919

H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929
THE IMPACT OF THE TIME WHEN CASTING THE SECOND
LAYER OF CONCRETE ON ITS MECHANICAL PROPERTIES
H. A. Mohamadien
Civil Engineering Department, Faculty of Engineering, Suez Canal University, Ismailia, Egypt,
Email: [email protected]
Received 16 March 2013, accepted 30 April March 2013
ABSTRAT
Cold joint is one of concreting problem due to delay of casting the second layer. This is due to
glitch of one of mechanical machines such as the concrete mixer, concrete truck, concrete batching
plants, concrete pumps, and concrete mobile; that cause the stopping of the casting process which
produce forced separator. Forced separation is different from known separators like: construction
joint, expansion joint and settlement joint, where its location event and shape cannot be determined
moreover the design engineer cannot put that in mind during the design phase of building
construction. Therefore, the target in this work is to study the effect of delay in time period when
casting the second layer of concrete after 4, 9, and 16 hour for two types of concrete with
compressive strength 250 kg/cm2 and 300 kg/cm2. Eexperimental work was performed at laboratory
to investigate the mechanical properties of concrete (compressive strength, splitting tensile strength
and flexural strength), first when sprinkle the first layer with water before casting and second when
coated with a grout material.The results were investigated and it indicates that, in case of delaying
in the time period for casting the second layer, there is a great effect on the mechanical properties of
concrete and the use of grout coating material in forced separation has a positive impact on
improving its mechanical properties.
Keywords: delay in casting concrete, forced separation, concrete joints
1. Introduction
Processes of casting concrete in flat slabs, raft foundation and massive concrete may be
faced delay in time period due to many reasons, such as glitch in casting machine that
causes the stopping of the casting process for a period that can produce a forced layer
separation. Therefore, knowledge of the setting characteristics of concrete is rather
important in the field of concrete construction, these will help in scheduling the various
stages involved in concrete construction operations such as transporting, placing,
compacting and finishing of concrete. Setting of concrete is the gradual transition from
liquid to solid, and the definition of any point at which the paste is considered set, is
somewhat arbitrary, Nevi Alle and A.M. [1]. Final setting of concrete relates to the point
where stresses and stiffness start to develop in freshly placed concrete. It has been reported
that the initial thermal gradient at setting (built-in curling) has a major impact on the long-
term performance of jointed concrete pavement, Yu et al [2]. Placing of concrete may be
delayed from the time of mixing due to many reasons. The investigation carried out by R.
Sri Ravindrarajah[3], it showed that although the delay causes considerable loss in
workability, there was no detrimental effect on compressive strength for concretes with or
without set-retarding admixture or superplasticizer. Incremental addition of
superplasticizer was capable of maintaining the concrete slump within a small variation

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929
throughout the delay period. The effectiveness of superplasticizer to improve the
workability was found to be a function of initial slump and the age of fresh concrete. Initial
and final setting times can be estimated within practicable ranges provided that mixture-
specific setting-maturity relationship and activation energy are used, S. A. Wade [4].

2. Materials used in mixture

2.1. Concrete material

Concrete mix was prepared from available local materials, natural siliceous sand, crushed
dolomite from Ataka quarries, ordinary Portland cement (OPC) and tap drinking water.
These materials were tested according to the relevant Egyptian Standard Specifications.
The physical and mechanical characteristics of the fine and coarse aggregates are shown in
Tables (1 and 2) respectively. The test results indicate that both fine and coarse aggregates
comply with the limits of Egyptian Standard Specifications No.1109-2003 [5]. Ordinary
Portland cement was used in preparation all concrete mixes; Table (3) shows the physical
and mechanical characteristics of the used cement.
Table 1
Physical properties of fine aggregate

Property Results Limits of ESS 1109[5]

Specific Weight 2.50 2.5 - 2.75

3
Bulk Density (t/m ) 1.73 -----
Clay and Fine Dust Content (% By Volume) 0.76 Not more Than 3

Table 2
Physical and mechanical properties of coarse aggregate
Property Results Limits of ESS 1109[5]
Specific Weight 2.52 -----
3
Bulk Density (t/m ) 1.51 -----
Water Absorption % 2.05 Not more than 2.5
Abrasion Index (loss Anglos apparatus) % 23.3 Not more than 30

2.2. Bonding materials (grout)

Grout consists of a cementations mix with grey colour and density 1.7 kg/ l mixed with
water of ratio water/grout 2:1 to produce a used liquid mortar, it used for bonding between
the old and new concrete.

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929
Table 3
Physical properties of ordinary Portland cement
Property Results Specifications Limits[6]

Compressive Strength of Standard 3 days 21.4 Not less than 18 *

Mortar (Map) 28 days 39.7 Not less than 36 *
2
Specific surface area (cm /gm.) - 3120 >2750 *
Initial 135 Not less than 45 *
Setting Time ( min )
Final 180 Not more than 600 *

* Egyptian Code of Practice for Concrete Structures No. 203-2007[6]

3. Experimental program

3.1. Concrete mixes

The method of mix design in this work was the absolute volume method and the following
equation was used,

Where C, S, G, W, is Cement, Sand, Gravel and Water respectability in kg/m3 and Ɣ is the
specific weight. Two mixtures were used with compressive strength 250kg/cm2 and
300kg/cm2 and the slump test for both of them was 10±2cm. Table (5) shows composition
of designed mixtures.
Table 5
Concrete mixture proportions at slump = 10±2cm

Materials compressive strength

250 kg/cm2 300 kg/cm2
Cement (kg/m3) 322 367
Water (kg/m3) 200 200
3
Natural sand (kg/m ) 447 412
3
Crushed stone (10 mm) (kg/m ) 671 680
3
Crushed stone (20 mm) (kg/m ) 549 556
Water/cement 0.62 0.55

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929
3.2. Tests procedure
Tests were done according to Egyptian Standard Specification “Testing of Concrete” [7].
Factors taken in consideration during experimental work were as follow:
a. Slump test conducted on fresh concrete to determine the slump value for the two types
of the concrete.
b. The casting directions of concrete were parallel to the direction of separator and the
other was perpendicular to it. Figure (1) shows the casting directions.

Fig. (1)
c. The separator in concrete molding, paint once with grout and the other sprinkle with
water
d. Two type of concretes 250 kg/cm2 and 300 kg/cm2 were used in the experimental
program.
e. The second layer of concrete was cast after 4, 9 and 16 hours for these two types of
concrete with compressive forces 250 kg/cm 2 and 300 kg/cm2
f. all the cast specimens were covered by plastic sheets and left in the laboratory at
203c for 24 hour then transferred to a saturated water curing tank at 25c until the age
of testing.
g. Three concrete cubes with side length 150mm for each type of concrete were casting
taking into consideration direction and the time period of casting the second layers that
were tested for compressive strength at 28 days after curing.
h. Three cylinder molds with dimension 150mm×300mm were casting taking into
consideration direction and time period of casting the second layers that were tested for
determination of splitting tensile strength at 28 days after curing.
i. Three beams of dimensions 100mm×100mm×500mm were casting taking into
consideration direction and time period of casting the second layers that were tested for
the determination of flexural strength at 28days after curing as shown in Figure (2).

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929

Fig. (2)
4. Results and discussion
4.1. Compressive strength
Figure (3) shows relation between relative compressive strength when casting the second
layer of concrete of 250 kg/cm2 and time when the concrete separator will be in the same
direction of test loading. It was noted that the compressive strength was decreased with
increasing the time period between casting of the first and second layer, and had no major
effect on compressive strength at time 4 and 9 hours when coated the separation between
the two layers by grout or water. The compressive strength of concrete was decreased by
15% when the second layer was casted after 16 hour in case of splashing the separator with
water while decreased by 11% when coating the separator with grout, this may be due to
the effect of finial sitting of cement. Figure (4) shows the relationship between the relative
of compressive when casting the second layer of concrete 300 kg/cm2 after 4, 9, 16 hours
of time casting the first layer. It can be noticed that: there was a good influence on the
properties of the compressive strength when painting the separator with material grout at
time 4, 9 and 16 hours during casting the second layer of concrete and has no major effect
when splashing the separator with water. The reduction in the compressive strength was
(3% and 4% and 7%) at time 4, 9 and 16 hour when painting the separator with grout while
it was (8% and 11% and 14%) when splashing the separator with water respectively, due to
the enhancement of grout on bonding between the two layers.
Figure (5) shows Relationship between compressive strength of concrete 250, 300 kg/cm2
and time when the separator is in same direction of load while painting the separator with
and without grout. It was observed that the impact of grout on concrete target 300 kg/cm2
has more effect than target 250 kg/cm2 when the separator paint with grout.

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929

Fig. 3. Relative Compressive strength and delay in time when the separator is in
same direction of load test of concrete 250 kg/cm2

Fig. 4. Relative Compressive strength and delay of time when the separator is in
same direction of load test of concrete 300 kg/cm2

4.2. Splitting tensile strength

Figure (6) present the relation of the splitting tensile strength and different times casting
the second layer of concrete target 250kg/cm2. It was observed that: The tensile strength of
concrete mixtures at casting the second layer of concrete after (4 and 9 hours), has no
major effect on splitting tensile strength. While at casting the second layer of concrete with
grout after (16 hours), it has a slight decrease in the tensile strength of concrete. The tensile
strength of concrete without grout is reduced by 11%, comparing with control mixtures at
28 days.
Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929

Fig. 5. Relative Compressive strength and delay in time when the separator is in
same direction of load test of concrete 250, 300 kg/cm2
Figure (7) presents the relative of the splitting tensile strength and different times casting
the second layer of concrete target300kg/cm2. It was observed that the tensile strength of
concrete mixtures at casting the second layer of concrete with grout after 4 and 9 hours,
has no major effect on tensile strength, After 16 hours, there is a slight decrease in the
tensile strength of concrete by 7%.At casting the second layer of concrete without grout
after 4 and 9 hours, there is a reduction in the compressive strength by 3% and 12%
respectively. On the other hand, the tensile strength of concrete without grout after 16
hours is reduced in the tensile strength by 27%, comparing with control mixtures at 28
days.

Fig. 6. Relative of splitting tensile strength and delay in time of concrete 250
kg/cm2
Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929

Fig. .7. Relative splitting tensile strength and delay in time of concrete 300 kg/cm2
Figure (8) shows Relationship between splitting tensile strength of concrete 250, 300
kg/cm2 and time when the separator is in the same direction of load when painting the
separator with and without grout. It can be seen that the impact of grouts on concrete target
300 kg/m2 has more effect than target 250 kg/cm2 when the separator paint with grout.

Fig. 8. Relative splitting tensile strength and delay in time of concrete 250, 300
kg/cm2

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929
4.3 . Flexural strength
Figure (9) present the relation of the flexural strength and different times casting the
second layer of concrete target 250kg/cm2. It was observed that: The flexural strength of
concrete mixtures at casting the second layer of concrete with or without grout after (4
hours) is reduced in the flexural strength by 10%. On the other hand, at casting the second
layer of concrete with grout after (9 and 16 hours) there is a decrease in the flexural
strength of concrete by (22% and 35%) respectively. The flexural strength of concrete
without grout is reduced by (25% and 40%) respectively, comparing with control mixtures
at 28 days.
Figure (10) presents the relation of the flexural strength and different times casting the
second layer of concrete target 300kg/cm2. It was observed that, the flexural strength of
concrete mixtures at casting the second layer of concrete with grout after (4 hours), has no
effect, while the flexural strength of concrete without grout, and is reduced in the flexural
strength by 12%. At casting the second layer of concrete with grout after (9 and 16 hours)
there is a decrease in the flexural strength of concrete by (9% and 30%) respectively, while
the flexural strength of concrete without grout is reduced in the flexural strength by (20%
and 43%) respectively, comparing with control mixtures at 28 days.
Figure (11) shows Relationship between flexural strength of concrete 250, 300 kg/cm2 and
time. In case of the separator is in perpendicular direction of test load while painting the
separator with and without grout. It can be seen that the impact of grouts on concrete target
300 kg/m2 was more effect than target 250 kg/cm2 at time 4 and 9 hour.

Fig. 9. Relative flexural strength and time with grout and without grout of concrete
250 kg/cm2

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929

Fig. 10. Relative flexural strength and different delay in time with and without
grout of concrete 300 kg/cm2

Fig. .11. Relative flexural strength and delay in time with grout and without grout
for 250 kg/cm2 &300 kg/cm2

5. Conclusions
This paper presented the mechanical properties of concrete contains cold joint treated with
grout and without grout after (4, 9 and 16 hours). The study results are summarized as
follows.

Journal of Engineering Sciences, Assiut University, Faculty of Engineering, Vol. 41, No. 3, May,
2013, E-mail address: [email protected]
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H. A. Mohamadien, the impact of the time when casting the second layer of concrete on its
mechanical properties, pp.919 - 929
1- By increasing the time casting the second layer of concrete, the compressive, splitting
tensile and flexural strengths of concrete will decrease.
2- The use of grout for treat the first layer just before casting the second layer will
improve the mechanical properties of concrete.
3- The mechanical properties of concrete grade 300kg/cm2 are more influence than
concrete grade 250kg/cm2.
4- The effect of grout on mechanical properties of concrete appears at 16 hour and has
low effect at 4, 9 hour.

6. References
[1] A. M., Nevivalle, 'Properties of concrete', 4th Edn, (John Wiley and Sons,
Incorporated, New York, 1996).
[2] Yu, H.T., Khazanovich, L., Darter, M.I., and Ardani, A., 'Analysis of concrete
pavement responses to temperature and wheel loads measured from instrumented
slabs', Transportation Research Record 1639 (1998), 94-101.
[3] R. Sri Ravindrarajah, May, (1985) “Casting delay on workability and strength of
concrete”, International Journal of Cement Composites and Lightweight Concrete,
Vol. 7, Issue 2, Pages 109-113
[4] S. A. Wade, J. M. Nixon, A. K. Schindler (2010) “Effect of Temperature on the
Setting Behavior of Concrete” journal of Materials in Civil Engineering, pp. 214-222.
[5] Egyptian Standard Specification for Concrete Aggregates from Natural Sources
No.1109, Egyptian General Authority for Standard Specifications, Egypt, 2003.
[6] Egyptian Code of Practice for Design and Construction of Reinforced Concrete
Structures, No. 203, Housing & Building National Research Center, Egypt 2007.
[7] Egyptian Standard Specification No.1658, Part 2, Concrete Testing, Committee
Compatibility No. (2/11), Egyptian General Authority for Standard Specifications,
Egypt, 2007.

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:‫الملخص‬
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‫ساع ل عي ن ال رسان ع ق‬61 ،9 ،4 ‫ه اس تأثيرال أخر في الف ر ال م ي لص الط ق الثاني من ال رسان بع‬
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‫ ع ها الط قه اا ل من ال رسانه ب ا الجر تق الصب الط قه الثانيه‬:‫ثانيا‬
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