Exercise 7: PORTLAND CEMENT MORTAR AND CONCRETE

The Pennsylvania State University

Department of Civil and Environmental Engineering
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ABSTRACT
The objective of part one of the laboratory exercise presented in this report was to learn about
mortar preparation and testing. Specifically, the objective was to learn about the effect of w/c age,
and curing condition on the strength of Portland Cement mortar. The test was performed using
Ottawa sand, Portland cement, tap water, 2-in cubical mortar molds, hydrated lime, and a
compression testing machine. The ingredients were mixed and filled into molds to be tested for
strength. Upon analysis of the experimental data, it was discovered that failure load was 7340 lbs.
In part two of the laboratory exercise the objective was to design and prepare a concrete mixture
to achieve the highest strength and lowest cost. The test was performed using sand, coarse
aggregate, cement, water, and plastic cylinder molds. The specimen was tested for strength
according ASTM C39. Upon analysis of the data, the maximum load and failure type was
observed. It was discovered that an error was made during the molding process. This led to a
decrease in strength.
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TABLE OF CONTENTS
Page
ABSTRACT ............................................................................................................. ii
TABLE OF CONTENTS ........................................................................................iii
LIST OF TABLES................................................................................................... iv
LIST OF FIGURES .................................................................................................. v
INTRODUCTION .................................................................................................... 1
RESULTS AND DISCUSSION ............................................................................... 2
PART I- PORTLAND CEMENT MORTAR .......................................................................... 2
PART II – PORTLAND CEMENT CONCRETE .................................................................... 4

CONCLUSIONS ...................................................................................................... 6
REFERENCES ......................................................................................................... 7
APPENDIX A: RAW DATA ................................................................................... 8
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LIST OF TABLES
Page
Table 1: Mix Proportions for Preparation of Mortars ......................................................... 2
Table 2: Test Results for Mortar Cubes .............................................................................. 2
Table 3: Concrete Tests ....................................................................................................... 4
Table 4: Concrete Mix ......................................................................................................... 4
Table 5: Compressive Strength of Concrete Results ........................................................... 5
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LIST OF FIGURES

Page
Figure 1. Slump Test ........................................................................................................... 1
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INTRODUCTION
Mortar is a mixture of cementitious material, aggregate, and water. Mortar can be used for seating
material for units, leveling the units, and providing an aesthetic quality to a structure. In the
laboratory, the mortar is evaluated using compressive strength according to ASTM C109. Unlike
concrete, the compressive strength is not the most important part of mortar. Mortar is used as an
adhesive; therefore, it is crucial that it forms a strong and durable bond with the masonry units.
Portland cement concrete is the most widely used manufactured construction material in the world.
It is used in structures such as buildings, bridges, tunnels, dams and pavements. The properties of
concrete depend on the mix proportions and the placing and curing methods. The hardening of
concrete is important to material’s strength, durability and porosity. In order to acquire durability,
strength and workability, the proportions should range from an arbitrary volume method (1:2:3
cement: sand: coarse aggregate) to the weight and absolute volume.

In part one of the exercise, the test performed according to ASTM C109 consists of mixing the dry
ingredients according to Table 1 thoroughly. Once the dry ingredients are properly mixed with
water, the mortar is place into plastic molds. Each layer is consolidated using a plastic tamper to
ensure the mortar is properly packed into the cube molds. After, the surface of the mortar is leveled
and covered with plastic wrap. The molds are then left to harden for 24 hours and finally they are
demolded. When the test specimens are removed from the mold, they are placed into lime water
for 6 days. The mortar is then tested for strength, applying a load between the upper and lower
platens. Finally, the maximum load is observed for all cubes tested.

In part two of the exercise, the test performed according to ASTM C39 consists of mixing the
concrete recipe created by each group using sand, coarse aggregate, and cement, and water. The
sand, coarse aggregates, and cement are mixed thoroughly. The water is then added in portions
until no dry material is seen in the mixture. After the concrete mix is created, a slump test is
performed (Figure 1). A slump test includes filling up a cone with the concrete mix, while rodding
each layer. The cone is removed in a vertical direction and placed next to the concrete. The tamping
rod is placed across the inverted surface, the distance from the bottom of the tamping to the center
of the slump concrete is measured. After the test, the mix is placed into plastic molds, where each
lift is rodded 25 times. The molds are left to harden, and then placed in a lime water bath after 24
hours. The concrete is then tested for strength and the maximum load and failure type is recorded.

Figure 1. Slump Test

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RESULTS AND DISCUSSION
PART I- PORTLAND CEMENT MORTAR

Table 1 presents the amount of mix proportions used for each individual group.

Table 1: Mix Proportions for Preparation of Mortars

Groups 1 and 2 Groups 3 and 4 Groups 5 and 6
Material Mass (gr)
Portland Cement 275 305 305
Water 138 138 138
Ottawa Sand 590 590 590
w/c 0.50 0.45 0.45
Curing Moist (bath) cured. Moist (bath) cured. Dry cured after
Tested at 7 days Tested at 7 days demolding

Table 2 presents the failure load, compressive strength, average strength, and standard deviation
for the 2in x 2in x 2in mortar cubes.

Equations for Table 1

𝑃𝑓𝑎𝑖𝑙𝑢𝑟𝑒
𝜎=
𝐴𝑐𝑢𝑏𝑒

Table 2: Test Results for Mortar Cubes

Group Specimen Failure Load Compressive Average Standard
number Number (lb.) Strength strength Deviation
(psi) (psi) (psi)
1&2 5-1-1 8560 2149 2149 0
3&4 5-3-3 7340 1835 1835 0
5&6 5-5-1 7340 1835 1835 0

Discussion Questions

1. When testing the compressive strength of the mortar it is important to test the specimens
on one of the sides that was casted out against the polyethylene mold. The free face of the
mortar could be slightly uneven from the plastic wrap covering the mold. The uneven sides
will decrease the compressive strength. Since the sides against the polyethylene molds are
flat it will give a more accurate compressive strength.
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2. The 14-day lime bath curing condition will have the higher compressive strength.
Compressive strength increases over time, so the 14- curing condition will have a higher
strength. All of the mortar cubes were cured the same in the experimental lab, so no trend
was observed.

3. The results showed that the group with the higher water to cement ratio had the most
durable mortar cube. The trend shows that the higher w/c ratio leads too stronger
compressive strength. Increasing w/c ration will increase the workability but decrease the
strength.

4. It is important to mix the mortar ingredients thoroughly, since mortar is used as a paste.
Since mortar is used as an adhesive and sealant, the mix needs to be moist enough to bond
to individual units. If the mortar is not mixed thoroughly, it can cause the specimen to fall
apart, and not attach to individual units.

5. The compressive strength of the specimen will increase if the load was applied very rapidly,
but it would fail in a short amount of time. If the specimen had an applied load at a slow
and steady rate, the compressive strength will decrease, but the failure will occur in a longer
amount of time.

6. The result of the mortar compressive strength for the cubes from all the groups showed that
the higher w/c resulted in a higher compressive strength. Group 1 and 2 had a w/c of .50
and had a compressive strength of 2149 psi, while the other groups received a lower
compressive strength of 1835 with a w/c od .45.
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PART II – PORTLAND CEMENT CONCRETE

Table 3 presents the data acquired for Concrete tests.

Table 3: Concrete Tests

Initial weight of water (kg) – per mix design 1.500
Final weight of water used (kg) 1.670
Slump (in) 2.5
Coarse Aggregate (kg) 6.000
Sand (kg) 4.400
Absorption of sand (%) 93.64
Absorption of coarse aggregate (%) 21.88
Total water absorbed to sand (kg) 1.564
Total water absorbed to coarse aggregate (kg) 0.365
Effective water (water used – water absorbed into aggregate) 1.929
Chemical mixture (g) 0
Cement (kg) 3.000
Fly ash or other SCMS (kg) 0
w/c or w/cm 0.55

Table 4 presents the individual concrete mixes for each group.

Table 4: Concrete Mix

Group Number Cement Water Sand Fly Ash Coarse Aggregate (kg)
(kg) (kg) (kg) (kg)

1 3 1.35 0 6 6

2 - - - - -

3 2.3 1.450 5.503 0 6.1037

4 3.2 1.5 4 0 6.25

5&6 3 1.67 4.4 0 6

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Table 5 presents the data acquired for compressive strength of concrete.

Equations for Table 5:

𝑃𝑓𝑎𝑖𝑙𝑢𝑟𝑒
𝜎=
𝐴𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟

Table 5: Compressive Strength of Concrete Results

Group Slump w/c Cost Specimen Failure Compressive Avg. St. Dev.
Number (in) ratio ($/yd^3) Number Load strength Strength Strength
(psi) (psi)
1 2.5 .45 60.34 5-1-1 49365 3927 3927 0
2 -- -- -- -- -- -- -- --
3 3 .63 34.97 5-3-1 25290 2012 2012 0
3 .63 34.97 5-3-2 27515 2189 2189 0
4 2.5 .47 42.67 5-4-1 53,965 4293 4293 0
5&6 2.5 .55 40.82 5-6-1 45,050 3584 3584 0

Discussion Questions

1. The challenges faced during this lab were the slump test and the filling of the molds. The
slump test did not meet the requirement so more water was added to achieve at least 2.5in.
Since our concrete mix was not leveled and smooth at the surface, only one of our cylinders
were able to be tested.

2. The changes made to improve strength would be to add less water and have a w/c of .465.
Group 4 received the highest compressive strength due to the w/c being .47, so obtaining
the same w/c would be ideal.

3. The results show that a w/c of .47 or .45 will have a higher strength. The conclusion can
be drawn that the lower the w/c the lower the compressive strength will be. The higher the
w/c the higher the compressive strength will be. The factors that affect strength are water,
cement and coarse aggregate. Also, volume voids affect the strength if the concrete is not
compacted in the cylinder molds correctly it can cause air bubbles to form which will
decrease the compressive strength.

4. Factors that lead to improved strength are using a low water to cement ratio, using well
graded angular aggregates, and proper compaction.

5. If the water content is adjusted after initial mixing, it does not make sense to also adjust
the cement. If more cement is added it will reduce the workability of the cement. In order
to increase workability more water must be added, but the cement content should remain
the same.
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CONCLUSIONS
The objective of the laboratory exercise presented in this report was split into two parts part. Part
one’s objective was to investigate the characteristics of the compressive strength of mortar using
three specimens. Results indicated that the maximum load before failure was around four tons.
Part two’s objective was to design a concrete mixture with a 7.5-liter volume to achieve the highest
compressive strength at the lowest cost. Results indicated that the maximum load before failure
was around twenty-two tons.

Our findings show:

 Water added in small increments increased the workability of the mixture in part II.

 Lower water to cement ratio increases the compressive strength of concrete

 Compacting the concrete mixture in several layers also increase the compressive strength
of concrete.
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REFERENCES
Iyer, S., Palomino, A., Plaks, N., Ostadi, N., Adams, B., Cartwright, C., & Rajabipour, F.
(n.d.). Civil Engineering Material Laboratory (7th ed.).

Mamlouk, M. S., & Zaniewski, J. P. (2017). Materials for civil and construction
engineers. Hoboken: Pearson Education.
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APPENDIX A: RAW DATA