Choosing a Standard Concrete Compression Testing ...

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Purpose of a concrete compression machine

The purpose of a Concrete Compression Machine is straightforward; it uses compressive force to load different types of concrete specimens to ensure the material meets design and structural strength requirements. These versatile machines are the centerpiece of any concrete testing lab. They can be configured in a variety of ways to adapt to different sample types, and the right one can shape the success of your testing program.

Advantages of having a compression machine

Technical advancements over time have enhanced the level of accuracy, repeatability, efficiency, and performance for testing concrete, grout, and mortar strengths in a wide range of sample types. These precision machines are often equipped for one specific sample type, for example, a 6x12in concrete cylinder specimen. However, they can be outfitted with adaptive accessories for testing multiple sample types and sizes. This blog post will guide you through the process of selecting the right machine and equipping it to be a versatile and efficient addition to your lab.

How to choose the right standard machine for your lab

In this blog, we created a 5-step buying guide to help you select the specific standard concrete compression machine and adaptive accessories that will best suit your laboratory concrete compressive testing needs.

Step 1: Understanding Frame Capacity and Stiffness

According to the National Ready Made Concrete Association, the compressive strength of concrete is &#;the most common performance measure used by the engineer in designing buildings and other structures.&#; It&#;s important to select a concrete compression machine that complies with ASTM C39 and other applicable ASTM and AASHTO standards. It should also adhere to rigidity recommendations in the ACI 363 Report on High-Strength Concrete. It states the load frame should have a total capacity of &#;at least 20% greater than the expected ultimate load of the cylinders.&#;

A load frame that is stiff, both longitudinally and laterally, assures uniform specimen loading, reduces explosive failures, and generally will have a longer service life. Explosive failures, especially with high-strength concrete samples, can produce shocks to the hydraulic and electronic systems, causing damage and loss of calibration.

Step 2: Know Your Sample Types and Strength Requirements

The size of specimens tested directly influences the maximum concrete strength the machine is capable of testing. For instance, following the guidelines indicated above, a compression machine with a total capacity of 250,000lbf can test 6x12in cylinders with expected strengths up to about 7,000psi. Using 4x8in cylinders in the same machine allows testing of concrete with strengths of 15,000psi or more, but precautions such as fragment guards should be in place.

Gilson's Standard Concrete Compression Machines are designed in a series of four different capacities: 250,000lbf, 300,000lbf, 400,000lbf, and 500,000lbf to meet such variances &#; and machines with greater capacities are available by special order.

There are other variables related to the machine&#;s functionality to keep in mind:

• Compatibility: Will you be testing only one sample type (for instance a cylinder), or do you want the capability to also test cubes, cores, prisms, and beams in a range of sizes? As stated earlier, there are accessories to adapt your compression machine for more than one testing application. Testing concrete beam specimens means you should make sure the machine retains its level of accuracy at lower loads. Flexural beam strengths are significantly lower than concrete cylinder compressive strengths.
• Strength: What range of strengths do you expect to test and are there specific precautions to consider? For instance, using 4x8in sample cylinders allows testing cylinders with higher design strengths, but some caution is advised since very high strength concrete samples can be prone to explosive failure. These failures can be hazardous due to flying fragments and may shock the electronic and hydraulic systems of the machines. It&#;s important to ensure that the compression machine is equipped with protective fragment guard doors and other safety features.
• Size: What are the specimen sizes you will be testing? The size of the compression machine&#;s frame openings, sometimes referred to as daylight openings, should be sufficient to accommodate the maximum size specimen and ensure ease of handling. Masonry prisms can require a surprising amount of space, especially if they are capped. Gilson Compression Machines have daylight openings up to 14x14.3in (356x363mm) WxH, with all platens in place. Machines with larger openings are also available. Spacers in a variety of sizes and thicknesses are available to adjust the opening size for each sample type.
• Type of Test: What do the test standards say? What are the requirements? In addition to ASTM C39, there are other industry standards that may apply to your specific testing applications. These include ASTM C109, ASTM C293, ASTM C78, ASTM E4, along with AASHTO T 22, BS and BS .
• Features: What about the hydraulics system? Look for features like two-stage hydraulic systems and reliable hydraulic valve controls to regulate loading. A common and costly operation error is to allow the hydraulic ram to over-extend. Select a model with a pressure bleed hole to prevent this &#; and pay close attention to the maximum extension warning label marked on the frame.

Step 3: Operation and Data Collection

How do you handle your test data and results? Decide how you want your test data to be collected and distributed. If you only have a few cylinders to break now and then, perhaps a pencil and paper will do, but Gilson&#;s basic Pro Controller helps you organize and retain what you need for most testing. The memory capability of this controller saves the results of up to 600 tests with optional transfer to a PC or printer.

However, if you test on a regular basis, leverage available technology for data collection, log your test results, and generate reports in a way that streamlines lab efficiency and minimizes human error - the Pro-Plus Controller saves information for sample ID, size and type, operator while displaying live load, rate of load, and stress. For a more in-depth comparison between the two controllers view the comparison chart or video below.

Step 4: Increase Versatility with Adaptive Products

Once you have determined features, capacities, and capabilities for your testing machine, choose the model-specific accessories to optimize it for your applications. Adaptive accessories enhance the functionality of each compression testing machine by equipping it with products that expand the testing capability. These accessories allow testing of flexural beams, masonry prisms, different cylinder sizes, cubes &#; and there are even cylinder splitting fixtures.

Consider not only the accessories you&#;ll need but what it will take to change over the machine to accommodate them. Upper platens for accessories used to test 6in cubes and masonry block prisms are very heavy and difficult to install unless you use carrier bracket options. Locking stems make switching platens quick and easy, but threaded draw rods allow easy height adjustments with the right spacers.

Step 5: Pick the Compression Testing Machine that Best Meets Your Needs

Specific characteristics of Gilson&#;s Concrete Compression Machines in four standard capacities are shown below. Each can be supplied ready for testing 6x12in concrete cylinders with sulfur caps or unbonded pads, and each can be outfitted for testing other cylinder sizes, different-sized cubes, concrete masonry units, and flexural beams. Special-order Compression Testing Machines with load capacities up to 1,000,000lbf (4,448kN), special control consoles, and multiple loading frames are also available.

Comparison Guide Testing
OptionsModelTotal Capacity
lbf (kN)Maximum
psi (kPa)
w/6x12 Cylinder2-Block
Masonry Prism
Configuration Pro Controller Compression,
Flexural, & Splitting MC-250P(F) 250,000 (1,112) 7,000 (48,265) X MC-300P(F) 300,000 (1,335) 8,500 (58,608) X MC-400P(F) 400,000 (1,780) 11,300 (77,914) X MC-500P(F) 500,000 (2,224) 14,100 (97,220) X Pro Plus Controller Compression,
Flexural, & Splitting MC-250PR(F) 250,000 (1,112) 7,000 (48,265) X MC-300PR(F) 300,000 (1,335) 8,500 (58,608) X MC-400PR(F) 400,000 (1,780) 11,300 (77,914) X MC-500PR(F) 500,000 (2,224) 14,100 (97,220) X MC-500PRP(F) 500,000 (2,224) 14,100 (97,220) &#;

We hope the information contained within this guide will help you select the compression testing machine that gets the job done right the first time, adheres to industry standards and recommendations &#; and maintains quality control and quality assurance protocols. For additional information about compression testing machines, contact our technical support professionals by calling (800) 444- or sending an to .

Need to verify concrete strength accurately? Whether for compliance or safety, the accuracy of a concrete break machine is indispensable for construction and testing laboratories. This article will detail the operation, types, and selection criteria of concrete break machines, equipping you with the know-how to choose the model that best fits your project&#;s testing demands.

Key Takeaways

• Concrete break machines, critical for assessing the compressive strength of concrete, can test various types of specimens and require precise operation to ensure accurate and consistent results.
• Advances in concrete break machine technology include automated controllers, data management systems, and additional accessories which enhance test precision and versatility for different concrete specimen shapes.
• Proper use, regular calibration, and maintenance of concrete break machines are essential for their longevity and precision, as well as to uphold safety during testing, especially when dealing with explosive failures in high-strength concrete samples.

Understanding Concrete Break Machines

As the backbone of our cities, concrete needs to be strong and reliable. Concrete break machines, also known as concrete compression machines, serve as the gatekeepers for this purpose. Engineers routinely use these machines to determine the compressive strength of concrete&#;a crucial performance measure for designing buildings and other infrastructure. These machines predict the load-bearing capacity of concrete materials, establishing their maximum load per unit area that they can withstand, which is paramount for construction projects.

Moreover, these machines can be configured to test different types of concrete samples, enhancing their versatility in concrete testing labs.

How Concrete Break Machines Work

The concrete break machine initiates the testing process by applying controlled loading to a cylinder or beam specimen until fracture. To maintain safety during testing and ensure uniform force distribution, these concrete cylinders must exhibit even, flat, and parallel bearing surfaces. The load application to concrete cylinders requires meticulous care since any mishandling can lead to injury or equipment damage.

The capacity of the concrete break machine, which determines the maximum concrete strength it can test, is restricted by the size of the specimens under test. Specimen size and shape significantly affect concrete compressive strength, with size effects being particularly noticeable in high-strength concrete and larger specimens.

To measure flexural beam strengths accurately, the machine must maintain precision even at lower peak load- levels for low strength concrete beams. However, challenges like friction between the ends of the specimen and the loading platens can result in artificially higher compressive strength readings, leading to inaccurate test results.

Key Components of Concrete Break Machines

More than what meets the eye, a concrete break machine is a complex system where various key components work in harmony. One such component is the two-stage hydraulic system, which includes reliable hydraulic valve controls that manage the loading process and prevent over-extension of the hydraulic ram. The load frame, typically constructed from high-strength metals like steel, must have sufficient frame openings or daylight openings to handle varying specimen sizes.

The components of a testing machine include:

• The actuator, which can be hydraulic or servo-electric, applies force to the specimen.
• A load cell measures the force applied by the actuator and translates it into an electrical signal.
• The machine&#;s crosshead and grip assemblies secure the load cell and the specimen, ensuring consistent application of load.
• The control panel serves as the interface for the operator to configure and oversee testing parameters like test speed and load limits.

Types of Concrete Break Machines

To cater to a wide array of needs, concrete break machines are available in various forms. High-capacity machines with appropriate safety features are essential for reducing the risk of accidents during compression testing. Depending on the specimen types like:

• cylinders
• cubes
• cores
• prisms
• beams

Additional accessories might be required to adapt the compression machine.

We&#;ll explore the two main types: manual and hydraulic compression testing machines.

Manual Compression Testing Machines

Manual concrete compression testing machines are commonly used for standard concrete testing applications, including compressive strength testing. They offer the benefit of simple operation, usually involving manual adjustment to apply compressive force to a concrete sample. However, simplicity comes with its challenges.

One operational challenge of manual machines is the requirement for the operator to manually adjust a valve to maintain specified rates of compression. This can be particularly difficult for standards demanding constant low-speed testing. As such, while manual machines are often sufficient, they may not always be the best choice for certain testing scenarios.

Hydraulic Compression Testing Machines

In contrast to their manual counterparts, hydraulic compression testing machines are equipped with a continuous duty hydraulic pump. This allows for consistent application of load, eliminating the need for manual pressure adjustments during the test with a compression testing machine.

Hydraulic systems in these machines are often more advanced, featuring two-stage hydraulic systems and hydraulic valve controls. These are essential for precise load regulation and avoiding over-extension of the hydraulic ram. This makes hydraulic compression testing machines a reliable option for tests demanding high precision and consistent load application.

Advanced Features of Modern Concrete Break Machines

Significant advancements have been made in the design of modern concrete break machines compared to their predecessors. They are equipped with:

• Advanced servo-control equipment
• Automatic controllers
• Closed-loop feedback control systems
• Advanced data management capabilities, storing up to tests and managing data points per test

These features are essential for large-scale testing and longitudinal studies.

Automatic data logging ensures detailed information is captured during each test, while their versatility allows them to perform tension, compression, and flexion tests due to their automated control and strain-rate feedback. Let&#;s further explore these cutting-edge features.

Automatic Controllers and Pro Controllers

Automatic controllers in concrete compression machines have the following features:

• Touchscreen interfaces for easy operation
• Ability to control two separate compression frames simultaneously
• Additional channel inputs for advanced testing like extensometer and compressometer testing
• Ability to perform rapid approach and apply initial loads automatically
• Data acquisition systems that record readings per second and enable data export via USB
• Real-time graphing that visualizes the stress-strain curve for immediate material behavior insight.

Pro controllers offer several advantages:

• They are designed with programmability for custom test cycles
• They have modular software architecture for easy updating and addition of new testing standards
• They automate complete test cycles through concrete compression machines with minimal operator input
• They increase efficiency and significantly reduce the possibility of human error.

Achieving Accurate and Repeatable Test Results

Modern concrete compression machines are intentionally designed to:

• Return accurate and repeatable test results, crucial for assessing the compressive strength of concrete and ensuring the safety and reliability of concrete structures.
• Fortify the reliability of these machines through precise operation and calibration capabilities.
• Provide exact force and deformation measurements through advancements such as high-precision load cells and displacement transducers.

Adaptability in testing various concrete specimen types is achieved through the use of specific accessories, such as compressometers and extensometers that measure deformation, strain, and Poisson&#;s ratio, as well as adaptive accessories for different concrete shapes. Moreover, the application of load during testing is meticulously regulated by the concrete compression machine&#;s hydraulic mechanism, providing precise control that ensures consistent test conditions for reliable results.

Selecting the Right Concrete Break Machine for Your Needs

The selection of an appropriate concrete break machine not only depends on understanding their operation but also aligning the testing range and their capabilities with your testing needs. The total capacity of the machine should be at least 20% greater than the expected ultimate load of the specimens to be tested, which can be considered as the indicated load. Also, consider the weight of the machine and its installation requirements which can significantly impact the testing space and portability.

Let&#;s further explore the process of assessing your testing requirements and considering additional features while selecting a machine.

Assessing Testing Requirements

When assessing your testing requirements, one of the first considerations should be the average load rate and the load frame capacities of the concrete break machines, taking into account the live load during the tests. These capacities typically range from 250,000 to 650,000 lbf (1,112 to 2,891 kN). The selection of a machine with the appropriate total capacity should be based on the types of tests it will conduct, including the final load for:

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• Compression tests
• Flexural tests
• Splitting tests
• Modulus of elasticity tests
• Poisson&#;s ratio tests

For example, a machine with a total capacity of KN can test 6x12in cylinders with expected strengths up to about 48.26Mpa, indicating the correlation between specimen size and maximum testable strength. Also, it is essential to choose a machine with daylight openings large enough to accommodate the biggest specimen size to ensure ease of handling during tests.

Considering Additional Features and Options

In addition to assessing your testing requirements, you might also want to consider additional features that can enhance your testing experience and results. Some of these features include:

• High-resolution color touchscreen displays for accurate precision machine operation, setup, and calibration
• Motor-control knobs for precise calibration load adjustments
• Support for calibration with 1 to 10 points in any chosen increment

These features can help improve the accuracy and efficiency of your testing process.

Adaptive accessories can enhance machine functionality and versatility, allowing testing of various sample types and shapes. However, bear in mind the weight and installation requirements of model-specific accessories. For instance, heavy accessories might necessitate carrier bracket options.

Proper Use and Maintenance of Concrete Break Machines

To ensure the longevity and precision of concrete compression break machines, their proper use and maintenance are of utmost importance. They should be equipped with safety features like fragment guard doors to handle explosive failures. Machines must also have the capability to test a range of expected strengths to accommodate different testing scenarios.

We&#;ll now examine how calibration, maintenance, and safety precautions contribute to the effectiveness of these machines.

Calibration and Maintenance

Regular calibration of concrete break machines is essential to the accuracy of compressive strength measurements, maintaining standardized testing procedures. It aids in detecting deviations caused by wear and tear, thus preserving the reliability of test results. Accurate machine calibration directly influences the consistency of test outcomes, which is important for evaluating concrete&#;s quality and structural integrity.

Comprehensive pump inspections, covering components from boom to hopper, should be conducted to ensure adequate lubrication and fluid levels, preventing equipment failure. Interestingly, manual compression machines can be upgraded with automatic controllers to increase automation without incurring the costs of complete equipment replacement.

Meeting industry standards such as ASTM C39 and those outlined in ACI 363 ensures that concrete break machines are appropriately calibrated and maintained.

Safety Precautions during Testing

Safety is paramount when it comes to operating concrete break machines. These machines should be equipped with protective fragment guard doors to manage explosive failures during the testing of high-strength concrete samples. The stiffness of a concrete break machine is crucial for ensuring uniform load application on the concrete strength specimens used, which helps mitigate the risk of explosive failures that can compromise machine functionality and safety.

Over the years, explosive failures during high-strength concrete sample testing have led to the advancement of safety protocols. The development of fragment guards and other safety features for concrete break machines is a testament to the continuous evolution in the pursuit of safer testing environments.

Case Studies: Concrete Break Machines in Action

Concrete break machines, beyond being mere lab equipment, serve as integral tools that shape and reshape our world. They play a pivotal role in large-scale infrastructure projects where ensuring the strength and quality of concrete is crucial. From the Crossrail project in London to the new San Francisco-Oakland Bay Bridge project, concrete break machines have been at the heart of these engineering marvels, verifying concrete strength for essential structures such as:

• bridges
• tunnels
• dams
• highways
• buildings

Let&#;s examine these applications in more detail.

Large-Scale Construction Projects

In the arena of large-scale construction projects, the use of concrete break machines is indispensable. The construction of the world&#;s tallest building, the Burj Khalifa, necessitated stringent testing, which was partly accomplished through the use of concrete break machines. The high-performance concrete used in the building was subjected to a rigorous testing process to ensure it met the necessary strength requirements.

By implementing these thorough checks, the concrete break machines played a pivotal role in upholding the Burj Khalifa&#;s structural safety. This is just one example of how these machines contribute to the safety and reliability of large-scale construction projects, ensuring the concrete used can:

• withstand the stress of these massive structures
• meet the required strength and durability standards
• prevent any potential structural failures
• provide a solid foundation for the entire building

Research and Development Applications

Beyond the construction site, concrete compression break machines play a vital role in research and development, aiding in the design of structures through non-destructive evaluation and acceptance testing. For instance, research at the University of Illinois at Urbana-Champaign utilized concrete compression testing machines to develop ultra-high-performance concrete with improved mechanical properties and durability.

These machines have also been instrumental in research involving mineral additions and admixtures that result in concretes with enhanced durability and mechanical properties. They&#;ve played a key role in the development of eco-friendly concrete mixtures that emphasize sustainability in the construction industry.

Additionally, researchers have tested fiber technology developments for concrete reinforcement using concrete break machines, leading to the introduction of diverse fibers that enhance concrete&#;s performance in:

• industrial flooring
• road construction
• bridge construction
• precast concrete products

and other applications.

Summary

From towering skyscrapers to intricate tunnels, concrete compression break machines are the unsung heroes behind our architectural marvels. These machines are not just about applying force; they are about precision, reliability, and innovation. They test the very fabric of our cities, ensuring the concrete we rely on is up to the task. They&#;ve evolved over time, incorporating advanced features that enhance their functionality and efficiency. Whether you&#;re looking to select a machine for testing needs or aiming to understand their workings better, remember that these machines are more than just equipment&#;they&#;re the guardians of our built environment. So, next time you&#;re admiring a towering structure or driving through a tunnel, spare a thought for the concrete break machines that helped make it possible.

Certified MTP has the largest selection of concrete testing supplies, showcasing industry-leading brands for Concrete Compression Testing Machines, Concrete Air Entrainment Meters, slump testers, Concrete Test Cylinder Molds, and fresh concrete testing equipment.

Frequently Asked Questions

What is a concrete compression machine?

Users employ a Concrete Compression Machine to apply compressive force to various types of concrete specimens, determining if the material meets design and structural strength requirements. This renders it an essential tool in any concrete testing lab.

How does a CTM machine work?

A CTM machine works by applying a compressive load to a material sample until it fails, using a piston that moves up and down inside a cylinder.

How do you carry out a compressive strength test on concrete?

To carry out a compressive strength test on concrete, you need to bring a cured concrete specimen to the lab and apply force until failure, determining the ultimate strength of the sample from the results.

What is the role of concrete break machines?

Concrete break machines, also known as concrete compression machines, apply a controlled load to concrete specimens to test their strength, thus determining their compressive strength, a crucial parameter in building and infrastructure design.

What advanced features do modern concrete break machines have?

Modern concrete break machines have advanced features such as servo-control equipment, automatic controllers, closed-loop feedback control systems, and advanced data management capabilities, allowing for more precise and efficient operation.

For more concrete testing needs, consider the popular Mini-Jaw Crusher

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