The compressive strength of mortar is typically determined using the American Societyfor Testing and Materials (ASTM) standard method using 2 inch cubes which are compressed tillfailure. There is however a disparity between the compressive strengths of mortar cubes, and insitumortar. This disparity is a result of the differences in thickness, aspect ratio, curingconditions, water content, and confinement between mortar cubes and mortar joints. While thesedifferences lead to mortar joints being stronger than mortar cubes, a relationship between theirstrengths is desired.Two less-common mortar strength tests were used to determine more accurately thecompressive strength of in-situ mortar. The results of both tests were compared to the results ofASTM standard compressive testing with mortars of the same water content. The first was theDouble Punch test which involves the use of two metal punches that compress either side of athin mortar sample till failure. The Double Punch test is more difficult to perform than theASTM standard compression test, but was useful because it simulates the confinement that insitumortar will experience. The Double Punch test was also used with mortar specimens ofvarying thickness to determine a relationship between specimen thickness and compressivestrength. The second test used was the Helix Pullout test. This test is performed by insertingmetal helical screws into a mortar joint, and pulling from the joint while restricting rotation. Themaximum load used to extract the Helix is recorded as the Pullout Load, and is used to find thecompressive strength by use of a calibration curve. This test was used on a masonry wall paneland mortar cubes were also made with the same mortar for compressive testing.The tested mortar exhibited decreased compressive strength with increased water content.The mortar also decreased in strength with increasing specimen thickness. Mortar joints wereshown to be significantly stronger than mortar cubes based on factors of specimen thickness andconfinement by an average factor of at least 2.40. Although results are affected by punchdiameter, the Double Punch test was shown to be a consistent and reliable means of estimatingmortar compressive strength. The Helix Pullout test exhibited wide variation, and wasdetermined to be primarily useful for qualitative comparison as opposed to quantitativedetermination of strength.

Mortar is the cementitious binding material placed between masonry blocks to create a composite system. The American Society of Testing and Materials (ASTM), along with other organizations, have established the testing of prismatic mortar specimens for evaluating mechanical properties, like compressive strength. Mortar joints, however, possess vastly different characteristics compared to prismatic specimens, especially in terms of geometry and water content. These differences prevent a direct comparison of compressive strength between prismatic specimens and actual mortar joints in the assembly. The objective of this study was to analyze Type S mortar joints, with particular emphasis on specimen shape and water content, to draw accurate comparisons of compressive strength to ASTM prescribed mortar prismatic specimens.To examine the effect of water on mortar compressive strength, three different water contents were evaluated across nearly all testing series. Cubic (2-in) and cylindrical (2 by 4-in) mortar specimens were prepared and tested according to ASTM guidelines to verify the compressive strength relationship described by ASTM and to be used as comparative data. In addition, a small masonry wall was assembled and cured in a laboratory to simulate true properties of mortar joints. Mortar joints subjected to testing were a combination of thin slices cut from prismatic specimens as well as in-place bed joints cured between concrete masonry units (CMU). Two unorthodox test methods, the double punch test (DPT) and helix pull-out test (HPT), were selected as methods for assessing mortar joints. In addition, confining effects from neighboring material common to DPT were evaluated as a function of specimen face dimensions. The compressive strength ratio obtained through testing of 2-in cubic and 2 by 4-in cylindrical specimens was lower than ASTM recommendations. This may have been in part due to testing cylindrical specimens with rough surfaces and no capping material. DPT confinement on 2-in square and 2-in diameter circular specimens was found to be equivalent. Thinly sliced specimens tested in DPT showed increases in compressive strength as water content and specimen thickness decreased. As a whole, DPT results on thin mortar slices showed promise for accurate comparison to prismatic mortar specimens. In-place mortar joints tested in HPT showed moderate to high scatter. In addition, evaluation via HPT was determined to be more appropriate for qualitative rather than quantitative assessments of in-situ mortar.

Os avanços na utilização do concreto reforçado com fibras (CRF) para fins estruturais trazem cada vez mais a necessidade de se desenvolver ensaios práticos que possam controlar o material, analisando a capacidade resistente residual do compósito para diferentes níveis de abertura de fissura. O ensaio de duplo puncionamento (EDP) é uma promissora alternativa nesta direção, uma vez que haja uma correlação já comprovada com outros métodos de ensaio bem estabelecidos. Este trabalho objetivou investigar a repetibilidade e reprodutibilidade do EDP, considerando os parâmetros de cargas de fissura da matriz cimentícia e cargas residuais, verificando se existe igualdade de médias e igualdade de variâncias nas diferentes situações criadas, para 95% de confiabilidade. A repetibilidade foi avaliada por meio de um programa experimental, com moldagem dos corpos de prova no Centro de Pesquisa e Desenvolvimento da Construção Civil - CPqDCC, da Escola Politécnica da Universidade de São Paulo, envolvendo dois teores de fibra de aço com ancoragem em gancho (30 kg/m³ e 55 kg/m³) em três séries iguais de moldagem. A reprodutibilidade foi avaliada em um programa interlaboratorial, com participação de 6 laboratórios independentes e empregando a mesma fibra e teores. Como ferramentas para comparação dos resultados e avaliar se houve repetição e reprodução dos parâmetros do ensaio, foi utilizada análise de variância (ANOVA) e a metodologia da ASTM E691. Os resultados mostraram que foi possível obter repetibilidade e reprodutibilidade de médias para os parâmetros de cargas residuais com um número limitado de corpos de prova. No entanto, as variâncias são mais sensíveis que as médias, e não mostraram repetição total quando a homogeneização das fibras no volume total do concreto é prejudicada. Ainda, as cargas de fissuração do ensaio (Pf) não se mostraram totalmente repetíveis e nem reprodutíveis, pois podem ser afetadas pela máquina de ensaio e operador. / The advances in the use of fiber reinforced concrete (CRF) for structural applications bring the need to develop more practical tests to control the FRC by analyzing the residual strength of the composite for different crack openings levels. The double punch test (DPT) is a promising alternative in that sense, once a correlation with already proven test methods is achievable. This work aimed to investigate the repeatability and reproducibility of the DPT, considering the parameters of crack load and residual loads, verifying if there is equality of means and equality of variances in the different situations created, for 95% reliability. The repeatability was evaluated by an experimental program, with the specimens molding at the Research and Development Center in Civil Construction - CPqDCC, at the Polytechnic School of the University of São Paulo, involving two hooked end steel fiber contents (30 kg/m³ and 55 kg / m³), in three equal molding series. The reproducibility was evaluated in an interlaboratory program, with the participation of six independent laboratories, and using the same fiber and contents. The analysis of variance (ANOVA) and the ASTM E691 methodology were applied as a tool to compare the results and to evaluate if there were repetition and reproduction of the test parameters occurred. Together with these tools, an inductive test was used on the reproducibility specimens to verify the scatter of the fiber among them. The results showed that it was possible to obtain repeatability and reproducibility of means for the parameters related to the residual loads. However, the variances are more sensitive than the means, and did not show total repetition when the homogenization of the fibers in the total volume of the concrete is compromised. Moreover, the cracking loads of the test (Pf) were not totally repeatable and reproducible, as they can be affected by the testing machine.

The objective of this study is to develop test protocols for comparing the effectiveness of fiber-reinforced concrete (FRC) mixtures with high-performance steel fibers. Steel fibers can be added to fresh concrete to increase the tensile strength, ductility, and durability of concrete structures. In order to quantify steel fiber-reinforced concrete (SFRC) mixtures for field applications, a material test capable of predicting the performance of SFRC for field loading conditions is required. However, current test methods used to evaluate the structural properties of FRC (such as residual strength and toughness) are widely regarded as inadequate; a simple, accurate, and consistent test method is needed. It was determined that the Double-Punch Test (DPT), originally introduced by Chen in 1970 for plain concrete, could be extended to fiber-reinforced concrete to satisfy this industry need. In the DPT, a concrete cylinder is placed vertically between the loading platens of the test machine and compressed by two steel punches located concentrically on the top and bottom surfaces of the cylinder. It is hypothesized that the Double-Punch Test is capable of comparing future fiber-reinforcement design options for use in structural applications, and is suitable for evaluating FRC in general. The DPT Research and Testing Program was administered to produce sufficient within-laboratory data to make conclusions and recommendations regarding the simplicity, reliability, and reproducibility of the DPT for evaluating the performance of SFRC. Several variables (including fiber manufacturer, fiber content, and testing equipment) were evaluated to verify the relevance of the DPT for FRC. In this thesis, the results of 120 Double-Punch Tests are summarized and protocols for its effective application to fiber-reinforced concrete are recommended. Also, fundamental data is provided that indicates the DPT could be standardized by national and international agencies, such as the American Society of Testing and Materials (ASTM), as a method to evaluate the mechanical behavior of FRC. This project is sponsored by the Texas Department of Transportation (TxDOT) through TxDOT Project 6348, "Controlling Cracking in Prestressed Concrete Panels and Optimizing Bridge Deck Reinforcing Steel," which is aimed at improving bridge deck construction through developments in design details, durability, and quality control procedures. / text

Um modelo de controle de qualidade é confiável quando devidamente vinculado a um modelo de dimensionamento de estruturas. O fib Model Code 2010 apresentou um modelo de dimensionamento e controle do concreto reforçado com fibras (CRF) para fins estruturais baseado no ensaio de flexão de prismas com entalhe (EN 14651), mas indica que outros métodos de ensaio podem ser aplicados através de correlação comprovada com o método de referência. Há dificuldades para a utilização do ensaio EN 14651 no Brasil, pois demanda máquinas de ensaio sofisticadas que dificilmente são encontradas em laboratórios de controle tecnológico. O ensaio de duplo puncionamento é um método alternativo para o controle do comportamento mecânico do CRF e utiliza máquinas de ensaio mais simples. No entanto, alguns estudos observaram que podem ocorrer instabilidades após a ruptura da matriz quando são usados CRFs com elevada força da matriz e baixa força residual pós-fissuração. Estas instabilidades ocorrem devido a alguns fatores dentre eles o sistema de controle de ensaio. As instabilidades podem comprometer a avaliação do material. Assim, esta pesquisa estudou os sistemas de controle para o ensaio de duplo puncionamento. Os ensaios foram realizados em máquinas com sistema aberto e fechado e com controle por deslocamento vertical da máquina e deformação do corpo de prova, para verificar se as instabilidades causadas após a fissuração da matriz comprometem a determinação da resistência residual. Os resultados mostraram que, quando os ensaios de duplo puncionamento são realizados em máquinas com sistema aberto, a instabilidade pós-fissuração é maior. No entanto, não influencia negativamente a determinação da resistência residual. Portanto, o ensaio de puplo puncionamento, mesmo realizado em máquinas com sistema aberto, pode ser utilizado como uma alternativa confiável para o controle tecnológico do CRF, estabelecendo como parâmetros de controle valores de forças residuais para determinados deslocamentos verticais. / A quality control model is reliable when properly linked to a structural design model. The fib Model Code 2010 presented a design model of fiber reinforced concrete (FRC) for structural applications where the control of the material is based on the notched beam test (EN 14651). However, this Code indicates that other test methods can be applied as long as proven correlation with the reference method. There are obstacles to the use of the EN 14651 test method in Brazil, as it requires sophisticated testing machines that are difficult to find in laboratories dedicated to quality control. The double punch test is as an alternative test method to control the mechanical behavior of FRC and requires simpler test machines. However, some studies have observed post-peak instabilities in FRC with high matrix strength and low post-crack residual strength low fiber contents are used. These instabilities occur due to some factors including the test control system. The instabilities may compromise the evaluation of the material. Thus, this research studied the control systems for the double punch test. Tests were performed in open and closed-loop test machines and with control by machine displacement and by deformation of the specimen to verify if the instabilities caused after the matrix cracking compromise the determination of residual strength. Results showed that when open-loop test machines are employed, post-crack instability is greater. However, it does not influence the determination of residual strength negatively. Therefore, the double punch test, even when performed in open-loop test machines, may be used for the routine analysis and characterization of FRC, establishing as control parameters residual forces values for certain axial displacement.

[pt] O presente trabalho investigou o comportamento mecânico do concreto projetado com fibras aplicado nas escavações da mina Cuiabá e o seu controle tecnológico através do ensaio de duplo puncionamento. Para essa pesquisa utilizouse o traço desenvolvido pelos engenheiros da mina Cuiabá com dois tipos diferentes de fibra sintética e uma fibra de aço. Inicialmente, caracterizou-se o material compósito através de ensaios de flexão em prismas (EN 14651) e de arrancamento. Em seguida, os resultados obtidos foram utilizados em conjunto com os ensaios de flexão em painéis circulares (ASTM C1550), quadrados (EN 14488-5) e de larga escala para o dimensionamento do sistema de suporte utilizado na mina Cuiabá. As frações mais baixas de fibras sintéticas são mais indicadas nos locais onde a qualidade da rocha é razoável ou boa, enquanto as fibras de aço podem ser aplicadas onde a qualidade do maciço rochoso é classificada como muito fraca. Em relação ao controle tecnológico do concreto com fibras, os ensaios de duplo puncionamento realizados em máquinas mais rígidas são mais eficientes em diminuir a extensão da instabilidade pós-fissuração, limitar os erros nas correlações com os ensaios de flexão (EN 14651) e em reduzir a variação das propriedades mecânicas do material. A aplicação do ensaio de duplo puncionamento com controle fechado pela corrente extensométrica foi o método mais efetivo em limitar a instabilidade pós-fissuração independente da máquina de ensaios selecionada. / [en] The present work investigated the mechanical behavior of the fiber reinforced shotcrete applied at the Cuiabá mine excavation and its quality control through the double punch test. For this research, the mix composition was developed by Cuiabá mine Engineers with the addition of two different types of synthetic fibers and one steel fiber. Firstly, the cement based composite was studied at the material level through bending (EN 14651) and pullout tests. Thereafter, the support system of the Cuiabá mine excavation was designed based on round (ASTM C1550), square (EN 14488-5) and large scale panel tests. The application of lower synthetic fiber volume fractions was more suited for the areas with good quality rock indexes, while steel fibers were better suited at field with lower rock classes. Regarding the quality control of FRC, the double punch tests that were conducted in stiffer testing machines were more effective in reducing the post-peak instability, in limiting the errors in the correlations with bending tests (EN 14651) and in reducing the mechanical properties variations of the material. Finally, the application of the double punch test with closed-loop control of the circumferential extensometer turned to be the most effective method in limiting the post-peak instability regardless of the selected machine.