Experimental Work CHP 7

CHAPTER NO 7
EXPERIMENTAL PROGRAM
Chapter - 7
The experimental study was carried out at the Construction Material Testing Laboratory, Faculty
of Civil Engineering, Mirpur University of Science And Technology Mirpur AJK.
Fig 6.1
Construction Material Testing Laboratory
STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

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DANISH AZAD AHTESHAM ALTAF IMRAN ASLAM MUHAMMAD UMER ABDULLAHKHAN Page
120
CHAPTER NO 7
7.1
Materials:
The materials used in this investigation are given below. The same type of materials were
used throughout the project but unavoidably they were from different querries.
There are many widely accepted methods of sampling and testing of concrete and steel. The
properties of the concrete and steel used were determined by standard tests according to the
ASTM. The designof the concrete mixes used in the project and the properties of the various
materials used are presented in this chapter
7.1.1 Coarse Aggregates:

Margalla Crush was used. We take 1 down crush material from crusher (TAXILA).
Besides grading, the size of aggregates is also important in the sense that it affects the
workability and strength of concrete mix. The larger the maximum size of the aggregate, the
smaller is the cement requirement for a particular water to cement ratio. This reduces the heat of
hydration and results in lesser thermal and shrinkage cracks. However, in structural works, the
maximum size of aggregates in concrete is usually restricted to 25 mm or 37.5 mm (1 in. or 1.5
in.) due to the limited size of concrete sections and spacing of reinforcing bars.
Figure:
crush
7.2 Margalla
plant taxila

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7.1.1.1
Quartering:
The quartering procedure is as follows:
1)
Place the sample on a hard, clean, level, non-absorptive surface where there will be
no222 loss of material nor the accidental addition of foreign material.
2)
Using a large trowel, shovel, or other suitable tool turn the entire sample over at least
three times. Form the sample into a conical pile by depositing individual lifts on top of the
preceding lift.
3)
Flatten the pile to a uniform thickness by pressing down the apex with a shovel or trowel.
Each quarter sector of the resulting pile is required to contain the material originally in the pile.
The diameter of the pile should be equal to 4-8 times the thickness of the pile.
4)
With a large trowel or other suitable tool, divide the sample into four equal quarters.
Remove two diagonally opposite quarters, including all fine material, and brush the cleared
spaces clean.
5)
Combine diagonally opposite quarters of the material into two samples. All fine materials
shall be included by brushing the surface clean. Store one of these two halves. If the remaining
material still weighs too much, repeat the entire quartering process until the proper test sample
size is obtained.

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Figure: 6.3Quartering of aggregates
7.1.2 FINE AGGREGATES

Lawrancepur sand was used. Because finess modulus of this sand is almost > 2.5 .The
fineness modulus is considered as a weighted average size of a sieve on which the material is
retained. The fineness modulus gives an indication of the probable behavior of a concrete mix
made with aggregate having a certain grading. A larger value of fineness modulus indicates a
coarser particle whereas a smaller value indicates a finer particle. Mathematically, the fineness
modulus is obtained by dividing the sum of cumulative percent mass retained at each sieve
(designated in ASTM C136-05) in a sieve analysis test, by 100.
7.1.3 Cement:
Ordinary
the trade name
used.
Portland cement with

Fauji Cement was

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CHAPTER NO 7
Figure 7.5
Fauji Cement
7.1.4 Water reducing
Agent:
The water reducing agent

manufactured and supplied
[PVT] LTD under the code
200. Chemrite AG-200 is a
super-plasticizer for
concrete, which prolongs
water-cement ratios.
used in this project was

by imporient chemicals
name of Chemrite AG
highly effective liquid
production of free flowing
slump retention at low
Figure: 7.6Water Reducing Agent
7.1.5 Steel bars:

Deformed steel Grade 40 for #8and #3 bars were used in the test beams.
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Figure 7.7Steel bars
6.1.7 Ferrocement
Two ferrocement meshes (rectangular and
hexagonal ) were used.both these meshes were
wrapped one on another (hexagonal mesh
wrapped on rectangular) so that the bond will
good with the concrete.
Fig
6.8
7.1.8
Steel formwork
used for casting beams
Rectangular and hexagonal

ferrocement
Formwork:
(molds) was

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CHAPTER NO 7
Figure 7.10
Steel Formwork
7.3
Mix Design: [56]
7.3.1 Introduction:
The ACI method 211.1 is used to design normal and heavy weight concrete mixes having
twenty eight days compressive strength of 35MPa or 5000 psi (maximum).
Sound design or analysis of a composite structure depends on reliable information about the
properties of the materials to be used. The strength of a reinforced concrete member and its
resistance to cracking and prevention of corrosion of reinforcement depend on many parameters,
particularly on the strength properties of concrete and steel. The deformations are related to the
stiffnesss of the members which in turn depend on the characteristics of their components

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7.3.2 Background Data:

To the extent possible, selection of concrete proportions should be based on test data or
experience with the materials actually to be used. Where such background is limited or not
available, estimates given in this recommended practice may be employed.
The following information for available materials will be useful:
Sieve analyses of fine and coarse aggregates.

Unit weight of coarse aggregate.
Bulk specific gravities and absorptions of aggregates.
Mixing-water requirements of concrete developed from experience with available
aggregates.
Relationships between strength and water-cement ratio or ratio of water-to-cement
plus other cementitious materials, for available combinations of cements, other
cementitious materials if considered, and aggregates.

Specific gravities of portland cement and other cementitious materials, if used.
Optimum combination of coarse aggregates to meet the maximum density grading for
mass concrete
7.3.3 Test:
i-Dry Sieve Analysis of Fine and Coarse Aggregates
(ASTM Designation: C l36)[57]
Scope & Significance:
This test method covers the determination of the particle size distribution of fine and
coarse aggregates by sieving.

This gradation gives an indirect measure if the workability and average particle size.
Accurate determination of materials finer than 75 micron (Sieve No 200) cannot be
achieved by this test
Apparatus
Standard set of sieves

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Sieve shaker
Sample of the aggregate
Figure: 7.11
Sieve analysis
Procedure:
Take the oven-dried sample. The sample should be perfectly dry because if there is some
moisture content present then the particles will stick together and will not pass through
the sieves.
Temperature of the oven = 1105 C
Place the set of standard and non-standard sieves one above another with the smallest
aperture opening at the bottom.

The pan is placed at the bottom-most position.
This experiment can be performed manually or with the aid of a machine called sieve
shaker.
The manual method should be performed in a proper sequence which is as follows;
i.
forward and backward motion
ii.
left and right motion
iii.
clockwise (CW) and counter-clockwise (CCW) motion

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iv.
Frequent jolting.
Time elapsed for the sieving process is 3-5 minutes and should not be less than 3 minutes
Weigh the mass retained on each sieve and calculate the percentage passing through each sieve.
Then the FM can be calculated by using the relation;
Cumulative retainedonstandardsievesof 150 morabove
Finess modulus =
Grading Requirement for Coarse Aggregates

(Quality of ASample):
Grading basically indicates the sizes of the aggregates and in which proportions they are present.
There are some limiting values for every sieve provided by ASTM or BS, we use these limiting
values to get our final answer. Take the minimum and the maximum values provided by ASTM.
Now take these minimum and maximum value as your reference and if the values of our own
data lies inside theseminimum and the maximum values provided by ASTM, then the quality of
our sample is OK but if your values lies outside these of maximum and minimum range then the
sample is not according to specifications.

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Observation & Calculation:
Sieve
size
mass
retained
Individual
retained
% Cumulative
retained
(g)
% Cumulative % Size 67
passing
Requirement
s
100
100
3/4
346
8.65
8.65
91.35
90-100
3/8
2840
71
79.65
20.35
20-55
#4
798
19.95
99.6
0.4
0-10
#8
0.1
99.7
0.3
0-5
Pan
12
0.3
100
Total
4000
Table 7.1: Results of Course aggregate (Margalla Crush)
Total Weight of Sample= 4000g
RESULTS
Material = 1 down material
Max nominal size = 3/4
Grading requirements for coarse aggregates = size 67 OK!
FINE AGGREGATES (Lawrancepur sand)

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Total Weight of Sample= 1000g
Table 7.2:Results of fine aggregate
Sieve size
Mass retained
(g)
Individual
retained
% Cumulative % Cumulative
retained
passing
#4
18
1.79
1.79
98.21
#8
60
5.96
7.75
92.25
#16
190
18.87
26.62
73.38
#30
320
31.78
58.40
41.60
#50
221
21.95
80.35
19.65
#100
185
18.37
98.72
1.28
Pan
13
1.29
100
Total
1007
Results:
Cumulative retainedonstandardsievesof
100
orabove
Finess modulus =
(1.79+7.75+ 26.62+58.40+ 80.35+98.72)

100
=2.7 OK!
ii-Dry rodded Unit weight of coarse aggregate

(ASTM Designation: C 29)[58]
This test method is used to determine the dry rodded unit weight of the given coarse
grained specimen.

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During the concrete mix design, when the aggregate is to be batched by volume or by
weight, then it becomes necessary to know the mass of the aggregates that will fill the
container of unit volume. If we know the bulk density of the aggregate material then we
can easily determine the mass required to fill a unit volume container.
Bulk density also indicates the percentage of voids present in the aggregate material. This
percentage of voids affects the grading of the aggregates which is important in high
strength concrete.
Bulk density also indicates the compactive effort required to compact the concrete.
Apparatus
Balance
Temping rod
Measuring Cylinder/Bucket
Shovel or Scoop
Figure: 7.12
Measuring Cylinder/Bucket

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Procedure:
Calibrate the metal bucket to determine its volume by determining the net weight of
water required to fill it and dividing it by the density of water. For this test procedure it is
sufficiently accurate to accept the density of water at room temperature to be 998 kg/m 3
(62.3 lbs. /ft3).
Rodding the aggregates. Fill the bucket one-third full and rod the aggregate layer with 25
strokes of the tamping rod, evenly distributed over the surface. Add another layer of
aggregates so that the bucket is approximately two-thirds full and repeat the rodding
procedure. The third layer of aggregates should fill the pail to overflowing. Again repeat
the tamping procedure and strike off the excess with the tamping rod. Manually try to
balance the depressions below the top of the bucket with slight projections above the top.
When tamping the first lift, do not permit the rod to penetrate to the bottom of the bucket.
However, the subsequent lifts should penetrate to the top of the previous lift.
The rodded unit weight is computed in kg/m3 (lb/ft3) from the net weight of the rodded
aggregates in the bucket divided by its volume.
Observation &Calculation:
Volume of cylinder =0.01374 m3
Weight of empty cylinder =7.4 kg
Weight of cylinder + weight of aggregates =29.80 kg
Dryroddedunitweight

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( Weightofcylinder + Weightofaggregates ) ( Weightofemptycylinder )

Volumeofcylinder
(29.807.4 )
0.01374
= 1630 kg/m3
iii-Specific gravity and absorption of coarse aggregates

(ASTM Designation: C 127 )[59]
This method covers the determination of specific gravity and absorption of coarse
aggregate. The specific gravity may be expressed as bulk specific gravity, bulk specific
gravity (saturated- surface-dry (SSD)), or apparent specific gravity. The bulk specific
gravity (SSD) and absorption are based on aggregate after 15 hours soaking in water. This
method is not intended to be used with lightweight aggregates.

It is used for the calculation of the volume occupied by the aggregates in various
mixtures
Definitions:
(a) Specific gravity:
The ratio of the mass (or weight in air) of a unit volume of a material to the mass of the
same volume of water at stated temperatures. Values are dimensionless.
(b)Absorption:
The increase in the mass of aggregate due to water in the pores of the material, but not including
water adhering to the outside surface of the particles, expressed as a percentage of the dry mass.
The aggregate is considered dry when it has been maintained at a temperature of 110 5C for
sufficient time to remove all uncombined water.
(c)Apparent specific gravity:
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The ratio of the weight in air of a unit volume of the impermeable portion of aggregate at a stated
temperature to the weight in air of an equal volume of gas-free distilled water at a stated
temperature.
(d)Bulk specific gravity (oven dry)
The ratio of the weight in air of a unit volume of aggregate (including the permeable and
impermeable voids in the particles, but not including the voids between particles) at a stated
temperature to the weight in air of an equal volume of gas-free distilled water at a stated
temperature.
(e)Bulk specific gravity (SSD)

The ratio of the mass in air of a unit volume of aggregate, including the mass of water within the
voids filled to the extent achieved by submerging in water for approximately 15 hours (but not
including the voids between particles) at a stated temperature, compared to the weight in air of
an equal volume of gas-free distilled water at a stated temperature.
Apparatus
Balance
Sample Container
Water Tank
Suspended Apparatus
Oven
Oven

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Figure: 7.13Specific Gravity Apparatus
Figure: 7.14Oven
Procedure:
The sample of the aggregate is immersed in water for 24hrs to essentially fill all the
pores.

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Figure: 7.15 Aggregates Sample and Drying Towel
Remove the test sample from the water and roll it in a large absorbent cloth until all visible
films of water are removed. Wipe the larger particles individually.
Figure: 7.16Rolling of moist aggregates

A moving stream of air is permitted to assist in the drying operation. Take care to avoid
evaporation of water from aggregate pores during the surface-drying operation

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Determine the mass of the test sample in the saturated surface-dry condition. Record this and
all subsequent masses to the nearest 0.5 g or 0.05 % of the sample mass, whichever is greater.
In order to calculate the volume of the aggregate, immediately place the saturated-surfacedry test sample in the sample container and determine its apparent mass in water at
232.0C.
Take care to remove all entrapped air before determining its mass by shaking the container
while immersed.
The difference between the mass in air and the mass when the sample is immersed in water
equals the mass of water displaced by the sample. This mass of water equals the volume of
water displaced because
mwater= Vwater
(water=1 gm/cm3)
water =mwaterx Vwater

Vwater= Vaggregate
Dry the test sample in the oven to constant mass at a temperature of 1105 C, cool in air
at room temperature 1 to 3 h, or until the aggregate has cooled to a temperature that is
comfortable to handle (approximately 50 C), and

determine the mass in order to calculate the oven specific gravity of the specimen
Observation& Calculation:
Weight of sample = 5 kg
Weight of bucket in air=1.188 kg
Weight of bucket in water =1.052 kg
Weight of S.S.D sample in air + bucket=6.21 kg
Weight of S.S.D sample in water + bucket =4.22 kg
A=oven dry weight in air =4.95 kg
B=mass of saturated-surface-dry test sample in air =6.21 1.188 = 5.022 kg
C=mass of saturated test sample in water = 4.22 1.052 = 3.168 kg
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Table - 7.3: Calculation of Specific Gravity
Apparent
gravity
specific Specific
Gravity Specific Gravity in Percentage
Oven Dry
SSD
Absorption
A
AC
4 . 95
= 4 . 953. 168
A
= BC
=
4.95
5.0223.168
B
BC
5.022
5.0223.168
BA
X 100
A
=
5.0224.95
X 100
4.95
= 2.78
= 2.67
= 2.71
= 1.45 %
Result: Percentage Absorption of our materials is 1.45 % which is acceptable
7.4
Mix Design Procedure:
Step 1. Choice of slump

TABLE - 7.4:Recommended slumps for various types of construction
As we have consider concrete for RC Beams, so we select slump from table 7.4.
From table 7.4:
Slump (max) = 4in
Step 2. Choice of maximum nominal size of aggregate

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We perform a sieve analysis on coarse aggregates according to ASTM C 136, so by
usingGrading Requirement for Coarse Aggregates ASTM C 33, weconcluded that this grading of
aggregates satisfy the size 67.
From table(sieve analysis)
Maximum nominal size of aggregates = 3/4 in
Step 3. Estimation of mixing water and air content

Table - 7.5: Approximate mixing water and air content requirements fordifferent slumps and
nominal maximum sizes of aggregates
For non-air entrained concrete, we deter mine the quantity of water by slump and maximum
nominal size of coarse aggregates from table 7.5. .
From table 7.5.
Amount of water for non-air entrained concrete = 340 lb/yd3

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Step 4. Selection of water-cement ratio

Table - 7.6: Relationship between water cement ratio and compressive strength of concrete
We used to design a concrete mix having 28 days compressive strength of 5000Psi, so water
cement ratio is calculate from table 7.6 Against compressive strength of 5000Psi.
From Table 7.6.
Water cement ratio = 0.48
Step 5. Calculation of cement content

The quantity of cement is calculated by using amount of water that was calculate in step 3 and
water cement ratio that was calculate in step 4.
Water/Cement = 0.48
Cement
= Water/0.48
= 340/0.48
=708 lb/yd3
Cement = 708 lb/yd3

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Step 6. Estimation of coarse aggregate content

Table 7.7: Volume of coarse aggregate per unit of volume of concrete
We determine the volume of coarse aggregates per unit volume of concrete from Table 7.7 by
comparing nominal maximum size of aggregate with fineness modulus of fine aggregates.
Nominal maximum size of aggregates = 3/4 in
Fineness modulus of fine aggregates = 2.7
From Table7.7.:
Volume of coarse aggregate per unit of volume of concrete = 0.63

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Step 7. Estimation of weight of fresh concrete

Table - 7.8: First estimate of weight of fresh concrete
We determine the weight of fresh concrete for non-air entrained concrete from table 7.8.By using
nominal maximum size of aggregates.
Nominal maximum size of aggregates = 3/4 in
From Table 7.8:
First estimate of weight of fresh concrete = 3960 lb/yd3
Step 8.Density of coarse aggregates

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By using the dry rodded unit weight of coarse aggregates that we found according to ASTM C
29 and Volume of coarse aggregate per unit of volume of concrete that was found in step 6,we
will calculate the density of coarse aggregates.
Dry rodded unit weight of coarse aggregates =1630 kg/m3
Volume of coarse aggregate per unit of volume of concrete = 0.63
Weight of coarse aggregates = 0.63 x 1630
= 1026.9 kg/m3
2.2045
= 1026.9 x 1.3079 lb/yd3
= 1731 lb/yd3
Step 9. Estimation of fine aggregate content
We determine the quantity of fine aggregates by using the weight of cement and weight of coarse
aggregates as given below.
Wt. of fine aggregate = Total wt. of fresh concrete - wt. of water - wt. of cement -wt. of
coarseaggregate
= 3960 340 708 1731
= 1181 lb/yd3
Wt. of fine aggregate = 1181 lb/yd3
Step 10. Ratio calculation

We determine the ratio of concrete mix design by using the weight of cement, fine aggregates,
and coarse aggregates as given below.
Required ratio = cement: sand : coarse aggregates
= 708: 1181: 1731
Dividing by 708, we get

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708
= 708
1181
708
1731
708
= 1 : 1.67 : 2.44
Approx. = 1: 1.6 : 2.5
Required Ratio = 1 : 1.6 : 2.5
Step 11. Admixture calculation

The water reducing agent used in this project was manufactured and supplied by IMPORIENT
CHEMICALS [PVT] LTD under the code name of Chemrite AG 200. Chemrite AG-200 is a
highly effective liquid super-plasticizer for production of free flowing concrete, which prolongs
slump retention at low water-cement ratios.
Admixture = 0.08% by weight of cement
By using this admixture, the water/cement will be reduced.
7.4
Water/cement = 0.44
Mixing Of Trial Batch
We prepare a trial batch of concrete by using this ratio 1:1.6:2.5 .

So we proceed with following steps
Apply slump test on fresh concrete

Find density of fresh concrete
Casting of 6 concrete cylinder
7.4.1 Standard Test Method for Slump of Hydraulic-Cement Concrete

(ASTM Designation C143/ C143M) [60]
The concrete slump test is an empirical test that measures the workability of
freshconcrete.

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This test method covers determination of slump of hydraulic-cement concrete, both in the
laboratory and in the eld.

This test method is considered applicable to plasticconcrete having coarse aggregate up to
1.5 in. [37.5 mm] insize. If the coarse aggregate is larger than 1.5 in. [37.5 mm] insize,
the test method is applicable when it is performed on thefraction of concrete passing a 1.5
in. [37.5-mm] sieve, with thelarger aggregate being removed in accordance with the
sectiontitled Additional Procedure for Large Maximum Size Aggregate Concrete in
Practice C 172.
Apparatus
Mold
Tamping Rod
Measuring Device
Scoop
Figure: 7.17 Slump test apparatus
Terminologies:
Collapse slump:
In a collapse slump the concrete collapses completely.
Shear slump:
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In a shear slump the top portion of the concrete shears off and slips sideways.
True slump:
In a true slump the concrete simply subsides, keeping more or less to shape.
Figure: 7.18 Types of slump
Procedure
The internal surface of the mold is thoroughly cleaned andapplied with a light coat of oil.
The mold is placed on a smooth, horizontal, rigid and nonabsorbentsurface.
The mold is then filled in three layers with freshly mixedconcrete, each approximately to
one-third of the height ofthe mold.

Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are
distributed evenly over the cross-section).

After the top layer is rodded, the concrete is struck off thelevel with a trowel.
The mold is removed from the concrete immediately byraising it slowly in the vertical
direction.
The difference in level between the height of the moldandthat of the highest point of the
subsided concrete ismeasured.

This difference in height is the slump of the concrete.

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Figure:7.18 Slump measuring

Observation& Calculation:
Slump = Height of cone - Height of subsided concrete cone
= 4.3 in
See from table 7.4Slump is OK!
7.4.2 Standard Test Method for the Density (Unit Weight) of fresh Concrete
(ASTM Designation C138 / C138M)[61]
Scope
This test method covers determination of the density of freshly mixed concrete
Unit weight was the previous terminology used to describe the property determined by this test
method, which is mass per unit volume.
Apparatus
Balance
Tamping Rod
Internal Vibrator
Measure
Strike-Off Plate
Mallet

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Figure: 7.19Mold for Cylinders
Procedure
Rodding
Place the concrete in the measure in three layers of approximately equal volume. Rod
each layer with 25 strokes of the tamping rod when nominal 0.5-ft3 [14-L] or smaller
measures are used, 50 strokes when nominal 1-ft3 [28-L] measures are used, and one
stroke per 3 in2 [20 cm3] of surface for larger measures. Rod the bottom layer throughout its depth but the rod shall not forcibly strike the bottom of the measure. Distribute the
strokes uniformly over the cross section of the measure and for the top two layers,
penetrate about 1 in. [25 mm] into the underlying layer. After each layer is rodded, tap the
sides of the measure 10 to 15 times with the appropriate malletusing such force so as to
close any voids left by the tamping rod and to release any large bubbles of air that may
have been trapped. Add the nal layer so as to avoid overlling.

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Strike off plate
After consolidation, strike-off the top surface of the concrete and nish it smoothly with
the at strike-off plate using great care to leave the measure just level full.
Cleaning and Weighing
After strike-off, clean all excess concrete from the exterior of the measure and
determine the mass of the concrete.
Observation & calculation

Volume of cylinder (measure) =0.196 ft3
Weight of empty cylinder (measure) = 9.553 kg
Weight of cylinder + fresh concrete = 23.3 kg
Weight of fresh concrete = 23.3 9.553
= 13.747 kg
Density =
weight of fresh concrete

volume of culinder
13.747
3
0.196 kg/ft
= 70.14 kg/ft3
2.2046
= 70.14 x 0.037037
lb/yd3
= 4174.89 lb/yd3
See from table 7.8, density of fresh concrete is OK!
7.4.3 Standard Practice for Making and Curing Concrete Test Specimens in
the Laboratory
(ASTM designationC 192/C 192M)[62]
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Scope & Significance
This practice covers procedures for making and curingtest specimens of concrete in the
laboratory under accuratecontrol of materials and test conditions using concrete that
canbe consolidated by rodding or vibration

This practice provides standardized requirements forpreparation of materials, mixing
concrete, and making andcuring concrete test specimens under laboratory conditions.
Apparatus
Molds (6x12 in)

Tamping Rods
Mallets
Internal Vibrator
Procedure
Making Specimens
Place of Molding
Mold specimens as near as practicableto the place where they are to be stored during the
first24 h. If it is not practicable to mold the specimens where theywill be stored, move
them to the place of storage immediatelyafter being struck off. Place molds on a rigid
surface free fromvibration and other disturbances. Avoid jarring, striking, tilting,or
scarring of the surface of the specimens when moving thespecimens to the storage place
Placing of concrete:
Place the concrete in the molds using ascoop, blunted trowel, or shovel. Select each
scoopful, trowelfull,or shovelful of concrete from the mixing pan to ensurethat it is
representative of the batch. It may be necessary toremix the concrete in the mixing pan
with a shovel or trowel toprevent segregation during the molding of specimens. Movethe
scoop or trowel around the top edge of the mold as the concrete is discharged in order to
ensure a symmetricaldistribution of the concrete and to minimize segregation ofcoarse
aggregate within the mold. Further distribute the concreteby use of a tamping rod prior to
the start of consolidation.In placing the final layer the operator shall attempt to add

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anamount of concrete that will exactly fill the mold aftercompaction. Do not add non
representative samples of concreteto an under filled mold.
Number of Layers:
Make specimens in layers as indicated in Table
Consolidation
Rodding
Place the concrete in the mold, in therequired number of layers of approximately equal
volume. Rodeach layer with the rounded end of the rod using the number of strokes and
size of rod specified in Table given below. Rod the bottom layer throughout its depth.
Distribute the strokes uniformly over the cross section of the mold and for each upper
layer allow the rod to penetrate through the layer being rodded and into the layer below
approximately 1 in. [25 mm]. After each layer is rodded, tap the outsides of the mold
lightly 10 to 15 times with the mallet to close any holes left by rodding and to release any
large air bubbles that may have been trapped. Use an open hand to tap light-gage singleSTRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU
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152
CHAPTER NO 7
use molds which are susceptible to damage if tapped with a mallet. After tapping, spade
the concrete along the sides and ends of beam and prism molds with a trowel or other
suitable tool.
Curing
After 24 hrs.specimens are de-moulded and immersed in curing tank.

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153
CHAPTER NO 7
Figure: 7.20Curing Tank

Observation & Calculation:
We casted 9 specimen of concrete cylinder and these concrete specimens are tested after 7, 14,&
28 days. The testing procedure is given below.
7.4.4 Standard Method of Test for Compressive Strength of Cylindrical

Concrete Specimens
(ASTM Designation: C 39/C 39M)[63]
This test method covers determination of compressive strength of cylindrical concrete

specimens such as molded cylinders and drilled cores. It is limited to concrete having a
unit weight in excess of 800 kg/m3 (50 lb/ft3).

Values obtained will depend on the size and shape of the specimen, batching, mixing
procedures, the methods of sampling, molding, and fabrication as well as the age,
temperature, and moisture conditions during curing.

The results of this test may be used as a basis for quality control of concrete
proportioning, mixing, and placing operations; determination of compliance with
specification; and control for evaluating effectiveness of admixtures and similar uses.
APPARATUS
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CHAPTER NO 7
Testing Machine
Figure: 7.21Compressive Strength testing machine

Procedure:
Compression tests of moist-cured specimens shall be made as soon as practicable after
removal from moist storage.

Test specimens shall be kept moist by any convenient method during the period between
removals from moist storage and testing. They shall be tested in the moist condition.
All test specimens for a given test age shall be broken within the permissible time
tolerances prescribed as follows:

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CHAPTER NO 7
Placing the Specimen: Place the plain (lower) bearing block, with its hardened face up,
on the table or platen of the testing machine directly under the spherically-seated (upper)
bearing block. Wipe clean the bearing faces of the upper- and lower-bearing blocks and
of the test specimen and place the test specimen on the lower bearing block
Zero Verification and Block Seating: Prior to testing the specimen, verify that the load
indicator is set to zero. In cases where the indicator is not properly set to zero, adjust the
indicator. As the spherically-seated block is brought to bear on the specimen, rotate its
movable portion gently by hand so that uniform seating is obtained.

Rate of Loading: Apply the load continuously and without shock.
The load shall be applied at a rate of movement (platen to crosshead measurement)

corresponding to a stress rate on the specimen of 0.25 0.05 MPa/s (35 7 psi/s) The
designated rate of movement shall be maintained at least during the latter half of the
anticipated loading phase.
During application of the first half of the anticipated loading phase, a higher rate of
loading shall be permitted. Apply the higher loading rate in a controlled manner so that
the specimen is not subjected to shock loading.

Do not adjust the rate of movement (platen to crosshead) as the ultimate load is being
approached and the stress rate decreases due to cracking in the specimen.
Apply the compressive load until the load indicator shows that the load is decreasing
steadily and the specimen displays a well-defined fracture pattern

Usually following type of fracture pattern are formed.

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156
CHAPTER NO 7
Figure: 7.22 Fracture Pattern
Figure: 7.23Capping of cylinder

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157
CHAPTER NO 7
Figure: 7.24Testing of cylinder

OBSERVATION & CALCULATION
Table 7.9:Compressive strength of concrete after 7 days
Sr no
Casting date
Testing date
1
20-04-14
27-04-14
2
20-04-14
27-04-14
3
20-04-14
27-04-14
f'cavg =22.3 Mpa(63.71% of strength 35Mpa)
Diameter
(mm)
150
150
150
Area
(mm2)
17662.5
17662.5
17662.5
f'c
(Mpa)
21.2
22.4
23.3
Area
(mm2)
17662.5
17662.5
17662.5
f'c
(Mpa)
32.2
33.2
33.7
Area
F'c

Sr no
Casting date
Testing date
1
20-04-14
04-05-14
2
20-04-14
04-05-14
3
20-04-14
04-05-14
f'cavg =33Mpa (94.30% of strength 35Mpa)
Diameter
(mm)
150
150
150

Sr no
Casting date
Testing date
Diameter

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158
CHAPTER NO 7
1
2
3
20-04-14
20-04-14
20-04-14
18-05-14
18-05-14
18-05-14
(mm)
150
150
150
(mm2)
17662.5
17662.5
17662.5
(Mpa)
35.2
38.6
38.7
f'cavg =37.5 Mpa(greater than the required strength of 35Mpa)
Figure: 25(a) Cylinder testing after 28 days

f'c 35.2 Mpa after 28 days

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159
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Figure: 27(b) Cylinder testing after 28 days
Figure: 27(c) Cylinder testing after 28 days

Final Result:
Required ratio of cement, sand, and coarse aggregate for 5000 psi (35 Mpa) at 28 days strength is
1: 1.6: 2.5.
So we will proceed to our main objective of strengthening of beam, so we want to cast a beam, for
this purpose we first design a beam in next step given below.
7.5 Structural design of beam:

Five RC Beam with constant cross section (6x9.5) and length (46), having same
[64]reinforcement in all beams as 2#8 bars on tension side and 2#3 on compression side as hanger

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160
CHAPTER NO 7
bar. And #3 @ 3.6 c/c stirrups for shears throughout the length except central portion of 6 of
the beam.grade of steel is 40.sections of beam is shown in figure given below.
7.6 Design and fabrication of steel mold:

We design a steel mold according to dimension of required beam (3-10'' x 6''
x 9.5'').steel mold can be separated in to two parts by using nuts bolts so
that beam can be easily removed from the mold. To overcome bulking of
mold we used steel pipe. And finishing is done with paint.

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161
CHAPTER NO 7
Figure: 7.26Steel framework
7.7 Casting and curing of beams:

For casting of beams, steel formwork was used. We make a concrete
mix according to ASTM designation C 192/C 192M for casting of 5 RC beams
(one control beam & 4 strengthening beams) and 6 concrete cylinder.
Concrete mix (1:1.6:2.5) by weight was made in concrete mixer and poured
manually in steel molds. Compaction was done by vibrator but before
pouring to steel mold, we apply proper oiling on internal surface of mold so
that beam do not stick with mold after removal and formwork easily remove.
And also see that there is no leakage from mold, to avoid leakage from mold,
we apply grease on different joints in mold. After 24 hours beam mold and
concrete cylinder were opened. And all green hardened beam were wrapped
in hessian cloth for curing, and concrete cylinder were putted in curing tank.
Concrete cylinder were tested at 7, 14 and 28 days but beam were left for
the next 28 days to achieve the desired strength for strengthening and
testing.

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Table 7.12: Compressive strength of concrete after 7 days
Sr no
Casting date
Testing date
1
2
26-05-14
26-05-14
02-06-14
02-06-14
Diameter
(mm)
150
150
Area
(mm2)
17662.5
17662.5
F'c
(Mpa)
22.5
22.7
Area
(mm2)
17662.5
17662.5
F'c
(Mpa)
32.1
33.3
Area
(mm2)
17662.5
17662.5
F'c
(Mpa)
36.1
38.6
f'cavg =22.6 Mpa(64.71% of strength 35Mpa)

Sr no
Casting date
Testing date
1
2
26-05-14
26-05-14
09-06-14
09-06-14
f'cavg =32.7Mpa
Diameter
(mm)
150
150
(93.42% of strength 35Mpa)

Sr no
Casting date
Testing date
1
2
26-05-14
26-05-14
23-06-14
23-06-14
f'cavg =37.35 Mpa
Diameter
(mm)
150
150
(greater than the required strength of 35Mpa)
7.8 Strengthening of RC Beams:

Strengthening of RC beams is done with following steps
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7.8.1
Surface preparation of beams:
The behavior of concrete element strengthened with Ferrocement laminates

is highly dependent on proper preparation and profiling of concrete surface,
because for strong bond between concrete and ferrocement.All surfaces
must be thoroughly cleaned and prepared. All loose particles, laitance, dust,
Curing compounds, oil, grease must be removed if good bond strength is to
be achieved. If oil grease, fat, etc. are present, they should be removed
before starting any other form of preparation
So for this reason bottom (tension side) surface of 4 beams were grinded and
rougher.
6.7.2 LAYING AND APPLICATION OF FERROCEMENT MATERIAL ON TOP OF

THE BEAM
Strengthening of the specimens by using following option.
Laying a pair of hexagonal and rectangular mesh ontension side throughout the
length of beam.
Laying a pair of one rectangular and two hexagonal meshon tension side throughout
the length of beam.

Laying two pair of rectangular and hexagonalon tension side throughout the length of the
beam.
Laying a pair of one rectangular and hexagonal mesh on tension side throughout
the length of the beam and also along the both sides of the beam.

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Following tests are performed ..

Beam no.
b1
B2
Concrete
cylinder
strength
(ksi)
7.53
Volume
fraction
Specific
surface
Slump
value
0.71%
0.0348
83
1.40%
0.0686
41

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165
CHAPTER NO 7
1.31%
0.0983
87
1.95%
0.03875
80
B3
B4

LAMINATES
166

Experimental Work CHP 7

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CHAPTER NO 7

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

7.1.1 Coarse Aggregates:

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

7.1.2 FINE AGGREGATES

Portland cement with

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

7.1.4 Water reducing

The water reducing agent

used in this project was

Figure: 7.6Water Reducing Agent

7.1.5 Steel bars:

Figure 7.7Steel bars

Rectangular and hexagonal

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

Mix Design: [56]

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

7.3.2 Background Data:

Sieve analyses of fine and coarse aggregates.

cementitious materials if considered, and aggregates.

coarse aggregates by sieving.

Standard set of sieves

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

aperture opening at the bottom.

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

Cumulative retainedonstandardsievesof 150 morabove

Grading Requirement for Coarse Aggregates

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

FINE AGGREGATES (Lawrancepur sand)

(1.79+7.75+ 26.62+58.40+ 80.35+98.72)

ii-Dry rodded Unit weight of coarse aggregate

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

( Weightofcylinder + Weightofaggregates ) ( Weightofemptycylinder )

iii-Specific gravity and absorption of coarse aggregates

method is not intended to be used with lightweight aggregates.

(e)Bulk specific gravity (SSD)

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

Figure: 7.13Specific Gravity Apparatus

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

Figure: 7.15 Aggregates Sample and Drying Towel

Figure: 7.16Rolling of moist aggregates

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

water =mwaterx Vwater

comfortable to handle (approximately 50 C), and

Mix Design Procedure:

Step 1. Choice of slump

Slump (max) = 4in

Step 2. Choice of maximum nominal size of aggregate

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

Maximum nominal size of aggregates = 3/4 in

Step 3. Estimation of mixing water and air content

Amount of water for non-air entrained concrete = 340 lb/yd3

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

Step 4. Selection of water-cement ratio

From Table 7.6.

Water cement ratio = 0.48

Step 5. Calculation of cement content

Cement = 708 lb/yd3

STRENGTHENING OF REINFORCED CONCRETE BEAM USING FERROCEMENT CAST INSITU

Step 6. Estimation of coarse aggregate content

Volume of coarse aggregate per unit of volume of concrete = 0.63