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Experimental Programme

CHAPTER: 3
EXPERIMENTAL PROGRAMME

3.1 GENERAL
The chapter describes the details of experimental programs for the measurements of
fresh properties, strength properties (compressive strength) and durability properties such as
Sorptivity and rapid chloride permeability of High performance concrete mixes made with
varying percentages of waste foundry sand as partial replacement of fine aggregates. The
basic tests carried out on concrete samples are discussed in this chapter, followed by a brief
description about mix deign and curing procedure adopted. At the end, the various tests
conducted on the specimens are discussed.
3.2 MATERIALS USED
3.2.1 CEMENT
Ordinary Portland Cement (OPC) Grade 53 Ultratech and Garde 43 Ultra tech was
used for casting cubes and cylinders for all concrete mixes.
The cement was of uniform colour i.e. grey with a light greenish shade and was free from any
hard lumps. It was tested as per Indian standard specification (BIS-8112:1989) for OPC 43
Grade. Test results are given in Table 3.1 as above.
Table 3.1: Physical Properties of Ordinary Portland Cement 43 grade
Physical Properties
BIS- 8112:1989
Test Results
Standard Consistency (%)

29.5

Setting time (min)


Initial

30 Min.

92

Final

600 Max

248

3 day

23

24.5

7 day

37.5

39.1

28 day

43

47.8

Specific gravity

3.15

Compressive Strength (MPa)

Table 3.2: Physical Properties of Ordinary Portland Cement 53 grade


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Physical Properties

BIS- 12269:2013

Test Results
29.5

Standard Consistency (%)


Setting time (min)
Initial

30 Min.

165

Final

600 Max

215

3 day

27

40.2

7 day

37

49.2

28 day

53

59.6

Specific gravity

3.15

Compressive Strength (MPa)

Table 3.3 Chemical Properties of Cement 43 Grade and 53 Grade


S.No

Chemica

Ultatech

l Content OPC.
43 & 53
1.

CaO

58-60.6

2.

SiO2

21-22

3.

Al2O3

5.5-4.8

4.

Fe2O3

4.3-4.8

5.

MgO

0.9-1.1

6.

SO3

2.2-2.6

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3.2.2 FINE AGGREGATES


3.2.5 USED Indian Standard Sand (Ennore Sand)
Indian Standard Sand IS650:1991 as per B.I.S. approval. The factory is situated at Ennore 15,
km. North of Chennai. The processed sand is used in trial is in two grades(Grade II & Grade
III).
Table.3.4: Physical Properties of Ennore Sand
Properties
Colour
Shape of grain
Specific Gravity
Water Absorption (%)

Observed values
Greyish White
Sub Angular
2.64
0.8

Fig 3.1 Indian Standard Sand IS 650:1991 GRADE III

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Experimental Programme

Fig 3.2 Indian Standard Sand IS 650:1991 GRADE II

3.2.3 Mineral Admixture


Three type of Mineral Admixture used to make High Perfomance Concrete, Alkofine 1203 ,
Metakolin and Elkem Undensified Silica Fume
Table.3.5: Chemical Properties of Alccofine 1203, Metakolin , Elkem Grade 920U
S.No

Chemical

Alccofine 1203

Metakolin

Content

Elkem Grade
920U

1.

CaO

32-34

04-0.8

0.2-1

2.

SiO2

28-32

54-54

85-97

3.

Al2O3

18-20

41-45

0.52

4.

Fe2O3

1.8-2

0.5-1

0.02-0.07

5.

MgO

8-10

6.

SO3

0.3-0.7

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Experimental Programme

3.2.4 Silica Fume


Silica Fume was used in cement concrete as replacement for cement to study its effectiveness
for development of ultra-high performance concrete. Silica fume was Obtained from Elkem
India Pvt Ltd . Silica fume received was grey in color .
Densified silica fume works very well in concrete. However, one caution when working with
this product form is to ensure that the mixing is adequate to break up the particle
agglomerations. But as in our design Coarse Aggregate is not part of Design Mix Mixing in
such type may not be adequate to break up the agglomeration.
So use of Un-densified Silica fume is more suitable where in Design Mix maximum size of
aggregate is 1mm .
Table.3.6: Physical Properties of Elkem Grade 920U
Specific Gravity
Bulk Density

2.2
200-350 kg/m3

Fig 3.3 Undensified Micro Silica

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3.2.5 Alccofine 1203- Micro Fine


Alccofine was used in cement concrete as replacement for cement to study its effectiveness
for development of ultra-high performance concrete .Alccofine was obtained from Ambuja
Cement Ltd (ALCCOFINE MICRO MATERIALS RANGE). Alccofine 1203 has an average
particle size of 4 to 5 microns, the top size is only 10 microns .The computed Blaine value is
around 12000 cm2/gm. Various Physical properties as follow :Table.3.7: Physical Properties of Alccofine 1203
Setting Time
Initial setting time
Final Setting Time
Technical Data
Fineness
Specfic gravity
Bulk Density

> 2 to 3 hours
< 6 Hours
12000 cm2/gm
2.86 0.02
600 to 700 kg/m2

Fig 3.4 ALCCOFINE 1203

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Experimental Programme

3.2.6 Metakolin
The Meta Prefix in the term is used to denote change .It is a borrowing from Greek meaning
after along with beyond .It is used and is recognizable, in the formation of compound words
metabolic, metamorphosis. The scientific use of the prefix is used for a combining form
denoting the least hydrated of a series. In the case of metakolin the change that is taking place
is de-hydroxylization brought on by the application of heat over a defined period of time.
At about 100-200 degrees C, clay minerals lose most of their absorbed water. The
temperature at which kaolinite loses water by de-hdroxilization is in the range of 500-800
degrees C. This thermal activation of a mineral is also referred to as calcining. Beyond the
temperature of de-hydroxylization kaolinite retains two- dimensional morder in the crystal
structure and the product is termed metakolin.

Fig 3.5 METAKOLIN


3.2.7 WATER

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Experimental Programme

Generally, water that is suitable for drinking is satisfactory for use in concrete. Water
from lakes and streams that contain marine life also usually is suitable. When water is
obtained from sources mentioned above, no sampling is necessary. When it is suspected that
water may contain sewage, mine water, or wastes from industrial plants or canneries, it
should not be used in concrete unless tests indicate that it is satisfactory. Water from such
sources should be avoided since the quality of the water could change due to low water or by
intermittent tap water is used for casting.
3.2.8 ADMIXTURE
MELFLEX 2651 F is a free Flowing ,Spray dried Powder of modified
Polycaboxylic ether .Melflex 2651 F is especially optimized for plastification and water
reduction of cementitious construction material .MELFLEX 2651 F provides an excellent
development of high performance superplasticizer intended for applications where high
water reduction is required , and it has been developed for use in Self levelling underlayment
,Cementious Floor screeds Repair Mortar ,Non Shrink Grout and

, High performance

concrete. It is based on a polycarboxylic ether polymer with long lateral chains. This
mechanism considerably reduces the water demand in flowable concrete. It combines the
properties of water reduction and workability. It allows the production of high performance
concrete with highly workable and High Strength (> 100MPA). Specifications of super
plasticizer are given in Table
Table 3.8: Specifications of Superplasticizer
Basis
Appearance
Dying Loss (%)
Bulk Density(Kg/m3)
PH- Value (20OC), 20%

Dried Powder of Modified Polycarboxylic ether


Yellowish to Brownish
Max 2.0
300 to 600

Solution

6.5 to 8.5

3.2.9 Mix proportion used in the present study


To cover the range of different mixture variation , total 30 Mixture were designed having four
different constant Cement and water /powder ratio of 0.13 and four Cement Content of
C1(720 kg/m3) , C2(840 kg/m3), C3(1180kg/m3) and C4(1201kg/m3). Which is gradually
increased on the basis of theory of propagation of crack in between transition zone. To
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Experimental Programme

achieve high strength ,Role of w/c ratio and Agg/cement ratio are very important. But in
particularly for high strength role of aggregate / cement is more significant. As crack initiate
at the vicinity of transition Zone, it take propagate more time to join each other and capable
to more load before failure ( J.C Maso 2004)
In which with every four Cement Content with binary blending with mineral mixture like
Undensified Silica fume ,Metakolin and Alccofine 1203 with different combination of
S25(Cement +Silica fume 25%) , M25 (Cement +Metakolin 25%) , G25 (Cement + Alkofine
25%) and Ternary blending of S20M05 (Cement +Silica fume 20% +Metakolin 5%) ,
M20G05 (Cement + Metakolin 20% +Alccofine 5%) and S20G05 (Cement +Silica fume
20% +Alccofine 5%) were used
All Mix Proportions of ingredient used for the development of UHPC are shown in Table 3.8
(a d ) for four Cement content where in the OPC 53 grade and OPC 43 grade was replaced
with Silica fume ,Metakolin and Alccofine 1203 in different percentage shown in table . A
constant wokability of Mini Slump Flow of range 250-300 mm was maintained for all the
mixes by varying the superplasticiser dosage between 0.6 to 0.8 % of cementious
Table 3.9 (a) Mix proportion of trial mixes for Cementitious 900kg/m3

C1

Cement

S25

720.00

M25

720.00

G25

720.00

S20 M05

720.00

M20 G05

720.00

S20 G05

720.00

Silica
fume

Metakolin

GGBS

in kg

0.13

244.4

552

368

0.13

244.4

552

368

0.13

244.4

552

368

0.13

244.4

36.00

552

368

0.13

244.4

36.00

552

368

0.13

244.4

180.0
0
36.00

144.0
0

w/p

368

180.00

144.00

Water

552

180

144.0
0

Sand
0.5
1mm
mm

Admixtue
in %
0.60
%
0.60
%
0.60
%
0.60
%
0.60
%
0.60
%

in kg
5.4
5.4
5.4
5.4
5.4
5.4

Table 3.9(b) Mix Proportion of trial Mixes for Cementitious 1050kg/m3

C2

Cement

S25

840.00

M25

840.00

Silica
fume
210.0
0

Metakolin

210.00

GGBS

Sand
0.5
1mm
mm

Water
w/p

in kg

699.6

470.4

0.13

288.6

699.6

470.4

0.13

288.6

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Admixtue
in %
0.70
%
0.70
%

in kg
7.35
7.35

Experimental Programme

G25

840.00

S20 M05

840.00

M20 G05

840.00

S20 G05

840.00

S60 M40

840.00

S60 M40

840.00

S40 M60

840.00

210.0
0

699.6

470.4

0.13

288.6

699.6

470.4

0.13

288.6

42.00

699.6

470.4

0.13

288.6

42.00

699.6

470.4

0.13

288.6

84.00

699.6

470.4

0.13

288.6

105.00

699.6

470.4

0.13

288.6

126.00

699.6

470.4

0.13

288.6

168.0
0

42.00
168.00

168.0
0
126.0
0
105.0
0
84.00

0.70
%
0.70
%
0.70
%
0.70
%
0.70
%
0.70
%
0.70
%

7.35
7.35
7.35
7.35
7.35
7.35
7.35

Table 3.9(c) Mix Proportion of trial Mixes for Cementitious 1475 kg/m3

C3
S25
M25
G25
S20 M05
M20 G05
S20 G05
S20 M0543+53

Cement
1180.0
0
1180.0
0
1180.0
0
1180.0
0
1180.0
0
1180.0
0
1180.0
0

Silica
fume
295.0
0

Metakolin

GGBS

0.13

206.5

383.5

0.13

206.5

383.5

0.13

206.5

383.5

0.13

59.00

206.5

383.5

0.13

59.00

206.5

383.5

0.13

206.5

383.5

0.13

59.00

236.0
0
236.0
0

w/p

383.5

295.0
0

236.00

Water

206.5
295.00

236.0
0

Sand
0.5m
1mm
m

59.00

Admixtue

in kg

in %

268.4
5
268.4
5
268.4
5
268.4
5
268.4
5
268.4
5
268.4
5

0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%

in kg
11.8
11.8
11.8
11.8
75
11.8
11.8

Table 3.9(d) Mix Proportion of trial Mixes for Cementitious 1501 kg/m3

C4
S25
M25
G25
S20 M05
M20 G05
S20 G05
S20 M0543+53

Cement
1201.0
0
1201.0
0
1201.0
0
1201.0
0
1201.0
0
1201.0
8
1201.0
8

Silica
fume
300.0
0

Metakolin

GGBS

0.13

310.8

207.2

0.13

310.8

207.2

0.13

310.8

207.2

0.13

60.00

310.8

207.2

0.13

60.00

310.8

207.2

0.13

310.8

207.2

0.13

60.00
240.00

60.00

w/p

207.2

300.0
0

240.0
0
240.0
0

Water

310.8
300.00

240.0
0

Sand
0.5m
1mm
m

3.3 CASTING AND CURING


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in kg
262.4
7
262.4
7
262.4
7
262.4
7
262.4
7
262.4
8
262.4
8

Admixtue
in %
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%
0.80
%

in kg
12.00
8
12.00
8
12.00
8
12.00
8
12.00
8
12.00
8
12.00
8

Experimental Programme

Before casting, the entire test specimen were cleaned and oiled properly. These were securely
tightened to correct dimensions before casting. Care was taken that there is no gaps left from
where there is any possibility of leakage of slurry. Careful procedure was adopted in the
batching, mixing and casting operations. The fine aggregates were weighed first with an
accuracy of 0.5 grams. The HPC mixture was prepared in Digi Mortar Mixer. Initially, fine
aggregates were mixed thoroughly by dry mixing in pan mixer. To this mixture, the cement,
First Melflex 2651 after that Silica fume, metakolin/Alkofine was added. These were mixed
to uniform colour. Then water was added carefully so that no water was lost during mixing
and admixture was added along with it. After proper mixing concrete is checked for fresh
properties, if concrete mix fulfil the workability requirements then the specimens are casted.
For each mix 32 samples were prepared, which consists of 6 cubes (70.7x70.7x70.7) for 7 ,
28 compressive strength , 6 cylinders (200x100) for RCPT and Sorptivity Test
3.4 FRESH CONCRETE TESTS
Test for Fresh Mortar/Concrete
Mortar tests are widely used to design and evaluate SCC. In fact, assessing the properties of
SCM is an integral part of SCC design [6]. EFNARC 2002 (European Federation of National
Trade Associations) [6] is the only available standard which is dedicated to special
construction chemicals and concrete systems. It describes various tests involved in mortar
tests to determine the optimum w/cm and optimum dosage of SP and VMA in mortar. They
are mini slump cone test to measure the relative slump of the mortar and mini V-funnel test to
measure the rate of flow or viscosity of the mortar. Here in our study, mini slump cone is used
to measure the spread of the mortar as described in EFNARC 2002.

Fig 3.6 (a) V-Funnel Test Appratus

Fig 3.6 (b) Mini Slump Cone

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Experimental Programme

3.4.1 Mini slump cone and graduated glass plate


The test apparatus for measuring the spread and viscosity of mortar comprises a mini frustum
(slump) cone and a graduated glass plate. Mini slump cone has top and bottom diameters of 7
cm and 10 cm respectively with a cone height of 6 cm. The graduated glass plate contains
two circular graduations of 10 cm and 20 cm in diameter marked at the centre of the glass
plate. With this test apparatus, both viscosity and spread of the mortar can be measured from
a single test.
Determination of spread
In this test, the truncated cone mould is placed exactly on the 10 cm diameter graduated circle
marked on the glass plate, filled with mortar and lifted upwards. The subsequent diameter of
the mortar is measured in two perpendicular directions and the average of the diameters is
reported as the spread of the mortar.
3.4.2 V-Funnel Test
The V-funnel test is used to assess the viscosity and filling ability of self-compacting
concrete.
A V shaped funnel is filled with fresh concrete and the time taken for the concrete to flow out
of the funnel is measured and recorded as the V-funnel flow time.
Apparatus
a) V-funnel, made to the dimensions (tolerance 1 mm) in figure 1, fitted with a quick
release, watertight gate at its base and supported so that the top of the funnel is
horizontal. The V-funnel shall be made from metal; the surfaces shall be smooth, and
not be readily attacked by cement paste or be liable to rusting.
b) Container, to hold the test sample and having a volume larger than the volume of the
funnel and not less than 12 l.
c) Stop watch, measuring to 0.1 s.
d) Straight edge, for striking off concrete level with the top of the funnel.
Procedure

Clean the funnel and bottom gate, the dampen all the inside surface including the gate. Close
the gate and pour the sample of concrete into the funnel, without any agitation or rodding,
then strike off the top with the straight edge so that the concrete is flush with the top of the
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Experimental Programme

funnel. Place the container under the funnel in order to retain the concrete to be passed. After
a delay of (10 2) s from filling the funnel, open the gate and measure the time tv, to 0,1 s,
from opening the gate to when it is possible to see vertically through the funnel into the
container below for the first time. tv is the V-funnel flow time.

3.5 COMPRESSIVE STRENGTH TEST (BIS: 516 1959)


Apparatus
Testing Machine - The testing machine may be of any reliable type, of sufficient
capacity for the tests and capable of applying the load at the rate specified. The permissible
error shall be not greater than 2 percent of the maximum load. The testing machine shall be
equipped with two steel bearing platens with hardened faces. One of the platens (preferably
the one that normally will bear on the upper surface of the specimen) shall be fitted with a
ball seating in the form of a portion of a sphere, the centre of which coincides with the
central point of the face of the platen. The other compression platen shall be plain rigid
bearing block. The bearing faces of both platens shall be at least as large as, and preferably
larger than the nominal size of the specimen to which the load is applied. The bearing surface
of the platens, when new, shall not depart from a plane by more than 0.01 mm at any point,
and they shall be maintained with a permissible variation limit of 0.02 mm. The movable
portion of the spherically seated compression platen shall be held on the spherical seat, but
the design shall be such that the bearing face can be rotated freely and tilted through small
angles in any direction.
Age at Test

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Tests shall be made at recognized ages of the test specimens, the most usual being 7
and 28 days. The ages shall be calculated from the time of the addition of water to the dry
ingredients.
Number of Specimens
At least three specimens, preferably from different batches, shall be made for testing at each
selected age.
Procedure
Cube specimens of size 70.06mm were cast for compressive strength as per Indian
standard specifications BIS: 516-1959. After casting, all tests specimens were finished with
steel trowel. Immediately after finishing, the specimens were covered with sheets to minimize
the moisture loss from them. Specimens were demoulded after 24-hours and then cured in
water at approximately room temperature till testing. Compressive strength tests for cubes
were carried out at 7 and 28. All the specimens were tested in an automated CTM shown in
Fig.3.7
The compressive strength was then calculated according to the formula:
=P/A
Where

= Compressive Strength (N/mm )

= Maximum load (N)

= Cross section area of cube (mm )

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Experimental Programme

Fig. 3.7 Compressive Strength Test


3.6 DURABILITY TEST
3.6.1 Sorptivity
The Sorptivity (ASTM C-1585) can be determined by the measurement of the capillary rise
absorption rate on reasonably homogeneous material. Water was used as test fluid .The
cylinder after casting were immersed in water for 28 days. The specimen size 100mm dia X
50 mm height after drying in oven at temperature of 100 + 10 0 C were drowened with water
level not more than 5mm above the base of specimen and the flow from peripheral surface
with non-absorbent coating /Plastic tape. The quantity of water absorbed in time period as per
ASTM C- 1585 was measured by weighting the specimen on a top pan balance weighting up
to 0.1mg ,surface water on the specimen was wiped off with a dampened tissue and each
weighting operation was completed as per standard time interval. Sorptivity (S) is a material
property which characterizes the tendency of a porous material to absorbed and transmit
water by capillarity . Table gives the Acceptance criteria for the Sorptivity. Table shows the
values at 28 days .The cumulative water absorption (per unit area of the inflow surface)
increase as the square root of elapsed time (t) , I = S.t1/2
Therefore I = S.t1/2
Where
S = Sorptivity in mm,
T = Elapsed time in min
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Experimental Programme

I = w/Ad
w = Change in weight = W2 W1
W1 = Oven dry weight of cylinder in grams.
W2 = Weight of Cylinder after 30 min capillary suction of water in grams
A = Surface area of the specimen through which water penetrated
D = Density of water
Acceptance criteria
Laboratory Concrete
As-built Structures
Full acceptance
Conditional acceptance
Remeadial measures
Rejection

OPI (Log Scale)


>10
>9,4
9,0 to 9,4
8,75 to 9,0
< 8.75

Sorptivity
<6
<9
9 to 12
12 to 15
>15

.
3.6.2 RAPID CHLORIDE PERMEABILITY TEST (ASTM C 1202)
The rapid chloride permeability test was originally developed for the Federal
Highway Administration (FHWA) by the Portland Cement Association (Whiting,1981) to
provide a rapid test method that correlated well with ponding tests, such as AASHTO T 259.
Ponding tests are considered to be the best method of determining the chloride permeability
of concrete, but they take 90 days or more to complete, making them impractical for project
quality assurance testing.Two very similar standards (AASHTO T 277 and ASTM C 1202)
describe the rapid chloride permeability test. The tests are performed using 2 in. (51 mm)
long, 3.75 in. (95 mm) diameter cylindrical specimens cut from cores obtained with a
diamond-dressed coring bit (alternatively, tests are performed using 4 in. (100 mm) diameter
cast cylinders, and the test values are normalized using the ratio of the standard to the actual
cross-sectional areas).After the curved surface of a test specimen is coated with epoxy, the
specimen is vacuum saturated with water Rapid Chloride Permeability Tests and then soaked
for 18 hours. As shown in Fig. 3.9. and Fig. 3.10. The specimen is then placed in the testing
apparatus where one end of the specimen is exposed to a solution containing sodium chloride
(NaCl) and the other end is exposed to a solution containing sodium hydroxide (NaOH). To
increase the rate of chloride penetration into the specimen, thus speeding up the test, a
constant 60 V potential is applied across the specimen. The current across the specimen is
measured at least every 30 minutes during the 6-hour test. In theory, as the chlorides
penetrate deeper into the concrete, the pore solution becomes more conductive and the
current readings
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Experimental Programme

increase. In concretes with high conductivity values, however, these effects are small relative
to changes in conductivity due to temperature rise. To reduce the effects of heating and
resultant changes in conductivity over the 6-hour period of the test, its been suggested that
earlier values be adjusted to obtain an equivalent 6-hour coulomb value. For example, data
taken at 30 minutes would be multiplied by 12 to obtain an equivalent 6-hour value. Because
the test results are highly variable (as with most, if not all, penetration resistance tests), two
or three specimens are usually tested for each concrete sample. The total charge passing
through the specimen (in coulombs) is found by calculating the total area under the plot of
time versus current. Therefore, higher coulomb values at the completion of the test indicate
higher permeability. The original researchers found good correlation between the coulomb
values and the results of ponding tests performed on specimens from the same mixture for a
wide variety of concretes.

Fig.3.9: Rapid chloride permeability test set up (ASTM C 1202).

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Experimental Programme

Fig.3.10: Schematic of rapid chloride permeability test setup(www.google.com)


The rapid chloride permeability test does not, however, directly measure the depth or rate of
chloride penetration. This makes it difficult to directly correlate results from the test with a
desired service life and has led to a significant amount of debate about the proper use and
applicability of the test. It should also be noted that, in quality control and acceptance testing
applications, ASTM C 1202 recommends the use of the qualitative terms shown in the righthand column of Table 3.15, rather than the numerical results of the test.
Table 3.15: Chloride Ion Penetrability Based on Charge Passed (ASTM C1202)
Charge passed (Coulomb)

Chloride Ion Penetrability

> 4000

High

2000 4000

Moderate

1000- 2000

Low

100 1000

Very Low

< 100

Negligible

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