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Chapter 4
Concrete
This chapter discusses the testing of both fresh and hardened concrete and
the construction materials used to mix it. These tests are performed to
ensure that the concrete meets design requirements before it is poured.
Since there are many factors that contribute to the success of the finished
product, all test methods must adhere to ASTM standards.
Further information on concrete types, components, design, and uses in
military construction can be found in FM 5-428.
SECTION I. CHARACTERISTICS AND IDENTIFICATION
Concrete is one of the most economical, versatile, and universally used
construction materials. It is one of the few building materials that can be
produced by the user directly on the job to meet the specific requirements.
Concrete is an artificial stone which, when first mixed, forms a plastic or
putty-like mixture. This mixture can then be placed into a form and allowed
to harden or cure for a prescribed length of time. When cured, the finished
concrete is a hard, stonelike material. It is used for pavements, foundations,
dams and retaining walls, bridges, and buildings of all types.
DESCRIPTION AND COMPONENTS
CEMENT
Concrete is a mixture of portland cement, fine and coarse aggregates,
entrapped or entrained air, and water. During mixing, the cement, air, and
water form a fluid paste that contributes to thorough mixing and effective
placement of the concrete. The cement and water, when mixed, combine
chemically to bind the aggregate particles together. This combining process—
called hydration—results in a rapid development of strength in the first few
hours after mixing, followed by less rapid gains in strength during the
following weeks.
Cement is a substance that hardens with time and holds or entraps objects or
particles in a definite relation to each other. For concrete, portland cement
usually is used.
Portland cement is a substance that when mixed with water, hardens and
binds objects or particles together to form concrete. This process begins
immediately and continues as long as moisture and temperature conditions
are favorable. As hydration continues, concrete becomes harder and stronger.
Most of the hydration takes place during the first 30 days. Hydration can
continue well over 50 years but at a much slower rate. References to cement
in this manual mean portland cement. The ASTM specifies eight common
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AIR-ENTRAINED CEMENT
4-2 Concrete
types of portland cement (ASTM C 150-97). These are adequate for most
purposes. The various types of portland cement are known as hydraulic
cements because they are capable of hardening and developing strength in the
presence of water. These cements include—
Typel. Cement used for general construction when special properties
for any other type are not required.
TypelA. Air-entraining cement used for the same purposes as Type |,
except that air entrainment is desired. Entrained air improves
workability and provides resistance to frost action, freezing, and
thawing.
Type ll. Cement used for general purposes, especially when moderate
sulfate resistance or moderate heat of hydration is desired. It has a
lower heat of hydration than the normal Type I, generates heat at a
slower rate, and has improved resistance to sulfate attack. Type II
cement is used in locations where a high temperature rise in the
concrete is objectionable, as in structures of considerable mass such as
large piers, heavy abutments, and heavy retaining walls.
Type IIA. Air-entraining cement used for the same purposes as Type
II, except that air entrainment is desired.
Type Ill. Cement used when a high strength is needed quickly. This
may be due to a demand for early use or in cold-weather construction
to reduce the period of protection against low or freezing
temper atures.
Type IIIA. Air-entraining cement used for the same purposes as Type
III, except that air entrainment is desired.
TypelV. Cement used when a low heat of hydration is desired to keep
the amount and rate of heat generated to a minimum. Type IV
cement develops strength at a slower rate than Type | cement but
helps prevent the development of high temperatures in the structure
with the attendant danger of thermal cracking later when it cools.
Type V. Cement used when high sulfate resistance is desired.
Sulfates react chemically with the cement compounds, causing
undesirable expansion of the mixture. The sulfates may be present in
the water used to mix the concrete or may be created by sulfurous
gases from nearby industrial areas. The principal source of sulfate
attack, however, occurs on foundations and other concrete in contact
with the earth in certain regions and is caused by a reaction between
the groundwater (containing dissolved reactive minerals or acid) and
the hardened cement. Type V cement is low in calcium aluminate and
is highly resistant to sulfate attack.
Concrete made with air-entrained cement is resistant to severe frost action
and to salts used for ice and snow removal. In general, air entrainment may
be controlled to a much greater extent by using admixtures with normal
cements during mixing. This combination results in concrete with tiny,
distributed and separated air bubbles (up to millions per cubic foot). The
WATER
Ordinary Water
Sea Water
AGGREGATES
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
entrained air bubbles improve the workability of fresh concrete. These
bubbles reduce the capillary and water-channel structure within water, which
prevents the buildup of damaging water. Air-entrained concrete has greatly
increased durability in outdoor locations exposed to freezing weather. Each of
the first three Types (I, Il, and III) are available as air-entrained. To signify
this characteristic, a letter A is added after the type. For example a Type II
cement with an air-entrained admixture is identified as Type IIA.
Water plays an important part in the concrete mix. Its principal uses are to
make the mix workable and to start the chemical reaction. Any material in
the water that retards or changes the reaction is detrimental. A good rule of
thumb is, "If it's good enough to drink, it may be used for concrete.”
The materials found in some types of water include organic compounds, oil,
alkali, and acid. Each has an effect on the hydration process.
e Organic material and oil. These compounds tend to coat the aggregate
and cement particles and prevent the full chemical action and
adherence. The organic material may also react with the cement and
create a weakened cementing action, thus contributing to
deterioration and structural failure of the concrete.
e Alkalies, acids, and sulfates. Certain limiting amounts of these
chemical impurities in the water tend to react adversely with the
cement. The result is inadequate cementing and weakened concrete.
Water must be substantially free of these chemicals for use in concrete
mixing.
The salts in sea water are normally thought of as being corrosive. However,
sea water is sometimes used for concrete mixing with satisfactory results. A
10 to 20 percent loss in compressive strength can be expected when using the
same amount of sea water as fresh water. This can be compensated for
somewhat by reducing the water-cement ratio.
The aggregates commonly used for concrete are natural deposits of sand and
gravel, where available, or crushed stone. Crushed aggregate may cost more
to produce; however, this may be the only way to obtain substantial quantities
of large-sized stone. Artificial aggregates such as a blast-furnace slag or
specially burned shales and clays are used.
Aggregates are divided into the following types:
e Fine aggregate
e Coarse aggregate.
When properly proportioned and mixed with cement, these two groups will
yield an almost voidless stone that is strong and durable. Aggregate should be
equal to or better in strength and durability than the hardened cement paste
if it is to withstand the design loads and effects of severe weather.
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FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
Fine Aggregates
Fine aggregates are the material that will pass a No. 4 sieve and will be
predominantly retained on a No. 200 sieve. To increase workability and for
economy as reflected by using less cement, the fine aggregates should have a
rounded shape. Their purpose is to fill the voids between coarse-aggregate
particles and to modify the concrete’s workability. This workability
characteristic is discussed more in the description of finished concrete
Coarse Aggregates
Coarse aggregates are the material that will be retained on a No. 4 sieve. In
determining the maximum size of coarse aggregate, other factors must also be
considered. The coarser the aggregate used, the more economical the mix, as
aggregate costs less than cement. Larger pieces offer less surface area of the
particles than an equivalent volume of small pieces. Using the largest
permissible maximum size of coarse aggregate permits a reduction in cement
and water requirements. One restriction usually assigned to coarse aggregate
is its maximum size. Large pieces can interlock and form arches or
obstructions within a concrete form. This restricts the area below to a void or
at best, fills the area below with the finer particles of sand and cement. This
is either a weakened area or a cement-sand concentration that does not leave
enough mortar to coat the rest of the aggregate. The capacity of mixing
equipment, the spacing of reinforcement, or the minimum width of forms
limits the maximum aggregate size. A listing of maximum sizes of coarse
aggregate is indicated in Section II of this chapter.
PROPERTIES OF CONCRETE
STRENGTH
4-4 Concrete
To combine the ingredients correctly and to form the required concrete, it is
essential to know the required physical properties of both the plastic and the
hardened concrete The hardened concrete must have the following
properties:
e Strength.
e Durability.
e Watertightness.
e Workability.
e Consistency.
e Uniformity.
The quality and character of the hardened concrete is greatly influenced by
the properties of the mix when it is plastic. To attain optimum quality, the
plastic mix must be uniform, consistent, and workable. This permits placing
the concrete without developing segregation, honeycombing, or other defects
in filling the forms or in producing the desired smooth, hard, and resilient
surface.
Strength is the concrete's ability to resist a load in compression, bending, or
shear (see Sections IV and V of this chapter). The desired design strength is
DURABILITY
WATERTIGHTNESS
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
obtained by proportioning the mixture with correctly graded aggregates, an
adequate amount of cement to coat the surface area of the particles, and the
proper amount of mixing water. The most important influencing factor on
strength is the ratio of water to cement (W/C ratio). For plastic and workable
mixes, lower values of the W/C ratio give higher strengths. Two and one-half
gallons of water is the minimum amount necessary to hydrate a sack of cement
adequately.
This minimal amount of water is not sufficient to economically provide the
needed plasticity and workability for freshly mixed concrete. Additional water
must be added to the mixture to improve workability but must be minimized to
obtain the desired strength with an economical cement content. Additional
water thins the paste content and therefore coats more particles. This increases
the yield from each sack of cement and produces a more economical mix.
Excessive amounts of water (too high a W/C ratio) weakens the paste by
allowing the cement particles to hydrate while suspended in water without
being in contact with the aggregate or other cement partides. This water
eventually evaporates, leaving holes or voids in the hardened concrete that
cause additional losses in strength. Minimum and maximum amounts of water
are specified to assure an economical mix with no loss in strength. This ranges
from 4 to 8 gallons per sack of cement (94 pounds).
Durability is the concrete's ability to resist the elements of weathering and
loading. The primary elements affecting concrete are wind, abrasion, freezing
and thawing, wetting and drying, and the chemical action of salts. As the W/C
ratio is increased (4 gallons per sack), more voids develop in the hardened
concrete. Therefore, more surface area is available for the detrimental
elements to attack, resulting in a less-durable structure. Weak or easily
crushed rock or other mineral particles that break down under applied loads
introduce internal stresses that cause a breakdown of the concrete. Rocks or
mineral particles that are absorptive or susceptible to swelling when
saturated will deteriorate when subjected to severe weather conditions.
Freezing moisture causes expansion stresses that can easily rupture
absorptive rocks. Rocks swollen from the sun's radiant heat and then
subjected to shrinkage from sudden cooling by rain or temperature drop may
break down from the severe weathering. The concrete aggregate must
withstand all these forces of nature.
A well-mixed, well-proportioned concrete presents a solid surface to prevent
water penetration. Superficial voids permit some water to enter below the
concrete’s surface but the water soon meets a dense, solid mass that prevents
further penetration. As the W/C ratio is increased, the excess water forms
more holes or voids that eventually interconnect to form channels into and
throughout the concrete. The end result is a more porous concrete that
permits water to pass. For watertightness, 6 gallons of water or less per sack
of cement will meet the requirement.
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WORKABILITY
CONSISTENCY
UNIFORMITY
Workability is the relative ease of difficulty of placing and consolidating
concrete. It is controlled primarily by the amount of each aggregate in
proportion toa given quantity of cement paste. As more aggregate is added toa
given amount of paste, the mixture becomes harsh and stiff. The increased
stiffness makes it more difficult to work the concrete into the forms and around
the reinforcing bars. The consistency needed depends on the conditions under
which the concrete must be placed and finished. Very dry and stiff mixtures
may be placed in most situations where high-frequency vibrations are used to
assist in consolidating and compacting fresh concrete In other situations,
difficult placing conditions may require a more fluid concrete mixture to fill
narrow forms and to flow around reinforcement.
Concrete is a fluid mixture containing particles of different size, shape, and
mass. Heavier particles have a tendency to settle out through the mixture
faster than lighter particles. Often the result is a segregated mixture of a very
poor quality. When concrete is properly proportioned and mixed and carefully
handled, segregation is held to a minimum. The mixture must have the
proper proportion of cement/sand mortar to prevent the larger coarse
aggregate particles from separating from the batch during mixing,
transporting, and placing. When cement is allowed to drop (free fall) over a
considerable distance, it can cause segregation of the mixture. To minimize
segregation for drops in excess of 3 to 5 feet, bottom dump buckets should be
used to place concrete as close to the final location as possible. See TM 5-742
for construction procedures.
Uniformity refers to a single batch of concrete and to all batches for an entire
project. The same amount of each ingredient should be mixed into each batch
or a nonuniform structure will result. Design would not be met in all sections
of the structure and possible failure of these sections could result. Proper
supervision in mixing and handling of the concrete ensures uniformity.
CONCRETE CURING
TEMPERATURE
4-6 Concrete
Concrete does not develop its full strength until the chemical process of curing
(hydration) is complete. Cement must have sufficient water to continue its
hydration. Curing is the means of keeping water available so the hydration
can continue. The curing process takes place over an extended period. The
most critical time is the first 7 days. The extent and rate of curing depends on
the—
e Temperature within the concrete.
e Presence of moisture.
The ideal temperature for concrete work is between 55° and 70°F. Above this
temperature, rapid evaporation of moisture creates serious problems such
as—
MOISTURE
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
e Increased water demand.
e Slump loss.
e Decreased setting time.
e Increased tendency for plastic shrinkage cracking.
The hydration process is delayed at lower temperatures. Temperatures below
32°F completely stop the hydration process. Since the chemical reaction gives
off some heat, proper methods must be used to keep the heat within the
structure during times of low temperatures. Cold-weather construction may
require heating the individual ingredients or the concrete and covering the
emplaced concrete or providing a heated enclosure. In hot weather, extra care
is required to prevent a high temperature rise and rapid drying of the fresh
concrete. Spraying the aggregate stockpiles with cool water helps lower the
concrete temperature. To keep the water as cool as possible, reflective white
or aluminum paint is applied to the water supply lines and storage tanks.
On massive construction projects, such as dams and heavy retaining walls, the
mixing water is often kept cool by substituting ice for part of the mixing water.
The ice must be melted by the time the concrete is fully mixed and is ready to
leave the mixer. Large voids result from unmelted ice in the concrete. Cement
replacement materials (such as pozzolans and diatomaceous earth, pumicites,
or fly ash) may be used to depress concrete temperature by reducing the heat
of hydration in a structure. However, pozzolans vary widely and may have
adverse effects on strength, air content, and durability if used in excessive
amounts.
Concrete curing depends on a chemical reaction in the presence of water.
Moisture lost during the curing process—by seepage or evaporation—delays
or prevents a complete hydration of the cement and ultimately prevents the
development of optimum strength and watertightness. Saturating the
subgrade on which the concrete will be placed will delay, if not prevent,
seepage from occurring. Impervious membranes (plastic or polyethylene
sheets) can also be used to prevent seepage through the subgrade. Wood
forms should be thoroughly wetted if they have not been otherwise treated
with a moisture sealer.
One method of reducing evaporation is to cover the concrete with a material
such as straw, burlap, plastic, or a sprayed-on chemical curing compound as
soon after finishing as possible. The preferred method of curing is by using
continuous sprays and flowing or ponded water after the concrete has set
initially so it does not damage the finish. This water application can also be
part of the temperature control during cold- and hot-weather concreting. The
increase of the concrete’s compressive strength with age is shown by the
curves in Figure 4-1, page4-8. Note the long-time gain in strength that occurs
when proper temperature and moisture conditions are maintained.
CONCRETE ADMIXTURES
Chemical agents or admixtures are available for almost any purpose such as
increasing workability, durability, and strength or compensating for
inadequate curing conditions.
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FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
150
125
10
75
50
25
Compressive strength
(percent)
Moist-cured entire time
In air after 7 days
In air after 3 days
In air entire time
180
Age, in days
ACCELERATORS
RETARDERS
Figure 4-1. Increase of compressive strength with curing age
Sometimes it is desirable to accelerate the hydration process to obtain a high-
early strength and a high rate of heat production. This combination is useful
for cold-weather concreting operations. The addition of a chemical
accelerating admixture (generally calcium chloride) to the concrete mixture
produces the desired reactions. The recommended maximum dosage for
calcium chloride is 2 percent by weight of cement. The ultimate strength of
concrete will be slightly lower with the use of an accelerator.
Retarders are used when excessively high heat or too-rapid setting of concrete
will prevent full hydration of the cement. Many materials retard the setting
of concrete, but the most common is hydroxylated carboxylic acid salts. Sugar
has also been used quite successfully.
AIR-ENTRAINING AGENTS
4-8 Concrete
The greatest improvement in watertightness and resistance to the disruptive
action of freezing and thawing is obtained by incorporating 4 to 7.5 percent by
volume of entrained air into the concrete. Workability of fresh concrete is also
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
enhanced by entraining air. Soaps, oils, acids, wood resins, alkali salts, fine
pozzolans, and several proprietary compounds are available for use as air-
entraining admixtures with hydraulic cement. These agents form very small,
uniformly spaced, discrete air voids that relieve the buildup of damaging
pressures from the expansion of freezing water into ice.
WATER REDUCERS (PLASTICIZERS)
The concrete’s workability is governed by the proportions of cement, water,
and aggregate in a concrete mixture When a reduction of aggregate or an
increase in cement is impractical, the concrete’s workability can be increased
by adding a water-reducing admixture or plasticizer. Another primary
characteristic is the strength gained from a decreased water demand. Less
water is required for the same workability, which leads to a lower W/C ratio,
and therefore higher strength. Water requirements may be reduced as much
as 10 percent for most water-reducing admixtures. Air-entraining agents are
also considered as plasticizers because the void system reacts as a lubricant in
concrete.
SECTION II. AGGREGATE TESTING
Aggregate used in mixing concrete is a mixture of fine and coarse material,
usually sand with either natural gravel or crushed rock. It serves as an
inert filler to provide the bulk material required. Well-graded aggregates
contain particles of all sizes, from the largest permitted by the dimension of
the member to be formed to sand fines. The smaller particles fill the spaces
between the larger particles, thus providing a dense material that requires a
minimum of cement paste for binder. The aggregate materials must be clean
and hard, resist weathering, and have no unfavorable reaction with the
cement.
An aggregate must provide maximum strength and durability in a concrete
mixture. Fineness, coarseness, and aggregate gradation are factors
considered when deriving the correct concrete mix for a specific construction
purpose. Specific gravity, absorption, and moisture also affect the
aggregate’s ability to bind well with cement and water in a concrete mix.
The components of the final mix (cement, water, and aggregate) must bond
adequately for structural strength and must resist weather and loads.
Correct aggregate selection also reduces the project’s cost. An engineering
analysis determines the aggregate best suited for a particular purpose.
Testing allows the best selection.
For the aggregate tests to be worthwhile, the samples for testing must be
representative of the aggregates to be used. Take aggregate samples as close
as possible to the finished product to give the best representative sample of
the aggregate. Take a sufficient size and number of samples from the
processing-plant’s discharge point to represent the material in the stockpile.
The sample should consist of at least four times as much material as is
needed for the tests and should be reduced to the desired size through
splitting and or quartering the sample. Minimum sample sizes can be found
in Table 4-1, page 4-10.
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FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
Table 4-1. Minimum sample sizes
Nominal Maximum Size Minimum Weight of Test Sample
mm in kg Ib
12.5 or less 1/2 or less 2 4.4
19.0 3/4 3 6.6
25.0 1 4 8.8
37.5 11/2 5 11.0
50.0 2 8 18.0
63.0 2 1/2 12 26.0
75.0 3 18 40.0
90.0 3 1/2 25 55.0
100.0 4 40 88.0
112.0 41/2 50 110.0
125.0 5 75 165.0
150.0 6 125 276.0
STOCKPILE SAMPLING (ASTM D 75-87)
It is difficult to ensure that unbiased samples are obtained from stockpiles.
This is due to the segregation that often occurs when material is stockpiled,
with coarser particles rolling to the outside base of the pile. For coarse or
mixed coarse and fine aggregates, every effort should be made to enlist the
services of power equipment to develop a separate, small sampling pile
composed of materials drawn from several increments.
When power equipment is not available, take samples from at least three
increments—from the top third, the midpoint, and the bottom third of the
pile. Shove a board vertically into the pile just above the sampling point to
prevent further segregation. When sampling fine-aggregate stockpiles,
remove the outer surface before taking the sample.
Take samples from near the top, middle, and bottom of the stockpile and
recombine them to represent their particular stockpile. Push a board into
the stockpile just above the points of sampling to prevent the material above
the sampling points from falling into the sample and causing size
contamination.
Pit samples are sources of sand and gravel. Sample them by channeling
exposed faces or channeling in pits if exposures are not available. Take care
to ensure that the samples indude only materials that are below the
overburden or strip zone.
GRADATION DETERMINATION
Gradation of aggregate refers to the distribution of particles of aggregate
among various sizes. Aggregates having a smooth grading curve and neither
4-10 Concrete
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
a deficiency nor an excess of any one particle size usually produces mixtures
with fewer voids between particles. A too-large proportion of coarse
aggregate leaves voids that require more cement paste to fill. This affects
the economy of the mix. Too much fine aggregate increases the amount of
surface area that must be coated with cement paste. This may weaken the
concrete and is uneconomical. Good gradation results in—
e A dense mass of concrete with a minimum volume of voids.
e An economical mix.
e A strong structure
Optimum strength, water tightness, and durability in the hardened concrete
require careful control of aggregate gradation.
A gradation or sieve analysis indicates whether an aggregate's particle-size
distribution meets the project’s requirements. Dense aggregates can result
in a concrete that is denser and stronger and more economical, watertight,
and resistant. See ASTM C 136-90 for analysis methods and Table 4-2 and
Tables 4-3 and 4-4, page 4-12, for recommended size and gradation limits.
Table 4-2. Maximum recommended size of coarse aggregate
Minimum Dimension (Inches)
Structure
21/2to5 6 to 11 12 to 29 30 or More
Reinforced walls, beams, and columns 1/2 to 3/4 3/4 to 1 1/2 1 1/2 to 3 1 1/2 to 3
Unreinforced walls 3/4 1 1/2 3 6
Slabs, heavily reinforced 3/4 to 1 11/2 1 1/2 to 3 1 1/2 to 3
Slabs, lightly reinforced 3/4 to 1 1/2 1 1/2 to 3 3 3 to 6
bars
NOTE: Maximum size not to exceed 1/5 of minimum dimension of a wall or similar structure,
1/3 of slab thickness for horizontal slab, or 3/4 of minimum clear spacing between reinforcing
APPARATUS, TEST PROCEDURES, AND CALCULATIONS
The apparatus, test procedures, and calculations required to determine the
gradation of aggregate for portland-cement concrete are the same as
explained for sieve analysis, except that the No. 4 sieve is taken as the
dividing line between fine and course aggregates. The minimum sample size
required in the sieve analysis of fine aggregate is 500 grams. The result of
this test is a gradation curve for the aggregate concerned.
MATERIAL FINER THAN .075 MILLIMETERS (No. 200 SIEVE)
The extremely fine mineral material (clay, silt, dust, or loam) occurring in
most aggregates requires relatively large increases in the amounts of mixing
water. Fines tend to work to the surface of concrete and cause cracking upon
drying, due to shrinkage. If the fines adhere to the larger aggregate particles,
they also tend to interfere with the bond between the aggregate particles and
cement-water paste. Specifications limit the amount of such material to a
small percentage. ASTM C 117-95 gives the standard test method for fine
Concrete 4-11
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
materials. The apparatus, test procedures, and calculations to determine this
percentage are described in the test for impurities. Fine material, not to
exceed 3 to 5 percent of the total aggregate weight, is generally not harmful to
concrete. For some purposes, a small amount of such fines may improve the
workability.
Table 4-3. Desirable gradation for coarse aggregate in concrete
Percent Passing Indicated Sieve
Nominal
Sieve Size | 4 | 312] 3 |212| 2 |112| 1 3/4 | 1/2 | 3/8 | No.4
(Inches)
31/201 1/2 | 100 | 200° ma o5 E
2 1/2 to 11/2 100 ch a to i. 0105
= wo [Re Ee [| foes
2 to No. 4 100 a a to ~ 9 0to5
1 1/2 to 3/4 100 oe = Š e 0to5
1 1/2 to No. 4 100 a a to T to | oig
1 to No. 4 100 | t00° A D
3/4 to No. 4 100 | $90" ER
1/2 to No. 4 100 ae z to a
3/8 to No. 4 P T to
4-12 Concrete
Table 4-4. Desirable gradation for fine aggregate in concrete
Sieve Size Percent by Weight
US Standard Passing
4 95 to 100
8 80 to 100
10 75 to 95
16 50 to 85
20 40 to 75
30 25 to 60
40 20 to 50
50 10 to 30
60 10 to 25
100 2 to 10
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
FINENESS MODULUS
Fineness modulus is an empirical factor that gives a relative measure of the
proportional particlesize distribution of an aggregate’s fine and coarse
particles. The fineness modulus does not represent any gradation of the
material although the process is similar. A 500-gram sample of sand is sieved
through a series of sieves (No. 4, 8, 16, 30, 50, and 100). The weight retained
on each sieve is converted into a cumulative weight and a cumulative
percentage retained, starting with the No. 4 sieve The sum of the 6
percentages divided by 100 is the fineness modulus. Another procedure for
determining the fineness modulus is calculated using the cumulative
percentage passing, the usual means of expressing aggregate gradation. The
total number of sieves involved times 100 minus the sum of the cumulative
percentage passing and divided by 100 gives the fineness modulus. The
fineness-modulus values range from 2.20 for fine aggregate to 7.50 for coarse
aggregate. Typical values are 2.70 for fine aggregate, 7.40 for coarse
aggregate, and 5.80 for 35 to 65 fine-coarse combination. Fineness-modulus
ranges for fine aggregate are shown in Table 4-5.
Table 4-5. Fineness-modulus ranges for fine aggregates
Fineness Modulus Designation
2.3 to 2.6 Fine sand
2.6 to 2.9 Medium sand
2.9 to 3.1 Coarse sand
TESTS FOR SPECIFIC GRAVITY, ABSORPTION, AND SURFACE
MOISTURE
Perform tests for specific gravity, absorption, and surface moisture on the
aggregates before making the necessary calculations to design the concrete
mixture. For aggregates used in portland-cement concrete, measure to
determine the bulk specific gravity of the aggregates in a saturated, surface-
dry (SSD) condition. This is the condition in which the pores in each
aggregate particle are filled with water and no excess water is on the particle
surface. When used in concrete, this moisture condition of an aggregate can
be defined as neither absorbing water from nor contributing water to the
concrete mixture. Specific gravity is thus based on determining the total
volume occupied by the aggregate particles, including the permeable pore
space. Absorption and surface-moisture determinations are necessary to
calculate the amount of mixing water used in a concrete mixture.
SPECIFIC GRAVITY AND ABSORPTION OF COARSE AGGREGATE (ASTM C 127-88)
This test method covers the specific gravity and absorption of coarse
aggregate. The specific gravity may be expressed as bulk specific gravity, bulk
specific gravity SSD, or apparent specific gravity.
Concrete 4-13
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
Equipment
Steps
4-14 Concrete
Use the following items to perform tests for bulk specific gravity SSD, percent
absorption, and surface moisture:
e A balance, sensitive to 0.5 gram, capable of suspending the sample
container in water from the center of the weighing platform or pan of
the weighing device
e A wire sample basket or a bucket with a 4- to 7-liter capacity for 1 1/2 -
inch or smaller aggregate and a larger basket or bucket for larger
aggregate sizes.
e A water tank large enough to hold the basket.
e A pycnometer, 2 to 3 cubic feet.
e A heat source (oven or hot plate).
e A metal sample container.
e A metal spatula.
e An absorbent towel.
Perform the following steps to determine the bulk specific gravity of coarse
aggregate in an SSD condition:
Step 1. Wash a representative sample over the No. 4 sieve to obtain a sample
size according to Table 4-1, page 4-10.
Step 2. Dry the sample to a constant weight at 110°C +5°.
Step 3. Allow the sample time to cool to 50°C, immerse it in water, and allow
it to soak at room temperature for 24 hours.
Step 4. Remove the sample from the water and roll it in a large absorbent
cloth until all visible films of water are removed. The surfaces of the particles
will still appear to be slightly damp. The larger fragments may be wiped
individually. The aggregate sample is now in an SSD condition. Weigh the
samplein air in its SSD condition. Record this and subsequent weights to the
nearest 0.5 gram on DD Form 1208.
Step 5. Place the weighed SSD sample immediately in the wire basket
container. Determine its weight in water at 23°C +1.7°. Shake the basket or
container while it is immersed to remove any entrapped air. This weight is
the immersed weight (or weight in water).
Step 6. Calculate the bulk specific gravity in an SSD condition as follows:
B-C
where—
B =weght, in grams, of SSD samplein air
C =weight, in grams, of SSD samplein water
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
SPECIFIC GRAVITY OF FINE AGGREGATE (ASTM C 128-93)
Equipment
Steps
This test method covers the specific gravity and absorption of fine aggregate.
The specific gravity of fine aggregate may be expressed as bulk specific
gravity, bulk specific gravity SSD, or apparent specific gravity. For this test
method, fine aggregate is defined as material smaller than the No. 4 sieve and
larger than the No. 200 sieve.
Use the following items to perform this test:
e A pycnometer; 500-milliliter.
e A mold; metal-frustum (half-cone brass mold) water-absorption cone.
« A metal flat-head tamper.
Perform the following steps to determine the bulk specific gravity of fine
aggregate in an SSD condition:
Step 1. Obtain a representative sample weighing about 1,000 grams.
Step 2. Dry the sample to a constant weight at 110°C.
Step 3. Cool the sample to a comfortable handling temperature. Immerse it
in water, and allow it to soak for 24 + 4 hours.
Step 4. Decant the excess water carefully, ensuring that no loss of fines
occurs. Spread the sample on a flat, nonabsorbent surface and stir it to obtain
uniform drying. Continue drying the sample until it approaches a surface-dry
condition.
Step 5. Place the metal frustum water-absorption cone (half-cone brass mold,
see Figure 4-2) with the large opening down on a smooth surface and fill it
loosely with the aggregate. Lightly tamp the surface (raise the metal tamper
about 5 millimeters and allow it to fall under its own weight) of the aggregate
25 times with the metal tamper.
Figure 4-2. Water-absorption cone and tamping rod
Concrete 4-15
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
Step 6. Remove the loose sand from around the base and lift the mold
vertically. The fine aggregate is at the SSD condition when it slightly slumps
when you lift the mold. If the material does not slump, continue the drying,
accompanied by constant stirring. Repeat the cone tests at frequent intervals
until the cone of fine artillery slumps slightly upon removal of the water-
absorption cone.
Step 7. Weigh 500 + 10 grams of the SSD sample, and introduce it into a
partially water-filled 500-milliliter pycnometer. Agitate the sample to remove
all entrapped air bubbles. Adjust the water temperature to 23°C + 1.7° and fill
the pycnometer to 90 percent of its calibrated capacity. Roll, invert, and agitate
the pycnometer 15 to 20 minutes to eliminate the air bubbles. Fill the
pycnometer to calibrated capacity, weigh it, and record the weight to the nearest
0.1 gram.
Step 8. Calculate the bulk specific gravity in an SSD condition as follows:
5S
B+S-C
where—
B =weght, in grams, of pycnometer filled with water to calibrated capacity
S =wedght, in grams, of SSD specimen
C =weght, in grams, of pycnometer filled with the sample and water to
calibrated capacity
COARSE- AND FINE-AGGREGATE ABSORPTION
Equipment
Steps
4-16 Concrete
Absorption in aggregates is the aggregate’s ability to steal moisture from the
concrete-mix design until its thirst or attraction is satisfied.
The following procedure is a continuation of the specificgravity
determinations; therefore, the same equipment shall be used.
Perform the following steps to determine the percent absorption of coarse and
fine aggregates.
Step 1. Weigh the coarse aggregate in water and the fine aggregate in the
pycnometer.
Step 2. Remove the aggregates and dry to a constant weight at a temperature
of 110°C + 5°.
Step 3. Weigh and record the oven-dried samples.
Step 4. Calculate the percent of absorption using the following formula:
S-A
P= a x 100
where—
P =absorption of the aggregate in percent
S =weight of SSD specimen, in grams
A =waght of SSD samplein the oven-dried state in grams
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
The percent absorption represents the moisture content (oven-dried basis) of
the aggregate when it is in an SSD condition.
SURFACE MOISTURE
Surface moisture is the excess moisture remaining after the absorption
requirement of the aggregate has been met. This excess moisture determines
how much water is added to the concrete mix to meet the required W/C ratio
for the proper strength requirements. Perform this test just before mixing the
concrete as designed. This allows for adjusting the water, coarse-, and fine-
aggregate weights to retain design integrity.
Surface moisture is the water present in both the fine and coarse aggregates,
exceeding that which corresponds to an SSD condition. This water will
become part of the mixing water when the aggregate is used in making
concrete. The amount of mixing water used must be corrected to allow for its
presence. See ASTM C 566-89 and ASTM C 70-79.
SECTION III. FRESH-CONCRETE TESTS
After concrete is first mixed, a slump test and an air-content test are
performed and used as a control measure to determine the concrete’s quality
and consistency throughout a project.
Take samples of concrete for test specimens at the mixer by repeatedly
passing a receptacle through the entire discharged stream until sufficient
concrete is collected into the pan. In the case of ready-mixed concrete, take
samples from the transporting vehicle while it’s discharging the concrete (see
Figure 4-3).
Figure 4-3. Sampling concrete from a truck mixer
Concrete 4-17
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
The contents of a paving mixer should be discharged into a pile and sample
material taken by a shovel from at least five different portions of the pile. The
sample of concrete from which test specimens are made will be representative
of the entire batch. Obtain two or more samples by repeatedly passing a scoop
or pail through the discharging stream of concrete from the middle portion of
the batch to obtain the amount of material required by the test method.
Transport the samples to the testing site. To counteract segregation, mix the
concrete with a shovel until the concrete is uniform in appearance Note the
truck, time, and location of the placement of the concrete for future reference
In the case of paving concrete, samples may be taken from the batch
immediately after depositing on the subgrade. Take at least five samples from
different portions of the pile, and mix these samples thoroughly to form the
test specimen.
SLUMP TEST (ASTM C 143-90A)
EQUIPMENT
STEPS
4-18 Concrete
When the mixture appears to have reached the desired consistency, perform a
slump test. This method of testing covers the procedure to be used in the
laboratory and in the field for determining the consistency of concrete, which
is a characteristic of workability. It is not an exact method, but it gives
sufficiently accurate results.
Use this test to measure the consistency of a concrete mix by measuring the
vertical distance that the concrete settles to the nearest 1/4 inch.
NOTE: This test is not applicable when there is a considerable amount of
aggregate over 1 1/2 inches in the concrete.
Use the following items to perform this test in a field or simulated field
environment:
e Aruler.
e A scoop.
e A trowel.
e A water source
e A flat, smooth surface.
e A slump cone with tamping rod.
e A pencil.
e Paper.
Perform the following steps to determine the slump:
Step 7. Moisten the inside of the slump cone and place it on a flat, moist,
nonabsorbent (rigid) surface. Hold it in place during filling by standing on the
two foot pieces.
Step 8. Fill the slump cone to one third of its volume (2 5/8 inches high) with
plastic concrete.
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
NOTE: From steps 2 to 10, a total time of no more than 2 1/2 minutes should
elapse.
Step 9. Rod the concrete by applying 25 evenly distributed strokes,
penetrating the full depth of the first layer in the slump cone.
Step 10. Add a second layer of concrete to the slump cone until two thirds of
its volume is filled (about 6 1/8 inches high).
Step 11. Rod the second layer in the same manner as the first, with the rod
just penetrating the underlying layer.
Step 12. Add the third and last layer of concrete, overfilling if possible
Step 13. Rod the third layer following the procedure in step 5. If the concrete
height subsides below the top of the cone, add additional concrete to keep it
above the top of the mold.
Step 14. Strike off the excess concrete with a screeding and rolling motion of
the tamping rod so the cone is completely filled.
Step 15. Removethe slump cone from the concrete.
a. Place the hands on the handles and press downward.
b. Step off the footholds.
c. Raise the cone carefully and quickly in a vertical direction. Raise the
cone a distance of 12 inches within 5 to 7 seconds by a steady upward lift
with no lateral or twisting motion.
d. Place the cone directly beside the slumped concrete. At this point
about 2 1/2 minutes should have elapsed since the start of filling in step 2.
Step 10. Measure and record the slump immediately (see Figure 4-4).
Figure 4-4. Measuring the slump of fresh concrete
Concrete 4-19
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
a. Place the tamping rod along the top of the cone so it projects over the
concrete.
b. Measure the slump from the bottom of the rod to the top center of the
concrete with a ruler.
c. Record the slump to the nearest 1/4 inch.
SUPPLEMENTARY TEST PROCEDURE
After completing the slump measurement, gently tap the side of the specimen
with the tamping rod. The behavior of the concrete under this treatment is a
valuable indication of the cohesiveness, workability, and placeability of the
mix. A well-proportioned, workable mixture will gradually slump to lower
elevations and retain its original identity. A poor mix will crumble, segregate,
and fall apart. Slump is usually indicated in the project specifications as a
range, such as 2 to 4 inches, or as a maximum value not to be exceeded. When
it is not specified, an approximate value can be selected from the list in Table
4-6.
Table 4-6. Recommended slumps for various types of construction
g Slump, in Inches
Types of Construction z a
Maximum * Minimum
Reinforced foundation walls and footings 3 1
Plain footings, caissons, and substructure walls 3 1
Beams and reinforced walls 4 1
Pavements and slabs 4 1
Mass concrete 2 1
* May be increased 1 inch for consolidation by hand methods such as rodding
and spading.
AIR-CONTENT TEST (ASTM C 231-97)
EQUIPMENT
4-20 Concrete
Add an air-entraining admixture to the concrete mix so that enough air will be
entrained to improve the mixture’s workability, durability, watertightness,
and freeze-thaw resistance but not enough to substantially reduce the
strength. Air-entrained cements may also be available for use in some
military situations. The desired amount of air is generally from 4.0 to 7.5
percent of the total mix.
Perform this test to determine the percentage (+ 0.5 percent) of entrained air
in a plastic (fresh) concrete sample.
Use the following items to perform this test in a field or simulated field
environment:
e An air-entrainment meter with 5 percent calibration cup and
instructions.
e A trowel.
STEPS
C2, FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
e A tamping rod (5/8 inch in diameter and 24 inches long with a rounded
end).
e A sample of plastic (fresh) concrete.
e Water.
e Oil.
e Rags.
« A pail.
« A mixing pan (from the concrete test set).
e A kitchen scoop.
e Paper.
e A pend.
e A rubber mallet.
There are many different air-entrainment meters currently fielded and
replacements of old equipment may not be the same. For this reason, it is
recommended that the steps outlined in the manufacturer’s user’s manual be
followed.
SECTION IV. FLEXURAL-STRENGTH TEST (MODULUS OF RUPTURE)
TEST BEAMS
The flexural strength of hardened concrete is measured by using a simple
concrete beam and third-point loading mechanism. The flexural strength is
determined by calculating measured breaks of the beam and is expressed as a
modulus of rupture in psi.
Beam forms for casting test beams from fresh concrete are available in many
sizes. The most commonly used size is 6 x 6 x 21 inches. Although equipment
for obtaining sawed specimens may not be available, the test may be
performed on beams sawed from existing concrete structures for evaluation
purposes.
FORMING THE BEAMS (ASTM C 192-90A)
Assemble a standard 6- x 6- x 21-inch concrete-beam mold and lightly oil the
inside. Fill the mold with two layers of concrete from the production batches,
each about 3 inches deep. Consolidate each layer by rodding, using one stroke
per 2 square inches (63 per layer), evenly distributed over the layer’s surface.
Tap the sides lightly 10 to 15 times with a rubber mallet to close the voids left
by rodding. Lightly spade the concrete along the mold’s sides with a trowel to
help remove surface voids. When rodding the second layer, penetrate the first
layer about 1/2 inch. Strike off the top surface with a straightedge, and finish
it with a wood or magnesium float.
Concrete 4-21
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221 (I)
TAKING THE SPECIMENS
Take test specimens at least once for each 100 cubic yards or fraction thereof,
for each class of concrete placed in any one day, or as directed in the project
specifications. Make at least three specimens for each test age and mixture
design being evaluated in the lab. Additional specimens may be made for
future testing. Test ages are normally 14 and 28 days for flexural-strength
tests. For testing field-placed concrete, a minimum of two specimens for each
test age is required.
CURING THE BEAMS
Place a suitable identifying label on the finished surface of the specimens.
Cover the entire specimens—still in the mold—with a double thickness of wet
burlap. Ensure that the specimens remain on site and are undisturbed for an
initial curing period (the first 16 to 48 hours after molding). After this curing
period, move them to the testing laboratory and remove them from the molds
for further curing. The most satisfactory curing range for concrete is 68° to
86°F, with 73.4°F being the most favorable temperature. Moist-cure the
beams in saturated lime water, totally submerged in a wet-tank humidity
room, or keep them wet until they are tested.
FLEXURAL-STRENGTH TEST (ASTM C 78-94)
EQUIPMENT
STEPS
4-22 Concrete
Perform this test to determine the flexural strength (modulus of rupture) of
the test specimen to + 10 psi. Record the specimen identification, modulus of
rupture, any defects noted, and specimen’s age.
Use the following items to perform this test in a laboratory environment:
e The flexural-strength test apparatus.
e A concrete beam, 6 x 6 x 21 inches.
e A measuring tape.
e A stopwatch.
e Pens.
e Pencils.
e Paper.
e Safety goggles.
e A proving-ring with proving-ring calibration and constant.
e Specimen identification.
¢« A calculator.
Perform the following steps to determine the flexural strength. Wear safety
goggles throughout this test.
Step 1. Assemble the test apparatus and check for functional operation (see
Figure 4-5).
C2, FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
Apply load here Steel rod
Loadi
gading Specimen
{i Steel rod Steel ball 1
T ae f i e a
Ti 173 —— v3 173 z]
Length of span
Figure 4-5. Apparatus for flexural-strength test
Step 2. Measure the length of span and record the measurement on a piece of
paper. The length of span is determined by measuring the distance from
center to center of the two loading points (or supports) on the base of the
apparatus (see Figure 4-5). The normal length of specimen is 21 inches and
the normal length of span is 18 inches.
Step 3. Place the specimen in the tester and bring the loading surface into
contact with the test specimen (see F igure 4-5).
Step 4. Zero the gauge. Some apparatus are equipped with a hydraulic pump
and corresponding gauge while others are equipped with a loading jack and
proving ring.
Step 5. Apply a load at a continuous rate that constantly increases the
extreme fiber stress between 125 and 175 psi per minute. This is an
approximate load of 1,500 to 2,100 pounds per minute.
Step 6. Obtain the total load, in pounds, at the time of specimen failure, and
record the weight on the paper provided. On machines equipped with
hydraulics, take the reading directly from the gauge. For machines equipped
with a proving ring, this reading is the product of the dial-gauge reading and
the proving-ring constant.
Step 7. Determine and record the width and depth of the specimen, in inches,
at the point of failure (normally 6 x 6 inches).
Step 8. Determine the point of failure in the specimen, and calculate the
modulus of rupture. If the specimen fails outside the middle third of the span
length by more than 5 percent of the total span length, then the specimen is
Concrete 4-23
C2, FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
4-24 Concrete
considered unusable and should be discarded (not more than 0.9 inches for an
18-inch span (18 x 0.05 =0.9).
a. Use the following formula to calculate the modulus of rupture if the
specimen fails within the middle third of the span length:
PXL
where— l bxd?
R =modulus of rupture in psi
P =applied load, in pounds
L =length of span, in inches
b =width of specimen at failure point, in inches
d =depth of specimen at failure point, in inches
b. Use the following formula to calculate the modulus of rupture if the
specimen fails outside the middle third of the length of span by not more
than 5 percent of the span length:
R= 3P xa
b xd?
where—
R =modulus of rupture in psi
P =applied load, in pounds
b =width of specimen at failure point, in inches
d =depth of specimen at failure point, in inches
a = distance between the failure point and the nearest support, measured
along the centerline of the bottom of the specimen, in inches
Step 9. Record the following information about the test (some information
may be unavailable at the time of the test):
e Specimen’s identification number.
e Average width to the nearest 0.05 inch.
e Average depth to the nearest 0.05 inch.
e Span length, in inches.
e Maximum applied load, in pounds.
e Modulus of rupture, to the nearest 10 psi.
e Curing history (how the specimen was cured) and apparent moisture
content of the specimen at the time of the test.
e Any defects noted in the specimen.
e The age of the specimen.
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
SECTION V. COMPRESSIVE-STRENGTH TEST
The compressive strength of hardened concrete, as measured by compression
tests on standard forms of cylindrical specimens, is used in the design of
structures. Compressive-strength tests are made on concrete trial mixtures to
evaluate the performance of available materials and to establish mixture
proportions that give the required strength. Strength tests are used also to
control the quality of concrete being manufactured in the field. Compressive
strength is defined as the average of the strengths of all cylinders of the same
age made from a sample taken from a single batch of concrete. At least two
cylinders are required to constitute a test. Therefore, a minimum of four
specimens are required if tests are to be made at 7 and 28 days. The test
results will be the average of the strengths of the two specimens tested at 28
days.
CASTING A CONCRETE CYLINDER
EQUIPMENT
The standard test specimen is a cylinder 6 inches in diameter by 12 inches
long, capped with a suitable material to provide smooth, bearing surfaces on
each end. Load is applied to the end surfaces through metal platens on the
testing machine (cylinder breaker), causing compressive stress in the
longitudinal direction of the cylinder.
Make the cylinders as near as possible to the place where they will be stored
for the first 16 to 48 hours. Sufficient concrete (about 1 cubic foot) for the
desired number of cylinders must be available in the trial mixture or field
sample. Material from the air-content test must not be reused, since this may
be contaminated with excess water. Use appropriate sampling procedures for
procuring your sample as stated in Section III.
Use the following items and information to perform this test in a field or
simulated field environment:
e A tamping rod (5/8 inch in diameter and 24 inches long with a rounded
end).
e A sample of fresh concrete.
e A trowel.
e Oil.
e Rags.
e A disassembled cylinder mold.
e A sheet of plastic or burlap.
e A kitchen scoop.
e A pan (24 inches wide x 24 inches long x 3 inches deep).
e A grease pencil.
Concrete 4-25
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
e Waterproof paper tags.
e Gummed labels.
e Anink pen.
e Paper.
e Water.
e The test-specimen number.
e Theorigin of a concrete sample.
STEPS
Perform the following steps to produce and label a concrete cylinder for
testing:
Step 1. Prepare the mold.
a. Clean and dry the mold.
b. Oil the mold lightly.
c. Assemble the mold.
Step 2. Make the cylinder.
a. Fill the mold one-third full with fresh concrete
b. Consolidate the concrete by applying 25 evenly distributed strokes over
the mold’s surface area with the tamping rod. The tamping rod must
totally penetrate the layer of concrete.
c. Tap the side of the mold 8 to 10 times with the tamping rod.
d. Add concrete to the mold so as to fill it two-thirds full.
e. Apply 25 evenly distributed strokes to the mold’s surface area using the
rounded end of the tamping rod, which must pass entirely through the
second layer of concrete and 1 inch into the preceding layer.
f. Tap the side of the mold 8 to 10 times with the tamping rod.
g. Add concrete to the mold to slightly overfill it.
h. Repeat step 2e. The tamping rod must pass entirely through the top
layer and 1 inch into the preceding layer.
i. Tap the side of the mold 8 to 10 times with the tamping rod.
j. Trowel off the concrete so that it is flush with the top of the mold and
smoothly finished.
Step 3. Label the mold. The label should include, as a minimum, all of the
following information:
e Thespecimen number.
e Thedate the cylinder was made.
e Theproject or placement that the concrete came from.
4-26 Concrete
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
The system of labeling is optional. The information should be recorded on a
paper tag or gummed label and attached to the mold.
Step 4. Cover the cylinder with plastic or wet burlap to maintain moisture in
the sample. The covering should be tight around the cylinder but should not
make contact with the fresh concrete.
Step 5. Allow the cylinder to cure undisturbed for 24 hours.
Step 6. Remove the covering and the mold from the cylinder after 24 (+ 8)
hours.
Step 7. Transfer the label from the mold to the concrete cylinder. The label
itself may be transferred or the information may be recorded directly on the
cylinder with a grease pencil.
Step 8. Cure the cylinder.
NUMBER OF SPECIMENS
The number of specimens tested depends on the job specifications. If no
requirement is listed in the specifications, a minimum of 2 will be molded for
each test age for each 100 cubic yards, or fraction thereof, of each class of
concrete placed in any one day. A third specimen may be taken to assist in
determining when forms may be removed. The test specimens must remain
on site and undisturbed for an initial curing period (the first 16 to 48 hours
after molding). Normally the test ages are 7 and 28 days for compressive
strength tests.
CURING AND STORING CYLINDERS
After an initial curing period for 16 to 48 hours, remove (from the jobsite)
specimens that are intended for checking the strength of laboratory trial
mixtures or to serve as the basis for acceptance or quality control of field
concrete. Take them to the testing laboratory and moist-cure them at 73.4°F.
Store them in moist rooms, in damp sand or sawdust, or in limewater to
maintain free water on all surfaces of the specimen at all times.
Occasionally, test specimens are made in the field to determine when forms
may be removed. Form these in addition to the specimens formed for strength
determination. Give these specimens (as much as possible) the same
protection from the elements on all surfaces as is given to the portions of the
structure that they represent. Store them in or on the structure as near as
possible to the point of use. Test them in the moist condition resulting from
the specified curing treatment. Specimens intended for testing to determine
when a structure may be put into use are removed from the molds at the same
time the forms are removed from the structure.
When shipping specimens from the field to the laboratory for testing, pack
them in a sturdy wooden box or other suitable container surrounded by wet
sawdust or wet sand. Provide protection from freezing during storage or
shipment. Moist curing is continued when the specimens are received in the
laboratory.
Concrete 4-27
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
CAPPING CYLINDERS
Plane the ends of compression-test specimens within 0.002 inch and within
0.5 degree of being perpendicular to the axis of the cylinder.
Cap (with neat cement) specimens formed in strong metal molds having
accurately flat baseplates 2 to 4 hours after molding. Make a stiff paste of
portland cement and water at the time the cylinder is molded so that the
capping mixture will shrink before application. Remove any free water or
laitance a (layer of fine particles on the surface) from the end of the
specimen. Apply the paste to the top of the concrete and work it with a flat
plate until it is smooth and level with the top of the mold.
Grind hardened concrete specimens to smooth the ends or cap them with a
material having greater compressive strength than the concrete. Prepared
mixtures of sulfur and granular materials, special high-strength gypsum
plasters, and neat high-early strength cement are satisfactory capping
materials (ordinary low-strength plaster of paris, compressible rubber, or
fibrous materials are not suitable for caps). Apply the selected material ina
plastic state and finish it to the desired plane surface by applying glass or
metal plates and squeezing out excess material to provide a cap that is as
thin as possible.
Apply sulfur caps in time to harden at least 2 hours before testing. Plaster
caps cannot be stored over 4 hours in the moist room. Age neat cement caps
6 days or more in the moist room (2 days when Type II cement is used).
During capping, protect moist-cured specimens against drying by covering
them with wet burlap. There are numerous alternatives to sulfur caps listed
in ASTM C 617-94. The metal cap with a rubber membrane is not an ASTM-
approved method; however, specific guidelines for their use are under review
by the ASTM. The test procedures used in this manual refer to the metal
caps due to their availability within the supply system. If you must use
sulfur caps, ensure that sulfur vapors are not inhaled while heating the
capping compound. Ensure that there is adequate ventilation and that
respiratory protection is used. Used sulfur capping compound is a
hazardous material and must be properly disposed of.
DETERMINING COMPRESSIVE STRENGTH OF A CYLINDRICAL
SPECIMEN (ASTM C 39-96)
EQUIPMENT
4-28 Concrete
Perform this test to determine the compressive strength of the concrete
cylinder to within breakage and to determine anything unusual about the
break.
Use the following items to perform this test in a well-ventilated laboratory:
e A concrete cylinder (6 inches in diameter and 12 inches in height).
e A concrete capping set.
e Heat-resistant gloves.
e Capping compound.
STEPS
FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
e A ruler accurate to 0.01 inch.
e Calipers with at least a 6-inch opening.
e Paper.
e Pencils.
e Safety goggles and protective apron.
e A face shield.
e Oil.
e Rags.
e A calculator.
e A concrete compression tester with a 250,000-pound capacity.
« A hammer (ball peen or carpenter’s).
Perform the following steps to determine the concrete cylinder’s compressive
strength:
Step 1. Prepare the concrete cylinder.
NOTE: If rubber-filled metal is used, go to step 1j.
a. Melt the capping compound in the melting pot. Ensure that you melt
enough compound to make several caps.
b. Clean and lightly oil the baseplate of the capping apparatus.
c. Set the baseplate into the capping-apparatus stand.
d. Pour asmall amount of the heated (liquid) capping compound into the
baseplate.
e. Position the cylinder at midheight against the backrest of the capping
apparatus. Slowly lower the cylinder into the baseplate while keeping the
cylinder flush against the backrest. If the cylinder is not kept flush with
the backrest while capping, the caps and the cylinder will not be
perpendicular, and a proper break will not occur.
f. Remove the cylinder from the capping apparatus once the capping
compound has solidified.
g. Inspect the cap for uniformity and defects. If you see any defects,
remove the cap and recap the cylinder; then return to step la.
h. Repeat steps 1a through 1g for the uncapped end of the cylinder.
i. Determine and record the average diameter of the concrete cylinder.
The average diameter is the average of two diameters taken perpendicular
to each other at midheight of the cylinder.
j. Clean and examine the bearing surface of the steel cap (if used) for
nicks, gouges, and warping. Check the rubber inserts for tears, rips, cuts,
and gouges. Replace them if they arein poor condition or if the maximum
Concrete 4-29
C2, FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
4-30 Concrete
number of serviceable uses has been exceeded. Place the steel cap firmly
on the cylinder’s ends.
Step 2. Prepare the compression tester (see Figure 4-6).
a. Clean the tester’s bearing plates (loading surfaces).
b. Check the tester for proper operation.
c. Set the gauge to zero.
Step 3. Place the capped cylinder into the compression tester and center it on
the bearing plates. Secure the protective cage around the cylinder.
Step 4. Apply the test load at a rate of 20 to 50 psi per second, not to exceed 50
psi per second (50 psi per second is about equivalent to a load [gauge reading]
of 1,400 pounds per second).
Step 5. Read the gauge and record the load applied at the time of failure.
Step 6. Inspect the broken cylinder and record the following information:
e Identification number.
e Diameter.
e Cross-sectional area, in square inches.
e Maximum load applied, in pounds.
e Compressive strength, calculated to the nearest 10 psi.
e Type of break (See Figure 4-7).
e Defects in either specimen or caps.
e Age of specimen.
Step 7. Calculate and record the compressive strength of the cylinder using
the following formula:
Compressive strength = £
where—
P =load at time of failure in pounds
A=nr
C2, FM 5-472/NAVFAC MO 330/AFJMAN 32-1221(I)
Cone Cone and split Cone and shear Shear Columnar
Figure 4-7. Types of fractures
Concrete 4-31