Reasons for cube failure

Introduction

At project site, we conduct concrete cube testing to check compressive strength of laid concrete.
If we get designed strength in testing, we can say that our structures are safe from compressive
strength point of view. At present at various projects across India cube failure occurs frequently,
which becomes major concern for all agencies involved in it like contractor, consultant, client and
TPIs. In this article various possible reasons are discussed in brief which may directly or indirectly
affect the compressive strength of concrete.

Identification of Various Reasons of Cube Failures In Different Stages

1. Before casting of cubes,
2. During casting of cubes,
3. During preservation of cubes
4. During testing of cubes.
5. Training and involvement of Sr. people.

1. Before Casting Cubes

1.1. Cube mould issues involved
Cube mould dimension are not as per specification.
Cube moulds screws are not properly tighten.
Oiling not done properly in cube mould.
Binding wire used instead of screws in cube mould.
Cube moulds are not cleaned properly.
Cube mould sizes not checked at regular interval.

1.2. Material testing issues involved

Cement not tested for every batch.
Cement strength not achieved as per cement grade.
10 mm, 20 mm, sand not tested and used as per specification/mix design.
Temperature not maintained for concrete/raw materials.
Admixtures dosage not maintained in concrete as per mix design.

1.3. Produced Concrete issues involved

Concrete produced with more water cement ratio.
Slump not maintained as per mix design.
Concrete not properly mixed before cube casting.
Concrete not consumed within specified time limit as per PSQP.
2. During Cube Casting

2.1. Cube casting procedure issues involved

Concrete Cube moulds are not tamped properly as per specification in 3
layers.
More & less vibration/tamping results into difference of results and failure of
cubes.
Cube moulds are cast by untrained helper.
Frequent change in manpower engaged in cube casting. More than one
helper engaged in cube casting for single concrete work.
Lack of supervision in cube casting.
If cubes are taken at the end of concrete work, due to closing of work, there
is more chance of improper cube casting.
Cube not casted within specified time limit. Fast and slow cube casting
results into cube failures. Consistency not maintained in cube casting.
Cube numbering not given.
Cube moulds are not casted on levelled ground surface.
Cube not levelled & finished from top after casting.

3. During Preservation of Cubes

3.1. Cube handling and curing issues involved

Cubes are not placed under shed after casting.
Improper handling/shifting of cast cubes.
Cubes are not placed in Curing tank after 24hrs.
Curing tank not full of water. Cubes not submerged in water. Minimum 25
mm water should remain above cubes throughout 28 days and till testing
carried out.
Curing tank was not covered with shed from top.
Curing tank not cleaned properly at regular interval. Muddy water/organic
matter inside curing tank.
Curing tank water temperature not maintained at 27 2 C

4. During Testing of Cubes

4.1. Cube testing procedure issues involved
Cube not tested as per numbering.
Cubes not placed at center of testing plate in CTM.
The testing cubes should be arranged in CTM machine in centre in such a way
that the load acts on the central axis of the cube.
Load should not be applied directly on top and bottom face of the cube. Load
should be applied at side of cubes.
Fast or slow rate of loading applied instead of as given in no. 6
Apply the load gradually without shock and continuously at the rate of 140
kg/ cm2/ minute till the specimen fails.
 4.2. CTM issues involved
CTM machine not calibrated.
Sudden power failure.
Dial gauge failure.
Dial gauge movement is not proper due to weather change or other reason.
CTM bottom plate not cleaned properly.

5. Training and Awareness

5.1. Training issues involved
Site engineer not aware of cube casting procedures.
Helper who casts cube, not received training of cube casting.
Awareness of cube casting lacking at site.
Standby trained helper for cube casting not available at site.
Cube identification training not given to helper.
Seriousness and impact of cube failures in project not explained to technician
and helpers.

5.2. Less involvement of Sr. People in testing

Lack of importance/seriousness of cube testing at site.
Less involvement of senior people for cube casting and cube testing.
Less awareness of adverse impact of cube failure in project.