Batching Plant - Cement & Concrete Quality Test 1.pdf

Cement

1. Quality Testing: A
Concrete Batching Plant

2. Objectives:
•Introduction to Concrete Batching
Plant Quality Testing
•Types of Quality Testing
•Benefits of Quality Testing
•Conclusion
•Safety Considerations
•Conclusion

3. Introduction to Concrete
Batching Plant Quality
Testing
•Concrete batching plant quality testing is an
important part of the manufacturing process. It
is used to ensure that the concrete produced
meets the required standards and specifications.
Quality testing helps to ensure the safety and
reliability of the concrete produced. It also helps
to identify any potential issues that may arise
during the manufacturing process.
•Quality testing involves a variety of tests and
inspections. These tests are designed to measure
the properties of the concrete and to identify
any potential deficiencies. The tests are
conducted in accordance with industry
standards and regulations. The results of these
tests are then used to make decisions about the
quality of the concrete produced.

4. Concrete Mix
Design
Components

5. Concrete Materials /
Ingredients
The principal ingredients that make up the concrete mix are: cement,
fine aggregate, coarse aggregate, water, chemical admixtures, and
mineral admixtures. Concrete used in construction may also contain
reinforcing bars, welded wire fabric (wire mesh), and various
reinforcing fibers.

6. Cement
There are various types of cement used in concrete
construction. Each type of cement has its properties,
uses, and advantages based on composition
materials used during its manufacture.
•Ordinary Portland Cement (OPC)
•Portland Pozzolana Cement (PPC)
•Rapid Hardening Cement
•Quick setting cement
•Low Heat Cement
•Sulfates resisting cement
•Blast Furnace Slag Cement
•High Alumina Cement
•White Cement
•Colored cement
•Air Entraining Cement
•Expansive cement
•Hydrographic cement

7. Sand
The sand binds everything together and makes
an artificial rock. The sand also enhances
concrete's most favorable properties such as
thermal expansion, compression strength, and
tensile strength. Water acts as a lubricant and is
key to mixing, setting, laying, and hardening
concrete

8. Aggregate
Gravels constitute the majority of coarse aggregate used in
concrete with crushed stone making up most of the remainder.
Natural gravel and sand are usually dug or dredged from a pit,
river, lake, or seabed. Crushed aggregate is produced by
crushing quarry rock, boulders, cobbles, or large-size gravel.
The usual range employed is between 9.5mm and 37.5mm in
diameter. - Fine aggregates are usually sand or crushed stone
that are less than 9.55mm in diameter. Typically the most
common size of aggregate used in construction is 20mm. A
larger size, 40mm, is more common in mass concrete

9. Admixtures
Admixtures are used in concrete to enhance the
performance of the mix in various ways.
Generally added before or during the mixing
process. Admixtures are used to concrete to alter
its properties in various ways. Some common
uses include improving workability , increasing or
decreasing cure time , and increasing concrete
strength. Admixtures can also be used to
aesthetic reasons, such as to change the color of
the cement.

10. Concrete Mixing Ratio

11. Concrete Mix
Design
•MPa is Measurement for PSI or pounds per
square inch. The mix ratio is of cement, sand,
and coarse aggregate.
•Ratio of Water Content of Concrete Mix
•The strength & workability of concrete
is fundamentally determined by water content.
The more amount of water, the workability of
concrete (more fluid) will be higher
•Conclusion
•In concrete mix there are some steps
and procedures like proper water mix,
Portland cement, sand, and stone aggregates.
We also found during the process of mixing
that more or less water makes the
concrete more workable or less workable. The
slump test is perfect for this kind of mix.
This Photo by Unknown author is licensed under CC BY-NC.

12. Normal
Concrete
Grades
Grades of Concrete

13. Standard
Concrete
Grades
Grades of Concrete

14. High
Strength
Concrete
Grades
Grades of Concrete

15. Types of Quality
Testing
•There are several types of quality testing that can be conducted on concrete
batching plants.
•These include the following
•Visual inspection - used to identify any potential issues with the concrete mix, such
as incorrect proportions of ingredients or foreign objects
•Strength testing - used to measure the strength of the concrete.
•Moisture content testing - used to measure the amount of water in the concrete
mix.
•Air content testing - used to measure the amount of air in the concrete mix.
•Setting Time Testing - Setting time testing is done to measure the amount of time
it takes for the concrete to set. This is an important measurement to ensure the
concrete is not too weak or too strong.
•These tests are conducted on a regular basis to ensure the quality of the concrete
produced. If any issues are identified, corrective action can be taken to ensure the
quality of the concrete produced meets the required standards

16. Visual Inspection
Visual inspection - Visual inspections are
an important part of quality control when it
comes to concrete batching plants. A
trained eye can identify any issues with the
concrete mix, such as incorrect proportions
of components or foreign objects.

17. Visual Defect of Concrete
•Different types of defects in concrete structures can
be cracking, crazing, blistering, delamination, dusting,
curling, efflorescence, scaling and spalling.
Surface Scaling of Concrete
Scaling is a form of disintegration and is due in most part to
freeze–thaw reactions which cause the concrete to flake or peel off
at the exposed surface.

18. Visual Defect of Concrete
Cracking of Concrete
Cracking frequently occurs in concrete structures. There are
various types of cracking that may occur. Cracks are caused by
numerous diverse reasons and can be detected by a Visual
Analysis. It should be noted that all concrete structures go
through the process of expansion and contraction as a result
of the fluctuation in surrounding temperature (from day to
night). The expansion of the concrete applies a tensile force
on the concrete; once the force is beyond the cracking
tension of the concrete, the concrete will crack.

19. Visual Defect of Concrete
Honeycombing of Concrete
Honeycombing occurs when there is an improper concrete
mix which is usually a short–term deterioration. It occurs
when the concrete is poured and not properly consolidated.
In order to fix honeycombing you need to remove and replace
the concrete. A visual condition survey will identify areas of
honeycombing by observation.

20. Visual Defect of Concrete
Surface Rust Stains
Rust stains are caused by corroded steel below the surface which has an inadequate
cover, or by corroded steel that is fully exposed due to spall or poor craftsmanship.
The process of corrosion of reinforcement yields oxidation products which expand
and tend to flake. The expansion of the oxidation products leads to cracking and
decreases the bond the concrete originally had with the rebar.
Rust stains are brownish–red in color and are detected using the visual survey. The
identification of rust stains on the surface of a concrete structure is critical because they
represent where corroded reinforcement is located below the surface. Ultimately, the
process of visually noticing rust staining will save the time and money necessary for
non–destructive tests to determine the actual location of the corroded steel.

21. Visual Defect of
Concrete
Efflorescence (Leaching)
Efflorescence is formed as a result of water
finding a way into the concrete through cracks
or openings at the surface, evaporating, and
leaving behind salts and other minerals which
were picked up on the way into or through the
concrete (i.e. water may pick up contaminants
from the soil before it reaches the exterior
surface of the concrete).
Efflorescence is detected by a visual survey and is
a non–structural defect. It is located at the
surface of a concrete structure along cracks and is
known for its white essence. The amount of
efflorescence present will distinguish how much
water is entering the concrete structure. For this
reason, it is important to record and include this
defect in the visual survey.

22. Concrete Strength
Testing
Concrete Strength Testing - The strength of
concrete is determined by testing a sample of
the concrete mix, to measure its compressive
strength, tensile strength, and shear strength.
Periodic testing of the concrete mix is essential
to ensure the desired strength and durability of
the concrete.
This Photo by Unknown author is licensed under CC BY-SA.

23. Methods for Testing
Compressive
Strength of Concrete
•Rebound Hammer or Schmidt Hammer
(ASTM C805)
•Penetration Resistance Test (ASTM
C803)
•Ultrasonic Pulse Velocity (ASTM C597)
•Pullout Test (ASTM C900)
•Drilled Core (ASTM C42)
•Cast-in-place Cylinders (ASTM C873)
•Wireless Maturity Sensors (ASTM
C1074)

24. Rebound Hammer or
Schmidt Hammer (ASTM
C805)
Method: A spring release mechanism is used to activate a
hammer which impacts a plunger to drive into the
surface of the concrete. The rebound distance from the
hammer to the surface of the concrete is given a value
from 10 to 100. This measurement is then correlated to
the concretes’ strength.
Pros: Relatively easy to use and can be done directly onsite.
Cons: Pre-calibration using cored samples is required for
accurate measurements. Test results can be skewed by
surface conditions and the presence of large aggregates or
rebar below the testing location.

25. Penetration Resistance
Test (ASTM C803)
Method: To complete a penetration resistance test, a
device drives a small pin or probe into the surface
of the concrete. The force used to penetrate the
surface, and the depth of the hole, is correlated to
the strength of the in-place concrete.
Pros: Relatively easy to use and can be done directly
onsite.
Cons: Data is significantly affected by surface
conditions as well as the type of form and aggregates
used. Requires pre-calibration using multiple concrete
samples for accurate strength measurements

26. Ultrasonic Pulse
Velocity (ASTM C597)
Method: This technique determines the velocity of a pulse of
vibrational energy through a slab. The ease at
which this energy makes its’ way through the
slab provides measurements regarding the concrete’s
elasticity, resistance to deformation or stress, and density.
This data is then correlated to the slab’s strength.
Pros: This is a non-destructive testing
technique which can also be used to detect flaws within
the concrete, such as cracks and honeycombing.
Cons: This technique is highly influenced by the presence of
reinforcements, aggregates, and moisture in the concrete
element. It also requires calibration with multiple samples
for accurate testing.

27. Pullout Test (ASTM
C900)
Method: The main principal behind this test is
to pull the concrete using a metal rod that is
cast-in-place or post-installed in the concrete.
The pulled conical shape, in combination
with the force required to pull the
concrete, is correlated to compressive
strength.
Pros: Easy to use and can be performed on
both new and old constructions.
Cons: This test involves crushing or
damaging the concrete. A large number
of test samples are needed at different
locations of the slab for accurate results.

28. Drilled Core (ASTM C42)
Method: A core drill is used to extract hardened concrete from
the slab. These samples are then compressed in a machine to
monitor the strength of the in-situ concrete.
Pros: These samples are considered more accurate than field-
cured specimens because the concrete that is tested for
strength has been subjected to the actual thermal history
and curing conditions of the in-place slab.
Cons: This is a destructive technique that requires damaging
the structural integrity of the slab. The locations of the cores
need to be repaired afterwards. A lab must be used to obtain
strength data.

29. Cast-in-place Cylinders
(ASTM C873)
Method: Cylinder molds are placed in the location of the pour.
Fresh concrete is poured into these molds which remain in
the slab. Once hardened, these specimens are removed
and compressed for strength.
Pros: Is considered more accurate than field-cured specimens
because the concrete is subjected to the same curing
conditions of the in-place slab, unlike field-cured
specimens.
Cons: This is a destructive technique that requires damaging
the structural integrity of the slab. The locations of the
holes need to be repaired afterwards. A lab must be used
to obtain strength data.

30. Wireless Maturity
Sensors (ASTM C1074)
Method: This technique is based on the principle that concrete strength is directly
related to its hydration temperature history. Wireless sensors are placed within
the concrete formwork, secured on the rebar, before pouring. Temperature data is
collected by the sensor and uploaded to any smart device within an app using a
wireless connection. This information is used to calculate the
compressive strength of the in-situ concrete element based on the maturity
equation that is set up in the app.
Pros: Compressive strength data is given in real-time and updated every 15 minutes.
As a result, the data is considered more accurate and reliable as the sensors are
embedded directly in the formwork, meaning they are subject to the same curing
conditions as the in-situ concrete element. This also means no time is
wasted onsite waiting for results from a third-party lab.
Cons: Requires a one-time calibration for each concrete mix to establish a maturity
curve using cylinder break tests.

31. CONCRETE COMPREHENSIVE
STRENGTH IS THE KEY PARAMETER
IN DESIGN AND EVALUATIONS
•ASTM C31 requires that
within 30 minutes of removal
from their molds, the
specimens remain at 73.5 ˚F
with free water on their
surfaces until they reach the
testing age. ASTM C39
specifies how to test the
cylinders for compressive
strength. The lab technician
must have proper
certification and supervision

32. Moisture Content Testing
Moisture content testing is an essential part of quality control
for concrete batching plants, as moisture content can
directly affect the strength and durability of the concrete.
It is important to test the moisture content of the concrete
mix before and during the mixing process to ensure that the
desired consistency is achieved.

33. Air Content Testing
•Air content testing is an
essential part of quality
control for concrete
batching plants, as it
determines the amount of
air in the concrete mix,
which affects the strength,
workability and durability
of the concrete.
•Air content testing is
typically done using a
pressure meter, which
measures the air pressure
in a concrete sample to
determine the air content
in the concrete mix.

34. Air Content Testing - The primary purpose of entraining air in concrete
is to increase its durability when exposed to freeze/thaw cycles with
water present. Air-entraining admixtures for concrete create small,
uniform, and stable air bubbles from around 0.01mm to 1mm
diameter in the cement matrix throughout a concrete mix.

35. Setting Time
Testing
Initial setting time is essential to transport,
placing and compaction of concrete. Initial
setting time is necessary to delay the
hydration process and hardening. Final
setting time helps to remove shuttering or
formwork safely. Cement completed its
chemical reaction with water till the final
setting time.
The final setting time is the time elapsed
between the moment the water is added to
the cement, and the time when the paste
has completely lost its plasticity and has
attained sufficient firmness to resist certain
definite pressure.
The process of continued hydration will increase
the strength of concrete. If the
environmental conditions to which the
concrete is exposed facilitates the hydration,
the strength is gained continuously with age

36. Cement
Laboratory
Test

37. Cement Testing
Methods
1. Fineness on Cement
2. Standard Consistency Test
3. Initial and Final Setting Time Of Cement Test
4. Soundness Test of Cement
5. Heat Of Hydration Test
6. Specific Gravity Test On Cement
7. Tensile Strength Test
8. Chemical Composition Test

38. 6 common quality tests on
concrete before and after
completion of casting on site.
1.Slump test before leaving
the batching plant and on
arrival on site
2.Compressive strength test
(this a common quality
tests of concrete)
3.Water Permeability test
4.Rapid Chloride Ion
Penetration Test
5.Water Absorption Test
6.Initial Surface Absorption
Test

39. Fineness on Cement - ASTM C184-94
•Procedure:
•Clean the sieve with the help of brush so that the
particles are removed.
•Attach the pan under the sieve no.100, now place 50
grams of cement in the sieve and cover it with lid.
Shake the pan for 3 minutes.
•Weight the residue left on the sieve after sieving and
calculate the fineness by the formula :
• Fineness of cement = 100 – (W
R / Wi x 100 )
W
R = Weight retained on sieve
W
i = Initial weight of sample
•Repeat the procedure for the next sample of cement.

40. Standard Consistency
Test – ASTM C187
This test method is intended to be used to
determine the amount of water required to
prepare hydraulic cement pastes with normal
consistency, as required for certain standard
tests.
According to ASTM C-187, the paste shall be
of normal consistency when the rod settles
to point 10 ± 1 mm below the original
surface level in 30 seconds after being
released

41. Initial and Final Setting Time
Of Cement Test ASTM C191-
82
This test covers determination of the time of Setting of cement by
means of the Vicat needles. Setting means the change from a fluid to
rigid state.
Time of initial set: is the time required for a cement paste to stiffen
considerably represented by the 1mm needle penetration of 25 mm
at less ( 35 mm penetration in B.S).
Time of final set : the time required for the cement to harden to a
point where it can sustain some load (Represented by no penetration
of Vicat needle).
Note: According to ASTM C150: Initial time of setting: not less than
45 min. Final time of setting: not more than 375 min.

42. Soundness Test of
Cement – ASTM C151 -
Autoclave Expansion
Test
The soundness test determines
whether hardened cement paste is
prone to excessive expansion by
boiling the test specimens for a fixed
period of time.
Figure 1. (a) Autoclave chamber, (b)
autoclave paste bars (center), and (c)
Le Chatelier split ring mold. (Figure 1(c)

43. Heat Of Hydration Test – ASTM
C186
This test method covers the determination of the heat of hydration
of a hydraulic cement by measuring the heat of solution of the dry
cement and the heat of solution of a separate portion of the
cement that has been partially hydrated for 7 and for 28 days, the
difference between these values being the heat of hydration for the
respective hydrating period.

44. Specific Gravity Test On
Cement ASTM C188
The specific gravity of cement is an important
parameter that informs about its density. In mix
design procedures, this is of paramount
importance since a higher value of specific
gravity than that generally accepted signifies
that it has more moisture content. This can
possibly affect the binding property of cement,
its workability, and strength.
The specific gravity of cement ranging from 3.1
to 3.16 g/cc. By this statement, we can ensure
that cement 3.1-3.16 times heavier than water
of the same volume. And it sinks in water.
Because the specific gravity is greater than 1.

45. Testing for Compressive Strength
ASTM C109 (Cubes) & ASTM C39 (Cylinders)
ASTM C109 is used to determine the compressive
strength of concrete by testing a 2 inch hydraulic cement
mortar cube to failure. This standard also outlines the
various equipment and procedures required to create,
mold and prepare the specimens prior to testing.
ASTM C39 determines the compressive strength of
cylindrical concrete specimens such as molded cylinders
and drilled cores. It is limited to concrete having a unit
weight in excess of 50 lb/ft3 (800 kg/m3). A compressive
axial load is applied to molded cylinders or cores until
failure occurs.

46. Chemical Composition
Test
Chemical Composition Test
Different tests are conducted to determine the amount of various constituents of
cement.
The ratio of the percentage of alumina to that of iron oxide should not be less
than 0.66.
•Lime Saturation Factor (LSF), i.e., the ratio of the percentage to that of alumina, iron
oxide and silica should not be less than 0.66 and not be greater than 1.02.
•Total loss on ignition should not be greater than 4%.
•Total sulphur content should not be greater than 2.75%.
•Weight of insoluble residue should not be greater than 1.50%.
•Weight of magnesia should not be greater than 5%.

47. Slump Test
ASTM C143
Slump is a measure of the
consistency of a sample of concrete,
and tells you how fluid the concrete
will be
The American standards explicitly
state that the slump cone should
have a height of 12-in (300 mm), a
bottom diameter of 8-in (200 mm)
and an upper diameter of 4-in (100
mm).

48. Type of Concrete
Slump

49. Compressive strength test
ASTM C39 ASTM C39 determines the
compressive strength of
cylindrical concrete
specimens such as molded
cylinders and drilled cores.
It is limited to concrete
having a unit weight in
excess of 50 lb/ft3 (800
kg/m3). A compressive
axial load is applied to
molded cylinders or cores
until failure occurs.

50. Cube Test of
Concrete
For cube test of concrete two
types of specimens either
cubes of 15cm X 15cm X
15cm or 10cm X 10cm x
10cm.
It’s depending upon the size of
aggregate used for concrete
making. For most concrete
works cubical molds of size,
15cm x 15cm x 15cm are
commonly used.

51. Preparation of Concrete
Cube Specimen
1. Specimen
Minimum 9 cubes of 15 cm size Max. M15 or above
2. Mixing of Concrete for Cube Test
Mix the concrete can be done by hand or in a laboratory batch mixer
3. Hand Mixing
Mix the coarse aggregate, cement, and fine aggregate on a water platform until the
mixture is thoroughly blended and is of uniform color.
After that add water and mix it until the concrete appears to be homogeneous and of
the desired consistency.
4. Pouring Concrete In Cubes
Clean the mounds of concrete and apply oil. Fill the concrete in the molds in 3 layers.
Compact each layer of mix with not less than 35 strokes per layer using a tamping
rod (steel rod 16mm diameter and 60cm long, bullet-pointed at lower end) The
top level of the concrete cube and smoothen it with a trowel.
5. Curing of Cubes
6. Precautions for Tests
The water used for curing should be tested every 7 days and the temperature of the
water must be at 27+-20 C.

52. Compressive Strength Of
Concrete & Cube Test
Result 7, 14, 28 Days
The compressive strength of concrete can be calculated by
dividing the load applied to the concrete cube at the point of
failure by the cross-section area of the cube (15x15x15 cm)
on which the load was applied.
The concrete compressive strength for normal construction work
varies from 15 MPa (2200 psi) to 30 MPa (4400 psi) and more
in commercial and industrial structures.
Check the Compressive Strength of Concrete
Size of the concrete cube = 15 cm x 15 cm x 15 cm
Area of the cube sample =225 cm
2
(22500 mm
2
)
The same calculation should be done for 28 days of compressive
strength
The maximum load applied or load at failure of cube = 400
KN (400×1000 N)
Compressive strength = (Load in N/ Area in
mm2)=400×1000/22500 N/mm
2
= 17.77 N/mm

53. Water Permeability
Test – ASTM C642
ASTM C642 measures the
adsorption of bulk concrete. In
this test, you dry a concrete
specimen to constant mass in an
oven, then immerse it in water
until it again reaches constant
mass. Then you boil it in water for
5 hours, weigh it again, and
determine the absorption

54. Rapid Chloride Ion
Penetration Test – ASTM
C1202
The rapid chloride permeability test RCPT-
ASTM C 1202 is commonly used to evaluate the
resistance of concrete to chloride ions ingress
owing to its simplicity and rapidity. RCPT is an
electrical indication of concrete's ability to
resist chloride ion penetration

55. Water Absorption Test
(Sorptivity Test) –
ASTM C1585
This test method is used to determine the rate of
absorption (sorptivity) of water by hydraulic cement
concrete by measuring the increase in the mass of a
specimen resulting from absorption of water as a
function of time when only one surface of the
specimen is exposed to water.

56. Initial Surface Absorption
Test - ASTM C1585-20
The initial surface absorption test (ISAT)
is a low pressure assessment of the
uniaxial water absorption per unit area
of the surface zone (i.e. zone
immediately behind the surface) of a
concrete at a stated interval ranging
from 10 minutes to 1 hour from the
start of the test and at a constant
applied head of 200mm of water which
is slightly greater than that which
would be caused by driving rain.

57. Concrete Batching
Plant
& Equipment
The process of measuring
ingredients or materials to
prepare concrete mix is known
as batching of concrete.
Batching can be done by two
methods, volume batching and
weight batching. Batching
should be done properly to get
quality concrete mix
Concrete batching plant is
used to mix and blend cement,
water, sand and aggregates to
form quality concrete without
which building any
construction project is not
possible. It becomes necessary
that the concrete batching
plant is efficient and speedy in
order to complete a
construction project as soon as
possible

58. Batching Plant Process Flow Chart

59. Aggregate Hopper
Primary hoppers are mainly used in the storage of aggregates (sand,
gravel, etc ) and in the storage of big size granular materials. They are
largely used in the storage of pre-mix aggregates for the production of
concrete or mortar, or used as loading station for the In-line hoppers of
production plants.
PLD batching machine of concrete batching plant is one automatic
batching equipment and is used with concrete mixer. PLD series
concrete Batching Machine is a kind of sandstone proportioning and
batching device, and it adopts lifting hopper or belt conveyor to supply
material to the mixer. Concrete batching machine can mix more than three
kinds of material. The aggregate ingredient system may be equipped with
2-5 aggregate storage bins and can automatically finish the batching
procedures of materials such as sand, stone, cement, according to users'
demand.

60. Aggregate
Weighing
System
In this method, Materials
are measured on the basis
of weight. It is accurate
method of batching. Weigh
batchers or other types of
weighing equipment are
used to measure weight of
materials. Cement, fine
aggregate, coarse aggregate
and water are taken by
weighing.

61. Conveyor & Cement Silo Storage

62. Concrete Mixer

63. Dust Collector

64. Working Process