UBGMY1-15-1 Practical Laboratory Workbook Practical-4: Concrete casting

Source the mix design is taken from Name of the mix used

BS EN 206
BS 2500

Mass used in sample Mass used for 1 m3

A B C A B C
0.395 0.197 0.395 395 197.5 395
Cement
0.660 0.660 0.660 660 660 660
Fine aggregate
1.17 1.17 1.17 1170 1170 1170
Coarse aggregate

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UBGMY1-15-1 Practical Laboratory Workbook Practical-4: Concrete casting

Mix Type of fine aggregate Type of coarse aggregate Type of Cement

Portland Cement

PC Cement CGBS

Portland Cement

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UBGMY1-15-1 Practical Laboratory Workbook Practical-4: Concrete casting

Results
Mix Mix-A Mix-B Mix-C
395 197.5 395
Portland cement (kg)
Ground granulated blast furnace slag 0 197.5 0
(GGBS) or fly ash (kg)
660 660 660
Fine aggregate(kg)
1170 1170 1170
Coarse aggregate(kg)
200 200 200
Water (litre)
100 70 140
Slump (mm)
2.562 2.459 2.650
Mass of concrete in mould (kg)

Calculations
Water/cement ratio 0.506 0.506 0.506
water/(PC + GGBS/fly ash)
Plastic density 25.62 x 106 24.59 x 106 26.5 x 106
mass of concrete/volume of mould

The plastic density of concrete is important because concrete manufacturers produce concrete in
quantities of mass, e.g. 10 tonnes, but the amount of concrete required on site to fill formwork is
measured in volume, e.g. 3.8 m3 . Plastic density is a way concrete manufacturers can check the mass
of concrete and produce the required volume.
Calculate proportions by mass using the information in the table above.

MIX A MIX B
_ _
Mass Proportion by Mass Proportion by
(kg) mass (kg) mass
395 395 197.5 395
Portland Cement
2562 4915
0 N/A 197.5 395
GGBS or Fly ash 4915
660 110 660 660
Fine aggregate 427 2459
1170 195 1170 1170
Coarse aggregate 427 2459
200 100 200 200
Water 1281 2459

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UBGMY1-15-1 Practical Laboratory Workbook Practical-4: Concrete casting

Based on your laboratory test results and further reading answer the following

1) Explain the importance of tapping of concrete in each layer of slump test (filling the
slump in 3 layers) in compliance with BS EN 12350-2:2019 Testing fresh concrete Part
2: Slump-test.
Ans- The importance of tapping of concrete in each layer of slump test (filling the slump
in 3 layers) in compliance with BS EN 12350-2:2019 Testing fresh
concrete Part 2: Slump-test are given below-
 To ensures Uniform Compaction
Compacting each of the three layers with 25 strokes uniformly distributed over the
cross-section ensures proper compaction throughout the concrete. For the bottom
layer, slightly inclining the rod and directing approximately half the strokes spirally
toward the center ensures the entire layer is compacted effectively
 To prevent Voids and Segregation
Compacting each layer thoroughly minimizes voids and reduces segregation of
aggregates and paste, which could compromise the integrity of the test results
 To accurate representation of workability
Compacting the top layer while keeping an excess of concrete above the cone
ensures no underfilling, which would result in a lower slump value. Striking off the
excess provides a level surface for consistent measurement.
 To avoid misleading result
Compacting the bottom layer without striking the base and compacting the top
layer while preventing subsidence ensures the test remains consistent.

2) Justify whether the concrete cube moulds comply with EN 12390-1:2012 Testing
hardened concrete Part 1: Shape, dimensions and other requirements for specimens
and moulds?
Ans-To justify compliance with EN 12390-1:2012, the following checks were carried out:
1. Designated Size: The mould’s actual size was verified to fall within ±10% of the
nominal size. For a 150 mm cube mould, the dimensions were confirmed to be
between 135 mm and 165 mm.
2. Tolerances:
o Between Moulded Surfaces: The tolerance was checked to be within
1.0% of the nominal size, meaning 150±1.5
o Between Trowelled and Moulded Faces: The tolerance was ensured to
be within 1.5%, meaning 150±2.25
o Flatness of Load-Bearing Surfaces: Measurements confirmed that the
deviation did not exceed 0.0006d mm (0.09 mm for 150 mm).
o Perpendicularity of Sides: It was verified that the sides were
perpendicular to the base within a tolerance of 0.5 mm.

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UBGMY1-15-1 Practical Laboratory Workbook Practical-4: Concrete casting

3. Aggregate Compatibility: The mould’s nominal size was confirmed to be at

least 3.5 times the maximum aggregate size Dmax, as per EN 206-1.
4. Surface Finish and Integrity: The mould was checked to ensure smooth
surfaces without defects, meeting the standards for accurate test results.
All criteria were satisfied, confirming the mould complied with EN 123901:2012.

3) Does the methodology used in the laboratory for preparing the concrete cure comply
with BS EN 12390-2:2019 Testing hardened concrete Part 2: Making and curing
specimens for strength testing? Justify your answer and comment on any meaningful
deviations

Ans - The methodology used for curing concrete test specimens, based on BS EN 12390-2:2019,
follows the required standards in the following way:
1. Initial Curing in Moulds: The test specimens were left in their moulds for at least 16 hours
but not longer than 3 days, at a temperature of 20 ± 5°C (or 25 ± 5°C in hot climates).
During this time, the specimens were protected against shock, vibration, and dehydration.
In cases where early testing was necessary, or rapid hardening concrete was used, the
moulds were removed before 16 hours.
2. Curing after Mould Removal: Once removed from the moulds, the specimens were cured
in water at 20 ± 2°C, or placed in a curing chamber at 20 ± 2°C with relative humidity ≥
95%. This ensured that the specimens remained hydrated properly until testing, which is
crucial for accurate strength results.
3. Maintenance of High Humidity: Maintaining a relative humidity of ≥ 95% in the curing
chamber at 20 ± 2°C was monitored closely. Regular checks were performed to ensure the
surfaces of the specimens remained continuously wet, which is essential to prevent
premature drying that could affect the test results.
By following these standards, the concrete specimens were cured appropriately, ensuring reliable
and accurate strength test results. Any deviations from these methods, such as improper
maintenance of humidity or temperature, would have compromised the curing process and
affected the outcomes of the tests.

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UBGMY1-15-1 Practical Laboratory Workbook Practical-4: Concrete casting

List of references
 BS EN 12350-1:2019 Testing fresh concrete Part 1: Sampling and common apparatus
 BS EN 12350-2:2019 Testing fresh concrete Part 2: Slump test
 BS EN 12350-6:2019 Testing fresh concrete Part 6: Density
 BS EN 12390 1:2021 Testing hardened concrete Part 1: Shape, dimensions and other
requirements for specimens and moulds.
 BS EN 12390 2:2019 Testing hardened concrete Part 2: Making and curing specimens for
strength tests