University of Nottingham

School of Civil Engineering

Structures & Materials 3

CONCRETE TESTING LABORATORY

1. Objectives The main objective of the laboratory is to study the behaviour of simply supported reinforced concrete beams under flexural and shear loading. This involves plotting load v deflection and load v curvature and, by doing so, making comparisons between: - experimental behaviour - theoretical prediction - limit state design to EC2 In addition to beam testing, the laboratory also includes studying the dynamic behaviour of plain concrete in order to determine its Youngs modulus Ecm for use in the theoretical prediction of the beam. The laboratory will include demonstrations of various nondestructive testing equipment. The work to be carried out in groups of 5 students, each group studying and testing one beam to destruction, whilst observing another two. The report consists of a group report of the laboratory exercise and an individual discussion.

2. The Beams Three reinforced concrete beams have been previously manufactured in a steel mould that is nominally 66 long x 8 deep x 4 wide (1677 x 203 x 102 mm). See Figure 1. The beams are designed to fail in three different ways, but the secret of this will not be known until the laboratory takes place. The beams are loaded in four-point bending as shown in Figure 1. The nominal spans L and a are 54 and 17 (1371 and 432 mm), however actual spans must be measured in class. The design 28 day compressive cylinder strength fck for the concrete is 30 N/mm2, however the actual strength will be measured by cylinders and given to you during the class. The EC2 design value is Ecm = 22((fck+8)/10)0.3 kN/mm2 (use this equation, not the rounded value in Table 3.1) but information to enable you to determine the actual value will be given in class. The longitudinal reinforcement is high tensile bar of design strength fyk = 500 N/mm2. The actual yield strength is known to be 560 N/mm2. Steel Es = 200 kN/mm2. These data are required in order for you to be able to predict BOTH the design and actual flexural strength and stiffness. The links are mild steel (but as you know from the previous coursework do not enter into the flexural calculations). P/2
Top steel 2 R8. Cover = 25 mm

P/2

Links b

d h

a L

Bottom steel 2 H16 or 2 H10. Assume that the design and actual cover to bottom bars = 25 mm

Cross Section bxh

Figure 1. General arrangement of beams. Not to scale.

(Note that the top bars are absent at the mid-span region to encourage compression failure in the concrete. This would NOT be the case in practice. The links are not shown in the elevation for clarity.)

PART 1 3. Predictions of Behaviour 3.1 Design Ultimate Flexural Strength to EC2 (do this before the class) Determine the ultimate moment of resistance MRd (kNm) of the RC beam in Figure 1 for BOTH cases of bottom steel (2H10 and 2 H16) using fck = 30 N/mm2 and fyk = 500 N/mm2. Use EC2 partial safety factors as you did in the previous coursework. (Note that one of these cases may be over-reinforced such that the strength of the beam is limited by the strength of concrete, not the rebars.) Use nominal dimensions for the breadth and depth of the beam, and effective depth of the bottom bars. Allowing for the self weight w of the beam (density may be taken as 25 kN/m3) and the self weight of the loading frame (known to be 38 kg, F = 0.38kN), determine the ultimate applied load resistance PRd (kN) using the general expression: M = Pa/2 + wL2/8 + Fa/2 (1) where L =1.371 m and a= 0.432 m are nominal values (given on page 1).
Hint work in kN & m units

3.2 Design Cracking Strength to EC2 (do this before the class) Determine the design cracking moment of resistance of the beams: Mc = fctm ZB Where from EC2 Table 3.1 fctm = 0.3 fck2/3 and ZB is the section modulus at the bottom of the beam as given in Section 4, obtained for nominal dimensions and the design modular ratio Es/Ecm (page 1). Determine the applied cracking load Pc as before using equation (1) for BOTH cases of bottom steel.

3.3 Actual Ultimate Flexural Strength (after the class) Determine the actual ultimate flexural strength MULT of your beam only without partial safety factors using actual concrete cylinder strength fck, and fyk = 560 N/mm2, i.e. concrete strength = 0.85fck and steel strength = 1.0fyk. Note that in this situation the balanced section occurs where:

x 0.0035 = d 0.0035 + ( f yk / E s )
Use actual dimensions for breadth and effective depth of the beam. Determine the corresponding applied load PULT using equation (1) where L and a are your actual values. Use same self weight for beam and rig as before.

3.4 Actual Cracking Strength (after the class) Determine the actual cracking moment of resistance of your beam only: MCRACK = fCRACK ZBTM where fCRACK is the actual flexural tensile cracking strength obtained (or given to you) during the class. See Section 8.5. ZBTM is the section modulus at the bottom of the beam as given in Section 4, this time obtained for actual dimensions and the actual modular ratio. Determine the corresponding applied load PCRACK as before equation (1) where L and a are your actual values. Use same self weight for beam and rig as before. NOTE L = effective span, not total length of beam!

4. Beam Deflection (after the class) The maximum deflection occurs at mid-span, and is given as:
= P 48 E
cm

a(3L2 4a 2 )

(2)

where I = second moment of area of the cross section. The value of I changes throughout the loading according to the amount of cracking. Where the beam is flexurally uncracked, i.e. total moment (including self weight of beam and rig) is less than the cracking moment, the uncracked value is determined using parallel axis theorem as (see Figure 2): Iu = bh3/12 + bh(0.5h xu)2 + (m-1)As (d xu)2
2 bh /2 + (m 1)As d bh + (m 1)As

(3)

where xu is depth to centroid of uncracked section =

where m = modular ratio = Es/Ecm (note the reason for (m-1) is because the steel replaces the area of concrete it occupies). Use design b, h, d and Ecm for design prediction, and actual values for the actual behaviour. Es and As are the same for both. The section modulus at the bottom of the beam ZB = Iu / (h xu) (4)

Where the beam is flexurally cracked, the centroidal axis rises up the beam and all tension below it is lost to cracking. Then the cracked value for I is (see Fig 2): Ic = bxc3/3 + mAs (d xc)2
bx 2 c bx

(5)
/2 + mAs d + mAs

where depth to centroid of cracked section xc =

Concrete in compression

xc xu
d
Concrete in tension

Centroidal axis

Area of bars always As

Uncracked in flexure

Cracked in flexure

Figure 2. Definition of flexurally uncracked and cracked sections From equations 2 to 5 it is possible to calculate the theoretical deflection for both states of cracking.

5. Curvature of Beam (after the class) The curvature of the beam is determined from the thru-depth strain-gradient. In the central part of the beam (between the loads) the bending moment is constant M = Pa/2. Here, curvature 1/R is determined using the theory of bending:
M I = E R = y

dividing by E and substituting, curvature is now expressed as the thru-depth strain gradient:
= y Pa 2 E cm I

(6)

where = strain measured at a distance y from the centroidal axis, P, a, Ecm and I are as before for both design and actual values. From equations 3 to 6 it is possible to calculate the theoretical strain-gradient for both states of cracking.

6. Theoretical Predictions From Sections 2 to 5 it is possible to plot (on separate graphs) the design and actual theoretical predictions (e.g. Figure 3 is shown for actual values) for: - load vs mid-span deflection - load vs strain gradient

Stiffness based on Iu PRd

Applied load (kN)

PCRACK

Stiffness based on Ic

Deflection or strain gradient Figure 3. Theoretical load v response curves.

A similar pair of graphs for deflection and strain gradient may be drawn for design values.

PART 2 7. Beam Testing Experiment (in the Structures Laboratory) When entering the laboratory your group will be working in the concrete laboratory and structural lab, your group will be split into three each of the subgroup will work on one of three beams. The choice of beam is quite random, and in any case you do not know the differences at this stage. Groups will swap over at the interval. Step 1 - Each subgroup will load the beam to first cracking, at least until 3-4 reasonably visible cracks appear. The beam will then be unloaded. Step 2 Each subgroup will restart the loading and take the beam nearly to failure (the demonstrator will decide when). The reason for not taking the beam directly to failure is that all students will gather around each beam to witness the failures in turn. Loads will be applied via a hydraulic jack, and measured using a hydraulic pressure attached to the hydraulic pump (see Figure 4). The output from the load cell is pressure, so you will be given a conversion chart into kN. Having previously calculated PR and Pcr can decide on the size of the load increment to reach 1st crack, and ultimate failure. demonstrator will give guidance. (It is suggested that about 8-10 equal increments required.) cell and you The are

Deflections are measured using a dial gauge, and strains using a DEMEC gauge at 5 thrudepth points. The dial and DEMEC gauges will be demonstrated in the laboratory. Subtracting the initial readings (due to setting up and bedding in) in order to obtain absolute values, plot applied load v deflection, and applied load v strain gradient on the SAME graphs as for the theoretical data. These graphs will form the basis for your main discussion of results. Whilst deflections may be plotted directly, note that there is an intermediate step to first determine strain-gradients as shown in Figure 5. (Because strains are very small, typically say 0.000257, suggest that you multiply by 106 and express them as micro-strain, e.g. 257.) Note that the unit of strain-gradient is mm-1.

5 pairs of DEMEC pips glued to face of beam (1 pair shown here). Measure distance to pips from top of beam

Applied load

Load spreader beam

Steel roller and plate

Measure breadth and depth at 3 places, taking the average.

Measure Measure

Measure

Dial (deflection) gauge

Figure 4. General arrangement of beam test

Plot your five strains X vs depth to DEMEC pip Top of beam Distance y from top of beam to DEMEC pips

Draw the best straight line through the points

x x x x
Strain-gradient = /y

Tension strain

Compression strain

Figure 5. Plotting out the strains to determine the strain gradient /y

Warning : if you use a spreadsheet to draw the plot make sure the gradient is /y and not y/ !!

PART 3 8. Plain Concrete Tests (in the Concrete Laboratory) 8.1 Youngs Modulus

Stress

Initial tangent modulus Ec(t)

Secant modulus Ecm

Strain

0.0035 or 3500

Figure 6. Definition of Youngs modulus This is determined: (a) Indirectly from dynamic methods, known as Ec(t) (b) Directly Ecm from cylinder results. Refer to Neville pages 631-634 for more information, where this is called Ecq or Ed. Ec(t) is also known as the initial tangent modulus because it is measured at a point of zero stress as shown in Figure 6.

(a) Two dynamic methods will be used, and the results averaged: 1. Portable Ultrasonic Non Destructive Instrument Tester (PUNDIT) 2. Electronic Resonant Ultrasonic Direct Instrument (ERUDITE) Both will be demonstrated. The 28 day results for your actual concrete beam will have previously been obtained and given to you during class. Results will be given for both water cured and air cured specimens because the RC beams have been water cured for 24 hours and air cured for a further 27 days. In the PUNDIT test the time taken for a pulse to travel along a 500 mm long x 100 mm square plain concrete prism is measured. The test is carried out at least five times, and the lowest time recorded. The pulse velocity V (m/sec) is found. The dynamic modulus is given as: Ec(t) = V2 where

(1 + ) (1 2 ) x 10-9 (kN/mm2) to 1 decimal place (1 )

(7)

dynamic Poissons ratio 0.25 = density of concrete (kg/m3) given to you in the lab.

In the ERUDITE test, the first natural resonant frequency n (Hz) is found. The dynamic modulus is given as: Ec(t) = 4 n2 L2 x 10-15 (kN/mm2) to 1 decimal place where L = 500 mm The static modulus, Ecm is determined using the EC2 equation: Ecm = Ec(t) /1.05 (9) (8)

FOUR values will be available 2 from the PUNDIT (air & water cured prisms) and 2 from the ERUDITE (ditto) (b) The direct static method is simply: Ecm = 22 ((fck+8)/10)0.3 (fck is N/mm2, Ecm is kN/mm2) TWO values will be available from air & water cured cylinders. The average of all SIX may be taken. (10)

8.2 Rebound (Schmit) Hammer This is used for determining the surface hardness of concrete. There is an approximate correlation between hardness and compressive strength, but this will not be used in this exercise. 8.3 Cover Meter This is a magnetic field device that is used to measure the cover depth to reinforcement. It will be demonstrated but not used a part of the experiment. (You may wish to check the cover of the reinforcement after the laboratory class.) 8.4 Cylinder and Cube Strength A sample 300 mm long x 150 mm dia cylinder (cast at same time as your beam) will be crushed in the DENISON machine. This result will be used in your theoretical predictions. A

sample 100 mm cube (not from your beam) will be crushed in the CONTEST machine, but the result will not be used in the exercise. 8.5 Flexural Tensile Strength A sample 500 x 100 x 100 mm prism will be subjected to four-point bending in the DENISON machine. If the breadth and depth of the prism a = 100 mm, and shear span is also a = 100 mm, and the failure load is P: fct =
M Z = Pa/2 3P = 3 2 a /6 a

PART 4 9. Report (due date 11th April 2012) Group Report (62% marks) 1. Introduction to the beam experiment; objectives, beam reference, dimensions, equipment, method, sketches. 2. Brief report on; PUNDIT, ERUDITE, cover meter, rebound hammer, plus cylinder, cube and prism tests. 3. Theoretical calculations for PR Pc Iu Ic and the gradients of P/ and P/(/y) according to EC2 design for both rebar cases. 4. Theoretical calculations for PR Pc Ec(t) & Ecm Iu Ic and the gradients of P/ and P/(/y) for the actual predictions of your beam only. 5. Experimental results for beam test (tabulated) including maximum load which is called out during final failure. 6. Plots of thru-depth strains at each loading point. 7. Graphs: experimental load v deflection and load v strain-gradient, including design and actual predictions from items 3 & 4 on the same graph. 8. Graphs: increase in concrete cube strength and Youngs modulus with age. Individual Submission (33% marks) 1. Discussion; behaviour of your beam only, crack patterns, failure mode, sketches, additional photo if you wish. 2. Assessment of errors and assumptions. 3. Comparison of design & actual theory with the experiment. 4. Conclusions: highlight the major findings with reference to the objectives. Mix design sheets (5% marks) Hand in your personal Mix Design Sheet from 1st semester. The group report should include clear evidence of the author(s) to each part. The group reference (A,B,C,D) and beam reference (C,S,T as marked on the beam by the technicians) should be included in the top right corner of the front sheet. If individual reports are submitted separately, make sure your group and beam reference is included so we know which group you belong to.

K S Elliott 26 November 2008