48352 S2013 Laboratory Handbook

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SCHOOL OF CIVIL AND ENVIRONMENTAL ENGINEERING

FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGYUNIVERSITY OF TECHNOLOGY,SYDNEY

SPRING SEMESTER 2013

SUBJECT 48352 CONSTRUCTION MATERIALS

LABORATORYTESTING HANDBOOK

TESTING OF CONSTRUCTION MATERIALS

LABORATORY INSTRUCTIONS

FOR THE EXPERIMENTAL TESTING OF

METALS,AGGREGATES AND CONCRETE

PREPARED BY :DR K.VESSALAS (LECTURER)


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TABLE OF CONTENTS

1.Student instructions 22. Introduction 5

3. Tensile testing of metals 64. Laboratory report one marking scheme 125. Testing of aggregates for concrete 136. Laboratory report two marking scheme 217. Testing of fresh and hardened concrete 228. Laboratory report three marking scheme 41


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STUDENT INSTRUCTIONS

General Instructions

1. Students must print out the laboratory handbook available on UTS Online and bring it with them to eachlaboratory session. It is also advisable to bring along a calculator and camera to each session to take

photos for enhancing the quality of the laboratory reports.

2. Students are responsible for recording all necessary experimental data covered during the laboratorysessions and, where applicable, obtain uploaded experimental data available from UTS Online.

3. Students must remain in their allocated group for laboratory session 3 unless prior permission has beengranted from the subject coordinator for students to change to another group.

4. Students should find out where the locations of the laboratory sessions are in advance.5. Students should read the laboratory handbook in advance of the laboratory session. It helps to know the

details of the experiment before entering the laboratory session.

6. Students should be punctual in attending the 3 laboratory sessions on time. The most important part of thelaboratory session is often the introduction. Missing this part by a few minutes could lead to confusion for

the remainder of the laboratory session.

7. Students should ask questions if in any doubt during the laboratory session to understand the reasonsbehind undertaking the experiment. It is often best to ask questions during the laboratory session and not

a few days before the report is due.

Important Instructions

a) Compulsory attendance is required for the full duration of laboratory session 3 that is, the laboratorysession dealing with the fresh and hardened testing of concrete.

b) Students need to attend their designated laboratory class session during tutorial week. A student grouplist comprised of 8 laboratory sessions scheduled to take place during tutorial week will be made

available on UTS Online. Students need to check the list and contact the subject coordinator in advance, if

a clash arises with another subject activity and students are unable to attend their designated session.

c) Failure to attend laboratory session 3 and record attendance details on the laboratory quiz given at theend of the session will result in instant disqualification of the laboratory report being marked.


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d) Students should ensure to wear fully enclosed shoes and appropriate clothing to the concrete testinglaboratory session or entry may be denied. Failure to comply with this requirement will result in instant

disqualification of the laboratory report being marked.

e)

Students should notify the subject coordinator in advance, or at the first available opportunity, when theyare physically unable to attend laboratory session 3 due to a legitimate certified UTS approved reason.

If the subject coordinator is contacted in advance, it may be possible for the student to attend another

scheduled laboratory session in place of their missed session.

f) Bonus marks are given based on a students compulsory attendance at laboratory session 3 andundertaking the laboratory quiz. The mark received for the quiz will be taken as a bonus mark and

added to the total assessment.

g) Laboratory reports are a team effort and must not be copied and/or plagiarised. Plagiarism is treatedvery seriously and can result in:

1) Failure of the assessment task2) Failure in the subject, or3) Exclusion from the universityThe following website links provide guidance on the definition and consequences of plagiarism and

academic misconduct:

http://www.gsu.uts.edu.au/rules/16-2.html

http://www.gsu.uts.edu.au/rules/s5-2.html

http://www.uts.edu.au/teachlearn/avoidingplagiarism/what/index.html

h) Follow instructions and marking guidelines given in the laboratory handbook when writing up the 3laboratory reports. All laboratory reports must be submitted by 12:00 pm on their due date listed in the

teaching schedule. Actual submission requires the laboratory report being physically placed in Kirk

Vessalas mailbox 28, which is located up the staircase on the left when entering level 5 of building 2

from level 5 of building 1.

i) A student is required to fill out an online special consideration application form to be considered for anyspecial review of awarded marks if they are absent from laboratory session 3. Failure to comply with this

UTS rule will mean that a students case for special consideration will not be considered nor will it be

reviewed separately. More information on how to fill out a special consideration application form can be

found at the following website link:

http://www.sau.uts.edu.au/assessment/consideration/online.html
http://www.gsu.uts.edu.au/rules/16-2.htmlhttp://www.gsu.uts.edu.au/rules/16-2.htmlhttp://www.gsu.uts.edu.au/rules/s5-2.htmlhttp://www.gsu.uts.edu.au/rules/s5-2.htmlhttp://www.uts.edu.au/teachlearn/avoidingplagiarism/what/index.htmlhttp://www.uts.edu.au/teachlearn/avoidingplagiarism/what/index.htmlhttp://www.sau.uts.edu.au/assessment/consideration/online.htmlhttp://www.sau.uts.edu.au/assessment/consideration/online.htmlhttp://www.sau.uts.edu.au/assessment/consideration/online.htmlhttp://www.uts.edu.au/teachlearn/avoidingplagiarism/what/index.htmlhttp://www.gsu.uts.edu.au/rules/s5-2.htmlhttp://www.gsu.uts.edu.au/rules/16-2.html


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j) Students are expected to work in teams of minimum 2 persons or maximum 3 persons when writing uplaboratory reports 1 and 2. In addition, students are expected to work in teams of minimum 2 persons or

maximum 5 persons when writing up laboratory report 3. It is the responsibility of the student to find a

suitable partner or partners in advance before their laboratory report is due. If for any reason students

are having trouble with team members contributing to the write up of laboratory reports, please contactthe subject coordinator via email in advance of the due date to arrange for alternate arrangements of

submission.

k) Assessment of each laboratory report will be based on a 10-point scale as follows:10 Excellent report

8 Very good report

7 Good report

6 Average report

5 Just acceptable

3 Unsatisfactory performance

0 Unacceptable performance

l) Late reports will incur a penalty. For each day the report is late, a deduction of 0.5 marks will apply upto 7 days. Any reports handed in 8 days and thereafter will result in 0 marks issued.

Laboratory Room Locations

Metals testing laboratory (CB02.04.29) Aggregates testing laboratory (CB02.04.29) Concrete testing laboratory (CB02.01.116)Student Signature

I have read and acknowledged all instructions stated above:

Student name:

Student number:

Student signature:

Date:


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1.INTRODUCTION1. Objectives of Materials TestingPractically, all branches of engineering, especially those dealing with structures and machines, are intimately

connected with materials. The properties of materials must be determined by tests using accepted or relevant

standard test methods. An understanding of the following testing areas is required for studying the properties

of materials:

a) Testing techniqueb) Physical principles involved in the testing apparatus and procedurec) Theory of measurementsd) Variability of materialse) Interpretation of resultsPrincipal materials used in civil engineering applications include steel, aluminium, concrete, bituminous mixes,

timber, masonry materials (including clay products), and plastics. The principal requirements of construction

materials in structures and in service are strength, rigidity, and durability. These requirements largely define

the properties of materials and, hence, broadly determine the nature of tests carried out on such materials.

The testing of materials may be performed according to one or more of the following three objectives:

a) To supply routine information on the quality of a product for commercial or control testingb) To develop or enhance known materials or to further develop new materials for materials research and

development work

c) To obtain physical constants or derive empirical relationships for adopting an accurate measure ofscientific measurements

2. Standard Specifications for Materials TestingA notable development over the last few decades, particularly in regards to materials testing, has been the

preparation and use of standard specifications. A standard specification used for materials testing is the

result of an agreement between those concerned in a particular field and involves acceptance for use by

participating agencies. A standard is a published and referenced document, which sets out specifications

and procedures designed to ensure that a material, product, method, or service is fit for purpose and, in

application, consistently performs the way it was designated.Standards Australia has developed several

specification requirements and methods for testing construction materials for their physical, chemical, and

engineering properties. It is essential for engineers and testing personnel to follow Australian Standard (AS)

procedures in all respects, if the results of testing are to be accepted by industry. In this laboratory-testing

handbook, the testing of metals, aggregates and concrete will be performed in accordance with relevant AS

testing standards. This will give an opportunity for civil engineering students to familiarise themselves with

these testing methods while carrying out measurements, recording, interpreting and reporting of the results.


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SCHOOL OF C IVIL AND ENVIRONMENTAL ENGINEERING

FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

UNIVERSITY OF TECHNOLOGY , SYDNEY

Subject 48352 Construction MaterialsSpring Semester 2013

TENSILE TESTING OF METALS

Student Names: (1) .. (2) ..

Student Nos: (1) .. (2) ..

Date of Submission: ..

MARK


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2.TESTING OF METALS IN DIRECT TENSION (AS 1391)1. ObjectiveTo determine the engineering properties of metals and compare the ductile and brittle behaviour of metals in

direct tension.

2. Metals tested(1) Mild Steel (black mild steel that has been annealed)

(2) Cast Iron

3. Test performedDirect uniaxial tensile test.

4. Equipment Universal testing machine (Shimadzu RH30) 30 tonne (300 kN) set to 60 kN range Instron extensometer 50.00 mm gauge length LVDT RPD LDC 2000 (that is, a 100 mm linear variable differential/displacement transducer/transformer) P3500 strain amp (Biolab/Davidson) DT605 data taker (data logger 10 channel and 1 sample per 1 second) Laptop computer (any computer with a serial port)5. Relevant information As a rule of thumb, the original gauge length of a metal specimen may be taken as: 5 x diameter (to be

exact: 5.65 x [area]0.5). Remember this equation, as the original gauge length may not be given in an

examination question. Students may need to calculate out this value from the cross-sectional area.

Percent (%) elongation is calculated from the gauge length taken before test and after fracture of the testspecimen by placing the broken sections together (first measure of ductility).

Percent (%) reduction in area is calculated from the diameter taken before test and after fracture of thetest specimen at the failed cross-section (second measure of ductility).

The extensometer is set to 50.00 mm and, thus, 0.2% proof stress would be taken at 0.1 mm. The extensometer is sensitive. It must be withdrawn from the specimen before fracture to avoid damage

(approximately 1.0 mm maximum travel is allowed). The extensometer readings are used to calculate strain

and for plotting the stress-strain curve to determine various mechanical properties.

The LVDT is attached to the cross head on the machine. It is used to produce a crosshead travel (CHT) graphfrom the data. It will show the elastic limit load (beginning of plastic deformation), maximum load, and load

at fracture and provide an overview of the material performance. This graph cannot be used for

determining % elongation or 0.2% proof stress (due to slippage and movement of the machine and jaws).


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The maximum load will be given (load at fracture can be obtained from the CHT graph). Students will be given raw data and will be expected to produce graphs (spreadsheet). Data will be uploaded on UTS Online over the next day or so. Please ask questions if in any doubt.

All tensile tests are carried out at room temperature (normally 23C). The universal testing machines are calibrated using National Association of Testing Authorities, Australia

(NATA) registered equipment to grade A requirements and are within 1% of their rated value per range.

The Shimadzu RH30 is set on the 60 kN range and the display is set to 60 kN full-scale range. The outputfrom all equipment is in volts.

6. Testing procedureRefer to AS 1391 Metallic materials tensile testing at ambient temperatures specification and test method

standard for more information. The metal test specimens are to be tested under uniaxial tension at room

temperature.

7. Properties to be determineda) Proportionality Limit (in MPa) for the 2 metalsb) Yield strength for mild steelc) Proof strength, plastic elongation Rp0.2 for cast irond) Proof strength, total elongation R t0.5 for cast irone) Percentage elongation for the 2 metalsf) Percentage area reduction for the 2 metalsg) Young's Modulus of Elasticity (E to the nearest 5 GPa) for the 2 metalsh) Elastic resilience = (proportional limit)2 / (2 x E) for the 2 metals (MJ/m3)i) Modulus of Toughness for cast iron only (MJ/m3)


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8. Test Records

Measurement Mild Steel Cast Iron

Original diameter (mm)

Final diameter (mm) at fracture location

Original gauge length (mm)

Final gauge length (mm)

Maximum load (kN)

Fracture load (kN)

Proportional limit load (kN)

Lower yield load (kN)

Note: Measure the diameter and length using a suitable measuring instrument and express the mean value (that is,

average of 3 readings)

SKETCH THE FRACTURE PATTERNS OF THE TEST PIECES

MILD STEEL CAST IRON


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9. Determination of metal propertiesa) Plot the load versus extension diagram for the 2 metal specimens and determine the yield load, maximum

load and fracture load

b)

Plot the engineering stress-strain relationship for both metal specimens from the load-extension dataprovided using excel software

c) Use the stress-strain plots to determine: (a) modulus of elasticity for the 2 metals; (b) both the upper andlower yield strengths for mild steel; and, (c) proof strength (R p0.2) for cast iron

d) Determine the ductility of the 2 metals (that is, both % elongation and % reduction in area)10.The joint group report must include the followinga) A brief description of the test method, including any digital photographsb) Sketches describing the fracture pattern of the 2 metal specimens (digital photographs may be included).For example This metal specimen was observed to have a ductile mode of failure from the large amount of

necking observed before fracture. The significant reduction in cross-sectional area experienced at the fracture zone

after failure indicates a metal exhibiting a high amount of ductility. A cup and cone fracture was also evident due to

a significant reduction in cross-sectional area just before fracture.

c) Plot the load-extension graph for the 2 metal specimensd) Establish the engineering stress-strain relationship for the 2 metal specimense) Determine the tabulated mechanical properties showing a typical sample calculation for each propertyf) Summarise the mechanical properties of the 2 metalsg) Discuss and compare the mechanical properties and behaviour observed between the 2 metals testedh) Discuss and compare the properties between the 2 metals tested with respect to their significance in civil

engineering applications

i) Comment on the test methods used, the accuracy of the measurements taken and general reflectionsgathered from undertaking this experiment

j) Conclusionsk) References


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SUMMARY OF METAL PROPERTIES

Property Black Mild Steel Cast Iron

Density (kg/m3) 7850 7150

Proportional Limit (MPa)

Tensile strength (MPa)

Fracture stress (MPa)

Upper Yield Strength (MPa)

Lower Yield Strength (MPa)

Proof Strength R p0.2(MPa)

Proof Strength R t0.5(MPa)

Percent Elongation

Percent Area Reduction

Experimental Young's Modulus (GPa)

Expected Young's Modulus (GPa)* 200 120

% Error in Youngs Modulus

Elastic Resilience (MJ/m3)

Modulus of Toughness (MJ/m3)


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GROUP REPORT ONE REQUIREMENTS AND MARKING SCHEME

Results and Discussion Section Requirements

Group reports will be assessed on the following criteria:

a) Presentation of resultsb) Analysis of resultsc) Comparison of results in tabulated and/or graphical formd) Comprehensive discussion of results including discussion of errors and applied engineering examplese) Conclusionsf) References Typed reports are required Reports are due 2 weeks after completing the laboratory testing exerciseReport Marking Scheme

Laboratory report no.:Date of submission:

Part Section Mark

1 Introductions, objectives and methods /2

2 Test results, sketches and sample calculations /2

3 Graphs and tabulated summaries /2

4 Discussions and conclusions /2

5 References, presentation format and style /2

Deductions

Total marks /10

Marking Criteria

Very good performance = 2/2 marks Acceptable performance = 1/2 marks Unacceptable performance = 0/2 marksGeneral Comments


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TESTING OF AGGREGATES FOR CONCRETE


Student Nos: (1) .. (2) ..


MARK


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3.1. SAMPLING OF AGGREGATES FOR TESTING (AS 1141)1.1.Sampling of aggregates - GeneralQuality control tests are routinely carried out on representative samples of aggregates to ensure that any

variation in quality is within specification limits. The need for representative samples cannot be over-

emphasized. Test results may misrepresent chemical and physical characteristics of the aggregates. Sampling

operations, therefore, must be conducted by such test methods to ensure that the samples obtained are as far as

possible representative of the given batch available. The basic-unit of sampling is called the sample increment,

which is defined as a portion of material taken directly from the conveyor, bin, truck, or stockpile. Sample

increments should be taken in sets of five and should be approximately the same size.

A bulk samplecomprises of five sample increments that are mixed thoroughly to give a uniform bulk sample.

The bulk sample may be subdivided into smaller fractions to produce a sample of appropriate size for further

testing. Division into smaller factions may be carried out to produce the test portionfor use in a particular test.

A refereed sample is a portion that is reserved for testing in the event a dispute arises with the test results

obtained.

1.2.Sample size and sampling frequencyTesting standards for materials (in this case aggregates) specifies the sample size required for the test as well

as the sampling method and sampling frequency. Therefore, for actual testing on site or during production, it is

essential to follow the recommendation from standards to assess the quality and property of the materialstested.

1.3.Sample ReductionWhen the amount of material has been reduced, it is essential that the representative nature of the sample be

maintained. Suitable methods for sample division are by coningand quarteringor by the use of a sample

divider.


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3.2. TESTING FOR COMPACTED BULK DENSITY (AS 1141.4)2.1.SignificanceThe dry density test provides a simple indicator of the variability of properties of aggregates in terms of

particle shape and particle size. It can be quickly performed and easily carried out in the field. A low bulk

density value for a particular aggregate may indicate a change in aggregate shape or grading, and in turn a

change in concrete properties such as porosity, strength, and durability. Furthermore, a change in bulk density

should prompt the user to carry out additional tests for proper characterisation of the aggregate.

2.2.Objectivesa) To determine the compacted bulk density of a sample of fine, coarse and mixed aggregateb) To determine the void content of a sample of fine, coarse and mixed aggregatec) To determine the optimum fine aggregate content to produce minimum void content, hence, maximum bulk

density

2.3.Apparatus An electronic balance Metal cylinder Metal scoop Tamping steel rod Water2.4.TheoryEquations:

Bulk density (Db) = aggregate weight (w) / aggregate bulk volume (vb)

Particle density (Dp) = aggregate weight (w) / aggregate solid volume (vs)

Db / Dp = vs / vb

Void content (%) = 100 [vb vs] / vbVoid content (%) = 100 [1 vs/vb]

Void content (%) = 100 [1 Db / Dp]


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2.5.Test Procedurea) Record the mass of the empty cylinder (w1) to the nearest gramb) Note down the moisture condition of the aggregate (e. g., air-dry, wet or damp)c)

Check the aggregate to see if it is fully mixed and if necessary remix

d) Place the cylinder on a horizontal flat surface. Fill the cylinder with aggregate to one-third of its heighte) Compact the aggregate by using the tamping rod with 25 strokes without striking the bottom plate of the

cylinder

f) Scoop more aggregate into the cylinder to two-thirds of its heightg) Compact the aggregate with another 25 strokes using the tamping rodh) Fill the cylinder with the remaining aggregate overflowing the top and level the surface with the tamping

rod

i) When compacting the aggregate with the tamping rod, ensure each stroke penetrates the previous layerj) Strike off the surface of the aggregate level with the rim using the tamping rodk) Record the mass of the cylinder + aggregate (w2) to the nearest gram2.6.Determination of Compacted Bulk Density and Void Contenta) Calculate the volume of the cylinder (litres) from the diameter (d) and depth (h) or using the water method

(for improved accuracy)

b) Calculate the compacted bulk density(CBD) of the aggregate using the following equation:

CBD (kg/m3) = 1,000 x aggregate mass (kg) / cylinder volume (litres)

CBD (kg/m3) = 1000 (w2 w1) / vc) Determine the theoretical void content of the aggregate assuming the particle density of normal weight

aggregate used in this experiment is 2,600 kg/m3

2.7.RecordsTray

Identity

No.

Fine Agg.

Content

(%)

Agg.

Identity

Type

Cylinder

Volume

[v] (m3)

Cyl.

Wt

[w1] (kg)

Cyl. +

Agg. Wt

[w2] (kg)

CBD

(kg/m3)

Void

Content

(%)

A 0 Coarse

B 20 Mixed

C 40 Mixed

D 60 Mixed

E 80 Mixed

F 100 Fine


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2.8.Calculations and Discussion Show typical calculations for calculating void content and bulk density Copy the results provided by the other groupsa) Plot the relationship between compacted bulk density and fine aggregate content (use straight lines to join

the points)

b) Plot the relationship between void content (%) and fine aggregate content (use straight lines to join thepoints)

Using the above plots, determine the optimum fine aggregate content required to obtain minimum void

content as well as maximum bulk density

a) Discuss factors that influence the optimum fine aggregate contentb) Discuss the reasons for blending fine and coarse aggregates for use in concrete mixes2.9.Conclusions2.10. References


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3.3 SIEVE ANALYSIS FINE AND COARSE AGGREGATES (AS 1141.11.1)3.1.SignificanceThe particle size distribution of aggregates is of significance to most civil engineering applications utilising

aggregates. Examples of the use of well-graded aggregates in construction materials include Portland cement

concrete, bituminous concrete and unbound road base material. Other applications include single-sized

aggregate filter beds, open graded concrete and bituminous mixes.

3.2.ObjectivesTo determine the particle size distribution of a sample of fine aggregate and a sample of coarse aggregate by

sieving using a set of standard-sizedsieves consisting of the following sizes:

37.5 mm 19.0 mm 9.5 mm 4.75 mm 2.36 mm 1.18 mm 600 m 300 m 150 m3.3.Testing Apparatus Electronic balance Set of AS compliant sieves3.4.Test Procedurea) Oven-dry the aggregate at 105C to constant mass.b) Stack the sieves in order of aperture size with the smallest aperture size at the bottom. Fit the pan at the

very bottom of the sieve stack.

c) Take a representative sample of aggregate of suitable mass.d) Transfer the weighed aggregate into the top sieve and fit the lid.e) Hold the stack of sieves by the base and lid and shake it to-and-fro at about 100 strokes per minute

turning through one-sixth of a turn about every 25 strokes. Continue until no more aggregate passes

through the sieves.

f) Weigh the aggregate that has been retained on the sieve.g) Remove sieves from the stack one by one, weighing each retained fraction including the portion contained

within the base pan.

h) Tabulate the mass of aggregate retained on each sieve.


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i) Calculate the percent total mass, which has been retained on each sieve, the cumulative percent retainedand the cumulative percent passing. Record these results in the table provided.

3.5.Test RecordsTable 1: Sieve Analysis Results Coarse aggregate

AS 1141

Sieve Size

Wt retained on

sieve (g)

Wt retained %

total mass

Cumulative

% retained

Cumulative

% passing

37.5 mm

19.0 mm

9.5 mm

4.75 mm

PanTotal

Table 2: Sieve Analysis Results Fine Aggregate

AS 1141

Sieve Size

Wt retained on


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3.6.Discussion of Resultsa) Comment on the shape of the grading curves (continuous graded or gap graded)b) Discuss the importance of aggregate grading on concrete propertiesc)

Comment on the accuracy of the plots

3.7.Conclusions3.8.References


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GROUP REPORT TWO REQUIREMENTS AND MARKING SCHEME





Part Section Mark


2 Test results, tables and calculations /2

3 Graphs /2



Deductions

Total marks /10

Marking Criteria



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TESTING OF FRESH AND HARDENED CONCRETE


Student Nos: (1) .. (2) ..


MARK


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4.MIXING AND TESTING OF CONCRETE (AS 1012)1. INTRODUCTIONConcrete is the most commonly used construction material for building civil engineering infrastructure. The quality

of concrete specified for an application varies significantly since the performance requirement will change with

different loading modes, different construction methods, different component materials, and different service

conditions. The use of a suitable concrete mix, having the specified properties in both fresh and hardened state,

is essential to achieve durable concrete construction. Standard tests on both fresh and hardened concrete are

undertaken to ensure that an appropriate quality of concrete is used in construction.

The purpose of the concrete laboratory session is to achieve the following objectives:

a) To introduce standard testing procedures following AS 1012b) To gain experience in batching, mixing, moulding and curing of concrete specimensc) To test the fresh and hardened properties of concreted) To report, analyse and discuss the test results obtained for four (4) concrete mixes (mixes A, B, C and D)

incorporating different water-to-cement ratio (w/c)

2. PREPARATION OF MATERIALSa) All raw materials, including water, should be brought to room temperature (anywhere between 20C to

26C) before beginning operationsb) As a basis for the batch masses, a decision should be made as to the moisture condition in which the

aggregates are to be used in the concrete The most common moisture conditions are field moisture

condition and saturated surface dry (SSD). Prior to batching, each aggregate used should be of uniform

moisture condition, determined to 0.1 % accuracy by oven drying to constant mass. Oven temperatures

should be in the range of 105C to 110C.

c) If added, admixtures should be prepared in accordance with the suppliers recommendations3. MEASUREMENT OF MATERIALSa) All raw materials used in a batch should be measured by mass or volume as appropriate to an accuracy of

0.2 % for cement and water; 0.2 % for aggregate; and, if added, 0.5 % for admixtures

b) Where liquid admixtures are added, the total volume of solution used should also be included in thecalculated amount of mixing water to be added


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4. MIXING CONCRETEa) The batch size used should exceed that required for test purposes and moulding of all test specimens for

fresh and hardened tests by at least 10 %

b)

Where a pan type mixer is used and concrete is transferred directly to the moulds, the inside of the panshould be moistened and the pan cleaned out between batches

c) Where admixtures are used, care should be taken to ensure these additives are uniformly distributedthroughout the concrete. Where applicable, admixtures should be added following the suppliers

specifications. Each admixture should be added separately. Admixtures may be added at other times

where specific effects of additions are being assessed. Water-soluble admixtures should be dissolved in

part of the balance of the mixing water to be added. Any such solutions should be counted as part of the

mixing water.

d) Unless otherwise specified, the following tolerances on the nominated slump, measured in accordance withAS 1012.3, should apply:

e) The procedure for handloading is as follows:i) Charge the mixer with the coarse aggregate, then the fine aggregate, before adding a sufficient

quantity of the mixing water to wet the aggregate

ii) Operate the mixer for 30 seconds and stopiii) Add the cement. Where the cementitious material comprises more than one component (such as the

addition of fly ash), all components should be added to the mixer together. To prevent loss of

powdered cementitious materials, cover the cement with some of the aggregate in the mixer prior to

commencing mixing.


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iv) Commence mixing as set out in Figure 1. Any variation to the procedure specified in Figure 1 should berecorded.


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5. SAMPLING OF FRESHLY-MIXED CONCRETEa) The trial batch prepared should be regarded as the sample for all subsequent tests. Where pan mixers not

fitted with discharging gates are used, the fresh concrete should be sampled directly from the pan.

b)

Where other types of mixers are used, the fresh concrete should be discharged onto a smooth clean dampnon-absorbent surface, briefly remixed with a shovel or scoop, and heaped together to ensure uniformity

c) Where a delay is anticipated between the completion of mixing and commencement of testing, the sampleshould be covered to prevent evaporation

6. USE OF FRESHLY-MIXED CONCRETEa) Any tests required in accordance with AS 1012 should be completed within the following time limits after

the completion of mixing:

i) 5 minutes for the determination of consistencyii) 10 minutes for other tests on freshly-mixed concrete, including determination of air content and mass

per unit volume

b) The preparation of specimens should be completed within the following time limits after completion ofmixing:

i) 30 minutes for the determination of setting timeii) 10 minutes for the determination of bleedingiii) 20 minutes for the determination of hardened concrete propertiesiv) 30 minutes for the determination of drying shrinkage

c) Unless noticeable loss of mixing water has occurred, concrete used to test consistency and mass per unitvolume of concrete (except when the mass per unit volume was determined during a test for air content)

may be remixed into the composite sample. The period of remixing should be 30 seconds. The remixing

should be done after all other samples for tests on freshly mixed concrete have been taken and prior to

making specimens for tests on hardened concrete.

7. TESTING OF FRESH CONCRETE7.1.ObjectiveTo measure the workability (by measurement of slump) and unit weight (wet density) of freshly mixed concrete

using AS 1012.

7.2.BackgroundDuring concrete construction, uniformity and compaction of freshly mixed concrete is required to fill formwork

properly. When mixed concrete lacks uniformity, difficulties are experienced with compacting and filling

formwork on a construction site. These difficulties will result in a significant reduction to the strength, stiffness, and

durability of the concrete. The single term workability is used to define the rheology of the freshly mixed

concrete. Workability is critical when pumping freshly mixed concrete to fill formwork.


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The workability of concrete required differs from a construction site to the next and depends on several factors

such as the reinforcement details, the compaction method used, the member size and shape, and method of

transporting the concrete to fill the formwork.

Four (4) standard test methods, specified by the Australian Standards (AS) 1012.3, are used to measure theworkability of concrete. They are the slump test, the compacting factor test, the Vebe test, and the

compactibility index test. The slump and compacting factor tests are more suitable for measuring the workability

of concretes requiring a medium level of workability, whereas the Vebe test is suitable for measuring concretes

requiring a low and very low level of workability. The compactibility index test is recommended only for

concrete mixes having a slump below 10 mm. For this laboratory session, the compacting factor, Vebe test, and

compactibility index test will not be performed; however, the use of such testing equipment will be briefly

demonstrated.

7.3.Slump Test (AS 1012.3.1)Scope

This AS test method sets out the method for determining the workability of concrete by measurement of slump

when the nominal size of aggregate does not exceed 40 mm.

Principle

a) This method describes the procedures of filling a slump cone (frustum) with fresh concrete in three equallayers and rodding each layer 25 times and then removing the slump cone vertically upwards away fromthe concrete

b) The vertical subsidence of the concrete that occurs, when the slump cone is raised, is termed the slump ofthe concrete

c) The slump will not vary between individual batches produced if the characteristics and proportions ofingredients used to make the concrete do not vary from batch to batch

Apparatus

Standard slump cone (measuring 200 mm bottom diameter, 100 mm top diameter and 300 mm height) Cone funnel Steel rod (measuring 600 mm long and 16 mm diameter) Scoop Graduated rulerProcedure

a) Dampen the slump cone, funnel, tamping rod and area of level concrete floor with water in preparation forthe test


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b) Assemble the slump cone on the prepared spot on the concrete floor and place both feet firmly on thefootplates. Ensure that the cone is seated flat on the floor. The cone should be held rigid by the feet of the

tester throughout the entire duration of the rodding procedure. Any slight movement of the cone will

invalidate the test result and the test will have to be repeated.

c)

Obtain a representative sample of concrete from the mixing pand) Fill the cone in three (3) equal height layers, rodding each layer 25 times with the rounded end of the

tamping rod. During the filling and rodding sequence of the top layer, sufficient concrete should be placed

in the funnel to ensure an excess of concrete is available above the top of the slump cone at all times

throughout the rodding procedure.

e) After the top layer has been rodded, the surface of the concrete should be struck off level with the top ofthe cone ensuring that throughout the operation the slump cone is firmly seated on the floor

f) The slump cone should now be raised slowly and carefully in a vertical direction, allowing the concrete tosubside. The raising of the slump cone should be completed in 3 + 1 seconds

g) Observe and record the shape of the slump obtained. Identify the slump as one of four types:i) Zero slumpii) True slumpiii) Shear slumpiv) Collapse slump

h) If the slump obtained is a shear slump, then repeat the test with another part of the sampleNote:An indication of the cohesiveness and workability of the concrete can be obtained if after slump measurement

the side of the test specimen is tapped gently with the tamping rod. Well-proportioned concrete, which has an

appreciable slump, will gradually slump further. Badly proportioned concrete is likely to fall apart.

Measurement of Slump

a) The slump of the concrete should be determined immediately by measuring the difference between theheight of the slump cone and the average height from three (3) measurements taken across the top

surface of the concrete

b) The whole operation from the start of filling the cone to the removal of the cone should be completed within2.5 minutes

c) Slump should be recorded to the nearest 5 mm for slumps measuring 100 mm and less and to the nearest10 mm for the slumps measuring greater than 100 mm

7.4.Mass Per Unit Volume of Freshly Mixed Concrete (AS 1012.5)Scope

This AS test method sets out the method for determining mass per unit volume of freshly mixed concrete that is in

its plastic state.


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Apparatus

A metal cylinder with a diameter-to-height ratio of 0.75-1.25 and a capacity of not less than 5 L forconcrete containing aggregates of nominal size not exceeding 40 mm

Weighing balance

A mallet A flat glass cover plate External vibratorConsolidation External Vibrating Table (Procedure)

a) Measure the volume of the cylinder by filling it with water (v). Convert the volume of the cylinder from litresto m3

b) Dampen the internal sides, and base of the cylinder and the underneath of the glass plate with water andweigh the empty cylinder plus glass plate (m1) in kg

c) Obtain a representative sample of concrete from mixingd) Fill the cylinder in two equal layers with the scoope) Compact each layer on a vibrating table only long enough to achieve full compaction. Avoid over vibration.

While the concrete is being consolidated on the vibrating table, securely hold the cylinder in place to

prevent it from moving.

f) Strike off the excess concrete and finish off the surface level using the flat glass cover plate to ensure thatthe concrete precisely fills the measure

g) Weigh the cylinder plus concrete plus glass plate (m2) in kgh) Calculate the mass of compacted concrete (mc = m2 m1) in kgi) Calculate the mass per unit volume of concrete (MPV) using the expression:

MPV (kg/m3) = mc (kg) / v (m3)

7.5.Making of Concrete Specimens for Strength Tests (AS 1012.8.1)Scope

This section sets out the method for making and curing of compression and indirect tensile test specimens of

concrete sampled in the laboratory or in the field.

Shape and Diameter of Test Specimens

a) The specimens used for both compressive and indirect tensile strength tests are 100 mm diameter by 200mm height. AS 1012 recommends the use of 150 mm diameter by 300 mm height cylinders for indirect

tensile strength testing of concrete mixes containing a maximum aggregate size of 40 mm. In addition, AS

1012 also specifies the use of 150 mm diameter by 300 mm height cylinders for compressive strength

testing of concrete mixes containing an aggregate size between 21 mm and 40 mm.

b) 100 mm cubes are used by some international standards such as British Standards


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Moulding Specimens

a) Check whether the moulds are properly clamped and clean. Thinly coat the inside surface of the steelmoulds and steel base-plates with mould oil.

b)

Take the sample of concrete and place the concrete in the mould in approximately two (2) equal layersusing a scoop. Compact the concrete without causing segregation.

c) Strike off and smooth the concrete surface using a moistened wooden floatd) Cover the moulded specimens with a plastic sheet or mould caps to avoid moisture loss and drying out of

the concrete test specimens. Make sure the mould caps and plastic sheets are not touching the concrete

surface.

Curing of test specimens

a) Leave the moulded test specimens in the laboratory to cure for 24 hoursb) Remove the test specimens from the moulds after an initial curing period of 24 hoursc) Identify the specimens with the date of moulding and weigh the specimensd) Store all specimens, except for three cylinders, in a water tank maintained at 23 2 oCe) Store three cylinders in laboratory ambient conditions (air-storage)Capping of test specimens

a) Where capping is required, the specimens should be tested using either:i) Moulded capping; orii) Restrained natural rubber capping system

b) Moulded caps should be as thin as practicable and not more than 6 mm in thickness. Only one layer ofcapping material should be used on each surface requiring capping, but small depressions may be filled

prior to capping.

c) Moulded capping materials should consist of one of the following five types:i) Filled sulphur mixturesii) Portland cement mortariii) High-alumina cement mortariv) Cement pastesv) Special gypsum plasters


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PART A: TESTING OF FRESH CONCRETE

1. Objectivesa) To batch and mix concrete using specified amounts of concrete making materialsb) To determine the workability and unit weight of freshly mixed concretec) To investigate the influence of increasing the w/c on the fresh properties of concreted) To mould a number of test specimens for determining hardened concrete properties2. Test ProceduresThe following tests on fresh concrete should be carried out and results recorded:

Slump Mass per unit volume of concrete3. Batch Weights (kg)

Material Sp. Gr. Mix A Mix B Mix C Mix D

Cement 3.15 16.0 16.0 16.0 16.0

Fine sand* 2.60 10.0 10.0 10.0 10.0

Coarse sand* 2.60 10.0 10.0 10.0 10.0

10 mm coarse aggregate* 2.65 25.0 25.0 25.0 25.0

20 mm coarse aggregate* 2.65 25.0 25.0 25.0 25.0

Mixing water 1.00 6.4 7.2 8.0 8.8

Mixing water/cement ratio 0.40 0.45 0.50 0.55

Free water**/cement ratio

* Aggregates have been batched from laboratory bins in air-dried storage conditions. This means that the

aggregates batched are notin saturated surface dry (SSD) condition.

** Calculate the free water using the given moisture contents and absorption capacities of the four (4) aggregates.

Given: Moisture Content (MC) and Absorption Capacity (AC) of the aggregates

1. Fine sand 0.6% MC 1.6% AC2. Coarse sand 0.5% MC 1.5% AC3. 10 mm coarse aggregate 0.3% MC 1.0% AC4. 20 mm coarse aggregate 0.2% MC 0.9% AC


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4. Test RecordsMeasurement Mix A Mix B Mix C Mix D

Cylinder diameter (mm)

Cylinder height (mm)Volume of cylinder (v) (m3)

Wt. of empty cylinder (mo)

Wt. of cylinder with concrete (m1)

Wt. of compacted concrete (mc = m1 mo)

Slump of concrete to nearest 5 mm

MPV (mc/v) to nearest 10 kg/m3

Notes:

Conduct the slump test immediately after mixing the concrete5. Observationsa) Sketch the slump pattern observed (digital photography is allowed)b) Note the type of slump: No / True / Shear / Collapse (circle the correct type)c) Note if the slump is stable: Yes / No (circle yes or no)d) Is the phenomenon of bleeding observed after moulding of the fresh concrete?6. Standard Test Specimens Moulding and Curing Operations (4 Mixes) 9 x 100 mm diameter by 200 mm height cylinders (1 to 9)

(6 cylinders for water-curing and 3 cylinders for air-storage)

3 x 100 mm cubes (water-curing) (10 to 12) 1 x 100 mm diameter by 200 mm height uncompacted cylinder (water-curing) (13)7. 28 Day Tests Required (4 Mixes)a) Compressive cylinder strength = 3 x water-cured (nos. 1 to 3)b) Compressive cylinder strength = 3 x air-stored (nos. 4 to 6)c) Indirect tensile strength = 3 x water-cured (nos. 7 to 9)d) Ultrasonic pulse velocity (non-destructive)= 3 x water-cured (nos. 10 to 12)e) Compressive cube strength = 3 x water-cured (nos. 10 to 12)f) Uncompacted compressive cylinder strength = 1 x water-cured (no. 13)


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8. Calculations and PlotsDetermine the cement content, aggregate content, and free water content for all four (4) mixes and show a

typical sample calculation.

Group Mix A Mix B Mix C Mix D

Unit weight of concrete (kg/m3)

Cement content (kg/m3)

Aggregate content (kg/m3)

Free water content (kg/m3)

Plot the relationship between slump and free water content Plot the relationship between unit weight and free water content9. DiscussionUsing the above relationships, discuss the influence of water content on the workability and unit weight of the

concrete.


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P A R T B: TESTING OF HARDENED CONCRETE

1. Objectivesa) To determine the compressive and indirect tensile strengths of hardened concreteb) To examine the effects of curing condition on strength development of concretec) To examine the influence of specimen shape (geometry) on compressive strengthd) To examine the effect of compaction on compressive strengthe) To examine the effect of increasing w/c on compressive and indirect tensile strengths of concrete2. Procedure (AS 1012)2.1.Compressive strength (AS 1012.9) In this test, standard cylinders and cubes will be subjected to uniaxial compressive loading with the load

applied at a standard stress rate of 20 MPa/min up to failure. The maximum applied load is recorded for

determining compressive strength.

When testing a cylinder, a capping material is required on the top rough surface of the cylinder to achievea plane surface for uniform loading

Load is applied to a planar surface when testing a cube, as no capping is required The compressive strength of concrete (fc) is calculated using the expression:

fc (MPa) = maximum load (N) / load bearing area (mm2)

Cylinder load bearing area = x (r2), where r is the cylinder radius Cube load bearing area = d x d, where d is the cube length, depth or height

2.2.Indirect Tensile Strength (AS 1012.10) In this test, a standard cylinder is placed on its side (that is, perpendicular) and subjected to compressive

loading with the load applied as a standard stress rate of 1.5 MPa/min along its length. The cylinder splits

in indirect tension along a diagonal direction due to induced tension resulting from Poisson's effect. It isnecessary to use bearing strips (5 mm thick, plywood strips) between each cylinder and testing machine

platens to avoid localised crushing.

The indirect tensile strength of concrete (fst) is calculated using the expression:fst (MPa) = 2000 x maximum load (kN) / x l (mm) x d (mm)

l = length of cylinder (in mm) d = diameter of cylinder (in mm)


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3. Test Results3.1.Compressive Strength Cylinders (Water cured for 28 days)

Specimen No. Diameter

(mm)

Height

(mm)

Weight

(g)

Max. load

(kN)

fc.28

(MPa)fcm.28 (MPa)

A1.1

A1.2

A1.3

B1.1

B1.2

B1.3

C1.1

C1.2

C1.3

D1.1

D1.2

D1.3

Note: Express the strength to 3 significant numbers

Observations

Draw typical failure patterns of the concrete cylinders in compression


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3.2.Compressive Strength Cylinders (Air stored for 28 days)

Specimen No.Diameter

(mm)

Height

(mm)

Weight

(g)

Max. load

(kN)

fc.28

(MPa)fcm.28 (MPa)

A1.4

A1.5

A1.6

B1.4

B1.5

B1.6

C1.4

C1.5

C1.6

D1.4

D1.5

D1.6


Observations

Draw typical failure patterns of the concrete cylinders in compression


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3.3.Indirect Tensile Strength Cylinders (Water cured for 28 days)

Specimen No.Diameter

(mm)Length (mm)

Weight

(g)

Max. load

(kN)

fst.28

(MPa)fstm.28 (MPa)

A1.7

A1.8

A1.9

B1.7

B1.8

B1.9

C1.7

C1.8

C1.9

D1.7

D1.8

D1.9


Observations and Remarks

Is failure observed through the aggregates or the aggregate-cement paste bond (comment on this observation)?


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3.4.Ultrasonic Pulse Velocity Cubes (Water cured for 28 days)

3.5.Compressive Strength Cubes (Water cured for 28 days)

Specimen No. Width (mm)Depth

(mm)

Weight

(g)

Max. load

(kN)

fc.28

(MPa)fcm.28 (MPa)

A1.10

A1.11

A1.12

B1.10

B1.11

B1.12

C1.10

C1.11

C1.12

D1.10

D1.11

D1.12


Observations

Draw typical failure patterns of the concrete cubes in compression

Specimen No. Path length (mm)Elapsed time

(sec)

Pulse velocity

(km/s)

Cylinder strength

(MPa)

A1.10

B1.10

C1.10

D1.10


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4. Calculationsa) Determine the unit weight of the hardened concreteb) Determine the mean compressive cylinder strengthc)

Determine the mean indirect tensile strength

d) Calculate the ultrasonic pulse velocity (3 significant numbers)e) Determine the mean cube strength5. Presentation of Test Results

Material Mix A Mix B Mix C Mix D

Cement content (kg/m3)

Free water content (kg/m3)

Free water/cement ratio

Hardened unit weight (kg/m3)

Cylinder strength (MPa)

Indirect tensile strength (MPa)

Ultrasonic pulse velocity (km/s)

Cube strength (MPa)

Plot the following graphical relationships and discuss these relationships

a)

Cylinder compressive strength versus free w/c [water-cured]b) Cylinder compressive strength versus free w/c [air-stored]c) Cylinder compressive strength [water-cured] to cylinder compressive strength [air-stored] ratio versus cylinder

strength [water-cured]

d) Cylinder indirect tensile strength versus free w/c [water-cured]e) Cylinder indirect tensile strength versus cylinder compressive strength [water-cured]f) Cylinder indirect tensile strength to cylinder compressive strength ratio versus cylinder compressive strength

[water-cured]

g) Cylinder compressive strength versus ultrasonic pulse velocity [water-cured]h) Cube compressive strength versus free w/c [water-cured]i) Cylinder compressive strength versus cube compressive strength [water-cured] include the theoretical

relationship cylinder compressive strength = 0.80 x cube compressive strength


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6. Discussion of Test ResultsUsing your results, discuss the following characteristics:

a) Effects of free water content on the fresh properties (workability and unit weight of concrete)b) Effects of free w/c on the hardened properties (compressive strength and indirect tensile strength)c) Effects of curing condition on the compressive strengthd) Relationship between compressive strength and ultrasonic pulse velocitye) Effect of specimen shape on compressive strengthf) Discuss possible errors that may have occurred during these testsg) Discuss your reflection on the importance of the laboratory session etc

7. Additional Instructionsa) Include sample calculationsb) Use Excel to plot relationships (ensure to select the appropriate scales)c) All results for the 4 mixes (A, B, C and D) should be used in writing up this reportd) Use the trend line function in Excel to plot the fitting relationships.e) The discussion is the most important part of the report and, therefore, should have more focus by being

detailed and descriptive

f) Ensure to include references (beyond my lecture notes and Wikipedia)g) Submit your combined fresh and hardened concrete report before the due datePlease do not submit instructions and procedures listed in the laboratory handbook. Students should briefly write

down the procedures used and present the results and your own analysis of results, discussion, and conclusions.

8. ConclusionsList the conclusions obtained from your analysis of the results and discussion. Both qualitative and quantitative

statements are required in your conclusions.

9. ReferencesReferences should be made to textbooks and notes used in your discussion

Importance Announcement

This is a laboratory report is worth 10% of your final assessment Three or more students must combine to write up the report Any copied report will not be marked Signed declarations by all students in the same group must be included on the cover page of the report


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GROUP REPORT THREE REQUIREMENTS AND MARKING SCHEME





Part Section Mark


2 Test results, tables and calculations /2

3 Graphs and illustrations /2



Deductions

Total marks /10

Marking Criteria


Documents

48352 S2013 Laboratory Handbook