Concrete surfaces face constant wear from traffic, machinery, and environmental factors. Testing abrasion resistance ensures durability and helps prevent costly repairs. Here are five key tests used to measure how well concrete withstands wear:

• ASTM C418 Sandblasting Test: Simulates wear from abrasive particles, like waterborne debris or traffic.
• ASTM C944 Rotating Cutter Test: Evaluates grinding and cutting forces, common in industrial settings.
• ASTM C779 Revolving Disk Test: Includes three methods to assess sliding, impact, and rolling wear.
• ASTM C1138 Underwater Abrasion Test: Measures resistance to waterborne erosion, ideal for hydraulic structures.
• BCA Abrasion Test: Focuses on rolling contact wear, often seen in industrial and manufacturing environments.

Each test targets specific wear scenarios, helping engineers and contractors choose the right materials and coatings for long-lasting concrete surfaces. Pairing these tests with protective solutions, like industrial-grade coatings, ensures enhanced performance and durability over time.

How Is Concrete Abrasion Resistance Tested? – Civil Engineering Explained

What Is Abrasion Resistance Testing

Abrasion resistance testing evaluates how well concrete surfaces stand up to friction, scraping, and rubbing. Essentially, it measures the material’s ability to endure the wear and tear it faces during everyday use.

These tests simulate the kinds of conditions concrete encounters daily. Think about vehicle tires grinding on a garage floor, heavy machinery scraping across a warehouse, or foot traffic wearing down a sidewalk. Over time, these forces can gradually erode the surface, and abrasion testing helps predict how a concrete surface will hold up under such pressures.

If concrete fails these tests, it’s a red flag. It means the surface could deteriorate quickly, leading to problems like exposed aggregate, surface pitting, and texture loss. Not only does this look unappealing, but it can also weaken the structural integrity of the concrete, making it less reliable in the long run.

In the U.S., the American Society for Testing and Materials (ASTM) sets the standard for abrasion resistance testing. ASTM provides various testing methods designed to mimic specific real-world conditions. For example, the forces acting on a pool deck are different from those on an industrial floor, so the test methods need to reflect those differences.

Some of the most widely used ASTM standards for abrasion testing include C418, C944, C779, and C1138. Each of these tests uses unique tools and procedures. For instance, some tests involve rotating cutters, others use sandblasting, and some even submerge concrete samples underwater while applying abrasive forces. Beyond ASTM, organizations like the British Cement Association (BCA) have also developed specialized testing protocols for specific situations or international applications.

These tests are crucial for assessing both the surface hardness of concrete and how it responds to prolonged mechanical stress. The results guide engineers, contractors, and property owners in choosing surface treatments, protective coatings, and maintenance schedules.

For residential and commercial projects, abrasion resistance testing plays a big role in selecting protective coatings. Take Croc Coatings‘ Penntek™ industrial coating, for example. It undergoes rigorous abrasion testing to ensure it’s four times stronger than traditional epoxy, which supports its lifetime warranty. This kind of testing provides the confidence needed to make smart decisions about concrete protection systems.

1. ASTM C418 Sandblasting Test

Type of Abrasion Simulated

The ASTM C418 test measures how well concrete can withstand abrasion. It replicates the impact of abrasives carried by water or traffic, which can gradually wear down weaker parts of the concrete surface.

Test Apparatus and Procedure

This test involves subjecting concrete samples to abrasive forces under controlled conditions. The setup is designed to mimic the cutting action of abrasives, ensuring the focus stays on how the concrete responds to simulated wear. This allows for a consistent and reliable evaluation of its durability.

Typical Applications

ASTM C418 is commonly used to assess concrete performance in areas exposed to abrasive forces, such as waterborne particles or traffic-related wear. This makes it a valuable test for environments where durability under such conditions is crucial.

2. ASTM C944 Rotating Cutter Test

After the ASTM C418 sandblasting test, the ASTM C944 rotating cutter test provides another method to evaluate wear, focusing on conditions typically found in industrial settings.

Type of Abrasion Simulated

The ASTM C944 test replicates the grinding and cutting forces experienced when heavy machinery, steel wheels, or metal objects move across concrete surfaces. This type of wear is common in industrial spaces like factories and warehouses, where equipment such as forklifts and pallet jacks exerts cutting forces on the concrete.

Test Apparatus and Procedure

This test employs a rotating steel cutter that exerts consistent pressure while spinning against a concrete sample. The cutter grinds the surface at a set speed and duration, mimicking the material removal caused by repeated contact with metal equipment in real-world industrial environments. The amount of weight lost by the concrete during the test serves as a measure of its abrasion resistance.

Typical Applications

The ASTM C944 test is especially useful for assessing concrete intended for industrial environments. This includes areas like factory floors, loading docks, and even airport runways – locations that demand high durability due to heavy traffic and equipment use. For those considering protective coatings, such as those from Croc Coatings, the results of this test can help confirm whether the concrete is suitable for supporting such treatments in tough conditions.

Strengths and Limitations

The test excels at simulating steel-induced wear, making it a reliable choice for industrial applications. However, it does not account for other types of wear, such as foot traffic, rubber tires, or environmental factors like freeze-thaw cycles. Additionally, the specialized equipment required for this test may not reflect the combined stresses concrete faces in real-world conditions.

While ASTM C944 is highly effective for evaluating concrete in industrial settings, it doesn’t provide a complete picture of wear under all possible circumstances.

3. ASTM C779 Revolving Disk, Dressing Wheel, and Ball Bearing Tests

Building on the ASTM C944 test, ASTM C779 offers a more detailed framework for assessing concrete’s durability. This standard includes three distinct testing methods, each designed to evaluate different types of wear. By addressing multiple wear scenarios, ASTM C779 provides a well-rounded view of how concrete performs in various real-world conditions.

Types of Abrasion Simulated

ASTM C779 focuses on three specific wear scenarios, each replicated through its unique procedures:

• Procedure A: Uses a revolving disk with abrasive grit to mimic sliding wear. This simulates the effect of materials sliding across concrete surfaces, often with embedded particles causing additional friction.
• Procedure B: Employs a dressing wheel to replicate the combined impact and sliding friction caused by wheeled traffic, such as forklifts and carts. This is particularly relevant for industrial and commercial environments.
• Procedure C: Utilizes ball bearings to simulate concentrated impact and abrasion. This test mirrors the stress caused by heavy objects repeatedly striking small areas on a concrete surface.

Together, these procedures cover a broad spectrum of wear patterns, providing a comprehensive evaluation of concrete’s resistance to abrasion.

Test Apparatus and Procedure

A major advantage of ASTM C779 is its use of portable testing equipment, making it suitable for both laboratory and on-site evaluations. This portability allows engineers and contractors to test concrete surfaces directly on-site, offering practical insights without the hassle of transporting samples to a lab.

Each procedure involves applying controlled forces to horizontal concrete surfaces using the respective apparatus – revolving disks, dressing wheels, or ball bearings. The main focus is on measuring material loss, providing valuable data about the concrete’s durability under specific conditions. This multi-method approach ensures the standard is versatile enough to prepare concrete for a wide range of applications.

Typical Applications

ASTM C779 is especially useful for assessing concrete in high-traffic areas like warehouse floors, loading docks, and commercial spaces. For example, Procedure B is ideal for evaluating surfaces exposed to heavy wheeled traffic, such as those in manufacturing plants or distribution centers.

For property owners considering protective treatments, such as Croc Coatings’ Penntek™ system, ASTM C779 test results help identify the main abrasion risks to their concrete surfaces. These insights guide decisions about surface preparation and the right coatings to ensure long-term durability.

Strengths and Limitations

One of the standout features of ASTM C779 is its multi-procedure approach, which provides a more thorough analysis of concrete’s performance under various wear conditions. By including three distinct methods in one standard, it offers a versatile tool for evaluating durability.

However, because each procedure focuses on a specific type of wear, a complete assessment often requires conducting all three tests. This means that while ASTM C779 delivers valuable insights, its results should be interpreted in the context of the expected traffic patterns and environmental conditions of the actual application.

sbb-itb-a0e5ae3

4. ASTM C1138 Underwater Abrasion Test

When concrete is exposed to continuous water flow carrying debris, standard abrasion tests often fall short. That’s where ASTM C1138 comes in – it’s specifically designed to evaluate how concrete holds up against underwater abrasion.

This test replicates the mechanical grinding caused by waterborne particles and the chemical effects of long-term water exposure. These factors can change the surface properties of concrete and its ability to resist wear. Unlike earlier tests, ASTM C1138 focuses on the unique challenges of underwater environments.

Type of Abrasion Simulated

ASTM C1138 recreates hydraulic conditions where concrete is subjected to high-speed water flow loaded with abrasive particles.

Test Apparatus and Procedure

The test uses a specialized setup involving steel balls submerged in water. These balls grind against concrete specimens under controlled conditions, simulating the abrasive forces found in hydraulic environments. The apparatus ensures consistent water flow, creating realistic wear patterns. Key metrics include mass loss, wear depth, and surface damage.

This method provides engineers with critical data to select the right concrete for aquatic structures.

Typical Applications

ASTM C1138 is essential for assessing concrete used in hydraulic structures like dams, spillways, and canals – places where high-speed water flow causes significant abrasion. As engineers design taller dams and more powerful spillways, ensuring that the concrete can withstand such conditions becomes even more critical.

"The ASTM C1138 standard underwater abrasion test can be considered as the best available experimental tool to qualitatively evaluate the abrasion resistance of concrete surfaces in hydraulic structures."

• Sallal R. Abid, Sajjad H. Ali, G. Murali, Thaar Al-Gasham (ResearchGate)

A study conducted in July–August 2023 used ASTM C1138 to compare traditional concrete with geopolymer concrete for hydraulic applications. The results showed that geopolymer concrete performed exceptionally well, making it especially useful for urgent maintenance projects requiring strong early-age abrasion resistance.

Strengths and Limitations

One of the standout features of ASTM C1138 is its ability to simulate real underwater conditions that hydraulic structures face. This sets it apart from other abrasion tests. However, the test does have some drawbacks. It requires specialized equipment and expertise, which might not be available in all labs. Additionally, the complexity of underwater testing can make it less practical for routine evaluations.

For property owners using Croc Coatings’ Penntek Evolution system, ASTM C1138 results can help determine whether additional waterproofing measures are necessary.

5. BCA Abrasion Test

The BCA (Ball Cratering Abrasion) test is another method for evaluating how concrete holds up against wear, particularly under rolling contact conditions. Unlike traditional tests that focus on grinding or cutting the surface, this approach examines how concrete withstands rolling contact wear – something often encountered in industrial environments.

Type of Abrasion Simulated

This test replicates micro-scale abrasive wear caused by rolling contact. A steel ball rolls against the concrete, creating a crater-like depression. This setup mimics the patterns of wear found in areas where heavy equipment or materials frequently roll over the surface. It’s especially useful for studying three-body abrasion, where abrasive particles get trapped between two moving surfaces, intensifying the wear.

Test Apparatus and Procedure

The equipment for the BCA test consists of a rotating steel ball, typically 25 mm in diameter, pressed against the concrete sample. During the test, an abrasive slurry – usually containing diamond particles or silicon carbide – flows between the ball and the concrete. The ball rotates at 400 RPM, creating a consistent crater on the surface.

After a set number of rotations (usually between 200 and 500, depending on the concrete’s properties), the crater’s depth and diameter are measured using precision tools. From these measurements, the volume loss is calculated, giving a clear indication of the concrete’s abrasion resistance. This method stands out for its repeatability, as the controlled contact area and pressure ensure consistent results.

Typical Applications

The BCA test is particularly useful in environments like manufacturing plants, warehouses, and distribution centers, where rolling contact wear is common due to heavy machinery. It’s also relevant for decorative concrete surfaces that face moderate traffic, as it helps assess their ability to maintain appearance and durability.

In the precast concrete industry, this test is often used for quality control of architectural panels and industrial flooring. Additionally, concrete coating manufacturers rely on BCA results to substantiate performance claims, especially for products designed to improve surface durability. It serves as a valuable complement to other abrasion tests, addressing the specific challenges posed by rolling contact wear.

Strengths and Limitations

The BCA test offers several advantages, including detailed, quantitative wear measurements. Its controlled conditions minimize variables, ensuring consistent and reliable data. This makes it a highly sensitive tool for assessing abrasion resistance.

However, there are a few drawbacks. The specialized equipment required for the test isn’t available in all facilities, and the diamond abrasive slurry can be costly. Moreover, since the test creates only small craters, it might not fully capture wear mechanisms in scenarios involving larger contact areas or different loading patterns.

For those considering Croc Coatings’ Penntek Evolution system, the BCA test results can provide valuable insights into whether the base concrete has the abrasion resistance needed to meet the coating’s lifetime warranty expectations.

Test Comparison Chart

This chart offers a quick reference to compare key abrasion test methods, complementing the detailed descriptions provided earlier. It helps you match each test’s focus with real-world conditions, making it easier to select the right method for your needs. Below is a breakdown of four major abrasion resistance tests and their main characteristics:

Test Method	Type of Abrasion Simulated	Real-World Applications	Test Apparatus	Key Strengths	Primary Limitations
ASTM C418 Sandblasting	Wind-borne particle abrasion	General surface wear	Sandblasting equipment	Produces a smooth surface that reveals aggregates	–
ASTM C944 Rotating Cutter	Mechanical cutting and grinding wear	Vehicle traffic wear, industrial floors, pavements	Rotating-cutter drill press	Highlights statistically measurable wear differences	Shows higher variability compared to compressive strength tests
ASTM C779 Revolving Disk	Sliding and scuffing abrasion	Horizontal concrete surfaces, traffic wear, interlocking block pavements	Steel disk (12 rpm) with silicon carbide grit and 22N load	Standardized evaluation for horizontal concrete surfaces	–
ASTM C1138 Underwater	Water-borne particle erosion	Hydraulic structures, marine environments, spillways	Underwater abrasion chamber with flowing water	Mimics real hydraulic structure conditions	Can take over 120 hours for high-performance concrete

These concise summaries help pinpoint the strengths and applications of each test, aiding in informed decision-making for specific projects.

Understanding Test Selection:
Underwater abrasion tests reveal rapid initial wear, with about 4.25% mass loss within the first 24 hours and up to 8.69% after 72 hours. For projects incorporating Croc Coatings’ Penntek Evolution system, testing the base concrete’s abrasion resistance ensures the coating aligns with its lifetime warranty.

Combining Test Methods:
Using multiple abrasion tests provides a more detailed understanding of concrete performance. Each test produces unique wear patterns and visual differences, so combining methods can offer a well-rounded prediction of real-world durability.

For high-performance concretes and aggregates, the High-Speed Underwater Method (HSUM) doubles the abrasion efficiency compared to standard tests, significantly reducing experimental time.

Conclusion

Selecting the right test is crucial for evaluating concrete durability under specific conditions. Each test is designed to mimic different abrasive forces, from sliding wear to erosion caused by waterborne particles. The key takeaway? Choose a test that mirrors the real-world stresses your concrete will face.

Pairing your project’s unique requirements with the right test ensures better long-term performance. For those looking for a reliable protective solution, Croc Coatings’ Penntek Evolution system stands out. This industrial-grade coating is 4x stronger than epoxy and offers exceptional protection for a range of surfaces – garage floors, patios, pool decks, basements, and industrial floors. Available across North Idaho and Eastern Washington, including Spokane and the Tri-Cities, the system comes with the peace of mind of a lifetime warranty.

Before applying protective coatings, it’s wise to conduct abrasion resistance tests on your concrete base. This step ensures the coating and substrate are compatible, maximizing durability. With thorough testing and robust solutions like Penntek Evolution, you can create concrete surfaces that endure heavy use while retaining their functionality and appearance for years to come.

FAQs

What’s the best way to test abrasion resistance for my concrete surface?

When it comes to testing abrasion resistance, the best method depends on how the concrete surface will be used and the kind of wear it will endure. For example, ASTM C779 is often the go-to for horizontal surfaces like industrial floors or pavements. On the other hand, the Taber Abrasion Test works well for coatings exposed to frequent wear, such as those on garage floors or patios.

Selecting the right test involves considering factors like the type of surface, the level of wear and tear it’s likely to face, and relevant industry standards. This approach ensures accurate results and helps in choosing materials or treatments that can boost durability.

How do ASTM C418 and ASTM C944 tests differ in evaluating concrete’s abrasion resistance?

ASTM C418 tests abrasion resistance by blasting air-propelled silica sand onto a concrete surface. This process gauges how much material is worn away by the sand, making it a great choice for evaluating surface durability under lighter abrasion conditions.

On the flip side, ASTM C944 uses steel rotary cutters under applied pressure to mimic more intense wear. It assesses resistance by measuring either the depth of penetration or the amount of material lost. This makes it especially useful for understanding how concrete holds up under heavy-duty abrasion.

Each test offers a unique perspective on concrete durability, tailored to different applications and environmental demands.

Why is it important to test the abrasion resistance of concrete before applying a protective coating like the Penntek Evolution system?

Testing how well concrete holds up against abrasion is a key step before applying protective coatings like the Penntek Evolution system. This process ensures the surface is tough enough to handle wear and tear over time, particularly in high-traffic areas, spots exposed to vehicles, or places facing tough environmental conditions. Knowing the concrete’s durability helps confirm that the coating will stick properly and perform as intended.

This preparation is essential for achieving a finish that lasts and getting the most out of advanced coating systems like Penntek Evolution, which is built to deliver exceptional strength and long-term performance. Testing also helps spot any surface problems that need fixing before application, ensuring a smooth, durable, and reliable result.

Related Blog Posts

• ASTM D2794: Impact Resistance Test Explained
• Top Abrasion Tests for Concrete Coatings
• Slip Resistance Test Methods Explained
• How To Assess Concrete Coating Durability