construction material lab manual

TESTING MANUAL

Krishna Digital Material Testing Laboratory

02, Bhawani Nagar Near J.K.Road Bhopal Madhya Pradesh

Telephone No. 0755-4228147 Fax No. 07554246045 e-mail [email protected]

Kdmtl testing manual All right reserved to kdmtl

Construction Material Testing

TRAINING

SPONSORED BY

MADHYA PRADESH RURAL ROAD DEVELOPMENT AUTHORITY

GIVEN BY

KRISHNA DIGITAL MATERIAL TESTING LABORATORY(AN NABL ACCREDITED LABORATORY)

BHOPAL

TO TRAINEE

NAME OF THE SDO DATE OF TRAINING

INDEX ABOUT NABL


ABOUT OUR LABORATORY

TRAINING COURSE

o 1.SOIL TESTING

Grain Size Analysis

Consistency Limits

Classification of Soils

Compaction Test

California Bearing Ratio

Free Swelling Index

Sand Replacement Test

o 2. COARSE AGGREGATE TESTING

SIEVE ANALYSIS

IMPACT VALUE

CRUSHING VALUE

ABRASION VALUE

SPECIFIC GRAVITY &WATER ABSORPTION

BULK DENSITY

3. FINE AGGREGATE TESTING

SIEVE ANALYSIS

SILT CONTENT

SPECIFIC GRAVITY

4. CEMENT TESTING

FINENESS OF CEMENT

STANDARD CONSISTENCY OF CEMENT


SOUNDNESSOF CEMENT

INITIAL & FINAL SETTING TIME OF CEMENT

SPECIFIC GRAVITY OF CEMENT

COMPRESSIVE STRENGTH OF MORTAR CUBES

5. CONCRETE TESTING

COMPRESSIVE STRENGTH

REBOUND HAMMER

Concrete Mix Design As Per Indian Standard Code

SLUMP CONE

National Accreditation Board for Testing and Calibration Laboratories

National Accreditation Board for Testing and Calibration Laboratories (NABL) is an autonomous body under the aegis of Department of Science & Technology, Government of India, and is registered under the Societies Act


1860. NABL has been established with the objective to provide Government, Industry Associations and Industry in general with a scheme for third-party assessment of the quality and technical competence of testing and calibration laboratories. Government of India has authorised NABL as the accreditation body for Testing and Calibration Laboratories.

In order to achieve this objective, NABL provides laboratory accreditation services to laboratories that are performing tests / calibrations in accordance with ISO/IEC 17025:2005 and ISO 15189:2007 for medical laboratories. These services are offered in a non-discriminatory manner and are accessible to all testing and calibration laboratories in India and abroad, regardless of their ownership, legal status, size and degree of independence.

NABL accreditation system complies with ISO/IEC 17011:2004 and Asia Pacific Laboratory Accreditation Cooperation (APLAC) MR001. Based on evaluation of NABL operations by APLAC in 2000, NABL has been granted signatory member status by APLAC and International Laboratory Accreditation Cooperation (ILAC) under their Mutual Recognition Arrangements (MRAs). Under these MRAs, the reports issued by NABL accredited laboratories are considered to be equivalent to reports issued by laboratories accredited by (currently) 76 accreditation bodies in 64 economies. NABL has undergone re-evaluation by four member APLAC evaluation team in July 2008. APLAC/ILAC has recommended NABL’s Mutual Recognition Arrangement (MRA) status for further four years with extension of scope for Medical Testing laboratory as per new international standard ISO 15189:2007. Recently, NABL also added a new dimension in the area of accreditation as a new program on "Accreditation of PT Providers" based on international standard ISO/IEC 17043 “Conformity Assessment- General Requirements of Proficiency Testing” and strive to obtain ILAC / APLAC Mutual Recognition Arrangement (MRA) Signatory Status for international acceptability also. The users have access to information regarding accredited laboratories through web-based directory of NABL accredited laboratories.NABL website is updated continuously with respect to status of accredited laboratories and their scope of accreditation. The list of laboratories which are either suspended or their scope of accreditation is partially or fully withdrawn is also available for the benefit of the users. The laboratories will be able to acquire the necessary NABL documents through the website thereby eliminating postal delays. Suggestions are welcome from users of the website for further improvement

SCOPE OF LABORATORY

I - COARSE AGGREGATE

S. No.

Name of TestMinimu

m Minimum Quantity


Period Require

d for Testing

of Sample Required for One

Test1 Impact Value 2 Days 20 Kg2 Sieve Analysis( Gradation) 2 Days 5 Kg3 Crushing Value 2 Days 20 Kg4 Abrasion Value 2 Days 20 Kg5 Water Absorption/Surface Moisture 3Days 5 Kg6 Specific Gravity 3 Days 5 Kg7 Bulk Density 2 Days 30 Kg8 Soundness 15 Days 15 Kg9 Flakiness Index 2 Days 20 Kg10 Elongation Test 2 Days 20 Kg11 Deleterious material* 5 Days 5 Kg12 10% fine value 2 Days 20 Kg

13 WMM Mix Design(as per MORT& H)* 6 Days

60mm - 30 Kg 20mm -

60 Kg 12.5mm — 60mm-30

Kg II — FINE AGGREGATE/SAND

S. No.

Name of Test

Minimum

Period Require

d for Testing

Minimum Quantity


Test1 Sieve Analysis( Gradation) 2 Days 10 Kg2 Bulk Density 2 Days 10 Kg3 Bulking* 3 Days 10 Kg4 Specific Gravity 2 Days 10 Kg5 Silt Content* (inclusive Gradation) 2 Days 10 Kg

6 Fineness Modulus* (inclusive Gradation) 2 Days 10 Kg.

7 Organic Impurities/Deleterious Material* 2 Days 5 Kg.

8 Surface Moisture Contents* 2 Days 2 Kg.9 Water Absorption 2 Days 5 Kg.10 Soundness 8 Days 10 Kg


III — CEMENT

S. No.

Name of Test

Minimum

Period Require

d for Testing

Minimum Quantity


TestA PHYSICAL TESTING 1 Fineness (Dry Sieving test) 3 Days 5Kg2 Consistency & Setting Time 3 Days 5Kg

3Compressive Strength of Cubes (3 Cement Cubes (including preparation of sample)

30 Days 1 Full Bag

CONSISTENCY WITH IST

Soundness (Lechatelier's test) 3 Days 2Kg4 Density 3 Days 5Kg

IV — CEMENT CONCRETE

S. No.

Name of Test

Minimum

Period Require

d for Testing

Minimum Quantity


Test

1Compressive strength (Cement / Cement concrete cubes / Paver Blocks)

7 Days/ 28 Days

Set of 3 Cubes 8 Paver blocks

2 Concrete Mix design including lab. Testing in normal conditions. *14 Days /30 days

1 Bag Cement 4 Bags Aggregate 2 Bag Sand

3Casting of C.C. cube and determination of Compressive Strength (Normal Condition)

10 days at field

Cement- 1 bag Sand-1 bag Agg. -1 bag

4 Slump test / Compaction Factor Test 3 days *

5 Core Cutting From the Structure / Pavement .

6 Rebound Hammer test (NDT)

V-- BRICKS

S. No.

Name of TestMinimu

m Period

Minimum Quantity

of Sample


Required for

Testing

Required for One

Test

1 Dimension tolerance* 2 Days 20 Nos.

2 Water Absorption 3 Days 5 Nos.3 Compressive strength 6 Days 9 Nos.4 Efflorescence 4 Days 5 Nos.5 Visual Examination * 2 Days 6 Nos.

VI-SOIL LABORATORY TEST

S. No.

Name of Test

Minimum

Period Require

d for Testing

Minimum Quantity


Test1 Natural Moisture content 3 Days 1kg2 Specific Gravity 3 Days 1Kg3 Liquid Limit/Plastic Limit 3 Days 5 Kg

4Proctor test (OMC & Max. Dry Density) for Light / heavy Compaction

3 Days 20 Kg

5

CBR test (i) Excluding of OMC / MDD) in Soaked / Unsoaked conditions

8 Days 25 Kg.

(ii) Including OMC/MDD 9 Days 26 Kg.6 Wet Sieve Analysis 3 Days 5 Kg7 Bulk Density* 2 Days 5 Kg8 Permeability of soil (Lab.) * 4 Days 30 Kg

9 Free Swelling Index 3 Days 5 Kg10 Triaxial Test 7 Days 10 Kg

11 Direct Shear Test 5 Days 10 Kg12 Swelling Pressure 3 Days 10 Kg

VII - BITUMEN

S. No.

Name of Test

Minimum

Period Require

d for Testing

Minimum Quantity


Test1 Specific gravity* 3 Days 5 Kg


2 Softening point 3 Days 5 Kg3 Penetration value 3 Days 5 Kg4 Viscosity 3 Days 5 Kg5 Ductility 3 Days 5 Kg6 Flash Point/Fire Point 3 Days 5 Kg7 Loss on heating % by weight* 3 Days 5 Kg8 Spot Test* 3 Days 2 Kg

9 Job mix formula by Marshall Stability Test * (a)B.M./DBM/SDBC 15 Days

2 full bag of each Aggregate 20mm,13.2mm 11.2mm,6.0mm stone dust filler (5Kg.)Bitumen (5 Kg)

10 Striping values * 2 Days 3 Kg

11 Bitumen Content* 2 Days5 Kg

Bituminous mix

VIII - CERAMIC TILES

S. No.

Name of Test

Minimum

Period Require

d for Testing

Minimum Quantity


Test1 Water Absorption 3 Days 6 Nos.2 Dimension 1 Days 6 Nos.3 Abrasion 3 Days 6 Nos.4 Chemical Resistance 7 Days 6 Nos.5 Hardness 2 Days 6 Nos.6 MOR 3 Days 6 Nos.

IX-CONCRETE TILES

S. No.

Name of Test

Minimum

Period Require

d for Testing

Minimum Quantity


Test1 Water Absorption 3 Days 6 Nos.2 Abrasion 3 Days 6 Nos.3 Dimension & Surface Regularity 3 Days 6 Nos.


X - FIELD TESTS

S. No.

Name of Test

1 Field density testing by core cutter method.

2Field density testing by sand replacement method / by DCPT method (excluding transportation)

3 Standard penetration test (spt)4 Core Cutting From the Structure / Pavement .

5 Rebound Hammer test (NDT)

XI - STEEL

S. No. Name of Test

1 Steel all Physical & Chemical Test

XII - PAVER BLOCK

S. No.

Name of Test

1 Water Observation 2 Compressive Strength3 Abrasion Resistence

XIII- SAMPLING

S. No.

Name of Test

1 Collection of Sample from Field excluding Transporation

TEST1-Grain Size AnalysisTheory: The soil is sieved through a set of sieves. The material retained on different sieves is determined. The percentage of

material retained on any sieve is given by

Where = mass of soil retained on sieve ‘n’


M= total mass of the sample.

The cumulative percentage of the material retained

Where , etc are the percentages retained on sieve 1, 2 etc which are coarser than sieve ‘n’. The percentage finer than the

sieve ‘n’

Equipment: 1. Set of fine sieves, 2mm, 1mm, 600micron, 425, 212, 150, and 75 micron.

2. Set of coarse sieves, 100mm, 80mm, 40mm, 10mm, and 4.75mm.

3. Weighing balance with accuracy of 0.1% of the mass of the sample.

4. Oven

5. Mechanical shaker

6. Trays

7. Mortar with a rubber covered pestle.

8. Brushes

9. Riffler

Part-I: Coarse Sieve Analysis

Procedure:

1. Take the required quantity of the sample. Sieve it through a 4.75mm Is sieve. Take the soil fraction retained on 4.75mm IS

sieve for the coarse sieve analysis (Part-I) and that passing through the sieve for the fine sieve analysis (Part-II).

2. Sieve the sample through the set of coarse sieves by hand. While sieving through each sieve, the sieve should be agitated such

that the sample rolls in irregular motion over the sieve, the material retained on the sieve may be rubbed with the rubber pestle in

the mortar, if necessary. Care shall be taken so as not to break the individual particles. The quantity of the material taken for

sieving on each sieve shall be such that the maximum mass of material retained on each sieve does not exceed the specified

value.

3. Determine the mass of the material retained on each sieve.

4. Calculate the percentage of soil retained on each sieve on the basis of the total mass of the sample, taken in step (1).

5. Determine the percentage passing through each sieve.

Part-II: Fine Sieve Analysis.


6. Take the portion of the soil passing 4.75 mm IS sieve. Oven dry it at 105 to 1100C. Weigh it to 0.1% of the total mass.

7. Sieve the soil trough the nest of fine sieves, the sieves should be agitated so that the sample rolls in irregular motion over the

sieves. However, no particles should be pushed through the sieve.

8. Take the material retained on various sieves in a mortar. Rub it with rubble pestle, but do not try to break individual particles.

9. Reserve the material through the nest of sieves. A minimum of 10min of shaking is required if a mechanical shaker is used.

10. Collect the soil fraction retained on each sieve in a separate container. Take the mass.

11. Determine the percentage retained, cumulative percentage retained, and the percentage finer, based on the total mass taken in

step (1).

TEST2-Consistency Limits

THE LIQUID LIMIT OF SOIL TEST

TO DETERMINE THE LIQUID LIMIT OF A SOIL SPECIMEN

Theory:

The liquid limit of a soil is the water content at which the soil behaves practically like a liquid, but has small shear strength. It

flows to close the groove in just 25 blows in Casagrande’s liquid limit device.

As it is difficult to get exactly 25 blows in a test, 3 to 4 tests are conducted and the number of blows (N) required in each test is

determined. A semi-log plot is then drawn between log N and the water content (w). The liquid limit is the water content

corresponding to N=25, as obtained from the plot.

Equipment


1. Casagrande’s liquid limit device

2. Grooving tolls of both standard and ASTM types

3. Oven

4. Evaporating dish or glass sheet

5. Spatula

6. 425 IS sieve

7. Weighing balance accuracy 0.01g.

8. Wash bottle.

Fig: Casagrande’s Liquid Limit Apparatus Fig: Casagrande’s Apparatus Details and Tools

Procedure:

1. Adjust the drop of the cup of the liquid limit device by releasing the two screws at the top and by using the handle of the

grooving tool or a gauge. The drop should be exactly 1cm at the point of contact on the base. Tighten the screw after adjustment.

2. Take about 120g of the air-dried soil sample passing 425 IS sieve.

3. Mix the sample thoroughly with distilled water in an evaporating dish or a glass plate to form a uniform paste. Mixing should

be continued for about 15 to 30 min, till a uniform mix is obtained.

4. Keep the mix under humid conditions for obtaining uniform moisture distribution for sufficient period. For some fat clays.

This maturing time may be upto 24 hours.

5. Take a portion of the matured paste and remix it thoroughly. Place it in the cup of the device by a spatula and level it by a

spatula or a straight edge to have a minimum depth of the soil as 1cm at the point of the maximum thickness. The excess soil, if

any should be transferred to the evaporating dish.


6. Cut a groove in the sample in the cup by using the appropriate tool. Draw the grooving tool through the paste in the cup along

the symmetrical axis, along the diameter through the centre line of the cup. Hold the tool perpendicular to the cup.

7. Turn the handle of the device at a rate of 2 revolutions per second. Count the number of blows until the two halves of the soil

specimen come in contact at the bottom of the groove along a distance of 12mm due to flow and not by sliding.

8. Collect a representative sample of the soil by moving spatula width-wise from one edge to the other edge of the soil cake at

right angles to the groove. This should include the portion of the groove in which the soil flowed to close the groove.

9. Remove the remaining soil from the cup. Mix it with the soil left in evaporating dish.

10. Change the water content of the mix in the evaporating dish either by adding more water if the water content is to be

increased or by kneading the soil, if the water content is to be decreased. In no case the dry soil should be added to reduce the

water content.

11. Repeat the steps 4 to 10 and determine the number of blows (N) and the water content in each case.

12. Draw the flow curve between log N and w, and determine the liquid limit corresponding to N=25.

TEST 3-DETERMINATION OF PLASTIC LIMIT OF SOIL

Theory:

The plastic limit of a soil is the water content of the soil below which it ceases to be plastic. It begins to crumble when rolled into

threads of 3mm diameter.

Equipment:


1. Porcelain evaporating dish about 120mm diameter or a glass plate 450mm square and 10mm thick.

2. Ground glass plate about 200mm x 150mm

3. Metallic rod 3mm dia and 100mm long

4. Oven

5. Spatula or plate knife

6. Moisture content can

Procedure:

1. Take about 30g of air dried soil from a thoroughly mixed sample of the soil passing 425 sieve.

2. Mix the soil with distilled water in an evaporating dish or on a glass plate o make it plastic enough to shape into a small ball.

3. Leave the plastic soil mass for some time for maturing. For some fat clay, this period may be even upto 24 hours.

4. Take about 8g of the plastic soil, and roll it with fingers on a glass plate. The rate of rolling should be about 80 to 90 strokes

per minute to form a thread of 3mm diameter counting one stroke when the hand moves forward and backward to the starting

point.

5. If the diameter of the thread becomes less than 3mm without cracks, it shows that the water content is more than plastic limit.

Knead the soil to reduce the water content and roll it again into thread. Repeat the process of alternate rolling and kneading until

the tread crumbles and the soil can no longer be rolled into thread.

Note: If the crumbling occurs when the thread has a diameter slightly greater than 3mm it may be taken as plastic limit, provided

the soil had been rolled into a thread of 3mm diameter immediately before kneading. Do not attempt to produce failure exactly at

3mm diameter.

6. Collect the pieces of the crumbled soil thread in a moisture content container.

7. Repeat the procedure at least twice more with a fresh samples of plastic soil each time.


Fig: Determination of Plastic Limit

TEST-3 Classification of Soils

Classification systems are used to group soils according to their order of performance under given set of physical conditions.

Soils that are grouped in order of performance for one set of physical conditions will not necessarily have the same order of

performance under some other physical conditions. Therefore, number of classification systems have been developed depending

on the intended purpose of the system. Soil classification has proved to be a very useful tool to the soil engineer. It gives general

guidelines in an empirical manner for making use of the field experience of others. Soil may be broadly classified as follows:

1. Classification based on grain size

2. Textural classification

3. AASHTO classification system

4. Unified soil classification system

INDIAN STANDARD CLASSIFICATION SYSTEM:

Indian Standard Classification System (ISC) was adopted by Bureau of Indian Standards is in many respect similar to the Unified

Soil Classification (USC) system.

Soils are divided into three broad divisions:

1. Coarse grained soils, when 50% or more of the total material by weight is retained on 75 micro IS sieve.

2. For fine grained soils, when more than 50% of the total material passes through 75 micron IS sieve.

3. If the soil is highly organic and contains a large percentage of organic matter and particles of decomposed vegetation, it is kept in a

separate category marked as peat (Pt).

In all there are 18 groups of soils: 8 groups of coarse grained, 9 groups of fine grained and one of peat.

GW – well graded gravel

GP – poorly graded gravel

GM – silty gravel


SW – well graded sand

SP – poorly graded sand

SM – silty sand

SC – clayey sand

CL – clay of low plastic

CI – clay of medium plastic

CH – clay of higher plastic

ML – silt of medium plastic

MI – silt of medium plastic

MH – silt of higher plastic

OL – organic silt and clays of low plastic

OI – organic silt and clays of medium plastic

OH – organic silt and clays of high plastic

Fig.2: Indian Standard Classification Plasticity Chart


TEST 4 COMPACTION OF SOIL PROCTOR’S TEST

Theory:

Compaction is the process of densification of soil by reducing air voids. The degree of compaction of a given soil is measured in

terms of its dry density. The dry density is maximum at the optimum water content. A curve is drawn between the water content

and the dry density to obtain the maximum dry density and the optimum water content.

Dry density

Where M = total mass of the soil, V= volume of soil, w= water content.

Equipment:

1. Compaction mould, capacity 1000ml.

2. Rammer, mass 2.6 kg.

3. Detachable base plate.

4. Collar, 60mm high.

5. IS sieve, 4.75 mm.

6. Oven

7. Desiccator

8. Weighing balance, accuracy 1g.

9. Large mixing pan

10. Straight edge.

11. Spatula

12. Graduated jar

13. Mixing tools, spoons, trowels, etc.

Procedure:


1. Take about 20kg of air-dried soil. Sieve it through 20mm and 4.7mm sieve.

2. Calculate the percentage retained on 20mm sieve and 4.75mm sieve, and the percentage passing 4.75mm sieve.

3. If the percentage retained on 4.75mm sieve is greater than 20, use the large mould of 150mm diameter. If it is less than 20%,

the standard mould of 100mm diameter can be used. The following procedure is for the standard mould.

4. Mix the soil retained on 4.75mm sieve and that passing 4.75mm sieve in proportions determined in step (2) to obtain about 16

to 18 kg of soil specimen.

5. Clean and dry the mould and the base plate. Grease them lightly.

6. Weigh the mould with the base plate to the nearest 1 gram.

7. Take about 16 – 18 kg of soil specimen. Add water to it to bring the water content to about 4% if the soil is sandy and to about

8% if the soil is clayey.

8. Keep the soil in an air-tight container for about 18 to 20 hours for maturing. Mix the soil thoroughly. Divide the processed soil

into 6 to 8 parts.

9. Attach the collar to the mould. Place the mould on a solid base.

10. Take about 2.5kg of the processed soil, and hence place it in the mould in 3 equal layers. Take about one-third the quantity

first, and compact it by giving 25 blows of the rammer. The blows should be uniformly distributed over the surface of each layer.

The top surface of the first layer be scratched with spatula before placing the second layer. The second layer should also be

compacted by 25 blows of rammer. Likewise, place the third layer and compact it.

The amount of the soil used should be just sufficient to fill the mould ad leaving about 5 mm above the top of the mould to be

struck off when the collar is removed.

11. Remove the collar and trim off the excess soil projecting above the mould using a straight edge.

12. Clean the base plate and the mould from outside. Weigh it to the nearest gram.

13. Remove the soil from the mould. The soil may also be ejected out.

14. Take the soil samples for the water content determination from the top, middle and bottom portions. Determine the water

content.

15. Add about 3% of the water to a fresh portion of the processed soil, and repeat the steps 10 to 14.


(a)MOULD b) Rammer

Fig: Standard Proctor Test (Compaction Test)

Plot a curve between w as abscissa and as ordinate.

Fig: Compaction Curve

TEST5-CALIFORNIA BEARING RATIO TEST

AIM:To determine the California Bearing Ratio value of the subgrade soil.

APPARATUS:Loading machine-any compression machine can operate at constant rate of 1.25mm per minute can be used.

Cylindrical moulds- moulds of 150mm diameter and 175mm height provided with a collar of about 50mm length and detachable

perforated base. Compaction rammer, surcharge weight-annular weights each of 2.5kg and 147mm diameter. IS sieve 20mm,

Coarse filter paper, balance etc.


THEORY:The California Bearing Ratio(CBR) test was developed by the California Division of Highways as a method of

classifying and evaluating soil- subgrade and base course materials for flexible pavements. CBR is a measure of resistance of a

material to penetration of standard plunger under controlled density and moisture conditions. CBR test may be conducted in

remoulded or undisturbed sample. Test consists of causing a cylindrical plunger of 50mm diameter to penetrate a pavement

component material at 1.25mm/minute. The loads for 2.5mm and 5mm are recorded. This load is expressed as a percentage of

standard load value at a respective deformation level to obtain CBR value.

PROCEDURE:

Sieve the sample through 20mm IS sieve. Take 5kg of the sample of soil specimen. Add water to the soil in the quantity such that

optimum moisture content or field moisture content is reached. Then soil and water are mixed thoroughly. Spacer disc is placed

over the baseplate at the bottom of mould and a coarse filter paper is placed over the spacer disc. The prepared soil water mix is

divided into five. The mould is cleaned and oil is applied. Then fill one fifth of the mould with the prepared soil. That layer is

compacted by giving 56 evenly distributed blows using a hammer of weight 4.89kg. The top layer of the compacted soil is

scratched. Again second layer is filled and process is repeated. After 3rd layer, collar is also attached to the mould and process is

continued. After fifth layer collar is removed and excess soil is struck off. Remove base plate and invert the mould. Then it is

clamped to baseplate.

Surcharge weights of 2.5kg is placed on top surface of soil. Mould containing specimen is placed in position on the testing

machine. The penetration plunger is brought in contact with the soil and a load of 4kg(seating load) is applied so that contact

between soil and plunger is established. Then dial readings are adjusted to zero. Load is applied such that penetration rate is

1.25mm per minute. Load at penetration of 0.5,1,1.5,2,2.5,3,4,5,7.5,10 and 12.5mm are noted.

Standard Load Values

Penetration(mm)

Standard

Load(kg)

Unit Standard

Load(kg/cm2)

2.5 1370 70

5 2055 105

7.5 2630 134

10.0 3180 162

12.5 3600 183


TEST 6-FREE SWELLING INDEX

Free swell or differential free swell, also termed as free swell index, is the increase in volume of soil without any external

constraint when subjected to submergence in water. The apparatus used :

i) IS Sieve of size 425µm

ii)Oven

iii)Balance,withanaccuracyof0.01g

iv) Graduated glass cylinder- 2 nos., each of 100ml capacity

Procedure to determine Free Swell Index Of Soil

i) Take two specimens of 10g each of pulverised soil passing through 425µm IS Sieve and oven-dry.

ii) Pour each soil specimen into a graduated glass cylinder of 100ml capacity.

iii) Pour distilled water in one and kerosene oil in the other cylinder upto 100ml mark.

iv) Remove entrapped air by gently shaking or stirring with a glass rod.

v) Allow the suspension to attain the state of equilibrium (for not less than 24hours).

vi) Final volume of soil in each of the cylinder should be read out.

TEST 7 IN-SITU DRY DENSITY BY SAND REPLACEMENT METHOD

Theory:A hole of specified dimensions is excavated in the ground. The mass of the excavated soil is determined.

The volume of the hole is determined by filling it with clean, uniform sand whose dry density ( ) is determined separately by

calibration. The volume of the hole is equal to the mass of the sand filled in the hole divided by its dry density.

The dry density of the excavated soil is determined as

Where M= mass of the excavated soil, V= volume of the hole and w= water content.


Equipment:

1. Sand – pouring cylinder

2. Calibrating container, 100mm diameter and 150mm height

3. Soil cutting and excavating tools, such as scrapper tool, bent spoon

4. Glass plate, 450mm square, 9mm thick

5. Metal container to collect excavated soil

6. Metal tray, 300mm square and 40mm deep with a hole of 100mm in diameter at the centre

7. Weighing balance

8. Moisture content cans

9. Oven

10. Desiccator

Clean, uniform sand passing 1mm IS sieve and retained on 600micron IS sieve in sufficient quantity.

Part-I: Calibration

Procedure:

1. Determine the internal volume of the calibrating container by filling it with water and determining the mass of water required.

The mass of water in grams is approximately equal to the volume in mililitres. The volume may also be determined from the

measured dimensions of the container.

2. Fill the sand-pouring cylinder with sand, within about 10mm of its top. Determine the mass of the cylinder (M1) to the nearest

gram.

3. Place the sand-pouring cylinder vertically on the calibrating container. Open the shutter to allow the sand run out from the

cylinder. When there is no further movement of the sand in the cylinder, close the shutter.

4. Lift the pouring cylinder from the calibrating container and weigh it to the nearest gram (M3).

5. Again fill the pouring cylinder with sand, within 10mm of its top.

6. Open the shutter and allow the sand to run out of the cylinder. When the volume of the sand let out is equal to the volume of

the calibrating container, close the shutter.


7. Place the cylinder over a plane surface, such as a glass plate. Open the shutter. The sand fills the cone of the cylinder. Close the

shutter when no further movement of sand takes place.

8. Remove the cylinder. Collect the sand left on the glass plate. Determine the mass of sand (M 2) that had filled the cone by

weighing the collected sand.

9. Determine the dry density of sand, as shown in the data sheet, part-I.

Part-II: Dry density

Procedure:

1. Expose an area of about 450mm square on the surface of the soil mass. Trim the surface down to a level surface using a

scrapper tool.

2. Place the metal tray on the leveled surface.

3. Excavate the soil though the central hole of the tray, using the hole in the tray as a pattern. The depth of the excavated hole

should be about 150mm.

4. Collect all the excavated soil in a metal container, and determine the mass of the soil (M).

5. Remove the metal tray from the excavated hole.

6. Fill the sand pouring cylinder within 10mm of its top. Determine its mass (M1).

7. Place the cylinder directly over the excavated hole. Allow the sand to run out the cylinder by opening the shutter. Close the

shutter when the hole is completely filled and no further movement of sand is observed.

8. Remove the cylinder from the filled hole. Determine the mass of the cylinder (M4).

9. Take a representative sample of the excavated soil. Determine its water content.

COARSE AGGREGATE TESTING

TEST 1GRAIN SIZE ANALYSIS

AIM:

To determine the particle size distribution of the given COARSE aggregate and to determine ,the

THEORY


Coarse aggregate is the broken stone used in concrete .The coarse aggregate unless mixed with fine aggregate serves no purpose

in cement works .the size of fine aggregate is limited to a maximum of 4.75 mm gauge beyond which it is known as coarse

aggregate .

EFFECTIVE SIZE

Effective size (in microns) is the maximum particle size of the smallest 10% of the aggregate or it is the sieve opening

corresponding to 10% finer and is designated by the symbol D10.

APPARATUES

Indian standard test sieves, weighing balance ,sieve shaker etc .

Size of sieves to be used

(I) For coarse aggregate-25mm,20mm 12.5mm, 10mm, 4.75mm

PROCEDURE

. (i)Take one kg of coarse aggregate

(ii)Arrange the sieves one over the other in relation to their size of opening.(25mm,20mm,12.5mm10mm,4.75mm)

(iii) Carry out the sieving for the specified time

(iv) Find the weight of agggregate retained on each sieve taken in order and tabulate in table.

GRADING LIMITS FOR AGGREGATES

GRADING LIMIT FOR SINGLE – SIZED AGGREGATES

(Clause 4.1 and 4.2 of IS: 383- 1970)

IS SievePercentage passing for single sized aggregates of nominal size(mm)

63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm

80 mm 100 - - - - -

63 mm 85 – 100 100 - - - -

40 mm 0 – 30 85 – 100 100 - - -

20 mm 0 – 5 0 – 20 85 – 100 100 - -

16 mm - - - 85 – 100 100 -

12.5 mm - - - - 85 – 100 100


10 mm 0 – 5 0 – 5 0 – 20 0 – 30 0 – 45 85 – 100

4.75 mm - - 0 – 5 0 – 5 0 – 10 0 – 20

2.36 mm - - - - - 0 – 5

GRADING LIMITS FOR FINE AGGREGATES

(Clause 4.3 of IS: 383 – 1970)

IS Sieve Designation

Percentage PassingGradingZone I

GradingZone II

GradingZone III

GradingZone IV

10 mm 100 100 100 100

4.75 mm 90 – 100 90 – 100 90 – 100 95 – 100

2.36 mm 60 – 95 75 – 100 85 – 100 95 – 100

1.18 mm 30 – 70 55 – 90 75 – 100 90 – 100

600 micron 15 – 34 35 – 59 60 – 79 80 – 100

300 micron 5 – 20 8 – 30 12 – 40 15 – 50

150 micron 0 – 10 0 – 10 0 – 10 0 – 15

TEST2-Aggregate Impact Value

Impact testing machine conforming to IS: 2386 (Part IV)- 1963,IS Sieves of sizes – 12.5mm, 10mm and 2.36mm, A

cylindrical metal measure of 75mm dia. and 50mm depth, A tamping rod of 10mm circular cross section and 230mm

length, rounded at one end and Oven.

Preparation of Sample

i) The test sample should conform to the following grading:

- Passing through 12.5mm IS Sieve – 100%

- Retention on 10mm IS Sieve – 100%

ii) The sample should be oven-dried for 4hrs. at a temperature of 100 to 110oC and cooled.

iii) The measure should be about one-third full with the prepared aggregates and tamped with 25 strokes of the tamping

rod.

A further similar quantity of aggregates should be added and a further tamping of 25 strokes given. The measure should

finally be filled to overflow, tamped 25 times and the surplus aggregates struck off, using a tamping rod as a straight edge.

The net weight of the aggregates in the measure should be determined to the nearest gram (Weight ‘A’).


Procedure to determine Aggregate Impact Value

i) The cup of the impact testing machine should be fixed firmly in position on the base of the machine and the whole of the

test sample placed in it and compacted by 25 strokes of the tamping rod.

ii) The hammer should be raised to 380mm above the upper surface of the aggregates in the cup and allowed to fall freely

onto the aggregates. The test sample should be subjected to a total of 15 such blows, each being delivered at an interval of

not less than one second.

TEST-AGGREGATECRUSHINGVALUE

This test helps to determine the aggregate crushing value of coarse aggregates as per IS: 2386 (Part IV) – 1963. The

apparatus used is Cylindrical measure and plunger, Compression testing machine, IS Sieves of sizes – 12.5mm, 10mm and

2.36mm

Procedure to determine Aggregate Crushing Value

i) The aggregates passing through 12.5mm and retained on 10mm IS Sieve are oven-dried at a temperature of 100 to 110oC

for 3 to 4hrs.

ii) The cylinder of the apparatus is filled in 3 layers, each layer tamped with 25 strokes of a tamping rod.

iii) The weight of aggregates is measured (Weight ‘A’).

iv) The surface of the aggregates is then leveled and the plunger inserted. The apparatus is then placed in the compression

testing machine and loaded at a uniform rate so as to achieve 40t load in 10 minutes. After this, the load is released.

v) The sample is then sieved through a 2.36mm IS Sieve and the fraction passing through the sieve is weighed (Weight

‘B’).

vi) Two tests should be conducted.

Aggregate crushing value = (B/A) x 100%.

TEST4-AGGREGATEABRASIONVALUE

This test helps to determine the abrasion value of coarse aggregates as per IS: 2386 (Part IV) – 1963.

The apparatus used in this test are Los Angles abrasion testing machine, IS Sieve of size – 1.7mm, Abrasive charge – 12

nos. cast iron or steel spheres approximately 48mm dia. and each weighing between 390 and 445g ensuring that the total

weight of charge is 5000 +25g and Oven.

Sample Preparation


The test sample should consist of clean aggregates which has been dried in an oven at 105 to 110oC to a substantially

constant weight and should conform to one of the gradings shown in the table below:

Procedure to determine Aggregate Abrasion Value

The test sample and the abrasive charge should be placed in the Los Angles abrasion testing machine and the machine

rotated at a speed of 20 to 33 revolutions/minute for 1000 revolutions. At the completion of the test, the material should be

discharged and sieved through 1.70mm IS Sieve.

Reporting of Results

i) The material coarser than 1.70mm IS Sieve should be washed, dried in an oven at a temperature of 100 to 110 oC to a

constant weight and weighed (Weight ‘B’).

ii) The proportion of loss between weight ‘A’ and weight ‘B’ of the test sample should be expressed as a percentage of the

original weight of the test sample. This value should be reported as,

Aggregate abrasion value = (A-B)/B x 100%.


TEST5-SPECIFIC GRAVITY OF CORSE AGGREGATES

AIM:To determine the specific gravity of given sample of fine and coarse aggregates.

Apparatus

1. A balance or scale of capacity not less than 3 kg, readable and accurate to 0.5 g and of such a type and shape as to permit the basket

containing the sample to be suspended from the beam and the weighed in water.

2. A well ventilated oven thermostatically controlled to maintain a temperature of 100oC to 110oC.

3. A wire basket of not more than 6.3 mm mesh or a perforated container of convenient size.

4. A stout water tight container of convenient size.

5. Two dry soft absorbent cloths each not less than 75×45 cm

6. A shallow tray of area no less than 650 cm2

7. An air tight container of capacity similar to that of the basket.

Procedure

(I) Take 2 kg of aggregate. Sample larger than 10mm

(ii)Wash the sample thoroughly to remove finer particle and dust.

(iii) Place the sample in a wire basket and immerse it in distilled water at a temperature between 22oC and 32oC with a cover of

at least 5 cm of water above the top of the basket.

(iv) Remove the entrapped air by lifting the basket containing the sample 25 mm above the base of the tank and allowing it to

drop per second, care being taken to see that the sample is completely immersed in water during the operation.

(v) With the sample in water at a temper of 220C-32oC (W).

(vi) Remove the basket and aggregate from water and allow To drain for a few minutes.

(vii) Empty the aggregate from the basket to a shallow tray.

(viii) Immerse the empty basket in water jolt 25 times and than the weight in water (w2).

(ix) Place the aggregates in oven at a temperature of 100oC to 110oC for 24+- 0.5 hours.

(x) Remove it from the oven and cool it and find the weight. (w2)


TEST 6-BULK DENSITY AND PERCENTAGE VOIDS OF AGGREGATES

Aim:To determine the bulk density and percentage voids of aggregate .

Apparatus

(I)Balance -A balance sensitive to 0.5% of the weight of the sample to be weighed .

(ii) Cylindrical Metal Measure- The measure shall be of 3,15 or 30 liters capacity and shall comply with the requirements given

below.

.

.

.

Size of largest particle Nominal capacity

4.75mm and under 3 liters

Over 4.75 mm to 40mm 15 liters

Over 40mm 30 liters

4. Tamping Rod- A straight metal tamping rod of cylindrical cross section 16 mm in diameters 60 cm long , rounded at one end .

Procedure

Take the weight of empty measure (W)

(ii) Fill the measure with aggregates sample for about one third height and tam evenly with 25 strokes of the rounded end of the

tamping rod

(iii) Add a similar quantity of aggregate as second layer and tamp it evenly with 25 strokes.

(iv) Fill the measure with a third layer of aggregate up to over following and tamp it with 25 strokes


(v) Strike off the surplus aggregate using the tamping rod as a straight edge.

(vi) Take the weight (w1)

(vii) Empty the measure and fill it again to over flowing by means of a shovel, the aggregate being discharged from a height not

exceeding 5 cm above the top of the measure.

(viii)Level the surface of the measure and weight it (w2).

r = Bulk density of aggregate in kg / liter.

3. FINE AGGREGATE TESTING

GRAIN SIZE ANALYSIS

AIM

To determine the particle size distribution of the given fine aggregate and to determine ,the fineness modulus,the effective .

THEORY

Fine aggregate is the sand used in mortars.the size of fine aggregate is limited to a maximum of 4.75 mm gauge beyond which it

is known as coarse aggregate .

FINENESS MODULUS.

Fineness modulus is only a numerical index of fineness, giving some idea of the mean size of the particle s in the entire body of

the aggregate. To a certain extent it is a method of standardization of the grading of the aggregate. It is obtained by adding the

percentage weight of material retained in each of the standard sieves and dividing it by 100.

To object of finding the fineness modulus is to grade a given aggregate for the most economical mix and workability with

minimum quantity of cement .Certain limits of fineness modulus for fine coarse aggregates are given in the table below and a

sample under test should satisfy these results so that the aggregate may give good workability under economical conditions.

LIMIT OF FINENESS MODULUS

Maximum size of aggregate

Fineness modulus

Minimum Maximum

Fine Aggregate 2 3.5

Coarse aggregate 20mm 6 6.9


Coarse aggregate 40mm 6.9 7.5

Coarse aggregate 75mm 7.5 8.0

APPARATUES

Indian standard test sieves, weighing balance ,sieve shaker etc .

Size of sieves to be used.

(I) for fine agggregate- 4.75mm, 2.36mm, 1.18mm, 600 microns, 300microns ,150microns .

.

PROCEDURE

FINE AGGREGATE

(i)Take one kg of sand from the laboratory sample

(ii)Arrange the sieves in order of IS sieves no’s 480, 240, 120, 60, 30 and 15, Keeping sieve no.480 at the top and 15 at the

bottom and cover the top.

(iii)Keep the sample in the top sieve no.480.

(iv) Carry out the sieving in the set of sieves for not less than 10 minutes .

(v) find the weight of sample retained in each sieve.

(vi) Tabulate the values in given tabular column .

4. Effective size =……………..micron


5. Uniformity coefficient =

6. Fineness modulus =

TEST 2-SILT CONTENT

TEST3- SPECIFIC GRAVITY OF FINE AGGREGATES

AIM

To determine the specific gravity of given sample of fine aggregates.

1.A balance of capacity not less than 3kg ,readable and accurate to 0.5 gm and of such a type as to permit the weighing of the

vessel containing the aggregate and water .

2.A well ventilated oven to maintain a temperature of 100ºC to 110ºC

3.Pyconometer of about 1 littre capacity having a metal conical screw top with a 6mm hole at its apex . The screw top shall be

water tight .

4.a means supplying a current warm air .

5.A tray of area not less than 32cm².

6.An air tight container large enough to take the sample.

7.Filter papers and funnel.

Procedure

(I) Take about 500g of sample and place it in the pycnometer.

(II) Pour distilled water into it until it is full.


(III) Eliminate the entrapped air by rotating the pycnometer on its side ,the hole in the apex of the cone being covered with a

finger.

(IV) Wipe out the outer surface of pycnometer and weigh it (W)

(V) Transfer the contents of the pycnometer into a tray , care being taken to ensure that all the aggregate is transferred .

(VI) Refill the pycnometer with distilled water to the same level .

(VII) Find out the weight (W1)

(VIII) drink water from the sample through a filter paper .

(IX) Place the sample in oven in a tray at a temperature of 100ºC to 110º C for 24±0.5 hours ,during which period ,it is stirred

occasionally to facilitate drying .

(X) Cool the sample and weigh it (W2)

PROPERTIES OF AGGREGATES

1. AGGREGATES: BULK DENSITY, SPECIFIC GRAVITY AND VOIDSBULK DENSITY

River sand

Fine 1.44

Medium 1.52

Coarse 1.60

Beach or river shingle 1.60

Broken stone 1.60

Stone screenings 1.44

Broken Granite 1.68

SPECIFIC GRAVITY

Trap 2.9

Granite 2.8

Gravel 2.66

Sand 2.65

VOIDS, PERCENT, AVERAGE

River sand


Fine 43

Coarse 35

Mixed and moist 38

Mixed and dry 30

Broken stone, graded

25 mm maximum size 46



Stone screenings 48

Note: Above values are indicative only

2. AGGREGATES: LIMITING VALUES OF MECHANICAL PROPERTIES

PROPERTIES

LIMITING VALUES (PERCENTAGE)

FOR WEARING SURFACESOTHERTHAN FOR WEARING SURFACES

Crushing value 30 45

Impact value 30 45

Abrasion value (Los Angeles) 30 50

Soundness (Average loss of weight after 5 cycles) When tested with Na2SO4 When tested with MgSO4

Fine aggregates 10 15

Coarse aggregates 12 18

*Source- IS: 383 – 1970

3. APPROXIMATE WATER ABSORPTION OF AGGREGATES, BY WEIGHTAverage sand 1.0 percentPebbles and crushed limestone 1.0 percentTrap rock and granite 0.5 percentPorous sandstone 0.5 percentVery light and porous aggregates may absorb as much as 25 percent by weight


Note: The coarser the aggregate, the less free water it carries.

4. LIMITS OF DELETERIOUS MATERIALS (Percentage by weight, maximum)

(Clause 3.2.1 of IS: 383 – 1970)DELETERIOUS SUBSTANCES

FINE AGGREGATES COARSE AGGREGATESUncrushed Crushed Uncrushed Crushed

Coal and lignite 1.00 1.00 1.00 1.00

Clay lumps 1.00 1.00 1.00 1.00

Materials finer than 75 micron sieve 2.00 15.00 3.00 3.00

Shale 1.00 - - -

Total of percentages of all deleterious materials ** 5.00 2.00 5.00 5.00

5. SURFACE WATER CARRIED BY AGGREGATES

AGGREGATESAPPROXIMATE QTY OF SURFACE WATERPercent by mass Ltr./cu.m

Very wet sand 7.5 120

Moderately wet sand 5.0 80

Moist sand 2.5 40

Moist gravel or crushed rock 1.25 – 2.5 20 – 40

Note: Coarser the aggregate, less the water it will carry

Source: Table 10 of IS: 456 – 2000

4. CEMENT TESTING

TEST1FINENESS

So we need to determine the fineness of cement by dry sieving as per IS: 4031 (Part 1) – 1996.The principle of this is that

we determine the proportion of cement whose grain size is larger then specified mesh size.

The apparatus used are 90µm IS Sieve, Balance capable of weighing 10g to the nearest 10mg, A nylon or pure bristle


brush, preferably with 25 to 40mm, bristle, for cleaning the sieve.

Sieve shown in pic below is not the actual 90µm seive.Its just for reference.

Procedure to determine fineness of cement

i) Weigh approximately 10g of cement to the nearest 0.01g and place it on the sieve.

ii) Agitate the sieve by swirling, planetary and linear movements, until no more fine material passes through it.

iii) Weigh the residue and express its mass as a percentage R1,of the quantity first placed on the sieve to the nearest 0.1

percent.

iv) Gently brush all the fine material off the base of the sieve.

v) Repeat the whole procedure using a fresh 10g sample to obtain R2. Then calculate R as the mean of R1 and R2 as a

percentage, expressed to the nearest 0.1 percent. When the results differ by more than 1 percent absolute, carry out a third

sieving and calculate the mean of the three values.

TEST2- STANDARD CONSISTENCY OF CEMENT

To determine the quantity of water required to produce a cement paste of standard consistency.

The standard consistency is that consistency, which will permit the vicat plunger to penetrate to a point 5 to 7mm from the

bottom of the vicat mould when tested as described below.

APPARATUS

1. VICAT APPARATUS

The vicat apparatus consists of a frame having a movable rod with a cap at one end and at the other end any one of the following

attachment, which are interchangeable.

i) Needle for determining the initial setting time

ii) Needle for determining the final setting time

iii) Plunger for determining the standard consistency

2.NEEDLES

NEEDLE FOR INITIAL SETTING TIME


The needle is having a cross sectional area of 1mm2. The end of the needle is flat.

NEEDLE FOR FINAL SETTING TIME

The needle is circular having a cross sectional area of 1mm2. The needle is fitted with a metal attachment. The end of the needle

projects beyond the cutting edge of the hollowed out metal attachment.

1. PLUNGER FOR STANDARD CONSISTANCY

It is of polished brass 10 ± 0.05mm in diameter with a projection at the upper end for insertion into the movable rod. The lower

end is flat.

MOVABLE ROD

Movable rod carries an indicator which moves over a graduated scale attached to the frame (certain models have an additional

attachment of dash pot, which facilitates lowering of movable rod slowly).

4. GRUADUATED SCALE

Graduated scale is 40mm in length and the smallest division of scale is 1mm.

5. VICAT MOULD

Single mould: – The vicat mould is in the foam of a frustum of a cone having an internal diameter of 60+/-0.5mm at the top, 70

+/- 0.5mm at the bottom and height 40 +/_ 0.5mm.

1.1.2.2.2 Split type vicat mould:- The split type vicat mould is used as an alternative to single mould. This mould consist of a

split ring having an internal diameter 80+/- 0.1mm and a height 40+/_0.5mm. A non-porous base plate is provided. The split

mould is provided with a suitable clamping ring.

PROCEDURE

1. Keep the vicat apparatus on a level base (when using vicat apparatus with dash pot, keep the bearing movable rod to its highest

position and pin it.) Unscrew the top of the dash pot. Half fill the dash pot with any suitable oil of viscosity and screw the top. Work

the plunger a number of times.

2. Attach the plunger for determining standard consistency to the movable rod. Work the plunger a number of times.

Take 400 gm of cement in a pan and a weighed quantity of water in a beaker.

3. Prepare a paste with the water added to cement. Start a stop watch at the time of adding water to cement.

4. Keep the vicat mould on a non porous plate and fill the cement paste in it.

5. After completely filling the mould, shake it slightly to expel the air. Smooth off the surface of the paste making it level with

the top of the moulder. The cement paste thus prepared is the test block.


6. Place the test block resting on the non porous plate under the movable rod, bearing the needle.

7. Lower the plunger gently to touch the surface of the cement paste and quickly release; (when vicat apparatus with dash pot is

used, place the mould filled with cement paste and the non absorbent plate on the base plate of the vicat apparatus. Raise the

plunger of the dash pot, bring it in contact with the top cap of the movable bearing rod. Remove the pin holding the movable

bearing rod to the surface of the cement paste and quickly release by pushing down the plunger to sink in to the paste). This

operation shall be done immediately after filling the mould.

8. Prepare trial test specimens with varying percentages of water until plunger penetrates to a point 5 to 7mm from the bottom of

the vicat mould, which is read on the scale. Express the water required as percentage by weight of the dry cement.

POINTS TO BE NOTED

1. The time of gauging should not be less than 3 minutes and not more than 5 minutes. Gauging time is the time elapsing from the

time of adding water to the dry cement until commencing to fill the mould.

2. The test should be conducted at room temperature 27oC +/- 2oC

3. There should be no vibration on the working table.

4. The plunger should be cleaned during every repetition.

TEST3-SOUNDNESS

Soundness of cement is determined by Le-Chatelier method as per IS: 4031 (Part 3) – 1988.

Apparatus – The apparatus for conducting the Le-Chatelier test should conform to IS: 5514 – 1969

Balance, whose permissible variation at a load of 1000g should be +1.0g and Water bath.

Procedure to determine soundness of cement

i) Place the mould on a glass sheet and fill it with the cement paste formed by gauging cement with 0.78 times the water

required to give a paste of standard consistency.

ii) Cover the mould with another piece of glass sheet, place a small weight on this covering glass sheet and immediately

submerge the whole assembly in water at a temperature of 27 ± 2oC and keep it there for 24hrs.

iii) Measure the distance separating the indicator points to the nearest 0.5mm (say d1 ).


iv) Submerge the mould again in water at the temperature prescribed above. Bring the water to boiling point in 25 to 30

minutes and keep it boiling for 3hrs.

v) Remove the mould from the water, allow it to cool and measure the distance between the indicator points (say d 2 ).

vi) (d2 – d1 ) represents the expansion of cement.

TEST-4 INITIAL SETTING TIME OF CEMENT (IS 4031, IS 269)

AIM

To find the initial setting time of cement

APPARATUS

Vicat apparatus, needle for initial setting time, stop watch.

PROCEDURE

Take 400 gm of cement in a pan. Prepare a neat cement paste by adding 0.85 times the water required to give a paste of standard

consistency by the previous test. Start a stop watch at the instant when water is added to the cement. Keep the vicat mould on a

non porous plate and fill the cement paste in it. After completely filling the mould, it should be shaken slightly to expel the air.

Smooth off the surface of the paste making it level with the top of the mould.

Place the test block and the non porous plate under the rod bearing the needle having 1sq.mm.cross section. Lower the needle

gently till in contact with the surface of the test block and quickly release allowing it to penetrate in to the test block.(When vicat

apparatus with dash pot is used, place the mould filled with cement paste and the non absorbent plate on the base of the vicat

apparatus .Raise the in the beginning the needle will completely pierce the block. Repeat the procedure until the needle fails to

pierce block for 5+-0.5mm measured from the bottom of the mould. The period elapsing between the time when water is added to

the cement and the time at which the needle fails to pierce the test block by 5+-0.5mm is the initial testing time.

TEST5-

SPECIFIC GRAVITY OF CEMENT

AIM

To determine the specific gravity is normally defined as the ratio between the weight of a given volume of material and weight of

an equal volume of water.To determine the specific gravity of cement, kerosene which doe snot recent with cement is used.


APPARATUES

Le Chaterlier”s flask, weighing balance, kerosene (free from water).

Le Chaterlier”s flask, is made of thin glass having a bulb at the bottom. The capacity of the bulb is nearly 250 ml. The bulb is 7.8

cm in mean diameter. The stem is graduated in millimeters. The zero graduation is at a distance of 8.8 cm from the top of the

bulb. At 2 cm from the zero, there is another bulb is of length 3.5cm and capacity 17 ml. At 1 cm from bulb, the stem is marked

with 18 ml and is grated up to 24 ml. The portion above 24ml mark is in the form of a funnel of diameter 5cm.

PROCEDURE

(I) Dry the flask carefully and fill with kerosene or naphtha to a point on the stem between zero and 1 ml.

(II) Record the level of the liquid in the flask as initial reading.

(III) Put a weighted quantity of cement (about 60 gm) into the flask so that level of kerosene rise to about 22 ml mark, care being

taken to avoid splashing and to see that cement does not adhere to the sides of the above the liquid.

(IV) After putting all the cement to the flask, roll the flask gently in an inclined position to expel air until no further air bubble

rise3s to the surface of the liquid.

(V) Note down the new liquid level as final reading.

TEST6- COMPRESSIVE STRENGTH OF MORTAR CUBES

AIM

To find the compressive strength of standard cement sand mortar cubes.

APPARATUS

7.06cm cubes moulds (50cm2 face area), apparatus for gauging and mixing mortar, vibrator, compression testing maching etc.


PROCEDURE

Take 200gm of cement and 600gm of standard sand in the proportion 1:3 by weight) in a pan. (The standard sand shall be of

quartz, of light, gray or whitish variety and shall be free from silt. The sand grains shall be angular, the shape of grains

approximating to the spherical form, elongated and flattened grains being present only in very small quantities.

Standard sand shall pass through 2mm IS sieve and shall be retained on 90 microns IS sieve with the following particle size

distribution.

Mix the cement and sand in dry condition with a trowel for 1minitues and then add water. The quantity of water shall be

(p/4+3)% of combined weight of cement and sand where, p is the % of water required to produce a paste of standard consistency

determined earlier. Add water and mix it until the mixture is of uniform colour. The time of mixing shall not be < 3 minutes &

not > 4 minutes. Immediately after mixing the mortar, place the mortar in the cube mould and prod with the help of the rod. The

mortar shall be prodded 20 times in about 8 sec to ensure elimination of entrained air. If vibrator is used, the period of vibration

shall be 2minitues at the specified speed of 12000+-400 vibrations /minutes. Then place the cube moulds in temperature of

27±2o C and 90% relative humidity for 24 hours. After 24 hours remove the cubes from the mould and immediately submerge in

clean water till testing. Take out the cubes from water just before testing. Testing should be done on their sides without any

packing. The rate of loading should be 350 kg/cm2/minute and uniform. Test should be conducted for 3 cubes and report the

average value as the test result for both 7day and 28 day compressive strength.

PHYSICAL & CHEMICAL PROPERTIES OF OPC OF VARIOUS GRADES

Physical and Chemical Properties of Ordinary Portland Cement (OPC) of Various Grades

Type of Cement

33 Grade(IS: 269-1989)

43 Grade(IS:8112-1989)

53 Grade(IS: 12269-1987)

PHYSICAL PROPERITES

Minimum Compressive Strength, N/mm2

3 day 16 23 27


7 day 22 33 3728 day 33 43 53

Fineness

Minimum specific surface (Blaine’s air permeability) m2/kg 225 225 225Setting times (minutes)Initial, minimum 30 30 30Final,maximum 600 600 600

Soundness, expansion (Le Chatelier Test, mm), maximum 10.0 10.0 10.0Autoclave test for MgO, percent, maximum 0.8 0.8 0.8

CHEMICAL PROPERTIESLoss on ignition, percent, maximum 5 5 4Insoluble residue, percent, maximum 4 2 2Magnesia Mgo, percent maximum 6 6 6

SO3 , percent, maximum for: C3A>5 percent 2.5 2.5 2.5C3A<5 percent 3 3 3 Lime saturation factor (LSF) 0.66 to 1.02 0.66 to 1.02 0.8 to 1.02

5. CONCRETE TESTING

TEST1-COMPRESSIVE STRENGTH OF CONCRETE CUBESTEST 2-REBOUND HAMMER


TEST 3-Concrete Mix Design As Per Indian Standard Code.

Concrete Mix DesignIntroductionThe process of selecting suitable ingredients of concrete and determining their relative amounts

with the objective of producing a concrete of the required, strength, durability, and workability

as economically as possible, is termed the concrete mix design. The proportioning of ingredient

of concrete is governed by the required performance of concrete in 2 states, namely the plastic

and the hardened states. If the plastic concrete is not workable, it cannot be properly placed and

compacted. The property of workability, therefore, becomes of vital importance.

The compressive strength of hardened concrete which is generally considered to be an index of

its other properties, depends upon many factors, e.g. quality and quantity of cement, water and

aggregates; batching and mixing; placing, compaction and curing. The cost of concrete is made

up of the cost of materials, plant and labour. The variations in the cost of materials arise from the

fact that the cement is several times costly than the aggregate, thus the aim is to produce as lean a

mix as possible. From technical point of view the rich mixes may lead to high shrinkage and

cracking in the structural concrete, and to evolution of high heat of hydration in mass concrete

which may cause cracking.

The actual cost of concrete is related to the cost of materials required for producing a minimum

mean strength called characteristic strength that is specified by the designer of the structure. This

depends on the quality control measures, but there is no doubt that the quality control adds to the

cost of concrete. The extent of quality control is often an economic compromise, and depends on

the size and type of job. The cost of labour depends on the workability of mix, e.g., a concrete

mix of inadequate workability may result in a high cost of labour to obtain a degree of

compaction with available equipment.

Requirements of concrete mix design

The requirements which form the basis of selection and proportioning of mix ingredients

are :

a ) The minimum compressive strength required from structural consideration

b) The adequate workability necessary for full compaction with the compacting

equipment available.

c) Maximum water-cement ratio and/or maximum cement content to give adequate

durability for the particular site conditions


d) Maximum cement content to avoid shrinkage cracking due to temperature cycle in

mass concrete.

Types of Mixes 1. Nominal Mixes

In the past the specifications for concrete

prescribed the proportions of cement, fine and

coarse aggregates. These mixes of fixed cement-

aggregate ratio which ensures adequate strength

are termed nominal mixes. These offer

simplicity and under normal circumstances, have

a margin of strength above that specified.

However, due to the variability of mix

ingredients the nominal concrete for a given

workability varies widely in strength.

2. Standard mixes

The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and may

result in under- or over-rich mixes. For this reason, the minimum compressive strength has been

included in many specifications. These mixes are termed standard mixes.

IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M20,

M25, M30, M35 and M40. In this designation the letter M refers to the mix and the number to

the specified 28 day cube strength of mix in N/mm2. The mixes of grades M10, M15, M20 and

M25 correspond approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and (1:1:2)

respectively.

3. Designed Mixes

In these mixes the performance of the concrete is specified by the designer but the mix

proportions are determined by the producer of concrete, except that the minimum cement content

can be laid down. This is most rational approach to the selection of mix proportions with specific

materials in mind possessing more or less unique characteristics. The approach results in the

production of concrete with the appropriate properties most economically. However, the

designed mix does not serve as a guide since this does not guarantee the correct mix proportions

for the prescribed performance.

For the concrete with undemanding performance nominal or standard mixes (prescribed in the

codes by quantities of dry ingredients per cubic meter and by slump) may be used only for very

small jobs, when the 28-day strength of concrete does not exceed 30 N/mm2. No control testing

is necessary reliance being placed on the masses of the ingredients.


Factors affecting the choice of mix proportions

The various factors affecting the mix design are:

1. Compressive strength

It is one of the most important properties of concrete and influences many other describable

properties of the hardened concrete. The mean compressive strength required at a specific age,

usually 28 days, determines the nominal water-cement ratio of the mix. The other factor affecting

the strength of concrete at a given age and cured at a prescribed temperature is the degree of

compaction. According to Abraham’s law the strength of fully compacted concrete is inversely

proportional to the water-cement ratio.

2. Workability

The degree of workability required depends on three factors. These are the size of the section to

be concreted, the amount of reinforcement, and the method of compaction to be used. For the

narrow and complicated section with numerous corners or inaccessible parts, the concrete must

have a high workability so that full compaction can be achieved with a reasonable amount of

effort. This also applies to the embedded steel sections. The desired workability depends on the

compacting equipment available at the site.

3. Durability

The durability of concrete is its resistance to the aggressive environmental conditions. High

strength concrete is generally more durable than low strength concrete. In the situations when the

high strength is not necessary but the conditions of exposure are such that high durability is vital,

the durability requirement will determine the water-cement ratio to be used.

4. Maximum nominal size of aggregate

In general, larger the maximum size of aggregate, smaller is the cement requirement for a

particular water-cement ratio, because the workability of concrete increases with increase in

maximum size of the aggregate. However, the compressive strength tends to increase with the

decrease in size of aggregate.

IS 456:2000 and IS 1343:1980 recommend that the nominal size of the aggregate should be as

large as possible.

5. Grading and type of aggregate

The grading of aggregate influences the mix proportions for a specified workability and water-

cement ratio. Coarser the grading leaner will be mix which can be used. Very lean mix is not

desirable since it does not contain enough finer material to make the concrete cohesive.

The type of aggregate influences strongly the aggregate-cement ratio for the desired workability

and stipulated water cement ratio. An important feature of a satisfactory aggregate is the

uniformity of the grading which can be achieved by mixing different size fractions.


6. Quality Control

The degree of control can be estimated statistically by the variations in test results. The variation

in strength results from the variations in the properties of the mix ingredients and lack of control

of accuracy in batching, mixing, placing, curing and testing. The lower the difference between

the mean and minimum strengths of the mix lower will be the cement-content required. The

factor controlling this difference is termed as quality control.

Mix Proportion designationsThe common method of expressing the proportions of ingredients of a concrete mix is in the

terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of

proportions 1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or the mix

contains one part of cement, two parts of fine aggregate and four parts of coarse aggregate. The

proportions are either by volume or by mass. The water-cement ratio is usually expressed in

mass

Factors to be considered for mix design

The grade designation giving the characteristic strength requirement of concrete.

The type of cement influences the rate of development of compressive strength of concrete.

Maximum nominal size of aggregates to be used in concrete may be as large as possible within the

limits prescribed by IS 456:2000.

The cement content is to be limited from shrinkage, cracking and creep.

The workability of concrete for satisfactory placing and compaction is related to the size and

shape of section, quantity and spacing of reinforcement and technique used for transportation,

placing and compaction.

Procedure1. Determine the mean target strength ft from the specified characteristic compressive strength at 28-

day fck and the level of quality control.

ft = fck + 1.65 S

where S is the standard deviation obtained from the Table of approximate contents given after

the design mix.

2. Obtain the water cement ratio for the desired mean target using the emperical relationship between

compressive strength and water cement ratio so chosen is checked against the limiting water

cement ratio. The water cement ratio so chosen is checked against the limiting water cement ratio

for the requirements of durability given in table and adopts the lower of the two values.

3. Estimate the amount of entrapped air for maximum nominal size of the aggregate from the table.

4. Select the water content, for the required workability and maximum size of aggregates (for

aggregates in saturated surface dry condition) from table.


5. Determine the percentage of fine aggregate in total aggregate by absolute volume from table for

the concrete using crushed coarse aggregate.

6. Adjust the values of water content and percentage of sand as provided in the table for any

difference in workability, water cement ratio, grading of fine aggregate and for rounded

aggregate the values are given in table.

7. Calculate the cement content form the water-cement ratio and the final water content as arrived

after adjustment. Check the cement against the minimum cement content from the requirements

of the durability, and greater of the two values is adopted.

8. From the quantities of water and cement per unit volume of concrete and the percentage of sand

already determined in steps 6 and 7 above, calculate the content of coarse and fine aggregates per

unit volume of concrete from the following relations:

where V = absolute volume of concrete

= gross volume (1m3) minus the volume of entrapped air

Sc = specific gravity of cement

W = Mass of water per cubic metre of concrete, kg

C = mass of cement per cubic metre of concrete, kg

p = ratio of fine aggregate to total aggregate by absolute volume

fa, Ca = total masses of fine and coarse

aggregates, per cubic metre of concrete,

respectively, kg, and

Sfa, Sca = specific gravities of saturated

surface dry fine and coarse aggregates,

respectively

9. Determine the concrete mix proportions for the first trial mix.

10. Prepare the concrete using the calculated proportions and cast three cubes of 150 mm size and

test them wet after 28-days moist curing and check for the strength.

11. Prepare trial mixes with suitable adjustments till the final mix proportions are arrived at.

EXAMPLE M-20 Mix Designs as per IS-10262-2009


M-20 CONCRETE MIX DESIGN

As per IS 10262-2009 & MORT&H

A-

1 Stipulations for Proportioning

1

Grade Designation M20

2

Type of CementOPC 53 grade confirming to IS-12269-1987

3

Maximum Nominal Aggregate Size 20 mm

4 Minimum Cement Content (MORT&H 1700-3 A) 250 kg/m3

5 Maximum Water Cement Ratio (MORT&H 1700-3 A) 0.5

6

Workability (MORT&H 1700-4) 25 mm (Slump)

7

Exposure Condition Normal

8

Degree of Supervision Good

9

Type of Aggregate Crushed Angular Aggregate

10 Maximum Cement Content (MORT&H Cl. 1703.2) 540 kg/m3

11

Chemical Admixture TypeSuperplasticiser Confirming to IS-9103

A-

2 Test Data for Materials

1

Cement Used Coromandal King OPC 53 grade

2

Sp. Gravity of Cement 3.15


3

Sp. Gravity of Water 1.00

4

Chemical Admixture Not Used

5

Sp. Gravity of 20 mm Aggregate 2.884

6

Sp. Gravity of 10 mm Aggregate 2.878

7

Sp. Gravity of Sand 2.605

8

Water Absorption of 20 mm Aggregate 0.97%

9

Water Absorption of 10 mm Aggregate 0.83%

10

Water Absorption of Sand 1.23%

11 Free (Surface) Moisture of 20 mm Aggregate nil

12 Free (Surface) Moisture of 10 mm Aggregate nil

13

Free (Surface) Moisture of Sand nil

14 Sieve Analysis of Individual Coarse Aggregates Separate Analysis Done

15 Sieve Analysis of Combined Coarse Aggregates Separate Analysis Done

15 Sp. Gravity of Combined Coarse Aggregates 2.882

16

Sieve Analysis of Fine Aggregates Separate Analysis Done

A-

3 Target Strength for Mix Proportioning

1

Target Mean Strength (MORT&H 1700-5) 30N/mm2


2

Characteristic Strength @ 28 days 20N/mm2

A-

4 Selection of Water Cement Ratio

1 Maximum Water Cement Ratio (MORT&H 1700-3 A) 0.5

2

Adopted Water Cement Ratio 0.5

A-

5 Selection of Water Content

1

Maximum Water content (10262-table-2) 186 Lit.

2

Estimated Water content for 25 mm Slump 145 Lit.

3

Superplasticiser used nil

A-

6 Calculation of Cement Content

1

Water Cement Ratio 0.5

2

Cement Content (145/0.5) 290 kg/m3

Which is greater then 250 kg/m3

A-

7 Proportion of Volume of Coarse Aggregate & Fine Aggregate Content

1

Vol. of C.A. as per table 3 of IS 10262 62.00%

2

Adopted Vol. of Coarse Aggregate 65.00%Adopted Vol. of Fine Aggregate ( 1-0.65) 35.00%

A-

8 Mix Calculations

1

Volume of Concrete in m3 1.00


2

Volume of Cement in m3 0.09(Mass of Cement) / (Sp. Gravity of Cement)x1000

3

Volume of Water in m3 0.145(Mass of Water) / (Sp. Gravity of Water)x1000

4

Volume of Admixture @ 0% in m3 nil(Mass of Admixture)/(Sp. Gravity of Admixture)x1000

5

Volume of All in Aggregate in m3 0.763Sr. no. 1 – (Sr. no. 2+3+4)

6

Volume of Coarse Aggregate in m3 0.496Sr. no. 5 x 0.65

7

Volume of Fine Aggregate in m3 0.267Sr. no. 5 x 0.35

A-

9 Mix Proportions for One Cum of Concrete (SSD Condition)

1

Mass of Cement in kg/m3 290

2

Mass of Water in kg/m3 145

3

Mass of Fine Aggregate in kg/m3 696

4

Mass of Coarse Aggregate in kg/m3 1429Mass of 20 mm in kg/m3 1029Mass of 10 mm in kg/m3 400

5

Mass of Admixture in kg/m3 nil

6 Water Cement Ratio 0.5


TEST 4-SLUMP CONE


construction material lab manual

Documents

calibration laboratories

medical testing laboratory

nabl accredited laboratories

nabl accreditation system

accreditation body

area of accreditation

accreditation bodies

medical laboratories