Material testing and analysis

Our interdisciplinary team can provide answers to questions relating to the manufacture and application of cement and concrete in line with the latest state-of-the-art. At the same time we can offer our customers a range of services encompassing all important testing activities and consultation work, right through to complex expert reports. Up-to-the-minute research and a professional attitude towards service combine to produce synergies which are reflected by the high quality and practical relevance of our work.

Main focus of our services

a) Material characterisation

With our qualified personnel and accredited laboratories, we are able to perform extensive analysis of numerous substances for you, including the chemical and mineralogical composition of cements and the raw materials and constituents of these, as well as of other binders, right down to trace level.
You can rely on the experience we have gained from performing more than 50,000 analyses per year on the following for example:

Cements and constituents such as clinker, limestone, blast furnace slag, trass, fly ash, burnt shale and clay, silica fume; sulphate agents, e.g. gypsum, anhydrite; raw meal; kiln dust
Mineral raw materials, e.g. clays, marl
Lime and lime products
Admixtures and additives for concrete and mortar, pigments
Fossil and alternative fuels
Aqueous solutions, e.g. eluates of concretes and mortars

Physical analyses
Service	Method
Bulk density	EN 459-2
Water demand	EN 196-3 or Punkte method
Water retention	EN 413-2
Penetrometer measurements, penetration	EN 413-2, DIN 4211
Flow diameter	DIN 1164 or ASTM C 185
Standard consistency	EN 413-2, EN 459-2, or ASTM C 185
Air content of fresh mortar	EN 459-2
Setting time	EN 196-3 or EN 480-2
Soundness	EN 196-3, DIN 1164, or ASTM C151
Flexural and compressive strength	EN 196-1
Determination of zeta potential	Electroacoustic measurement method
Thermal analysis	DSC up to 600 °C, TG/DTA (STA) up to 1500 °C
Determination of net and gross calorific value	Combustion calorimetry
Heat of hydration	EN 196-11
Sulphate resistance	SVA, Wittekindt, CEN method
Alkali-silica reaction (ASR)	Accelerated mortar bar test (DAfStb, RILEM AAR-2)

Chemical analyses
Service	Method
Standard analyses of cement, clinker and other cement constituents, e.g. CO₂ content, ignition loss, insoluble residue, sulphide, chloride, alkalis (sodium oxide (Na₂O), potassium oxide (K₂O))	DIN EN 196-2
X-ray fluorescence analysis (CaO, SiO₂, Al₂O₃, Fe₂O₃, MgO, K₂O, Na₂O, SO₃, Mn₂O₃, TiO₂, P₂O₅, S²-, Cl)	Pressed or fused tablet DIN EN 196-2
Alkalis in concrete admixtures	DIN EN 480-12
Chlorid in concrete admixtures	DIN EN 480-10
Ion chromatography	DIN EN ISO 10304-1, DIN EN ISO 14911
Metals, metalloids (trace analysis), possibly including microwave assisted digestion(As, Ag, Al, B, Ba, Be, Ca, Cd, Cr, Co, Cu, Fe, Hg, K, Mg, Mn, Mo, Na, Ni, P, Pb, Rb, Sb, Se, Si, Sn, Sr, Te, Ti, Tl, V, W, Zn (further elements on request)	DIN EN ISO 17294-2, DIN EN ISO 12846-2, DIN EN 13565, DIN EN 13657, DIN EN 15587-2, DIN EN 15411, DIN 22022-1, DIN EN 14385, DIN EN 13211, EPA 7473, EPA 30b, EPA 12b
Elementary analysis (H, C, N, O, S)	DIN 51721, DIN 51732, ISO 13878, ISO 20884 DIN EN 15104 DIN EN ISO 16948 DIN EN 15407
TOC and TC	DIN EN 13639
Water-soluble chromate	DIN EN 196-10 or TRGS 613
Fluoride, bromine, sulphite
Aluminium, iron, silicon	(photometric)
Reactive SiO₂	DIN EN 450 / EN 197-1
Reactive CaO	DIN EN 450 / EN 197-1
Free lime	DIN EN 451
Determination of pozzolanicity	DIN EN 196-5
Determination of cement main constituents	CEN / TR 196-4
Fuels - Ash	DIN 51719, DIN EN 15403
Fuels - Volatile constituents	DIN 51720, DIN EN 15402
Fuels - Alkalis, halogens, sulphur, nitrate	DIN EN 14582, DIN EN 15408
Fuels - Total carbon	DIN EN 13639
Fuels - Biogenic component	EN 15440
Fuels - Water	Karl Fischer, ISO 12937
Fuels - Moisture	DIN EN 15414-3, DIN 51718
Fuels - Calorific value	DIN 51900, DIN EN 14918
Analysis of outgassing of volatile components from solids (VOC, CO, NO_x, SO₂)
Organic components	GC-MS or IR spectroscopy
BTEX analysis	VDI 2100, sheet 2
PCB, BTEX, PCP, PAH
Leaching test	DAfStb directive, DIN CEN/TS 16637-2, DEV-S4 / DIN EN 12457-4

Mineralogical analyses
Service
Methylene blue method
Slag content from counting
Light-optical photomicrograph of thin sections and ground sections
Clinker microscopy
Petrography of aggregates
Scanning electron microscopy (SEM) and microanalysis (EDX)
Qualitative and quantitative X-ray diffraction / X-ray diffractometry (XRD), Rietveld refinement

b) Consultation and product optimisation

We would also be pleased to advise you on all aspects of product and process optimisation. Our many years of expertise, our wide range of services and our extensive equipment ideally complement one another. We will work out suitable practical solutions for you in the following areas for example:

Product and process optimisation
Characterisation of Portland cement clinkers (influence of firing and cooling conditions as well as of alternative raw materials and fuels)
Causes of incrustation build-up in cement and lime kilns
Sulphate optimisation of cements (setting behaviour / strengths / interaction with admixtures)
Effectiveness of chromate reducers
Characterisation of new binders
Performance of individual cement constituents
Hydration behaviour of cementitious binders
Action of concrete admixtures
Hygienic properties of cement-bound building materials (e.g. in the drinking water sector)
Approval inspection to obtain national technical approval as SR cement

c) Damage analysis and expert reports

Our experienced interdisciplinary team of scientists, made up of chemists, mineralogists, geologists, physicists and engineers, can advise you on the clarification of damage, for instance in the case of crack formation or surface discoloration on structures and building components made of mortar and concrete. We can assist you with determination of the causes of damage and produce expert reports.

A whole range of high-performance processes is available for the analysis of damaged samples:

Damage analysis and expert reports
Qualitative and quantitative X-ray phase determination
Structural analysis on thin sections employing light microscopy
Structural analysis employing scanning electron microscopy
Phase determination employing thermal analysis
Determination of concrete composition

d) Laboratory reviews, round robin tests and comparison trials

Laboratory reviews, round robin tests and comparison trials permit the customised identification and economic assessment of optimisation potential for analytical methods and laboratory procedures (from sampling right through to results reporting). Depending on the objective, this involves the planning, preparation and implementation of tailor-made reviews (on-site inspection, analyses of data), round robin tests or comparison trials. In particular you can benefit from our many years of international experience in the fields of physical, chemical and mineralogical analysis.

Our reviews provide you with an independent and reliable assessment of the quality of your analyses and existing potential, as well as specific proposals for improvements.

e) Concrete constituents

1) Cement

see above

2) Aggregates

Our accredited testing laboratories, as well as those of our associates, establish the chemical, mechanical and physical properties of aggregates in line with the applicable standards and regulations. We examine the thermal properties of your material and analyse its weathering properties, for example. In addition, we conduct extensive tests on the alkali reactivity (alkali-silica reaction) of aggregates.

Sampling and petrography
Service	Method
Sampling	DIN EN 932-1
Reducing laboratory samples	DIN EN 932-2
Procedure and terminology for simplified petrographic description	DIN EN 932-3

Geometrical properties
Service	Method
Particle size distribution - sieving method	DIN EN 933-1
Particle shape - flakiness index	DIN EN 933-3
Particle shape - shape index	DIN EN 933-4
Percentage of crushed and broken surfaces in coarse aggregate particles	DIN EN 933-5
Surface characteristics - flow coefficient of aggregates	DIN EN 933-6
Shell content - percentage of shells in coarse aggregates	DIN EN 933-7
Assessment of fines: - Sand equivalent test - Methylene blue test - Particle size distribution of filler aggregates (air jet sieving)	DIN EN 933-8 DIN EN 933-9 DIN EN 933-10
Classification test for the constituents of coarse recycled aggregate	DIN EN 933-11

Mechanical and physical properties
Service	Method
Resistance to wear (micro-Deval)	DIN EN 1097-1
Resistance to fragmentation (Los Angeles test)	DIN EN 1097-2
Loose bulk density and voids	DIN EN 1097-3
Voids of dry compacted filler	DIN EN 1097-4
Water content by drying in a ventilated oven	DIN EN 1097-5
Particle density and water absorption	DIN EN 1097-6
Particle density of filler - Pyknometer method	DIN EN 1097-7
Polished stone value (PSV)	DIN EN 1097-8
Water suction height	DIN EN 1097-10
Wehner-Schulze method
Thaulow- method - Bulk density of aggregates with dense microstructure

Thermal properties and weathering properties
Service	Method
Resistance to freezing and thawing	DIN EN 1367-1
Magnesium sulphate test	DIN EN 1367-2
Boiling test for "Sonnenbrand basalt"	DIN EN 1367-3
Resistance to thermal shock	DIN EN 1367-5
Resistance to freezing and thawing in the presence of salt (NaCl)	DIN EN 1367-6

Chemical properties
Service	Method
Water-soluble chlorides using the Volhard method (reference method)	DIN EN 1744-1, Section 7
Water-soluble sulphates	DIN EN 1744-1, Section 10
Total sulphur content	DIN EN 1744-1, Section 11
Acid-soluble sulphates	DIN EN 1744-1, Section 12
Acid-soluble sulphides	DIN EN 1744-1, Section 13
Possible presence of humus	DIN EN 1744 1, Section 15.1
Water solubility	DIN EN 1744-1, Section 16
Ignition loss	DIN EN 1744-1, Section 17
Preparation of eluates by leaching of aggregates	DIN EN 1744-3
Acid-soluble chlorides	DIN EN 1744-5
Influence of recycled aggregate extract on the initial setting time of cement	DIN EN 1744-6

Alkali reactivity (alkali-silica reaction)
Service	Method
Petrographic test	Alkali guidelines of the DAfStb
Percentage of opal sandstone including siliceous chalk
Flint bulk density
Percentage of reactive flint
Accelerated mortar bar test	RILEM AAR-2, Alkali guidelines of the DAfStb, TP B-StB 1.1.11
Accelerated mortar bar test	TP B-StB 1.1.12
Concrete test with fog chamber storage (40 °C)	Alkali guidelines of the DAfStb
60 °C concrete test	Alkali guidelines of the DAfStb or RILEM AAR-4.1
WS aggregate testing	ARS no. 04/2013, V2 method

3) Concrete admixtures

Concrete admixtures are substances added to the concrete in small quantities in relation to the cement content during mixing to alter the properties of the fresh or hardened concrete. These include superplasticisers and plasticisers, air entraining agents, retarders and accelerators, waterproofing compounds and stabilisers, for example. The substances are characterised in accordance with the standards listed in the following table. Special testing services are given by way of example.

Service	Method
Suitability testing for concrete admixtures	DIN EN 480, DIN EN 934
Electrochemical corrosion test	DIN EN 480‑14
Suitability testing of grout for pre-stressing tendons	DIN EN 934-4, DIN EN 445

VDZ can also offer assistance with the approval and certification of corresponding products.

4) Additions

Additions are finely distributed substances added to the concrete to enhance certain properties. Additions are classified as virtually inactive substances (type I, e.g. stone dusts) and pozzolanic or latently hydraulic substances (type II, e.g. fly ash or blast furnace slag).
The substances are characterised in accordance with the standards listed in the following table.

Service	Method
Testing of fly ash	DIN EN 450-1
Testing of silica fume	DIN EN 13263-1
Testing of ground granulated blast furnace slag	DIN EN 15167-1

VDZ can also offer assistance with the approval and certification of corresponding products.

5) Steel fibres

Steel fibres are straight or formed fibres which can be homogeneously introduced into the concrete and enhance certain properties, for instance tensile strength and flexural strength.
The following tests can be performed at the VDZ laboratories:

Service	Method
Tensile strength of steel fibres	DIN EN ISO 6892-1
Flexural strength of steel fibre concrete beams to determine performance classes	DAfStb directive "Steel fibre concrete"
Flexural strength of steel fibre concrete beams	DIN EN 14651

6) Pigments

Pigments are substances used to colour building materials on the basis of cement and cement/lime mixtures.
The substances are characterised in accordance with the standard given in the following table.

Service	Method
Testing of pigments	DIN EN 12878

f) Fresh and hardened concrete including durability

Our concrete laboratory, accredited in accordance with ISO 17025, is provided with extensive technical equipment for the performance of all important tests on fresh concrete and hardened concrete as well as mortar in accordance with the standard series DIN EN 12350 and DIN EN 12390. Concrete compositions can be optimised and special testing procedures developed on customer request.

Testing of fresh concrete and fresh mortar
Service	Method
Sampling	DIN EN 12350-1
Consistency - slump test	DIN EN 12350-2
Consistency - Vebe time	DIN EN 12350-3
Consistency - degree of compactability	DIN EN 12350-4
Consistency - flow table test	DIN EN 12350-5
Fresh concrete density	DIN EN 12350-6
Air content using pressure method	DIN EN 12350-7
Consistency of fresh mortar (flow table/Hägermann table)	DIN EN 1015-3
Water content using kiln drying method	DIN 1048-1
Rheological analyses: - Dynamic viscosity - Yield value - Saturation point - Production of flow curves	Viskomat
Determination of zeta potential	Electroacoustic measurement method
Expansion and Bleeding of Freshly Mixed Grouts for Preplaced-Aggregate Concrete in the Laboratory	ASTM C940
Flow Table for Use in Tests of Hydraulic Cement	ASTM C230
Flow of Hydraulic Cement Mortar	ASTM C1437, implementation standard for ASTM C230
Time of Setting of Hydraulic Cement by Vicat Needle	ASTM C191

Testing of hardened concrete and hardened mortar
Service	Method
Making and curing specimens	DIN EN 12390-2
Compressive strength	DIN EN 12390-3
Flexural strength	DIN EN 12390-5
Tensile splitting strength	DIN EN 12390-6
Density of hardened concrete	DIN EN 12390-7
Depth of penetration of water under pressure	DIN EN 12390-8
Surface tensile strength, adhesive strength, tensile adhesion strength	DIN 1048-2; ZTV-ING; DAfStb repair directive: Part 3, Annex C
Modulus of elasticity	DIN 1048-5; EN 12390-13
Dynamic modulus of elasticity	Grindosonic method
Moisture content and dry-bulk density	DIN 1048-5
Flexural strength of steel fibre concrete beams to determine performance classes	DAfStb directive "Steel fibre concrete"
Flexural strength of steel fibre concrete beams	DIN EN 14651
Taking of drill cores and examination for compressive strength	DIN EN 12504-1
Non-destructive testing of compressive strength (rebound number)	DIN EN 12504-2
Composition of hardened concrete	DIN 52170
Examination of pore structure employing mercury intrusion porosimetry and water absorption	DIN 60133, in accordance with DAfStb, no. 422
Crack recording, use of gypsum marks
Forcing-out of pore solution and chemical analysis
Non-destructive determination of concrete cover	electromagnetic
Static Modulus of Elasticity and Poisson’s Ratio of Concrete in Compression	ASTM C469
Creep of Concrete in Compression	ASTM C512, with cooperation of third parties

Examination of pore structure and development of heat of hydration
Service	Method
Determination of air void characteristics in hardened concrete	DIN EN 480-11 DAfStb, no. 422
Water absorption at atmospheric pressure / at 15 MPa	DAfStb, no. 422
Capillary water absorption	DAfStb, no. 422 DIN EN 480-5
Pore content and pore distribution in concrete, mortar and hardened cement paste employing mercury intrusion porosimetry	DIN 66133
Measurement of permeability to gas	DAfStb, no. 422 RILEM TC 116-PCD, Part B
Determination of heat of hydration of cement	DIN EN 196-9
Heat of hydration and compressive strength development of concrete	Thermos flask test
C-value determination for cement	DAfStb, no. 422

Examination of shrinkage of concrete and mortar
Service	Method
Autogenous shrinkage	Shrinkage cone method Shrinkage ring method Corrugated tube method
Drying shrinkage	ISO 1920-8 DAfStb, no. 422 Shrinkage ring method DIN 52450 DIN EN 12617
Restraint stress as a result of shrinkage	Shrinkage ring method
Shrinkage cracking tendency	VDZ method
Length Change of Hardened Hydraulic-Cement Mortar and Concrete	ASTM C157 / C157M
Use of Apparatus for the Determination of Length Change of Hardened Cement Paste, Mortar, and Concrete	ASTM C490 / C490M, implementation standard for ASTM C157 / C157M and others
Determining Age at Cracking and Induced Tensile Stress Characteristics of Mortar and Concrete under Restrained Shrinkage	ASTM C1581
Autogenous Strain of Cement Paste and Mortar	ASTM C1698

The durability of concrete has always been a principal aspect of the analyses performed at the VDZ laboratory. The focal points of the studies include:

Resistance to carbonation
Resistance to chloride penetration
Freeze-thaw resistance and freeze-thaw resistance with de-icing salt
Abrasion resistance
Sulphate resistance
Alkali-silica reaction

Durability analyses
Service	Method
Freeze-thaw test and freeze-thaw test with de-icing salt - CIF/CDF Test - Slab test - Cube test - Beam test	DIN CEN/TS 12390-9, DIN CEN/TR 15177, BAW Code of Practice "Freeze-thaw test"
Chloride migration coefficient	BAW Code of Practice "Resistance to chloride penetration", NT Build 492, EN 12390-18
Chloride diffusion coefficient (profile grinding)	DIN SPEC 1176, EN 12390-11
Carbonation depth	DAfStb no. 422, EN 12390-10, EN 12390-12, EN 13295
Characteristics based on degree of hydration for prediction of concrete durability	VDZ method
Wear test using grinding wheel according to Böhme	DIN 52108 DIN EN 13892-3
Testing of mortars and concretes for resistance to sulphate and sea water attack	Civieltechnisch Centrum Uitvoering Research en Regelgeving Aanbeveling 48 (CUR 48), SIA 262, Annex D
Penetration resistance of concrete to water-polluting substances (FD and FDE concrete)	DAfStb-Rili BUmwS
Electrical Indication of Concrete’s Ability to Resist Chloride Ion Penetration	ASTM C1202

ASR resistance (ASR performance test) and residual expansion potential
Service	Method
60 °C concrete test with alkali supply	TP B-StB 1.1.09 RILEM AAR-12
60 °C concrete test (without alkali supply)	NF P 18-454 RILEM AAR-11
38 °C concrete test	RILEM AAR-10
60 °C concrete test on two drill core halves (with or without alkali supply)	VDZ
40 °C fog chamber storage of drill cores	VDZ

Our methods

a) Process optimisation

Technical analysis of the clinker burning process/the entire rotary kiln plant
Weak point analysis
Chemical and physical analysis of all materials, checking and optimisation of clinker and cement quality
Optimisation of kiln plant operation
Diagnosis and consultation in the event of incrustation build-up

b) Optimisation of product quality

Chemical/mineralogical recording and assessment
In-depth study of the influence of burning and cooling conditions as well as of raw materials and fuels on product properties

c) Enhancement of energy efficiency

Determination and analysis of energy demand taking into account plant-specific production processes
Production of complete and sequential energy balances, benchmarking with respect to the VDZ database and BAT values
Identification and quantification of savings potential
Consideration of CO₂ abatement measures
Determination of potential for cost savings

d) Measurements in high-temperature processes

Measurement of gas composition, dust content and temperatures in the range up to 2000 °C and dust content up to 500 g/Nm³
Sampling of solids and liquids

e) Alternative fuels and alternative raw materials

Conducting of combustion-technology studies on the use of alternative fuels and raw materials
Effects and material cycles (sulphur, chlorine, alkalis)
Analysis of alternative fuels
Thermographic flame investigation using a mobile thermographic system
Production of proposals for optimisation of the burner setting and the use of alternatives

f) Process technology modelling

Simulation studies with practice-oriented process model
Assessment and design of plant conversions
Assessment of planned operational activities before implementation
Determination of data not measured (e.g. kiln profiles with regard to temperatures, gas composition, chemical/mineralogical material transformation etc.)
Effect of operational changes and process-modifications on clinker quality

Your benefits

Sustained optimisation of the production process
Maintenance and enhancement of cost-effectiveness and competitiveness
Consultation taking account of the latest developments
Internationally experienced plant specialists to diagnose weak points and develop solutions
Specific energy efficiency analyses for the identification of potential opportunities for savings in the production process
Benchmarking of data gathered by comparison with the VDZ database and BAT (best available techniques)
Accredited and quality-assured measurement procedures
Results are presented in comprehensible form in a report
Integrated study of kiln operation, product quality and environmental performance taking into account economic aspects
Incorporation of the latest findings from research and technology
Simulation studies with practice-oriented process model
The VDZ process model can be used as a substitute for tests on the kiln system which could result in damage

Weitere Dienstleistungen, die für Sie interessant sein könnten.

Environmental analysis

The VDZ laboratories are equipped with high-performance analytical devices for the examination of environmental sam-ples (solids or solutions) to establish the amount of environ-mentally relevant components or the release of environmentally relevant substances. We analyse samples from our own projects with regard to environmental relevance and also offer the same service for samples from external customers.

To the service

Damage analysis

Do you have a problem with a damaged concrete structure? We will analyse the damage and assess the actual state of your structure. On the basis of the results obtained we can plan the protection and maintenance work required for your structure.

To the service

Reference materials

We can supply you with a variety of reference materials for use in the laboratory to help you check and assure the quality of your analyses. Materials for the analysis of cements and alternative fuels are currently available. We can provide a standard ASR test cement for checking the alkali reactivity of aggregates.

To the service

Laboratory reviews and laboratory training

A plant laboratory has to perform analyses which are both precise and efficient to be able to guarantee a consistently high level of quality in production. With their experience of research and practical work, our experts can carry out regular checking of your laboratory procedures and test methods as a means of identifying further potential for optimisation.

To the service

Performance of cement

We can offer you various comprehensive services for the purpose of optimising the performance of cement. In doing so we provide you with full support throughout the entire process. Our interdisciplinary teams of experts have many years of experience gained from customer projects around the world and also further their knowledge by working on practical research projects.

More information

Concrete technology

Our experienced team of experts provides answers to all questions relating to the production and processing of concrete. We can offer the full spectrum of important testing and consultation services, together with complex expert reports, ranging from structure management and material and durability tests right through to sustainability assessments and approval inspections.

More information

Person to contact

Do you have questions regarding this service?

Dr Christoph Müller
Concrete technology

+49-211-45 78-351
bte@vdz-online.de