split a long its generatrix. Two indicators with
pointed ends are attached to the cylinder on either side of the split. The cylinder
(which is open on both ends) is placed on a glass plate filled with cement paste of
normal consistency, and covered with another glass plate. The whole assembly is then
immersed in water at 20 ± 1°C for 24 hours.
At the end of that period the distance between the indicator point is measured.
The mold is then immersed in water again and brought to a boil. After boiling for
three hours, the mold is removed from the water, after cooling; the distance between
the indicator points is measured again. The decrease represents the expansion of the
cement paste for Portland cement; expansion is limited to 1mm. The test results of
soundness of Crown cement are shown in Table 3.1.

Table 3.1.Test Result of Soundness of Cement (Crown)

Test No. 1 2

Before boiling (mm) 25 26

After boiling (mm) 24 25.1
Difference (mm) 1 0.9

Average (mm) 0.95 mm

3.2.6. Compressive Strength Test

The quality of cement is determined from the compressive strength of the
cement and sand mortar mix 1:3. Compaction of the specimen is done by means of
external vibrator. The percentage of water is calculated from the following formula;

Water = (p/4 + 3.5) % of combined weight of cement and sand (3.1)

where,
p = standard consistency of cement
 39

In the compressive strength test, 2.75 in cement mortar cube specimens,

shown in Fig. 3.3, are used. The compressive strength should not be less than the
following values and referred according to ASTM (1975).
After 3 days ± 1 hrs 1200 psi
After 7 days ± 2 hrs 2000 psi

Figure 3.3. 2.75 in Cube Molded Specimens

The results for the compressive strength of the Crown cement is shown in
Table 3.2.

3.2.7. Summary Test results of Crown Cement and ASTM Specifications

Comparison of Crown Cement and ASTM specifications are shown in Table
3.2. These tables include many test results such as normal consistency test, specific
gravity test, fineness test, soundness test, setting times test and compressive strength
test.

Table 3.2. Comparison of Test Results of Crown Cement and ASTM Specifications

No Sample Cement Crown Cement ASTM Specifications

1 Normal Consistency 30% 26-33%

2 Specific gravity 3.15 3.1-3.25

3 Fineness 4356 cm²/gm 2800 cm²/gm(min)

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4 Soundness 0.95mm 1 mm (max)

Initial 1 hrs: 50 mins 45 mins(min)

5 Setting time
Final 3 hrs: 10 mins 10 hrs(max)

Table 3.2. (Continued)

No Sample Cement Crown Cement ASTM Specifications

3 days 4795 psi 1740 psi(min)

Compressive
6 7 days 5439 psi 2799 psi (min)
strength
28 days 6189 psi 3915 psi (min)

3.3. Testing of Coarse Aggregate

The coarse aggregate proposed to be used for making concrete specimen is
crushing stone from Htone Pho. Coarse aggregates are carried out by the following
tests.

3.3.1. Fineness Modulus of Aggregate (ASTM C 136)

The larger the fineness modulus, the coarser the aggregate. The gradation of a
particular aggregate is most often determined by a sieve analysis. In a sieve analysis, a
sample of dry aggregate of known weight is separated through a series of sieves with
progressively smaller openings. Once separated, the weight of particles retained on
each sieve is measured and compared to the total sample weight.  Particle size
distribution is then expressed as a percent retained by weight on each sieve size. The
test results for sieve analysis of coarse aggregate are shown in Table 3.3.

Table 3.3. Sieve Analysis of Coarse Aggregate

Percent Retained
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Sieve
Average Percent Accumulated Specified Limit
Sieve Opening
Retained Percent Retained Percent Retained
No. (mm)

1˝ 25 0 0 0

(3/4)˝ 19 6.57 6.57 0 ~ 10

Table 3.3. (Continued)

Percent Retained

Sieve
Sieve
Opening Average Percent Accumulated Specified Limit
No.
(mm) Retained Percent Retained Percent Retained

12.7 47.14 53.71 35 ~ 45

(1/2)˝

9.5 29.75 83.46 20 ~ 28

(3/8)˝

4.75 15.73 99.19 27 ~ 45

(3/16)˝

No. 8 2.36 0.81 100 0~8

(-) No.8 0.00 0~2

FM 6.89
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Figure 3.4. Test Results of Sieve Analysis of Coarse Aggregate

3.3.2. Specific Gravity Test of Coarse Aggregate

Aggregate specific gravity is useful in making weight-volume conversions and
in calculating the void content in compacted. Test method for finding the specific
gravity of Coarse aggregate is described in ASTM C 127-07. To find specific gravity,
aggregates are thoroughly washed, dried to constant mass at 110 ± 5°C in an oven,
cooled in air and immersed in water and dried to a saturated surface dry state with a
large absorbent cloth. Care is taken to avoid evaporation of water from the aggregate
pores during this operation. The test result is shown in Table 3.4. The specific gravity
of aggregates are calculated as follows.
B
Specific Gravity (SSD) = B−C
(3.2)
where,
B = Saturated surface – dry weight of sample (g)
C = weight of saturated sample in water (g)
Table 3.4. Test Results of Specific Gravity of Coarse Aggregate

Coarse Aggregates Chipping

Wt. of SSD aggregate, B (g) 1505

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Wt. of saturated sample in water, C (g) 964

Difference, (B – C) (g) 541

Specific Gravity 2.78

3.3.3. Water Absorption of Coarse Aggregates (ASTM C 127)

The water absorption of Coarse aggregate (20 mm or 3/4″) is determined
according to ASTM C 127. To calculate the mixing water content of concrete, the
absorption of aggregate and total moisture content must be known. Absorption is
computed as a percentage by subtracting the oven-dry mass from the saturated
surface dry mass, divided by the oven dry mass, and multiplying by 100. The
test results of Chipping (20 mm or 3/4″) aggregate is shown in Table 3.5. The water
absorption of Chipping (20 mm or 3/4″) aggregate are calculated as follows.

ww - w d
Absoption (%) = wd × 100 (3.3)
where,
Ww = weight of saturated surface dry sample (g)
Wd = weight of oven dry sample (g)

Table 3.5. Test Results of Absorption of Coarse Aggregate

Coarse Aggregates Chipping

Wt. of saturated surface dry sample, Ww (g) 1330

Wt. of oven dry sample, Wd (g) 950

Difference, Ww – Wd, (g) 380

Absorption (%) 0.40

3.4. Fine Aggregate

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Fine aggregate proposed to be used for making mortar cubes and concrete
sample is river sand. Fine aggregates are carried out by the following tests.
(a) Specific Gravity Test of Fine Aggregate
(b) Fineness Modulus of Sand
(c) Absorption of Sand
(d) Organic Impurities Test

3.4.1. Specific Gravity Test of Fine Aggregate (ASTM C 128-01)

The saturated surface-dry (SSD) of sand is recorded. The specific gravity of
fine aggregate is the ratio of its mass to the mass of an equal absolute volume of
water. It is used in certain computations for mixture proportioning and control, such
as the volume occupied by the aggregate in the absolute volume method of mix
design. It is not generally used as a measure of aggregate quality; though some
porous aggregates exhibit accelerated freeze-thaw deterioration do have low specific
gravities. Most natural fine aggregates have specific gravities between 2.4 and 2.9.
Test method for determining specific gravity for fine aggregate is described in ASTM
C 128-01. The test results of specific gravity of fine aggregate is shown in table 3.6.
Table 3.6. Test Results of Specific Gravity of Fine Aggregate

Bottle No 1 2

Weight of bottle, w1(g) 152.8 154.1

Weight of bottle + sand, w2(g) 538 542.6

Weight of bottle + sand + water, w3(g) 922.2 924.5

Weight of bottle + water only, w4(g) 684.1 683.6

Weight of sand used, (w2 – w1) (g) 385.20 388.5

Weight of water used, (w3 – w2) (g) 384.2 381.9

 45

Weight of water used, (w4 – w1) – (w3 – w2) (g) 147.1 147.6

w 2 - w1
Specific Gravity of sand, Gs = (w 4 - w1 ) - (w3 - w 2 ) 2.62 2.63

Average Specific Gravity 2.62

3.4.2. Fineness Modulus of Sand

The particle size distribution of aggregates is called grading. The grading
determines the paste requirement for a workable concrete since the amount of void
requires need to be filled by the same amount of cement paste in concrete mixtures.
To obtain a grading curve for concrete, sieve analysis has to be conducted. The
method of test covers the procedure of the determination the particle size distribution
of fine aggregates using sieve with square openings. The fineness modulus is defined
as,

¿
Fineness modulus ¿ ∑ (cummulative retained percentage ¿ 100

(3.4)

To calculate the fineness modulus, the sum of the cumulative

percentages retained on a definitely specified set of sieves need to be
determined, and the result is then divided by 100. The sieve specified for the
determination of fineness modulus are No.4, 8, 16, 30, 50, 100, and pan are used for
fine aggregate. The fineness modulus for fine aggregates should lie between 2 and
3.3. This test is to determine the fineness modulus of sand. The screen analysis of
sand is obtained by screening a representative sample of the size indicated through –
No (8) inches screens by hand shaking. Before making a screen analysis, test samples
of sand should be dried to substantially constant weight. Each sample is placed on a
set of screens nested in order of decreasing size of opening from top to bottom. The
gradation samples should be retained for determining the percentage of material
passing the No. 200 screen. The test result for sieve analysis of fine aggregate is
shown in Table 3.7.

Table 3.7. Test Results for Sieve Analysis of Fine Aggregate

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Test Name Sieve Analysis for Fine Aggregate

Description of Ayeyarwaddy River Sand
Sample Percentage Retained
Cumulative Specified Limits
Sieve No. Percent Retained
Percent Retained % Retained
4 1.80 1.80 0~5
8 3.52 5.32 5~15
16 4.04 9.36 10~25
30 9.64 19.00 10~30
50 52.06 71.06 15~35
100 23.92 94.98 12~20
200 4.24 99.22 2~4
Pan 0.78 100.00 1~3
F.M 2.02 2.2~2.8

F.M 
 (cumulative percentage retained on specified sieves)
100
= 202/100
= 2.02

Figure 3.5. Test Results for Sieve Analysis of Fine Aggregate

3.4.3. Absorption of Sand

The water absorption of sand is determined by measuring the increase in
weight of an oven-dried sample when immersed in water for 24 hours (the surface
water being removed). The ratio of the increase in weight of the dry sample,
 47

expressed as a percentage, is termed absorption. At first, the saturated surface-dry

sample is weighted to the nearest 0.5 gram. The sample is dried in the oven or on the
hot plate or stove to a constant weight (mass). And then, the sample is allowed to cool
and weigh to the nearest 0.5 gram.
The percent absorption, based on the oven dry mass (weight) is calculated to
the nearest 0.01 percent as follows:
Saturated surface dry mass  oven dry mass
Percent Absorption = ×100
oven dry mass (3.5)
The surface-dry condition is determined by means of the cone test described in
ASTM. From time to time, a portion of the sand which is being dried is tamped lightly
into a small conical mold open at top and bottom, and the mold is lifted vertically. If
the pile of sand retains the shape of the mold, surface moisture is present. At the point
in the series of tests when the pile begins to slump, the sand is saturated and surface-
dry. The mold is 1 ½ inch in diameter at the top, 3 ½ inch in diameter at the bottom,
7
and 2 8 inches in high. The metal tamping rod weighs 12 oz and has a flat circular
tamping face 1 inch in diameter. The test result of absorption is as shown in Table 3.8.
Table 3.8. Test Results of Absorption of Sand

Test No. 1 2

Wt. of container + wet sand, (g) 141.2 137.2

Wt. of container + dry sand, (g) 140.2 136.2

Wt. of container, (g) 25.2 24.2

Wt. of SSD sample, (Ww – Wd), (g) 1 1

Wt. of dry sand (Wd), (g) 115 112

W w −W d
×100 0.87 0.89
Absorption (%) = W d

Average (%) 0.88

3.4.4. Organic Impurities Test

The test is to determine the organic impurities of sand. A 12 percent oz
graduated clear glass bottle is filled to the 4 ½ oz with the sand to be tested. A 3
solution of sodium hydroxide in water is added until the volume of the sand and liquid
 48

after shaking is 7 liquid oz (200 CC). The bottle is stoppered, shaken vigorously, and
allowed to sand for 24 hours. If the temporary solution is to be used as the standard, it
should be made up immediately after the sample is shaken vigorously. After the
solution has stood 24 hours, the colour of the clear liquid above the sand is compared
with that of the standard colour solution or with a glass of similar colour. If the
solution colour remains darker than the standard colour, further test required to
determine the nature of the material and its effect on the time of set and strength of
cement. If the colour equal to or lighter than standard is obtained the sand is
considered suitable (from an organic standpoint) without further testing.

3.5. Testing of Fly Ash

Fly ash is a finely divided byproduct resulting from the combustion of coal in
power plants. It contains large amounts of silica, alumina and small amount of
unburned carbon, which pollutes environment. Fly ash in concrete makes efficient use
of the hydration products of Portland cement by consuming calcium hydroxide to
produce additional cementing compounds. When concrete containing fly ash is
properly cured, fly ash reaction products partially fill in the spaces originally occupied
by mixing water that are not filled by the hydration products of the cement, thus
lowering the concrete permeability to water and aggressive chemicals. The fly ash
was used as a partial replacement of cement in concrete mixes using the following
quantities: 15, 25 and 35 percent by weight of the total cementitious content.
Fly ash proposed to be used as mineral admixture is available from Tigyit
Coal Fired Thermal Power Station (Triple Dragon Brand). In this study, specific
gravity, fineness, normal consistency and setting times of fly ash are tested.

3.5.1 Specific Gravity of Fly Ash

The specific gravity of fly ash is determined by Pycnometer. The specific
gravity of fly ash is in the range of 1.99 to 2.96. The specific gravity of fly ash is
shown in Table 3.9.
Table 3.9. Test for Specific Gravity of Fly Ash

Data Sheet for Specific Gravity of Fly Ash

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Test Name Bottle No.

Sample Name I II

Bottle No. 3277 4432

Wt of Bottle, W1 (g) 43.17 43.65

Wt of Bottle + fly ash, W2 (g) 53.17 53.65

Wt of Bottle + fly ash + kerosene, W3 (g) 129.28 134.42

Wt of Bottle + kerosene, W4 (g) 122.83 128.00

Wt of fly ash, (W2 – W1) (g) 10.0 10.0

Table 3.9. (Continued)

Data Sheet for Specific Gravity of Fly Ash

Test Name I II

Bottle No. 3277 4432

Wt of kerosene (W3 – W2) 76.11 80.77

Wt of (W4 – W1) – (W3 – W2) 3.55 3.58

G.S (Fly Ash) =

(W2  W1 ) 2.81 2.79

(W4  W1 )  (W3  W2 )

Average Specific Gravity 2.80

3.5.2. Fineness Test of Fly Ash

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The fineness of fly ash is expressed by specific surface. This must be

determined by Blaine Air Permeability Method. Test result of fineness modulus of fly
ash is 2488 cm2/gm.

3.5.3. Normal Consistency Test of Fly Ash

It is necessary to determine the water required to produce a standard paste.
The consistency of fly ash is fined out by Vicat apparatus. The procedure is same as
in cement. The consistency of fly ash in this study is 33 %.

3.5.4. Initial and Final Setting Time of Fly Ash

The setting time of fly ash is determined by Vicat apparatus and the procedure
is the same in testing cement. The initial setting time and final setting time of fly ash
are 0 hrs: 40 mins and 3 hrs: 22 mins in this study.

3.5.5. Summary of Test Results of Fly Ash

The summary of test results of fly ash such as fineness, consistency, specific
gravity, setting time is shown in Table 3.10.
Table 3.10. Summary of Test Results of Fly Ash

Sample Name Fly Ash

Fineness (cm2/gm) 2488

Consistency (%) 33 %

Specific Gravity 2.8

Initial Setting Time 0:40

Setting Time(hr:min)
Final Setting Time 3:22

3.6. Testing of Mixing Water

Water is an important constituent in concrete. It chemically reacts with cement

(hydration) to produce the desired properties of concrete. There are various tests on
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water to check its quality for suitability of concrete construction. Mixing water is the
quantity of water that comes in contact with cement, impacts slump of concrete and is
used to determine the water to cementitious materials ratio (w/cm) of the concrete
mixture. Strength and durability of concrete is controlled to a large extent by its
w/cm.
Mixing water is obtained from tube well of Irrigation Technology Center
(ITC, Upper Myanmar, Mandalay). It is noted that the water is portable and drinkable
as well. The test result of water is as shown in Table 3.11.
Table 3.11. Test Result of Water

Highest Maximum
Myitnge Plant Desirable permissible
No. Characteristics Unit
Water Level level

1 Appearance

2 Color 5 Units 50 Units

3 Turbidity _ 5 NTU 25 NTU

Table 3.11. (Continued)

Highest Maximum
Myitnge Plant Desirable permissible
No. Characteristics Unit
Water Level level

4 PH Value 8.1 7.0 to 8.5 6.5 to 9.2

5 Total Solids ppm _ 500 mg/l 1500 mg/l

6 Total Hardness ppm _ 100 mg/l 500 mg/l

7 Total Alkalinity ppm _ 600 mg/l 950 mg/l

8 Calcium ppm _ 75 mg/l 200 mg/l

9 Magnesium ppm 30 mg/l 150 mg/l

10 Chloride ppm 16 mg/l 200 mg/l 600 mg/l

11 Sulphate ppm 49 mg/l 200 mg/l 400 mg/l

12 Total Iron ppm 0.21 mg/l 0.3 mg/l 0.3 mg/l
 52

3.7. Sikament -520

Sikament - 520 is a highly effective superplasticizer with a set-retarding effect

for producing free-flowing concrete in hot climates. Also, it is a substantial water
reducing agent for promoting high early and ultimate strengths. According to ASTM
C-494, it is the type G of high-range water reducer. It is used wherever high quality
concrete is demanded under difficult placing and climatically conditions.
Sikament - 520 can be used 800 – 2500 cc. per 100 kg of cement weight.
Exact dosage rates are dependent on the type of effect sought, quality of cement and
aggregates, Water/Cement-ratio and ambient temperature. Therefore, it is advisable to
carry out trial mixes. Sikament - 520 is compatible with all types Portland Cement,
including S.R.C.
Sikament - 520 can be added separately to the freshly mixed concrete or
directly to the mixing water prior to its addition to the aggregates. When added
separately to the freshly mixed concrete, further mixing should take place for at least
one minute per cubic meter. When accidental overdosing occurs, the set retarding
effect increases. During this period the concrete must be kept moist in order to
prevent premature drying out. The sikament-520 used in this study is shown in Fig.
3.6. Technical data of sikament-520 are shown in Table 3.12.
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Figure 3.6. Sikament-520

Sikament -520 provides the following properties:

(a) As a superplasticizer:
(i) Substantial improvement in workability without increased water or the
risk of segregation
(ii) Long lasting control of slump loss;
(iii) No adverse effect on ultimate strength.
(b) As a water reducer:
(i) Early strength significantly increased
(ii) High ultimate strengths
(iii) Especially suitable for hot climate
(iv) No excessive air-entrainment
(v) No adverse shrinkage effect
(vi) Improved surface finish
(vii) Increased watertightness

Table 3.12. Technical Data for Sikament-520

Form Blended Polymer
Colour Brown Liquid
Specific Gravity 1.170-1.190 kg/ltr
pH Value 8.0-9.5 (Approx.)
Store at protected area form direct
sunshine at temperature between 5 and
Storage Condition
40 degree Celsius.
Shelf Life 1 year when unopened
Packaging 200 L/drum, tote