CE3161 ENGINEERINGMATERIALS LABORATORYMANUAL

Fall2012
Instructor:TitoNyamuhokya

Last revised: 8/31/2012

LABORATORY SCHEDULE FALL 2011 Tentative

DATE Aug. 29-31 Sep. 5-7 Sep. 12-14 Sep. 19-21 Sep. 26-28 Oct. 3-5 Oct. 10-12 Oct. 17-19 Oct. 24-26 LAB 1 2 3 TOPIC Aggregates Aggregates Aggregates TEST 1.1 Material <0.075mm Sieve by Washing (Decantation) 1.2 Specific Gravity and Absorption of Coarse Aggregates 1.3 Percent Solids and Voids in Concrete Aggregates 2.1 Sieve Analysis 2.2 Specific Gravity and Absorption of Fine Aggregates 3.1 Sand Equivalent - demo 3.2 LA Abrasion Test 3.3 Fine Aggregate Angularity 4.1 Normal Consistency of Hydraulic Cement with the Vicat Apparatus 4.2 Time of Setting of Hydraulic Cement 4.3 Blaine Fineness Test Concrete Mix Design - Lecture (REPORT DUE: AGGREGATES & CEMENT) 6.1 Mix Design-Batching, Making, Curing Concrete Specimens 6.2 Slump test 6.3 Air Content by the Pressure Method 6.4 Measuring Temperature of Freshly Mixed Concrete 7.1 7-Day Flexural Strength by Simple Beam 3rd Point Loading 7.2 Mixing of Mortar and Building of Brick Prism 7.3 Self Consolidating Concrete - Demo 8.1 Compressive Strength of Hydraulic Cement Mortars 8.2 Compressive Strength of Brick Prism HMA Mix Design - Lecture 10.1 HMA Specimen Preparation- Texas Gyratory Compaction 10.2 Superpave Gyratory Compaction to Determine the Density of HMA 10.3 Viscosity of Asphalt Binders with the Rotational Viscometer demo 10.4 Shear Modulus and Phase Angle of Asphalt Binders (DSR) - demo (REPORT DUE: MORTAR & BRICK) 9.1 28-Day Compressive Strength of Concrete 9.2 28-Day Splitting Tensile Strength ANOVA data analysis 11.1 Theoretical Maximum Specific Gravity or Density of HMA 11.2 Bulk Specific Gravity of Compacted HMA using SSD Specimens 11.3 Dynamic Modulus of Asphalt Concrete demo (REPORT DUE: CONCRETE) 12.1 Tensile Strength of Steel (Strain-stress Curve) 12.2 Compressive Strength of Wood Parallel to the Grain 12.3 Flexural Strength/ Modulus Rupture of Timber (REPORT DUE: HMAC & STEEL & TIMBER)

4 5 6

Cement Concrete Concrete Concrete Mortar & Brick Mortar & Brick HMAC

7 8 10

Oct 31

to Nov. 2 Nov. 7-9 Nov. 14-16

9 11 12

Concrete HMAC

Steel & Timber Final Exam

Dec. 3 - 5

TEST 1.1: Materials Finer than 0.075mm (No. 200) Sieve by Washing (AASHTO T11-91; ASTMC29; TxDOT 406-A) Equipment needed: Plastic bucket with handle (about 1-gal size or slightly larger) 0.075mm (No. 200) sieve Either a 2.36 (No. 8) or 1.18 (No. 16) mm sieve Large metal pan Access to at least one sinks Prepare before class: One ziplock bag (1-gal size) with 2,500 g of oven dry aggregate Steps in class: 1. Record dry mass of aggregate on sieve analysis data sheet. 2. Stack sieves with No. 200 on bottom and place in sink 3. Put aggregate in bucket and enough water to cover aggregate 4. Agitate sample so that fine material is washed off aggregate surface 5. Immediately, pour water with suspended fine material over sieves 6. Repeat until water is reasonably clean after agitation 7. Empty aggregate from bucket into pan 8. Wash any material retained on each sieve into pan 9. Place pan in oven and dry overnight. Record dry mass in appropriate spot on sieve analysis data sheet. In Your Report: Initial weight of aggregates Weight of oven dry sample Weight of fines less than 0.075mm Therefore % fines = A = B = A-B = ((A-B)/A) * 100

TEST 1.2: Specific Gravity and Absorption of Coarse Aggregate (ASTM C127) Equipment needed: Scale that reads to 0.1 grams with an attachment for weighing samples under water Wire basket with handle Water tank 4 buckets or large pans for soaking aggregates Large terry cloth towels Spray bottle filled with water Prepare before class: Screen a large sample of the coarse aggregate over a 4.75 mm screen Save the material retained and waste the material passing For each group, prepare one sample of: 2,500 g of coarse aggregate washed and left in pan under water Steps in class: OPTION 1 WIRE BASKET METHOD 1. Remove the test aggregates sample from the water and roll it in a large pre-dampened towel until all free water is no longer visible on the aggregates surfaces (SSD condition). 2. Determine in air mass of the sample in surface dry condition (SSD). 3. Hang wire basket under water, (and record the underwater mass).re-zero the scale. 4. Remove the basket from water (do not zero the balance), fill it with the SSD conditioned sample then hang it back into the water. Record the mass of the sample under water. 5. Remove the basket and the sample from water. Empty the sample into a pan of known mass (measured in advance). 6. Oven - dry the sample for about 20hrs. Measure the mass of pan and the sample after that (next day). 7. Compute Bulk Specific Gravity, Bulk SG = A / (B-C) A = weight of oven dry sample, g, B = weight of SSD test sample in air, g C = weight of SSD sample in water Steps in class: OPTION 2 PICNOMETER (JAR) METHOD 1. Determine mass of the picnometer/jar filled with water. Make sure you wipe the sides well and that the jar is filled properly. 2. Empty aggregate onto pre-dampened towel. Dry aggregate until surface is uniformly dull (no free water). Take care to keep aggregate not being dried covered with sides of towel. 3. Empty some aggregate into a pan and determine mass of aggregate at SSD. 4. Put the SSD aggregated into the jar. Fill the jar with water all the way and measure the mass of the jar with aggregates and water. Record. 5. Record mass of an empty metal pan. Empty the jar (aggregates + water) into pan. Take care not to lose any material. Dry the sample overnight. 6. Next morning: Remove pans from oven, cool to room temperature, and determine dry mass of pan and aggregate. Post for students. In Your Report: Bulk specific gravity, Bulk SG = A / (B+C-D) Where: A = weight of oven dry sample, g, B = weight of SSD test sample in air, g C = weight of jar filled to the top with the SSD test sample and water, g D = weight of jar filled to the top with water only, g Water absorption (in both cases), % Absorption = 100 % * (B-A) / A 4 Where:

TEST 1.3: Percent Solids and Voids in Concrete Aggregates (ASTM C29, C127, C128; TxDOT 405-A) Equipment needed: Balance 5/8-in diameter tamping rod (24-in long) Cylindrical metal measure (minimal capacity of ft3 for coarse aggregate size not larger than 1 in and of 1/10 ft3 for fine aggregate Prepare before class: Dry aggregate to constant weight, preferably in an oven at 110 5 C Steps in class: 1. Find empty weight of the cylindrical metal measure. 2. Fill the measure to one-third full with the dry sample. 3. Rod the layer of aggregate with 25 strokes. (Do not allow the rod to strike the bottom of the measure) 4. Fill the measure two-thirds full, level, and rod as in step 3 5. Fill the measure overflowing and rod as in step 3 6. Level the surface of the aggregate with a finger and tamping rod such that any slight projection of the larger pieces of the coarse aggregate approximately balances the larger voids in the surface below the top of the measure 7. Weigh the measure with aggregate and find the net weight of the aggregate: A. In Your Report: Calculate unit weight and void for gravel, 3/4 in crushed stone, 1/2 in crushed stone, and sand using the following formulas: Unit Weight or bulk density, B = (A / V) Where V is the volume of the measure Void (%) = lb/ft3 or kg/m3

S W B 100 S W

S is the bulk specific gravity (dry basis see 1.2), W is the unit weight of water

TEST 2.1: Sieve Analysis of Fine Aggregates (AASHTO T27-93; ASTM C136, TxDOT401-A) Fineness Modulus Calculation (ASTM C33, TxDOT 402-A) Equipment needed: Stack of sieves from 12.5 to 0.075 mm with pan and lid Mechanical shaker Soft brushes for cleaning fine mesh screens Wire brushes for cleaning large wire screens Misc. pans for transferring aggregates from sieves after weighing Prepare before class: Obtain an aggregate sample from each stockpile (see test method for amount for a given size aggregate) Oven dry, record the oven dry mass, and wash each sample the day before class (or earlier). Store in ziplock bag with original mass information if done further ahead than one day. Step for Class: 1. Clean, tare (record), and stack sieves with the largest on top and the smallest on the bottom. 2. Pour oven dry aggregate from T11-91 into top of sieve stack, place lid on stack, and position in the mechanical shaker. 3. Start shaker and run for 10 minutes. 4. After equipment stops shaking, take stack out, separate sieves and obtain the mass of both the sieve and the aggregate retained on each one. Record each measurement. 5. Clean and re-stack sieves.

TEST 2.2: Specific Gravity and Absorption of Fine Aggregates (AASHTO T 84-95; ASTM C134, TxDOT 403-A) Equipment needed: (need 2 sets so that 2 groups can work at the same time) Digital scale, which can read to the nearest 0.1 grams 500 ml glass volumetric flask Metal cone mold and tamper Hair drier (for warm, gently moving air) Large flat metal pan if non-absorptive surface not available (large cookie sheet) 4 large metal pans (for drying aggregate) Pan turner Wash bottle filled with water Felt pens for labeling pans Prepare before class: Screen fine aggregate over 4.75 mm screen and keep material that passes screen For each group, place 1,000 g of this material in ziplock bags Add about 4 percent water by mass of aggregate (this assumes that the absorption of the aggregate is less than 4 percent) and seal the bag. Steps in class: 1. Empty damp aggregate onto cookie sheet and spread out. 2. Use hair drier to help dry aggregate to saturated surface dry (SSD). 3. Use pan turner to continually move aggregate around so that it dries uniformly. 4. When aggregate approaches SSD, clear a space on cookie sheet, place metal cone in center and loosely fill with aggregate. 5. Lightly tamp aggregate with 25 light drops starting about 0.5 mm (0.2 inches) above the surface each time. 6. Firmly hold cone and brush aggregate away from base. 7. Lift mold vertically. At least a portion of the aggregate will not be able to hold its shape at SSD. 8. Repeat steps 2 through 7 until SSD condition is reached. Measure the mass of SSD aggregate to be used (500 +/- 10). 9. Calibrate a specific gravity flask pycnometer by filling with water at 73.4F (23C) to the calibration line and determine the mass. (C) 10. Partially fill flask (pycnometer) with water and add 500 10 g of SSD aggregate. 11. Fill flask with additional water until about 90% full. Roll and gently agitate to eliminate all air bubbles. The tip of a paper towel can be used to disperse foam. 12. Bring the water level in the flask up to the volumetric mark. Determine and record mass of flask, water, and aggregate. 13. Tare pan, record mass and empty aggregate and water into pan. Use wash bottle to rinse flask into pan. 14. Label pan and place in oven to dry overnight. 15. Next morning, remove pans from oven, cool to room temperature and determine the mass of the pan and aggregate. Post results for students. In Your Report: Bulk specific gravity of sand, Bulk SG = A/ (B+C-D) Where: A = weight of dried sample B = Mass of SSD sand sample C = weight of flask + water D = weight of flask + sample + water to the mark Water Absorption of Sand = 100* (B - A) / A

TEST 3.1: Sand Equivalent (AASHTO T176) Equipment needed: A graduated plastic cylinder, rubber stopper, irrigator tube, weighted foot assembly, and siphon assembly An 85 + 5 mL (3 oz) tinned box, about 57 mm (2.25 in) in diameter, with Gill style cover A wide mouth funnel approximately 100 mm (4 in) in diameter A clock or watch reading in minutes and seconds A mechanical shaker as described in AASHTO T 176 2.5 Working calcium chloride solution: Prepare the working calcium chloride by diluting one measuring tin full of the stock calcium chloride solution to 3.79 L (1 gal) with water. Use distilled water for the normal preparation of the working solution. A straightedge suitable for striking off the excess material from tin measure. A thermostatically controlled drying oven capable of maintaining a temperature of 110 + 5oC (230 + 9oF). Steps in class: Maintain the temperature of the working solution at 22 + 3oC (72 + 5oF) during the performance of this test. SAMPLE PREPARATION 1. Perform the sand equivalent test on combined aggregate materials passing the 4.75 mm (No. 4) sieve. Pulverize all aggregates of fine-grained soil materials to pass the 4.75 mm (No. 4) sieve, and clean all fines from the particles retained on the 4.75 mm (No. 4) sieve and include with the material passing the 4.75 mm (No. 4) sieve. 2. Split or quarter enough of the original sample to yield slightly more than four-85 mL (3 oz) tin measures of material passing the 4.75 mm (No. 4) sieve. Use extreme care to obtain a truly representative portion of the original sample. 3. Prepare the desired number of test samples using one the following method: a. Pre-wet sand. You pre-wet the sample of sand with water in the proper moisture condition. This condition is determined by tightly squeezing a small portion of the thoroughly mixed sample in the palm of the hand. If the cast that is formed permits careful handling without breaking, the correct moisture range has been obtained. After the minimum 15minute tempering period, fill the 85 mL (3 oz) tin measure by pushing it through the base of the pile while exerting pressure with the hand against the pile on the side opposite the measure. Strike off the tin measure level full with spatula or straightedge. Obtain the 85 mL (3 oz) tin measure of material, then dry the test sample to constant mass at 110 + 5oC (230 + 9oF), and cool to room temperature before testing. b. Dry sand. PROCEDURE 1. Siphon 101.6 + 2.5 mm (4 + 0.1 in) of working calcium chloride solution into the plastic cylinder. Pour the prepared sample from the measuring tin into the plastic cylinder using the funnel. Tap the bottom of the cylinder sharply on the heel of the hand several times to release air bubbles and to promote thorough wetting of the sample. 8

2. Allow the wetted sample to stand undisturbed for 10 + 1 minutes. At the end of the 10-minute soaking period, stopper the cylinder, then loosen the material from the bottom by partially inverting the cylinder and shaking it simultaneously. 3. After loosening the material from the bottom of the cylinder, place the stoppered cylinder in the mechanical1 sand equivalent shaker and secure. Make sure the timer is set for 45 seconds then turn the shaker on. 4. Following the shaking operation, set the cylinder upright on the work surface and remove the stopper. 5. Insert the irrigator tube in the cylinder and rinse material from the cylinder walls as the irrigator is lowered. Continue to apply the stabbing and twisting action while flushing the fines upward until the cylinder is filled to the 381 mm (15 in) mark. Then raise the irrigator slowly without shutting off the flow. Regulate the flow just before the irrigator is entirely withdrawn and adjust the final level to 381 mm (15 in). 6. Allow the cylinder and contents to stand undisturbed for 20 minutes + 15 seconds. Start the timing immediately after withdrawing the irrigator tube. 7. At the end of the 20-minute sedimentation period, read and record the top level of the clay suspension. This is referred to as the "clay reading". If no clear line of demarcation has formed at the end of the specified 20-minute sedimentation period, allow the sample to stand undisturbed until a clay reading can be obtained, then immediately read and record the top level of the clay suspension and total sedimentation time. If the total sedimentation time exceeds 30 minutes, rerun the test using three individual samples of the same material. Read and record the clay column height of that sample requiring the shortest sedimentation period only. 8. Obtain the "sand reading" by placing the weighted foot assembly over the cylinder and gently lowering the assembly toward the sand. As the weighted foot comes to rest on the sand, tip the assembly toward the graduations on the cylinder until the indicator touches the inside of the cylinder. Subtract 254 mm (10 in) from the level indicated by the extreme top edge of the indicator and record this value as the sand reading. 9. If clay or sand readings fall between 2.5 mm (0.1 in) graduations, record the level of the higher graduation as the reading. For example, a clay reading of 199 mm (7.95 in) would be recorded as 200 mm (8.0 in), and a sand reading of 83 mm (3.32 in) would be recorded as 85 mm (3.4 in). Perform the test in a location free of vibrations; vibrations may cause the suspended material to settle at a rate greater than normal. In Your Report: 1. Calculate the sand equivalent (SE) to the nearest 0.1 using the following formula: SE = 100* (Sand Reading) / Clay Reading 2. Round-up to a whole number.

TEST 3.2: LA Abrasion Test (ASTM C131) Equipment needed: Los Angeles Testing Machine

Sample size will be selected according to nominal maximum size and grading of the aggregate: Sieve Size Weight of Grading No. of Indicated Size, g Designation Charges Passing 3/4 in 1/2 in Retained on in 3/8 in 2500 10 2500 10 B B 11 11

Steps in class: 1. Wash and oven dry the test sample to a constant weight at a temperature of 110 5C, then weight it (A). 2. Place the sample in the Los Angeles machine and rotate the machine at a speed of 30-33 rpm for 500 revolutions. The charge shall consist of steel spheres averaging 1 27/32 in. (46.8 mm) in diameter and each weighting between 390 and 445 g. 3. Discharge the material and sieve it through the 1.7-mm (No.12) sieve. 4. Wash the material remained on the sieve and dry to a constant weight at a temperature of 110 5C, then weight it (B). In Your Report: Compute % of the weight of material loss from weight of initial aggregate sample. LA Abrasion Number = 100* (A B) / A

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TEST 3.3: Fine Aggregate Angularity Equipment needed: Funnel - The lateral surface of the right frustum of a cone sloped 60 + 4 degrees from the horizontal with an opening of 12.7 + 0.6 mm (0.50 + 0.024 in) diameter. The funnel shall be smooth on the inside and at least 38 mm (1.5 in) high. It shall have a volume of at least 200 mL (12.2 in3) or shall be provided with a supplemental container to provide the required volume. Funnel Stand - A support capable of holding the funnel firmly in position with its axis collinear with the axis of the measure and funnel opening 115 + 2 mm (4.5 + 0.1 in) above the top of the cylinder. A suitable arrangement is shown in Figure 5.16.50-1. Measure - A right angle cylinder of approximately 100 mL (6.1 in3) capacity having an inside diameter of 39 + 1.3 mm (1.53 + 0.05 in), and an inside height of approximately 86 mm (3.37 in), made of drawn copper water tube meeting ASTM B 88, Type M or equally rigid material.

Pan - A metal or plastic pan of sufficient size to contain the funnel stand and to prevent loss of material. The purpose of the pan is to catch and retain aggregate grains that overflow the measure during filling or strike off Metal spatula about 100 mm (4 in) long with sharp straight edges. The straight edge of the spatula is used to strike off the fine aggregate Balance 200 mL Volumetric flasks TC at 20oC (68oF) accurate and readable to + 0.10 mL Brush - A brush small enough to use to dislodge aggregate from the measure's base while inside the funnel stand Utility funnel - A small plastic or metal or glass funnel with a neck small enough to insert into the 200 mL volumetric flasks but sufficiently large enough in inside diameter to transfer all the contents of the measure to the flask.

Steps in class: SAMPLE PREPARATION 1. Wash the sample over the 75 mm (No. 200) sieve. Dry the plus 75 mm (No. 200) material to a constant mass. Sieve the dry aggregate over the 2.36 mm (No. 8), 1.18 mm (No. 16), 600 mm (No. 30), 300 mm (No. 50), and 150 mm (No. 100) sieves. Discard all material retained on the 2.36 mm (No. 8) and passed through the 0.150 mm (No. 100). 2. Weigh out and combine the following quantities of dry aggregate from each of the sizes: Individual Size Fraction Mass, g 2.36 mm (No. 8) to 1.18 mm (No. 16) 44 1.18 mm (No. 16) to 600 mm (No. 30) 57 600 mm (No. 30) to 300 mm (No. 50) 72 300 mm (No. 50) to 150 mm (No. 100) 17 Total 190 The tolerance on each of these amounts is + 0.2 g. Mix the test sample until it is homogenous. 11

TEST PROCEDURE 1. Mix the test sample until it is homogenous. Using a finger to block the opening of the funnel, pour the test sample into the funnel. Level the material in the funnel with the spatula. Center the measure under the funnel, remove the finger, and allow the sample to fall freely into the measure. 2. After the funnel empties, remove excess-heaped aggregate from the measure by a single pass of the spatula with the blade vertical using the straight part of its edge in light contact with the top of the measure. Until this operation is complete, exercise care to avoid vibration or disturbance that could cause compaction of the fine aggregate in the measure. After strike-off, the measure may be tapped lightly to compact the sample to make it easier to transfer the measure. Brush adhering grains from the outside of the measure. 3. Pour contents of cylinder into 200 mL volumetric flask using a funnel to assure total transfer of aggregate. 4. Weigh the flask and sample, record as A. 5. Add distilled water (deionized water can be substituted) and removed trapped air by slowly turning the flask at an angle along it's base. Do not shake. Allow the flask to sit for several minutes then roll flask again. Continue the process until there is no visible air bubbles present or for a maximum of 15 minutes, 6. Adjust distilled water to the calibrated volume mark on the neck of the flask. 7. Weigh flask and contents, record as B.

In Your Report: CALCULATION The uncompacted void content (U) in 0.01 percent is calculated by this method: U = 100 [Vc (A + Vf - B)] /Vc Where: A = mass of flask and aggregate, g B = mass of flask, water and aggregate, g Vf = Volume of the flask (normally 200 mL as specified), mL. Vc = Calibrated volume of cylinder, mL.

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Suitable Funnel Stand Apparatus with Cylindrical Measure in Place

Nominal 100 mL Cylindrical Measure

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TEST 4.1: Normal Consistency of Hydraulic Cement with the Vicat Apparatus (ASTM C-187) Purpose: To determine the normal consistency of hydraulic cement (ASTM C-187) and time of setting of hydraulic cement (ASTM C-191). Equipment Needed: Vicat Apparatus Model CT-1A (Consists of a frame bearing a sliding rod of specific weight (300g). The larger end of the sliding rod is known as the plunger end while the other end has a removable needle of one-millimeter diameter. The sliding rod carries as indicator moving over a scale graduated in millimeters to measure travel.)

CT-2 Vicat Mold, hard plastic CT-3A Vicat Needle, 1mm diameter LT-479 ASTM Standards Vol. 04.01, Cement, Lime, Gypsum LT-755 AAASHTO Standards, Part I & II 650g of cement

Prepare before class:

Steps in class: 1. Preparation of cement paste. Mix 650g of cement with a measured quantity of clean water following the procedure described in section 6 of ASTM C-305, Mechanical Mixing of Hydraulic Cement Pastes and Mortars of Plastic Consistency. a. Place the mixing water in the bowl b. Add cement to water and allow 30 seconds for the absorption of water c. Mix at slow speed for 30 seconds d. Stop the mixer for 15 seconds and scrap down into the batch any paste that may have been collected on the sides of the bowl. e. Mix at medium speed for 1 minute 2. Molding the test specimen. a. Quickly form the cement paste, prepared as described in section 6 of ASTM C-305 into the approximate shape of a ball with gloved hands. b. Then toss 6 times through a free path of about 6 inches (150 mm) from one hand to another to produce a nearly spherical mass that may be easily inserted into the Vicat ring (mold) with a minimum amount of additional manipulation. c. Press the ball, resting in the palm of one hand, into the larger end of the conical ring, G, (Fig.1) held in the hand, completely filling the ring with paste. d. Remove the excess at larger end by a single movement of the palm of hand. e. Place the ring on its larger end on the glass plate, H, slice off the excess paste at the smaller end at the top of the ring by a single oblique stroke of a sharp edged trowel held at a slight angle with the top of the ring, and smooth the top. If necessary, with a few light touches of the pointed end of the trowel. Note: during these operations of cutting and smoothing, take care not to compress the paste.

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3. Consistency Determination. a. Center the paste confined in the ring (mold), resting on the glass plate under the rod, B, (Fig. 1), the plunger C of which shall be brought in contact with the surface of the paste, and tighten the set screw, E. b. Center the paste confined in the ring (mold), resting on the glass plate under the rod, B, (Fig. 1), the plunger C of which shall be brought in contact with the surface of the paste, and tighten the set screw, E. c. Then set the movable indicator F to the upper zero mark of the scale, or take an initial reading, and release the rod immediately. This must not exceed 30 sec. after mixing. d. The paste shall be of normal consistency when the rod (the blunt smaller side; no needle) side settles to a point of 10 1 mm below the original surface in 30 sec. after being released. e. Make trial pastes with various percentages of water until obtain normal consistency. f. Make each trial with fresh cement. 4. Calculate the amount of water required for normal consistency to the nearest 0.1% and report it to the nearest 0.5% of the weight of the dry cement.

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TEST 4.2: Time of Setting of Hydraulic Cement (ASTM C-191) Steps in class: 1. Preparation of Cement Paste Mix 650g of cement with the percentage of mixing water required for normal consistency following the procedure described in ASTM C-305, Mechanical Mixing of Hydraulic Cement Pastes and Mortars of Plastic Consistency. Distilled water is preferable and shall be used for all referee or cooperative tests. a. Place the mixing water in the bowl b. Add cement to water and allow 30 seconds for the absorption of water c. Mix at slow speed for 30 seconds. d. Stop the mixer for 15 seconds and scrap down into the batch any paste that may have been collected on the sides of the bowl. e. Mix at medium speed for 1 minute The test specimen used to determinate normal consistency may be used for determination of time of setting by Vicat needle following below procedure. 2. Molding the Test Specimen a. Quickly form the cement paste, prepared as described in section 1.1 into the approximate shape of a ball with gloved hands. b. Then toss 6 times through a free path of about 6 inches (150 mm) from one hand to another to produce a spherical mass that may be easily inserted into the Vicat ring (mold) with a minimum amount of additional manipulation. c. Press the ball, resting in the palm of one hand, into the larger end of the conical ring, G, (Fig.1) held in the hand, completely filling the ring with paste. d. Remove the excess at larger end by a single movement of palm of the hand. e. Place the ring on its larger end on the glass plate, H and slice off the excess paste at the smaller end at the top of the ring by a single oblique stroke of a sharp edged trowel held at a slight angle with the top of the ring and smooth the top. If necessary, with a few light touches of the pointed end of the trowel. During these operations of cutting and smoothing, take care not to compress the paste. f. Immediately after molding, place the test specimen in the moist closet or room and allow it to remain there except when determinations of time of setting are being made. The specimen shall remain in the conical mold, supported by the glass plate, H, throughout the test period. 3. Time of Setting Determination. a. Allow the time of setting specimen to remain in the moist closet for 30 min. after molding without being disturbed. b. Determine the penetration of the 1mm needle and every 15 minutes thereafter (every 10 min. for Type III cements) till obtain a penetration of 25mm or less. For the penetration test, lower the needle D of the rod B until it rests on the surface of the cement paste c. Tighten the setscrew E and set the indicator F at the upper end of the scale of the initial reading. 16 additional

d. Release the rod quickly by releasing the setscrew, E, and allow the needle to settle for 30 sec.; then take the reading to determine the penetration. Note: (a) If the paste is quite soft on the early readings, the fall of the rod may be retarded to avoid bending the 1mm needle; but only the setscrew shall release the rod when actual determinations for the setting time are made. (b) No penetration test shall be made closer than 1/4 inch (6.4mm) from any previous penetration and no penetration test shall be made closer than 3/8 inch (9.5mm) from the inside of the mold. e. Record the results of all penetration tests and, by interpolation, determine the time when penetration of 25mm is obtained. This is the initial setting time. *The final setting time is when the needle does not sink visibly into the paste. GILMORE APPARATUS 1. Preparation of Cement Paste: Mix 650 g of cement with the percentage of mixing water required for normal consistency in accordance with Test Method C 187, following the mixing procedure for cement paste outlined in 1.1. 2. Molding Test Specimen: From the cement paste, make a pat with a flat top and the sides tapering to a thin edge on a plane non-absorptive plate, conforming to the dimensions and tolerances in Figure 1 (a). In molding the pat, flatten the cement paste first on the plate and then form the pat by drawing the trowel from the outer edge toward the center, then flattening the top. After making, place the pat in the moist cabinet or moist room and allow it to remain there except when the determinations of time of setting are made. 3. Time of Setting Determination: Hold the needles in vertical position and apply lightly to the surface of the pat. Consider the cement paste to have acquired its initial set when the pat will bear, without appreciable indentation, the initial Gilmore needle. The difference, in minutes, between the time of contact of cement and mixing water and the time the cement paste acquires its initial set is the initial setting time. Consider the cement paste to have acquired its final set when the pat will bear, without appreciable indentation, the final Gilmore needle. The difference, in minutes, between the time of contact of cement and mixing water and the time the cement paste acquires its final set is the final setting time.

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TEST 4.3: Blaine Fineness Test (ASTM C204) Equipment Needed: Blaine air permeability apparatus (consists of manometer, a stainless steel permeability cell, a perforated metal disk, and a stainless steel plunger) Balance 0.001g Timer 0.5 sec Prepare before class: 3.0g Hydraulic cement Filter paper- Type 1, Grade B with a 12.7-mm diameter Manometer liquid- light grade of mineral oil (low viscosity and density) Steps in class: 1) Place approximately 4 oz of cement in a small covered jar or tin container. Shake vigorously for 2 minutes to fluff the cement and break up lumps and agglomerates. Allow the covered container to stand for 2 minutes, then remove the cover and stir gently to homogenize the sample. 2) Weigh out the cement to the nearest 0.001g. The weight of sample shall be determined as follows: W = V (1-n) Where is the density of the cement (3.15 g/cm3), n is a standard porosity of the bed (0.5) and V is the total volume of the cement bed determined by calibration (See ASTM for calibration procedure using NIST SRM No. 114). Prior calibration has established that this volume is: V = 1.8372 cm3 3) Gently seat the perforated metal disk in the permeability cell on the ledge at the bottom of the cell using a rod having a diameter slightly smaller than that of the cell. Place a filter paper on the metal disk and press the edges down with this same rod. 4) Place the cement in the cell on top of the first filter paper. Tap the side of the cell lightly in order to level the bed of cement. Place a second filter paper on this bed of cement. 5) Compress the cement with the plunger until the plunger collar contacts the top of the cell. Slowly withdraw the plunger a short distance, rotate the plunger 90, and compress the cement a second time until the collar contacts the top of the cell. Slowly remove the plunger. Note that fresh filter papers must be used for each determination. 6) Attach the permeability cell to the manometer tube (use a little stopcock grease to ensure an airtight connection). 7) Slowly evacuate the air in the right arm of the manometer using the pressure bulb until the liquid reaches the top mark, and then close the manometer valve. The liquid will start to slowly lower because of airflow through the cement sample into the manometer.

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8) Start the timer when the bottom of the meniscus of the liquid reaches the second mark from the top and stop the timer when the bottom of the meniscus reaches the third mark (next to the bottom mark). Record this time, T, to the nearest 1 second. 9) Calculate the specific surface values in accordance with the following equation:

Ss T Ts

where T is the measured time interval of the manometer drop for the test sample, Ss is the specific surface area of the standard reference material (NIST SRM #114), and Ts is the measured time interval of the manometer drop for the SRM. This equation is valid for cement tests performed at the same temperature as the standard reference test, and at the same porosity (n=0.5). Prior calibration has established that these SRM values are as follows: Ss = 377.4 m2/kg, and Ts = 92.2 s In Your Report: The specific surface area to the nearest 1 m2/kg.

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Test 6.1: Mixing of Concrete (ASTM C192) Purpose: To mix concrete and obtain test samples Equipment Needed: Pan Tamping rod Mixer Shovel Scoop By Hand Mixing: 1. Hand mixing should be limited to batches of 0.25 ft3 volume or less. 2. Mixing apparatus and accessories should be clean thoroughly. 3. Mix the batch in a damp, watertight metal pan. 4. Mix the cement, powder admixture if used and fine aggregates. 5. Add the coarse aggregate and mix the entire batch without the addition of water until the coarse aggregate is uniformly distributed throughout the base. 6. Add water and admixture solution (if used) and mix until the concrete is homogenous in appearance. By Machine Mixing: 1. Add coarse aggregates, some of the mixing water, and admixture solution (if used) to the mixer. 2. Start the mixer. 3. Add fine aggregate, cement, and the balance of the water when the mixer is running. (If it is impractical to add these materials when the mixer is running, they may be added to the stopped mixer after permitting it to run a few revolutions following the addition of coarse aggregates and part of mixing water). 4. Mix for 3 minutes followed by a 3 minutes rest, follow by 2 minutes of final mixing. 5. Tilt the mixer while it is running and pour the concrete into a clean and wet wheelbarrow. 6. Remove any concrete stuck in the mixer using scoops or shovels. 7. Remix concrete in the wheelbarrow using a shovel.

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Test 6.2: Slump Test (ASTM C143, AASHTO T-119) The slump test is used to determine the consistency of the fresh mix. Timing is critical in the slump test. It must be: Started within 5 minutes after the sample is collected, and Completed (though removal of the mold) within 21/2 minutes after starting the test. The equipment used in the slump test includes a: Rigid, non-absorbent base Bucket with water Metal scoop Standard slump mold Tamping rod Ruler The procedures for conducting the slump test are summarizes as follows: 1. Prepare for the test by: a. seeing that all the equipment is clean, b. setting the base on a level surface away from any equipment or other vibrations, and c. wetting the base and mold with water. 2. Fill the mold by: a. placing the mold on the base and firmly in place, b. placing the first layer to 1/3 of the volume of the mold (about 2.5 inches deep since the mold is conical), c. consolidating the first layer with the tamping rod 25 times, to the full depth of the layer, but being careful to avoid striking the base forcefully, and using a spiral pattern working from the edge to the center. d. placing the second layer to 2/3 of the volume of the mold (about 6 inches in height form the base), e. rodding this second layer 25 times; in a spiral pattern, and slightly penetrating the first layer. f. placing the third layer to overflowing, rodding this third layer as before, and strike off the excess concrete with the tamping rod. 3. Remove the mold by: a. stepping off the footholds, b. pulling straight up (in one motion without twisting), and c. completing the removal in 3 to 7 seconds. 4. Measure the slump by: a. setting the mold near to the specimen without jarring the base or specimen, b. holding the tamping rod at the top of the mold to provide a horizontal reference over the specimen, and using the ruler to measure the slump at the center of the top of the specimen. If the molded specimen shears off or falls away sharply to the side, repeat the test on another portion of the composite sample. The concrete used in the slump test must be discarded and all equipment should be cleaned. However, since timing is also critical for other testing procedures, you may wait until after the air content and the molding of strength specimens have been completed. 22

Test 6.3: Air Content by the Pressure Method (ASTM C231; TxDOT 416-A) Equipment Needed: Air Meter Type B consists of a measuring bowl (capacity of 0. 20 ft3) and cover assembly with pressure gauge Tamping Rod (5/8 diameter) Scale (0.01 lb accuracy) Mallet - rubber, weighing approximately 1.25 lb Strike off bar 0.4 ft3 of mixed plastic concrete Steps in Class: 1. Place the concrete in the measuring bowl in three layers of approximately equal volume. Consolidate each layer of concrete with 25 strokes of the tamping rod evenly distributed over the cross section. After each layer is rodded, tap the sides of the measure smartly 10-15 times with the mallet. The rodding action should only penetrate previous placed layers by about 1 inch. 2. Strike off the top surface with a sawing motion of the flat strike off bar. 3. Clean all excess concrete from the exterior of measuring bowl and top bowl flange. 4. Assemble the apparatus by clamping on the cover with petcocks open. 5. Using the rubber syringe, inject water through one petcock until all air is forced out the opposite petcock. Leave petcocks open. 7. Pump up air to initial pressure line on gauge. Wait a few seconds for compressed air to cool to normal temperature and then bleed off as needed so gauge reads at the initial pressure line. 6. Close both petcocks and press down on thumb lever to release the air into the bowl. Hold down lever for a few seconds and lightly tap gauge with finger to stabilize the gauge reading. Do not tilt the air meter. 7. Read the apparent air content (%) and record. = to the nearest 0.1% Report this value. 8. Open the petcocks to release pressure in the air meter. Remove the cover. Clean the base, cover, and petcock openings.

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Test 6.4: Measuring Temperature of Freshly Mixed PCC (ASTM C1064; TxDOT 422-A) Equipment Needed: Container made of non-absorptive material and large enough to provide at least 75 mm (3 in.) of concrete in all directions around the sensor of the temperature measuring device. The concrete cover must also be at least three times the nominal maximum size of the coarse aggregate. Temperature-measuring device, capable of measuring the temperature of the freshly mixed concrete to 0.5 C ( 1 F) throughout the entire temperature range likely to be encountered in the fresh concrete. Partial immersion liquid-in-glass thermometers (and possibly other types) shall have a permanent mark to which the device must be immersed without applying a correction factor.

Steps in Class: 1. Sampling Concrete: a. The temperature of freshly-mixed concrete may be measured in the transporting equipment provided the sensor of the temperature measuring device has at least 75 mm (3 in.) of concrete cover in all directions around it. b. Temperature of the freshly mixed concrete may be obtained following concrete placement using the forms as the container. c. If the transporting equipment or placement forms are not used as the container, a sample shall be prepared as follows: Immediately prior to sampling the freshly-mixed concrete, dampen the sample container with water. Sample the freshly mixed concrete according to Test Method "Tex-407-A, Sampling Freshly-Mixed Concrete" except that composite samples are not required if the only purpose for obtaining the sample is to determine temperature. Place the freshly mixed concrete into the container. 2. Measuring Temperature: a. Place the temperature-measuring device in the freshly mixed concrete so that the temperature sensing portion is submerged a minimum of 75 mm (3 in.). b. Gently press the concrete around the temperature-measuring device at the surface of the concrete so that ambient air temperature does not affect the reading. c. Leave the temperature-measuring device in the freshly mixed concrete for a minimum period of 2 minutes or until the temperature reading stabilizes, then read and record the temperature. d. Complete the temperature measurement of the freshly mixed concrete within 5 minutes after obtaining sample. Report: Record the temperature of the freshly mixed concrete to the nearest 0.5 C (1 F)

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TEST 7.1: 7-Day Flexural Strength of Concrete by Simple Beam Third-Point Loading (ASTM C78; TxDOT 448-A) Equipment Needed: Compressive strength device Electronic device, for recording the tensile strength at failure of the beam. Prepare before class: 7-day-old concrete beam Steps in Class: 1. Measure the beam first before we break the concrete beams. 2. Place the concrete beam in the compressive strength machine. 3. Make sure the beam is triple point loaded. 4. Use the computer to input the diameter of the beam. 5. Using the compressive strength device and computer, compress the beam until failure has reached. 6. Once failure has reached, record the tensile strength of the concrete beam at failure. In Your Report: Record the ultimate load and show in your report all the calculations including shear force and bending moment diagrams we have discussed in the class. Use the table below as a data sheet for flexural or modulus of rupture testing: Specimen Span Average Average Ultimate Flexural Strength No. Length Width Depth Load (lbs), (psi) (in), L (in), B (in), D Pmax = Pmax*L / (B*D2)

Average Note: If the beam fails by fracture in the tension surface outside of the middle third of span length by not more than 5% of the span, calculate the modulus of rupture or flexural strength as follows: Flexural strength (or modulus of rupture) = MOR = 3* Pmax *a / (B*D2) a= average distance between line of fracture and the nearest support measured on the tension surface of the beam, in.

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TEST 7.2: Mixing of Mortar and Building of Brick Prism Equipment Needed:

Mixing water Cement Bricks Spatula used to mix the mortar on the bricks Cement Mixer Lime and Sand

Steps for Class: Mixing of Mortar for Brick Prism 1. 2. 3. 4. Weight and mix 10.1 lb of sand, 2.63 lb of cement, 0.56 lb of lime. (homogeneous) Add water little by little. Mix them until it meets some consistency. After the mixture mixed well, put them into a tray.

Building of Brick Prism 1. Use the mortar to place on the bricks. Slam the mortar on the bricks. 2. Place 5 bricks on top of each other with mortar in between. 3. After the bricks have been added with the mortar in bonding them together, check the bond connection by pulling a brick off the prism. The amount of mortar should be close to half on each brick to have a good bond between the brick and the mortar.

Mixing of Mortar for Compressive Strength Test see Test 8.1

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Test 8.1: Compressive Strength of Hydraulic Cement Mortars (ASTM C109) Equipment Needed: Scale Specimen Molds Mixer, Mixing Bowl, Mixing Paddle, & Scraper Flow Table and Flow Mold Tamper Trowel Testing Machine Materials Needed: Graded Standard Sand - Natural silica sand, form Ottawa, Illinois, conforming to the requirements of ASTM Specification C778. Portland cement per ASTM C150 Mold Release Agent Procedures: Mortar Composition - The proportions of materials for the standard mortar shall be one part of cement to 2.75 parts of graded standard sand by weight. Use a water-cement ratio of 0.485 for all Portland cements and 0.460 for all air-entraining Portland cements. The water-cement ratio for other than Portland and air-entraining Portland cements shall be such as to produce a flow of 110 +/- 5. Batch the following, which is sufficient for 6 samples: Cement, g 500 Sand, g Water, g Portland (w/c=0.485) 242 1,375

(Air-entraining Portland (w/c=0.460) 230 Non-Portland (As required for flow of 110)

Specimen Mold Preparation - Apply a thin coating of mold release to the interior surfaces of the molds and base plates. Wipe surfaces with a cloth to remove any excess. Mortar Mixing Procedure (ASTM C305) - Place dry paddle and dry bowl in the mixing position of the mixer. Introduce the materials into the bowl in the following manner: 1) Place all the mixing water in the bowl. 2) Add cement to the water; start the mixer and mix at slow speed (140 rpm) for 30sec. 3) Add sand slowly over a 30 s period, while continued mixing at slow speed. 4) Stop the mixer, change to medium speed (285 rpm), and mix for an additional 30 s. 5) Stop the mixer and let the mortar stand for 1.5 minutes. During the first 15 s, quickly scrape down into the batch any mortar that may have collected on the side of the bowl; then for remainder of the interval, cover with the lid. 6) Finish mixing for 1 minute at medium speed (285 rpm). 7) Determine flow of mortar as follows: a) Wipe table clean and dry and place flow mold at center b) Place a layer of mortar about 1 inch thickness in the mold and tamp 20 times. c) Then fill the mold and tamp this second layer 20 times. 27

d) Cut mortar flush with top of mold with a trowel, held perpendicular to the mold, using a sawing motion. e) Wipe table around mold clean of all mortar and dry; then remove mold. f) Drop table through inch height 25 times in 15 s. g) Use calipers to measure the diameters along the 4 scribed lines on the table. The sum of the four readings is the flow (the percent increase in the original diameter). 8) Following flow test, return all mortar to the mixing bowl. Scrap down the sides and remix for 15 s at medium speed (285 rpm). Molding Test Specimens - Start molding within 2 minute and 30 s after completion of the original mixing of the mortar. 1) Place a layer of mortar about 1 in. (25 mm) (approximately one-half of the depth of the mold) in all of the cube compartments. 2) Tamp the mortar in each cube compartment 32 times in about 10 s in four (4) rounds, each round to be at right angles to the other and consisting of eight adjoining strokes over the surface of the specimen (see Figure 1). 3) Fill the compartments with the remaining mortar and tamp as specified for the first layer. During tamping of the second layer, bring in the mortar forced out onto the tops of the molds after each round of tamping using gloved finger and the tamper. On completion of the tamping, the tops of all cubes should extend slightly above the top of the mold. 4) Trowel mortar of each cube both laterally and longitudinally. Cut off mortar to a plane surface with the top of the mold by drawing the straight edge of the trowel, held perpendicular to the mold, with a sawing motion over the length of the mold. 5) Place molded specimens in a moist room for 24 hours. Keep specimens in their molds for this initial curing period. After 24 hours remove specimens from the molds and immerse in a saturated lime water curing tank. Compressive Strength Determination - Test all specimens according to the specified testing schedule. 3, 7, and 28-day strengths will be obtained to ascertain the strength gain as a function of time. 1) Remove specified specimen from the curing tank. Wipe to a surface dry condition and remove any loose sand grains or incrustations for surfaces. 2) Apply the load to specimen faces that were in contact with the true plane surfaces of the mold. Check the straightness of these faces with a straight edge. Note that grinding is required if the surfaces have appreciable curvature. Select opposing surfaces that have the straightest profiles. 3) Place specimen below the center of the upper bearing block of the testing machine. Ascertain that this spherically seated block is free to tilt. Test at a loading rate such that the peak load will be reached in a period of 20 s to 80 s. Make no adjustments in the controls of the testing machine while specimen is yielding prior to failure. 4) Schematically show how the specimen failed. 5) Record the total maximum load as indicated by the testing machine. Calculate the compressive strength of the specimen in pounds per square inch (psi). Express this strength in Pascals (Pa). 6) Calculate the average of all like specimens and report to the nearest 10 psi (70 kPa). In Your Report: After testing at 1, 3, and 7 days, generate curves, using all group data for each cement type, of compressive strength vs. time of testing. Show all data points and plot an average curve. Plot the ASTM C150 Specifications. 28

TEST 9.1: 28-Day Compressive Strength of Concrete (ASTM C39) Equipment Needed: Compressive strength device Electronic device, for recording the compressive strength at failure of the concrete cylinder Prepare before class: 28-day-old concrete cylinder Steps in class: 1. Place the caps on the cross section of the cylinder to help distribute the loading on the cross section more efficiently. 2. Input the diameter of the cylinder. 3. Place the cylinder in the middle of the loading plate of the compressive strength machine 4. Use the computer to compress the cylinder from the machine. 5. Once failure occurs, use the computer program to print out your results. 6. Check the results using the formulas by hand calculation. 7. If any large differences occur, make an observation in the report. In Your Report: Use the table below as a data sheet for compressive testing: Team Specimen Diameter Area Maximum No. (in.) (in2) Load (lbs) 1 2 Average Compressive strength can be calculated using formula; Compressive strength (psi or Mpa) = Pult / A, , where Pult= the ultimate compressive load in lbs (kg), A = cross-sectional area of the cylinder in in (m)

Compressive Strength, fc (psi)

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TEST 9.2: 28-Day Splitting Tensile Strength (ASTM C496) Equipment Needed: Compressive Strength machine Diagonal cross section plate for the cross section of the cylinder Computer program or electronic device Prepare before class: 28-day-old concrete cylinder Steps in class: 1. Place the longer side of the concrete cylinder on the center of the loading plate. 2. Place a diagonal cross sectional plate on cross section of the beam to help distribute the loading. 3. Use the computer to initiate tension strength on the concrete cylinder. 4. After failure has occurred, use the computer to print out the results. 5. Compare the results from the computer with the calculations by the formulas. 6. Note any differences between the experimental results and the formulated results. In Your Report: Use the table below as a data sheet for tensile testing: Team Specimen Diameter Length Maximum No. (in) (in) (lbs) 1 2 3 4 Average Tensile strength can be calculated using formula: , where T is tensile strength (psi), P is load(lb), L is length(in), d is diameter (in)

Load Tensile Strength, fc (psi)

T = 2*P/( *L*d)

Compare the results of tensile strength from experiment and equation: Team Calculation (psi) Experiment (psi) 1 2 3 4 Average

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TEST 10.1: HMA Gyratory Specimen Preparation Equipment Needed: Gyratory Compactor Hot asphalt mixture Converted arbor press Spatula Paper Spoon Prepare before class: Heat 960g of asphalt in the oven to the compaction temperature. Steps in class: 1. Get 960 g of asphalt mix from the oven and place the mix into 2-in mold with 3 equal layers. 2. Spatula around the edges. 3. Use spoon to flatten the top of mold. Make sure to get all mixture stuck on the spoon. 4. Put paper on top and place on the Gyratory Compactor. 5. Pump pressure until low-pressure gage reach 50 psi and rotate the mold. 6. Repeat step 5 until one full stroke hit 150 psi. 7. After it reaches 150 psi, add pressure until high-pressure gage reads 2,500 psi, and then release pressure all the way. 8. Pump the ram up and out of the mold. 9. Slide the mold out of the machine, remembering to place a gloved hand beneath the mold to keep the base plate from falling out. 10. Invert the mold and remove the specimen from the mold with a converted arbor press. 11. Clean the inside of the mold with a rag lightly moistened with kerosene or light lube oil before molding another specimen.

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TEST 10.2: Superpave Gyratory Compaction to Determine the Density of HMA PREPARATION OF APPARATUS 1. Immediately prior to the time when the paving mix is ready for the placement in the mold, turn on the main power for the compactor for the manufacturer's required warm-up period. 2. Verify machine settings are correct for angle, pressure and number of gyrations, as shown in TABLE 1. 3. Lubricate any bearing surfaces as needed. Lightly lubricate the surface of the rotating base along the surface of the four rollers. 4. Turn on the printer and make sure it has paper Steps in class: COMPACTION PROCEDURE After completing the mixture preparation, place the loose mix in a shallow, flat pan and short-term age it. Place the mixture on a baking pan and spread it to an even thickness. Place the mixture and pan in the aging oven for 2 hours + 5 minutes at a temperature of 135 + 3oC (275 + 5.4oF). Stir mixture every 60 + 5 minutes to maintain uniform aging. Place a compaction mold, base and top steel plates and the steel funnel in an oven at required compaction temperature for 30 to 60 minutes prior to the estimated beginning of the compaction (during the time the mixture is being conditioned). After the 2 hour conditioning period, remove the pan with asphalt mix from the oven and allow it to achieve the proper compaction temperature. The compaction temperature range is defined as the range of temperature where the unaged asphalt binder has a kinematic viscosity of 280 + 30 mm2/s (approximately 0.28 + 0.03 Pa-s) measured in accordance with ASTM D4402. If the compaction temperature is different from 135 + 3oC (275 + 5.4oF), place the mix in another oven at the compaction temperature for a brief time (maximum of 30 minutes) to achieve the required temperature. If loose HMA plant mix is used, the mixture shall be brought to the compaction temperature range by careful uniform heating in an oven immediately prior to molding. When compaction temperature is achieved, remove the heated mold and base plate from the oven and place a paper disk on the bottom of the mold. Thoroughly mix the material then place the mixture into the mold in one lift, using the heated funnel. Care should be taken to avoid segregation in the mold. After all the mix is in the mold, level the mix and place another paper disk on top of the leveled material. Place the top steel plate. Load the specimen mold with the paving mix into the compactor and center the mold under the loading ram. Lower the ram until pressure on the specimen reaches 600 + 60 kPa (87.02 + 0.87 psi). Apply a 22.0 + 0.35 mrad (1.25 + 0.02 degrees) angle to the mold assembly and begin the gyratory compaction. Allow the compaction to proceed until the desired number of gyrations is reached and the gyratory mechanism shuts off. Make sure the printer writes the height of the specimen for each gyration. Remove the angle from the mold assembly, raise the loading ram, remove the mold from the compactor and extrude the specimen from the mold. Specimen can be extruded from the mold immediately for most HMA paving mixes. For lean, rich or tender mixtures, a cooling period of 5 to 10 minutes in front of a fan may be necessary before extruding the specimen. 32

Remove the paper disks from the top and bottom of the specimens. Before reusing the mold, place it in an oven for at least 5 minutes. The use of multiple molds will speed up the compaction process. Keep the print-out and write down your group number on it. Clean all steel parts (trays, molds, plates, funnel).

DENSITY PROCEDURE When the specimen height is to be monitored, the following steps are required in addition to those specified in h. a. Determine the maximum specific gravity (Gmm) of the loose mix. The companion sample shall be aged to the same extent as the compaction sample. b. Record the specimen height to the nearest 0.1 mm (0.004 in) after each revolution. c. Record the mass of the extruded specimen to the nearest gram and determine the bulk specific gravity (Gmb) of the extruded specimen.

Table 1 Gyratory Compactive Effort in Superpave Volumetric Mix Design Compaction Parameters 20-year Design ESALs Nini (millions) 6 <0.3 0.3 - <3 3 - <30 >30 7 8 9 Ndes 50 75 100 125 Nmax 75 115 160 205

SAFETY NOTES:

ALL STUDENTS CARRYING HEATED STEEL PARTS OR TRAYS WITH ASPHALT MIX MUST WEAR THICK INSULATING GLOVES AND MUST HAVE LONG-SLEEVED SHIRTS. BE VERY CAREFUL!!! HELP WITH THE CLEANING!!!

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TEST 11.1: Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures (AASHTO T209-94) Equipment Needed: Scale that reads to 0.1 g with apparatus for weighing under water Water bath Large flat tray or cookie sheet Dual stage vacuum pump with fittings per test method Residual vacuum manometer Shaker table Metal bowl with vacuum lid Prepare before class: Use the loose mix sample prepared for you Steps in class: 1. Warm sample and break up clumps. 2. Determine mass of bowl (without lid), A. 3. Place sample in the bowl and measure the mass of bowl + mix, B. 4. Cover with water, place vacuum lid on bowl, then place entire set up on shaker table. Clamp down. 5. Start vacuum pump and gradually increase pressure until residual vacuum manometer reads 3.7 0.3kPa. Start shaker table and maintain both pressure and agitation for 15 2 minutes. 6. Stop shaker table and pump. Gradually release pressure and remove top. 7. Measure the total weight of bowl + mix immersed entirely in water, C. 8. Remove the mix from the bowl 9. Measure the mass of the empty bowl immersed entirely in water, D.

In Your Report: Compute maximum theoretical specific gravity, Gmm, = M / V = Mair / ( Mair - Mwater ) = (B A) / [(B A) (C D)] where Mair (mass of the sample in air) = B - A Mwater (mass of the sample under water) = C - D

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TEST 11.2: Bulk Specific Gravity of Compacted Bituminous Mixtures Using SSD Specimens (AASHTO T166-93) Equipment Needed: Scale Water bath Large terry cloth towels Spray bottle filled with water Prepare before class: Use the HMA mix cylinder compacted the previous week. Steps in class: 1. Dampen towel. 2. Determine the mass of the dry specimens, as A and record it. 3. Place specimen in water for 3 to 5 minutes. Determine mass under water at the end of this time, as B and record it. 4. Remove specimen form water and quickly blot dry on damp towel (dull finish is SSD condition). 5. Place SSD specimen on scale and determine mass in air as C. Record it. In Your Report: Compute bulk specific gravity at Nmax, Gmb,(@Nmax) = M / V Where M (mass of the sample) = A V (bulk volume of the sample) = C - B Compute bulk specific gravity at Ndes: Gmb,(@Ndes) = Gmb,(@Nmax) * HNmax / HNdes You get HNmax / HNdes from the printout data you obtained the previous week for the sample you compacted Compute percent air voids at Ndes: % AV = 100 * [1 - Gmb,(@Ndes) / Gmm]

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TEST 12.1: Tensile Strength of Steel (ASTM A370) Equipment Needed: Tension testing machine Wedge grips Micrometer Extensometer Computer Prepare before class: Standard 0.5-in round tension steel with 2-in long gage Steps in class: 1. Measure the diameter at the center of the gage length, which is the smallest section of the specimen, to the nearest 0.001 in (0.025 mm). 2. Mark the gage length. Gage points should be approximately equidistant from the smallest section of the specimen. 3. Grip the specimen at sections outside the gage length. 4. Apply load at constant rate. 5. Measure extensions at the predetermined load intervals. 6. When the increase in load stops or hesitates, record the load. This is the yield point. 7. When no yield is noticed, determine yield strength using the offset (0.2% offset) or percent extension method from the stress-strain diagram. 8. Plot the stress-strain diagram. 9. Calculate the tensile strength by dividing the maximum load during the test by the original cross-sectional area. 10. Calculate the elongation over the gage length and percentage increase. In Your Report: Report tensile strength, elongation and percent increase (%). Specimen Tensile strength Elongation Percentage No. (psi) (in.) elongation (%) 1 2 3 Report the stress-strain diagram.

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TEST 12.2: Compressive Strength of Wood Parallel to the Grain (ASTM D143) Equipment Needed: Universal testing machine

Compressometer

Prepare before class: 4x4x12 in. wood Steps in class: 1. Make sure the end of the specimen is level. 2. Position the specimen under the crosshead of the testing machine. 3. Apply load continuously at 0.024 in/min. 4. Measure the change in length using the compressometer with a central gauge length of 6 in (150 mm). 5. Continue loading past the proportional limit. 6. Read deformation to the 0.0001 in. (0.002 mm). In Your Report: Record the length, area and compressive strength of the wood. Length, in= , Area, in2= Specimen Peak load (lb) Peak stress (psi) 1 2

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TEST 12.3: Modulus Rupture of Lumber (ASTM D143) Equipment Needed: Universal testing machine

Hard maple bearing block Dial gage

Prepare before class: 2 x 4 x 20 in. wood Steps in class: 1. Measure the cross sectional dimensions accurately. 2. Position the specimen on support with span length of 18 in 3. Apply load at center of specimen through the loading block at a rate of 0.1 in/min 4. Measure the deflection to the nearest 0.001 in (0.02 mm) and load at intervals. 5. Continue loading until failure. 6. Note maximum load and type of failure. 7. Plot the load- deflection diagram. 8. Measure the slope of the load- deflection diagram: (P/) 9. Calculate the modules of elasticity, E as E= (P/)*L/ (48I), where L =span length, I =moment of inertia = b*h3 / 12. E has psi units and P is in pounds. 10. Draw the moment diagram for the failure and calculate MOR as MOR= 3PL/ (2bh) , where P is the failure load, b is the wood width, h is the wood depth In Your Report: Record the width, depth, span and area of the wood. Also, fill the following table on both horizontal and vertical placement of the wood. Specimen Peak load (lb) Peak stress (psi) 1 2 3 Final Original Final Original Peak length diameter diameter Area load (in) (in) (in) (in2) (lb)

Specimen No. 1 2 3

Original length (in)

Yield @ 0.20% Offset (psi)

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