Department of

Civil

Technology

Written By: Ahmed Zakaria 1

Summer Office Training Report 2015

AHMED ZAKARIa

BS CIVIL TECHNOLOGY

Department of

Civil

Technology

Written By: Ahmed Zakaria 2

INTERNSHIP SUPERVISOR: Engr. Ahmed Yahya

AUTHOR: Ahmed Zakaria

(670-2013)

Hosting Organization: Al-Haramain Company of

Commerce and Contracting.

Commencement Date: September 1, 2015

Completion Date: September 20, 2015

Approved By:

Name of supervisor:Engr. Ahmed Yahya

Signature:

Name of mentor: Muhammad Munawwar Khan

Signature:

Hosting company stamp

Department of

Civil

Technology

Written By: Ahmed Zakaria 3

ACKNOWLEDGEMENT

I would like to thank Al-Haramain Company of Commerce and Contracting for giving me

the opportunity to undertake my three week training in their laboratory work area. I would

like to convey my heartiest thanks to Lab engineer Mohammad Munawwar Khan and the

project manager Engr. Ahmed Yahya for their immense support and cooperation which

made this experience very learning and worthwhile

Dated: September 25, 2015

Department of

Civil

Technology

Written By: Ahmed Zakaria 4

List of Tables

Table No. Title Page No.

Table 1 F.A Gradation 08

Table 2 L.A.A Test 12 Table 3 Grading of 3/4 Aggregate 16 Table 4 Grading of 3/8

Aggregate 16

Table 5 Aggregate Blend 17 Table 6 Sample for specific

gravity 18

Table 7-A Specific gravity of 3/4 19 Table 7-B Specific gravity of 3/8 20 Table 8 Specific gravity record 21 Table 9 Calculation of Ave.

specific gravity 21

Table 10 Nominal Max. Size conversions

22

Table 11 Gradation standards C.A 23 Table 12 Gradation standards F.A 23 Table 13 Concrete Class

Designation 24

List of Figures

Figure No. Title Page No.

Fig 5

Collage of C.A

specific gravity

procedure

Fig 6 Recording weight of sample on weighing

scale

Department of

Civil

Technology

Written By: Ahmed Zakaria 5

CONTENTS

Chapter Title Page No.

Chapter One

Introduction

Concrete Mix Design Things Should Know

Before Designing

Concrete.

Precautions And Things To Remember During Design

Concrete Mixes

03

04

05

06

Chapter Two

Fine Aggregate

Gradation Test. Fine Aggregate Angularity

Test

Sand Equivalent Test Fine Aggregate Specific

Gravity Test

07

08

09

09

10

Chapter Three

Coarse Aggregate

Los Angeles abrasion test. Soundness Test of

Aggregate

Determination of Flakiness index

Determination of Elongation Index

Calculation of percentage passing of aggregate 3/4 &

3/8 separately.

Making Blend of Aggregate 3/4 & 3/8.

11

11

13

14

15

16

17

Chapter Four Concrete Mix Design 22

Chapter Five Asphalt 31

Pictorial Explanation 34

References 37

Department of

Civil

Technology

Written By: Ahmed Zakaria 6

CHAPTER ONE

INTRODUCTION

A wide range of problem associated with concrete mix design has to be faced during graduation period. Keeping in view such difficulties it has been written in a way to gain

the complete knowledge of Concrete Mix Design before stepping into professional life.

The report is written on standards followed by KSA and its calculation, method will only

applicable in the kingdom. However report is written briefly and divided into five parts:

Fine Aggregate

Coarse Aggregate

Concrete Mix Design

Asphalt

Pictorial Explanation

Concrete:

Concrete is the most building material on earth it was the building block of the Roman Empire. Today

its the material for new generation. The raw ingredients that create this magic formula can nearly

found in every country on earth. The basic formula is simple, sand, crush rock aggregate, water and

cement.

Concrete can take nearly any shape thats why it is being used in mega dam structures, sky scrapers or

bridges or any structure on earth.

Department of

Civil

Technology

Written By: Ahmed Zakaria 7

Concrete mix Design

Concrete mix design may be defines as the art of selecting suitable ingredients of concrete and

determining their relative proportions with the object of producing concrete of certain minimum

strength & durability as economically as possible.

Similarly the common method of expressing the proportions of ingredients of a concrete mix is

in the terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of

proportions 1:2:4.

1. Standards for Mix design

ACI and other standards only serves as a guide, initial designs must be confirmed by

laboratory trial and plant trial, adjustments on the design shall be done during trial

mixes.

Initial design on paper is never the final design.

2. Trial Mixes

Always carry out trial mixes using the materials for actual use

3. Design Variation Tests

Carry out 2 or 3 design variations for every design target

4. Safety Factors

Consider always the factor of safety, (1.125, 1.2, 1.25, 1.3 X target strength)

5. Material Sources

Before proceeding to plant trials, always confirm the source of materials to be the

same as the one used in the laboratory trials.

6. Batching Plant Calibration

Check calibration of batching plant before trials

7. Tests at Batching Plant

Carry out full tests of fresh concrete at the batching plant, specially the air content

and yield which is very important in commercial batching plants

8. Quality Control

Correct quality control procedures at the plant will prevent future concrete problems

9. Admixture

Follow admixture recommendations from your supplier

10. Strength Development Check

Check and verify strength development, most critical stage is the 3 and 7 days strength

Technical knowledge is an advantage for batching plant staff, even if you have good concrete design but

uncommon or wrong procedures are practiced it will eventually result to failures

Department of

Civil

Technology

Written By: Ahmed Zakaria 8

Things should know before designing concrete.

1. What are the strength requirements?

Compressive (on cube or cylinder specimen) strength

Flexural strength

Tensile strength

2. What is the placing method?

By pump or direct pouring.

3. How far is the JOB SITE from the batching plant?

4. How many Transit Mixers are available on plant?

5. How much cubic meter concrete to be done in one working day?

6. Capacity of each Transit Mixer?

7. What is the capacity of Batching Plant?

8. What will be the expected temperature of site?

9. Which type of water is provided to use in concrete?

10. What type of cement is provided?

11. Fine and Coarse Aggregates quality test results.

12. Water temperature?

13. What is the structure for casting?

Pavement, foundation, elevated slab, etc.

14. What are the projects specifications?

Maximum or minimum cement contents

Maximum water/cement ratio

Slump or consistency limit

Minimum Strength requirement @28 days

Material specifications

15. Latest testing results of materials is needed in the preliminary selection of materials and

design calculation

Department of

Civil

Technology

Written By: Ahmed Zakaria 9

PRECAUTIONS AND THINGS TO REMEMBER DURING

DESIGN CONCRETE MIXES

1. Increasing the sand/totalaggregate ratio, increases the water requirement at the

same consistency.

2. Increasing the water/cement ratio decreases the strength of concrete at the same

cement content.

3. Remember that adding 5 liters of water per cubic meter increases the slump by

2.5cm.

4. Remember that adding 5 liters of water per cubic meter decreases strength by

approximately 4%.

5. Always follow recommended admixture dosage.

6. Always have control when performing trial mixes, always perform trial mixes with

another mix using the same materials. This data can be useful in diagnostics if a

problem occurs.

7. Always adjust batching quantities to the actual moisture condition of theaggregates.

8. Volume tolerance for 1m3 concrete is 1 0.2 m3.

9. Range of normal weight concrete is from 2,200 kg/m3 to 2,400 kg/m3

10. Always take 3 samples for each test.

11. Calculate the average of all 3 samples for accuracy.

12. Complete all the required necessary tests before you start Concrete Mix Design

calculations and make a table of their resulted values.

Department of

Civil

Technology

Written By: Ahmed Zakaria 10

CHAPTER TWO

FINE AGGREGATE

Fine Aggregate Test Section

The tests are used to determine the material characteristics and properties of

aggregate materials for use in pavemen