MATERIAL TESTING AND PRACTICE by Mostafa Sameer

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mostafasameer447@gmail.com
MATERIAL TESTING AND PRACTICE
Prepared By
Mostafa Sameer
B.Sc Engg (Civil), AUST.

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Contents
1.1 Compression test
1.2 Slump test
1.3 Taking a sample of cement
1.4 Sand testing and practice
1.5 Water: cement ratio (weight)
1.6 Cement: sand ratio (weight)
1.7 Additional tests

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1.1 Compression test
The compression test is carried out on either cube or cylindrical samples taken from a cross
section of mixes during the casting of the ferrocement hull, and any other section of construction
that is cast on a different day. The size of the cubes or cylinders will be laid down by the local
testing authority.
Test cubes
The moulds for test cubes should be made of steel or cast iron, with the inner surfaces parallel to
each other and machine faced. Timber moulds should not be used. Each mould should have a
metal base plate with a true surface to support the mould and prevent leakage. It is essential to
keep the mould and base plate clean and both should be oiled lightly to prevent the mortar
sticking to the sides. No undue strain should be used when the sides are fixed together.
Figure 1. Sample of test cylinder

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A 100 mm cube should be filled in three layers, from three different mixes. Each layer should be
rammed at least 25 times with a steel bar 600 mm long and having a ramming face of 16 mm
square, the weight of which compiles to the local standard. The surface of the cube should be
trowelled smooth.
A variety of institutions, eg universities, civil engineering, etc. will normally have the facilities to
carry out the tests.
It is usual to produce six cubes at a casting and send two 100 mm cubes for testing at seven days,
28 days, and 96 days, after casting. The minimum results obtained, from experience, should be in
the order of the following:
lb/in2
kg/cm2
7 days 4500 315
28 days 5500 387
96 days 6000 422

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In the UK, over many castings and using 150 mm cubes, the results exceeded:
lb/in2
kg/cm2
7 days 6000 422
28 days 7500 527
96 days 9000 633
Classification societies will have their own procedure and minimum strength requirements to
satisfy their rules.
Figure 3. Samples of test cube

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Test specimens should be cured at not less than 10°C and in the same way as the hull is cured,
and for the same period. Specimens should be transferred to the testing station on the seventh
and twenty-eighth day, wrapped in damp hessian/gunny cloth or similar.
A test cube data sheet (ref. Fig. No. 4) should be kept as a record for that craft and as a build-up
of accumulated strength data over successive castings.
Casting date : - ...................
Cube
No
Date
tested
Age at
test
Weight of
cube
Load at
failure
kg/cm2
Load at
failure
lb/in2
Comments on manufacture
and testing
/7
/7
/28
/28
/96
/96

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Figure 6. Example of test cube data form

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1.2 Slump test
The slump test is a practical means of measuring the consistency of mix. Since changes in the
values of slump obtained indicate material changes in the water content or proportions of the
mix. It is therefore useful in controlling the quality of the mortar produced.
The apparatus consists of a steel mould 100 mm diameter at the top, 200 mm at the bottom and
300 mm high, complete with a 16 mm dia. steel tamping rod 600 mm long and rounded on one
end. (Local standards may vary the size of the equipment.) The inside of the mould should be
clean before each test, and the mould placed on a hard flat surface. The mould should be filled in
four layers, each layer rodded 25 times with the tamping rod. After the top layer has been
rodded, the surface of the mortar is struck off level. Any leakage is cleaned away from the base
of the mould and the mould is lifted vertically from the mortar.
The slump is the difference between the height of the mix before and after removal of the mould.
If any specimen shears off laterally or collapses, the test should be repeated.
By using the correct mix and water: cement ratio prior to undertaking any casting, as a sample
test(s) the average slump achieved from several tests will give the range of slump acceptable
when the actual casting takes place. Because the mix is a mortar mix, the slump can be
exaggerated by a very little increase in the water: cement ratio. Therefore, it is a handy guide but

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should not be an over-riding conclusion when the practicalities of the construction and need for
full impregnation of the reinforcement are of priority during a casting.
1.3 Taking a sample of cement
If there is any doubt as to the quality of the cement purchased, a sample can be sent for test,
providing the facilities are available.
A sample of cement taken for test purposes must be representative of the consignment and be
taken within one week of delivery. It should be a mixture of at least 12 equal sub-samples taken
from 12 separate bags in the consignment. The sample should weigh at least 7 kg and be sealed
in an airtight container, with the relevant particulars clearly marked on the outside.
Figure 8. Testing
1.4 Sand testing and practice
Bulking of sand
When mixes are specified by volume, the sand is assumed to be dry. The volume of a given
weight of sand, however, varies according to its moisture content. Equal weights of dry and
inundated sand have practically the same volume but the same weight of sand in a damp
condition can occupy a volume as much as 40% greater. This phenomenon is known as 'bulking'.

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It may be demonstrated by filling a gauge box with dry sand. If the sand is flooded with water
the level will sink a little, but not to any great extent. When the box is similarly filled with damp
sand and the surface is flooded the drop in level will be very much greater.
Unless allowance is made for bulking when batching by volume, the mortar may contain too
little sand. This is one of the reasons why measurement by weight is preferable. Bulking occurs
far more with fine sands.
Figure 9. Test Procedure
Testing for impurities
Sands are usually washed by the suppliers to remove clay, silt, and other impurities which, if
present in excessive amounts, result in poor quality mortar. A guide to the amount of clay and
silt in sand can be obtained from the field settling test. An excessive amount recorded in this test
will indicate that other more sensitive tests should be made.
The test involves placing about 50 ml of a 1% solution of common salt in water (roughly one
teaspoon per pint/0.57 liter) in a 250 ml measuring cylinder. Sand as received is then added
gradually until the level of the top of the sand is at the 100 ml mark and more solution is added
to bring the liquid level to the 150 ml mark. The cylinder is shaken vigorously and the contents
allowed settling for about three hours. The thickness of the silt layer is measured and expressed
as a percentage of the height of the sand below the silt layer.
The amount of clay and silt in the sand may be considered acceptable if it does not exceed 10%.
If a measuring cylinder is not available, a jam jar filled to a depth of 50 mm with sand and to a
depth of 75 mm with the solution, will give a comparable result if the contents are allowed to
settle for three hours. The thickness of the silt layout in this case should not be more than 3 mm.
A simple check for organic impurities is to fill a medicine bottle with sand as delivered, to the
115 ml mark, and then add a 3% solution of sodium hydroxide (caustic soda) in water, until the

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level of the liquid after shaking is 200 ml. A solution of this strength may be purchased from
local chemists. The bottle is then stopper, shaken vigorously, and allowed to stand for 24 hours.
If at the end of that time the color of the solution above the sand is darker than the standard color
shown in BS 812, or similar local standard, laboratory tests should be undertaken to determine
whether the sand is acceptable.
Sand sieve analysis
The sand sieve analysis is carried out as often as is required to maintain the correct grading of
sand that is to be used. The grading of a sand aggregate for ferrocement is found by passing a
representative sample of dry sand through a series of BS sieves Nos. 7, 14, 25, 52, 100 (or local
equivalent standard), starting with the largest sieve. A record should be maintained (see Fig. No.
8) of the result and be compared to the required acceptable envelope (Fig. No. 6). The envelope
may vary slightly from the one shown depending on working rules, but is one used by the author
for many years.
Sample No ......... Sample obtained from .................
Total weight of sample .......... grammes
Sieve
No.
Weight retained on each sieve
grammes
Total weight passing sieve
grammes
% Passing each
sieve
Ideal
%
7 100
14 68-96
25 35-65
52 10-36
100 2-10
Tray
Comments on test:-
______________________________________________________
______________________________________________________
______________________________________________________
If the sieving is done manually, each sieve is shaken separately over a clean tray for not less than
two minutes. If machine sieving is applied, a nest of sieves should be shaken for at least 15
minutes. The material retained on each sieve, together with any material cleaned from the mesh
is weighed and recorded. The percentage by weight passing each sieve is then calculated. Sieving
will not be accurate if there is too much material left on any mesh after shaking.

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1.5 Water: cement ratio (weight)
The two essential properties of hardened mortar are durability and strength. Both of these are
closely related to density. In general, the more the mortar is compacted, the stronger and more
durable it is. The mortar must be dense to be impervious to water and to protect the
reinforcement adequately.
Figure 10. Water:cement ratio
The strength and durability of the mortar is governed by the amount of water used for mixing but
the overall grading of the aggregate has an indirect effect. Fine grindings require more water than
coarser grading to obtain the same degree of workability. It follows that in practice the grading
of the aggregate influences the amount of water which must be added.
It has been established that the strength of the mortar depends primarily on the relative
proportions of water and cement. The higher the proportion of water, the weaker is the mortar.
An allowance for the moisture present in the sand should always be taken into account. A typical
list of water: cement ratios are set out below:
Imperial gallons per 112 lb cement litres per 50 kg water: cement ratio by weight
3.5 15.5 0.31
4.0 18.0 0.36
4.5 20.0 0.40
5.0 22.5 0.45
5.5 24.5 0.49
6.0 27.0 0.54

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The water:cement ratio for ferrocement construction which gives the required strength and
workability will be in the region of 0.35-0.45, although 0.40 should not be exceeded under
tentative rules set by Det Norske Veritas.
If, due to local conditions, a more workable mix is required then admixtures may have to be used
to enhance the workability subject to their suitability.
1.6 Cement: sand ratio (weight)
The cement: sand ratio has been established to fall between 0.4 and 0.6, for dry sand. From
experience the value should be nearer 0.6, although many boats have been constructed using 0.5
as the ratio.
Figure 11. Cement:sand ratio.
For more details visit my Channel on YouTube:
https://www.youtube.com/watch?v=6ESIp53VJJE .(Part-01).
https://www.youtube.com/watch?v=omMsakFZIxg . (Part-02).

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Figure 12. Preparing Mixture using mixer.
1.7 Additional tests
Further additional tests will almost certainly be required if a boat is built to classification.
Indeed, many of these tests can be used by the builder to enlarge the information on the
particular form of construction that may be undertaken even if the structure is not being built to
rules. Out of necessity one will need to have the use or availability of the correct testing facilities
and specimens will need to be of a size to suit the testing equipment.
Tensile testing and compression testing on reinforced material
Tensile tests can be carried out on the ferrocement in order to establish the relationship between
tensile stress and elongation.
Tensile test on unreinforced specimens
The tensile strength can be determined by a split 'cylinder' test using similar apparatus as in the
compression test. However, the true tensile strength will lie between 50 and 70% of the splitting
'tensile strength'.

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Bending tests with reinforced material
Bending tests can be carried out on the ferrocement in order to establish the relationship between
bending moment, tensile bending stresses and elongation.
Bending fatigue tests
Bending fatigue tests can also be carried out on test specimens of the hull construction.
Impact test
An impact test can be performed on representative reinforced panels by using a drop weight.
Failure occurs when the test panel develops a leak.
All test specimens should have references to:
a) Identification number
b) dimension of the specimen
c) curing history and moisture condition at test
d) defects of specimen, if any, and age
e) ambient conditions at time of test
It should be noted that as a vast array of tests on ferrocement have been carried out, and with
many more still in progress around the world, the preferred method and size of specimen to be
tested may be arrived at by contacting classification societies who are locally available, the
International Ferrocement Information Center, or indeed establishments such as local universities
and colleges who have had experience in this regard, in order to establish a common method and
application of test work to suit the country being worked in.
The overall information is collected from the source below.
Source : http://www.fao.org/docrep/003/V9468E/v9468e08.htm#b1-
5.1%20Compression%20test
Prepared By
Engr. Mostafa Sameer
B.Sc Engg (Civil),
Ahsanullah University of Science & Technology (AUST),
Associate Member, IEB.
E-mail: mostafasameer447@gmail.com.

MATERIAL TESTING AND PRACTICE by Mostafa Sameer

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