Quality Assurance Hand Book For Rural Roads VolumeII

Ministry of Rural Development Government of India
Quality Assurance Handbook for Rural Roads

Volume-II
EQUIPMENT AND TEST PROCEDURES
May 2007
National Rural Roads Development Agency
Quality Assurance Handbook for Rural Roads has been developed by: Indian Roads C
ongress Kamakoti Marg, Sector-6, R.K. Puram, New Delhi-110022
© All Rights Reserved Published by National Rural Roads Development Agency, Mini
stry of Rural Development, Government of India, New Delhi
Copies can be obtained from National Rural Roads Development Agency Ministry Of
Rural Development, Government Of India #5th, Floor, 15 NBCC Tower, Bhikaji Cama
Place, New Delhi-110066 Ph.: 011-26716930, 011-41000472
QUALITY ASSURANCE HANDBOOK FOR RURAL ROADS VOLUME II CONTENTS
PAGE NO. FORWARD PREFACE ABBREVIATIONS INTRODUCTION Section 100 GENERAL Preamble
119 120 121 Section 300 301 A 301.1 301.2 301.3 301.4 301.5 301.6 B 301.7 (a) 3
01.7 (b) 301.7 (c) Equipment for Field Laboratory Equipment for Laboratory at Di
strict Level Equipment for Central Laboratory EARTHWORKS Embankment Construction
Materials Grain Size Analysis Liquid Limit, Plastic Limits and Plasticity Index
Proctor Density and Relationship between Dry Density and Moisture Content Free
Swell Index Test Deleterious Content (Organic Matter) Deleterious Content (Solub
le Sulphate) Construction & Workmanship Water Content of Soil – Oven Drying Meth
od (Standard Method) Sand Bath Method (Subsidiary Method) Alcohol Method (Subsid
iary Method)
III
1 TO 4 100-1 to 100-11
300-1 to 300-48
301.7 (d) 301.7 (e) 301.8 301.8(a) 301.8(b) 301.8(c) 301.9 301.10 301.11 302 A 3
02.1 302.2 302.3 302.4 302.5 302.6 302.7 B 302.8
Rapid Determination of Water Content with Infra-red Lamp Torsion Balance Moistur
e Meter Rapid Determination of Water Content from Gas Pressure developed by the
Reaction of Calcium Carbide with the Free Water of the Soil Measurement of In-si
tu Density / Degree of Compaction (a) Sand Replacement Method (b) Core Cutter Me
thod (c) Nuclear Density Gauge Horizontal Alignment Surface Levels Surface Regul
arity Earthwork in Cutting Materials Grain Size Analysis Liquid Limit, Plastic L
imit and Plasticity Index Proctor Density Free Swell Index Deleterious Content (
Organic Matter) Deleterious Content (Soluble Sulphate) CBR of Remoulded and Soak
ed Samples Construction & Workmanship Determination of Moisture Content (a) Oven
Drying Method (b) Sand Bath Method (c) Rapid Determination of Moisture Content
using Calcium Carbide
302.9
Density of Compacted Material / Degree of Compaction (a) Sand Replacement Method
(b) Core Cutter Method (c) Nuclear Density Gauge
302.10 302.11
Horizontal Alignment Surface Levels
IV
302.12 303 A 303.1 303.2 303.3 303.4 303.5 303.6 303.7 B 303.8
Surface Regularity Subgrade Construction Materials Grain Size Analysis Liquid Li
mit, Plastic Limit and Plasticity Index Proctor Density Free Swell Index Deleter
ious Content (Organic Matter) Deleterious Content (Soluble Sulphate) CBR of Remo
ulded and Soaked Samples Construction & Workmanship Moisture Content of In-situ
Soil (a) Oven Drying Method (b) Sand Bath Method (c) Rapid Determination of Mois
ture Content using Calcium Carbide
303.9
In-situ Density / Degree of Compaction (a) Sand Replacement Method (b) Core cutt
er Method (c) Nuclear Density Gauge
303.10 303.11 303.12 304
Horizontal Alignment Surface Levels Surface Regularity Rock Cutting Construction
& Workmanship
304.1 304.2 306 A 306.1 306.2
Deviations of Pre-Split Face from Plane passing through adjacent holes. Deviatio
n from Drawings Flyash Embankment Construction Materials Grain Size Analysis of
Fly Ash (Pond Ash) Grain Size Analysis of Soil for Cover
V
306.3 306.4 306.5 306.6 306.7 306.8 306.9 306.10 B 306.11 306.12 306.13 306.14 3
07
Liquid Limit and Plastic Limit of Soil for Cover Proctor Density of Fly Ash (Pon
d Ash ) Proctor Density of Soil for Cover Free Swell Index of Soil for Cover Fre
e Swell Index of Subgrade Material Deleterious Content(Organic Matter) of Soil D
eleterious Content (Soluble Sulphate) of Soil CBR on Remoulded Samples of Soil f
or Cover Construction & Workmanship Measurement of Field Density Horizontal Alig
nment Surface Levels Surface Regularity Surface Drains Cement for Brick Masonry
Drains Bricks for Brick Masonry Drains
307.1 307.2 307.3 307.4
Colour and Size of Bricks Water Absorption of Bricks Efflorescence of Bricks Com
pressive Strength of Bricks Cement for Brick Masonry Drains
307.5
Initial and Final Setting Time of Cement Lime in Lime – Cement Composite Mortar
307.6
Purity of Lime (Available CaO) Sand / Stone Dust / Marble Dust
307.7 307.8
Grain Size Analysis Deleterious Material and Organic Impurities Water
307.9
Suitability of Water for Masonry Work
VI
Cement Sand Mortar 307.11 307.12 307.13 Consistency of Mortar Water Retentivity
of Mortar Compressive Strength of Mortar Construction &Workmanship of Masonry Dr
ains 307.14 307.15 307.16 307.17 Dimensional Tolerances of Bricks Thickness of J
oints for General Brick Work – Tolerance Thickness of Joints for Arches – Tolera
nce Plaster Finish – Tolerance Stone Masonry for Drains 307.18 Cement for Stone
Masonry for Drains Sand or Stone Dust or Marble Dust for Stone Masonry for Drain
s 307.19 Grain Size Analysis Cement Sand Mortar for Stone Masonry for Drains 307
.20 307.21 Compressive Strength of Mortar Water Retentivity of Mortar Stones for
Stone Masonry Drains 307.22 307.23 307.24 307.25 307.26 Section 400 401 A 401.1
401.2 401.3 401.4 Dimensional Tolerance of Stones Water Absorption of Stones Co
nsumption of Mortar in Stone Masonry Water Cement Ratio of Mortar Compressive St
rength of Stones GRANULAR CONSTRUCTION Granular Sub Base Materials Gradation Ana
lysis of GSB Materials Liquid Limit and Plastic Limit of Material passing 425Mic
ron size Grading and Plasticity Index Tests on Combined Materials from Different
Sources Proctor Compaction Test
VII
400-1 to 400-42
401.5 401.6 B 401.7 401.8 401.9 401.10 401.11 401.12 401.13 401.14 401.15 402 A
402.1 402.2 402.3 402.4 402.5 402.6 B 402.7 402.8 402.9 402.10 402.11 402.12 401
.13 401.14
Aggregate Impact Value (Wet) of Soft Aggregates CBR on Representative Sample com
pacted at 100% Proctor Density Construction & Workmanship Wet Sieve Analysis on
Combined GSB Material Liquid Limit and Plastic Limit Placement Moisture Content
Compacted Thickness In-situ Density / Degree of Compaction Aggregate Impact Valu
e Horizontal Alignment Surface Levels Surface Regularity Gravel / Soil Aggregate
Base and Surface Course Materials Gradation Analysis Aggregate Impact Value (We
t) Flakiness Index Water Absorption of Aggregates Soundness with Sodium Sulphate
Soundness with Magnesium Sulphate Construction & Workmanship Wet Sieve Analysis
on Combined GSB Material Liquid Limit and Plastic Limit Placement Moisture Cont
ent Compacted Thickness In-situ Density / Degree of Compaction Aggregate Impact
Value Horizontal Alignment Surface Levels
VIII
401.15 403 A 403.1 403.2 403.3 403.4 403.5 B 403.6 403.7 403.8 403.9 403.10 403.
11 403.12 403.13 404 A 404.1 404.2 404.3 B 404.4 404.5 404.6 404.7 404.8
Surface Regularity Lime Treated Soil for Improved Subgrade / Subbase Materials P
urity of Lime Determination of Optimum Quantity of lime Plasticity Index of Lime
Treated Soil CBR of Lime Treated Soil Unconfined Compressive Strength of Treate
d Soil Construction & Workmanship Pulverisation of Soil Clods Placement Moisture
Content Maximum Dry Density and Degree of Compaction Plasticity Index of Lime T
reated Soil Unconfined Compressive Strength of Sample extracted from Compacted L
ayer Horizontal Alignment Surface Levels Surface Regularity Cement Treated Soil
Sub Base and Base Materials Quality of Cement Purity of Lime Unconfined Compress
ive Strength Test Construction & Workmanship Degree of Compaction Unconfined Com
pressive Strength Horizontal Alignment Surface Levels Surface Regularity
IX
405 A 405.1 405.2 405.3 405.4 405.6 405.7 B 405.8 405.9 405.10 405.11 405.12 405
.13 405.14 405.15 405.16 406 A 406.1 406.2 406.3 406.4 406.5 406.6 406.7 B 406.8
406.9
Water Bound Macadam Sub-base / Base/ Surfacing Materials Aggregate Impact Value
(Dry and Wet) Water Absorption of Aggregates Soundness with Sodium Sulphate Soun
dness with Magnesium Sulphate Gradation Analysis of Aggregates and Screenings Li
quid Limit and Plastic Limit of Binder Material Construction & Workmanship Gradi
ng of Stone Aggregates and Screenings Flakiness Index of Stone Aggregates Plasti
city Index of Crushable Screenings/Binding Material Aggregate Impact Value Layer
Thickness Volumetric Analysis Horizontal Alignment Surface Levels Surface Regul
arity Wet Mix Macadam Base Materials Aggregate Impact Value of Coarse Aggregates
Flakiness Index Soundness with Sodium Sulphate Soundness with Magnesium Sulphat
e Gradation Analysis Liquid Limit and Plastic Limit of Aggregate passing 425 Mic
ron sieve Proctor Compaction Test (After Replacing the Aggregate fraction retain
ed on 22.4 mm sieve with material of 4.75 mm to 22.4 mm size) Construction & Wor
kmanship Grading Analysis Placement Moisture Content
X
406.10 406.11 406.12 406.13 407 A 407.1 407.2 407.3 407.4 407.5 407.6 407.7 407.
8 407.9 407.10 407.11 407.12 B 407.13 407.14 407.15 408 A 408.1 408.2 408.3 408.
4 408.5 408.6
Density of Compacted Layer Horizontal Alignment Surface Levels Surface Regularit
y Shoulder Construction Materials Free Swell Index for Earthen Shoulders Dry Den
sity for Earthen Shoulders Grain Size Analysis for Earthen Shoulders CBR of Remo
ulded and Soaked Material of Hard Shoulders Aggregate Impact Value of Hard shoul
ders Liquid Limit and Plastic Limit of Material passing 425 Micron Sieve Compres
sive Strength of Bricks for Brick Edging Efflorescence of Bricks for Brick Edgin
g Water Absorption of Bricks for Brick Edging Compressive Strength of Stones for
Stone Edging Water Absorption of Stones for Stone Edging Impact Value of Stones
(Dry and Wet) Construction & Workmanship Horizontal Alignment Surface Levels Su
rface Regularity Local Materials for Road Construction Materials Aggregate Impac
t Value (Dry and Wet) of Kankar, Laterite, Dhandla Liquid Limit and Plastic Limi
t of Naturally Occurring Gravels CBR on Soaked Material for Soil-Gravel Material
Gradation Analysis for Soil Gravel Mix Determination of Total Calcium Oxide in
Lime Placement Moisture Content for Treated Stabilization
X1
408.7 408.8 408.9 408.10 B 408.11 408.12 408.13 408.14 408.15 409 A 409.1 409.2
409.3 409.4 409.5 409.6 B 409.7 409.8 409.9 409.10 410 A
Unconfined Compressive Strength of Stabilized Soil Samples Compressive Strength
of Cement for Cement Treated Stabilization Setting time of Cement Tests on Water
for Use in Cement Stabilisation Construction & Workmanship Placement Moisture C
ontent Degree of Compaction Horizontal Alignment Surface Levels Surface Regulari
ty Lime- Flyash Stabilised Soil Sub-base Materials Fineness of Flyash by Blaine
Apparatus Particles Retained on 75 Micron IS Sieve Lime Reactivity Soundness by
Autoclave Expansion Soundness by Le Chatelier Method Quality of Water Constructi
on & Workmanship Unconfined Compressive Strength of Lime-Flyash Mix Horizontal A
lignment Surface Levels Surface Regularity Industrial Wastes for Road Constructi
on Material Fly-Ash (Pond Ash) in Embankment Construction
410.1 410.2 410.3
Grain Size Analysis of Fly Ash (Pond Ash) Grain Size Analysis of Soil for Cover
Liquid Limit and Plastic Limit of Soil for Cover
XII
410.4 410.5 410.6 410.7 410.8 410.9 410.10
Proctor Density of Fly Ash (Pond Ash ) Proctor Density of Soil for Cover Free Sw
ell Index of Soil for Cover Free Swell Index of Subgrade Material Deleterious Co
ntent(Organic Matter) of Soil Deleterious Content (Soluble Sulphate) of Soil CBR
on Remoulded Samples of Soil for Cover Fly Ash in Lime-Fly Ash Stabilised Soil
Base
410.11 410.12 410.13 410.14 410.15 410.16
Fineness of Flyash by Blaine Apparatus Particles Retained on 75 Micron IS Sieve
Lime Reactivity Soundness by Autoclave Expansion Soundness by Le Chatelier Metho
d Quality of Water Fly Ash in Lime Fly Ash Bound Macadam
410.17 410.18 410.19 410.20 410.21 410.22 410.23 410.24 410.25
Aggregate Impact Value (Dry and Wet) Water Absorption of Aggregates Soundness wi
th Sodium Sulphate Soundness with Magnesium Sulphate Gradation Analysis of Aggre
gates and Screenings Liquid Limit and Plastic Limit of Binder Material Horizonta
l Alignment Surface Level Surface Regularity Slag in Gravel/Soil-Aggregate Base/
Surfacing
410.26 410.27 410.28 410.29 410.30
Gradation Analysis Aggregate Impact Value (Wet) Flakiness Index Water Absorption
of Aggregates Soundness with Sodium Sulphate
XIII
410.31
Soundness with Magnesium Sulphate Slag in Water Bound Macadam
410.32 410.33 410.34 410.35 410.36 410.37 410.38 410.39
Aggregate Impact Value (Dry and Wet) Water Absorption of Aggregates Soundness wi
th Sodium Sulphate Soundness with Magnesium Sulphate Gradation Analysis of Aggre
gates and Screenings Liquid Limit and Plastic Limit of Binder Material Aggregate
Impact Value Water Absorption Slag in Cement Treated Sub Base / Base
410.40 410.41 410.42 B 410.43 410.44 410.45 411 A 411.1 411.2 411.3 411.4 411.5
411.6 411.7 B 411.8
Quality of Cement Purity of Lime Unconfined Compressive Strength Test Constructi
on & Workmanship Horizontal Alignment Surface Levels Surface Regularity Crusher
Run Macadam Base Materials Aggregate Impact Value Flakiness Index Water Absorpti
on Liquid Limit and Plastic Limit of Material passing 425 Micron Soundness of ro
cks Gradation Analysis Density of Compacted Layer Construction & Workmanship Hor
izontal Alignment
XIV
411.9 411.10 412 A 412.1 412.2 412.3 412.4 B 412.5 412.6 412.7 413 A 413.1 413.2
B 413.3 413.4 413.5 Section 500 501 A 501.1 501.2 501.3 501.4 501.5 501.6
Surface Level Surface Regularity Brick Soling Materials Size and Colour of Brick
s Compressive Strength of Bricks Water Absorption Efflorescence of Bricks Constr
uction & Workmanship Horizontal Alignment Surface Levels Surface Regularity Ston
e Set Pavement Materials Aggregate Impact Value Water Absorption Construction &
Workmanship Horizontal Alignment Surface Level Surface Alignment BITUMINOUS CONS
TRUCTION Preparation of Surface Materials Grain Size Analysis of Crusher Dust Vi
scosity of Bitumen Emulsion (Saybolt Furol) Test on Bitumen Emulsion Residue on
600 Micron Storage Stability Tests on Emulsion Flash Point of Cutback Bitumen Bi
nder for Tack Coat 500-1- 500-38
XV
B 5017 501.8 501.9 502 A 502.1 502.2 502.3 502.4 502.5 502.6 B 502.7 502.8 503 A
503.1 503.2 503.3 503.4 503.5 503.6 B 503.5 503.6 504 A 504.1 504.1(a)
Construction & Workmanship Horizontal Alignment Surface Levels Surface Regularit
y Prime Coat Over Granular Base Materials Grain Size Analysis of Crusher Dust Vi
scosity of Bitumen Emulsion (Saybolt Furol) Residue of Bitumen Emulsion on 600 M
icron Storage Stability Test Flash Point Test for Bitumen Cutback Viscosity of B
itumen Cutback Construction & Workmanship Temperature of Binder Rate of Spread o
f Binder Tack Coat Materials Grain Size Analysis of Crusher Dust Viscosity of Bi
tumen Emulsion (Saybolt Furol) Residue of Bitumen Emulsion on 600 Micron Storage
Stability Test Flash Point Test for Bitumen Cutback Viscosity of Bitumen Cutbac
k Construction & Workmanship Temperature of Binder Rate of Spread of Binder Bitu
minous Macadam Materials Quality of Binder – Straight –run Bitumen Penetration T
est
XVI
504.1 (b) 504.1 (c ) 504.2 504.2 (a) 504.2 (b) 504.2 (c) 504.2 (d) 504.3 504.4 5
04.5 504.6 504.7 504.8 B 504.9 504.10 504.11 504.12 504.13 504.14 504.15 504.16
504.17 505 A 505.1 505.1(a) 505.1 (b) 505.1 (c )
R&B Softening Point Ductility of Bitumen Quality of Binder – Modified Bitumen Pe
netration Test R&B Softening Point Elastic Recovery Test Separation Test Aggrega
te Impact Value Flakiness Index Bituminous Stripping of Aggregate Test Water Abs
orption of Aggregates Soundness with Sodium Sulphate Soundness with Magnesium Su
lphate Construction & Workmanship Grading of Aggregates Binder Content Density o
f Compacted Layer Temperature of Binder before Mixing Temperature of Binder Duri
ng Laying and Compaction Thickness of Compacted Layer Horizontal Alignment Surfa
ce Level Surface Regularity Built up Spray Grout Materials Quality of Binder – S
traight –run Bitumen Penetration Test R&B Softening Point Ductility of Bitumen
XVII
505.2 505.2 (a) 505.2 (b) 505.2 (c) 505.2 (d) 505.3 505.4 505.5 505.6 505.7 505.
8 A 505.9 505.10 505.11 505.12 505.13 505.14 505.15 505.16 506 A 506.1 506.1(a)
506.1 (b) 506.1 (c ) 506.2 506.2 (a) 506.2 (b)
Quality of Binder – Modified Bitumen Penetration Test R&B Softening Point Elasti
c Recovery Test Separation Test Aggregate Impact Value Flakiness Index Bituminou
s Stripping of Aggregate Test Water Absorption of Aggregates Soundness with Sodi
um Sulphate Soundness with Magnesium Sulphate Construction & Workmanship Rate of
Spread of Binder Rate of Spread of Aggregates Grading of Aggregates Temperature
of Binder during Spraying Thickness of Compacted Layer Horizontal Alignment Sur
face Level Surface Regularity Modified Penetration Macadam Materials Quality of
Binder – Straight –run Bitumen Penetration Test R&B Softening Point Ductility of
Bitumen Quality of Binder – Modified Bitumen Penetration Test R&B Softening Poi
nt
XVIII
506.2 (c) 506.2 (d) 506.3 506.4 506.5 506.6 506.7 506.8 B 506.9 506.10 506.11 50
6.12 506.13 506.14 506.15 506.16 507 A 507.1 507.1(a) 507.1 (b) 507.1 (c ) 507.2
507.2 (a) 507.2 (b) 507.2 (c) 507.3 507.3 (a)
Elastic Recovery Test Separation Test Aggregate Impact Value Flakiness Index Bit
uminous Stripping of Aggregate Test Water Absorption of Aggregates Soundness wit
h Sodium Sulphate Soundness with Magnesium Sulphate Construction & Workmanship R
ate of Spread of Binder Rate of Spread of Aggregates Grading of Aggregates Tempe
rature of Binder during Spraying Thickness of Compacted Layer Horizontal Alignme
nt Surface Level Surface Regularity Surface Dressing Materials Quality of Binder
– Straight –run Bitumen Penetration Test R&B Softening Point Ductility of Bitum
en Quality of Binder – Bitumen Emulsion Viscosity Residue on 600 Micron IS Sieve
Storage Stability Test Quality of Binder – Modified Bitumen Penetration Test
XIX
507.3 (b) 507.3 (c) 507.3 (d) 507.4 507.5 507.6 507.7 507.8 507.9 B 507.10 507.1
1 507.12 507.13 507.14 507.15 507.16 508.1 A 508.1.1 508.1.1(a) 508.1.1 (b) 508.
1.1 (c ) 508.1.2 508.1.2 (a) 508.1.2 (b) 508.1.2 (c) 508.1.3 508.1.3 (a)
R&B Softening Point Elastic Recovery Test Separation Test Aggregate Impact Value
Flakiness Index Bituminous Stripping of Aggregate Test Water Absorption of Aggr
egates Soundness with Sodium Sulphate Soundness with Magnesium Sulphate Construc
tion & Workmanship Rate of Spread of Binder Rate of Spread of Aggregates Grading
of Aggregates Temperature of Binder during Spraying Horizontal Alignment Surfac
e Level Surface Regularity 20 mm Thick Premix Carpet using Bitumen Materials Qua
lity of Binder – Straight –run Bitumen Penetration Test R&B Softening Point Duct
ility of Bitumen Quality of Binder – Bitumen Emulsion Viscosity Residue on 600 M
icron IS Sieve Storage Stability Test Quality of Binder – Modified Bitumen Penet
ration Test
XX
508.1.3 (b) 508.1.3 (c) 508.1.3 (d) 508.1.4 508.1.5 508.1.6 508.1.7 508.1.8 508.
1.9 B 508.1.10 508.1.11 508.1.12 508.1.13 508.1.14 508.1.15 508.1.16 508.2 A 508
.2.1 508.2.1 (a) 508.2.1 (b) 508.2.1 (c) 508.2.1 (d) 508.2.2 508.2.3 508.2.4 308
.2.5 508.2.6
R&B Softening Point Elastic Recovery Test Separation Test Aggregate Impact Value
Flakiness Index Bituminous Stripping of Aggregate Test Water Absorption of Aggr
egates Soundness with Sodium Sulphate Soundness with Magnesium Sulphate Construc
tion & Workmanship Grading of Aggregates Binder Content Before Seal Coat Tempera
ture of Binder Thickness Before and After Compaction Horizontal Alignment Surfac
e Levels Surface Regularity 20mm Thick Premix Carpet using Bitumen Emulsion Mate
rials Quality of Binder (Bitumen Emulsion) Penetration Softening Point Test Elas
tic Recovery Separation Test Aggregate Impact Value Flakiness Index Bitumen Stri
pping of Aggregates Water Absorption Soundness with Sodium Sulphate
XXI
508.2.7 B 508.2.8 508.2.9 508.2.10 508.2.11 508.2.12 508.2.13 508.2.14 508.2.15
509 A 509.1 509.2 509.3 509.4 509.5 509.6 509.7 509.8 B 509.9 509.10 509.11 510
A 510.1 510.2 510.3
Soundness with Magnesium Sulphate Construction & Workmanship Grading of Aggregat
es Binder Content before Seal Coat Temperature of Binder Thickness before and af
ter Compaction Thickness of Layer with Seal Coat Horizontal Alignment Surface Le
vel Surface Regularity Mix Seal Surfacing Materials Flakiness Index of Aggregate
Aggregate Impact Value Soundness with Sodium Sulphate Soundness with Magnesium
Sulphate Water Absorption Coating and Stripping of Bitumen Aggregate Mixture Gra
dation Analysis Binder Construction & Workmanship Horizontal Alignment Surface L
evel Surface Regularity Seal Coat Materials Gradation Analysis Flakiness Index o
f Aggregate Aggregate Impact Value
XXII
510.4 510.5 510.6 510.7 510.8 510.9 510.10 510.11 510.12 510.13 510.14 510.15 B
510.16 510.17 512 A 512.1 512.2 512.3 512.4 Section 600 A 600.1 600.2 600.3 600.
4 600.5 600.6
Soundness with Sodium Sulphate Soundness with Magnesium Sulphate Water Absorptio
n Coating and Stripping of Bitumen Aggregate Mixture Temperature of Binder Penet
ration on Paving Bitumen/Modified Emulsion Softening Point on Paving Bitumen/Mod
ified Emulsion Ductility on Paving Bitumen Elastic Recovery of Modified Bitumen
Viscosity Residue on 600 Micron Storage Stability Test for Emulsion Construction
& Workmanship Rate of Spread of Binder Rate of Spread of Aggregates Modified Bi
tumen Materials Penetration Softening Point Elastic Recovery Separation BRICKWOR
K FOR STRUCTURES Materials Colour and Dimensional Check of Bricks Water Absorpti
on of Bricks Efflorescence of Bricks Compressive Strength of Bricks Setting Time
of Cement Purity of Lime 600-1 to 600-22
XXIII
600.7 600.8 B 600.9 600.10 600.11 600.12 600.13 600.14 600.15 Section 700 A 700.
1 700.2 700.3 700.4 700.5 700.6 700.7 700.8 700.9 700.10 700.11 700.12 700.13 B
700.14 700.15 700.16 700.17
Grain Size Analysis of Sand / Stone / Marble dust Water for Construction Constru
ction & Workmanship Height, Bond and Verticality by Plumb Bob Consistency of Cem
ent Mortar Water Retentivity of Mortar Compressive Strength of Mortar Thickness
of Joints in General Brick Work Thickness of Joints in Arches Plaster Finish STO
NE MASONRY FOR STRUCTURES Materials Shape and Dimensions of Stones Water Absorpt
ion of Stones Dressing of Stones Setting Times Cement Purity of Lime Gradation o
f Sand Deleterious Material and Organic Impurities Water for Construction Size o
f Precast Concrete Blocks Consistency of Cement Mortar Water Retentivity of Mort
ar Mix Proportions for Different Works Compressive Strength of Mortar Constructi
on & Workmanship Horizontality and Verticality Height and Thickness Thickness of
Joints of Masonry Thickness of Joints in Arches
XXIV
700-1 to 700-6
Section 800 A
CONCRETE FOR STRUCTURES Materials Cement
800-1 to 800-33
800.1 800.2 800.3
Setting Times of Cement Soundness of Cement Compressive Strength of Cement Coars
e Aggregates
800.4 800.5 800.6 800.7 800.9 800.10 800.11
Gradation Analysis Flakiness Index of Coarse Aggregates Deleterious Materials an
d Organic Impurities Water Absorption / Water Content Aggregate Impact Value Sou
ndness Alkali Aggregate Reactivity Fine Aggregates
800.12 800.13 800.14 800.15 800.16 B 800.17 800.18 800.19 800.20 800.21 800.22 8
00.23 800.24 800.25
Gradation of Fine Aggregates Deleterious Constituents Alkali Aggregate Reactivit
y Water for Construction Mix Design for Each Work Construction & Workmanship Moi
sture Content of Coarse and Fine Aggregates Cement Consumption Workability of Co
ncrete by Slump Test Workability of Concrete by Compaction Test Formwork and Con
struction Joints Curing of Concrete Schmidt’s Rebound Hammer Ultrasonic Pulse Ve
locity Accelerated Curing Test
XXV
800.26 800.27 Section 900 901 902 903 Section 1000 A 1000.1 1000.2 1000.3 1000.4
B 1000.5 Section 1100 A 1100.1 1100.2 1100.3 1100.4 1100.5 1100.6 1100.7 1100.8
1100.9 1100.10 Section 1200 A 1200.1
Compressive Strength of Concrete Cubes (150 mm x150 mmx150 mm) at 28 days Flexur
al Strength of Concrete FORMWORK AND SURFACE FINISH FOR STRUCTURES 900-1 to 900-
3 Materials and Design Construction Operations Removal of Formwork STEEL REINFOR
CEMENT Material Grade, Percentage Elongation and Ultimate Tensile Strength of St
eel Pitch of the Ribs and Nominal Diameter Bending and Placing of Reinforcement
Splicing, Welding and Tolerances Construction & Workmanship Route Inspection and
Testing PIPE CULVERTS Materials Colour and Dimensional Check of Bricks Water Ab
sorption of Bricks Efflorescence of Bricks Compressive Strength of Bricks Shape
and Dimensions of Stones Water Absorption of Stones Dressing of Stones Dimension
s of Concrete Pipes Manufacturing Defects and Tolerances Three Edge Bearing Test
RCC SLAB CULVERTS AND MINOR BRIDGES Materials Tests on Bricks
XXVI
1000-1 to 1000-6
1100-1 to 1100-5
1200-1 to 1200-2
1200.2 1200.3 1200.4 1200.5 1200.6 1200.7 B 1200.8 1200.9 1200.10 1200.11 1200.1
2 1200.13 1200.14 1200.15 1200.16 Section 1300 A 1300.1 1300.2 1300.3 1300.4 B 1
300.5 1300.6 1300.7 1300.8 Section 1400 A 1400.1
Tests on Stone Tests on Concrete Ingredients Tests on Water Tests on Steel Reinf
orcement Certification of Composition of steel by the Manufacturer Certification
of Mechanical Properties of steel by the Manufacturer Construction & Workmanshi
p Tolerances in Various Dimensions and Levels Reinforcement Cage Workability of
Concrete Compaction of Concrete Curing of Concrete Compressive Strength of Concr
ete Flexural Strength of Concrete Tests on Sealants (Poly Sulphate or Bituminous
) Test Certificates from the Manufacturers for Elastomeric Bearings, Expansion J
oints, Plasticisers PROTECTION WORKS AND DRAINAGE Materials Brick Masonry Stone
Masonry Concrete for Structures Wire Crates (Size and Mesh Size) Construction &
Workmanship Brick Masonry Stone Masonry Tests on Mortar for Joint Cross Sections
, Gradient, General Workmanship CEMENT CONCRETE CAUSEWAY Materials Tests on Bric
ks
XXVII
1300-1 to 1300-2
1400-1 to 1400-2
1400.2 1400.3 1400.4 B 1400.5 1400.6 1400.7 1400.8 1400.9 1400.10 1400.11 1400.1
2 Section 1500 1501 A
Tests on Stones Tests on Ingredients of Cement Concrete Pavement Materials GSB,W
BM,CC Construction & Workmanship Workability of Concrete Curing of Concrete Stre
ngth of Concrete Formwork Cement Concrete Pavements Pipes Bearings and Expansion
Joints Measurement of Dimensions, Levels and Joint Thickness CEMENT CONCRETE PA
VEMENTS Plain Cement Concrete Pavements Materials Tests on Cement 1500-1 to 1500
-12
1501.1(a) 1501.1(b) 1501.1(c) 1501.1(d) 1501.1(e)
Consistency of Cement Compressive Strength of Cement Setting time of Cement Fine
ness of Cement Soundness of Cement Fine Aggregates
1501.2(a) 1501.2(b) 1501.2(c)
y Coarse Aggregates
1501.3(a) 1501.3(b) 1501.3(c)
d Organic Impurities
XXVIII
1501.3(d) 1501.3(e) 1501.3(f) 1501.3(g)
Water Absorption / Water Content Aggregate Impact Value Soundness Alkali Aggrega
te Reactivity Water
1501.4
Suitability of Water for Construction Other Materials
1501.5 1501.6 1501.7 1501.8 1501.9 1501.10 1501.11 1501.12 B 1501.13 1501.14 150
1.15 1501.16 1501.17 1501.18 1501.19 1501.20 1501.21 1501.22 1501.23 1501.24 150
1.25 1501.26
Admixtures Dowel Bars Premoulded Joint Filler Joint Sealing Compound Tools, Plan
ts and Equipment Mix Design for Cement Mortar Granular Sub Base Trial Length Con
struction & Workmanship Subgrade and Subbase Gradation and Moisture Content of A
ggregates Concrete Workability Compressive Strength of Concrete Straightness of
Side Forms Size, Spacing, Paralleling of Dowel Bars and Location of Different Jo
ints Batching and Mixing of Materials Hot/Cold Weather Concreting and Compaction
Compaction Equipment (Needle, Screed and Plate Vibrators Separation Membrane Su
rface Levels Surface Regularity Width of Pavement Pavement Thickness
XXIX
1501.27 1501.28 1501.29 1502 A 1502.1(a) 1502.1(b) 1502.1(c) 1502.1(d) 1502.1(e)
Alignment of Joints Depth of Dowel Bars Texturing and Edging Roller Compacted Co
ncrete Pavements Materials Consistency of Cement Compressive Strength of Cement
Setting time of Cement Fineness of Cement Soundness of Cement Tests on Fine Aggr
egates Fine Aggregates
1502.2(a) 1502.2(b) 1502.2(c)
y Coarse Aggregates
1502.3(a) 1502.3(b) 1502.3(c) 1502.3(d) 1502.3(e) 1502.3(f) 1502.3(g)
ndness Alkali Aggregate Reactivity Fly Ash
1502.4(a) 1502.4(b) 1502.4 (c) 1502.4(d) 1502.4(e)
d
XXX
Water 1502.5 Suitability of Water for Construction Other Materials 1502.6 1502.7
1502.8 1502.9 1502.10 1502.11 1502.12 1502.13 Admixtures Dowel Bars Premoulded
Joint Filler Joint Sealing Compound Tools, Plants and Equipment Mix Design for C
ement Mortar Granular Sub Base Trial Length Construction & Workmanship 1502.14 1
502.15 1502.16 1502.17 1502.18 1502.19 1502.20 1502.21 1502.22 1502.23 1502.24 1
502.25 1502.26 1502.27 1502.28 1502.29 1502.30 Subgrade and Subbase Gradation an
d Moisture Content of Aggregates Batching and Mixing Concrete Workability Compre
ssive Strength of Concrete Straightness of Side Forms Transverse Contraction Joi
nts (Width and Depth) In-situ Density of Trial Length by Sand Replacement Method
Compaction and Surface Correction Surface Levels Surface Regularity Width of Pa
vement Pavement Thickness Cumulative Length of Cracks Core Density Performance o
f 30 m Trial Length Texturing and Edging
XXXI
1503 A
Rectangular Concrete Block Pavements Materials Tests on Cement
1503.1(a) 1503.1(b) 1503.1(c) 1503.1(d) 1503.1(e)
ness of Cement Soundness of Cement Tests on Fine Aggregates
1503.2(a) 1503.2(b) 1503.2(c)
y Coarse Aggregates
1503.3(a) 1503.3(b) 1503.3(c) 1503.3(d) 1503.3(e) 1503.3(f) 1503.3(g)
1513.4(a) 1503.4(b) 1503.4 (c) 1503.4(d) 1503.4(e)
d Water
1503.5
1503.6
Admixtures
XXXII
1503.7 1503.8 1503.9 1503.10 1503.11 1503.12 1503.13 B 1503.14 1503.15 1503.16 1
503.17 1503.18 1503.19 1503.20 1503.21 1503.22 1503.23 1503.24 1504 A
Joint Details, Pattern of Laying and End Restraints Tools, Plants and Equipment
Mix Design for Concrete Subgrade and Sub Base Method of Manufacturing and Compac
ting Blocks Trial Length Grading for Bedding and Joint Filling Sand Construction
& Workmanship Subgrade and Subbase Compressive Strength of Concrete Pattern of
Laying Blocks and End Restraints Earthen Shoulders (Width and Camber) Width of J
oints between Blocks Horizontal Alignment Surface Levels Surface Regularity Dime
nsions of Blocks (Size and Thickness) Performance of Trial Length General Workma
nship Interlocking Concrete Block Pavements Materials Tests on Cement
1504.1(a) 1504.1(b) 1504.1(c) 1504.1(d) 1504.1(e)
ness of Cement Soundness of Cement Tests on Fine Aggregates
1504.2(a) 1504.2(b)
Gradation of Fine Aggregates Deleterious Constituents
XXXIII
1504.2(c)
Alkali Aggregate Reactivity Coarse Aggregates
1504.3(a) 1504.3(b) 1504.3(c) 1504.3(d) 1504.3(e) 1504.3(f) 1504.3(g)
1504.4(a) 1504.4(b) 1504.4 (c) 1504.4(d) 1504.4(e)
d Water
1504.5
1504.6 1504.7 1504.8 1504.9 1504.10 1504.11 1504.12 1504.13 1504.14 B 1503.15 15
04.16
Admixtures Joint Details, Patter of Laying and End Restraints Tools, Plants and
Equipment Mix Design for Concrete Base Course Method of Manufacturing and Compac
ting Blocks Trial Length of 30 m before Commencing Work Block Size and Thickness
Water Absorption , Compressive Strength of Blocks Construction & Workmanship Su
bgrade and Subbase Dimensions and Tolerances of Paving Blocks
XXXIV
1503.17 1503.18 1504.19 1504.20 1504.21 1504.22 1504.23 Section 1600 A
Compressive Strength of Concrete Blocks Paving Pattern of Blocks and End Restrai
nts Horizontal Alignment Surface Levels Surface Regularity Performance of 30 m T
rial Length General Workmanship Hill Road Construction Materials Tests on Stone
1600-1 to 1600-3
1600.1 1600.2
Compressive Strength of Stone Water Absorption of Stones Tests on Cement
1600.3 1600.4 1600.5
Compressive Strength of Cement Fineness of Cement Setting time of Cement Tests o
n Sand
1600.6
Grain Size Analysis of Sand / Stone / Marble dust Tests on Coarse Aggregate
1600.7 1600.8 1600.9 1600.10 1600.11 1600.12 1600.13
Flakiness Index of Coarse Aggregates Deleterious Content and Organic Material Sp
ecific Gravity, Density, Voids and Absorption Crushing Strength Aggregate Impact
Value Soundness Aggregate Alkali Reactivity Tests on Water for Construction
1600.14
Suitability of Water for Construction Tests on Steel
1600.15
Characteristic Strength of Steel
XXXV
1600.16 1600.17 B 1600.18 1600.19 1600.20 1600.21
Modulus of Steel Ultimate Tensile Strength and Elongation Construction & Workman
ship Degree of Compaction Workability of Concrete by Slump Test Compressive Stre
ngth of Concrete Flexural Strength of Concrete Surface Level
1600.22 1600.23 1600.24 1600.25 1600.26 1600.27 1600.28 Section 1700 A 1700.1 17
00.2 1700.3 1700.4 1700.5 1700.6 1700.7 1700.8 Section 1900
Horizontal Alignment Surface Levels Surface Regularity Earthworks Granular Sub b
ase and Base and Bituminous Work Cement Concrete Pavements, Blocks etc. Cross Dr
ainage Works Traffic Signs and Markings Materials Colour, Configuration, Size, L
ocation, Dimensions Concrete Reinforcing Steel Bolts,Nuts and Washers MS Sheets,
Plates and Supports Reflectorised Paint Non Reflectorised Paint Paints for Road
Markings Maintenance Maintenance of Earthworks and Drains 1900-1 to 1900-4 1700
-1 to 1700-2
A 1900.1 1900.2
Materials Soils Stones
XXXVI
1900.3 B 1900.4 1900.5 1900.6
Bricks, Cement, Mortar Construction & Workmanship Horizontal Alignment Surface L
evels Surface Regularity Maintenance of Bituminous Roads
A 1904.1 1904.2 B 1904.3 1904.4 1904.5
Materials Bituminous Materials Granular Materials / Aggregates Construction & Wo
rkmanship Horizontal Alignment Surface Levels Surface Regularity Maintenance of
Gravel Roads
A 1905.1 B 1905.2 1905.3 1905.4
Materials Gravels / Soil Aggregates Construction & Workmanship Horizontal Alignm
ent Surface Levels Surface Regularity Maintenance of WBM Roads
A 1906.1 B 1906.2 1906.3 1906.4
Materials WBM Construction & Workmanship Horizontal Alignment Surface Levels Sur
face Regularity Maintenance of Culvers and Bridges
A 1908.1
Materials Materials for Culverts and Bridges
XXXVII
B 1908.2 1908.3 1908.4
Construction & Workmanship Horizontal Alignment Surface Levels Surface Regularit
y Maintenance of Causeway
A 1909.1 B 1909.2 1909.3 1909.4
Materials Materials for Causeway Construction & Workmanship Horizontal Alignment
Surface Levels Surface Regularity Maintenance of Road Signs
A 1910.1
Materials Materials for Road Signs Maintenance of Markings and Appurtenances
A 1911.1
Materials Materials for Markings and Appurtenances APPENDICES
Appendix-1 Appendix-2 Appendix- 3 Appendix -4 Appendix - 5 Appendix – 6 Appendix
-7
List of Indian Standards List of Tests List of Forms List of Photographs List of
Tables List of Figures Measurement Conversion Factors
1 to 14 1 to 5 1 to 2 3 to 4 5 to 6 7 (i) to (ii)
XXXVIII
ABBREVIATIONS
AE AIV BOQ CBR CD CRMB cum EE g GBFS GSB GTS h IS JE kg km kN
: : : : : : : : : : : : : : : : : : : : : : :
Assistant Engineer Aggregate Impact Value Bill of Quantities California Bearing
Ratio Cross-Drainage Crumb Rubber Modified Bitumen Cubic metre Executive Enginee
r Gram Granulated Blast Furnace Slag Granular Sub-Base Grand Triangulation Surve
y Hour Indian Standard Junior Engineer Kilogram Kilometre Kilo Newton Litre Metr
e Modified Binder minutes Millilitre
λ
m MB min m
XXXIX
mm MORD MORTH
: : :
Mi imetre Ministry of Rura Deve opment Ministry of Road Transport & Highways M
inistry of Shipping, Road Transport & Highways Mega Pasca Modified Penetration
Macadam Medium Setting Nationa Rura Roads Deve opment Agency Nationa Qua ity
Monitor Optimum Moisture Content Po ymer Modified Bitumen Rubber Modified Bitume
n Rapid Setting seconds State Qua ity Coordinator State Qua ity Monitor Square m
etre S ow Setting Unconfined Compressive Strength Water Bound Macadam Wet Mix Ma
cadam
MOSRTH : MPa MPM MS NRRDA NQM OMC PMB RMB RS secc SQC SQM sqm SS UCS WBM WMM : :
: : : : : : : : : : : : : : :
XXXX
FOREWORD
Focus on qua ity has been a singu ar feature of the Pradhan Mantri Gram Sadak Yo
jana (PMGSY) right from its inception. In fact, the report of the Nationa Rura
Roads Deve opment Committee, which formed the conceptua basis of this programm
e, specifica y high ighted the need for inbui t qua ity assurance mechanisms, a
s a first step towards institutiona izing qua ity assurance system in the progra
mme imp ementation, a qua ity contro handbook for rura roads was brought out i
n 2002 by the Nationa Rura Roads Deve opment Agency (NRRDA) covering various t
ests to be conducted, frequency of these tests and detai s of the test procedure
s. However, at that time separate specifications were not avai ab e for the ow
vo ume rura roads. In 2004 the Ministry of Rura Deve opment brought out Specif
ications For Rura Roads, which was pub ished by the Indian Roads Congress (IRC)
. Fo owing this technica experts as we as the programme managers fe t that t
here was a consequentia need to revise the Qua ity Contro Handbook. According
y, the work of revising the handbook was entrusted to the IRC which constituted
a group of experts headed by Shri S. C. Sharma, former Director Genera (Road De
ve opment) and Additiona Secretary, Ministry of Road Transport and Highways. Th
e other members of this expert group were Shri D. P. Gupta, Dr. V. M. Sharma, Dr
N. B. La , Shri M. V. B. Rao, Shri G. S. Khinda and Shri S. P. Singh. This revi
sed version of the qua ity Assurance Handbook for rura roads does not restrict
itse f to qua ity contro on y. It has widened the scope by adopting the princip
es of qua ity assurance as aid down by the IRC. Vo ume-I of this handbook dea
s with the qua ity management system and qua ity contro requirements and Vo ume
-II covers the equipments and test procedures. Qua ity monitoring of the project
s through independent, third party monitors at the State eve as we as at the
Centra eve has a so been dea t with in Vo ume-I. Un ike the ear ier practice
of seeking qua ity contro on y during construction, this handbook recommends e
xercising qua ity contro at three stages – at the stage prior to construction,
during the construction phase and qua ity checks by the fie d engineers after co
mp etion of each stage of construction, which is termed as “stage passing”. A nu
mber of carefu y thought out “Do’s and Don’ts” for each activity and item of wo
rk have a so been prescribed for the guidance of users. In its present form, thi
s handbook incorporates va uab e suggestions and recommendations which were rece
ived during a workshop which was specifica y organized to review the draft on A
pri 16-17, 2007 at Centra Road Research Institute, New De hi. I wou d ike to
express my sincere appreciation to the IRC, the members of the expert group for
their painstaking efforts, to a the members of the peer review group for their
meticu ous and methodica scrutiny, and to a the participants of the nationa
workshop which was he d in Apri 2007 for their va uab e contributions. I do be
ieve that in the imp ementation of PMGSY in substantia measure.
(J. K. Mohapatra) Joint Secretary (RC) Ministry of Rura Deve opment & Director
Genera Nationa Rura Roads Deve opment Agency
XXXXI
PREFACE
A good road network has an important bearing on the economic growth of the count
ry. Rura Connectivcity is perceived as one of the major component in increasing
the agricu tura output and earning capacity of the rura popu ation. There is
a marked improvement in qua ity of ife by way of better educationa faci ities,
improved hea th services, improved attendance by the schoo teachers as we as
students. Accessibi ity a so provides improvement in governance and provision o
f other faci ities ike post offices, access to po ice in case of emergencies an
d other communication system ike te ephones. As a measure of poverty reduction,
Government of India has aunched Pradhan Mantri Gram Sadak Yojana (PMGSY) in De
cember, 2000. The management systems deve oped for imp ementation of the program
me are centered on qua ity and the guide ines c ear y prescribe to provide good
a -weather connectivity to target habitations. Construction of qua ity roads re
quires concerted efforts on many fronts, therefore, a three tier qua ity mechani
sm has been operationa ized under the programme. The first tier provides for in-
house qua ity contro , wherein, the Programme Imp ementation Unit (PIU) is requi
red to contro the qua ity of work through performing mandatory tests for the ma
teria and workmanship. The second and third tier of qua ity mechanism provides
for monitoring of qua ity by the independent qua ity monitors at the State Leve
and at the Nationa Leve . The PMGSY Guide ines provides that the NRRDA wi is
sue genera guide ines on qua ity contro and prescribe a Qua ity Contro Hand B
ook to regu ate the qua ity contro process at works eve . According y, a Qua i
ty Contro Hand Book was brought out in 2002. Based on feedback received from St
ates, executing agencies and other organizations, it was fe t that handbook may
a so contain detai s about the tests invo ved in construction of cross drainage
works, rigid and semi-rigid pavements and protection works etc. The Rura Roads
Specifications provide for mandatory testing of materia and workmanship and fee
dback of the fie d formations regarding the frequency of tests indicated that th
ere is a scope to revisit these frequencies. Therefore, Nationa Rura Roads Dev
e opment Agency decided to review the Qua ity Contro Hand Book and the work of
review was entrusted to Indian Roads Congress (IRC). The IRC was requested to re
view the content of Qua ity Contro Hand Book with a view to inc ude detai s abo
ut a the tests required for construction of roads and re ated cross drainage w
orks etc. It was a so requested that the IRC may review the prescription of freq
uency of tests and examine whether the concept of stage passing may be introduce
d to ensure c ear accountabi ity. The IRC constituted Expert Group headed by Shr
i S. C. Sharma, Former Director Genera , Ministry of Road Transport and Highways
. The Expert Group prepared the contents of the Handbook and based on the eve
of work and its uti ity, the tit e of the handbook was decided as ‘Qua ity Assur
ance Hand Book for Rura Roads’. The drafts of Qua ity Assurance Hand Book were
reviewed in a series of meetings and de iberations by a Peer Review Committee, c
onstituted by NRRDA as be ow: Prof. C. E. G. Justo, Emeritus Fe ow, Banga ore U
niversity – Chairman Shri Prabha Kant Katare, Director (Projects-III), NRRDA – C
onvener MEMBERS Dr. Ashok Kumar, Rura Roads Specia ist, Wor d Bank Dr. Praveen
Kumar, Indian Institute of Techno ogy, Roorkee
XXXXIII
Shri H. L. Meena, Chief Engineer PWD, Rajasthan Engineer-in-Chief, PWD (R&B), Na
ga and Shri V. V. Gu ati, Former Chief Engineer P.W.D, Uttarakhand. Shri Vidya S
agar Singh, Former Chief Engineer, U.P.P.W.D. Shri H. K. Srivastava, Director (P
rojects-I), NRRDA Dr. B. P. Chandrasekhar, Director (Technica ), NRRDA Shri S. B
a iga, Director (Projects-II), NRRDA State Qua ity Coordinator (PMGSY), MPRRDA,
Madhya Pradesh State Qua ity Coordinator (PMGSY), HPPWD, Himacha Pradesh The su
ggestions of members of Peer Review Committee and officers of NRRDA on the draft
Hand Book were incorporated and fina draft document was prepared. A Nationa W
orkshop on Qua ity Assurance Hand Book was organized on 16-17th Apri , 2007 at C
RRI to review of the contents of Draft Handbook. Dr. Subas Pani, Secretary, Mini
stry of Rura Deve opment inaugurated the Workshop and in addition to his va uab
e guidance about interna izing the qua ity consciousness, he mentioned that eno
rmous efforts have been made in preparation of the Hand Book and it shou d be us
ed extensive y by the fie d officers engaged in imp ementation of PMGSY. It was
suggested by him that the Qua ity Assurance Hand Book shou d be made avai ab e o
n the Programme Website, so that the officers, contractors and other constructio
n agencies can have easy access to the provisions of qua ity assurance. The work
shop was attended by representatives of a most a the States and experts. A num
ber of va uab e suggestions and comments made at the Workshop were suitab y inco
rporated in the present form of Qua ity Assurance Hand Book. Vo ume I of the Han
dbook covers qua ity management system and detai s about qua ity contro require
ments. The revised frequency of tests and requirements about stage passing in fo
rm of qua ity contro checks have been e aborated in this Vo ume. Vo ume II give
s detai ed description about equipment and test procedures. I wou d ike to expr
ess my sincere gratitude to members of Expert Group, members of Peer Review Comm
ittee and Shri R. S. Sharma, Former Secretary, IRC whose pains taking efforts ha
ve brought out this wonderfu document. I wou d a so ike to express my sincere
appreciation to the efforts made by Shri V. K. Sinha, Secretary Genera IRC, off
icers and other staff of IRC in bringing out this handbook in the present form.
I thankfu y acknow edge the contribution made by the participants of the worksh
op organized at CRRI in Apri , 2007. The document of this nature cannot remain s
tatic with continuous upgradation of techno ogy. User of this handbook wou d be
the best judge of the deficiencies, if any sti eft in the document. We wou d
great y va ue the feedback and suggestions in this regard to keep this document
updated. I am confident that this document wou d serve its intended purpose.
(Prabha Kant Katare) New De hi May, 2007
XXXXIV
Director (Projects) & Chief Qua ity Coordinator Nationa Rura Roads Deve opment
Agency
INTRODUCTION
1.
1.1
BACKGROUND
A major rura road programme known as Pradhan Mantri Gram Sadak Yojana (PMGSY) i
s being imp emented since December 2000 by the Government of India through the M
inistry of Rura Deve opment (MORD). The Nationa Rura Roads Deve opment Agency
(NRRDA), working under the aegis of the MORD, provides the overa administrati
ve, technica and programme support to the states in the execution of works. The
scheme envisages construction of good qua ity a -weather roads to provide conn
ectivity to habitations with a popu ation of 500 and above (250 and above in cas
e of hi s, deserts and triba areas). Emphasis is being aid on p anning, desig
n, construction and maintenance of rura roads based on sound engineering princi
p es, which conform to specifications, codes of practice and manua s of the Indi
an Roads Congress. A comprehensive document, IRC:SP:20 entit ed Rura Roads Manu
a has been brought out in 2002 for adoption in case of a rura roads inc udin
g works being carried out under the PMGSY programme. Subsequent y, the NRRDA bro
ught out its own Handbook on Qua ity Contro for Rura Works and Operations Manu
a for PMGSY works. A detai ed Book of Specifications for Rura Roads and Standa
rd Data Book for Ana ysis of Rates have a so been prepared and pub ished through
the Indian Roads Congress. A strong technica underpinning has been given so th
at roads taken up under this programme conform to the MORD Specifications. The G
overnment of India have recent y reviewed the progress of the PMGSY and other sc
hemes re ating to rura deve opment and have decided to undertake a bo d initiat
ive of bui ding infrastructure in rura areas under an umbre a programme, known
as ‘Bharat Nirman’. The PMGSY is one of the six components of the Bharat Nirman
and the fo owing targets have been set: (i) (ii) (iii) Provide a -weather con
nectivity to habitations of popu ation above 1000 (500 in case of hi s, deserts
and triba areas). The task wou d invo ve connectivity to 66,802 habitations. T
he work invo ves construction of over 140,000 km of new roads and upgradation of
over 190,000 km of existing rura roads at an estimated cost of Rs 48,000 crore
.
1.2
2.
2.1
QUALITY ASSURANCE
A three-tier qua ity management mechanism has been operationa ized under PMGSY f
or ensuring that the qua ity of assets created conform to the prescribed standar
ds. The first tier of qua ity management mechanism is in-house qua ity contro a
t the eve of the executing agencies whereas the second tier provides for qua i
ty monitoring through independent State Qua ity Monitors (SQM). Monitoring by in
dependent Nationa Qua ity Monitors (NQM) constitutes the third tier of this arr
angement. Under this arrangement, it is the responsibi ity of the State Governme
nt to
XXXXV
operationa ize the first and the second tiers of the qua ity management structur
e. It is proposed to widen the scope of qua ity contro by inc uding the princip
es of Qua ity Assurance aid down by the Indian Roads Congress in their guide i
nes on qua ity systems for roads (IRC:SP:572000) and for bridges (IRC:SP:47-1998
). A Tota Qua ity Management approach is envisaged. The concept of Tota Qua it
y Management (TQM) as defined by ISO reads as “TQM is a management approach of a
n Organisation, centered on Qua ity, based on participation of a its members a
nd aiming at ong-term success through customer satisfaction, and benefits to a
the members of the Organisation and the Society”. In fact the TQM is a managem
ent strategy aimed at embedding awareness of Qua ity in a organisationa proce
sses. The TQM concept in the context of Rura Roads suggests that qua ity has to
be seen as the basic po icy starting from conception ti the operation and man
agement of Rura Road assets. The objective of the PMGSY is to provide “Good A
Weather Roads” and the imp ementation strategies of the programme are therefore
, centered on the word ‘Qua ity’. 2.2 C ass of Qua ity Assurance (QA) for Rura
Roads: Four c asses of Qua ity Assurance are prescribed as under:
C ass Q1 Q2 Q3 Q4 Nomina QA Norma QA High QA Extra High QA
Qua ity Assurance 1. 2. 3. 4.
For rura roads, C ass Q 2 may be adopted. However, for a particu ar project or
even for particu ar activities, decision regarding upgradation of QA c ass cou d
be taken by the Project Imp ementation Unit keeping in view the eve of qua it
y and the eve of contro expected beyond C ass Q 2. The qua ity assurance requ
irements in respect of materia s and workmanship to be achieved during execution
are described against each item of road and bridge work in re evant Sections. 2
.3 For day-to-day reference of the Engineers in the fie d and the Contractors en
gaged in construction of rura roads, this Handbook on Qua ity Assurance has bee
n prepared drawing heavi y on the fo owing sources: (i) (ii) (iii) (iv) Specifi
cations for Rura Roads, MORD (2004). Rura Roads Manua IRC:SP:20-2002. Handboo
k on Qua ity Contro : Road Works NRRDA (2002). Hi Road Manua : IRC:SP:48-1998.
The frequency of tests has been further rationa ized and NRRDA wi bring out th
e necessary modifications in MORD Specifications for Rura Roads. The qua ity co
ntro requirements prescribed in the Book wi be mandatory for a PMGSY works.
This book wou d a so serve as a usefu reference to the State Technica Agencie
s, State- eve Qua ity Contro Units, and Nationa Qua ity Monitors.
XXXXVI
3.
COVERAGE OF THE HANDBOOK- VOLUME II Qua ity Assurance Handbook for Rura Roads h
as been prepared in two vo umes: Vo ume I: Qua ity Management System and Qua ity
Contro Requirements Vo ume II: Equipment and Test Procedures The Vo ume I cove
rs qua ity management systems and describes in detai procedure for qua ity cont
ro of works, qua ity requirements for materia s and workmanship, and various te
sts to be performed and their frequencies. The Vo ume II covers the test procedu
res to be fo owed for conducting various tests, aboratory set up and equipment
required for fie d aboratory and the aboratories at the District and the Cent
ra eve . It describes in detai a the tests specified in MORD Specifications
for various materia s and workmanship. In addition, some non-destructive tests
for concrete and other materia s have a so been inc uded. The test procedures ar
e in accordance with the methods given in the re evant IS Standards. The purpose
and significance of the test has a so been given for each test. For ease of ref
erence, the numbers given to various Sections and Sub sections in Vo ume-II are
same as given in the Vo ume I, which in turn, corresponds to the Sections of the
MORD Specifications for Rura Roads. A the test procedures given in the Vo um
e II have been divided into two major categories: (A) (B) Materia s Construction
and Workmanship
There are some tests which are required to be performed on a particu ar materia
/ workmanship which get repeated. For examp e, the tests on cement get repeated
in the ist of tests required for cement concrete. To avoid repetition, whenever
a test procedure has been described once, it has on y been referred to, at its
re evant p ace in a tabu ar form. A comp ete ist of tests required under a part
icu ar Section or Sub-section have been given at its appropriate p ace and a so
in the Contents. A ist of Indian Standards which are referred to in the Handboo
k is given in Appendix 1. In case of any doubt or confusion, the users may refer
to the Indian Standards. In order to faci itate the reference to particu ar tes
ts, an a phabetica ist of a the tests has been prepared and given under Inde
x in Appendix 2. Most of the test procedures have inc uded a form in which the d
ata is to be recorded. A conso idated ist of a such forms is given in Appendi
x 3.
XXXXVII
Qua ity Assurance Handbook for Rura Roads
SECTION 100 GENERAL
1
Preamb e
For ensuring the requisite qua ity of construction, the materia s and workmanshi
p sha be subjected to qua ity contro tests. These tests have been specified i
n respective Sections in Vo .I of this Handbook. The frequency of tests required
to be performed on different materia s and the finished products sha be as sp
ecified in respective Sections in Vo ume I. The testing frequencies set forth ar
e the desirab e ones and the Engineer sha have the fu authority to carry out
additiona tests as frequent y as he may deem necessary, to satisfy himse f tha
t the materia s and the workmanship comp y with the appropriate specifications.
Setting up and maintaining an adequate y equipped Fie d Laboratory as required f
or qua ity contro of materia s and workmanship sha be the responsibi ity of t
he Contractor. The Fie d Laboratory shou d have the needed equipment, trained ma
n-power and essentia documentation regarding samp ing and test procedures. Rout
ine tests for Qua ity Contro which are required to be conducted on a day to day
basis sha be conducted by the Fie d Laboratory Staff. The Fie d Laboratory sh
ou d preferab y be ocated adjacent to the office of the Site Engineer and provi
ded with amenities ike water supp y, e ectric supp y, and proper access. The re
quirements of water supp y and e ectricity supp y wi depend on the avai abi it
y of these faci ities in the vicinity of the project site. The Fie d Laboratory
wi have on y those test equipment which are re evant to the project specificat
ions. The tests which are required to be done during the project preparation sta
ge such as those pertaining to the suitabi ity of construction materia s, se ect
ion of quarries etc. or the tests which are required on y once in a whi e for qu
a ity contro sha be conducted in the District Laboratory. The District Labora
tory wi cover the testing requirements on a district eve . Tests requiring hi
gh eve of ski s and sophisticated equipment as a so for the other qua ity che
cks wi be carried out at the Centra Laboratory under the contro of the Chief
Engineer, State Rura Road Deve opment Agency. The Centra Laboratory wi , thu
s, act as the Contro Testing Laboratory at the State eve . Any specia or soph
isticated tests for which the necessary equipment and expertise are not avai ab
e in the Centra Laboratory sha be outsourced.
119 Equipment for Fie d Laboratory
The fie d aboratory shou d be equipped with essentia equipment required for da
y to day tests for exercising qua ity contro during construction. Further, on y
those test equipment which are re evant to the project specifications wi be n
ecessary. Where the Contractor is required to carry out the maintenance of road
and structures, the fie d aboratory shou d have necessary equipment during main
tenance period for exercising qua ity over maintenance activities.
119.1
(a) (b)
List of Essentia Equipment - For Earthwork, Granu ar Construction and other Gen
era Requirements
Post Ho e Auger with extensions Digging too s ike pick axes, shove s etc.
3
One set One set
Section - 100
(c)
IS Sieves with id and pan (125 mm, 100 mm, 90 mm, 80 mm,75 mm, 63 mm, 53 mm, 50
mm, 45 mm, 40 mm, 31.5 mm, 26.5 mm, 25 mm, 22.4 mm 20 mm, 19 mm, 16 mm, 13.2 mm
, 12.5 mm, 11.2 mm, 10 mm, 9.5 mm, 6.3 mm, 5.6 mm, 4.75 mm, 3.35 mm, 2.36 mm, 2
mm, 1.18 mm, 600 micron, 425 micron, 300 micron, 180 micron, 150 micron, 90 micr
on and 75 micron) Standard Proctor Density Test Apparatus with Rammer Sand Pouri
ng Cy inder with tray comp ete for fie d density test Core Cutter (10 cm dia), 1
0 cm/15 cm height comp ete with do y and hammer Speedy moisture meter comp ete
with chemica s Straight Edges Liquid Limit and P astic Limit testing apparatus G
as Burner, sand bath Camber Board E ectronic/digita ba ance 1 kg with the east
count of 0.01 g E ectronic /digita ba ance 5 kg Pan ba ance with weight box, 5
kg Oven (200 oC), thermostatica y contro ed Ename ed tray Measuring tape, sp
atu a, spirit eve s, g assware, porce ain dish, pest e mortar Aggregate Impact
Test Apparatus F akiness Gauge Essentia survey equipment for checking surface
eve s Lab CBR equipment Uppa ’s Syringe for P asticity Index Pocket Penetrometer
For other tests ike Soundness of Aggregate, De eterious Materia , Su phate Con
tent etc. faci ities at the District Laboratory wi be used.
One set
(d) (e) (f) (g) (h) (i) (j) (k) ( ) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v) (w)
One set One set One set One set Two nos. One set One set Two nos. One no. One no
. One no. One no. Six nos. One set One set Six nos. One set One set One set One
set
119.2
(a) (b)
Additiona Equipment for Bituminous Construction
Digita Thermometers Water bath (ambient to 100 oC) Three nos. One no.
4
(c) (d) (e)
Penetration apparatus (Bitumen) Trays for measurement of tack coat quantity Bitu
men extraction apparatus
One set Three nos. One no.
For other tests ike R&B Softening Point, Viscosity, Storage Stabi ity, Ducti it
y, E astic Recovery and Separation Difference, faci ities at the District Labora
tory wi be used.
119.3
(a) (b) (c)
Additiona Equipment for Cement Concrete Works and Structures
S ump Cone Cube Mou ds Core Cutting Machine For other tests ike physica and ch
emica tests on Cement, A ka i Aggregate Reactivity Test, Chemica Tests for Wat
er, Compressive and F exura Strength of Concrete etc., faci ities at the Distri
ct /Centra Laboratory wi be used. Two nos. Twe ve nos. One no.
119.1
First Aid Box
One set
120 Equipment for District Laboratory
120.1 Genera Equipment
120.1.1 Equipment for Samp ing
(a) (b) Digging too s pick axes, shove s, hammers, chise s etc. Post ho e augers
(b ade type) with extension rods and accessories Two sets Three set (75 mm, 100
mm & 150 mm dia) Four sets (38 mm, 50 mm & 100 mm dia) One set each
(c) (d)
Thin wa ed samp ing tubes Samp e extruder – hand operated 38 mm, 50 mm, 100 mm
dia
120.1.2 Sieves
Standard set of sieves, id and pan 450 mm dia for coarse aggregates and 200 mm
dia for soi s and fine aggregates, sieve shaker.
Coarse Aggregates
125 mm, 106 mm ,100 mm ,90 mm, 80 mm, 75 mm, 63 mm, 53 mm, 50 mm 45 mm, One set
40 mm, 37.5 mm, 31.5 mm, 26.5 mm, 25 mm, 22.4 mm, 20 mm, 19 mm, 16 mm, 13.2 mm,
12.5 mm, 11.2 mm, 10 mm, 9.5 mm, 6.3 mm , 5.6 mm, 4.75 mm, 2.80 mm, 2.36 size wi
th id and cover
5
Section - 100
Fine Aggregates and Soi s
10 mm, 5.6 mm, 4.75 mm, 2.80 mm, 2.36 mm, 2.00 mm, 1.70 mm, 1.18 mm, 1 mm, 850 m
icron, 710, 600, 500, 425, 355, 300, 250, 212, 180, 150, 90 and 75 micron with p
an and cover One set
120.1.3 Ba ances
(a) (b) E ectronic/digita ba ance (1 kg) with the east count of .01 g E ectron
ic/digita ba ance (5 kg) One no. One no.
120.1.4 Proving rings
10 kg, 50 kg, 100 kg capacity One each
120.1.5 Dia gauges
25 mm, 50 mm trave , (sensitivity 0.01 mm/division) Six nos.
120.1.6 Water bath
E ectrica y operated and thermostatica y contro ed Gas burner and sand bath O
ne no.
120.1.7 Thermometers
Digita thermometers Three nos.
120.1.8 G assware
F asks, graduated cy inders, stirring apparatus, spatu as, wire gauges, scoops,
stee sca es, measuring tapes, cassero es, assorted sizes of ename ed trays, por
ce ain dish, fi ter paper, desiccator, funne , measuring tape, g ass marking pen
ci s, heat resistant hand g oves, spirit eve s, vernier ca ipers, mortar with r
ubber-covered pest e etc. One set
120.1.9 Oven
E ectricity operated and thermostatica y contro ed up to 200 oC (sensitive y 1
oC) with interior of non-corroding materia One no.
120.1.10 Reagents
Hydroch oric acid, sodium hexametaphosphate, hydrogen peroxide, ca cium carbide
One no. One set
120.1.11 First Aid Box 120.2
(a) (b)
Equipment for Testing of Soi s
Water sti (capacity 4 itres per hour) Rapid Moisture Meter comp ete with Chem
ica s
6
One no. One no.
(c) (d) (e) (f) (g) (h) (i) (j) (k) ( )
Liquid Limit and P astic Limit Testing Apparatus Samp ing Pipette 10m Standard
Proctor Density Test Apparatus with Rammer (Light compaction) Standard Proctor D
ensity Test Apparatus with Rammer(Heavy compaction) Sand Pouring Cy inder with T
ray comp ete for fie d density test. Samp ing tins with ids 100 mm dia, 50 mm h
eight Lab CBR equipment (comp ete set) with 12 mou ds Nuc ear Density Gauge Pock
et Penetrometers Uppa ’s Syringe for P asticity Index
One no. One no. One set One set Four nos. Twenty nos. One set Two sets Four nos.
Four nos.
120.3
(a) (b) (c) (d) (e) (f) (g)
Equipment for Testing of Aggregates
F akiness Gauge Standard equipment for Aggregate Crushing Va ue a ong with stand
ard tamping rod Specific gravity determination test apparatus with pycnometre /
specific gravity bott es, vacuum pump Aggregate soundness test apparatus Water a
bsorption test apparatus Aggregate Impact Va ue test apparatus Stripping test ap
paratus One no. One set One set One set One set One set One set
120.4
(a) (b) (c)
Equipment for Testing of Concrete
S ump cone Cube mou ds (150 mm x 150 mm x 150 mm) Compression Testing machine (2
00 Tonnes Capacity) Two Nos. Twe ve Nos. One No.
120.5
(a) (b) (c) (d) (e)
Equipment for Testing of Bitumen
Penetration test apparatus with standard need es R & B Softening Point Test Appa
ratus Ducti ity Test Apparatus C eve and Open Cup Test Saybo t Furo Viscometrer
Test Apparatus
7
One set One set One set One set One set
Section - 100
(f) (g) (h) (i)
Residue on 600 Micron Sieve Test Apparatus Storage Stabi ity Test for Bituminous
Emu sion E astic Recovery Test Apparatus Separation Difference Test Apparatus
One set One set One set One set
120.6
(a) (b)
Equipment for Testing Bituminous Mixes
Mechanica mixer of 0.02 m3 capacity, e ectrica y operated and fitted with heat
ing jacket E ectrica y operated centrifuge type bitumen extractor and commercia
benzene One no. One no.
120.7
(a) (b)
Equipment for Testing Workmanship
Camber Board / Temp ate with 3m straight edge Thickness gauge One No. One No.
121 Equipment for Centra Laboratory
121.1 Genera Equipment
One No.
121.1.1 Equipment for Samp ing items (i) to (iv) as in the equipment at District
eve , (v) Portab e sma size dri ing machine (diese operated) 121.1.2 Sieve
s & Sieve Shaker Standard set of sieves, id and pan 450 mm dia for coarse aggre
gates and 200 mm dia for soi s and fine aggregates, Sieve Shakers. Coarse Aggreg
ates 125 mm, 106 mm, 100 mm, 90 mm, 80 mm, 75 mm, 63 mm, 53 mm, 50 mm, 45 mm, 40
mm, 37.5 mm, 31.5 mm, 26.5 mm, 25 mm, 22.4 mm, 20 mm, 19 mm, 16 mm, 13.2 mm, 12
.5 mm, 11.2 mm, 10 mm, 9.5 mm, 6.3 mm, 5.6 mm, 4.75 mm, 2.80 mm size & pan and c
over Fine Aggregates and Soi s 5.6 mm, 4.75 mm, 2.36 mm, 2.00 mm, 1.70 mm, 1.18
mm, 1 mm, 850 micron, 710, 600, 500, 425, 355, 300, 180, 150, 90, 75 micron & pa
n and cover 121.1.3 Oven E ectricity operated and thermostatica y contro ed up
to 200oC and 300 oC (sensitivity 1oC) 121.1.4 Ba ances (with weights where neces
sary) (a) (b) P atform type 300 kg capacity Beam type ba ance 20 kg capacity (1g
accuracy)
8
One set
One set
One set
One no. One no.
(c) (d) (e) (f) (g) (h)
Chemica ba ance 100 g capacity (0.001 g accuracy) Physica ba ance 250 g capaci
ty (0.01 g accuracy) Pan ba ance 5 kg capacity (1 g accuracy) Se f indicating ty
pe ba ance 7 kg capacity (1 g accuracy) E ectronic ba ance (digita ) of 1 kg cap
acity ( 0.01 g accuracy) E ectronic/digita ba ance 5 kg capacity
One no. Two nos. One no. One no. One no. One no.
121.1.5 Proving rings (a) (b) 100 kg, 200 kg, 500 kg capacity 1000 kg, 2000 kg,
5000 kg capacity Two each One each
121.1.6 Dia gauges 25 mm, 50 mm trave (sensitivity 0.01 mm/division) 121.1.7 H
ot P ate E ectrica y operated and kerosene or gas stoves 121.1.8 Water bath E e
ctrica y operated and thermostatica y contro ed 121.1.9 Thermometers a) b) Me
ta ic type (Mercury in stee ) with 30 cm stem and 3 m stem for near and distant
reading G ass type (Mercury-in-g ass) ranges of 110 oC, 250oC, 400oC Six nos. S
ix nos. Two sets One each Six nos.
121.1.10 G assware Beakers, pipettes, f asks, graduated cy inders, spatu as, fun
ne , g ass rod, wire gauges, scoops, stee sca es, measuring tapes, cassero es,
assorted sizes of ename ed trays, fi ter paper, g ass marking penci s, spirit e
ve s, heat resistant hand g oves, vernier ca ipers, stop watch, etc. One set
121.1.11 First Aid Box
121.2 (a) (b) (c) (d) Equipment for Testing of Soi s Water sti (capacity 4 it
res per hour) Rapid Moisture Meters, comp ete with chemica s Liquid Limit device
with standard grooving too s P astic Limit device with rod comparator and g ass
p ate
One no.
One no. One no. One set One no.
9
Section - 100
(e) (f) (g) (h) (i) (j) (k) ( ) (m) (n) (o)
Post ho e auger (100 mm dia) with extensions for samp ing Samp ing pipette 10 m
Compaction test apparatus for heavy and ight compaction Sand rep acement equip
ment Samp ing tins with ids 100 mm dia, 50 mm height Lab CBR equipment (comp et
e set with 2 dozen CBR Mou ds) Core cutter Proctor Need e Uppa ’s Syringe for P
asticity Index Pocket Penetrometer Nuc ear Density Gauge
Four nos. One no. One set Four nos. Hundred nos. One set Six nos. Six nos. Six n
os. Six nos. Six nos.
121.3
(a) (b) (c) (d) (e) (f) (g) (h) (i)
Equipment for Testing of Cement and Aggregates
Riff e Divider for samp ing of coarse and fine aggregates F akiness Gauge Standa
rd mou ds of 30, 15 and 3 itres capacity a ong with standard tamping rod Specif
ic gravity determination test apparatus with pycnometrer/ specific gravity bott
es vacuum pump Aggregate soundness test apparatus Water absorption test apparatu
s Aggregate Impact Va ue test apparatus Stripping test apparatus Equipment for t
esting Fineness, Setting time & Strength of cement One no. One no. One set One s
et One set One set One set One no. One set
121.4
(a) (b) (c) (d) (e) (f)
Equipment for Testing of Concrete
S ump cone Cube mou ds Compression Testing Equipment 2000 kN Capacity U trasonic
Pu se Ve ocity Measuring Device Rebound hammer Water Bath for Acce erated Curin
g test. Two nos. Twe ve nos. One no. One set One set One set
10
(g)
F exura Strength Test with Compression Testing Machine
One set
121.5
a) b) c) d) e)
Equipment for Testing Straight Run and Liquid Bitumens
Penetration test apparatus with standard need es Ring & Ba softening point tes
t apparatus with ring, ba , thermometer etc. Ducti ity test apparatus F ash poi
nts: C eve and open cup test apparatus Saybo t Furo Viscometer One set One set
One set One set One set
121.6
Equipment for Testing of Bituminous Mixes
One no. One no. One no.
121.6.1 Mechanica mixer of 0.02 m 3capacity, e ectrica y operated and fitted w
ith heating jacket 121.6.2 E ectrica y operated centrifuge type bitumen extract
or and commercia benzene 121.6.3 Pavement Core Cutting Machine
11
SECTION 300 EARTHWORK
13
301 Embankment Construction
Sec No. A) Materia s 301.1 301.2 301.3 301.4 301.5 301.6 B) 301.7 (a) 301.7 (b)
301.7 (c) 301.7 (d) 301.7 (e) Grain Size Ana ysis
Tit e
Test Ref No.
301.1 301.2 301.3 301.4 301.5 301.6
Liquid Limit, P astic Limit and P asticity Index Proctor Density and Re ationshi
p between Dry Density and Moisture Content Free Swe Index Test De eterious Con
tent (Organic Matter) De eterious Content (So ub e Su phate) Construction & Work
manship Water Content of Soi – Oven Drying Method (Standard Method) Sand Bath M
ethod A coho Method Rapid Determination of Water Content with Infra-red Lamp To
rsion Ba ance Moisture Meter Rapid Determination of Water Content from Gas Press
ure deve oped by the Reaction of Ca cium Carbide with the Free Water of the Soi
Measurement of In-situ Density / Degree of Compaction (a) Sand Rep acement Meth
od (b) Core Cutter Method (c) Nuc ear Density Gauge Horizonta A ignment Surface
Leve s Surface Regu arity
301.7 (a) 301.7 (b) 301.7 (c) 301.7 (d) 301.7 (e)
301.8 301.8(a) 301.8(b) 301.8(c) 301.9 301.10 301.11
301.8 301.8(a) 301.8(b) 301.8(c) 301.9 301.10 301.11
A
Materia te
301.1.Grain Size Ana ysis Purpose Grain size ana ysis is carried out to determin
e the re ative percentages of different sizes of partic es in the samp e. These
sizes contro the mechanica behaviour of coarse grained soi . Dry method of sie
ving is used for coarser fractions (retained on 4.75 mm sieve) and wet method is
used for finer fractions (retained on 75micron sieve) and pipette method is use
d for fractions passing 75 micron sieve.
15
Section - 300
Procedure A. Dry Sieve Ana ysis (For soi fraction retained on 4.75 mm sieve) Pr
epare the samp e by drying it in air or oven and bring it to room temperature. C
ean a the sieves to be used (100 mm, 75 mm, 19 mm, and 4.75 mm). The sieves s
hou d conform to the requirements of IS 460 (Part I) – 1985. Weigh the required
quantity of materia from the prepared samp e in accordance with Note 1 given be
ow:
1. 2. 3.
Note 1: Depending on the maximum size of materia present in substantia quantit
ies in the soi , the mass of soi samp e taken for ana yses may be as fo ows:
Tab e 301.1.1 Mass of Various Sized Materia s to be Taken for Sieve Ana ysis Max
imum Size of Materia Present in Substantia Quantities (mm) 75 40 25 19 12.5 10
6.5 4.75 Mass to be taken for test (kg) 60 25 13 6.5 3.5 1.5 0.75 0.4
4. 5.
P ace the sieves over a c ean tray one over the other in the ascending order of
size. Shake the sieve with a varied motion, backwards and forwards, eft to righ
t, circu ar c ockwise and anti c ockwise, and with frequent jerking, so that the
materia is kept moving over the sieve surfaces. Do not force the materia thro
ugh the sieve by hand, except for sizes coarser than 19 mm. Break the umps of f
ine partic es, if any, with fingers against the side of the sieve. Light brushin
g with a soft brush on the under side of sieves may be done to c ear surface.
6. 7. 8.
16
9. 10.
Find the individua weight of materia retained on each sieve and record. The qu
antity taken for sieving sha be such that the wt. of materia retained on each
sieve does not exceed the va ues given in Note 2.
Note 2: Maximum weight of materia to be retained on each sieve at the comp etio
n of sieving sha be as fo ows:
17
Section - 300
Tab e 301.1.2: Maximum Weight of Materia to be Retained on Each Sieve IS Sieve
Designation 80 mm 20 mm 4.75 mm 450 mm Dia Sieves (kg) 15 4 1.0 300 mm Dia Sieve
s (kg) 6 2 0.5
11.
Ca cu ate the percentage by weight of the tota samp e passing each sieve and re
port the resu ts in Form EW-1.
Figure 1 Typica Grain Size Distribution Diagram
B.
Wet Sieve Ana ysis
(for soi fraction passing 4.75 mm sieve and retained on 75 micron sieve)
1. 2.
Take a portion of the samp e prepared by drying in oven at 105oCto 110 oC and br
ought to room temperature. Soak the samp e in water containing two grams of sodi
um hexametaphosphate or one gram of sodium hydroxide and one gram of sodium carb
onate per itre of water and eave it for soaking overnight. Wash out the finer
fraction passing through 75 micron sieve. Washing shou d be continued unti the
water pressure through 75 micron sieve is substantia y c ean. Then dry it in ov
en for 24 h and sieve the dry partic es on 2 mm and 425 micron sized sieves and
find the percentage of soi passing through each sieve and report the resu ts in
form EW-1
18
3. 4.
5.
Care sha be taken to see that the sieves are not over oaded. See Note 3.
Note 3: The permissib e maximum mass of samp e on the 200 mm diametre sieves sha
be as fo ows :
Tab e 301.1.3 Permissib e Maximum Mass of Samp e on 200 mm Diameter Sieves IS Si
eve Designation 2 mm 425 micron 75 micron Maximum Mass of Samp e (g) 200 50 25
Form EW-1 Sieve Ana ysis of Soi Dry Sieving Weight of Soi Samp e Taken: (g)
I. S. Sieve * Designation 100 mm 75 mm 19 mm 4.75 mm Weight of Samp e Retained (
g) Percent of Wt. Retained Cumu ative Percent of Wt. Retained (%) Percentage of
Wt. Passin
Wet Sieving Weight of Soi Samp e Taken: (g)
I. S. Sieve * Designation 2 mm 425 µ 75 µ Weight of Samp e Retained (g) Percent
of Wt. Retained Cumu ative Percent of Wt. Retained (%) Percentage of Wt. Passin
Summary of Resu ts
C ay / si t (-75 micron) percent Sand (-4.75 mm + 75 micron) percent Grave (-10
0 mm + 4.75 mm) percent
Sieves of intermediate sizes may a so be used, if desired. Reference IS: 2720 (P
art 4) – 1985 (Second Revision)
19
Section - 300
301.2.Liquid Limit, P astic Limit and P asticity Index Purpose The Liquid and P
astic Limits (Atterberg Limits) of soi indicate the water contents at which cer
tain changes in the physica behaviour of soi can be observed. From Atterberg
imits, it is possib e to estimate the engineering properties of fine-grained soi
s. P asticity is the property that enab es a materia to undergo deformation wi
thout noticeab e e astic recovery and without cracking or crumb ing. P asticity
is a major characteristic of soi s containing an appreciab e proportion of c ay
partic es. Procedure
A.
1. 2.
Liquid Limit (LL)
Take 120 g of soi passing IS: 425 micron sieve. Mix it with disti ed water to
form a uniform paste. The paste sha have a consistency that wi require 30 to
35 drops of the cup to cause required c osure of the standard groove. In case o
f c ayey soi s, paste may be eft standing for 24 h to ensure uniform distributi
on of moisture throughout the soi mass. Remix the soi thorough y and p ace a p
ortion of the paste in the cup of the apparatus. Squeeze down and spread the sam
p e with as few strokes of spatu a as possib e, at the same time trim it down to
a depth of 1cm at the point of maximum thickness, Leve the specimen to ha f th
e cup. Cut the paste with the standard grooving too a ong the centre ine In ca
se where grooving too type A does not give a c ear groove as in sandy soi , use
grooving too type B or C. Start rotating the hand e at 2 revo utions per secon
d. Count the number of b ows ti two parts of the samp e come into contact at t
he bottom of the groove a ong a distance of 12 mm. This ength sha be measured
with the end of the grooving too or a ru er. Record the number of b ows and de
termine moisture content of the samp e taken near the c osed groove.
3. 4.
5. 6. 7.
8.
Liquid Limit Device
20
9. 10. 11.
Repeat the test by changing the moisture content so that the number of b ows to
c ose the groove is not ess than 15 or more than 35, such that the points on th
e f ow curve are even y distributed. P ot a graph between og (number of b ows)
and moisture content and fit a straight ine. Read the moisture content correspo
nding to 25 number of b ows from the graph. This gives the Liquid Limit of the s
oi .
Figure 2 Determination of Liquid Limit
B.
1. 2.
P astic Limit (PL)
Take about 20 g of soi passing IS: 425 micron sieve. Mix it with disti ed wate
r to form a paste which is p astic enough to be easi y mou ded with fingers. In
the case of c ayey soi s, eave the soi mass standing for 24 h to obtain a unif
orm distribution of moisture. Take about 8 g of soi from the paste and make a b
a . Ro the ba on a g ass p ate with hand to make a thread of uniform diamet
re throughout its ength. The rate of ro ing sha be between 80 and 90 strokes
per minute counting a stroke as one comp ete motion of the hand forward and bac
k to the starting position again. When the diametre of thread reaches 3 mm, remo
u d the soi again to a ba . Repeat the process of ro ing and remou ding unti
the thread of soi just starts crumb ing at a dia greater than 3 mm. This sha
be considered a satisfactory end point, provided the soi has been ro ed into
a thread 3 mm in diametre immediate y before. At no time, sha an attempt be ma
de to produce fai ure at exact y 3 mm diametre by a owing the thread to reach 3
mm, then reducing the rate of ro ing or pressure or both, and continuing the r
o ing without further deformation unti the threads fa apart. Determine the m
oisture content of the crumb ed threads.
21
3. 4.
5. 6.
7.
Section - 300
8. 9.
Repeat the test two more times with fresh portion of the soi mix. The average o
f the moisture content of the soi in the three tria s gives the P astic Limit o
f the soi .
C.
P asticity Index (PI)
P asticity Index is determined by subtracting the va ue of p astic imit from th
e va ue of the iquid imit. PI =LL – PL Report the resu ts in Form EW-2. Form E
W-2 Atterberg Limits Test Determination of Liquid Limit (LL)
1 Container Number Weight of container + wet soi Weight of container + dry soi
Loss of Moisture Wt. of container Wt. of dry soi Moisture content % Number of
b ows 2 3 4 5 6 Remarks
Liquid Limit (LL) = ……………………per cent Determination of P astic Limit (PL)
1 Container Number Weight of container + wet soi Weight of container + dry soi
Loss of Moisture Wt. of container Wt. of dry soi Moisture content % (mc1) (mc
2) (mc3) 2 3 Remarks
P astic Limit (PL) =
mc 1 + mc2 + mc3 ---------------------------- = ---------------------------- per
cent 3
P asticity Index (P ) = LL - PL = ---------------------------- per cent Referenc
e : IS 2720 (Part 5) - 1985
22
301.3
Proctor Density (Light Compaction)
Purpose Compaction is measured in terms of dry density achieved. This is a funct
ion of water content, the compactive effort and the nature of soi . For the same
compactive effort, this test determines the optimum moisture content and the ma
ximum dry density of a given soi .
UNIVERSAL AUTOMATIC COMPACTOR
Procedure 1. 2. Weigh the mou d (W1) to the nearest 1g with base p ate attached.
Take about 6 kg of air dried soi passing 20 mm IS sieve for soi s not suscepti
b e to crushing during compaction, or about 15 kg of materia s passing a 19 mm s
ieve for soi s susceptib e for crushing during compaction (see Note 1). Sieve th
is portion on a 19 mm sieve and reject the coarse fraction after recording its p
roportion of the tota samp e.
NOTE 1- The soi shou d be considered susceptib e to crushing during compaction
if the samp e contains granu ar materia of a soft nature, such as soft imeston
e, sandstone, etc. which is reduced in size by the action of the 2.6 kg rammer.
The procedure given for soi s susceptib e to crushing during compaction can be a
pp ied to a soi s, if it is convenient to do so. Aggregations of partic es sha
be broken down so that, if the samp e was sieved on a 4.75 mm IS sieve, on y
separated individua partic es wou d be retained. Two separate procedures for th
e test sha be used depending on whether the soi is susceptib e to crushing du
ring compaction or not.
23
Section - 300
Procedure for Soi not Susceptib e to Crushing during Compaction: A 5 kg samp e
of air-dried soi passing the 19 mm IS test sieve sha be taken. The samp e sha
be mixed thorough y with a suitab e amount of water depending on the soi typ
e (see Notes 2, 3 and 4). The mou d, with base p ate attached, sha be weighed
to the nearest 1g (m1). The mou d sha be p aced on a so id base, such as a con
crete f oor or p inth and the moist soi sha be compacted into the mou d, with
the extension attached, in three ayers of approximate y equa mass, each ayer
being given 25 b ows from the 2.6 kg rammer dropped from a height of 310 mm abo
ve the soi . The b ows sha be distributed uniform y over the surface of each
ayer. The operator sha ensure that the tube of the rammer is kept c ear of soi
so that the rammer a ways fa s free y. The amount of soi used sha be suffi
cient to fi the mou d, eaving not more than about 6 mm to be struck off when
the extension is removed (see Note 5). The extension sha be removed and the co
mpacted soi sha be eve ed off carefu y to the top of the mou d by means of
the straight edge. The mou d and soi sha then be weighed to the nearest 1g (
m 2). The compacted soi specimen sha be removed from the mou d and p aced on
the mixing tray. The water content of representative samp e of the specimen sha
be determined as in IS: 2720 (Part 2)-1973. The remainder of the soi specimen
sha be broken up, rubbed through the 19 mm IS test sieve, and then mixed with
the remainder of the origina samp e. Suitab e increments of water (see Note 6)
sha be added successive y and mixed into the samp e, and the above procedure
from operations 5.1.2 to 5.1.4 sha be repeated for each increment of water add
ed. The tota number of determinations made sha be at east five, and the rang
e of moisture contents shou d be such that the optimum moisture content, at whic
h the maximum dry density occurs, is within that range. Soi Susceptib e to Crus
hing during Compaction (See Note 1)a) Five or more 2.5 kg samp es of air-dried s
oi passing the 19 mm IS test sieve, sha be taken (see Note 2). The samp es sh
a each be mixed thorough y with different amounts of water to give a suitab e
range of moisture contents (see Notes 3 and 4). The range of moisture contents,
at which the maximum dry density occurs, is within that range (see Note 6). Each
samp e sha be treated as stated ear ier. Each compacted specimen sha be tre
ated as stated ear ier. The remainder of each soi specimen sha be discarded.
b) c) d)
Compaction in Large Size Mou d- For compacting soi containing coarse materia u
p to 37.5 mm size, the 2 250 m mou d shou d be used. A samp e weighing about 6
kg and passing the 40 mm IS sieve is used for the test. Soi is compacted in thr
ee ayers, each ayer being given 55 b ows of the 2.6 kg rammer. The rest of the
procedure is same as stated ear ier. NOTE 2- The remova of sma amounts of st
one (up to 5 percent) retained on a 19 mm IS Sieve wi affect the density obtai
nab e on y by amounts comparab e with the experimenta error invo ved in measuri
ng the maximum dry density. The exc usion of a arge proportion of stone coarser
than 19 mm may have a major effect on the density obtained compared with that o
btainab e with the soi as a who e, and on the optimum moisture content. There i
s at present no genera y accepted method of test or of ca cu ation for dea ing
with this difficu ty in comparing aboratory compaction test resu ts with densit
ies obtained in the fie d. For soi s containing arger proportions of grave , th
e use of a bigger mou d (2 250 m ) wi avoid major errors. If proportion of gra
ve is more than 10%, modified MDD shou d be invariab y
24
found out or ca cu ated so that FDD is correct y compared. NOTE 3- The amount of
water to be mixed with air-dried soi at the commencement of the test wi vary
with type of soi under test. In genera , with sandy and grave y soi s, a moist
ure content of 4 to 6 percent wou d be suitab e, whi e with cohesive soi s moist
ure content about 8 to 10 percent be ow the p astic imit of the soi wou d (p a
stic imit minus 10 to p astic imit minus 8) usua y be suitab e. NOTE 4- It is
important that the water is mixed thorough y and adequate y with the soi , sinc
e inadequate mixing gives rise to variab e test resu ts. This is particu ar y im
portant with cohesive soi s when adding a substantia quantity of water to the a
ir-dried soi . With c ays of high p asticity or where hand mixing is emp oyed, i
t may be difficu t to distribute the water uniform y through the air-dried soi
by mixing a one, and it may be necessary to store the mixed samp e in a sea ed c
ontainer for a minimum period of about 16 h continuing with the test. NOTE 5- It
is necessary to contro the tota vo ume of soi compacted; since it has been f
ound that if the amount of soi struck off after removing the extension is too g
reat, the test resu ts wi be inaccurate. NOTE 6- The water added for each stag
e of the test shou d be such that a range of moisture contents is obtained which
inc ude the optimum moisture. In genera , increments of 1 to 2 percent are suit
ab e for sandy and grave y soi s and of 2 to 4 percent for cohesive soi s. To i
ncrease the accuracy of the test, it is often advisab e to reduce the increments
of water in the region of the optimum moisture content. Ca cu ations Bu k Densi
ty ãm in g/m of each compacted specimen sha be ca cu ated from the equation:
γm
where
m2 – m1 = --------------------Vm
m1 = mass in of mould and base; m2 = mass in of mould, base and soil; and Vm
= volume in ml of mould. The dry density, γd in /ml, shall be calculated from
the equation: 100 * γm = --------------------100 + w
γd
where
w = water content of soil in percent. The dry density γd obtained in a series of
determinations shall be plotted aainst the correspondin moisture contents w.
A smooth curve shall be drawn throuh the resultin points and the position of t
he maximum on this curve shall be determined. Reportin of results: The experime
ntal points and the smooth curve drawn throuh them showin the
25
Section - 300
relationship between moisture content and dry density shall be reported. The dry
density in /ml correspondin to the maximum point on the moisture content/dry
density curve shall be reported as the maximum dry density to the nearest 0.01.
The percentae moisture content correspondin to the maximum dry density on the
moisture content/ dry density curve shall be reported as the optimum moisture co
ntent and quoted to the nearest 0.2 for values below 5 percent, to the nearest 0
.5 for values below 5 to 10 percent; and to the nearest whole number for value e
xceedin 10 percent (see Note 7). The amount of stone retained on the 19 mm IS S
ieve shall be reported to the nearest 1 percent. The method of obtainin the res
ult shall be stated (2.6 k rammer method). The procedure used shall also be sta
ted, that is, sinle sample or separate sample and size of the mould used. NOTE
7- For some hihly permeable soils such as clean ravels, uniformly raded and c
oarse clean sands, the results of the laboratory compaction test (2.6 k rammer
method) may provide only a poor uide for specification on field compaction. The
laboratory test often indicates hiher values of optimum moisture content than
would be desirable for field compaction and the maximum dry density is often muc
h lower than the state of compaction that can readily be obtained in the field.
Form EW-3 Proctor Density
Description of Sample Type of Test Weiht of mould W1 () Volume of mould Vm (cm
3) Percent retained on 20 mm IS Sieve Standard Proctor
S.No.
Weiht of mould + compacted soil () W2
Weiht of wet soil () W2 - W1
Wet density (/cc)
Container No.
Weiht of container ()
Weiht + wet soil ()
Weiht of container + dry soil ()
Weiht of Water (Ww) ()
Weiht of dry soil (Ws) ()
Moisture Dry Content density (%) (W) (/cc)
1 2 3 4 5
26
Factors affectin Compaction Compaction is measured in terms of the dry density
achieved. This is found to be a function of 1. 2. 3. the water content the compa
ctive effort applied to the soil, and the nature of the soil.
These effects are briefly discussed below The effect of water content on compact
ion : The shearin resistance to relative movement of the soil particles is lar
e at low water contents. As the water content increases, it becomes relatively e
asier to disturb the soil structure, and the dry density achieved with a iven c
ompactive effort increases. However if the dry density is plotted aainst the wa
ter content for a iven compactive effort, it will be seen that the dry density
reaches a peak, after which any further increase in water content results in a l
ower dry density. From the dry density / water content curve, we can determine t
wo quantities; (a) (b) the maximum dry density, and the optimum water content at
which this maximum dry density is achieved
The effect of variations in compactive effort: Both the maximum dry density and
the optimum water content are found to depend on the compactive effort used. Inc
reasin the compactive effort increases the maximum dry density, but reduces the
optimum water content. The air void ratio at the peak density remains very much
the same. It may be seen that, at hih water contents, there is little to be a
ined by increasin the compactive effort beyond a certain point. The effect of s
oil type on compaction: The hihest dry densities are produced in well-raded co
arse-rained soils, with smooth rounded particles. Uniform sands ive a much fla
tter curve, and a lower maximum dry density. Clayey soils have much hiher optim
um water contents, and consequently lower maximum dry densities. The effect of i
ncreasin the compactive effort is also much reater in the case of clayey soils
. Fiures 3 and 4 show typical results of compaction tests for different soils a
nd different moisture contents.
27
Section - 300
Note : 1 /cm3 = 9.81 kN/m3
Fiure 3. Modified Proctor Test Curve (Dry Density vs Mositure Content)
Note : 1 /cm3 = 9.81 kN/m3
Fiure 4. Compaction Curve for a Rane of Soil Types
28
Table 301.3.1 Typical Values of Maximum Dry Density and Optimum Water Content BS
Liht Hammer (Proctor) test Type of Soil Clay Silty Clay Sandy Clay Sand Gravel
-sand-clay-mixture Max.dry density (kN/m3) 15.2 16.3 18.1 19.0 20.0 Optimum wate
r content (%) 28 21 14 11 9 BS Heavy hammer (AASHO) test Max.dry density (kN/m3)
18.2 19.1 20.4 20.6 22.0 Optimum water content (%) 18 12 11 9 8
Reference: IS : 2720 (Part 7) – 1980 reaffirmed 1987. 301.4 Free Swell Index Tes
t Purpose On saturation, certain soils expand in volume due to the presence of p
articular minerals. Soil with free swell index more than 50% is considered inade
quate for use as fill material. Procedure 1. 2. 3. 4. 5. 6. 7. 8. Take two sampl
es of oven dry soil passin throuh 425 micron sieve- 10 each. Take two 100 ml
raduated lass cylinders. Pour the soil sample in each cylinder. Fill distilled
water in one cylinder and kerosene in the other cylinder upto 100 ml marks. Rem
ove the entrapped air by entle shakin or stirrin with a lass rod. Leave the
samples to settle and allow sufficient time (24 h or more) for the soil samples
to attain equilibrium state of volume. Read the final volume of soil in each cyl
inder. Determine the differential free swell index S d usin the formula Volume
of soil in water - Volume of soil in kerosene Sd = -----------------------------
--------------------------------------------------------------------------------
-- x 100 Volume of soil in kerosene. 9. If the value of Sd is 50 per cent or mor
e, the soil is expansive and not suitable for use as embankment fill material.
29
Section - 300
Form EW-4 Free Swell Index
Sample No. Final volume of soil in water Vw Final Volume of soil in kerosene Vk
Free Swell Index Vw – Vk Sd = ------------------- x 100 Vk
Note : Permissible Limit ……………….. Max 50 per cent Reference: IS: 2720 (Part 40)
– 1977 301.5 Deleterious Content (Oranic Matter) Purpose Deleterious contents o
f soil such as oranic matter affect its characteristics and behaviour adversely
and must therefore be within 2%. Procedure 1. Take an air dried sample of soil
and determine its moisture content. Usin another sample, produce about 100 of
soil passin the 10 mm I.S. sieve. Pulverise this sample to pass throuh 425 mi
cron I.S.sieve. In case the soil contains a hih percentae of sulphides or chlo
rides it may be neutralised with dilute sulphuric acid or washed with distilled
water to remove the salts. Take 5 of soil from thorouhly mixed soil passin 42
5 micron sieve and place it in a lass weihin bottle. The weiht of the sample
should be less (upto 0.2) for soils with hiher content of oranic matter. Add
10 millilitres of potassium dichromate solution into the conical flask with a b
urette and add 20 ml of concentrated sulphuric acid. Swirl the mixture for about
one minute and keep it on a heat insulated surface for 30 min to allow oxidatio
n. Add 200 ml of distilled water alon with 10 ml of orthophosphoric acid and 1
ml of sodium fluoride as the indicator. Shake the mixture viorously. If the ind
icator ets absorbed, add another 1 ml of the indicator. Add ferrous sulphate so
lution from a second burette until the colour of the solution chanes from blue
to reen. Add a further 0.5 ml of potassium dichromate to chane the colour from
reen to blue. Add ferrous sulphate solution drop by drop with continuous swirl
in until the colour of the solution chanes with a sinle drop. Note the total
volume of ferrous sulphate solution used in the experiment.
2. 3.
4.
5.
6.
7.
30
Calculations The total volume of potassium dichromate used to oxidise the orani
c matter in the soil is iven by the followin formula V = 10.5 (1.0-Y/X) Where
Y = total volume of ferrous sulphate used in the test X = total volume of ferrou
s sulphate used in the standardization test The percentae of oranic matter pre
sent in the oven-dried sample may be calculated from the followin formula 0.67*
W2*V The oranic matter, percent by weiht = ------------------------W1*W3 Where
W2 = weiht on oven-dry basis of the soil sample passin 10 mm sieve V = total
volume of potassium dichromate used to oxidise the oranic matter W1 = weiht on
oven-dry basis of the total soil sample before sievin W3 = weiht on oven-dry
basis of the soil specimen used in the test
FORM EW - 5 Determination of Oranic Matter Content
S.No. Total volume of potassium dichromate used to oxidize the Oranic MatterV W
t. of soil sample (oven dried) before sievin W1 () Wt. of soil sample (oven dr
ied) passin 10 mm size W 2 () Wt. of soil sample (oven dried) used in the test
W 3 () Oranic matter percent by weiht 0.67 x W2 x V = ----------------------
-W1 x W3
Reference I.S. 2720 (Part 22) - 1972 301.6 Deleterious Content (Soluble Sulphate
) Purpose Sodium sulphate is present in some Indian soils. The salt is easily hy
drated and dehydrated under the influence of climatic chanes. There are enormou
s volume chanes durin this process of hydration and dehydration, which influen
ce the enineerin properties of soils.
31
Section - 300
Procedure 1. Take the soil sample in a state in which it can be crumbled. If nec
essary, dry it in oven at 105 oC to 110oC. Break the lumps in a mortar with a ru
bber covered pebble. Mix the sample thorouhly and sub-divide it by quarterin.
Take 10 of soil from the sample in a 250 ml bottle with 100ml of distilled wat
er. Shake it occasionally for about 2 h with a mechanical shaker. Allow the soil
to stand overniht. In case the soil is dispersive, add 0.5 to 1.0 of pure po
tassium nitrate to flocculate the particles. Filter and take 25 ml of filtrate i
n a beaker. See if the solution is alkaline from phenolphthalein indicator. If s
o, add concentrated hydrochloric acid to just neutralize the solution. Add furth
er 4 ml of hydrochloric acid to make the solution acidic. Boil the solution. Rem
ove the solution from heat and add hot barium chloride solution in a fine stream
with constant stirrin, till there is no precipitation with further addition. P
lace the beaker on a steam bath for a minimum period of 4 h and allow precipitat
e to settle. Further the precipitate throuh ashless filter paper wash free from
chloride irons, dry and inite filtration can be done throuh a pre-weihed sin
tered lass crucible or a Gooch crucible. In case of filter paper after dryin,
ashin shall be done. On a low flame and the precipitate then inited over a bur
ner or in a muffle furnace at 600oC to 700oC for half an hour. Cool in a dessica
tor, weih and note the residue. This is the weiht of the barium sulphate. Calc
ulate the correspondin weiht of sodium sulphate and determine its percentae a
s follows: a) b) Sulphate (SO4) percent by mass = 41.15 W1/W2 Sodium Sulphate (N
a2 SO4)percent by mass = 60.85 W1/W2
2.
3.
4. 5.
6. 7.
Where W1 = mass in of the precipitate W2 = Mass of of the soil contained in
the solution taken for precipitation.
FORM EW-6 Determination of Soluble Sulphate Content
S.No. Mass of the Precipitate W1 () Mass of the Soil contained in the solution
W2 () Sulphate as SO4 Sulphate as SO3 = SO4 X 80/96
Reference: IS : 2720 (Part 27) –1977
32
B
Construction & Workmanship
301.7 Water Content of Soil Purpose The properties of soil like shear strenth a
nd compaction characteristics are reatly influenced by its water content and th
e chanes therein. Water content thus indicates the likely behavior of soil.
ELECTRIC OVEN
DIGITAL BALANCE
33
Section - 300
Procedure a. Oven-Dryin Method (Standard Method) 1. 2. 3. 4. 5. 6. 7. 8. Take a
ny suitable non-corrodible air-tiht container. Clean the container tin with lid
, dry and weih (W I). Take the required quantity of soil specimen in container,
crumbled and placed loosely and weih with lid (W2). Then keep it in an oven wi
th the lid removed and maintain the temperature of the oven at 110°C + 5°C. If t
he soil contains ypsum or other minerals havin loosely bound water of hydratio
n or with sinificant amount of oranic material, the dryin may be carried out
at 60-80oC. Dry the specimen in the oven for 24 h. Take out container from oven,
place the lid back on the container and cool the container in a desiccator. Rec
ord the final weiht (W3) of the container with lid and dried soil sample. Calcu
late the percentae of moisture content usin the formula: W2 -W3 Moisture conte
nt.= ---------------------------------- x 100 W 3 - WI 9. Report the results in
Form EW-7
Form EW-7 Moisture Content Test of Soil by Oven-dryin Method
Sample No. Tin No. Wt. of Tin wet () (W1) Wt. of Tin+ soil () (W2) Wt. of Tin+
dry soil () (W3) Loss of water () (W 2- W3) Wt. of dry soil () (W3 – W1 ) Mo
isture Content (%) W2 -W3
= ---------------------- x 100
W3 - WI
Note: Speedy Moisture Metres are also available in market. These are based on th
e principle that water will react with calcium carbide to form acetylene as. Qu
antity of as formed is directly proportional to the water present. The quantity
of as can be read from a pressure aue which is calibrated in percentae of m
oisture on wet weiht basis. This can then be converted to moisture content base
d on dry weiht. Reference I.S. 2720 (Part2) – 1973
34
b.
Sand Bath Method
Purpose The properties of soil like shear strenth and compaction characteristic
s are reatly influenced by its water content and the chanes therein. Procedure
1. 2. 3. 4. 5. 6. 7. Take an open vessel of 150 mm diametre containin sand fil
led (called as sand bath) to a depth of 3 cm or more. Take the required quantity
of soil specimen in tray, crumbled and placed loosely and weih (W1). Place few
pieces of white paper on the sample. Then keep the tray on the sand bath and he
at it with stove. Dryin takes place about 20 to 60 min, dependin upon the type
of soil. The white paper turns brown when overheatin occurs. Take tray out of
the sand bath, once dryin is over and cooled and weihed. Record the weiht of
the dried soil sample (W2). Calculate the percentae of moisture content usin t
he formula: Moisture content: [(W1-W2)/W2]* 100 8. Report the results in Form EW
-8.
Form EW-8 Moisture Content by Sand Bath Method
Sample No. Wt. of wet soil () (W1 ) Wt. of dry soil () (W2 ) Loss of water ()
(W 1 - W2 ) Moisture Content (%) W1 –W2
= ------------------------------------ x 100
W2
c.
Rapid Determination of Water Content with Alcohol Method
Purpose It is a rapid method of determinin the moisture content. Thouh less ac
curate, it is more suitable as a field test. Procedure 1. 2. Clean the evaporati
n dish, dry and weih (W1). Take appropriate quantity of soil specimen in the e
vaporatin dish and weih (W2).
35
Section - 300
3. 4. 5. 6.
Pour methylated spirit over the soil at the rate of about one millilitre for eve
ry ram of soil taken so that the soil is well covered. Work the methylated spir
it well into the soil with the palate knife and break up any lare lumps of soil
. Place the evaporatin dish on a surface which will not be affected by heat and
inite the methylated spirit. Stir the soil constantly with the spatula or knif
e takin care to see that none of the soil is lost. After the methylated spirit
has burnt away completely allow the dish to cool and weih it with the contents
(W3).
Calculations The percentae of water content shall be calculated as follows: (W
2 – W3) w = ----------------------(W1 - W1) where w = water content present W1 =
mass of dish in W2 = mass of dish with wet soil in W3 = mass of dish with d
ry soil in d. Rapid Determination of Water Content with Infra – Red Lamp Torsi
on Moisture
Meter Procedure 1. 2. 3. Set the 100 percent scale division of the calibrated dr
um to alin with the index mark with the help of drive knob. With the pan placed
on the pivot check that the pointer is alined with the index line and the 100
percent scale division. If not, set the pointer with the help of initial settin
knob. Rotate the drum drive knob anti-clockwise and brin the 0 percent scale d
ivision in line with the index mark, thus prestressin the wire throuh an amoun
t equal to 100 percent scale division (this represents the amount of unbalance).
The pointer will now be above the index mark. Raise the lamp housin and carefu
lly distribute the test material evenly on the sample pan until the pointer retu
rns to the index mark (approximately 25 of the material will be needed in one
operation). Lower the lamp housin and switch on the infra – red lamp with the h
elp of the switch provided on the left hand side. Insert the thermometer in its
socket and bracket. Adjust the control knob between 95 and 100 on the scale if i
t is desired that the temperature of dryin is around 110°C. The sample will now
bein to lose water and pointer will rise above the index.
4.
5.
36
e.
Rapid Determination of Moisture Content from Gas Pressure developed by the React
ion of Calcium Carbide with the Free Water of the Soil
Purpose The purpose of this test is to determine the moisture content of soil qu
ickly, without havin to wait for the moisture to evaporate.
Fiure 5 Set up for Rapid Determination of Moisture Content
Procedure 1. The apparatus required for the test includes one metallic pressure
vessel with clamp for sealin cup and a aue calibrated in percentae water. On
e counterpoint balance, a scoop for measurin calcium carbide and three steel ba
lls of 12.5 mm diameter and one steel ball of 25 mm diameter. Set up the balance
and place the sample in the pan till the mark on the balance arm mass lines up
with the index mark. Unclamp the clampin screw to move the U-clamp off the cup.
Lift off the cup. Clean the cup and the body. Hold the body horizontally and e
ntly deposit one level scoopful of calcium carbide halfway inside the chamber. T
hen lay the chamber down without disturbin the absorbent chare and transfer th
e soil weihed out as above from the pan to the cup.
37
2. 3. 4.
Section - 300
5. 6.
Holdin cup and chamber approximately horizontal brin them toether, without di
sturbin sample or absorbent, brin the U clamp round and clamp the cup tihtly
into place. With the aue downwards, shake the moisture meter up and down vior
ously for 5 seconds, then quickly turn it so that the aue is upwards, ive a t
ap to the body of the moisture meter to ensure that all the contents fall into t
he cup. Hold the rapid moisture meter downwards, aain shake for 5 seconds, then
turn it with aue upwards and tap. Hold for one minute. Repeat this for a thir
d time. Once more invert the rapid moisture meter and shake up and down to cool
the as. Turn the rapid moisture meter with the aue upwards, and dial horizont
al held at chest heiht when the needle comes to rest, take the readin. The rea
dins on the meter are the percentaes of water on the wet mass basis. Alternati
vely, the three smaller steel balls can be placed in the cup alon with the soil
and the larer one in the body alon with the absorbent and seal up the unit as
usual. Hold the rapid moisture meter vertical so that the material in the cup f
alls into the body. Now holdin the unit horizontally, rotate it for 10 seconds
so that the balls are rolled round the inside circumference of the body. Rest fo
r 20 seconds. Repeat the rotation – rest cycle until the aue readin is consta
nt (usually this takes 4 to 8 min). Note the readin as usual. Finally release t
he pressure slowly (away from the operator) by openin the clamp screw and takin
the cup out, empty the contents and clean the instrument with a brush. Calcula
te the water content (w) on the dry mass from the water content (m) obtained on
the wet mass basis as the readin on the rapid moisture meter, as follows: w= wh
ere, w = percent water content of the dry mass m = percent water content of the
wet mass m ------------------ x 100 percent (100-m)
7.
8.
9. 10.
Reference IS 2720 (Part II) - 1973 301.8 a. Measurement of In-situ Density / De
ree of Compaction Sand replacement method
Purpose Field density of soil affects its permeability and compressibility. Also
the compaction of soil is measured in terms of dry density achieved. Procedure
1. The pourin cylinder shall be filled so that the level of the sand in the cyl
inder is within about 10 mm of the top. Its total initial weiht (WI ) shall be
found and shall be maintained constant throuhout the tests for which the calibr
ation is used. Volume of sand equivalent to that of the excavated hole in the so
il (or equal to that of the calibration container) shall be allowed to run out
38
of the cylinder. The shutter on the pourin cylinder shall then be closed and th
e cylinder placed on a plane surface such as the lass plate. (Sand should be cl
ean natural sand passin 1.0 mm IS sieve and retained on 600 micron). 2. The shu
tter on the pourin cylinder shall be opened and sand allowed to run out. When n
o further movement of sand takes place in the cylinder, the shutter shall be clo
sed and the cylinder moved carefully. The sand that has filled the cone of the p
ourin cylinder (that is the sand that is left on the plane surface) shall be co
llected and weihed to the nearest ram repeated at least three times and the me
an weiht (W 2) taken. The internal volume (V) in cc of the calibratin containe
r may be calculated from its internal dimensions. The pourin cylinder shall be
placed concentrically on the top of the calibratin container after bein filled
to the constant weiht (W1). The shutters on the pourin cylinder shall be clos
ed durin this operation. The shutters shall, be opened and sand allowed to run
out. When no further movement of sand takes place, the shutter shall be closed.
The pourin cylinder shall be removed and weihed to the nearest ram. These mea
surements shall be repeated at least three times and the mean weiht (W 3) taken
. A flat area, approximately 45 cm square, of the soil to be tested shall be exp
osed and trimmed down to a level surface, preferably with the aid of the scraper
tool. A round hole approximately 10 cm dia and the depth of the layer to be tes
ted upto a maximum of 10 cm depth shall be excavated in the soil. No loose mater
ial shall be left in the hole. The metal tray with a central hole shall be laid
on the prepared surface of the soil with the hole over the portion of the soil t
o be tested - the hole in the soil shall then be excavated usin the hole in the
tray as a patter. This tray shall be removed before the pourin cylinder is pla
ced in a position over the excavated hole. The excavated soil shall be carefully
collected and weihed to the nearest ram. The moisture content (W) of the exca
vated soil shall be determined by takin representative sample of soil. Alternat
ively, the whole of the excavated soil may be dried and weihted (Wd). The pouri
n cylinder filled to the constant weiht (W I) shall be placed so that the base
of the cylinder covers the hole concentrically, the shutters on the pourin cyl
inder shall be closed durin this operation. The shutter shall then be opened an
d sand allowed to run out into the hole. The pourin cylinder and surroundin ar
ea shall not be vibrated durin this period. When no further movement of sand ta
kes place, the shutter shall be closed. The cylinder shall be removed and weihe
d to the nearest ram (W4) (See Note). Note: 0It is necessary to make a number o
f repeated determinations say 4 to 5 and to averae the results, since the dry d
ensity of the soil varies appreciably from point to point.
3.
4. 5.
6. 7. 8.
9. 10.
11.
39
Section - 300
12.
The weiht of sand (Wa) in required to fill the calibratin container shall be
calculated from the followin formula. Wa = WI – W2 - W3 Where WI - Weiht of p
ourin cylinder and sand before pourin into calibratin Cylinder in . W2 - Mea
n weiht of sand in cone in . W3 - Mean weiht of cylinder with residual sand a
fter pourin into calibratin cylinder and cone in
13.
The bulk density of the sand Ys in (/cc) shall be calculated from the formula:
Ys =Wa /V Where V = Volume of calibratin cylinder in cc
14.
The weiht of sand (Wb) in required to fill the excavated hole shall be calcul
ated from the followin formula. W b =W1-W4-W 2 Where W1 - Weiht of cylinder an
d sand before pourin into hole in W2 - Mean weiht of sand in cone, in W4 -
Weiht of cylinder and sand after pourin into hole and cone in
15.
The bulk density of the soil Yb shall be calculated from the followin formula:
Ww Yb = --------------------- Y s /cc or Wb Where Ww - Weiht of natural soil e
xcavated in Wb - Weiht of sand required to fill the hole in Ys - Bulk densi
ty of sand
16.
The density of the dry soil Yd shall be calculated from the followin formula. Y
d Ww 100 = ------------- x Ys /cc or -------------------- x Yb /cc Wb 100 + W
40
Where W - Moisture content of the soil in percent WW - Weiht of dry soil from t
he hole in and Wb - Weiht of sand required to fill the hole in The followin
values shall be reported. (Form EW-9 for recordin results) (a) (b) Dry densit
y of soil in /cc. Moisture content of the soil in percent.
SAND POURING CYLINDER APPARATUS
41
Section - 300
FORM EW-9 Field Density of Soil (Sand replacement method) Road/Section Details:
Location of test point.: Observation Tables
a) Calibration (i) Mean weiht of sand in cone (of pourin cylinder) (W2)in . (
ii) Volume of calibratin cylinder (V) in cm3, (iii) Weiht of sand (+ cylinder)
before pourin into calibratin container (W1 )in . (iv) Mean weiht of sand (
+cylinder) after pourin into calibratin container. (W3) in . (v) Weiht of sa
nd to fill calibratin cylinder. (Wa = W1 - W2- W3) in . (vi) Bulk density of s
and Ys = (Wa/V) /cm3 b) Determination of soil density (i) Determination number
(ii) Weiht of wet soil from hole (Ww)in , (iii) Weiht of sand (+ cylinder) be
fore pourin into hole (W1)in . (iv) Weiht of sand (+ cylinder) after pourin
into hole and cone (W4)in . (v) Mean weiht of sand in cone (W2) in . (vi) Wei
ht of sand in hole, in . Wb= (W1 - W4- W2) (vii) Bulk density Yb= (Ww/Wb)x Ys
/cm3 (viii) Moisture content container number (ix) Moisture content (W) percent
(x) Weiht of dry soil from the hole in . (Wd ) (xi) Dry density Yd= (Wd / Wb)
x Ys Qm/cm3 Layer Below Subrade Subrade Value* Permissible Limit Not less than
97 per cent Not less than 100 per cent
Date of Testin: Thickness of layer: mm
Reference IS : 2720 (Part 28) -1974
42
b.
Core Cutter Method for Field Density
Field density can be determined by core cutter also. The method can be used succ
essfully whenever soil conditions permit pushin of cutter for samplin and taki
n it out in the laboratory without much disturbance. This is briefly described
as under:1. 2. 3. 4. 5. 6. 7. 8. Measure the inside dimensions of the cutter and
calculate its volume. Weih the cutter without dolly. Remove loose soil from th
e site. Place the dolly over the cutter and ram it ently into the soil till abo
ut one cm of the dolly protrudes above the surface. Di out the cutter containin
the soil extrudin from the round. Remove the dolly and trim off any soil ext
rudin from the ends. Weih the cutter full of soil and keep a representative sa
mple for water content determination. Calculate the dry density of the soil by k
nowin its weiht, volume and water content. Form EW10 for recordin results.
Reference : IS : 2720 (Part 28) – 1974 Determination of Field Density of Soil (C
ore Cutter Method) Form EW-10
S.No. 1. 2. 3. 4. 5. Bulk Density Yb 6. 7 8 9. 10. 11. 12. Container No. Weiht
of Container + Soil Sample = W2 Weiht of Container after oven dryin = W3 M
oisture Content = W2 – W 3 Weiht of empty Container = W4 Weiht of Dry Soil
= W3 – W4 Percentae of Moisture Content W2 – W 3 w = ----------------------
x 100 % W3 – W 4 Dry Density 100 Yd = --------------------x Yb /cm3 100 + m Obs
ervation Volume of Core Cutter = V cm
3
1
2
3
Weiht of empty Core Cutter = W Weiht of Core Cutter + Wet Soil = W1 Weiht
of Wet Soil = W1-W W1 - W = ------------------- /cm3 V
13.
Reference: IS : 2720 (Part 29) – 1966.
43
Section - 300
c.
Measurement of Density of Soil in place by Nuclear Density Gaue
Purpose This is a quick method of determinin the in-situ density of soil which
is based on the radiation. Procedure For this test a special equipment which mea
sures in place density usin amma radiation is used. Gaue usually contains a s
mall amma source (about 10mCi) such as Cesium – 137 on the end of a retractable
rod. Gamma rays are emitted from the source which interact with electrons in th
e surroundin material. Density of material is then correlated to the number of
amma rays received by the detector. The followin procedure is used for measuri
n the density of soil. 1. 2. 3. Make the surface even by usin a uide plate or
any other suitable equipment. Make a hole by poundin a steel rod with a simila
r diameter to that of aues retractable rod. The hole should be at least 50mm d
eeper than the intended depth of measurement. Nuclear Density Gaues normally op
erate in two modes. i) ii) Direct Transmission Back Scatter
For measurin the density of soil, set the equipment to ‘Direct Transmission Mod
e’. 4. 5. 6. 7. Lower the source rod into the hole. Set the handle to the depth
position required. Read the detector count on the panel. Use the calibration cha
rt provided by the manufacturer to obtain density of material. It may be noted t
hat the detector count is inversely proportional to the density of the surroundi
n material. The Nuclear Density Gaues are calibrated at the factory. Since the
source material underoes decay, it needs to be calibrated from time to time in
accordance with the procedure iven by the manufacturer.
44
Nuclear Density Gaue
301.9 Horizontal Alinment Purpose It is necessary to check the horizontal alin
ment to ensure that the work is set out in accordance with the approved drawins
and dimensions. Procedure Horizontal alinment shall be reckoned with respect t
o the centerline of the carriaeway as shown on the drawins. The permitted tole
rances for the edes of the carriaeway and the roadway and lower layers of pave
ment in plain and rollin terrain and in hilly terrain are iven below. Permitte
d tolerances In Plain and Rollin Terrain Edes of carriaeway Edes of roadway
and lower layers of pavement 301.10 Surface Levels Purpose Checkin of levels of
subrades and different pavement courses is required to ensure that desin thic
kness of various layers are actually transferred on to the round.
45
In Hilly Terrain + 30 mm
+ 20 mm
+ 30 mm
+ 50 mm
Section - 300
Procedure The levels of the subrade and different pavement courses as construct
ed, shall not vary from those calculated with reference to the lonitudinal and
cross-profile of the road shown on the drawins or as directed by the Enineer b
eyond the tolerances mentioned in Table 301.10.1.
Table 301.10.1 Tolerances in Surface Levels** S. No. 1 2 Subrade Subbase a) Fle
xible pavement b) Concrete pavement (Dry lean concrete or rolled concrete) 3 Bas
e course for flexible pavement a) Bituminous course b) Other than bituminous i)
Machine laid ii) Manually laid 4 Wearin course for flexible pavement i) Machine
laid ii) Manually laid 5 Cement concrete pavement + 6mm - 6mm + 10mm -10mm +5mm
- 6mm* + 10mm - 10mm + 15mm -15mm + 6mm - 6mm +10mm - 20mm +6mm - 10mm Layer To
lerance Limits +20mm -25mm
* This may not exceed 8 mm at 0-300 mm from the edes ** This Table 301.10.1 wil
l be referred to for construction of various pavement layers dealt with in subse
quent Sections.
Provided, however, that the neative tolerance for wearin course shall not be p
ermitted in conjunction with the positive tolerance for base course, if the thic
kness of the former is thereby reduced by more than 6 mm for flexible pavements
and 5 mm for concrete pavements. For checkin compliance with the above requirem
ent for subrade, sub-base and base courses, measurements of the surfaces levels
shall be taken on a rid of points placed at 10 m lonitudinally and 2.5 m tran
sversely. For any 10 consecutive measurements taken lonitudinally or transverse
ly, not more than one measurement shall be permitted to exceed the tolerance as
above, this one measurement bein not in excess of 5 mm above the permitted tole
rance. For checkin the compliance with the above requirement for bituminous wea
rin courses and concrete pavements, measurements of the surface levels shall be
taken on a rid of points spaced at 6.25 m alon the lenth and at 0.5 m from t
he edes and at the centre of the pavement. In any lenth of pavement, complianc
e shall be deemed to be met for the final road surface, only if the tolerance i
ven above is satisfied for any point on the surface.
46
301.11
Surface Reularity (Usin a 3 m Straiht Ede)
Purpose Reularity of surface is essential for a smooth ridin on the road surfa
ce. Procedure 1. The 3 metre straiht ede may be made of steel or seasoned hard
wood. When made of wood, it may be 75 mm wide and 125 mm deep and its test face
should preferably be shod with a metallic plate. The ede should be perfectly s
traiht and free from warps, rots or defects of any kind. Periodically, the stra
iht ede should be checked for its trueness with a strin or a metallic master
straiht ede. The straiht ede should be rectified or replaced as soon as the
same has lost its trueness. The depressions under the straiht ede are to be me
asured with a raduated wede. The wede should be metallic. The depressions sho
uld be raduated to read undulations up to 25 mm with a least count of at least
3 mm. For recordin depressions in the lonitudinal profile of the road surface,
the straiht ede is placed lonitudinally, parallel to the centre line of the
road. Measurements alon two parallel lines are sufficient for a sinle lane roa
d. The straiht ede may be placed at the startin point with the wede inserted
between it and the test surface, where the ap is maximum. Take the readin. Th
e straiht ede may then be slid forward by about 1.5 m distance and the wede r
eadin repeated. This process may be continued. . Mark the locations with depres
sions in excess of the specified manitude. Count the number of undulations exce
edin the specified manitude. Note: (i) A team of three persons consistin of t
wo workmen and a supervisor would be required for one straiht ede and two rad
uated wedes. The two workmen will operate the straiht ede, while the supervis
or will record measurements with the wedes and do the markins on the road. (ii
) At vertical curves, additional templates will be required.
2.
3.
4.
5. 6. 7. 8.
47
Section - 300
302 EARTHWORK IN CUTTING
Sec No. A) Materials 302.1 302.2 302.3 302.4 302.5 302.6 302.7 B) Grain Size Ana
lysis Liquid Limit, Plastic Limit and Plasticity Index Proctor Density Free Swel
l Index Deleterious Content (Oranic Content) Deleterious Content (Soluble Sulph
ate) CBR of Remoulded and Soaked Samples 301.1 301.2 301.3 301.4 301.5 301.6 302
.7 Title Test Ref No.
Construction & Workmanship 302.8 Determination of Moisture Content (a) Oven-dryi
n Method (b) Sand Bath Method (c ) Alcohol Method (d) Infrared Lamp Torsion Bal
ance Method (e) Rapid Method of Determinin Moisture Content 302.9 In-situ Densi
ty / Deree of Compaction (a) Sand Replacement Method (b) Core Cutter Method (c)
Nuclear Density Gaue 302.10 302.11 302.12 Horizontal Alinment Surface Levels
Surface Reularity 301.8 (a) 301.8 (b) 301.8 (c) 301.9 301.10 301.11 301.7 (a) 3
01.7 (b) 301.7 (c ) 301.7 (d) 301.7 (e)
302.7 CBR of Remoulded and Soaked Soil Samples (Static Method and Dynamic Method
) Purpose CBR value of a soil is an index which is related to its strenth, modu
lus of subrade reaction, modulus of resilience and plasticity index. The index
is hihly dependent on the condition of material at the time of testin. The tes
t will be performed on remoulded specimens which may be compacted either statica
lly or dynamically.
48
LABORATORY CBR TEST APPARATUS
Preparation of Specimens Remoulded Specimens: The dry density for remouldin sho
uld be either the field density or if the subrade is to be compacted, at the ma
ximum dry density value obtained from the Proctor Compaction test. If it is prop
osed to carry out the CBR test on an unsoaked specimen, the moisture content for
remouldin should be the same as the equilibrium moisture content which the soi
l is likely to reach subsequent to the construction of the road. If it is propos
ed to carry out the CBR test on a soaked specimen, the moisture content for remo
uldin should be at the optimum and soaked under water for 96 hours. Soil Sample
– The material used in the remoulded specimen should all pass throuh a 19 mm I
S sieve. Allowance for larer material may be made by replacin it by an equal a
mount of material which passes a 19 mm sieve but is retained on a 4.75 mm IS sie
ve. This procedure is not satisfactory if the size of the soil particles is pred
ominantly reater than 19 mm. The specimen may be compacted statically or dynami
cally. Procedure I. 1.1 1.2 Compaction by Static Method Find the weiht of oiled
empty CBR mould with base plate and filter paper placed in. Calculate the weih
t of soil required at OMC by usin the formula: OMC Percentae Compaction Requir
ed x MDD (/cc) x (1 + ----------------) x volume of mould 100 1.3 Take about 6
k of dry soil and mix it thorouhly after addin the quantity of water required
to brin it to OMC at which it can be compacted to attain its maximum dry densi
ty.
49
Section - 300
1.4 1.5 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3. 3.1 3.2 3.3 3.4 4. 4.1
Take the required quantity of this soil as calculated in step 1.2. Place this so
il in the mould and obtain compaction by pressin in the displacer disc, placin
a filter paper between the disc and the soil. Compaction by Dynamic Method Take
6 k of oven dried soil. Add water (optimum water content required to attain ma
x. dry density) to it and mix it thorouhly. Take the empty weiht of oiled CBR
mould. Fit the extension collar to the mould. Place a spacer disc in it and then
place one filter paper over it. Fill the soil mixture in the mould in 3 layers
by ivin 55 blows of 2.6 k rammer with a drop of 310 mm to each layer. Remove
the collar and trim off by a straiht ede. Then remove the mould from base plat
e, take the spacer disc out. Invert the mould and fix it in position on the base
plate after placin a filter paper. The dynamically compacted specimen is now r
eady for testin. Findin deree of compaction After compaction, weih the mould
with specimen. Find the weiht of the specimen. Take a portion of the remainin
sample left in the tray and find the moisture content. (As in Test EW-7) Find t
he dry density and compare it with the maximum dry density and find the deree o
f compaction (%) by comparin this with the maximum dry density. Determinin Swe
llin Index After weihin the moulds, place weihts to produce a surchare equa
l to the weiht of the base material and pavement to the nearest 2.5 k shall be
placed on the compacted soil specimen. Place this assembly in the mould. Place
the tripod havin the micrometer in place and adjust the stem to touch the micro
meter indicator and find the initial readin on the micrometer. Then place the m
ould in water tank and soak it for 96 h. After 96 h, find the micrometer readin
. Find the difference in readins. Find the swellin index by dividin the swell
in by the heiht of the specimen before soakin. Express this in percentae. (F
orm EW-11)
4.2 4.3 4.4 4.5 4.6
50
Form EW-11 Determinin Swellin Index
Mould Nos. Heiht of specimen (mm) (A) Dial aue readin Initial (B) Final (C)
Least Count of dial aue (mm) (D) Total Swellin (C-B) x D (mm) (E) Swellin In
dex Ex100 A (Percent)
5.
Determinin CBR
CBR in Dry Condition The material used for conductin the test will be in a dry
condition. The mould containin the specimen with the base plate in position but
the top face exposed shall be placed on the lower platen of the testin machine
. Surchare weihts, sufficient to produce an intensity of loadin equal to the
weiht of the base material and the pavement shall be placed on the testin mach
ine. Rest of the procedure will be same as described below for the test in soake
d condition CBR in Soaked Condition 5.1 5.2 5.3 5.4 5.5 5.6 5.7 After 96 h of so
akin and after measurin the swellin, find the weiht of the mould with soaked
specimen (to be used for findin deree of compaction after soakin). Drain the
excess water by keepin the specimen vertically or by tiltin for 10- 15 min (f
or sandy specimen no tiltin is to be done). Remove the filter paper on the spec
imen and keep it in the CBR testin machine to show penetration when the specime
n is loaded. Place the same surchare weiht as used while soakin. Adjust the p
enetration measurin micrometer and the platform on which the CBR mould containi
n the specimen rests, to show penetration when the specimen is loaded. Start lo
adin the specimen, after adjustin the penetration dial and the provin rin to
zero mark. Note the deflections in the dial aue of the provin rin for corre
spondin penetrations as per the requirement. (deflections are noted for penetra
tions of 0.5, 1.0, 1.5, 2.0, 2.5, 4.0, 5.0, 7.5,10.0 and 12.5 mm of the pluner)
. Plot the deflections aainst the penetration (in mm) in a semi-lo raph. (Alt
ernatively, deflections can be converted into loads and plot penetration versus
load). Find the correction required to be applied for the deflections (when an S
-type curve is formed, the lower bend can be avoided by drawin a straiht line)
, see Fiure 1.
51
5.8 5.9
Section - 300
5.10 Correct the deflection by shiftin the points actually plotted, (if a corre
ction of 0.5 mm is observed, instead of takin deflection for penetration of 2.5
mm, deflection for 3 mm shall be taken). 5.11 Take the deflection for 2.5 mm an
d, 5 mm (for corrected curves, corrected deflection shall be taken). 5.12 Conver
t these deflections into loads by applyin the calibration factors. Find the CBR
values for these penetrations by usin the formula. P T x 100 CBR = -----------
------------Ps Where PT =Load correspondin to the chosen penetration. P s=Stand
ard load for the penetration from the table iven below.
Table 302.7.1: Standard Loads for the CBR Test Penetration Depth 2.5 mm 5 mm Uni
t Standard Load 70 k/sqm 105 k/sqm Total Standard Load 1370 k 2055 k
5.14 The hiher of the two values is reported as CBR (Form EW-12). Generally the
CBR value at 2.5 mm penetration will be hiher than that at 5 mm penetration an
d in such case, the former shall be taken as the CBR value for desin purpose. I
f the CBR value correspondin to a penetration of 5 mm exceeds that for 2.5 mm,
the test shall be repeated. If identical results follow, the CBR correspondin t
o 5 mm penetration shall be taken for desin.
52
Fiure 6 Correlation of Load Penetration Curves
6. 6.1 6.2 6.3
Determinin deree of compaction after soakin Before testin itself, the weiht
of the specimen is noted as explained earlier. After testin, take a portion of
soil from the specimen (top portion where penetration tested) and find the mois
ture content as explained in test EW-3. Find the deree of compaction.
53
Section - 300
FORM EW-12 CBR Test of Soil
Time of Penetration min – sec 1 Penetration in mm Provin Rin ReadinNo. of div
isions 3 I 0- 0 0- 24 0- 48 1- 12 1- 36 2- 0 2- 24 3- 12 4- 0 6- 0 8- 0 10- 0 0.
0 0.5 1.0 1.5 2.0 2.5 3.0 4.0 5.0 7.5 10.0 12.5 20.14 KN 25.78 KN 31.17 KN 35.28
KN 13.43 KN II III I Corrected Load (3) x value of one division.In (kN) 4 II II
I Standard Load on Pluner area.(kN) on 19.64cm2 5 Std I Unsoaked/ Soaked CBR (%
) C x 100 D 6 II III Averae CBR(%)
2
7
Averae CBR at 2.5 mm penetration Averae CBR at 5.0 mm penetration Averae Satu
ration Moisture Content Averae Swellin Reference: IS : 2720 (Part – 16 ) 1987
(%) (%) (%) (%)
54
303 SUBGRADE CONSTRUCTION
Sec No. A) Materials 303.1 303.2 303.3 303.4 303.5 303.6 303.7 Grain Size Analys
is Liquid Limit, Plastic Limit and Plasticity Index Proctor Density Free Swell I
ndex Deleterious Content (Oranic Content) Deleterious Content (Soluble Sulphate
) CBR of Remoulded and Soaked Samples 301.1 301.2 301.3 301.4 301.5 301.6 302.7
Title Test Ref No.
B) Construction & Workmanship 303.8 Moisture Content of In-situ Soil (a) Oven-dr
yin Method (b) Sand Bath Method (c ) Alcohol Method (d) Infrared Lamp Torsion B
alance Method (e) Rapid Method of Determinin Moisture Content 303.9 In-situ Den
sity / Deree of Compaction (a) Sand Replacement Method (b) Core Cutter Method (
c) Nuclear Density Gaue 303.10 303.11 303.12 Horizontal Alinment Surface Level
s Surface Reularity 301.8 (a) 301.8 (b) 301.8 (c) 301.9 301.10 301.11 301.7 (a)
301.7 (b) 301.7 (c ) 301.7 (d) 301.7 (e)
304 ROCK CUTTING
Sec No. Construction & Workmanship 304.1 304.2 Deviations of Pre-Split Face from
Plane passin throuh adjacent holes. Deviation from Drawins 304.1 304.2 Title
Test Ref No.
55
Section - 300
B
304.1 Deviations of pre-split face from plane passin throuh adjacent holes Pur
pose The purpose of pre-splittin is to make sure that the rock plane created af
ter blastin is as smooth and free from disturbance as possible. Procedure The e
xtent of rock projectin outside the plane shall be measured in the direction pe
rpendicular to the plane. The maximum projection shall not exceed 300 mm. Also t
he drains shall not be encroached due to irreular surface of the plane. 304.2 D
eviation from Drawins Purpose This is to check whether all construction activit
ies at site are carried out as per drawins; issued by a competent authority. Pr
ocedure All dimensions must be measured at site to check whether all constructio
ns are bein carried out as per authorized drawins.
306 Flyash Embankment Construction
Sec No. A) Materials 306.1 306.2 306.3 306.4 306.5 306.6 306.7 306.8 306.9 306.1
0 B) Grain Size Analysis of Flyash Grain Size Analysis of Soil for Cover Liquid
Limit and Plastic Limit of Soil for Cover Proctor Density of Fly Ash (Pond Ash)
Proctor Density of Soil for Cover Free Swell Index of Soil for Cover Free Swell
Index of Subrade Material Deleterious Content (Oranic Matter) of Soil Deleteri
ous Content (Soluble Sulphate ) of Soil CBR on Remoulded samples of Soil for Cov
er 301.1 301.1 301.2 301.3 301.3 301.4 301.4 301.5 301.6 301.7 Title Test Ref No
.
Construction & Workmanship 306.11 306.12 306.13 306.14 Measurement of Field Dens
ity Horizontal Alinment Surface Levels Surface Reularity 302.9 301.9 301.10 30
1.1
56
307. Surface Drains
Sec No. 307.1 307.2 307.3 307.4 Colour and Size of Bricks Water Absorption of Br
icks Efflorescence of Bricks Compressive Strenth of Bricks Cement for Brick Mas
onry Drains 307.5 Initial and Final Settin Time of Cement Lime in Lime – Cement
Composite Mortar 307.6 Purity of Lime (Available CaO) Sand / Stone Dust / Marbl
e Dust 307.7 307.8 Grain Size Analysis Deleterious Material and Oranic Impuriti
es Water 307.9 Suitability of Water for Masonry Work Cement and Mortar 307.11 30
7.12 307.13 Consistency of Mortar Water Retentivity of Mortar Compressive Stren
th of Mortar Construction and Workmanship of Masonry Drains 307.14 307.15 307.16
307.17 Dimensional Tolerances of Bricks Thickness of Joints for General Brick W
ork – Tolerance Thickness of Joints for Arches – Tolerance Plaster Finish – Tole
rance Stone Masonry for Drains 307.18 Cement for Stone Masonry for Drains Sand o
r Stone Dust or Marble Dust for Stone Masonry for Drains 307.19 Grain Size Analy
sis Cement Sand Mortar for Stone Masonry for Drains 307.20 307.21 Compressive St
renth of Mortar Water Retentivity of Mortar Stones for Stone Masonry Drains 307
.22 307.23 307.24 307.25 307.26 Dimensional Tolerance of Stones Water Absorption
of Stones Consumption of Mortar in Stone Masonry Water Cement Ratio of Mortar C
ompressive Strenth of Stones 700.1 700.2 700.18 700.12 700.9 600.12 600.11 600.
7 800.1, 800.2, 800.3 600.1 600.13 600.14 600.15 600.10 600.11 600.12 600.8 301.
1 800.6 403.1 600.5 Title Test Ref No. 600.1 600.2 600.3 600.4
57
SECTION 400 GRANULAR CONSTRUCTION
59
401 Granular Sub Base
Sec No. A) 401.1 401.2 401.3 401.4 401.5 401.6 B) 401.7 401.8 401.9 401.10 401.1
1 401.12 401.13 401.14 401.15 Materials Gradation Analysis of GSB Materials(Wet
Sieve Analysis) Liquid Limit and Plastic Limit of Material passin 425Micron siz
e Gradin and Plasticity Index Tests on Combined Materials from Different Source
s Proctor Compaction Test Areate Impact Value CBR on Representative Sample co
mpacted at 100% Proctor Density Construction & Workmanship Wet Sieve Analysis on
Combined GSB Material Liquid Limit and Plastic Limit Placement Moisture Content
Compacted Thickness In-situ Density / Deree of Compaction Areate Impact Val
ue Horizontal Alinment Surface Levels Surface Reularity 401.1,301.1 301.2 301.
7 401.10 301.8 401.5 301.9 301.10 301.11 401.1,301.1 301.2 401.1, 301.1, 301.2 3
01.3 401.5 302.7 Title Test Ref No.
A
Material
401.1 Gradation Analysis of Areates Purpose A combination of well raded coar
se and fine areates is essential for producin a durable ranular mix for pav
ement courses.
SIEVES FOR AGGREGATES
61
Section - 400
Procedure 1. The coarse areates used for ranular construction are normally o
f the sizes 80 mm, 40 mm, 20 mm, 10 mm and 4.75 mm. The fractions from 4.75 mm t
o 150 micron are termed as fine areates. The size 4.75 mm is a common size ap
pearin in both the fractions. Gradin pattern of areates – coarse, fine or c
ombined – is determined by sievin a sample successively throuh all the sieves
mounted one over the other in order of size, with the larer sieve on the top. T
he material retained on each sieve after shakin, represents the fraction of a
reate coarser than the sieve in question and finer than the sieve above. Sieve
analysis ives the radation and the fineness modulus which is an empirical fact
or obtained by addin the cumulative percentaes of areates retained on each
of the dividin standard sieves and dividin by 100. The larer the fiure, the
coarser the material. Brin the sample to an air dry condition either by dryin
at room temperature or in oven at a temperature of 100oC to 110oC. Take the wei
ht of the sample. Clean all the sieves and sieve the sample successively on the
appropriate sieve startin with the larest. Shake each sieve separately over a
clean tray. On completion of sievin, note down the weiht of the material retai
ned on each sieve. Report the results as percentae by weiht of sample passin
each of the sieves as shown in Form SB-1
2.
3.
4. 5. 6. 7. 8.
Form SB-1 Granular Base / Sub Base Gradation Analysis of Areates
Road / Section Details : Sample No. :
I. S. Sieve * Desination Wt. of Sample Retained () Percent of Wt. Retained
Weiht of Sample Taken () : Date of Testin :
Cumulative Percent of Wt. Retained (%) Percentae of Wt. Passin (%) Permissible
Rane
62
401.5 Areate Impact Value (Dry and Wet) Purpose The purpose of determinin th
e Areate Impact Value is to assess its resistance to disinteration aainst i
mpact loadin. Procedure 1. Take the test sample consistin of areates the wh
ole of which passes 12.5 mm IS sieve and is retained on 10 mm IS sieve. Dry the
areate comprisin the test sample in an oven for a period of four hours or ti
ll such time that its weiht becomes constant at a temperature of 105oC to 110 o
C. Cool the areates. Use the areates as obtained above for conductin the
test in a dry condition, followin the procedure described below. For conductin
the test under wet conditions, immerse the oven dried sample in water for 3 day
s. Surface dry the sample by suitable cloth and follow the procedure described l
ater in this Section. Areate shall be filled in the cylindrical measure in 3
layers by tampin each layer by 25 blows. Determine the net weiht of areate
in the measure (Wd). Transfer the sample from the measure to the cup of the ar
eate impact testin machine and compact it by tampin 25 times. The hammer is r
aised to heiht of 38 cm above the upper surface of the areate in the cup and
is allowed to fall freely on the specimen. After subjectin the test specimen t
o 15 blows, the crushed areate is sieved on IS 2.36 mm sieve. Weih the fract
ion passin throuh IS 2.36 mm sieve (W2). Form SB-2 W2 Areate Impact Value (
AIV) = ----------------- x 100 WI
2.
3.
4. 5. 6. 7.
IMPACT TESTER
63
Section - 400
Form SB-2 Areate Impact Value (AIV)
Observation 1 Weiht of areate sample fillin in the cylinder = W1 () Weiht
of areate passin 2.36 mm sieve after the test = W2 () AIV = (W2/W 1) x 100
Test Nos. 2 3 Averae
Note : Permissible Limit ………… Max 50 subbase; 40 base; 30 wearin course. Refere
nce: IS : 2386 (Part 4) – 1963 Areate Impact Value (Wet) 1. 2. 3. 4. 5. Subme
re the sample in water for three days. Make it surface dry, and put the sample
in the cup of Testin Machine. Fix the cup firmly on position on the base of the
machine. Raise the hammer until its full face is 380 mm above the upper surface
of areate in the cup and allow it to fall freely. Subject the test sample to
15 such blows. Remove the crushed areate from the cup and sieve it on 2.36 m
m IS sieve. Wash it with water till no further sinificant amount passes in one
minute. Dry the fraction retained on the sieve at 105oC to 110 oC and weih to a
n accuracy of 0.1 . Subtract the weiht of the portion retained on the sieve (w
eiht B) from the weiht of the oven dried sample to et the weiht of the porti
on passin the sieve. Express this weiht as the percentae of oriinal weiht t
o et the Areate Impact Value as shown below A-B Areate Impact Value = ---
-------------- x 100 A where A = weiht of oven dried sample B = weiht of fract
ion retained on 2.36 mm IS sieve Reference IS 5640 - 1970 (Reprinted in 1991)
6.
64
B
401.10 Compacted Thickness The thickness of the compacted layer shall be measure
d at a few places and averae taken.
402 GRAVEL/ SOIL AGGREGATE BASE AND SURFACE COURSE
Sec No. A) 402.1 402.2 402.3 402.4 402.5 402.6 B) 402.7 402.8 402.9 402.10 402.1
1 402.12 402.13 402.14 402.15 Materials Gradation Analysis Areate Impact Valu
e (Dry and Wet) Flakiness Index Water Absorption of Areates Soundness with So
dium Sulphate Soundness with Manesium Sulphate Construction & Workmanship Wet S
ieve Analysis on Combined GSB Material Liquid Limit, Plastic Limit and Plasticit
y Index Placement Moisture Content Compacted Thickness In-situ Density and Dere
e of Compaction Areate Impact Value Horizontal Alinment Surface Levels Surfa
ce Reularity 401.1,301.1 301.2 301.7 401.10 301.8 401.5 301.9 301.10 301.11 401
.1,301.1 401.5 402.3 402.4 402.5 402.6 Title Test Ref No.
402.3 Flakiness Index Purpose Use of flaky areate results in loss of strenth
of ranular base and surface course. Procedure 1. 2. 3. 4. 5. The sample is sie
ved throuh IS sieve 63, 50, 40, 31.5, 25, 20, 16, 12.5, 10 and 6.3 mm Minimum 2
00 pieces of each fraction to be tested are taken and weihed (W1 ). Separate t
he flaky material by usin the standard flakiness aue. Take the weiht of flak
y material which passes throuh standard aue (W2 ) Weiht of material passin
the aue W 2 Flakiness Index (FI) = ------------------------------------------
------------------- x 100 Total weiht of sample W1
65
Section - 400
6.
Report the observations in Form GB-1.
Form GB-1 Flakiness Index of Areates
Size of Areate Passinthrouh IS Sieve, (mm) 63 50 40 31.5 25 20 16 12.5 10 T
otal Retained on IS Sieve (mm) 50 40 31.5 25 20 16 12.5 10 6.3 Wt. of the fracti
on consistin of at least 200 pieces () W1 = W2 = W3 = W4 = W5 = W6 = W7 = W8 =
W9 = W= Thickness aue size, (0.6 times the mean sieve) (mm) 33.90 27.00 21.50
16.25 13.50 10.80 8.55 6.75 4.89 Weiht of areate in each fraction passin t
hickness aue, () M1 = M2 = M3 = M4 = M5 = M6 = M7 = M8 = M9 = M=
M Flakiness Index (F.I.) = ------------------ x 100 = (%) W Note : Permissible L
imit ………. Max 30 in sub base, 25 in Base and 20 in Surface Course Reference: IS
: 2386 (Part 1) – 1963
66
402.4 Water Absorption of Areates Purpose Water absorption shows the porosity
of areates in one way. The more, it absorbs, the less it is durable. Procedu
re The test piece about 1 k shall be washed to remove dust and immersed in dist
illed water in a lass vessel at a room temperature 20 oC to 30oC for 24 h. Soon
after immersion and aain at the end of the soakin period, entrapped air shall
be removed by entle aitation. This will be done by rapid clock wise and antic
lock wise rotation. The vessel shall then be emptied and test piece be allowed t
o drain. The test piece shall then be placed on a dry cloth and ently surface d
ried with the cloth. It shall be transferred to a second dry cloth when the firs
t one removes no further moisture. It shall be spread out not more than one ston
e deep on the second cloth and left exposed to atmosphere away from direct sunli
ht or any other source of heat for less than 10 min until it appears to be comp
letely surface dry. The sample shall then be weihed (B). The sample will be dri
ed in an oven at 100 to 110 oC for not less than 24 h. It shall then be cooled i
n a dessicator to room temperature and weihed (A) The water absorption shall be
calculated from the formula. Water Absorption (B – A) = ------------------- x 1
00 A
Report the results in the form GB-2
Form GB-2 Water Absorption of Areates
S.No.
Specimen No.
Wt of Saturated Surface Dry Sample B ()
Wt of Oven Dried Sample A ()
Water Absorption (%) B-A = -------------- x 100 A
402.5 Soundness with Sodium Sulphate Purpose The test determines the resistance
to disinteration of areate by saturated solution of Sodium Sulphate. It indi
cates soundness aainst weatherin action.
67
Section - 400
Acceptance Criterion The averae loss of weiht after 5 cycles should not exceed
12% when tested with sodium sulphate. Procedure 1. Prepare saturated solutions
of Sodium Sulphate by addin sufficient quantities of salt into water at a tempe
rature of 25 to 30oC. The solution may be cooled to 27+1oC. and kept at that tem
perature at least for 48 h before use. Prepare the samples as iven below:
2.
Fine Areate Fine areates for the test shall pass throuh 10 mm IS Sieve. T
he sample shall be of such a size that it will yield not less than 100 of each
of the followin sizes, which shall be available in amount of 5% or more express
ed in terms of the followin sieves: Passin IS Sieve 600 micron 1.18 mm 2.36 mm
4.75 mm 10 mm Coarse Areate Coarse Areates for the test shall consist of
materials from which sizes finer than 4.75 mm have been removed. The sample shal
l be of such a size that it will yield not less than the followin amounts of th
e different sizes which shall be available in amounts of 5% or more. Size -Squar
e hole sieve 10 mm to 4.75 mm 20 mm to 10 mm Consistin of 12.5 mm to 10 mm 20 m
m to 12.5 mm 40 mm to 20 mm Consistin of 25 mm to 20 mm 40 mm to 25 mm 33 perce
nt 67 percent 33 percent 67 percent 1500 Yield 300 1000 Retained on IS Sie
ve 300 micron 600 micron 1.18 mm 2.36 mm 4.75 mm
68
63 mm to 40 mm Consistin of 50 mm to 40 mm 63 mm to 50 mm 80 mm and larer size
by 20 mm
3000
50 percent 50 percent
Spread in sieve size, each fraction 3000 . 3. 4. 5. 6. 7. 8. Wash the sample an
d dry to the constant weiht at 105oC to 110oC. Separate into different sizes as
shown above by sievin to refusal. Weih out the samples and keep them in separ
ate containers. Immerse the samples in prepared solutions of sodium sulphate for
not less than 16 h and not more than 18 h in such a manner that the solution co
vers them to a depth of at least 15 mm. Cover the container to reduce evaporatio
n and maintain the solution at a temperature of 27+1oC. Remove the sample after
the immersion period and allow it to drain for 15+5 min. Place it in the dryin
oven at a temperature of 105o to 110oC; and dry it to a constant weiht. Repeat
a number of cycles and determine the loss of weiht of specimen after each cycle
in accordance with the procedure iven below. After the sodium sulphate solutio
n has been removed, each fraction of the sample shall be dried to constant weih
t at 105 oC to 110 oC and weihed. Fine areates shall be sieved over the same
sieve on which it was retained before the test, and coarse areate over the s
ieve shown below for the appropriate size of particle. Size of Areate 63 mm t
o 40 mm 40 mm to 20 mm 20 mm to 10 mm 10 mm to 4.75 mm 9. Report percentae loss
of weiht (Form GB-3) Sieve used to Determine Loss 31.5 mm 16 mm 8 mm 4 mm
69
Section - 400
Form GB-3 Soundness with Sodium Sulphate Sample No.: Name of Quarry / Location:
Type of Reaent Used :
Sieve Size, mm Passin 1 60 40 20 10 Retained 2 40 20 10 4.75 Number of particle
s affected, classified as to the number disinteratin, splittin, crumbin, cra
ckin or flankin Gradin of Oriinal Sample (%) 3
Date of Samplin : Date of Testin : No. of Cycles :
Wt. Of each fraction before test () 4 Percentae passin finer sieve after test
(actual percent loss) 5 Weihted averae (corrected percentae loss) 6
Number of particles coarser than 20mm before test Passin 40 mm 60 mm Layer Reta
ined 20 mm 40 mm Number before test
Value
Permissible Limit Maximum 12 percent (Sodium Sulphate Solution in 5 cycles)
Checked by :
Tested by :
402.6 Soundness with Manesium Sulphate Purpose To see if the areate disinte
rates by saturated solutions of Manesium Sulphate. It indicates soundness aain
st weatherin action. Acceptance Criterion The averae loss of weiht after 5 cy
cles should not exceed 18% when tested with manesium sulphate. Procedure 1. Pre
pare the saturated solution of Manesium Sulphate by addin sufficient quantitie
s of salt into water at a temperature of 25 to 30oC. The solution may be cooled
to 27+1oC. and kept at that temperature at least for 48 h before use. Prepare th
e samples as iven below:
2.
70
Fine Areate Fine areates for the test shall pass throuh 10 mm IS Sieve. T
he sample shall be of such a size that it will yield not less than 100 of each
of the followin sizes, which shall be available in amount of 5% or more express
ed in terms of the followin sieves: Passin IS Sieve 600 micron 1.18 mm 2.36 mm
4.75 mm 10 mm Coarse Areate Coarse Areate for the test shall consist of m
aterials from which sizes finer than 4.75 mm have been removed. The sample shall
be of such a size that it will yield not less than the followin amounts of the
different sizes which shall be available in amounts of 5% or more. Size - Squar
e hole sieve 10 mm to 4.75 mm 20 mm to 10 mm Consistin of 12.5 mm to 10 mm 20 m
m to 12.5 mm 40 mm to 20 mm Consistin of 25 mm to 20 mm 40 mm to 25 mm 63 mm to
40 mm Consistin of 50 mm to 40 mm 63 mm to 50 mm 80 mm and larer size by 20 m
m Spread in sieve size, each fraction 3000 . 3. 4. 5. Wash the sample and dry t
o the constant weiht at 105oC to 110oC. Separate into different sizes as shown
above by sievin to refusal. Weih out the samples and keep them in separate con
tainers. Immerse the samples in prepared solutions of Manesium Sulphate for not
less than 16 h and not more than 18 h in such a manner that the solution covers
them to a depth of atleast 15 mm. Cover the container to reduce evaporation and
maintain the solution at a temperature of 27+1oC.
71
Retained on IS Sieve 300 micron 600 micron 1.18 mm 2.36 mm 4.75 mm
Yield 300 1000 33 percent 67 percent 1500 33 percent 67 percent 3000 50
percent 50 percent
Section - 400
6.
Remove the sample after the immersion period and allow it to drain for 15+5 min.
Place it in the dryin oven at a temperature of 105o to 110oC; and dry it to a
constant weiht Repeat a number of cycles and determine the loss of weiht of sp
ecimen after each cycle in accordance with the procedure iven below.
7.
After the manesium sulphate solution has been removed, each fraction of the sam
ple shall be dried to constant weiht at 105 oC to 110 oC and weihed. Fine ar
eates shall be sieved over the same sieve on which it was retained before the t
est, and coarse areate over the sieve shown below for the appropriate size of
particle. Size of Areate 63 mm to 40 mm 40 mm to 20 mm 20 mm to 10 mm 10 mm
to 4.75 mm Sieve used to Determine Loss 31.5 mm 16 mm 8 mm 4 mm
Form GB - 4 Soundness with Manesium Sulphate Sample No.: Name of Quarry / Locat
ion: Type of Reaent Used:
Sieve Size, mm Passin 1 60 40 20 10 Retained 2 40 20 10 4.75 Number of particle
s affected, classified as to the number disinteratin, splittin, crumbin, cra
ckin or flankin Gradin of Oriinal Sample (%) 3
Date of Samplin : Date of Testin : No. of Cycles :
Wt. Of each fraction before test () 4 Percentae passin finer sieve after test
(actual percent loss) 5 Weihted averae (corrected percentae loss) 6
Number of particles coarser than 20mm before test Passin 40 mm 60 mm Layer Reta
ined 20 mm 40 mm Number before test
Value
Permissible Limit Maximum 18 percent (Manesium Sulphate Solution in 5 cycles)
Checked by :
72
Tested by :
403 LIME TREATED SOIL FOR IMPROVED SUBGRADE/ SUB-BASE
Sec No. A) 403.1 403.2 403.3 403.4 403.5 B) 403.6 403.7 403.8 403.9 403.10 403.1
1 403.12 403.13 Materials Purity of Lime Determination of Optimum Quantity of Li
me Plasticity Index of Lime Treated Soil CBR of Lime Treated Soil Unconfined Com
pressive Strenth of Treated Soil Construction & Workmanship Pulverisation of So
il Clods Placement Moisture Content Maximum Dry Density and Deree of Compaction
Plasticity Index of Lime Treated Soil Unconfined Compressive Strenth of Sample
extracted from compacted layer Horizontal Alinment Surface Levels Surface Reu
larity 403.6 301.7 301.8 301.2 403.5 301.9 301.10 301.11 403.1 403.2 301.2 302.7
403.5 Title Test Ref No.
403.1 Purity of Lime (Determination of Total Calcium Oxide in Lime) Purpose The
lime should have a purity of at least 70% by weiht of CaO when tested as follow
s: Procedure 1. 2. 3. Take one ram of powdered lime, accurately weihed, in a p
latinum crucible. Place it in an oven maintained at 105 + 2oC until, on coolin
and weihin, constant mass is obtained. Heat the crucible first ently and then
inite in a muffle furnace at 1000oC. Cool the crucible in a desiccator and wei
h to a constant mass. Transfer the inited lime, to a beaker, add 50 ml of wate
r and mix well, add 10 to 15 ml of concentrated hydrochloric acid, and boil for
15 min. Filter, wash with hot water, inite and weiht to constant mass. To the
filtrate, add concentrated hydrochloric acid, if necessary, in sufficient amount
to make the total amount equivalent to 10 to 15 ml of concentrated hydrochloric
acid. Add a few drops of nitric acid and boil. Dilute to 200-250 ml. Add sliht
excess of ammonium hydroxide and keep just below the boilin point until the od
our of ammonia is barely perceptible. Filter off the iron and aluminium hydroxid
e while hot, collectin the filtrate in a 250 ml volumetric flask. Wash with hot
water. Inite the residue in a platinum crucible, blast, cool in a desiccators
and weih as aluminium oxide and ferric oxide. Make up the filtrate to 250 ml.
73
4.
Section - 400
5.
Pipette out 50 ml of the filtrate in a beaker and dilute to 100 ml. Heat to boil
in and add slowly about 35 ml of boilin ammonium oxalate solution. Continue bo
ilin for 2 or 3 min and allow the precipitated calcium oxalate to settle for ha
lf an hour. Filter the precipitated calcium oxalate throuh filter paper. Wash t
horouhly with small portions of dilute ammonium hydroxide (1 N) and then with h
ot water until the washin do not decolourise a hot dilute potassium permananat
e solution in the presence of dilute sulphuric acid. Puncture the filter paper a
nd transfer the precipitate to the beaker already used for precipitation with a
fine jet of hot water. Add abut 50 ml of dilute sulphuric acid, heat to 60oC and
titrate with standard potassium permananate solution with constant stirrin. T
owards the end of the titration, introduce the filter paper which was used for f
iltration into the titration vessel and carry out the titration till the end poi
nt is reached. Carry out a blank with all reaents followin the procedure as ou
tlined for this method. In the case of manesium limes, decant throuh a filter
paper, redissolve the calcium oxalate in the beaker and in the filter paper with
dilute hydrochloric acid and wash the filter paper four times with hot water an
d finally with dilute ammonium hydroxide (5 N) in a sliht excess and proceed as
before. For the second filtration, use the same filter paper as was used before
. If it is desired to complete the analysis in as short a time as possible, a po
rtion of 50 ml of the filtrate from the ferric and aluminium oxide determination
should be precipitated in the usual way with excess of ammonium oxalate. Boil f
or about 5 min and let the calcium oxalate settle clear. Decant throuh a qualit
ative filter paper and cool the filtrate (with ice water if possible). Add diamm
onium hydroen phosphate solution in lare excess and 5 to 10 ml of ammonium hyd
roxide solution. Stir rapidly with rubber ‘policeman’. From the amount of precip
itate thus formed, one can jude whether the lime contains sufficient manesium
oxide to require a double precipitate or not. For accurate work, if there is mor
e than a sliht amount of manesium oxide, a double precipitation should be carr
ied out, usin a fresh 50 ml aliquot.
6.
7.
8.
9.
Calculation 14.02 (V1 – V 2) N Total calcium oxide (as CaO), percent by mass = -
---------------------------------M Where V1 = volume, in ml, of standard potassi
um permananate solution used for the test; V2 = volume, in ml of standard potas
sium permananate solution used for the blank; N = normality of standard potassi
um permananate solution; and
M = mass, in , of the material taken for the test Reference: IS : 1514 - 1990
74
403.2 Determination of Optimum Quantity of Lime to Attain the Specified Reductio
n in PI and \ or to achieve the Specified CBR Purpose When clayey soils with hi
h plasticity are treated with lime, the plasticity index is decreased and the so
il becomes friable and easy to be pulverised, havin less affinity with water. A
ll these modifications are considered desirable for stabilization work. Procedur
e The various factors on which the properties of soil-lime depend are soil type,
lime content, compaction, curin and additives, if any. However, there is no st
andard method of mix desin. If lime is used mainly for hihly plastic clay, the
n the lime content may be decided based on lime fixation limit or at a hiher va
lue to reduce the plasticity index and swellin values up to the desired limits.
Unconfined Compressive Strenth Tests may be considered as a criterion for the
desin of mix. A number of trials may be required to arrive at the optimum propo
rtions. 403.5 Unconfined Compressive Strenth of Stabilised Soils Purpose Unconf
ined Compressive Strenth of stabilised soil is an indication of the suitability
of modified soil.
Section A Test for Fine and Medium Grained Stabilised Soil
Procedure For the purpose of this test, soils shall be rouped as follows : a) b
) c) Fine Grained Soils – Not less than about 90 percent of the soil passin a 2
.36 mm IS Sieve Medium Grained Soils – Not less than about 90 percent of the soi
l passin a 20 mm IS Sieve. Coarse Grained Soils – Not less than about 90 percen
t of the soil passin a 40 mm IS Sieve.
Tapered Moulds shall be used : a. b. For fine rained soil 100 mm hih x 50 mm m
ean diametre For medium rained soils 200 mm hih x 100 mm mean diametre
Ejectin pluners and displacin collars for use with the above moulds will be u
sed. The weiht of the stabilised soil (W1) required for mouldin into a specime
n of the required dry density shall be calculated in accordance with the mould u
sed. In the case of soils stabilised with a solid stabiliser, for example, cemen
t, this weiht shall be calculated from the formulae : For fine rained soils (1
00 x 50 mm moulds) : Vfm W 1 = (Vf + ----------------- ) 100
γd = (196 + 1.96 m) γd
75
Section - 400
For medium rained soils (20 mm x 100 mm moulds) Vmm W1 = (Vm + ------------- )
γd = (1570 + 15.7m) 100 Where V = volume of mould for fine rained soil in cm
3 m = the moisture content of the soils plus stabiliser in percent
γd
γd
= density of dry soil plus stabiliser in /cm3, and
Vm = volume of mould for medium rained soils in cm3. The appropriate weiht of
material shall be placed in the mould into which, usin a displacin collar, the
lower plu has been inserted to a distance of 15 mm. Durin fillin, the stabil
ised soil shall be tamped ently and uniformly so that the upper plu can be ins
erted at a distance of 15 mm. The upper plu should be inserted and the mould as
sembly placed in the compression device or testin machine. After removal of the
displacin collars, pressure shall be applied to the plus until the flanes ar
e in contact with the barrel of the mould. After the pressure has been maintaine
d for about ½ min, the load shall be released and the mould removed from the pre
ss. The plus shall then be removed from the mould. The pluner shall then be in
serted into the end of the mould havin the smaller diameter and the specimen re
leased from the taper by entle hammerin or pressure. The specimen shall then b
e removed from the mould and weihed to the nearest 1 (W 2). Curin The specim
en shall be completely coated with paraffin wax or other suitable wax or otherwi
se suitably projected by methods such as wrappin in polyethylene to maintain it
at its specified moisture content care bein taken not to leave holes in the wa
x film and to complete the coatin as quickly as possible to prevent the absorpt
ion of wax, and it shall then be weihed to the nearest 1 (W 3). It shall subs
equently be stored for a period dependin on the process and type of stabiliser
employed, under conditions in which it is protected from mechanical damae and k
ept at a temperature of 27 + 2oC . After the curin period and before testin, t
he specimen shall aain be weihed to the nearest 1 (W4). Any 100 mm hih x 50
mm diametre specimen which has lost more than 2 in weiht and any 200 mm hih
x 100 mm diametre specimen which has lost more than 5 in weiht durin the cur
in period shall be discarded. Test Procedure After weihin, the wax shall be r
emoved form the end of the specimen and, if desired, from the sides, care bein
taken to avoid damain the soil surface. The lenth of the specimen (L) shall b
e measured to the nearest 0.25 mm by means of the callipers, and recorded. The s
pecimen shall then be placed centrally on the lower platen of the compression te
stin machine and the load shall be applied to the ends of the specimen. The loa
d shall be applied so that the rate of deformation is uniform, approximately 1.2
5 mm/min. The maximum load exerted by the machine durin the test shall be recor
ded P k. The moisture content shall be determined on a representative sample of
framents taken from the interior of the specimen, and recorded.
76
Calculations The unconfined compressive strenth (p) of the specimen shall be ca
lculated from the formulae : a) for fine rained soils p = P/Af = P/1963 MN/m2 b
) for medium rained soils p = P/Am = P/7854 MN/m2 where P = maximum recorded lo
ad, N A f = cross sectional area of specimen for fine rained soils (mm2) A m =
cross sectional area of specimen for medium rained soils (mm2) In the case of s
oils stabilised with solid stabiliser, the weiht of the dry solids /cm 3 [dry s
oil plus stabiliser density (•d )] in the specimen shall be calculated from the
formulae : For fine rained soils
γd
100 W2 100 W2 = ----------------------- = -------------------------- /cm3 AfL (
100 + m) 19.63 L (100 + m)
For Medium rained soils
γd
100 W2 100 W2 = ----------------------- = -------------------------- /cm3 Am L
(100 + m) 78.54 L (100 + m)
Where W 2 = weiht of specimen before coatin with wax in ; A f = cross section
al area of specimen for fine rained soils (cm2); A m = cross sectional area of
specimen for medium rained soils (cm2); L = lenth of specimen (cm); and M = mo
isture content of the soil plus stabiliser after curin, in percent. Report The
unconfined compressive strenth of the specimen shall be reported as follows : a
) b) Values of compressive strenth up to 2 MN/m2 (20 k/cm2) report to the near
est 0.05 MN/m2 (0.5 k/cm2) Values of compressive strenth above 2 MN/m2 (20 k/
cm2) report to the nearest 0.1 MN/m2 (1 k/cm2)
77
Section - 400
Section B Test for Medium and Coarse Grained Stabilised Soil For the purpose of
this test, soils shall be rouped as follows : a) b) c) Fine Grained Soils – Not
less than about 90 percent of the soil passin a 2.36 mm IS Sieve Medium Graine
d Soils – Not less than about 90 percent of the soil passin a 20 mm IS Sieve. C
oarse Grained Soils – Not less than about 90 percent of the soil passin a 40 mm
IS Sieve.
Preparation of Specimen For Specimens Compacted to a Pre-determined Dry Density
Usin only material passin the 20 mm IS Test Sieve for medium rained soils, an
d only material passin the 40 mm IS test sieve for coarse rained soils, the st
abilised soil shall be prepared as described in IS : 4332 (Part 2) – 1967. The w
eiht of the stabilised soil (W1) required for mouldin into a specimen of the r
equired dry density shall be calculated from the formulae : For soils stabilised
with solid stabiliser : V W1 = (V + ----------------- m 100 Where V = volume of
mould in cm 3 m = the moisture content of the soils plus stabiliser in percent,
and ) γd = (3375 + 33.75m) γd
γd
= density of dry soil plus stabiliser in /cm3,
The material (W1) shall be divided into three equal parts by weiht. One of the
parts shall be placed in an assembled mould and the surface levelled off. Usin
a tamper fitted with a collar at the 10cm mark and a vibratin hammer, the mater
ial shall be compacted uniformly until the collar comes into contact with the up
per surface of the mould. The surface of the layer shall be scarified with the p
alette knife before addin the next layer, which shall be compacted in similar m
anner to the first layer, but usin a tamper fitted with a collar at the 5 cm po
sition. A 150 mm cube mould, less base plate shall then be placed squarely on to
p of the cube mould, the compacted surface scarified with the palette knife, and
the final layer added usin the tamper with the collar at the 150 mm position.
The upper mould shall then be removed and the surface of the specimen carefully
levelled off the end of the mould usin the trowel and vibratin tamper, care be
in taken not to spill any loose material durin this final operation. The mould
containin the specimen shall then be covered with a metal plate and stored at
temperature of 27 oC + 2oC until the followin day when the specimen shall be re
moved from the mould for further curin. The specimen shall then be weihed to t
he nearest 1 (W 2). Curin The curin tin shall be placed over the specimen, a
nd the tin and specimen then inverted. The lid shall then be placed in position
and sealed with suitable tape. The tin containin the specimen shall then be wei
hed to the nearest 1 (W2). It shall subsequently be stored for a period depend
in on the process and type of stabiliser employed, at a temperature of 27oC + 2
oC.
78
After the curin period, and before testin, the tin containin the specimen sha
ll aain be weihed to the nearest 1 (W 4). Any specimen that has lost more th
an 10 in weiht durin the storae period shall be discarded. Test Procedure (a
) (b) After weihin, the specimen shall be removed from the tin. The specimen s
hall then be placed centrally on the lower platen of the compression testin mac
hine in such a manner that the load shall be applied to opposite sides of the cu
be as cast, that is, not to the top and bottom. The load shall be applied withou
t shock and increased continuously at a rate of approximately 35 kf/cm2/min unt
il the resistance of the cube to the increasin load breaks down and no reater
load can be sustained. The maximum load exerted by the machine can be recorded (
P k). The moisture content shall be determined on a representative sample of f
raments taken from the interior of the specimen and recorded. The unconfined co
mpressive strenth (p) of the specimen shall be calculated from the formula : p
= P/A MN/ m2 = P/22 500 MN/m2 Where P A = = maximum recorded load, N; and area o
f cross-section of specimen in mm2
(c) (d)
In the case of soils stabilised with a solid stabiliser, the weiht of dry solid
s per cubic foot (dry soil plus stabiliser density d) in the specimen shall be
calculated from the formula
γ
100.W2 = ---------------------- /cm3 V(100+m 1) 100.W2 = ----------------------
----- /cm3 3375 (100+m1)
Where W 2 = weiht of specimen after removal from the mould in , V = volume of
mould in cm3, and m1 = moisture content of soil plus stabiliser after curin in
percent. Report The unconfined compressive strenth of the specimen shall be rep
orted as follows: a) b) Values of compressive strenth up to 3.5 MN/m2 (35 k/cm
2), report to the nearest 0.1 MN/m2 (1 k/cm2). Values of compressive strenth a
bove 3.5 MN/m2 (35 k/cm2), report to the nearest 0.15 MN/m2 (1.5 k /cm2).
Reference : IS :4332 (Part 5) – 1970
79
Section - 400
403.6 Pulverisation of Soil Clods Purpose Better the pulverisation and deree of
mixin, hiher is the strenth. Presence of unpulverised dry lumps of soil redu
ces strenth and durability of stabilised soil. Procedure 1. Pulverise the soil
usin aricultural implements like tractor – towed disc harrows and rotavators t
o the extent that it passes the requirements iven below.
Table 403.6.1 SOIL PULVERISATION REQUIREMENTS FOR LIME STABILISATION IS Sieve De
sination 26.5 mm 5.6 mm Minimum per cent by Weiht Passin the IS Sieve 100 80
2. 3.
Take a sample of pulverised soil approximately 1 k in weiht. Weih it accurate
ly (W1). Spread it on the 425 micron sieve and shake it ently, Takin care to b
reak the soil lumps as little as possible. Sieve the soil and weih the soil ret
ained on the sieve (W2 ). Break the lumps of finer soil in the retained material
until all the individual particles finer than the aperture size of the sieve ar
e separated. Place the soil aain on the sieve and shake until sievin is comple
te. Weih the retained material on the sieve (W3). Calculate the per cent soil p
assin the sieve from the followin expression (W1- W2) x 100 ------------------
----------------(W1- W 3)
4. 5.
404 CEMENT TREATED SOIL SUBBASE AND BASE
Sec No. A) 404.1 404.2 404.3 B) 404.4 404.5 404.6 404.7 404.8 Materials Quality
of Cement Purity of Lime Unconfined Compressive Strenth Test Construction & Wor
kmanship Deree of Compaction Unconfined Compressive Strenth Horizontal Alinme
nt Surface Levels Surface Reularity 301.8 403.5 301.9 301.10 301.11 801.1 to 80
1.3 403.1 403.5 Title Test Ref No.
80
405 WATER BOUND MACADAM SUB-BASE / BASE / SURFACING
Sec No. A) 405.1 405.2 405.3 405.4 405.6 405.7 B) 405.8 405.9 405.10 405.11 405.
12 405.13 405.14 405.15 405.16 Materials Areate Impact Value (Dry and Wet) Wa
ter Absorption of Areates Soundness with Sodium Sulphate Soundness with Mane
sium Sulphate Gradation Analysis of Areates and Screenins Liquid Limit and P
lastic Limit of Binder Material Construction & Workmanship Gradin of Stone Ar
eates and Screenins Flakiness Index of Stone Areates Plasticity Index of Cr
ushable Screenins/Bindin Material Areate Impact Value Layer Thickness Volum
etric Analysis Horizontal Alinment Surface Levels Surface Reularity 401.1 402.
3 301.2 401.5 402.10 405.13 301.9 301.10 301.11 401.5 402.4 402.5 402.6 402.1 30
405.13 Volumetric Analysis Purpose The test is conducted to make sure that adequ
ate quantity and composition of material have been used in the construction. Pro
cedure 1. 2. Di a pit 0.5 m x 0.5 m in the area where random checkin is to be
carried out. Take out all the WBM material from the pit. One of the test procedu
res iven below can be used. Test 1 Refill the pit with the du material without
compactin. If the pit can be filled by usin not more than 65% of the du mate
rial, it is indicative of adequate compaction and use of specified quantity of a
ll materials combined toether. 3. Test 2 (i) Separate out the portions of the W
BM material passin and retained on 11.2 mm size sieve when type B Screenins ha
ve been used. When Type A Screenins have been used, the proportions of WBM mate
rial passin and retained on 13.2 mm size sieve should be determined.
81
Section - 400
(ii)
Measure the loose volumes of the two portions usin cylinders of known volume an
d compare the combined volume with the combined specified quantities of Coarse A
reate + Screenins + Bindin Material. The volume of material retained on 11.
2 mm size sieve ( or 13.2 mm size sieve, as the case may be) shall be compared w
ith the specified quantities of coarse areate viz 0.91 to 1.07 cu. M per 10 s
q m for WBM radins 2 and 3. Due allowance shall be made for crushin durin ro
llin. The material passin 11.2 mm size sieve ( or 13.2 mm size sieve, as the c
ase may be) shall be compared with the specified quantities of Stone Screenins
and Bindin Material or Crushable Screenins as the case may be. For the Coarse
Areates, the quantity may be checked by conductin an Areate Impact Test a
nd determinin the presence of any oversize areate. For the finer fractions p
assin 425 micron size sieve, the Plasticity Index shall be determined to check
that it is less than 6.
(iii)
(iv)
(v) (vi)
406 WET MIX MACADAM BASE
Sec No. A) 406.1 406.2 406.3 406.4 406.5 406.6 406.7 B) 406.8 406.9 406.10 406.1
1 406.12 406.13 406.14 406.15 Materials Areate Impact Value of Coarse Area
tes Flakiness Index Soundness with Sodium Sulphate Soundness with Manesium Sulp
hate Gradation Analysis Liquid Limit and Plastic Limit of Areate passin 425
Micron sieve Proctor Compaction Test Construction & Workmanship Gradin Analysis
Placement Moisture Content Density of Compacted Layer Horizontal Alinment Surf
ace Levels Surface Reularity Compacted Thickness Areate Impact Value 401.1 3
01.7 301.8 301.9 301.10 301.11 401.10 401.5 401.5 402.3 402.5 402.6 401.1 301.2
82
407 SHOULDER CONSTRUCTION
Sec No. A) 407.1 407.2 407.3 407.4 Materials and Workmanship Earthen Shoulders H
ard Shoulders Brick Edin Stone Edin 303 401 600 700 Title Test Ref No.
408 LOCAL MATERIALS FOR ROAD CONSTRUCTION
Sec No. A) 408.1 408.2 408.3 408.4 408.5 408.6 408.7 408.8 408.9 408.10 B) 408.1
1 408.12 408.13 408.14 408.15 Materials Areate Impact Value (Dry and Wet) of
Kankar, Laterite, Dhandla Liquid Limit and Plastic Limit of Naturally Occurrin
Gravels CBR on Soaked Material for Soil-Gravel Material Gradation Analysis for S
oil Gravel Mix Determination of Total Calcium Oxide in Lime Placement Moisture C
ontent Unconfined Compressive Strenth Compressive Strenth of Cement Settin ti
me of Cement Tests on Water for Use in Cement Stabilisation Construction & Workm
anship Placement Moisture Content Deree of Compaction Horizontal Alinment Surf
ace Levels Surface Reularity 301.7 301.8 301.9 301.10 301.11 401.5 301.2 302.7
401.1 403.1 301.7 403.5 800.3 800.1 600.9 Title Test Ref No.
83
Section - 400
409 LIME – FLYASH STABILISED SOIL SUB-BASE
Sec No. A) 409.1 409.2 409.3 409.4 409.5 409.6 B) 409.7 409.8 409.9 409.10 Mater
ials Fineness of Flyash by Blaine Apparatus Particles Retained on 75 Micron IS S
ieve Lime Reactivity Soundness by Autoclave Expansion Soundness by Le Chatelier
Method Quality of Water Construction & Workmanship Unconfined Compressive Stren
th of Lime-Flyash Mix Horizontal Alinment Surface Levels Surface Reularity 403
.5 301.9 301.10 301.11 409.1 301.1 409.3 409.4 409.5 600.9 Title Test Ref No.
409.1
Fineness of Cement / Flyash
Purpose The fineness of cement / flyash has an important bearin on the rate of
hydration and hence on the rate of ain of strenth and also on the rate of evol
ution of heat. Finer the cement, faster the ain in strenth.
BLAINE’S TEST APPARATUS
84
Procedure Two methods are used for the determination of fineness of cement. Siev
e Test 1. 2. 3. 4. 5. Weih correctly 100 of cement and take it on a standard I
S Sieve No.9 (90 micron) Break down the air-set lumps in the sample with finers
. Continuously sieve the sample by ivin circular and vertical motions for a pe
riod of 15 min. A sieve shaker may also be used. Weih the residue left on the s
ieve. This residue should not be more than 10 per cent, for ordinary cement.
Air Permeability Method 1. This method is based on the relationship between the
flow of air throuh the cement bed and the surface area of particles comprisin
the cement bed. The cement bed is 1cm hih and 2.5cm in diametre. Knowin the de
nsity of cement, calculate the weiht required to make a cement bed of porosity
0.500 ( = 0.500 x ρx V whe e ñ – density of cement, V – volume). Place this quan
tity of cement in the pe meability cell in a standa d manne . Slowly pass on ai
th ough the cement bed at a constant velocity against the ate of ai flow unti
l flow met e shows a diffe ence in level of 30-50cms. Read the diffe ence in lev
el (h1) of manomet e and the level of the flowmet e. Repeat these obse vations t
o ensu e that steady conditions have been eached as shown by a constant h 1/h2
value. Specific su face Sw is calculated as = K √e3 ---------- ---------ρ (1-e)
2.
3. 4.
5. Sw
√t
----------√0.1η cm 2/g

W ere K e t ist e apparatus constant is t e porosityof t e bed is t e measured

time (S) is t e density of cement (g/cm 2), and is t e viscosity of air at t e
test temperature
ρ η

wit t e specified porosity of e = 0.500, and temperature 27oC +/- 2 oC, s = 521
.08 k √t ------------------------ (cm2/g)
ρ
85
Section - 400
The Appa atus constant can be dete mined f om the use of Standa d Cement as foll
ows: S o ρ o (1 – e) √0.1η K = -----------------------------
√e3 √to

W ere So = Specific surface of Standard Cement
ρ o = Density of Refe ence Cement
t o = Mean of th ee measu ed time

ηo = Air viscosity
at mean of t e t ree temperatures
wit e = 0.500, t e equation reduces to K= 6. 1.414 So ρo = ------------------
√0.1 ηo √to

T e specific surface (sq.cm/g) s ould not be less t an 2250 for Ordinary Cements
.
86
Form Gb-5 Determination of Fineness of Cement
S.No (1) Measurement of Time (2) (3) Average of t ree values Calculations
Determination of Specific Surface
S.No (1) Measurement of Time (2) (3) Average value of time Calculations 521.08 x
k”t Sw = -----------------------p

Reference
I.S. 4031 (Part2 ) - 1988 409.3 Lime Reactivity T is met od of test co
vers
t e procedure for determining t e reactivity of te pozzolanic material wit
ydrated lime, as represented by compressive strengt of standard mortar test
cubes prepared
and tested under specific conditions. Size and Number of TestSpe
cimens - T e tests specimen s all be 50 mm cubes. At least t ree specimens s all
be made for eac periodof test specified. Apparatus Cube Moulds - Mould for t
e 50 mm cube specimens sall be of metal not attacked bycement-pozzolana or lim
e-pozzolana mortar and t eres all be sufficient strengt and stiffness to preve
nt spreading and wrapping. T e moulds s all be rigidly constructed
in suc a man
ner as to facilitate
t e removal
of t e moulded specimen wit out damage. T e mou
lds s all be mac ined so t at w en assembled
ready for use
t e dimensions
and in
ternalfaces s all be accurate to t e following limits: T e eig t of t e moulds
and t e distance between t e oppositefaces s all be 50 + 0.1 mm for new moulds
, and 50 + 0.5 mm for moulds in use. T e angle between adjacent interior
faces a
nd bet-ween interior
faces and top and
bottom planes
of t e mould s all be
90 +
0.5 degrees. T e interior faces of t e moulds s all be plane surfaces wit a per
missiblevariation of 0.02 mm for new moulds and 0.05 mm for moulds in use. Eac
mould s all be provided wit a base plate aving a plane surface mac ined to a
tolerance of 0.1 mm and made
of non-absorbent and non-corrodable
material.
T e b
ase plate s all be of suc dimensions as tosupport t e mould during t e filling
wit out leakage.
Preparation of Moulds - T e interior faces of t e specimen mou
lds s all be t inly covered wit mineraloil or lig t cup grease. After assembli
ng t e moulds, excessive oil or greases all be removedfrom t e interior faces
and t e top and bottom surfaces of eac mould. Moulds s allt en be set on plane
, nonabsorbent base plates t at ave been t inly coated wit mineral oil, or lig
t cup grease.
87
Section - 400

Preparation
of Mortar- Cleanappliances s allbe used for mixing. T e temperatu
re of t e water and t at of t e test room at t e time w en t e mixing operation
is being performed
s all be from 27°C + 2oC T e dry materials of t e standard te
st mortar
s all be lime : pozzolana
: standard sand in proportion 1 : 2M : 9 by
weig t blended intimately. w ere M Specific gravity of pozzolana = -------------
------------------------------------Specific
gravity of lime to give a flow of 7
0 + 5 percent wit

T e amount of water for gauging s all be equal to t at required 10 drops in 6 se
c (as determined by t e procedure given below)

T e following quantities of materials are suggested for preparation of mortar: 1
50 g 300 x Mg 1350 g Hydrated lime Pozzolana Standard sand

T ese quantities will suffice
for preparing six test specimens. Determination of
Flow Trial mixing - Wit dry material as given above, make mortars wit differe

nt percentagesof water until specified flow is obtained. Make eac trial wit f
res mortar.
T e mixing s all be done mec anically
by means of mixing apparatus.

Place t e dry paddle and t e dry bowl in t e mixing position in t e mixer. T en
introduce t e materials for batc into t e bowl and mix in t e following, manne
r: (a) (b) (c)(d) (e) Place all t e mixing water in t e bowl.
Add t e pozzolani
c mixture to t e water, t en start t e mixer and mix at t e slow speed ( 140 + 5
rev/min)
for 30 sec. Add t e entire quantity of sand
slowly over a period of 30
sec, w ile mixing at slow speed. Stop t e mixer, c ange to medium speed (285+ 1
0 rev/min),
and, mix for 30 sec. Stop t e mixer, and let t e mortar stand for on
e and a alf min. During t e first 15 sec of t is interval, quickly scrape down
into t e batc any mortar t at may ave collected
on t e
side of t e bowl,
t en
for t e remainder of t is interval, cover t at bowl wit t e lid. Finis by mixi
ng for one minute at medium speed (285 + 10 rev/min).In any case requiring a re
mixing interval, any mortar
ad
ering to t e side of t e bowl s all be quickly sc
raped down into a batc wit t e scraper prior to remixing.
(f) (g)

Upon t e completion
of mixing, t e mixing paddle s all be s aken to remove exces
s mortar into t e mixing bowl.
88

Carefully wipe t e flow-table top clean anddry and place t e mould at t e centr
e. Place
a layer of mortarabout 25 mm in t ickness in t e mould and tamp 20 tim
es wit t e tamping rod. T e tamping
pressure s all be first sufficient to ensur
e uniform filling
of t e mould. T en fill t e mould wit mortar and tamp as
spec

ified for t e first layer. Cut
off t e mortar to a plane surface
flus wit t e
top of t e mould by drawing t e straig t edge ofa trowel (eld nearly perpendic
ular to t e mould) wit a sawing motion across t e top of t e mould. Wipe t e ta
ble
top cleanand dry, particularly taking care to remove any water from around
t e edge of te flow mould. Lift t e mould away from t e mortarone minute after

completing t e mixing operation. Im-mediately drop t e table t roug a eig t o
f 12.5 mm ten times in 6 sec. T e flow is t e resulting increase in average base
diametre of t e mortar mass, measured on at least fourdiametres at approximate
ly equi-spaced intervals expressed
as a percentage
of t e original base diametre
. T e materials for eac batc of moulds s all be mixed separately using t e qua
ntities of dry materials, conforming to t e proportions specified
and t e quanti
ty of water as determined. Mixing of mortar s all be done mec anically as descri
bed. Moulding
Test Specimen - Immediately following t e preparation of t e morta
r place t e mortarina 50 mm cube mould in a layer of about 25 mm t ickness and
tamp 25 times wit t e tamping rod. T e tamping
s all be just sufficient to ens
ure uniform filling of t e mould.T en fill t e mould to overflow and tamp as sp
ecified for t e first layer. On t e
completion of t e tamping, t etops of all c
ubes s all extend slig tly
above t e tops
of t e moulds. Cut off t emortar to a
plane surface
flus wit t e top of t e
mould by drawing
t e straig t edge ofa
trowel (eld nearly perpendicular to t e mould) wit a sawing motion across t e
top of t e mould. Storage and Curing
of Specimens – Cover t e surface
of t e sp
e-cimen
in t e mould wit a smoot and greased glass plate. Keep t e specimens
w
it t e moulds along wit t e cover plates under wet gunny bags for 48 our. Te
n remove t e specimens from t e moulds and cure at 90 to 100
percent relative u
midity at 50°C + 2oC for a period of eig t days. Samples
s all not be cured unde
r water. Note -T is maybe ac ieved by keeping t e specimens in a one liter cap
acity wide mout jar wit screwed lid over a galvanised iron s eet platform plac
ed at bottom oft e jar. T e platform is covered wit a
piece of paper.
Water is
kept to a dept of about 10 mm at te bottom, below t e level of t e platform.
After placing t e specimen fitting t e lid, t e jar is sealed wit insulation ta
pe and kept in an incubator adjusted for 50° +2°C for eig t days. Procedure for
Test - Remove t e specimens after curing foreig t days in t eincubator as desc
ribed above and test for compressive strengt
after,
t ey reac t e room
tempera
ture.
Test not less t an t ree cubes. T e cubes s all be tested on t eirsides w
it outany packingbetween t e cube and steel platens on t e testing mac ine. On
e of t e platens s all be carried on a ball and s all be self-adjusting, and t e
load s all be steadily and uniformly applied, starting from zeroand at a rate
of 35 kg/cm2/min. Calculation - Calculate
t e compressive strengt from t e crus
ing load and t e average area over w ic t e load is applied. Express t e resul
t nearest to 1 kg/cm2. Faulty
Cubes and Retests
- Cubes t at are manifestly faul
ty or t at give strengt differing by more t an 15 percent from t e average valu
e of
all test specimens, made from t e same sample and tested at e same period
t
, s allnot be consideredin determiningt e compressive strengt . After discard
ing suc cubes, if less t an two strengt test values are left for determining t
e compressive strengt at any given period, a retest s all be made.
89
Section - 400

409.4 Soundness
by Autoclave Expansion T e test s all be done as specified in 30
7.5
except t at a mixture of pozzolana and cement in t e proportion as indicated

s all be used in place of cement.
W en determining soundness by t is met od, no
t less t an six specimens s all be tested at a time for arriving at an average r
esult. Determination of Initial andFinal Setting TimeT e test for initial and
final
setting
time of pozzolana wit lime and cement s all be done in accordance
wit t e requirements
of IS: 4031- 1968. except
at a mixture of pozzolana and
t
cement in te proportion 0.2N : 0.8 by weig t s all be used in place
of cement
for making t e paste. T e determination
of standard consistency s all also be ca
rried out in accordance wit IS: 4031-1968* using t e mixture of pozzolana and c
ements
in t e proportion as indicated above instead of cement for making t e pas
te. W ere Specific gravity of pozzolana N = ------------------------------------

----------Specific
gravity of cement 409.5 SoundnessbyLe C atelier Met od T e
test s all be done as specified in IS : 4031-1968, w ic is same as except t at
in place ofcement, a mixture of pozzolana
and cement
in t e proportion 0.2 N :
0.8 by weig t, blended intimately s all be used : W ere Specific gravity of pozz
olana N = ------------------------------------------------Specific gravity of ce
ment
90
410 INDUSTRIAL WASTES FOR ROAD CONSTRUCTION
Sec No. A) 410.1 410.2 410.3 410.4 410.5 410.6 410.7 410.8 410.9 410.10 410.11 4
10.12 410.13 410.14 410.15 410.16 410.17 410.18 410.19 410.20 410.21 410.22 410.
23 410.24
410.25 410.26
410.27 410.28 410.29 410.30 410.31 410.32 410.33 Materia

l Fly-As
(Pond As ) in Embankment Construction Grain Size Analysis of Fly As (
Pond As ) Grain Size Analysis of Soil for Cover Liquid
Limit and Plastic Limit o
f Soil for Cover Proctor Density of Fly As (Pond As ) Proctor Density of Soil
for Cover Free Swell Index of Soil for Cover Free Swell Index of Subgrade Materi
al Deleterious Content(Organic Matter) of Soil Deleterious Content
(Soluble Sulp

ate) of Soil CBR on Remoulded Samples of Soil for Cover Fly As in Lime-Fly As
Stabilised Soil Base Fineness of Flyas by Blaine Apparatus Particles Retained
on 75 Micron
IS Sieve Lime Reactivity Soundnessby Autoclave Expansion
Soundness
by Le C atelier Met od Quality of Water Fly As in Lime Fly As Bound Macadam A
ggregate Impact
Value (Dry and Wet) Water Absorption
of Aggregates Soundness wit
Sodium Sulp ate Soundness wit Magnesium Sulp ate Gradation Analysis of Aggreg
ates and Screenings Liquid Limit and Plastic Limit of Binder Material Horizontal
Alignment Surface Level Surface Regularity Slag in Gravel/Soil-Aggregate Base/S
urfacing Gradation Analysis AggregateImpact Value(Wet) Flakiness Index
Water A
bsorption
of Aggregates Soundness wit Sodium Sulp ate Soundness wit Magnesium
Sulp ate Slag in Water Bound Macadam Aggregate Impact Value (Dry and Wet) Water
Absorption of Aggregates 401.5 402.4 401.1 401.5 402.3 402.4 402.5 402.6 401.5 4
02.4 402.5 402.6 401.1 301.2 301.9 301.10 301.11 409.1 301.1 409.3 409.4 409.5 6
00.8 301.1 301.1 301.2 301.3 301.3 301.4 301.4 301.5 301.6 302.7 Title Test Ref
No.
91
Section - 400
Sec No. 410.34 410.35 410.36 410.37 410.38 410.39 410.40 B 410.41 410.42 410.43

Title Soundness wit Sodium Sulp ate Soundness wit Magnesium Sulp ate Gradation
Analysis of Aggregates and Screenings Liquid Limit and Plastic Limit of Binder
Material Slag in Cement TreatedSub Base / Base Quality of Cement
Purity of Lime
Unconfined Compressive Strengt Test Construction & Workmans ip Horizontal Alig
nment Surface Levels Surface Regularity
Test Ref No. 402.5 402.6 401.1 301.2 800 403.1 403.5 301.9 301.10 301.11
411 CRUSHER RUN MACADAM BASE
Sec No. A) 411.1 411.2 411.3 411.4 411.5 411.6 411.7 B) 411.8 411.9 411.10 Mater
ials Aggregate Impact Value Flakiness Index Water AbsorptionLiquid Limit and Pl
astic Limit of Material passing 425 Micron Soundness of Crus er Run Macadam
Base
Gradation Analysis Density of Compacted Layer Construction & Workmans ip Horizo
ntal Alignment Surface Level Surface Regularity 301.9 301.10 301.11 401.5 402.3
402.4 301.2 402.5, 402.6 401.1 301.8 Title Test Ref No.
92
412 BRICK SOLING
Sec No. A) 412.1 412.2 412.3 412.4
B) 412.5 412.6 412.7 Materials Size and Colou
r of Bricks Compressive Strengt
of Bricks Water Absorption Efflorescence of Bri
cks Construction & Workmans ip Horizontal Alignment Surface Levels Surface Regul
arity 301.9 301.10 301.11 600.1 600.4 600.2 600.3 Title Test Ref No.
413 STONE SET PAVEMENT
Sec No. A) 413.1 413.2 B) 413.3 413.4413.5 Materials Aggregate Impact Value Wat
er Absorption Construction & Workmans ip Horizontal Alignment Surface Level Surf
ace Alignment 301.9 301.10 301.11 401.5 402.4 Title Test Ref No.
93
SECTION 500 BITUMINOUS CONSTRUCTION
95
501 PREPARATION OF SURFACE
Sec No. A) 501.1 501.2 501.3 501.4 501.5 501.6 B) 501.7 501.8 501.9 Materials Cr
us er Dust passing 4.75 mm size Viscosity of Bitumen Emulsion (Saybolt Furol ) T
est of Bitumen Emulsion
: Residue on 600 micron IS Sieve Storage Stability Test
on
Emulsion Flas Point of Cutback Bitumen Paving Bitumen Construction & Workman
s ip Horizontal Alignment Surface Level Surface Regularity 301.9 301.10 301.11 3
01.1 502.2 502.3 502.4 502.5 504.1 Title Test Ref No.
502 PRIME COAT OVER GRANULAR BASE
Sec No. A) 502.1 502.2 502.3 502.4 502.5 502.6 B) 502.7 502.8 Materials Slow Set
ting Emulsion Viscosity of Bitumen Emulsion (Saybolt
Furol) Residue of Bitumen E
mulsion on 600micron Storage Stability Test Flas Point
Test for Bitumen Cutback
Viscosity of Bitumen Cutback Construction & Workmans ip Temperature of Binder R
ate of Spread of Binder 502.7 502.8 502.2 to 502.4 502.2 502.3 502.4 502.5 502.6
Title Test Ref No.
A)
Materials
502.2 Test for Bitumen Emulsion : Viscosity by Saybolt – Furol Viscometer Purpos
e Viscosity
indicates te resistance to flow due to its internal friction. Hig e
r t e viscosity lower te rate of flow. T e test is conducted to see if it is in
t e specified
range. T e Saybolt Furol Viscometer is used
for determining te V
iscosity. T e Test result
is expressed in seconds for t e flow of 60 cc of t e e
mulsion
sample t roug a 3.8 mm
diameter orifice under t e specified conditions
of t e test. Procedure using t e special equipment is given below.
97
Section - 500

Procedure 1. 2. 3. Clean t e oil tube wit a solvent, suc asbenzene, and remov
e excess solvent from t e gallery. Pass t e entire material t roug a 150 micron
wire strainer before introducing into t e oil tube. After t e tube is cleaned,
pour into t e tube a quantity of t e material to betested, sufficient to wet t
e entire
surface of te tube. Allow to drain out. T e plunger commonly supplied
wit t eviscometer s all never beused on instruments maintained as standards.
Insert t e cork stopper not less t an 6.0 mm and
not more t an 9.5 mm into t e l
ower end of te air c amber at t e bottom of t e oil tube, taking care t at t e
cork fits tig tly enoug to prevent t e escape of air, as tested by t e absence
of oil on t e cork after
it is wit drawn. If t e test temperature is above t at
of t e room, eat t e material to not more t an 1.5oC below t e temperatureof t
est. Pour t e material into t eoil tube until it ceases to overflow into t e ga
llery. Keep it well stirred wit t e oiltube t ermometer, care being taken to a
void touc ing t e outflow tube. Adjust t e bat
temperature until
t e temperatur
e of t ematerial remains constant. After t ermal equilibrium as been attained,
no furt er adjustment s all be made in
t e bat temperature. T e test
results s
all be discarded if t e indicated bat temperature
varies
by more t an +0.03oC.
After t e temperature of t e material in t e oil tube asremained constant wit
in
+0.02oC of t e desired temperature for one minute wit constant stirring, w
it draw t e oil tube t ermometer and remove t e surplus
liquid quickly from t e
gallery by means oft e wit drawal tube so t at t e level of t e material in e
t
gallery is below t e levelin t e oil tube proper. Insert t e tip of t e wit dr
awal
tube at
one point in t e gallery.
T
e test s all be started over again t
if
etip of t e wit drawal tube touc es t e overflow rim. Under no condition
s all
t e excess liquid be removed by rotating t e wit drawal tube around t e gallery
. Place t e receiving flaskin position so t at t e stream of
liquid from outlet
tube
strikes t e neck of t e flask, care being taken t at t e graduation mark o
n t ereceiving flask is not less t an 10cm, not more t
an 13cm, from t e bottom

of t e bat .Snap t e cork from its position and at t e same
instant start
te
timer. Stop t e timerw en t e bottom of t e meniscus of t e liquid reac est e
mark on t e neck of t ereceiving flask. Time in seconds as determined by t e pr
escribed procedure, wit t e proper
calibration correction,
is t e Saybolt Furol
viscosity of t e
material at t e temperature at w ic t e test is made. Report
t e results
to t e nearest 0.1 second for viscosity values below 200 seconds and
to t e nearest w ole second for values 200 seconds or above.
4. 5.
6.
7.
8.
9.
10. 11.
98
Requirement Criterion Type of Emulsion Rapid Setting (RS-1) Rapid Setting (RS-2)
Medium Setting (MS) Slow Setting (SS-1) Slow Setting (SS-2) Acceptance Limitsat
50 o C 20-100 100-300 50-400 20-100 30-150
Reference : IS 3117 - 1965 (Appendix A) and IS 8887 - 2004
Saybolt Furol Viscometer
502.3
Residue of Bitumen Emulsion on 600 Micron Sieve

Purpose T ree tests are required to assess t e suitability
of Bituminous materia

l for road construction
work. Procedure 1. 2.
Was t e 600
micron IS sieve wit
xylene and ten acetone. Place it in t e dis ,dry in te ovenat 100 o C to 110
oC for one our, cool and weig , toget
er wit t edis , to t e nearest 0.01g (
W1). Remove t e sieve from t e dis and moisten wit t e solution. Remove unifor

mly t e 4-litre
sample by gentle
agitation and strain immediately
t roug
t e si
eve into t e clean, dry weig ed container (W4). Sieve te low and ig viscosity
emulsion
at room temperature
and 50 oC respectively. W ole of t e emulsion
en w
as passed t roug t e sieve, remove t e sieve and weig t e container to t e n
earest 1 g (W2).
3.
99
Section - 500
4.

Was t e sieve repeatedly
wit distilled wateruntil t ewas ings run clear. Pla
ce t e sieve in t e small
dis to dry for two ours in t e oven at 105+/-5 oC. C
ool and reweig toget er to nearest 0.01 g (W3).

Calculate t e Residue as follows:
W3 – W1 Residue, percentage retained = -------
--------------
x 100 W2 – W4 w ere W1 W2 W3 W4 = = = = mass in g, of sieve and s
mall dis mass in g, of container and emulsion mass in g, of sieve, small dis a
nd residue; and mass in g, of container

Take t e average of t ree values obtained for residue, percent.
Requirement Criterion Type of Emulsion Residue on 600 micron IS sieve (percentag
e by mass, max) RS-1 0.05 RS-2 0.05 MS 0.05 SS-1 0.05 SS-2 0.05

Reference IS 8887 - 2004 502.4
Storage Stability Test on Emulsions Purpose T is
test is used to determine t e ability of an emulsion to remain as a uniform disp
ersion during
storage
Procedure 1. 2. 3. 4. 5. 6. 7. Place 500 ml ofemulsion sa
mple in eac of t e two cylinders. Stopper t e cylinders
and allow t em to stand
undisturbed
for 24 . About 55 ml is sip oned from
t e top and placed in oven f
or about 2 at a temperature of 163°C + 2.8°C. T eyare removed, allowed to coo
l and weig
ed.
After removal of t e top sample, anot er 390 ml is sip onedoff f
rom eac of t e cylinders. Weig about 50 g and place inoven for about 2 at a
temperature of 163°C
+ 2.8°C. Remove t e samples from t e oven, allow t e sampl
e to cool andweig . T e storage stability is expressed as t e numerical differe
nce between t e average percentage of bituminous residue found in two top sample
s and two bottom samples (Form BC-1).
100
Form BC-1 Storage Stability Test
Sample No. 1 2 Average Percentage of residue from top sample (A) Percentage of r
esidue from bottom sample (B) Settlement (B-A)
Requirement Criterion
Grade of Emulsion Storage Stability after 24 , percent, Max, 2 0.05 1 0.05 1 0.
05 2 0.05 2 0.05

Reference:
IS : 8887-2004 502.5 Flas Point Test of Bitumen Cutback Purpose T e
flas
point of bitumen t at contains a volatile distillate is t e temperature at
w ic it begins to give off ignitable vapour. T e principal purpose of flas -po
int testing is to determine maximum safe mixing and applying temperatures. Proce
dure 1. Cleanand dry all parts of t e cup and its accessories t oroug ly before
conducting t e test. Take particular care to avoid t e presence of any solvent
used
to cleant e apparatus after
a previous test. Fill bitumen
into t e cup up t
o t e indicated
mark. Place t
e lid and set in t e stove to eat t e
bitumen. In
sert t e t ermometer. Apply eat at 5 0 - 60C per minute. Stir at t e rate
of 60
rpm.First apply t e test flame at a temperature at least 170C below t e actual
flas
point and t en at interval of 10Cto 30C. Discontinue t e stirring during
t e application
of
test flame. Record t e
temperature reading
on t e t ermomete

r at
t e time of t e flame application w ic causes a brig t flas to give t e f
las point of bitumen (Form BC – 2).
2. 3. 4. 5. 6. 7. 8. 9.
101
Section - 500

Form BC-2 Flas point of Bitumen
Sample No. Flas Point 0C Corrected flas point
Requirement Criterion
Type of Cutback Bitumen Medium Curing MC 30 MC 70 MC 250 Flas Point Pensky Mart
ens Closed Type (minimum) 38 38 65
Reference IS 217 - 2004 502.6 Viscosity of Bitumen Cutback ( Kinematic Viscosity
)
Purpose Kinematic Viscosity of Bitumen Cutback is determined to ascertain its su
itability as a construction material for roads.
102

Procedure 1. Capillary type of Viscometers eit er Cannon-Fenske Viscometer ( for
opaque
liquids ) or BS U-Tube Modified
Reverse Flow Viscometer s all be used fo
r t e test. 2. To calibrate,
c arge t e clean dry viscometer by pouring
t e refe

rence material.
Place t e c arged viscometer in t e viscometer bat long enoug
to reac t e testtemperature. Measure to wit in 0.1s t e time required for t e
leading edge of t e meniscus to pass from t e first timing
mark to t e second. C
alculate t eViscometer constant as follows : C=V/t W ere V = viscosity in centi
stokes for t e standard liquid, and
t = efflux time in seconds Procedure for Can
non-Fenske Viscometer 3. C arge t e Cannon-Fenske Viscometer by inverting it and
applying
suction
to t e tube L immersing tube
N in t e liquid sample. Draw liqu
idt roug t e tube N filling bulbs D to t e fill mark G. Wipe excess sample off
t e tube N and invert
t e viscometer to its normal position. Align t e viscomet
er vertically in t e bat . Visual observation for t is purpose is sufficient, o
wever,
it can be done more accurately and quickly by suspending a plumb bulb in
t e tube L. 5. Allow t e viscometer to
remain in t e constant temperature bat f
or a sufficient time to ensure t at t e sample reac es temperature equilibrium.
Ittakes about 20 min. at 38oC, 25 min at 100 o C and 30 min at 135 o C. 6. W en
t e test temperature is reac ed, remove t e stoppers in t e tubes N and L respe
ctively and allow t esample to flow by gravity. Measure to t e nearest 0.1 s t
e time required for t e leading edge of t e meniscus to pass from timing mark E
to timing mark F. If t is efflux time is less t an 60 s select a viscometer of s
maller capillary
diameter
and repeat t e operation. Upon completion of t e test,
clean t e viscometer t oroug ly by several rinsings wit an appropriate solvent
completely
miscible wit t e sample, followed by a completelyvolatile solvent.
Dry t e tube by passing a slow stream of filtered dried air t roug t e capilla
ry for 2min or until last trace of solvent is removed.
4.
7.
103
Section - 500

Procedure for BS U-Tube Modified Reverse Flow Viscometer 1. Mount t e BS U-Tube
viscometer
in t e constant temperature bat keeping tube L vertical. pour sample
t roug
t e tube N to a point just above
filling
mark G. Allow t e sample to fl
ow t roug capillary R, taking care t at t e liquid column remains unbroken unti
l t e lower mark H and t en arrest its flow by closing t e timing tube wit a co
rk or rubber stopper
in tube L Add more liquid, if
necessary, to bring t e upper
meniscus slig tly above mark G. After allowing t e sample to attain bat temper
ature and any air bubble to rise to t e surface
(usually 20-30 minutes are requi
red), gently loosen t e stopper allowing t e sample to flow until it is approxim
ately at t e lower filling mark H and press back t e stopper to arrest t e flow.
Remove t e excess sample above filling mark G by inserting t e special pipette
until its
cork rests
on top of t e tube N and apply gentle suction until air is
drawn t roug . T e upper meniscus s all coincide wit t e mark G. Allow t e visc
ometer
to
remain in t e
constant temperature bat for a sufficient time to ensur
e t at t e sample reac es temperature equilibrium. It takes about 20 min at 38 o
C. 25 min at 100 oC and 30 min at 135 oC Remove t e stopper in t etube N and L
respectively
and allow t esample to flow by gravity. Measure to t e nearest 0.1
s t e time required for t e leading edge of t e meniscus to pass from timing ma
rk E to timing mark F. If t is efflux time is less 60 s, selecta viscometer of
smaller diameter and repeat t e operation.
Upon completion of t e test, clean t
e viscometer t oroug ly, following t e procedure earlier. described
2.
3.
4.
5. 6.

Calculate
t e kinematic viscosity up to t ree significant figures wit t e elp
of t e following
equation : Kinematic viscosity cSt = Ct w ere C = calibration c
onstant of t e viscometer in centistokes per second,and t = efflux time in secon
ds
Requirement Criterion Type of Cutback Bitumen Medium Curing MC 30 MC 70 MC 250 M
in 30 70 250 Kinematic Viscosity at 60 o C, cSt Max 60 140 500
104
Reference IS : 1206 (Part 3) - 1978
B)

Construction & Workmans ip

502.7 Temperature
of Binder Temperature
of binder s all bemeasured
by using
met
alliccontact t ermometer wit digital display to ensure t at it as been eated
to t e required extent.
T e range
of t ermometer for different type of bitumino
us materials and t eir accuracy s all be as under, (1) (2) (3) Melted Bitumen :
ambient to 2000C accuracy + 1.00C Cutback Bitumen : ambient to 1000C, accuracy +
0.50C Bitumen Emulsion : ambient to 800C, accuracy + 0.50C
Form BC-3 Determination of Temperature of Binder
Sl.No. Time Temperature Range and Least Count of T ermometer
Acceptance Limit : As per Contract Document

502.8 Rate of Spread of Binder Purpose T e test gives a measure of variation in
rate of spread of bitumen along t e road and a good approximation to t e average
rate of spread of bitumen. Procedure 1. Take lig t metal trays of 20cm x 20cm s
ize and 3cm dept . Put a t ick paper in t e bottom of all
t e trays to save t em
from bitumen sticking
.
Place t em along t e road in t e pat
of t e bitumen di
stributor
between t e w eel tracks.
After t e distributor
as passed
over, remov
e t e trays
and wrap t em in s eets of paper so t at t ey can be andled, stocke
d and weig ed as soon as convenient. Useat least five trays, suiting conditions
at site. Weig t e trays correctly to t e first decimal place. T e maximum
long
itudinal distribution
error in rate of spread of bitumen s ould be wit in + 10 p
ercent of t e specified rate of spread of bitumen.
2. 3. 4. 5.
105
Section - 500
6.

Similarly c eck t e transverse
distribution
by placing a number of trays to coll
ect bitumen sprayed
over eac 5cm widt of spray bar.
T e variation in transvers

e distributions ould be wit in + 20 percent from t emean. Do not take t e extr
eme 15 cm widt on eit er side into account. Record t e results in Form BC – 4.
7. 8.
Form BC-4 Rate of Spread of Binder
Tray No. Wt. of Bitumen on tray Rate of spread
503 TACK COAT
Sec No. A) 503.1 503.2 503.3 503.4 503.5 503.6 B) 503.7 503.8 Materials Rapid Se
tting Emulsion Viscosity of Bitumen Emulsion ( Using Saybolt – Furol Viscometer
) Residue (Bitumen Emulsion) on 600 Micron IS Sieve Storage Stability Tests Flas
Point
Test for Bitumen Cutback Viscosity of Bitumen Cutback Construction & Wor
kmans ip Temperature of Binder Rate of Spread of Binder 502.7 502.8 502.2 to 502
.4 502.2 502.3 502.4 502.5 502.6 Title Test Ref No.
106
504 BITUMINOUS MACADAM
Sec No. A) 504.1 504.1(a) 504.1 (b) 504.1 (c ) 504.2 504.2 (a) 504.2 (b) 504.2 (
c) 504.2 (d) 504.3 504.4 504.5 504.6 504.7 504.8 B) 504.9 504.10 504.11 504.12 5
04.13 504.14 504.15 504.16 504.17 Materials Quality of Binder – Straig t –run Bi
tumen Penetration Test R&B Softening Point Ductility of Bitumen Quality of Binde
r – Modified Bitumen Penetration Test R&B Softening Point Elastic Recovery Test
Separation Test Aggregate Impact Value Flakiness Index Test Bituminous
Stripping

of Aggregate Test Water Absorption
of Aggregates Soundness
wit Sodium Sulp ate
Soundness wit Magnesium Sulp ate Construction & Workmans ip Grading of Aggrega
tes Binder Content Density of Compacted Layer Temperature
of Binder before Mixin
g Temperature of mix during Laying and Compaction T ickness of Compacted Layer H
orizontal Alignment Surface Level Surface Regularity 401.1 504.10 301.8 502.7 50
2.7 401.10 301.9 301.10 301.11 504.1 504.1(a) 504.1 (b) 504.1 (c ) 504.2 504.2 (
a) 504.2 (b) 504.2 (c) 504.2 (d) 401.5 402.3 504.5 402.4 402.5 402.6 Title Test
Ref No.
A) Materials
504.1
Quality of Binder – Straig t-run Bitumen 504.1 (a) Purpose
Penetration
is
t e consistency
test
used to designate grades of Bitumen. T e greater t e penetr
ation, t e softer t ematerial. Procedure
1. 2. 3. Heat t e bitumen to softening

point + 90°C. Pour t e bitumen
into t e container at least 10 mm above t e expe
cted penetration.
Allow t e sample containers to cool in atmosp eric temperature
for one our.
107
Penetration Test
Section - 500
4. 5. 6. 7. 8.

Place t e sample containers in temperature
controlled
water bat at a temperatur

e of 25.0°C+ 0.1°C for a period of one our. Fill t e transfer dis wit water f
rom water
bat to cover t e container
completely.
Take off t e sample
container
from t e water bat ,place in t e transfer dis and place under t e needle of pe

netrometer. Adjust t e needle to make contact wit surface of
t e sample. See t
e dial reading and release t e needle exactly for 5 s Note t e final reading.

T e difference between
t e initial and final readings is taken as t e penetratio
n value in one tent of mm. (Form BC-5)
Form BC-5 Penetration of Bitumen
1. 2. 3. 4. 5. Pouring Temperature, oC Period of
cooling in atmosp ere, min Room
Temperature, oC Period of cooling in water bat , min Actual test temperature, o
C Sample No. Test 1 Initial Final Penetration value Mean penetration value Test
2 Test 3 Mean value Test 1 Sample No. Test 2 Test 3 Mean value
Penetrometer dial reading
Reference : IS 1203 - 1978
504.1 (b) Purpose
R&B Softening Point Test

Softening point is t e temperature measured in 0C at w ic a bituminous binder a
ttainsa particular degree of
softness under specified test conditions. It signi
fies t e temperature
at w ic
bitumen passes fromsemi
solid state to liquid sta
te and indicates t e atmosp eric temperature at w ic t e bitumen is likely to b
leed.
108
Ring and Ball Apparatus

Procedure 1. Heat t e bitumen to a temperature between 75°C and 100°C above its
softening point, stir until it is completely fluid and free from air bubbles and
water,
and filter, if necessary, t roug IS Sieve 30 (see IS : 460-1962). Heat
t e rings
at same temperature on a ot plate and place it on a glass plate coate
d wit equal parts of glycerine anddextrine. Fill up t e rings wit bitumen. Co
ol
it for 30 min in air and level
t e surface wit a ot knife. Set t e ring in
t e assembly
and place it in t e bat containing
distilled
water at 5°C and
main
tain t at temperature for 15 min. Place t e balls on t e rings and raise t e tem
perature
uniformly
at + 0.5°C
per minute till t
e material
softens
and ball pass
es t roug t e ring. Note t e temperature at w ic eac
of t e ball and sample
t
ouc es t e bottomplate of t e Support. Temperature sall be recorded as t e sof
tening point of t e bitumen (Form BC – 6). In case, t e softening point is above
80oC, use glycerine in place of water in t e bat and start t e test at a tempe
rature of 35oC.
109
2. 3. 4. 5. 6. 7. 8. 9.
Section - 500
Form BC-6 Softening Point of Bitumen
Grade of bitumen Approximate softening point Liquid used in water bat
(water/gl
ycerine) Period of air cooling (min) Period of cooling in water bat (min)

Test Property Temperature at w ic sample touc es bottom plate ( C) Mean Value,
softening point
o
Sample No.1 Ball No. 1 2 1
Sample No.2 Ball No. 2

Reference
: IS : 1205-1978 504.1 (c) Purpose
Ductility indicates t e amount of s
tretc t at t ebitumen
will undergo wit outbreaking. It signifies t e property
by virtue
of w ic bitumen can exist in a t in film wit out breaking. Procedure

1. 2. T e bitumen sample is melted to a temperature
of 75°C to 100°C above t e
approximate
softening point until it becomes t oroug
ly fluid. It is strained t
roug IS sieve 30 (see US: 460-1962), poured in t e mould assembly and placed on
a brass plate,
after a solution of glycerine
and dextrine is applied
at all sur
faces of t emould exposed to bitumen. T irty to forty
min after t e sample is p
oured into t e moulds, t e plate Assembly along wit t e sample is placed in wat
er bat maintained at 27.0°C + 0.50C for 30 min. Ductility Test
3.
Ductility Test Apparatus
110
4. 5. 6. 7. 8. 9.

T e sample and mould assembly are removed from water bat and excess bitumen mat
erial is cut off by levelling t e surface using ot knife. After trimming t e sp
ecimen, t e mould assembly containing sample
is replaced
in water bat
maintaine
d at
27.0°C + 0.50C for 85to 95 min.T e sides of t e mould are t en removed an
d t eclips are carefully ooked on t e mac ine wit out causing any initial stra
in.T e pointer is set
to read zero.
T e mac ine is started and t e two clips
ar
et us pulled apart
orizontally.
W ile t e test is in operation,
it is c
ecked
w et er water in t e tank of t e testing mac ine covers t e specimen bot above
and below it by at least 25mm and is maintained continuouslywit in +0.50C of t
e specified temperature. T e distance at w ic t e bitumen t read breaks is rec
orded (in cm) and reported as ductility value (Form BC – 7).
10.
Form BC- 7 Ductility of Bitumen
1 2 3 4 4.1 4.2 4.3 Grade of Bitumen Pouring temperature,
0C Test temperature,
0
C Period of cooling, (min) In Air In water bat before trimming In water bat af
ter trimming Briquette Number (a) Ductility value (cm) (b) (c ) Mean Value
Test Property
Reference: IS: 1208-1978 504.2 (a) Quality of Binder – Modified Bitumen Penetrat
ion Test

T e test will be conducted as per t e procedure described in 504.1 (a) Reference
IS 15462 - 2004 504.2 (b) R&B Softening Point

T e test will be conducted as per t e procedure given in 504.1 (b) Reference IS
: 15462 - 2004
111
Section - 500

504.2 (c)
Elastic
Recovery Test Purpose T e test is conducted to find out t e pr
operty w ic indicates its elastic recovery after a stretc . Procedure 1. 2. 3.
4. 5. 6. 7. Prepare
t ree test specimens andcondition it ata temperature of 15
°C. Elongate t e test specimen to 10 cm in t e ductility mac ine at t e rate of

5 + 0.25 cm per minute. Immediately
cut t e test specimen into two alves at t e
mid point using Scissors.
Keep t e test specimen in water bat in an undisturbe
d condition for one our. After one our,move t eelongated alf of t e test sp
ecimen back into position near t e fixed alf of t e test specimen
so t at t e t
wo pieces of modified bitumen
just touc . Record t e lengt of t e recombined sp
ecimen as X Calculate t e per cent elastic recovery as under 10 - X Elastic Reco
very (%) = ------------------- x 10 100
Form BC-8 Elastic Recovery Test
Sample No. Lengt of recombined Specimen after 1 our Elastic Recovery 10-X ----
----------- x 100 10

Reference IS 15462 – 2004 504.2 (d) Purpose
T e separation
of modifier and bitum
en during ot storage isa property t at indicates ow long will it take to sepa
rate and t us controls t e laying operations Procedure 1. 2.T e separation is e
valuated by comparing t e ring and ball softening point of t e top and bottom sa
mples taken from aconditioned, sealed tube
of polymermodified bitumen. Place t
e empty tube, wit sealed end down in t e rack Heat t e sample carefully until
sufficiently fluid to pour.
112
Separation Test
3. 4.

Pass t e molten sample t roug IS Sieve of600 micron mes size. After t oroug
stirring, pour 50.0 g into t e vertically eld tube. Fold t e excess tube over t
wo times and crimp andseal. Place t e rack containing te sealed tubes in a 163
+/- 5°C oven. Allow
t e tubes
to stand undisturbed
in t e oven
for a period of
24 +/- 4 . Att e end of t e period, remove t e rack from t e oven and place im
mediately in t e freezer at 6.7 +/-5°C, taking careto keep t e tubes in a verti
cal
position at all
t e times. Leave t e tubes in t efreezer for aminimum of 4
to solidify t e sample completely. Upon removing
t e tube from t e freezer,
p
lace it on a flat
surface. Cut t e tube into t ree equal lengt portions wit t
e spatula and ammer. Discard t e centre section, and
place t e top and bottom p
ortions of t e tube into separate beakers. Place t e beakers into a 163 +/-5°C o
ven until te bitumen
is sufficiently fluid to remove t e pieces of aluminium tu
be. After t oroug ly stirring, pour t e top bottomsamples into appropriately ma
rked ring
and ball softening point test. Prepare t e rings and apparatus accordi
ng to t e test procedure givenin 504.1(b). T etop and bottom sample from t e s
ame tube s ould be tested at t e same time in t e softening point test. Report t
e difference, in °C, between t e softening points of t e respective top and bot
tom samples. IS 15462 - 2004
5.
6.
7.
Reference :

504.5Bituminous Stripping
of Aggregates Test Purpose T e stripping value indica
tes t e property
of ad esion of aggregates wit different types of bituminous bi
nders so t at t e suitability of aggregates could be ascertained. Procedure 1. 2
. 3. 4. 5. 6. 7. 8. Take about 200g of aggregates passing 20 mm sieveand retain
ed on 12.5 mm sieve. Dry, clean
and mix wit 5 percent binder by weig t in a sma
ll casserole,
binder being eated previously to 1600C if bitumen and 110 0C if t
ar. Heat t e aggregate before mixing to a temperature of 1500C and
1000C if t es
e are to be mixed wit bitumen and tar respectively.
Transfer t e contents to a
500 ml beaker after completecoating of t e mixture and allow to cool at te roo
m temperature
for about two . Cover t e beaker and keep it in a water
bat
taki
ng care t at t e level of water in water bat comes upto at least alf t e eig
t of beaker.
Take out t e beaker after 24 , cool it at room temperature and est
imate t e extent of stripping visually
w en t e specimen is still under water. C
alculate t e stripping value as t e ratio of uncovered area to t e total
area ex
pressedas a percentage.
Conduct t ree
tests and express t e mean of t ree resul
ts to t e nearest w ole number as t e stripping value. (Form BC – 9)
113
Section - 500
Form BC-9 Stripping Test of Aggregate
Type of Aggregate
Type of Binder Percentage ofBinder Used Total Weig t of Aggre
gate Total Weig t of Binder Temp. of Water Bat No. of Observations 1. 2. 3. Ave
rage Value Stripping (%)

Reference: IS : 6241-1971
504.10 Binder Content Purpose T e test determines t e
bitumen content in t e bituminous mix by cold solvent extraction.
Centrifuge Apparatus
114
Procedure 1. 2. 3. 4. 5. 6. 7.Take a representative

sample of about 500 g, weig
it exactlyand place it in t e bowl of t e extraction apparatus (W1). Cover t
e sample
wit commercial grade tric loroet ylene. Let t e mixture
stand for abou
t one our before starting t e centrifugal
mac ine. Weig
t e dried
filter ring
and t en fit it around te edge of t e bowl. Clamp t e cover of e bowl tig tly
t
. Place a beaker
under t e drain
to collect t e extract. T e mac ine is revolved
slowly and t en graduallyt e speed is increased to a maximum of 3600 rpm.T e
speed is maintained till t e solvent ceases to flow from t e drain. T e mac ine
is allowed to stop, 200 ml of solvent is added and te above procedure is repeat
ed. A number of 200 ml solvent additions (not
less t an t ree) are used
till t e
extract is clear and not darker t an a lig t straw colour.
Remove t e fitter ri
ng from t e bowl, dry it first in t e air and t en in t e oven at 1150C to a con
stant
weig
t, and weig it. Collect back t e fine material
t at mig t ave passe
d troug t e filter, by centrifuging.
Was and dry t e material
to a constant w
eig t, as before. Calculate t e percentage of binder in t e bituminous mix sampl
e as follows : Present t e results in Form BC -10 W1 – (W2 + W3 + W4) Percentage
of Binder= -------------------------------------
x 100 W1 W ere W1 W2 W3W4 =
== = Weig t of t e sample g Weig t of t e sample after extraction, g Weig t of
t e fine material recovered from t e extract, g Increase in weig t of filter rin
g, g
8. 9. 10. 11.
115
Section - 500
Form BC–10 Percentage of Binder
Sl.No. 1. 2. 3. 4. 5. 6. 7. 8. Observations Wt. of mix taken before extraction (
W1) Wt. of filter paper before extraction (B) Wt. of mix after extraction (W2 )
Wt. of filter paper after extraction (D) Wt. of filler collected from extract af
ter allowing for setting (W4) Wt. of filler collected in filter paper (B-D) = W3
Wt. of Aggregate
+ filler collected after extraction = W2 + W3 + W4 Percentage
of Bitumen (in t e mix) (W1-( W2 + W3 + W4 ))*100/ W1 1 2 3
505 BUILT UP SPRAY GROUT
Sec No. A) 505.1 505.1(a) 505.1 (b) 505.1 (c ) 505.2 505.2 (a) 505.2 (b) 505.2 (
c) 505.2 (d) 505.3 505.4 505.5 505.6 505.7 505.8 B) 505.9 505.10 505.11 505.12 5
05.13 505.14 505.15 505.16 Materials Quality of Binder – Straig t –run Bitumen P
enetration Test R&B Softening Point Ductility of Bitumen Quality of Binder – Mod
ified Bitumen Penetration Test R&B Softening Point Elastic Recovery Test Separat
ion Test Aggregate Impact Value Flakiness Index Bituminous
Stripping
of Aggregat
e Test Water Absorption
wit Sodium Sulp ate Soundness w
it Magnesium Sulp ate Construction & Workmans ip Rate of Spread of Binder Rate
of Spread
of Aggregates Grading of Aggregates Temperature of Binder during Spray
ing T ickness of Compacted Layer Horizontal Alignment Surface Level Surface Regu
larity 502.8 505.10 401.1 502.7 401.10 301.9 301.10 301.11 504.2 (a) 504.2 (b) 5
04.2 (c ) 504.2 (d) 401.5 402.3 504.5 402.4 402.5 402.6 504.1 (a) 504.1 (b) 504.
1 (c) Title Test Ref No.
116

505.10 Rate of Spread ofAggregates T e rate of spread of aggregates by t e aggr
egate spreaderor any ot er suitable means can be c ecked by measuring t e area
covered
by eac lorry/truck/any
ot er device of known capacity. T is can also be
c ecked
by removing t e spread aggregates from small
areas of t e road and weig
ingt em. A 20 cm square
metal frame is laid on t e new surface
dressing, and a
ll t e aggregates wit in t e
enclosed area are collected, was ed in solvent to r
emove bitumen and t en weig ed, and t e rate of spread of aggregates iscalculat
ed. It is measured along t e road at intervals
of between
4 m to 8 m. T e variat
ion in t e rate of spread of aggregates s ould be wit in -+/- 20 per cent of t e
mean.
506 MODIFIED PENETRATION MACADAM
Sec No. A) 506.1 506.1(a) 506.1 (b) 506.1 (c ) 506.2 506.2 (a) 506.2 (b) 506.2 (
c) 506.2 (d) 506.3 506.4 506.5 506.6 506.7 506.8 B) 506.9 506.10 506.11 506.12 5
06.13 506.14 506.15 506.16 Materials Quality of Binder – Straig t –run Bitumen P
enetration Test R&B Softening Point Ductility of Bitumen Quality of Binder – Mod
ified Bitumen Penetration Test R&B Softening Point Elastic Recovery Test Separat
ion Test Aggregate Impact Value Flakiness Index Bituminous
Stripping
of Aggregat
e Test
Water Absorption
of Aggregates Soundness wit Sodium Sulp ate `Soundness
wit Magnesium Sulp ate Construction & Workmans ip Rate of Spread of Binder Rate
of Spread
of Aggregates Grading of Aggregates Temperature of Binder during Spra
ying T ickness of Compacted Layer Horizontal Alignment Surface Level Surface Reg
ularity 502.8 505.10 401.1 502.7 401.10 301.9 301.10 301.11 504.2 (a) 504.2 (b)
504.2 (c ) 504.2 (d) 401.5 402.3 504.5 402.4 402.5 402.7 504.1 (a) 504.1 (b) 504
.1 (c) Title Test Ref No.
117
Section - 500
507 SURFACE DRESSING
Sec No. A) 507.1 507.1(a) 507.1 (b) 507.1 (c ) 507.2 507.2 (a) 507.2 (b) 507.2 (
c) 507.3 507.3 (a) 507.3 (b) 507.3 (c) 507.3 (d) 507.4 507.5 507.6 507.7 507.8 5
07.9 B) 507.10
507.11 507.12 507.13 507.14 507.15 507.16 Materials Quality of Bi
nder – Straig t –run Bitumen Penetration Test R&B Softening Point Ductility of B
itumen Quality of Binder – Bitumen Emulsion Viscosity Residue on 600 Micron IS S
ieve Storage Stability Test Quality of Binder – Modified Bitumen Penetration Tes
t R&B Softening Point Elastic Recovery Test Separation Test Aggregate Impact Val
ue Flakiness Index Bituminous
Stripping
of Ag
gregates Soundness
wit Sodium Sulp ate Soundness wit Magnesium Sulp ate Constr
uction & Workmans ip Rate of Spread of Binder Rate of Spread of Aggregates Gradi
ng of Aggregates Temperature of Binder during Spraying Horizontal Alignment Surf
ace Level Surface Regularity 502.8 505.10 401.1 502.7 301.9 301.10 301.11 504.2
(a) 504.2 (b) 504.2 (c ) 504.2 (d) 401.5 402.3 504.5 402.4 402.5 402.6 502.2 502
.3 502.4 504.1 (a) 504.1 (b) 504.1 (c) Title Test Ref No.
118

508.1 20 mm T ick Premix Carpet using Bitumen
Sec No. A) 508.1.1 508.1.1(a) 508.1.1 (b) 508.1.1 (c ) 508.1.2 508.1.2 (a) 508.1
.2 (b) 508.1.2 (c) 508.1.3 508.1.3 (a) 508.1.3 (b) 508.1.3 (c) 508.1.3 (d) 508.1
.4 508.1.5 508.1.6 508.1.7 508.1.8 508.1.9 B) 508.1.10 508.1.11 508.1.12
508.1.1
3 508.1.14 508.1.15 508.1.16 Materials Quality of Binder – Straig t –run Bitumen
Penetration Test R&B Softening Point Ductility of Bitumen Quality of Binder – B
itumen Emulsion Viscosity Residue on 600 Micron IS Sieve Storage Stability Test
Quality of Binder – Modified Bitumen Penetration Test R&B Softening Point Elasti
c Recovery Test Separation Test Aggregate Impact Value Flakiness Index Bituminou

s Stripping
wit Sodi
um Sulp ate Soundness wit Magnesium Sulp ate Construction & Workmans ip Grading
of Aggregates Binder Content Before Seal Coat Temperature of Binder T ickness B
efore and After Compaction Horizontal Alignment Surface Levels Surface Regularit
y 401.1 504.10 502.7 401.10 301.9 301.10 301.11 504.2 (a) 504.2 (b) 504.2 (c ) 5
04.2 (d) 401.5 402.3 504.5 402.4 402.5 402.6 502.2 502.3 502.4 504.1 (a) 504.1 (
b) 504.1 (c) Title Test Ref No.
119
Section - 500
508.2 20 mm THICK PREMIX CARPET USIGN BITUMEN EMULSION
Sec No. A) 508.2.1 508.2.1 (a) 508.2.1 (b) 508.2.1 (c) 508.2.1 (d) 508.2.2 508.2
.3 508.2.4 308.2.5 508.2.6 508.2.7 B) 508.2.8 508.2.9 508.2.10 508.2.11 508.2.12
508.2.13 508.2.14 508.2.15 Materials Quality of Binder (Bitumen Emulsion) Penet
ration Softening Point Test Elastic Recovery Separation Test Aggregate Impact Va
lue
Flakiness Index
Bitumen Stripping
of Aggregates
Water Absorption Soundness w
it Sodium Sulp ate Soundness wit Magnesium Sulp ate Construction & Workmans ip
Grading of Aggregates Binder Content
before Seal Coat Temperature
of Binder T i
ckness before and after Compaction T ickness of Layer wit Seal Coat Horizontal
Alignment Surface Level Surface Regularity 401.1 504.10 502.7 401.10 401.10 301.
9 301.10 301.11 504.1 (a) 504.1 (b) 504.2 (c ) 504.2 (d) 401.5 402.3 504.5 402.4
402.5 402.6 Title Test Ref No.
120
509 MIX SEAL SURFACING
Sec No. A) 509.1 509.2 509.3 509.4 509.5 509.6 509.7 509.8 B) 509.9 509.10 509.1

1 Materials
Flakiness Index of Aggregate Aggregate
Impact Value Soundness wit S
odium Sulp ate Soundness wit Magnesium Sulp ate Water Absorption Coating and St
ripping
of Bitumen Aggregate Mixture Gradation Analysis Binder Construction & Wo
rkmans ip Horizontal Alignment Surface Level Surface Regularity 301.9 301.10 301
.11 402.3 401.5 402.5 402.6 402.4 504.5 401.1 508.1 Title Test Ref No.
510 SEAL COAT
Sec No. A) 510.1 510.2 510.3 510.4 510.5 510.6 510.7 510.8 510.9 510.10 510.11 5
10.12 510.13 510.14 510.15 B) 510.16 510.17 Materials Gradation
Analysis
Flakine
ss Index of Aggregate Aggregate
Impact Value Soundness wit Sodium Sulp ate Soun
dness wit Magnesium Sulp ate Water Absorption Coating and Stripping of Bitumen
Aggregate Mixture Temperature of Binder Penetration on Paving Bitumen/Modified E
mulsion Softening Point on Paving Bitumen / Modified Emulsion Ductility on Pavin
g Bitumen Elastic Recovery of Modified Bitumen Viscosity Residue
on 600 Micron S
torage Stability Test for Emulsion Construction & Workmans ip Rate of Spread of
Binder Rate of Spread of Aggregates 502.8 505.10 401.1 402.3 401.5 402.5 402.6 4
02.4 504.5 502.7 504.2 (a) 504.2 (b) 504.1 (c) 504.2 (d) 502.2 502.3 502.4 Title
Test Ref No.
121
Section - 500
512 MODIFIED BITUMEN
Sec No. A) 512.1 512.2 512.3 512.4 Materials Penetration Softening Point Elastic
Recovery Separation 504.2 (a) 504.2 (b) 504.2 (c ) 504.2 (d) Title Test Ref No.
122
SECTION 600 BRICKWORK FOR STRUCTURES
123
600 BRICK WORK FOR STRUCTURES
Sec No. A) 600.1 600.2 600.3 600.4 600.5 600.6 600.7 600.8 B) 600.9 600.10 600.1
1 600.12 600.13 600.14 600.15 Materials Colour and Dimensional C eck of Bricks W
ater Absorption of Bricks Efflorescence of Bricks Compressive Strengt of Bricks
Setting Time of Cement Purity of Lime Grain Size Analysis of Sand
/ Stone / Mar
ble dust Water for Construction Construction & Workmans ip Heig t, Bond and Vert
icality by Plumb Bob Consistency
of Cement Mortar Water Retentivity of Mortar Co
mpressive Strengt of Mortar T ickness
of Joints in General Brick Work T ickness
of Joints in Arc es Plaster Finis 600.9 600.10 600.11 600.12 600.13 600.14 600
.15 600.1 600.2 600.3 600.4 800.1 403.1 301.1 600.8 Title Test Ref No.

600.1 Colour and Dimensional C eck of Bricks Purpose It is necessary
to c eck t
esize and colour of bricks before using t em. Procedure It s ould be seen t at
t e bricks ave a uniform colour andare free
from cracks, organic matter and fl
ows and nodules of free lime. T ey s ould ave rectangular
faces wit s arp corn
ers and
emit a ringing sound w en struck. T e size s ould be as per local practi
cewit
tolerance of +5 percent.
600.2 Water Absorption of Bricks Purpose
Bricks
w ic absorb more water t an normal will produce weaker masonry, as t ey will m
ake t e mortar dry.
125
Section - 600

Procedure Dry t e specimen in a ventilated oven at atemperature of 105 to 115oC
till it attains substantially
constant mass. Cool t especimen to room temperat
ure and obtain its weig t M1. Do not use specimen w ic are warm to touc . Immer
se completely
dried
specimen in clean water at a room temperature
of 27+ 2oCfor
24 .Remove
t e specimen and wipe
out any traces of water
wit a damp
clot an
d weig t e specimen. Complete t e weig ing 3 min after t e specimen as been re
moved from water (M 2). Waterabsorption, percent by mass after 24 our immersio
n in cold water is given by t e following formula M2 – M1 Water Absorption = ---
------------------- x 100 Observations are recorded in Form BR-1
Water Absorption
of Bricks Form- BR-1
S.No. Weig t of t e dried specimen cooled
at air temperature M 1 Weig t of t e s
pecimen after immersion in water for 24 M2 Water absorption percent by mass M2
– M 1 = -------------------- x 100 M1
Reference:
IS : 3495 (Part 2) - 1992 600.3 Efflorescence of Bricks Purpose Brick
s t at s ow moderate to serious efflorescence are considered unfit for use in ro
ad structures. Procedure A s allowflat bottom dis containing sufficient distil

led water
to completely
saturate
t e specimens
is used for t e test. Place t e e
ndof t e bricks in t e dis , t e dept of immersion in water being 25 mm. Place
t e w olearrangement in a warm (between 20 oCand 30oC) well ventilated
room u
ntil all t e water int e dis is absorbed
by t e specimens
and t e surplus wate
r evaporates.
Cover t e dis containing
t e brick wit a suitable
glass
cylinder

so t at excessive evaporation from t e dis may not occur. W en t e water as b
een absorbed
and brick appears to be dry, place a similar quantity of water in t
e dis and allow it to evaporate as before. Examine t e bricks for efflorescenc
e after t e second evaporation and report t e results.
126

T e liability to efflorescence s all be reported as ‘Nil’, ‘Slight’, ‘Mode ate’,
‘Heavy’ o ‘Se ious’ in acco dance with the following definitions. (a) (b) (c )
Nil Slight : : When the e is no pe ceptible deposit of efflo escence When not m
o e than 10 pe cent of the exposed a ea of b ick is cove ed with a thin deposit
of salts When the e is a heavie deposit than unde ‘Slight’ and cove ing up to
50 pe cent of the exposed a ea of the b ick su face but unaccompanied by powde i
ng o flaking of the su face. When the e is a heavy deposit of salts cove ing 50
pe cent o mo e of the exposed a ea of the b ick su face but unaccompanied by p
owde ing o flaking of the su face. When the e is a heavy deposit of salts accom
panied by powde ing and / o flaking of the exposed su faces.
Mode ate :
d) e)
Heavy Se ious
: :
600.4 Comp essive St ength of B icks Pu pose The Comp essive St ength of b icks
b oadly indicates the ove all quality of the aw mate ial and its manufactu ing
p ocess. P ocedu e Remove unevenness obse ved in the bed faces of b icks to p ov
ide two smooth and pa allel faces by g inding. Imme se in wate at oom tempe at
u e fo 24 h. Remove the specimen and d ain out any su plus moistu e at oom tem
pe atu e. Fill the f og and all voids in the bed face flush with cement mo ta (
1 cement, clean coa se sand of g ade 3 mm and down). Sto e unde the damp jute b
ags fo 24 h followed by imme sion in clean wate fo 3 days. Remove and wipe ou
t any t aces of moistu e. Places the specimen with flat faces ho izontal, and mo
ta filled face facing upwa ds between two 3 ply plywood sheets each of 3 mm th
ickness and ca efully cente ed between plates of testing machine. Apply load axi
ally at a unifo m ate of 14 N/mm 2 pe minute till failu e occu s. Note the max
imum load at failu e. The load at failu e is conside ed the maximum load at whic
h the specimen fails to p oduce any fu the inc ease in the indicato eading on
the testing machine. Obse vations a e eco ded in Fo m BR-2.
127
Section - 600
Fo m BR-1
Sl.No. Length Width of of bed bed face no.1 no.1 (mm) (mm) A ea of Length of bed
face bed face no.1 mm2 no.2 (mm) Width of bed face no.2 (mm) A ea of bed face n
o. 2(mm2) Ave age A ea of bed face (mm2) Maximum Comp essive load at St ength =
failu e in Maximum Newtons load / Ave age A ea of bed faces
Fo m fo the Test on Comp essive St ength of B icks BR-2 Refe ence: IS : 3495 (P
a t 1) - 1992 600.8 Suitability of Wate fo Const uction
Pu pose Wate plays an impo tant pa t in deciding the quality of the final conc
ete. Acceptance C ite ion 1. 2. 3. 4. The pH value of wate shall not be less th
an 6. Limits of Acidity - To neut alize 100ml of wate , using phenolphthalein as
an indicato it shall not equi e mo e than 5ml of .02 no mal NaOH. (IS : 3025
Pa t 22). Shall not equi e mo e than 25ml of 0.02 no mal H2SO4. (IS : 3025 pa t
23). Pe missible Limits of Solids
Table 600.8.1: Pe missible Limits of Solids in Const uction Wate O ganic Ino ga
nic Sulphat es (as SO4 ) Chlo ides Suspended Matte 200mg/lit e (IS : 3025 pa t
18) 3000mg/lit e (IS : 3025 pa t 18) 400mg/lit e (IS : 3025 pa t 24) 2000 mg/lit
e fo plain conc ete (IS : 3025 pa t 32) 2000mg/lit e (IS : 3025 pa t 17)
5.
Pe missible loss in st ength - The 28 days comp essive st ength of at least th e
e 150mm conc ete cubes p epa ed with the p oposed wate shall not be less than 9
0 pe cent of the ave age st ength of th ee simila cubes p epa ed with distilled
wate . Setting Time – The initial setting time of test blocks with the app op i
ate cement and wate p oposed to be used shall not be less than 30 minutes and s
hall not diffe by + 30 mt s f om the initial setting of cont ol test blocks p e
pa ed.
6.
Refe ence: IS : 3025 (Pa ts 17, 18, 22, 23, 24, 32)
128
Quality Assu ance Handbook fo Ru al Roads
600.9 Height, Bond and Ve ticality by Plumb Bob Pu pose It is necessa y to check
the height of each cou se, its bond and ve tically fo ensu ing long te m du ab
ility P ocedu e All b icks shall be tho oughly soaked in wate and made skin d y
befo e use. All b ickwo k shall be laid in English Bond even time to time, in a
cco dance with the d awings o as di ected by the Enginee . The ve tically will
be measu ed with a plumb. The height will be measu ed with a steel tape to the n
ea est millimete s. 600.10 Consistency of Cement Mo ta Pu pose The consistency
of mo ta dete mines its behavio du ing application. It depends upon initial fl
uidity, wate etentivity etc. P ocedu e A standa d cone weighing 300 + 2g; 150
mm in height and a diamet e of 75 mm at the base. The cone is mounted on a ve ti
cal shaft fastened to an adjustable holde (Fig. 2). The holde has a mechanism
which eleases the shaft. The appa atus also has an inst ument dial which eco d
s the depth of penet ation of the cone into a mo ta mix kept in a conical conta
ine below. The conical containe fo mo ta is 180 mm deep with a diamet e of 1
50 mm at the top. Fill the conical containe with mo ta mix to a level 1cm belo
w its im. Place the mo ta mix in the conical mould in one continuous ope ation
and compact it by a tamping od, which is 25 mm squa e and 200 mm long. Bump th
e mould filled with mo ta mix 5 o 6 times ove a flow table so as to level the
su face of the mo ta . Place the containe ove the base below the penet ation
cone of the appa atus. B ing the apex of the penet ating cone in contact with th
e su face of the mo ta and clamp the cone in position. Release the cone now and
allow it to sink into the mo ta mix. Afte the cone has stopped penet ating in
to the mo ta , set the dial once mo e to eco d the position of cone. The diffe
ence between dial eadings befo e and afte penet ation gives the depth of penet
ation of the cone into the mo ta . Repeat the test on anothe sample; epo t th
e ave age of two dete minations as the consistency of the mo ta .
129
Section - 600
DIAL GAUGE ROD INSTRUMENT DIAL
SHAFT ADJUSTABLE HOLDER
PENETRATING CONE STAND
CONICAL CONTAINER PLATFORM
Figu e 7 Standa d Cone Appa atus
Refe ence : IS : 2250 - 1981 600.11 Wate Retentivity of Mo ta Pu pose Wate e
tentivity is the ability of mo ta s to etain wate against suction and evapo at
ion in gene al . It is indi ectly a measu e of the wo kability of mo ta s. P oce
du e The appa atus used fo this test consists of a wate aspi ato o othe sou
ce of vacuum cont olled by way of a th ee way stopcock to a funnel upon which
ests a pe fo ated dish. The pe fo ated dish shall be made of metal, not attacked
by mason y mo ta s. The metal in the base of the dish shall have a thickness of
1.7 to 1.9 mm and shall confo m to the outline shown in figu e . The bo e of th
e stopcock shall have a minimum inside diamete of 4 mm. A me cu y manomete , co
nnected as shown in Fig. 3 , indicates the vacuum. A synthetic ubbe gasket sha
ll be pe manently sealed to the top of the funnel and shall be lightly coated wi
th pet oleum o light cup g ease du ing the test to ensu e a seal between the fu
nnel and the dish. Ca e shall be taken to ensu e that none of the holes in the p
e fo ated dish is clogged f om the g ease used on the ubbe gasket. Ha dened fi
lte pape of a g ade equivalent to Ca l Schleiche and Schuell filte pape No.
576 o to Whatman No.50 filte pape shall be used. It shall be of such diamet e
that it will lie flat and completely cove the bottom of the dish.
130
Adjust the me cu y elief column so as to maintain a vacuum of 5cm as measu ed o
n the manomete . Seat the pe fo ated dish on the g eased gasket of the funnel. P
lace a wetted filte pape in the bottom of the dish. Tu n the stopcock to apply
the vacuum to the funnel and check the appa atus fo leaks and to dete mine tha
t the equi ed suction is obtained. Then tu n the stopcock to shut off the vacuu
m f om the funnel.
1.4 to 1.6 Ø Holes 48 Holes 42 Holes 36 Holes 30 Holes 24 Holes 18 Holes 12 Hole
s 6 Holes 1 Holes B@ 8.75 Rubbe Gasket Th ee-way Stopcock Funnel 1.7 Min 19 to
20 2R 154 to 156 Ø 1409 Pe fo ation 1.7 to 1.9
Filte Pape 150ø 154 to 156 Ø
1 lit e Flask
Me cu y Manomete
To Aspi ato P essu e Cont ol Device
50 Me cu y
All dimensions in millimete s
Figu e 8 Appa atus Assembly fo Wate Retention Test
Mix the mo ta to a consistency to give a flow of 110 to 115. Immediately afte
making the flow test etu n the mo ta on the flow table to the mixing bowl and
emix the enti e batch fo 15 sec at medium speed. Immediately afte emixing of
the mo ta , fill the pe fo ated dish with the mo ta to slightly above the im.
Tamp the mo ta 15 times with the tampe . Ten of the temping st okes shall be a
pplied at app oximately unifo m spacing adjacent to the im of the dish and with
the long axis of the tamping face held at ight angles to the adius of the dis
h. The emaining five tamping st okes shall be applied at andom points dist ibu
ted ove the cent al a ea of the dish. The tamping p essu e shall be just
131
Section - 600
sufficient to ensu e filling of the dish. On completion of tamping, the top of t
he mo ta should extend slightly above the im of the dish. Smooth off the mo ta
by d awing the flat side of the st aight edge (with the leading edge slightly
aised ) ac oss the top of the dish. Then cut off the mo ta to a plane su face
flush with the im of the dish by d awing the st aight edge with a sawing motion
ac oss the top of the dish in two cutting st okes, sta ting each cut f om nea
the cente of the dish. If the mo ta is pulled away f om the side of the dish d
u ing the p ocess of d awing the st aight edge ac oss the dish, gently p ess the
mo ta back into contact with the side of the dish using the tampe . Tu n the s
topcock to apply the vacuum to the funnel. The time elapsed f om the sta t of mi
xing the cement and wate to the time of applying the vaccum shall not exceed 8
min. Afte suction fo 60 sec quickly tu n the stopcock to expose the funnel to
atmosphe ic p essu e. Immediately slide the pe fo ated dish off f om the funnel,
touch it momenta ily on damp cloth to emove d oplets of wate and set the dish
on the table. Then, using the bowl sc ape , flow and mix the mo ta in the dish
fo 15 sec. Upon completion of mixing, place the mo ta in the dish fo 15 sec.
Upon completion of mixing, place the mo ta in the flow mould and dete mine the
flow. The enti e ope ation shall be ca ied out without inte uption and as qui
ckly as possible, and shall be completed within an elapsed time of 11 min afte
the sta t of mixing the cement and wate fo the fi st flow dete mination. Calcu
lation : Calculate the wate etention value fo the mo ta as follows ; Wate
etention value = A/B x 100 Whe e A B = = flow afte suction and flow immediately
afte mixing
Refe ence: IS : 2250 – 1981 600.12 Comp essive St ength of Mo ta Pu pose Comp e
ssive st ength of mo ta indicates ove all quality of the mo ta . P ocedu e The
following equipment shall be used Specimen and Moulds - The test specimens shall
be cubes of size 50 mm and shall confo m to the equi ements given below: Cube
Moulds - The moulds fo the 50 mm cube specimen shall be metal not attacked by c
ement, cementpozzolana mixtu e o lime--pozzolana mixtu e and the e shall be suf
ficient st ength and stiffness to p event sp eading and wa ping. The moulds shal
l be igidly const ucted in such a manne as to facilitate the emoval of the mo
ulded specimen without damage. The moulds shall be machined so that when assembl
ed eady fo use, the dimensions and inte nal faces shall be accu ate to the fol
lowing limits: The height of the mould and the distance between the opposite fac
es shall be 50+ 0.1 mm. The angle between adjacent inte io faces and between in
te io faces and top and bottom planes of the mould shall
132
be 90+0.5 deg ees. The inte io faces of the moulds shall be plane su faces with
a pe missible va iation of 0.03 mm. Each mould shall be p ovided with a base pl
ate having a plane su face machined to a tole ance 0.10 mm and made of non-abso
bent, non-co odible and non- eactive mate ial. The base plate shall be of such
dimensions as to suppo t the mould du ing the filling without leakage. The pa ts
of the mould when assembled shall be positively held togethe , and suitable met
hods of ensu ing this, both du ing the filling and on subsequent emoval of the
filled mould shall be p ovided in o de to p event the moulded specimen f om dam
age. Mixing Appa atus - The mixing appa atus shall confo m to the equi ements s
pecified below:
Mixe - The mixe shall be an elect ically d iven mechanical mixe which shall c
onsist essentially of the following: a) A stainless steel mixing bowl with a nom
inal capacity of 5 lit es of the shape and dimensions as shown in Fig. 4 and p o
vided with means by which it can be secu ely fixed to the mixing f ame du ing mi
xing, and A mixe blade of the fo m and dimensions shown in Fig 5 evolving abou
t its axis as it is d iven in a planeta y movement a ound the bowl by an elect i
c moto .
b)
The two di ections of otation shall be opposite. The speed of otation du ing m
ixing shall be as follows: a) b) Blade evolving about its own axis Planeta y mo
vement 140 + 5 ev/min 62 +5 ev/min
3R 3
200 DIA
SIDE HANDLE BACK BOWL PIN ASSY
80
175 + 1
100 R 30 27.5 R
66.5
50
30 R All dimensions in millimete s
Figu e 9 Mixing Bowl
133
Section - 600
16
16 DIA 70 8 0.8
35
5
5
8
135 6
12
8
5
Figu e 10 A Mixe Blade
A plastic sc ape . Tamping Rod- A metal ba 25 mm squa e and 200 mm long. T owel
- This shall have a steel blade 100 to 150 mm in length with st aight edges. Flo
w Table – The standa d table P epa ation of Moulds - The inte io faces of the s
pecimen moulds shall be thinly cove ed with mine al oil o light cup g ease. Aft
e the moulds a e assembled, excessive oil o g ease shall be emoved f om the i
nte io faces and the top and bottom su faces of each mould. Moulds shall then b
e set on plane, non-abso bent, non-co odible and non- eactive base plates that
have been thinly coated with mine al oil o light cup g ease. P epa ation of Mo
ta - The mo ta shall be of the mate ials and p opo tions intended fo use in t
he const uction mixed to give a flow of 110 to 115. The mixing p ocedu e fo sam
ple made in the labo ato y shall be as given above. T ial Mixing - T ial mo ta s
shall be made with specified p opo tion of d y ing edients and adding diffe ent
pe centages of wate until the specified flow is obtained. Each t ial shall be
made with f esh mo ta s. The mixing shall be done mechanically as desc ibed ea l
ie . The mixing of the ing edients shall be ca ied out at a tempe atu e of 27 +
2°C and all ing edients befo e
134
mixing shall be b ought to the same tempe atu e. The d y ing edients shall then
be placed in the mixing bowl and mixed fo 30 sec. Ove the next 30 sec, while m
ixing, wate shall be pou ed at a unifo m ate into the bowl and the mixing shal
l be continued fo 60 sec. The mixe shall then be stopped and the paddle and si
des of the bowl shall be cleaned down in about 15 sec with the plastic sc ape .
The bowl shall be cove ed with a damp cloth and the mo ta be allowed to stand f
o a pe iod of 10 min. The mo ta shall then be emixed fo 60 sec. When using l
ime putty, the p ocedu e shall be as desc ibed above, except that the sand and l
ime putty shall be p emixed by hand o in the mixe until the lime appea s to be
unifo mly dist ibuted. Remixing of Mo ta s in the Labo ato y - Samples of mo ta
eceived in the labo ato y fo testing shall be examined fo any leakage o ev
apo ation and seg egation o bleeding of the liquid. The whole of the sample, wi
th any liquid which has sepa ated o has condensed inside the containe , shall b
e t ansfe ed as completely as possible to an impe meable wo king su face and e
mixed, using a t owel, until it appea s homogeneous. The top of the flow table s
hall be ca efully wiped clean, d ied and the flow mould shall be placed at the c
ent e. A laye of mo ta about 25 mm in thickness and mixed in acco dance with A
-4.1.1 shall be placed in the mould and tamped 20 times with the tamping od. Th
e tamping p essu e shall be just sufficient to ensu e unifo m filling of the mou
ld. The mould shall then be filled to ove flow with mo ta and tamped, as specif
ied fo the fi st laye . The mo ta shall be cut off plane and level with the to
p of the mould by d awing the st aight edge of a t owel (held pe pendicula to t
he mould) with a sawing motion ac oss the top of the mould. The top of the table
shall be wiped clean and d ied, taking ca e to emove any wate f om a ound the
edge of the flow mould. The mould shall then be lifted away f om the mo ta and
the flow table shall be immediately d opped th ough a height of 12.5 mm, 25 tim
es in 15 sec. The flow is the esulting inc ease in ave age base diamet e of the
mo ta mass, measu ed on at least fou diamet e at app oximately equispaced int
e vals exp essed as a pe centage of the o iginal base diamet e. Test Specimens C
ubes - The mould as p epa ed shall be filled with the mo ta to about half heigh
t and the laye compacted by tamping it with the tamping od in a unifo m manne
ove the mo ta su face in such a way as to p oduce full compaction of the mo t
a with neithe seg egation no excessive laitance. The mould shall then be comp
letely filled and the uppe laye of the mo ta compacted in a simila manne , a
fte which the su face of the mo ta shall be st uck off plane and level with th
e top of the mould, using a t owel. Cu ing and Sto age of Test Specimens - The s
pecimens shall be sto ed at a place f ee f om vib ation, eithe in moist ai at
a tempe atu e of 27 + 2°0 and elative humidity of not less than 90 pe cent o u
nde damp sacks, matting o othe suitable damp mate ial cove ed completely with
polyethylene o othe simila impe vious sheeting, at a tempe atu e of 27 + 2°C
fo 1 to 3 days, depending on the ea ly st ength of the mo ta , f om the time o
f adding the wate to the othe ing edients. The specimen shall then be ma ked f
o late identifications, emoved f om the moulds and sto ed in clean wate unti
l the time of test. The tempe atu e of the sto age wate shall be 27 +2°C. When
cubes a e made at site, eco ds of the maximum and minimum ai and wate sto age
tempe atu e shall be kept du ing the pe iod, using maximum and minimum the mome
t es o continuous eco ding inst uments. The cubes shall be sent to the testing
labo ato y when they a e not less than 3 days no mo e than 7 days old, well pa
cked in damp sand o in wet sacks, and when necessa y enclosed in
135
Section - 600
polyethylene bag o sealed containe , so that they a ive at the labo ato y in a
damp condition not less than 24 h befo e the time of test. On a ival at the te
sting labo ato y, the cubes shall be sto ed in clean wate maintained at a tempe
atu e of 27 +2°C until the time of test. Numbe of Specimens - Th ee o mo e sp
ecimens shall be made fo each pe iod of test specified. P ocedu e The specimen
shall be tested immediately on emoval f om the cu ing wate in which it has bee
n sto ed and while it is still in a wet condition. Any loose mate ial shall be
emoved f om the sides of the specimen. The dimensions of the specimen shall be n
oted befo e testing. The bea ing su faces of the testing machine shall be wiped
clean and the specimen shall be placed in the machine in such a manne that the
load shall be applied to opposite sides of the cube as cast, that is, not to the
top and bottom. The axis of the cube shall be ca efully aligned with the cent e
of th ust of steel plates bea ing the testing machine. No packing othe than au
xilia y steel plates shall be used between the faces of the specimen and steel p
latens of the testing machine. The load on the specimen shall be applied without
shock and at a unifo m ate of 2N/mm2 to 6N/mm2 pe min until failu e occu s. T
he maximum load at failu e shall be noted. Calculation The comp essive st ength
shall be calculated as follows : Maximum load at failu e (N) Comp essive st engt
h (N/mm 2) = -----------------------------------------------C oss-sectional a ea
(mm2) The individual esults shall be calculated to the nea est 0.05N/mm 2. Rep
o t The ave age of all the dete mination shall be epo ted (Fo m BR-3).
Comp essive St ength of Mo ta Fo m BR-3
S.No. Specimen No. Plan A ea of Cube Mould A (mm 2) Load at failu e W (N) Comp e
ssive St ength = W/A (N/mm2 )
136
600.13
Thickness of Joints fo Gene al B ick Wo k - Tole ance
The thickness of joints fo gene al b ick wo k shall be measu ed with a ve nie
callipe with a least count of 0.1 mm. The thickness of joints fo gene al b ick
wo k shall not be mo e than 10 mm. 600.14 Thickness of Joints fo A ches – Tole
ance The thickness of joints fo a ches shall be measu ed with a ve nie callip
e with a least count of 0.1 mm. The thickness of joints fo a ches shall not be
less than 5 mm and not mo e than 15 mm. 600.15 Plaste Finish – Tole ances The
thickness of plaste shall be measu ed with a ve nie callipe with a least coun
t of 0.1mm. The plaste thickness as p ovided shall not be less than the specifi
ed thickness by mo e than 3 mm.
137
SECTION 700 STONE MASONRY FOR STRUCTURES
139
700 STONE MASONRY FOR STRUCTURES
Sec No. A) 700.1 700.2 700.3 700.4 700.5 700.6 700.7 700.8 700.9 700.10 700.11 7
00.12 700.13 B) 700.14 700.15 700.16 700.17 700.18 Mate ials Shape and Dimension
s of Stones Wate Abso ption of Stones D essing of Stones Setting Times Cement P
u ity of Lime G adation of Sand Delete ious Mate ial and O ganic Impu ities Wate
fo Const uction Comp essive St ength of Stones Consistency of Cement Mo ta W
ate Retentivity of Mo ta Mix P opo tions fo Diffe ent Wo ks Comp essive St en
gth of Mo ta Const uction & Wo kmanship Ho izontality and Ve ticality Height an
d Thickness Thickness of Joints of Mason y Thickness of Joints in A ches Consump
tion of Mo ta in Stone Mason y 700.14 700.15 600.13 600.14 700.18 700.1 700.2 7
00.3 800.1 403.1 301.1 800.6 600.8 600.12 600.10 600.11 700.12 600.12 Title Test
Ref No.
700.1 Shape and Dimensions of Stones Pu pose The quality and du ability of stone
mason y depends on the size and shape of stones besides othe ing edients. P oc
edu e The stone shall be ha d, sound, f ee f om defects like cavities, flaws, sa
nd holes and patches of soft mate ial. Stones shall confo m to the equi ements
of IS : 1597 (Pa t 1). The shape and dimensions of stones shall be checked befo
e use. 700.2 Wate Abso ption of Stones Pu pose Wate abso ption shows the po os
ity of stones in one way. The mo e, it abso bs, the less it is du able.
141
Section - 700
P ocedu e The test piece about 1 kg shall be washed to emove dust and imme sed
in distilled wate in a glass vessel at a oom tempe atu e 20 oC to 30oC fo 24
h. Soon afte imme sion and again at the end of the soaking pe iod, ent apped ai
shall be emoved by gentle agitation. This will be done by apid clock wise an
d anticlock wise otation. The vessel shall then be emptied and test piece be al
lowed to d ain. The test piece shall then be placed on a d y cloth and gently su
face d ied with the cloth. It shall be t ansfe ed to a second d y cloth when t
he fi st one emoves no fu the moistu e. It shall be sp ead out not mo e than o
ne stone deep on the second cloth and left exposed to atmosphe e away f om di ec
t sunlight o any othe sou ce of heat fo less than 10 min until it appea s to
be completely su face d y. The sample shall then be weighed (B). The sample will
be d ied in an oven at 100 to 110oC fo not less than 24 h. It shall then be co
oled in a dessicato to oom tempe atu e and weighed (A) The wate abso ption sh
all be calculated f om the fo mula. (B – A) Wate Abso ption = --------------- x
100 A Repo t the esults in the fo m ST-1
Wate Abso ption of Stones Fo m ST-1
S.No. Specimen No. Wt of Satu ated Su face D y Sample B (g) Wt of Oven D ied Sam
ple A (g) Wate Abso ption (%) B-A = --------------- x 100 A
700.3 D essing of Stones Pu pose The d essing of stone is done to b ing them int
o the equi ed shape. P ocedu e The d essing of stones shall be done as pe the
equi ement and methods specified in IS : 1129. 700.12 Mix P opo tions fo Diffe
ent Wo ks Pu pose Mix design is equi ed to optimize the quantity of va ious in
g edients.
142
P ocedu e Mix design is essentially ca ied out by t ial and e o . Taking the e
ffect of va ious elements like, wate cement atio, g adation, st ength etc. int
o account an initial mix is wo ked out. It is then efined on the basis of tests
fo the equi ed pa amete s. 700.14 Ho izontality and Ve ticality Pu pose The d
u ability of stone mason y depends upon these pa amete s. P ocedu e Ho izontalit
y is checked with spi it levels on a small scale and with a su veying inst ument
s on a la ge scale. Simila ly the ve ticality is checked with a Plumb bob. 700.1
5 Height and Thickness Pu pose Height and thickness of each cou se effect the lo
ng te m pe fo mance of the mason y. P ocedu e The height and thickness of indivi
dual cou ses as well as the total height needs to be measu ed egula ly with a s
teel tape on a small scale and with a su veying inst ument on a la ge scale. 700
.18 Consumption of Mo ta in Stone Mason y The consumption of mo ta in stone ma
son y should be noted. The amount of mo ta should be 0.25 to 0.30 cubic mete f
o each cubic mete of stone mason y.
143
SECTION 800 CONCRETE FOR STRUCTURES
145
800 CONCRETE FOR CONSTRUCTION
Sec No. A) 800.1 800.2 800.3 800.4 800.5 800.6 800.7 800.8 800.9 800.10 800.11 8
00.12 800.13 800.14 800.15 800.16 B) 800.17 800.18 800.19 800.20 800.21 800.22 8
00.23 800.24 800.25 800.26 800.27 Mate ials Setting Time of Cement Soundness of
Cement Comp essive St ength of Cement G adation Analysis of Agg egates Flakiness
Index of Coa se Agg egate Delete ious Mate ials and O ganic Impu ities Wate Ab
so ption / Wate Content C ushing St ength of Coa se Agg egates Agg egate Impact
Value Soundness Alkali Agg egate Reactivity G adation of Fine Agg egate Delete
ious Constituents of Fine Agg egates Alkali Agg egate Reactivity Wate fo Const
uction Mix Design fo Each Wo k Const uction & Wo kmanship Moistu e Content of
Coa se and Fine Agg egates Cement Consumption Wo kability of Conc ete by Slump T
est Wo kability of Conc ete by Compaction Test Fo mwo k and Const uction Joints
Cu ing of Conc ete Schmidt’s Rebound Hamme Ult asonic Pulse Velocity Accele ate
d Cu ing Test Comp essive St ength of Conc ete Cubes (150 mm x150 mmx150 mm) at
28 days Flexu al St ength of Conc ete 800.17 800.18 800.19 800.20 900 800.22 800
.23 800.24 800.25 800.26 800.27 800.1 800.2 800.3 401.1 402.3 800.6 402.4 800.8
401.5 402.5, 402.6 800.11 301.1 800.6 800.11 600.8 800.16 Title Test Ref No.
147
Section - 800
800.1 Initial and Final Setting Time of Cement Pu pose Cement, when used in cons
t uction, should set in a easonable time. It should not set too ea ly, so that
it can be t anspo ted to the place whe e it is to be placed. Also it should not
take too long fo setting, so that the fo mwo ks can be emoved and fu the wo k
sta ted. P ocedu e 1. 2. 3. 4. 5. 6. 7. P epa e a neat cement paste by mixing t
he cement with 0.85 times the wate equi ed to give a paste of standa d consist
ency, using potable o distilled wate . Sta t a stop watch at the instant when w
ate is added to the cement. Fill the Vicat mould with the cement paste, the mou
ld esting on a non-po ous plate. Fill the mould completely and smooth off the s
u face of the paste making it level with the top of the mould. Lowe the needle
gently until it comes in contact with the su face of the test block and quickly
elease, allowing it to penet ate into the test block. In the beginning, the nee
dle will completely pie ce the block. Repeat this p ocedu e until the needle fai
ls to pie ce the block beyond 5.0 + 0.5 mm measu ed f om the bottom of the mould
. The pe iod elapsing between the time when wate is added to the cement and the
time at which the needle fails to pie ce the test block to a point 5.0 + 0.5 mm
measu ed f om the bottom , is called the initial setting time. Replace the need
le by the annula attachment. The cement shall be conside ed as finally set when
, upon applying the needle gently to the su face of the test block, the needle m
akes an imp ession, the eon, while the attachment fails to do so. The pe iod ela
psing between the time when wate is added to the cement and the time when cemen
t is finally set as indicated above, shall be the final setting time. In the eve
nt of a scum fo ming on the su face of the test block, use the unde side of the
block fo the dete mination.
Final Setting time 1. 2.
3. 4.
Setting Time of Cement Fo m CC-1
S.No. Sta ting Time (Stop Watch ) T0 Time when Initial set has taken place (s) T
1 Time when Final set has taken place (s) T2
Initial Setting Time = T1 – T0 Final Setting Time = T2 – T0 Refe ence : I.S. 403
2 ( Pa t 5 ) – 1988
148
800.2 Soundness of Cement Pu pose The testing of soundness of cement is done to
ensu e that the cement does not show any app eciable subsequent expansion. The n
on soundness of cement is due to the p esence of excess of lime, excess of magne
sia o excessive p opo tion of sulphates.
LE-CHATELIER MOULD
P ocedu e Requi ements Soundness of cement can be dete mined by two methods, nam
ely Le-Chatelie method and Autoclave method. The unae ated cement should not ha
ve an expansion of mo e than 10 mm and 0.8 pe cent espectively when tested by t
he two methods. In the event of cements failing to comply with any o both the
equi ements mentioned above, fu the tests would be unde taken on anothe po tio
n of the same sample afte ae ation. Ae ation shall be done by sp eading out the
sample to a depth of 75 mm at a elative humidity of 50 to 80% fo a total of 7
days. The expansion of cements 80% ae ated shall be not mo e than 5 mm and 0.6%
when tested by Le-Chatelie and Autoclave method espectively. Method 1: Le-Cha
telie Method 1. 2. 3. 4. P epa e a cement paste by gauging cement with 0.78 tim
es the wate equi ed to give a paste of standa d consistency. Oil the mould lig
htly. Keep it on a lightly oiled glass plate and fill up the mould with cement p
aste. Cove the mould with anothe piece of lightly oiled glass sheet and immedi
ately subme ge the whole assembly in wate at 27+ 2oC and keep it the e fo 24 h
. Measu e the distance sepa ating the indicato points. Subme ge the mould again
in wate and b ing it to boil in 25-30 minutes. Keep it boiling fo 3 hou s. Re
move the mould f om wate and allow it to cool. Measu e the distance between the
indicato points. Diffe ence between two measu ements gives the expansion of ce
ment. Repo t the esults in the Fo m CC-2
149
5. 6.
Section - 800
Soundness of Cement by Le-Chatelie Method Fo m CC-2
Specimen No. Wt. of cement W (g) Distance sepa ating the indicato points (mm) B
efo e subme gence Afte subme gence
Pe missible value 10 mm Method 2 : Autoclave Method 1. 2. A cement paste shall b
e made with 500g of cement and sufficient wate to give standa d consistency. A
mould of 25 mm x 25 mm size and inte nal length of 282 mm shall be thinly oiled;
and filled with cement paste in two laye s; compacting with thumb o fo efinge
s by p essing the paste into co ne s. Afte compacting the top laye , flush it w
ith a t owel. Remove the specimen f om the mould afte 24+ 0.5 h and place it in
the autoclave at oom tempe atu e in a ack so that the fou sides of each spec
imen a e exposed to satu ated steam. Initially the ai will be allowed to escape
f om the autoclave by keeping the vent valve open. The valve shall be closed wh
en the steam begins to escape and the gauge p essu e of autoclave allowed to ea
ch 2.1 MPa in about 1 to 1.25 h f om the time the heat is tu ned on. Maintain th
e p essu e of 2.1 +0.1 MPa fo 3 hou s. Shut off the heat supply and allow it to
cool at a ate such that p essu e comes down to 0.1 MPa at the end of one hou .
Any p essu e emaining shall be eleased. Open the autoclave and immediately ke
ep the test specimen in wate , the tempe atu e of which is above 90oC. The wate
su ounding the specimens is cooled at a unifo m ate to 27+2oC in 15 min. The
tempe atu e of wate is then maintained at 27+2oC fo 15 min. Take the specimens
out of wate , make them su face d y and measu e thei lengths. The diffe ence i
n lengths of the test specimen befo e and afte autoclaving shall be calculated
to the nea est 0.01 pe cent of the effective gauge length which is the length be
tween the inne most points of the metal inse ts used as efe ence points shall b
e epo ted as the autoclave expansion of the cement. A cont action (negative exp
ansion) shall be indicated by p efixing a minus sign to the pe centage expansion
epo ted.
3. 4.
5.
6.
7. 8.
Refe ence I.S. 4031 (Pa t3) - 1988 800.3 Comp essive St ength of Cement Pu pose
The comp essive st ength of ha dened cement is the most impo tant p ope ty as it
cont ols the mix design. St ength tests a e not conducted on neat cement paste
because of difficulties of excessive sh inkage and subsequent c acking. St ength
of cement is the efo e found indi ectly, by testing cement mo ta in a specific
p opo tion.
150
VIBRATING MACHINE FOR CEMENT CUBES
HAND OPERATED COMPRESSION TESTING MACHINE
151
Section - 800
P ocedu e 1. Take 200 g of Cement and 600 g of Standa d Sand (Enno e) in a non-p
o ous enamel t ay and mix them with a t owel fo one minute, then add wate equa
l to (P/4 + 3.5) pe cent of combined weight of cement and sand and mix the th ee
ing edients tho oughly until the mixtu e is of unifo m colou . The time of mixi
ng should not be less than 3 min. Immediately afte mixing, the mixtu e is fille
d into a cube mould of 7.06cm; the a ea of each face being 50 sq.cm. Compact the
mo ta eithe by placing it on the vib ationing table fo two minutes at the sp
ecified speed of 12000+ 400 vib ations pe min. Keep the compacted cube in the m
ould at a tempe atu e of 270 C + 2 0 C and at least 90 pe cent humidity fo 24 h
. At the end of 24 h, emove the moulds and immediately subme ge them in clean f
esh wate and keep them the e until taken out just befo e conducting the test.
Test th ee cubes fo comp essive st ength afte 3 days and 7 days. The cubes sha
ll be tested on thei sides without any packing. The ate of loading shall be 35
N/mm2 pe min. The comp essive st ength is calculated by dividing the maximum l
oad applied to the cubes du ing the test divided by the c oss sectional a ea.
2. 3. 4. 5. 6. 7.
Comp essive St ength of Cement Fo m CC-3
Comp essive St ength afte 3 days S.No. Obse vations Plan A ea Load at Comp.St e
ngth A (mm2 ) Failu e W(N) N/mm2 Ave age St ength Comp essive st ength afte 7 d
ays Obse vations PlanA ea Load at Comp.St ength A(mm2 ) Failu eW(N) N/mm2 Ave ag
e St ength
Refe ence : I.S. 4031 (Pa t 6 ) – 1988 800.6 Delete ious Mate ials and O ganic I
mpu ities Pu pose D edged sand f om ive beds contains decayed vegetable matte
, humus, o ganic matte and othe impu ities, pa ticula ly when the e is not muc
h flow in the ive . The o ganic matte s inte face with the setting action of ce
ment and the bond cha acte istics of agg egates. Moss and algae esults in ai e
nt ainment educing its st ength; excessive silt and clay esult in g eate wate
equi ement, inc eased sh inkage and inc eased pe meability.
152
P ocedu e 1. O ganic Impu ities
Mix the soil sample with 3% solution of Sodium hyd oxide in wate . Keep it fo 2
4 h and compa e the colo development with a standa d colo cha t. If the colo
of sample is da ke than the standa d colo , o ganic impu ities a e mo e than pe
missible, and eithe the sample should be ejected o co ective measu es taken
. 2. 1. 2. 3. 4. Clay, Fine silt and Fine Dust Pou a sample of agg egate into a
g aduated measu ing ja containing wate and od the agg egate nicely to emove
the pa ticles of clay and silt adhe ing to agg egate pa ticles. Shake the ja s
o that all the clay and silt pa ticles get mixed with wate and keep it in undis
tu bed condition. Measu e the thickness of laye of clay and silt standing ove
the fine agg egate pa ticles to calculate the pe centage of clay and silt in the
sample of agg egate. The limits of delete ious mate ial as given in IS 383 1970
a e given below. Please note that the sum of the pe centages of all the delete
ious mate ial should not exceed 5.
Table 800.6.1 Limits of Delete ious Mate ials Delete ious Substance Fine Agg ega
te Unc ushed Coal and Lignite Clay Lumps Soft F agments Mate ial passing 75 mic
o sieve Shale 1.00 1.00 3.00 1.00 C ushed 1.00 1.00 3.00 Coa se Agg egate Unc us
hed 1.00 1.00 3.00 3.00 C ushed 1.00 1.00 3.00 -
Refe ence: I.S. 2386 (Pa t 2) - 1963 800.8 C ushing St ength of Coa se Agg egate
s Appa atus Appa atus fo the standa d test shall consist of the following: (a)
(b) A 15 cm diamete open ended steel cylinde , with plunge and base plate. The
su faces in contact with the agg egate shall be machined and case-ha dened. A c
omp ession testing machine capable of applying a load of 40 tonnes and which can
be ope ated to give a unifo m ate of loading so that the maximum load is each
ed in 10 min. The machine may be used with o without a sphe ical seating.
153
Section - 800
P epa ation of Test Sample The mate ial fo the standa d test shall consist of a
gg egate passing a 12.5 mm IS Sieve and etained on a 10 mm IS Sieve, and shall
be tho oughly sepa ated on these sieves befo e testing. Test the agg egate in a
su face-d y condition. If d ied by heating. The pe iod of d ying shall not excee
d fou h, the tempe atu e shall be 100°C to 110°C and the agg egate shall be coo
led to oom tempe atu e befo e testing. The quantity of agg egate shall be such
that the depth of mate ial in the cylinde , afte tamping shall be 10 cm. The ap
p op iate quantity may be found conveniently by filling the cylind ical measu e
in th ee laye s of app oximately equal depth, each laye being tamped 25 times w
ith the ounded end of the tamping od and Dete mine the weight of mate ial comp
ising the test sample and take the same weight of sample fo the epeat test. T
est P ocedu e - Put the cylinde of the test appa atus in position on the base-p
late and the test sample added in thi ds, each thi d being subjected to 25 st ok
es f om the tamping od. The su face of the agg egate shall be ca efully leveled
and the plunge inse ted so that it ests ho izontally on this su face, ca e be
ing taken to ensu e that the plunge does not jam in the cylinde . Place the app
a atus with the test sample and plunge in position, between the platens of the
testing machine and loaded at as unifo m a ate as possible so that the total lo
ad is eached in 10 min. The total load shall be 40 tonnes. Replace the load and
emove the whole of the mate ial f om the cylinde and sieve on a 2.36 mm IS Si
eve fo the standa d test. The f action passing the sieve shall be weighed (Weig
ht B) In all of these ope ations, ca e shall be taken to avoid loss of the fines
. Two tests shall be made. Calculation Exp ess the atio of the weight of fines
fo med to the total sample weight in each test as a pe centage, the esult being
eco ded to the fi st decimal place: B Agg egate c ushing value = -------------
-- x 100 A Whe e B = weight of f action passing the app op iate sieve, and A = w
eight of su face-d y sample. Repo t the esults in Fo m CC – 4
154
C ushing St ength of Coa se Agg egate Fo m CC-4
S.No. Wt. of the Containe C (g) Wt. of Su face D y Specimen + Containe A (g) W
t. of Fines Passing 2.36 mm + Containe B (g) C ushing Value B-C = -------------
-x 100 A-C
800.11 Alkali Agg egate Reactivity Pu pose The pu pose of the test is to assess
the potential alkali agg egate eactivity so that the suitability of agg egates
could be judged.
LENGTH COMPARATOR
BAR MOULD
155
Section - 800
P ocedu e 1. Using the standa d moulds fo the mo ta ba tests, and using the g
ading given below, p epa e at least fou mo ta ba s fo test as pe the p oced
u e given below:
Table 800.11.1 G ading of Fine Agg egates fo Alkali Agg egate Reactivity Test S
ieve Size Passing 4.75 mm 2.36 mm 1.10 mm 600 mic on 300 mic on Retained on 2.36
mm 1.10 mm 600 mic on 300 mic on 150 mic on 10 25 25 25 15 Pe centage Weight
2. 3. 4.
Cove the moulds thinly with mine al oil and set the gauge studs in position, ta
king ca e to keep them clean and f ee of oil. Apply a mixtu e of th ee pa ts of
pa affin to five pa ts of esin by weight, heated between 110oC and 120oC to the
outside contact lines of the moulds to make them wate tight. P opo tion the d
y mate ials fo the test mo ta using 1 pa t of cement to 2.25 pa ts of g aded a
gg egate by weight. The equi ed quantities fo 2 mo ta ba s a e 300g of cement
and 675 g of agg egate. Use an amount of wate which gives a flow of 105 to 120
as dete mined on the flow table except that the flow table shall be given 12.5
mm d ops in app oximately 6 sec instead of twenty five, 12.5 mm d ops in 15 sec.
Place the mate ial in the bowl using following sequence (a) (b) (c) (d) Place t
he wate in the d y bowl. Add cement to wate , mix fo 30 sec Add app oximately
half the agg egate and mix fo 30 sec Add the emainde agg egate and mix fo 1
½ min.
5.
6.
7. 8.
Mix the mo ta in the bowl by vigo ous and continuous squeezing and kneading wit
h one hand p otected by a glove. Immediately afte the mixing, fill the mould in
two laye s, each laye being compacted with the tampe . Wo k the mo ta into co
ne s, a ound the gauge studs and along the su face of the mould with the tampe
till a homogeneous specimen is obtained. Afte the top laye has been compacted
, cut off the mo ta flush with the top of the mould and smooth the su face with
a few st okes of the t owel. Keep the mould in the moist oom immediately afte
filing, fo a pe iod of 24 + 2 hou s.
9.
156
10. 11. 12. 13.
Remove the test specimen afte 24 + 2h f om the mould and measu e the length usi
ng a compa ato ; at a tempe atu e of 270 + 2o C. Afte the initial measu ement,
place the specimen on end in a metal o plastic containe maintained at 380 + 2o
C. When length measu ements a e to be made. Subsequently, emove the containe
holding the specimen f om the sto age and place it in a oom at a tempe atu e of
270 + 2o C. Each time length measu ements a e made clean the containe and chan
ge the wate afte measu ements, eplace the specimen in inve ted position as co
mpa ed with the p evious sto age pe iod. Measu e the length of the specimen at a
ges of 1, 2, 3, 6, 9 and 12 months and if necessa y eve y six months the eafte .
Calculate the diffe ence in length of the specimen when emoved f om the moulds
at one day and any subsequent pe iod to the nea est 0.001 pe cent of effective
gauge length as expansion. Repo t the ave age of the expansion of the fou speci
mens of a given cement agg egate combination to the nea est 0.001 pe cent as the
expansion fo a given pe iod. Note and epo t the following at the end of the t
esting pe iod. (a) (b) (d) (e) Wa ping – measu ed to the nea est 0.2 mm P esence
, location and patte n of c acking Appea ance of su faces, su face mottling . Su
pe ficial deposits o exudations, thei natu e thickness and continuity.
14.
15. 16.
Refe ence IS : 2386 (Pa t VII) – 1963 800.16 Pu pose It is necessa y to develop
an optimum conc ete mix fo use at site to ensu e economy and du ability. P oced
u e Conc ete Mix may be developed by t ial and e o . Any standa d p ocedu e suc
h as those given in Indian Standa ds IS : 10262-1982 and SP 23 ( S & T) – 1982 m
ay be used. The mix so developed must be app oved by the Executive Enginee in c
ha ge of wo ks befo e use at site. 800.17 Pu pose The st ength of conc ete depen
ds upon the amount of wate p esent in it, hence the impo tance. P ocedu e Oven
d ying methods as desc ibed unde the clause 301.7 shall be used fo this pu pos
e. The moistu e content of agg egates can be dete mined sepa ately fo coa se an
d fine agg egates as well as fo the combined agg egates.
157
Mix Design fo Each Wo k
Moistu e Content of Coa se and Fine Agg egate
Section - 800
800.18 Cement Consumption Pu pose Cement being a costly commodity, its consumpti
on affects the total cost. P ocedu e Cement must be sto ed p ope ly on wooden pl
atfo ms, stacking not mo e than eight bags high and at least 450mm clea off the
walls. The cont acto shall keep p ope eco ds in espect of type of cement, l
ot no., date of manufactu e, manufactu e ’s ce tificate ega ding quality, test
esults, and its consumption on va ious wo ks f om time to time. 800.19 Wo kabil
ity of Conc ete by Slump Test This method of test may be used in the labo ato y
o du ing the p og ess of wo k in the labo ato y o du ing the p og ess of wo k
in the field, fo dete mining the consistency of conc ete whe e the nominal maxi
mum size of the agg egate does not exceed 38 mm. Appa atus Mould - The mould fo
test specimen shall be in the fo m of the f ustum of a cone having the followin
g inte nal dimensions : Dimensions Bottom diamete Top diamete Height Cm 20 10
30
The mould shall be const ucted of metal (b ass o aluminum shall not be used) of
at least 1.6 mm (o 16 BG) thickness and the top and bottom shall be open and a
t ight angles to the axis of the cone. The mould shall have a smooth inte nal s
u face. It shall be p ovided with suitable foot pieces and also handles to facil
itate lifting it f om the moulded conc ete test specimen in a ve tical di ection
as equi ed by the test. A mould p ovided with a suitable guide attachment may
be used. Sampling In the case of conc ete containing agg egate of maximum size m
o e than 38 mm, sc een the conc ete th ough 1 ½ inch sc een to exclude agg egate
pa ticles la ge than 38 mm. P ocedu e Clean tho oughly the inte nal su face of
the mould so that it is f ee f om supe fluous moistu e and any set conc ete bef
o e commencing the test. Place the mould on a smooth, ho izontal, igid and nona
bso bent su face, such as a ca efully leveled metal plate, the mould being fi ml
y held in place while it is being filled. Fill the mould in fou laye s, each ap
p oximately one – qua te of the height of the mould. Each laye with twenty fiv
e st okes of the ounded end of the tamping od. The st okes in a unifo m manne
ove the c oss-section of the mould and fo the second and subsequent laye s pe
net ate into the unde lying laye . The bottom laye shall be tamped th oughout i
ts depth. Afte the top laye has been odded, the conc ete shall be st uck off
level with a t owel o the tamping od, so that the mould is exactly filled. Any
mo ta which may have leaked out between the mould and the base plate
158
shall be cleaned away. The mould is emoved f om the conc ete immediately by ai
sing it slowly and ca efully in a ve tical di ection. This allows the conc ete t
o subside and the slump shall be measu ed immediately by dete mining the diffe e
nce between the height of the mould and that of the highest point of the specime
n being tested. The above ope ations shall be ca ied out at a place f ee f om v
ib ation o shock, and within a pe iod of two min afte sampling. Slump - The sl
ump measu ed shall be eco ded in te ms of millimet es of subsidence of the spec
imen du ing the test. Any slump speci-men which collapses o shea s off late all
y gives inco ect esult and if this occu s the test shall be epeated with anot
he sample. If, in the epeat test also, the specimen should shea , the slump sh
all be measu ed and the fact that the specimen shea ed, shall be eco ded. 800.2
0 Wo kability of Conc ete by Compaction Facto Test Compacting Facto Test This
clause specifies a p ocedu e fo dete mining the wo kability of conc ete, whe e
the nominal maximum size of the agg egate does not exceed 38 mm. The test is des
igned p ima ily fo use in the labo ato y, but if ci cumstances pe mit, it may a
lso be used in the field. It is mo e p ecise and sensitive than the slump test a
nd is pa ticula ly useful fo conc ete mixes of ve y low wo kability as a e no m
ally used when conc ete is to be compacted by vib ation; such conc ete may consi
stently fail to slump. P ocedu e The sample of conc ete to be tested gently in t
he uppe hoppe , using the hand scoop. Fill the hoppe with its b im and open th
e t ap doo so that the conc ete falls into the lowe hoppe . Ce tain mixes have
a tendency to stick in one o both of the hoppe s. If this occu s, the conc ete
may be helped th ough pushing the od gently into the conc ete f om the top. Du
ing this p ocess, cove the cylinde by t owels. Immediately afte the conc ete
has come to est, the cylinde shall be un-cove ed, the t ap-doo of the lowe
hoppe opened, and the conc ete allowed to fall into the cylinde . The excess of
conc ete emaining above the level of the top of the ‘cylinde shall then be cu
t off by holding a t owel in each hand, with the plane of the blades ho izontal,
and moving them simultaneously one f om each side ac oss the top of the cylinde
, at the same time keeping them p essed on the top of the cylinde . Wipe clean
the outside of the cylinde . The above ope ation shall be ca ied out at a place
f ee f om vib ation o shock. . The weight of the conc ete in the cylinde shal
l then be dete mined to the nea est 109 g. This weight shall be known as the wei
ght of pa tially compacted conc ete. The cylinde shall be efilled with conc et
e f om the same sample in laye s app oximately 5 cm deep, the laye s being heavi
ly ammed o p efe ably vib ated so as to obtain full compaction. The top su fac
e of the fully compacted conc ete shall be ca efully st uck off level with the t
op of the cylinde . Calculation The compacting facto is defined as the atio of
the weight of pa tially compacted conc ete to the weight of fully compacted con
c ete to the weight of fully compacted conc ete. It shall no mally be stated to
the nea est second decimal place ( Fo m CC – 5 ).
159
Section - 800
Wo kability of Conc ete Fo m CC – 5
Sample Identification No. : Date of Testing : Quality of Conc ete Weight of wate
(g) S.No. Specimen No. Conc ete taken f om (Place) Value of Slump Test o comp
acting facto test No. of Sample Good / Bad
Laye
Value Slump Compacting Facto
Pe missible Value 10-25 mm 0.87 + .03
Checked By
Tested by
800.22 Cu ing of Conc ete Pu pose Cu ing is the p ocess fo p eventing the loss
of moistu e f om the conc ete. P evention of moistu e is necessa y fo conc ete
to develop st ength. P ocedu e 1. 2. 3. 4. 5. Sta t cu ing immediately afte the
compaction of conc ete. Use wate which is good fo const uction (clause 600.9)
P otect the conc ete by cove ing with moist gunny bags, canvas, Hessian o simi
la mate ial. Keep all exposed su face of conc ete afte 24 hou s in a wet o da
mp condition by pounding o by cove ing with a laye of sacks, canvas, Hessian o
simila mate ial. Keep the su face wet fo a pe iod of not less than 14 days f
om the date of placing of conc ete.
160
800.23 Schmidt’s Rebound Hamme Test Pu pose Rebound hamme test is used fo ass
essing the likely comp essive st ength of conc ete with the help of suitable co
elation between ebound index and comp essive st ength. Acceptance C ite ion A
co elation should be developed by simultaneously testing the two p ope ties on
the same sample and used fo establishing acceptance c ite ion.
REBOUND HAMMER
800.24 Ult asonic Pulse Velocity Pu pose Ult asonic Pulse Velocity method is use
d to estimate the quality of in-situ conc ete.
161
Section - 800
ULTRA SONIC PULSE VELOCITY TESTER If the pulse velocity of conc ete by c oss p o
bing is 3.0 km/sec o mo e, the conc ete is of acceptable quality. If the veloci
ty is less than 3 km/sec, fu the investigations a e called fo . Method 1. Take
two t ansduce s ope ating in the f equency ange of 20 KHz to 150 KHz. Keep one
t ansduce in contact with one end of conc ete membe and the othe t ansduce w
ith the othe su face of the conc ete membe . Measu e the length L of the pole a
nd also time taken T fo the pulse to t avel this distance. Thus the ave age vel
ocity = L/T Use the following cha t to get some idea about the quality of conc e
te; howeve , co elations developed at site a e the best.
Table 800.24.1 Ult asonic Pulse Velocity and Quality of Conc ete S.No. 1. 2. 3.
4. Pulse Velocity km/sec Above 4.5 3.5 to 4.5 3.0 to 3.5 Below 3.0 Conc ete Qual
ity G ading Excellent Good Medium (Doubtful fu the investigations necessa y)
2. 3.
Refe ence IS: 13311(Pa t 1) - 1992
162
800.25 Accele ated Cu ing Test of Conc ete Pu pose No mally, the st ength of con
c ete is found out afte 7 days and 28 days. Fo some const uction activities, i
t may be too late and no need to know the st ength ea lie .
ACCELERATED CURING TANK
Tole ances Tole ances can be specified depending upon the equi ed st ength of t
he conc ete and its impo tance. Method 1. 2. 3. 4. 5. P epa e the specimen and s
to e it in moist ai of at least 90% elative humidity and at a tempe atu e of 2
7+2oC fo 23 h s + 15 minutes. Lowe the specimen, into a cu ing tank with wate
at 100 deg C and keep it totally imme sed fo 3 ½ hou s + 5 minutes. The tempe
atu e of wate shall not d op mo e than 3oC afte the specimens a e placed and s
hould etu n to boiling within 15 minutes. Afte cu ing fo 3 ½ hou s + 5 minute
s in the cu ing tank, the specimen shall be emoved f om the moulds and cooled b
y imme sing in cooling wate 27+2oC fo a pe iod of at least one hou . The co e
sponding st ength at 28 days can be found out f om the following co elation. (I
t is howeve suggested that a new specific co elation should be developed fo t
he specific conc ete used at site.) R28 = st ength at 28 days = 8.09 + 1.64 Ra W
he e Ra = Accele ated Cu ing St ength in MPa. Refe ence IS : 9013 - 1978
163
Section - 800
800.26 Pu pose
Comp essive St ength of Conc ete Cubes (150 mmx 150 mmx 150 mm) at 28 days
The tests a e equi ed to dete mine the st ength of conc ete and the efo e its s
uitability fo the job.
HAND OPERATED COMPRESSION TESTING MACHINE
MOULDS
Tole ance Limits Tole ances a e specified depending upon the impo tance of st uc
tu e, fo oads, it may be necessa y to get 80% of samples having st ength mo e
than specified. Method 1. 2. Rep esentative samples of conc ete shall be taken a
nd used fo casting cubes 15cmx15cmx15cm o cylind ical specimens of 15cm dia x
30cm long. The conc ete shall be filled into the moulds in laye s app oximately
5cm deep. It would be dist ibuted evenly and compacted eithe by vib ation o by
hand tamping. Afte the top laye has
164
been compacted, the su face of conc ete shall be finished level with the top of
the mould using a t owel; and cove ed with a glass plate to p event evapo ation.
3. The specimen shall be sto ed at site fo 24+ ½ h unde damp matting o sack.
Afte that, the samples shall be sto ed in clean wate at 27+2oC; until the tim
e of test. The ends of all cylind ical specimens that a e not plane within 0.05
mm shall be capped. Just p io to testing, the cylind ical specimen shall be cap
ped with sulphu mixtu e comp ising 3 pa ts sulphu to 1 pa t of ine t fille su
ch as fi e clay. Specimen shall be tested immediately on emoval f om wate and
while they a e still in wet condition. The bea ing su face of the testing specim
en shall be wiped clean and any loose mate ial emoved f om the su face. In the
case of cubes, the specimen shall be placed in the machine in such a manne that
the load cube as cast, that is, not to the top and bottom. Align the axis of th
e specimen with the steel platen, do not use any packing. The load shall be appl
ied slowly without shock and inc eased continuously at a ate of app oximately 1
40 kg/sq.cm/min until the esistance of the specimen to the inc eased load b eak
s down and no g eate load can be sustained. The maximum load applied to the spe
cimen shall the be eco ded and any unusual featu es noted at the time of failu
e b ought out in the epo t. P esent the esults in the Fo m of CC– 6
4. 5. 6.
7. 8.
9.
Comp essive St ength of Conc ete Cubes Fo m CC-6
Sample Identification No.: Date of Testing : Tempe atu e and Humidity Mix P opo
tion by weight Rate of Loading Wo kability S.No. Specimen No. Plan A ea of cube
mould 150 mm x 150 mm Age (Days) 7 and 28 days Minimum No. of Samples = 3 fo ea
ch test 27 + 2oC, Relative Humidity = 90% As specified o as pe Mix Design IRC
:44/IS:10262-1982 140 kg/sqcm/minute As pe the equi ement o Slump / Compactio
n Facto Maximum Applied Load just befo e failu e at 7 and 28 days (kg) Wf Comp
essive St ength (kg/cm 2) Wf Sa = --------------Ap 7 days 28 days
Ap 1 2 3
Ave age flexu al st ength of conc ete sample (kg/cm2) at 7 and 28 days nea est t
o 1 kg/sqcm
165
Section - 800
Laye
Value
Pe missible Limit Specified comp essive st ength of conc ete sample (kg/cm2) at
7 and 28 days Individual Va iation = + 15% of the ave age
Checked by
Tested by
Refe ence IS: 516 – 1959 800.27 Pu pose To dete mine the Flexu al St ength of Co
nc ete, which comes into play when a oad slab with inadequate subg ade suppo t
is subjected to wheel loads and / o the e a e volume changes due to tempe atu e
/ sh inking. P ocedu e Test specimens shall be p epa ed by moulding conc ete to
a beam section, cu ing and sto ing in acco dance with standa d p ocedu e. The s
ection of the beam shall be squa e of 100 mm o 150 mm. The ove all length of th
e specimen shall be 4d to 5d. The atio of d to the maximum pa ticle size of agg
egate shall be not less than th ee. Ci cula olle s manufactu ed out of steel
having c oss section with diamet e 20 to 40 mm will be used fo p oviding suppo
t and loading points to the specimens. The length of the olle s shall be at lea
st 10 mm mo e than the width of the test specimen. A total of fou olle s shall
be used, th ee out of which shall be capable of otating along thei own axes.
The distance between the oute olle s (i.e span) shall be 3d and the distance b
etween the inne olle s shall be d. The inne olle s shall be equally spaced b
etween the oute olle s, such that the enti e system is systematic. The specime
n sto ed in wate shall be tested immediately on emoval f om wate ; whilst they
a e still wet. The test specimen shall be placed in the machine co ectly cente
ed with the longitudinal axis of the specimen at ight angles to the olle s. F
o moulded specimens, the mould filling di ection shall be no mal to the di ecti
on of loading. The load shall be applied slowly without shock at such a ate as
to inc ease the st ess at a ate of .06 + .04 N/ mm2 pe second. Flexu al St eng
th of Conc ete
166
FLEXURE TEST APPARATUS
The Flexu al St ength is given by Fct F x –ι = --------------------d1 x d22
Where F s the break ng load ( n N), d1 and d 2 are the lateral d mens ons of th
e cross sect on n mm. –ι s the d stance between support ng rollers ( n mm) Pre
sent the results n Form CC-7
167
Sect on - 800
Flexural Strength of Concrete Beam Form CC-7
Sample Ident f cat on No.: Date of Test ng : Temperature and Hum d ty M x Propor
t on by we ght Rate of Load ng Workab l ty S.No. Spec men No. S ze of beam mould
10x10x50 L –40cm B – 10cm D – 10cm L – Effect ve Length B – Breadth D - Depth Ag
e (Days) 7 and 28 days M n mum No. of Samples = 3 for each test 27 + 2oC, Relat
ve Hum d ty = 90% As spec f ed or as per M x Des gn IRC :44/IS:10262-1982 7 kg/s
qcm/m nute or 100 kg/m nute As per the requ rement or Slump / Compact on Factor
Max mum Appl ed Load just before fa lure at 7 and 28 days (at two po nts) as per
IS : 516-1959 (kg) W Flexural Strength (kg/cm2) (Wf L/BD2) f a > 11cm (3Wf L/B
D2) f a less than 13.3cm but greater than 11cm a= equals the d stance between t
he l ne of fracture and the nearest support measured on central l ne of the tens
le s de of the spec men 7 days 28 days
1 2 3 Average flexural strength of concrete sample (kg/cm2) at 7 and 28 days Nea
rest to 0.5 kg/sqcm Spec f ed flexural strength of concrete sample (kg/cm2 ) at
7 and 28 days
Layer
Value
Perm ss ble L m t Spec f ed flexural strength of concrete sample (kg/cm2) at 7 a
nd 28 days Ind v dual Var at on = + 15% of the average The flexural strength of
` concrete for pavement qual ty concrete or roller compacted concrete for wear n
g course shall not be less than 40 kg/cm2
Checked by Reference : IS : 516 - 1959
Tested by
168
Qual ty Assurance Handbook for Rural Roads
SECTION 900 FORMWORK AND SURFACE FINISH FOR STRUCTURES
169
901 Mater als and Des gn
All mater als, des gn, erect on and removal of formwork shall conform to IRC: 87
“Gu del nes for Des gn and Erect on of Falsework for Road Br dges” and these Sp
ec f cat ons. The forms shall be constructed w th metal or t mber. The Contracto
r shall subm t the des gn and draw ngs of complete formwork ( .e. the formwork a
s well as ts supports) for the approval of the Eng neer before any erect on s
taken up.
902 CONSTRUCTION OPERATIONS
Forms shall be mortar-t ght and shall be made suff c ently r g d by the use of t
es and brac ngs to prevent any d splacement or sagg ng between supports. They s
hall be strong enough to w thstand all pressures, ramm ng and v brat on, w thout
deflect on from the prescr bed l nes occurr ng dur ng and after plac ng the con
crete. The ns de surfaces of forms shall be coated w th a release agent suppl e
d by an approved manufacturer or a mater al approved by the Eng neer to prevent
adhes on of concrete to the formwork. Release agents shall be appl ed str ctly
n accordance w th the nstruct ons of the manufacturer and shall not be allowed
to come n contact w th the re nforc ng steel. The workmansh p of formwork shall
be strong and jo nts shall be leak-proof.
903 REMOVAL OF FORMWORK
The scheme for removal of formwork ( .e. de-shutter ng and decenter ng) shall be
planned n advance and furn shed to the Eng neer for scrut ny and approval Wher
e not approved, the t me of removal of formwork (when Portland Cement s used w
thout any adm xtures at an amb ent temperatures exceed ng 10 0C) shall as under
(a) (b) (c) (d) (e) Walls, p ers, abutments, columns and vert cal faces of struc
tural members Soff ts of slabs (w th props left under) Props (left under slabs)
Soff t of g rders (w th props left under) Props (left under g rders) : : : : : 1
2 to 48 hours as shall be dec ded by the Eng neer 3 days 14 days 7 days 21 days
171
SECTION 1000 STEEL REINFORCEMENT
173
1000 STEEL REINFORCEMENT
Sec No. A) 1000.1 1000.2 1000.3 1000.4 B) 1000.5 1000.6 Mater al Grade, Percenta
ge Elongat on and Ult mate Tens le Strength of Steel P tch of the R bs and Nom n
al D ameter Bend ng and Plac ng of Re nforcement Spl c ng, Weld ng and Tolerance
s Construct on & Workmansh p Rout ne Inspect on and Test ng Tolerances and Gener
al Workmansh p 1000.5 As spec f ed 1000.1 1000.2 As spec f ed As spec f ed T tle
Test Ref No.
A
Mater als
1000.1 Grade, Percentage Elongat on and Ult mate Strength of Steel The max mum l
oad reached n a tens le test d v ded by the effect ve cross- sect onal area of
the gauge length port on of the test p ece. Also termed as ult mate tens le stre
ngth. Y eld Stress Stress (that s load per un t cross sect onal area) at wh ch
elongat on f rst occurs n the test p ece w thout ncreas ng the load dur ng ten
s le test. 1000.2 P tch of the R bs and Nom nal D ameter of Bars Deformed steel
bars for use as re nforcement n concrete are ava lable n three strength grades
as Fe 415 (N/mm2), Fe 500 (N/mm2) and Fe550 (N/mm2)
175
Sect on - 1000
Normal S ze D ametres The r s zes are:
Nom nal S ze (D ametre) (mm) 4 5 6 7 8 10 12 16 18 20 22 25 28 32 36 40 45 50 Cr
oss Sect onal Area (mm2) 12.6 19.6 28.3 38.5 50.3 78.6 113.1 201.2 254.6 314.3 3
80.3 491.1 616.0 804.6 1018.3 1257.2 1591.1 1964.3 Mass Per Run (kg) 0.099 0.154
0.222 0.302 0.395 0.617 0.888 1.58 2.00 2.467 2.985 3.855 4.836 6.31 7.99 9.869
12.490 15.424
Note : - The nom nal s ze (d ameter) of a deformed bar s equal to that of a pla
n round bar hav ng the same mass per meter length. Tolerances On spec f ed leng
ths On m n mum length + 75 mm 25 mm 0 mm + 50 mm
Nom nal Mass - For the purpose of check ng the nom nal mass, the dens ty of stee
l shall be taken as 0.00785 kg/mm 2 of cross sect onal area per meter run. Mecha
n cal Propert es of H gh Strength Deformed Bars and W res Property ( ) ( ) 0.2
percent proof stress/ y eld stress, M n (N/mm2) Elongat on, percent, M n, (on ga
uge length of 5.65 √A, where A s the cross sect onal area)
176
Fe415 415.0 14.5
Fe500 500.0 12.0
Fe550 550.0 8.0
( )
Tens le strength, M n
10 per cent more than the actual 0.2 percent proof stress but not less than 485.
0 N/mm 2
8 percent more than the actual 0.2 percent proof stress but not less than 545.0
N/mm 2
6 percent more than the actual 0.2 percent proof stress but not less than 585.0
N/mm2
Chem cal Compos t on Const tuent Fe 415 Carbon Sulphur Phosphorus Sulphur and Ph
osphorus 0.30 0.060 0.060 0.11 Percent, Max mum Fe 500 0.30 0.055 0.055 0.105 Fe
550 0.30 0.055 0.050 0.10
H gh Tens le Steel Bars used n Prestressed Concrete H gh tens le steel bars (al
loy steel hav ng tens le strength of not less than 980 N/mm2) are used n prestr
essed concrete. Freedom from Defects – F n shed bars shall be sound and free fro
m spl ts, harmful surface flaws, rough, jagged and mperfect edges, and other de
fects. Nom nal S zes – 10, 12, 16, 20, 22, 25, 28 and 32 mm d ameter Tolerances
a) b) Nom nal s ze + 0.50 mm for bars upto 25 mm + 0.6 mm for bars above 25 mm M
ass + 5 percent (we ght calculated on the bas s that h gh tens le steel we ghs 0
.785 kg/cm2 of cross sect onal area per meter run) for bars upto 16mm. + 3 perce
nt percent (we ght calculated on the bas s that h gh tens le steel we ghs 0.785
kg/cm2 of cross sect onal area per meter run) for bars above 16mm. Phys cal Requ
rement 1. 2. 3. Tens le Strength, M n – 980 N/mm2 Proof Stress – Not less than
80 percent of the m n mum spec f ed tens le strength Elongat on at Rupture on a
gauge length 5.65 √A, where A s the area of cross sect on – M n 10 percent.
Relaxat on – Relaxat on of stress shall not exceed 49 N/mm2 at the end of 1000 h
.
177
Sect on - 1000
B
Construct on & Workmansh p
1000.5 Rout ne Inspect on and Test ng As per IS : 1786-1985, all steel shall be
subject to rout ne nspect on and test ng by the manufacturer or suppl er n acc
ordance w th th s standard shall be kept by the manufacturer or the suppl er. Th
e records shall be ava lable for nspect on by the purchaser or h s representat
ve. In the case of mater al del vered to a suppl er, the manufacturer shall supp
ly a cert f cate conta n ng the results of all the requ red tests on samples tak
en from the del vered mater al. Such cert f cates should be obta ned by the qual
ty control personnel. However, n case of any doubt, tests may be performed at
a standard laboratory. References IS : IS : 1786 – 1985 2090 - 1983
178
SECTION 1100 PIPE CULVERTS
179
1100 PIPE CULVERTS
Sec No. A) 1100.1 1100.2 1100.3 1100.4 1100.5 1100.6 1100.7 1100.8 1100.9 1100.1
0 B) 1100.11 1100.12 1100.13 1100.14 1100.15 1100.16 Mater als Colour and D mens
onal Check of Br cks Water Absorpt on of Br cks Efflorescence of Br cks Compres
s ve Strength of Br cks Shape and D mens ons of Stones Water Absorpt on of Stone
s Dress ng of Stones D mens ons of Concrete P pes Manufactur ng Defects and Tole
rances Three Edge Bear ng Test Construct on & Workmansh p He ght, Bond and Vert
cal ty by Plumb Bob Cons stency of Cement Mortar Compress ve Strength of Mortar
Th ckness of Jo nts n General Br ck Work Invert Level, Long tud nal Grad ent Me
asurements of Length, Internal D ameter, Barrel Th ckness 700.14 600.10 600.12 6
00.13 Us ng Survey ng Equ pment 1100.8 600.1 600.2 600.3 600.4 700.1 700.2 700.3
1100.8 As per IS 458 1100.10 T tle Test Ref No.
A Mater als
1100.8 D mens ons of Concrete P pes (Measurement of Length, Internal D ameter, B
arrel Th ckness) Purpose To check whether d mens ons are w th n tolerance l m ts
. Procedure A vern er cal per w th a least count of 0.1 mm shall be used. The me
asured d mens ons should be w th n the tolerances spec f ed n IS 458. Typ cal p
erm tted tolerances for d ameter and th ckness are, ( ) ( ) P pe d ameter over
600 mm and upto and nclud ng 1200 mm s +/- 7 mm. Wall th ckness over 80 mm and
upto and nclud ng 95 mm s +/- 6 mm
181
Sect on - 1100
1100.10 Purpose
Three Edge Bear ng Test
Th s test s carr ed out on both re nforced concrete and prestressed concrete p
pes and of pressure and non pressure types to evaluate whether t can take the l
oad when put n ts place. Procedure Three edge bear ng test shall be performed
when the p pe s surface dry. The test spec men shall be tested n a mach ne so
des gned that a crush ng force may be exerted n a true vert cal plane through o
ne d ameter and extend ng the full length of the barrel of the p pe but exclud n
g the sockets, f any. Any mechan cal or hand powered dev ce may be used n wh c
h the head that appl es the load moves at such a speed as to ncrease the load a
t a un form rate of approx mately 20 percent of the expected crush ng load per l
near meter per m n. The load ng dev ce shall be cal brated w th n an accuracy o
f +2 percent. The test ng mach ne used for the load tests should produce a un fo
rm deflect on throughout the length of the p pe. The lower bear ng block shall c
ons st of two hardwood or hard rubber str ps fastened to a wooden or steel beam
or d rect to a concrete base, wh ch shall prov de suff c ent r g d ty to perm t
appl cat on of max mum load w thout apprec able deflect on. The upper bear ng sh
all be a r g d hardwood block or a block w th hard rubber fac ng at least 150 mm
x 150 mm n cross sect on. After plac ng the spec men n the mach ne on the bot
tom str ps, the top bear ng shall be symmetr cally al gned n the test ng mach n
e. Load shall be appl ed at the rate nd cated above unt l e ther the format on
of 0.25 mm w de crack or ult mate strength load, as may be spec f ed, has been r
eached. The 0.25 mm crack load s the max mum load appl ed to the p pe before a
crack hav ng a w dth of 0.25 mm measured at close ntervals, occurs throughout a
length of 300 mm or more. The crack shall be cons dered 0.25 mm n w dth when t
he po nt of the measur ng gauge penetrates 1.5 mm at close ntervals throughout
the spec f ed d stance of 300 mm. The ult mate load w ll be reached when the p p
e w ll susta n no greater load.
182
½ L1
Barrel of P pe Socket Beyond Bear ng L L1
Lower Bear ng R 13 mm
Lower Bear ng At Least 150 x 150 mm
Space Between Two Str ps Not More Than 1/12 of P pe D a But not Less Than 25 mm
Enlarged Deta l of Lower Bear ng
F gure 11. Three Edge Bear ngF gure 11. Three Edge Bear ng
The crush ng strength n Newton per l near meter of p pe shall be calculated by
d v d ng the total load on the spec men by the nom nal lay ng length. Effect ve
length of the p pe shall be taken as the nom nal lay ng length of the spec men.
Reference: IS : 3597 – 1998.
183
SECTION 1200 RCC SLAB CULVERTS AND MINOR BRIDGES
185
1200 RCC SLAB CULVERTS AND MINOR BRIDGES
Sec No. A) 1200.1 1200.2 1200.3 1200.4 1200.5 1200.6 1200.7 B) 1200.8 1200.9 120
0.10 1200.11 1200.12 1200.13 1200.14 1200.15 1200.16 Mater als Tests on Br cks T
ests on Stone Tests on Concrete Ingred ents Tests on Water Tests on Steel Re nfo
rcement Cert f cat on of Compos t on of steel by the Manufacturer Cert f cat on
of Mechan cal Propert es of steel by the Manufacturer Construct on & Workmansh p
Tolerances n Var ous D mens ons and Levels Re nforcement Cage Workab l ty of C
oncrete Compact on of Concrete Cur ng of Concrete Compress ve Strength of Concre
te Flexural Strength of Concrete Tests on Sealants (Poly Sulphate or B tum nous)
Test Cert f cates from the Manufacturers for Elastomer c Bear ngs, Expans on Jo
nts, Plast c sers 800.26 800.27 As spec f ed As spec f ed Us ng Level,Stra ght
Edge and Camber Board etc. 600 700 800 600.8 1000 As spec f ed As spec f ed T tl
e Test Ref No.
187
SECTION 1300 PROTECTION WORKS AND DRAINAGE
189
1300 PROTECTION WORKS AND DRAINAGE
Sec No. A) 1300.1 1300.2 1300.3 1300.4 B) 1300.5 1300.6 1300.7 1300.8 Mater als
Br ck Masonry Stone Masonry Concrete for Structures W re Crates (S ze and Mesh S
ze) Construct on & Workmansh p Br ck Masonry Stone Masonry Tests on Mortar for
Jo nt Cross Sect ons, Grad ent, General Workmansh p 600 700 600 Levels, stra ght
edge, measur ng tape,v sual 600 700 800 As spec f ed T tle Test Ref No.
191
SECTION 1400 CEMENT CONCRETE CAUSEWAY
193
1400 CEMENT CONCRETE CAUSEWAY
Sec No. A) 1400.1 1400.2 1400.3 1400.4 B) 1400.5 1400.6 1400.7 1400.8 1400.9 140
0.10 1400.11 1400.12 Mater als Tests on Br cks Tests on Stones Tests Cement Conc
rete Ingrd ents Tests on Pavement Mater als GSB,WBM,CC Construct on & Workmansh
p Workab l ty of Concrete Cur ng of Concrete Strength of Concrete Formwork Cemen
t Concrete Pavement P pes Bear ngs, Expans on Jo nts Measurement of D mens ons a
nd Level and Jo nts Th ckness 800 800 800 900 1500 1100 Maufacturers Spec f cat
ons Levels,measur ng tape, stra ght edge,v sual 600 700 800 400,800,1500 T tle T
est Ref No.
195
SECTION 1500 PLAIN CEMENT CONCRETE PAVEMENT
197
1501 PLAIN CEMENT CONCRETE PAVEMENTS
Sec No. A) 1501.1 1501.2 1501.3 1501.4 1501.5 1501.6 1501.7 1501.8 1501.9 1501.1
0 1501.11 1501.12 B) 1501.13 1501.14 1501.15 1501.16 1501.17 1501.18 1501.19 150
1.20 1501.21 1501.22 1501.23 1501.24 1501.25 1501.26 1501.27 1501.28 1501.29 Mat
er als Cement F ne Aggregate Coarse Aggregate Su tab l ty of Water for Use n Co
ncrete Adm xtures Dowel Bars Premoulded Jo nt F ller Jo nt Seal ng Compound Tool
s Plants and Equ pment Concrete M x Granular, Sub-base Tr al Length Construct on
& Workmansh p Sub-grade and Sub-base Gradat on & Mo sture Content of Aggregate
Concrete Workab l ty Strength of Concrete Stra ghtness of s de forms S ze, Spac
ng, Parallel ng of Dowel Bars and Locat ons of D fferent Jo nts Batch ng and M x
ng of Mater als Hot / Cold Weather Concret ng and Compact on Compact on Equ pme
nt (Needle, Screed and Plate V brators Separat on Membrane Surface Level Surface
Regular ty W dth of Pavement and Pos t on of Pav ng Edges Pavement Th ckness Al
gnment of Jo nts Depth of Dowel Bars Textur ng and Edg ng 400 401.1 800.15 800.
17 900 As spec f ed 1501.19 1501.20 1501.21 1501.22 301.10 301.11 As spec f ed A
s spec f ed As spec f ed As spec f ed As spec f ed 800.1 to 800.3 307.10 800 600
.8 1501.5 1501.6 1501.7 1501.8 1501.9 1501.10 401 1501.12 T tle Test Ref No.
199
Sect on - 1500
1501.5 Adm xtures Purpose Adm xtures are used to reduce the water content w thou
t affect ng ts workab l ty. Procedure The opt mum quant ty of adm xtures s det
erm ned by tr al tests. The mater als and the test procedures should conform to
IS:6925 and IS : 9103. 1501.6 Dowel Bars Purpose Dowel bars are prov ded n the
jo nts to perm t movements and transfer of stresses. Procedure Pla n m ld steel
bars of 25 mm d ameter conform ng to IS : 432 (Part 1) hav ng m n mum y eld stre
ngth 240 N/mm 2 shall be used as dowel bars. These shall be free from o l, d rt,
loose rust, scale, rregular t es and burr ng restr ct ng sl ppage n the concr
ete. 1501.7 Premoulded Jo nt F ller Purpose Jo nt f llers are used to f ll up th
e jo nts. Procedure B tumen mpregnated f ller board, premoulded synthet c jo nt
f ller board for expans on jo nts shall be 20mm th ck w th a tolerance of +1.5m
m and of a f rm compress ble mater als n conform ty of the requ rements of IS :
1838. 1501.8 Jo nt Seal ng Compound Purpose These compounds are used for seal n
g the jo nts. Procedure Jo nt seal ng compound shall be hot poured seal ng compo
und / type hav ng flex b l ty, res stance to age harden ng and durab l ty. It sh
all conform to IS : 1834. 1501.9 Tools, Plants and Equ pment Purpose It s mpor
tant to ensure that proper tools, plants and equ pment are used for carry ng out
the work. Procedure
200
It w ll be ensured that the tools, plants and equ pment used for construct on wo
rk are as spec f ed n the Contract. 1501.10 Concrete M x The Concrete M x shall
conform to the requ rements spec f ed n the Contract documents and shall be te
sted n accordance w th the procedure and tests descr bed n Sect on 800. 1501.1
2 Tr al Length The tr al length w ll show the mater als, equ pment and construct
on proposed to be used for the ma n construct on. It w ll be checked whether th
e tr al meets w th the spec f cat ons. Four full depth cores of at least 100mm (
2 cores for each day’s work) at 28 days w ll be cut by core cutt ng mach ne. Th
e cores shall be tested as per IS : 516. The tr al length shall sat sfy surface
levels and regular ty; and demonstrate that the jo nt-form ng methodology s sat
sfactory. The hardened concrete shall be cut over 3m w dth and reversed to nsp
ect the bottom surface for any segregat on tak ng place. 1501.19 Batch ng & M x
ng of Mater als Purpose The strength and durab l ty of concrete depends upon the
mater als, the r proport ons, and proper m x ng. Procedure It must be ensured t
hat all batch ng s done by we ght. Volume batch ng of aggregates may be perm tt
ed as a spec al case n small projects w th the approval of the Eng neer. The sy
stem of we gh batch ng w ll be checked and ts cal brat on carr ed out from t me
to t me. 1501.20 Hot / Cold Weather Concrete nclud ng Compact on Purpose Prope
r precaut ons must be taken, f concret ng s to be done n extreme weather cond
t ons. Procedure No concret ng shall be done when the concrete temperature s a
bove 30 oC measured at the po nt of plac ng and the amb ent temperature s more
than 35 oC. S m larly n cold weather, no concret ng shall be done when the conc
rete temperature s below 5oC and the temperature s descend ng. 1501.21 Compact
on Equ pment (Needle, Screed and Plate V brators) Purpose For concrete to devel
op ts des red propert es, t s essent al that ts compact on s done properly.
201
Sect on - 1500
Procedure The compact on of pavement s normally ach eved by a v brat ng screed
supplemented by two nternal v brators. V brat ng screed may be supplemented by
portable needle v brator. It may be ensured that proper compact on equ pment s
prov ded as per spec f cat ons and that the compact on act v ty s carr ed out f
or the spec f ed durat on. 1501.22 Separat on Membrane (Th ckness and Lay ng) Pu
rpose A separat on membrane usually of polythene sheet, s prov ded between the
concrete slab and the subbase. Procedure It must be checked whether the separat
on membrane to be prov ded s as per spec f cat ons, part cularly w th regard to
ts th ckness and that t s la d w thout creases. 1501.25 Al gnment of Jo nts
Purpose The al gnment of jo nts should be as per spec f cat ons. Procedure The a
l gnment of jo nts shall be checked at the end of each days work and made sure t
hat t s as per spec f cat ons. 1501.26 Depth of Dowel Bars Purpose Dowel bars
are prov ded n jo nts. Procedure The depth at wh ch dowel bars are prov ded w l
l be as per spec f cat ons and draw ngs. 1501.27 Textur ng and Edg ng Purpose Th
e pavement surface s g ven a texture before t hardens so that s prevents sk d
d ng. Procedure Just before the concrete becomes non-plast c, the surface shall
be textured w th an approved long handled steel or f bre brush conform ng to the
st pulat ons la d down n IRC : 43. After belt ng and / or textur ng has been c
ompleted, but before the concrete has taken ts n t al set, the edges of the sl
ab shall be carefully f n shed so as to leave the pavement edges smooth and true
to l ne. The float ng, f n sh ng and edg ng etc. shall be done us ng a wooden /
steel br dge w th legs straddled apart so as not to touch the pavement.
202
1502
Sec No. A) 1502.1 1502.2 1502.3 1502.4 1502.5 1502.6 1502.7 1502.8 1502.9 1502.1
0 1502.11 1502.12 1502.13 B) 1502.14 1502.15 1502.16 1502.17 1502.18 1502.19 150
2.20 1502.21 1502.22 1502.23 1502.24 1502.25 1502.26 1502.27 1502.28 1502.29 150
2.30
Roller Compacted Concrete Pavement
T tle Mater als Tests on Cement Tests on F ne Aggregate Tests on Coarse Aggregat
e Tests on Flyash Su tab l ty of Water for Concrete Adm xtures Dowel Bars Premou
lded Jo nt F ller Jo nt Seal ng Compound Tools, Plant and Equ pment Concrete M x
Des gn Granular Subbase Tr al Length Construct on & Workmansh p Subgrade and Su
b-base Grad ng and Mo sture Content of Aggregates Batch ng and M x ng Workab l t
y of Concrete Compress ve Strength of Concrete Stra ghtness of S de Forms Transv
erse Contract on Jo nts (W dth and Depth) In-s tu Dens ty by Sand Replacement Me
thod Compact on and Surface Correct on Surface Levels Surface Regular ty W dth o
f Pavement Pavement Th ckness Cumulat ve Length of Cracks Core Dens ty Performan
ce of Tr al Length Textur ng and Edg ng 400 401.1 1501.19 800.15 800.17 900 1501
.27 308.1(a) 1501.21 / 1501.29 301.10 301.11 1501.25 1501.26 Measur ng Steel Tap
e 401.9 1501.12 1501.29 800.1 to 800.3 800.12 to 800.16 400 409 600.8 1501.5 150
1.6 1501.7 1501.8 1501.9 1501.10 401 1501.12 Test Ref No.
203
Sect on - 1500
1503
Sec No. A) 1503.1 1503.2 1503.3 1503.4 1503.5 1503.6 1503.7 1503.8 1503.9 1503.1
0 1503.11 1503.12 1503.13 B) 1503.14 1503.15 1503.16 1503.17 1503.18 1503.19 150
3.20 1503.21 1503.22 1503.23 1503.24
RECTANGULAR CONCRETE BLOCK PAVEMENT
T tle Mater als Tests on Cement Tests on F ne Aggregates Tests on Coarse Aggrega
tes Tests on Flyash Su tab l ty of Water for Construct on Adm xtures Jo nt Deta
ls, Pattern of Lay ng and End Restra nts Tools, Plants and Equ pment M x Des gn
for Concrete Subgrade and Subbase Method of Manufactur ng and Compact ng Blocks
Tr al Length before commencement of regular work Grad ng of Bedd ng and Jo nt F
ll ng Sand Construct on & Workmansh p Subgrade and Sub-base Compress ve Strength
of Concrete Pattern of Lay ng of Blocks and End Restra nts Earthen Shoulders (w
dth and camber) W dth of Jo nts between blocks Hor zontal Al gnment Surface Lev
els Surface Regular ty D mens ons of Blocks (s ze and th ckness) Performance of
Tr al Length General Workmansh p 400 800.17 To check f t s as per draw ng 150
1.25 1501.18 301.9 301.10 301.11 To check f t s as per spec f cat ons 1501.12
To check the qual ty of construct on n general 800.1 to 800.3 800.12 to 800.16
400 409 600.8 1501.5 1501.27 1501.9 1501.10 400 As per the Spec f cat ons 1501.
12 401.1 Test Ref No.
204
1504
Sec No. A) 1504.1 1504.2 1504.3 1504.4 1504.5 1504.6 1504.7 1504.8 1504.9 1504.1
0 1504.11 1504.12 1504.13 1504.14 B) 1504.15 1504.16 1504.17 1504.18 1504.19 150
4.20 1504.21 1504.22 1504.23
INTERLOCKING CONCRETE BLOCK PAVEMENT
T tle Mater als Tests on Cement Tests on F ne Aggregates Tests on Coarse Aggrgat
es Tests on Flyash Su tab l ty of Water for Construct on Adm xtures Jo nt Deta l
s,Pattern of Lay ng and End Restra nts Tools, Plants and Equ pment M x des gn fo
r Concrete Base Course Method of Manufactur ng and Compact ng Blocks Tr al Lengt
h 30m before commencement of regular work Block s ze and th ckness Water Absorpt
on and Compress ve Strength of Blocks Construct on & Workmansh p Subgrade and S
ub-base D mens ons and Tolerances of Pav ng Blocks Compress ve Strength of Concr
ete Blocks Pav ng Pattern of Blocks and End Restra nts Hor zontal Al gnment Surf
ace Levels Surface Regular ty Performance of Tr al Length General Workmansh p 40
0 To check f t s as per spec f cat ons 800.17 To check f t s as per spec f
cat ons 301.9 301.10 301.11 1501.12 Qual ty of work n general 800.1 to 800.3 8
00.12 to 800.16 400 409 600.8 1501.5 1501.27 1501.9 1501.10 400 As per Spec f ca
t ons 1501.12 To check f t s as per spec f cat ons 307.23 / 800.17 Test Ref N
o.
205
SECTION 1600 HILL ROAD CONSTRUCTION
207
1600 HILL ROAD CONSTRUCTION
Sec No. A) Mater als Tests on Stones 1600.1 1600.2 Compress ve Strength of Stone
Water Absorpt on of Stones Tests on Cement 1600.3 1600.4 1600.5 Compress ve Str
ength of Cement F neness of Cement Sett ng T me of Cement Tests on Sand 1600.6 G
ra n S ze Analys s of Sand / Stone Dust Tests on Coarse Aggregates 1600.7 1600.8
1600.9 1600.10 1600.11 1600.12 1600.13 Flak ness Index of Coarse Aggregates Del
eter ous Content and Organ c Matter Spec f c Grav ty, Dens ty, Vo ds and Absorpt
on Crush ng Strength Aggregate Impact Value Soundness Alkal Aggregate React v
ty Tests for Su tab l ty of Water 1600.14 Su tab l ty of Water for Construct on
Tests on Steel 1600.15 1600.16 1600.17 B) 1600.18 1600.19 1600.20 1600.21 1600.2
2 1600.23 1600.24 1600.25 1600.26 1600.27 1600.28 Character st c Strength of Ste
el Modulus of Elast c ty of Steel Ult mate Tens le Strength and Elongat on Const
ruct on & Workmansh p Degree of Compact on Workab l ty of Concrete by Slump Test
Compress ve Strength of Concrete Flexural Strength of Concrete Hor zontal Al gn
ment Surface Levels Surface Regular ty Earthworks Granular Sub base and Base and
B tum nous work Cement Concrete Pavements, Blocks etc. Cross Dra nage Works 301
.8 (a) 800.19 800.26 800.27 301.9 301.10 301.11 300 400,500 1500 600,800,1400 10
00.1 1000.2 1000.3 600.8 800.8 401.5 402.5,402.6 800.11 402.3 800.13 800.12 800.
3 409.1 800.1 600.12 700.2 T tle Test Ref No.
209
SECTION 1700 TRAFFIC SIGNS AND MARKINGS
211
1700 TRAFFIC SIGNS AND MARKINGS
Sec No. A) Mater als Unless nd cated otherw se, the mater als w ll be as per th
e follow ng spec f cat ons: 1700.1 1700.2 1700.3 1700.4 1700.5 1705.6 1705.7 170
5.8 Colour, Conf gurat on, S ze, Locat on and D mens ons Concrete Re nforc ng St
eel Bolts, Nuts and Washers MS Sheets, Plates and Supports Reflector sed Pa nt N
on Reflector sed Pa nt Pa nts for Road Mark ngs As per IRC 67 Sect on 801 As per
IS : 1786 As per IS : 1367 As per IS : 2062 As per IS : 5 As per IS : 164 As pe
r IS : 164 T tle Test Ref No.
213
SECTION 1900 MAINTENANCE
215
1900 MAINTENANCE 1901, 1902, 1903, 1907 & 1914 Ma ntenance of Earthworks and Dra
ns
Sec No. A) 1900.1 1900.2 1900.3 B) 1900.4 1900.5 1900.6 Mater als So ls 301, 302
, 303 T tle Test Ref No.
Stones 700 Br cks, Cement, Mortar Construct on & Workmansh p Hor zontal Al gnmen
t Surface Levels Surface Regular ty 301.9 301.10 301.11 600
1904 Ma ntenance of B tumen Raods
Sec No. A) 1904.1 1904.2 B) 1904.3 1904.4 1904.5 Mater als B tum nous Mater als
Granular Mater als / Aggregates Construct on & Workmansh p Hor zontal Al gnment
Surface Levels Surface Regular ty 301.9 301.10 301.11 500 400 T tle Test Ref No.
1905 Ma ntenance of Gravel Roads
Sec No. A) 1905.1 B) 1905.2 1905.3 1905.4 Mater als Gravels / So l Aggregates Co
nstruct on & Workmansh p Hor zontal Al gnment Surface Levels Surface Regular ty
301.9 301.10 301.11 402 T tle Test Ref No.
217
Sect on - 1900
1906 Ma ntenance of WBM Roads
Sec No. A) 1906.1 B) 1906.2 1906.3 1906.4 Mater als WBM 405 T tle Test Ref No.
Construct on & Workmansh p Hor zontal Al gnment Surface Levels Surface Regular t
y 301.9 301.10 301.11
1908 Ma ntenance of Culverts and Small Br dges
Sec No. A) 1908.1 B) 1908.2 1908.3 1908.3 Mater als Mater als for Culverts and S
mall Br dges Construct on & Workmansh p Hor zontal Al gnment Surface Levels Surf
ace Regular ty 301.9 301.10 301.11 1200 T tle Test Ref No.
1909 Ma ntenance of Causeways
Sec No. A) 1909.1 B) 1909.2 1909.3 1909.4 Mater als Mater als for Causeways Cons
truct on & Workmansh p Hor zontal Al gnment Surface Levels Surface Regular ty 30
1.9 301.10 301.11 1400 T tle Test Ref No.
218
1910Ma ntenance of Road S gns
Sec No. A) 1910.1 Mater als Mater als for Road S gns 1700 T tle Test Ref No.
1911, 1912, 1913, 1915 Ma ntenance of Mark ngs and Appurtenances
Sec No. A) 1911.1 Mater als Mater als for Mark ngs and Appurtenances 1700 T tle
Test Ref No.
219
Append x -1
LIST OF INDIAN STANDARDS REFERRED TO IN THE HANDBOOK
Sect on 300 EARTHWORKS Tests on So l 1 2 3 4 5 6 7 8 9 10 11 12 Preparat on of d
ry so l samples for var ous tests IS : 2720 (Part 1) – 1983 Determ nat on of Wat
er Content IS : 2720 (Part 2) – 1973 (Second Rev s on) Gra n S ze Analys s IS :
2720 (Part 4) – 1985 (Second Rev s on) Determ nat on of L qu d L m t and Plast c
L m t IS: 2720 (Part 5) – 1985 (Second Rev s on) Determ nat on of Water Content
– dry dens ty relat onsh p us ng l ght compact on IS : 2720 (Part 7) – 1980 (Se
cond Rev s on) Determ nat on of Water Content – dry dens ty relat onsh p us ng h
eavy compact on IS : 2720 (Part 8) – 1983 (Second Rev s on) Laboratory Determ na
t on of CBR IS : 2720 (Part 16) – 1987 Determ nat on of Total Soluble Sol ds IS
: 2720 (Part 21) – 1965 Determ nat on of Organ c Content IS : 2720 (Part 22) – 1
972 Determ nat on of pH value : IS : 2720 (Part 26) – 1987) Determ nat on of Tot
al Soluble Sulphates n So l IS : 2720 (Part 27) – 1977 Determ nat on of dry den
s ty of so ls n place, by the sand replacement method IS : 2720 (Part 28) - 197
4 Tests on Stab l sed So ls 13 14 15 16 17 18 19 Determ nat on of Mo sture Conte
nt of stab l zed so l m xture IS L: 4332 (Part 2 ) – 1967 Determ nat on of Mo st
ure Content – dry dens ty relat on for stab l zed so ls m xtures IS : 4332 (Part
3) – 1967 (Amendment No.1) Determ nat on of Unconf ned Compress ve Strength of
stab l zed so ls IS : 4332 (Part 5) – 1970 Determ nat on of Cement Content of Ce
ment Stab l sed So ls IS : 4332 (Part 7) – 1973 Determ nat on of L me Content of
L me Stab l sed So ls IS : 4332 (Part 8) – 1969 Determ nat on of the B tum nous
Stab l zer Content of B tumen and Tar Stab l sed So ls IS : 4332 (Part 9) – 197
0 Tests for So l/b tum nous m xture IS : 4332 (Part 10) – 1969 (Amendment No.1)
Tests on Cement 20 21 22 23 Determ nat on of F neness of Cement by dry s ev ng I
S : 4031 (Part 1) – 1996 (Second Rev s on) Determ nat on for F neness of Cement
by Bla ne’s A r Permeab l ty Method IS : 4031 (Part 2)-1999 (Second Rev s on) De
term nat on of Soundness IS : 4031 (Part 3) – 1988 (F rst Rev s on) Determ nat o
n of Cons stency of Standard Cement Paste IS : 4031 (Part 4) – 1988
Append x-1/1
Append x - 1
24 25 26
Determ nat on of In t al and F nal Sett ng t mes IS : 4031 (Part 5) – 1988 (F rs
t Rev s on) Determ nat on of Compress ve Strength of Hydraul c Cement other than
masonry cement IS : 4031 (Part 6) – 1988 (F rst Rev s on) Determ nat on of Fals
e Set IS : 4031 (Part 15) – 1991 Tests on Br cks
27 28 29 30
Determ nat on of Compress ve Strength of Br cks IS : 3495 (Part 1) – 1992 Determ
nat on of Water Absorpt on of Br cks IS : 3495 (Part 2) – 1992 Determ nat on of
Efflorescence of Br cks IS : 3495 (Part 3) – 1992 Determ nat on of Warpage IS :
3495 (Part 4) – 1992 Tests on Cement Sand Mortar
31 32 33 34
Determ nat on of Cons stency of Masonry Mortar IS : 2250 – 1981 Measurement of W
ater Retent v ty of Masonry Mortar IS : 2250 – 1981 Determ nat on of Compress ve
Strength of Masonry Mortars IS : 2250 – 1981 Code of Pract ce for Preparat on a
nd Use of Masonry Mortars IS : 2250-1981 (F rst Rev s on) Tests on Qu ck L me an
d Hydrated L me
35 36
Determ nat on of ava lable l me (as CaO) IS : 1514-1990 Method of Sampl ng and T
est for qu ckl me and hydrated l me IS : 1514-1990 (F rst Rev s on) Tests on San
d / Stone Dust
37 38 39
Sand for masonry mortars IS : 2116- 1980 (F rst Rev s on) Measur ng Mortar mak n
g propert es of f ne aggregate IS : 2386 (Part 6) – 1963 (Amendment No.2) Coarse
and F ne Aggregates from natural sources from concrete IS : 383 – 1970 (Second
Rev s on) Tests on Stones
40 Sect on 400
Method of test for determ nat on of water absorpt on, apparent spec f c grav ty
and poros ty of natural bu ld ng stones IS : 1124 – 1974 (F rst Rev s on) GRANUL
AR CONSTRUCTION / USE OF LOCAL MATERIALS Tests on Aggregates / WBM / Base / Sub-
base
1 2 3 4 5 6 7 8
Spec f cat ons for Coarse Aggregate for Water bound Macadam IS : 6579-1981 (F rs
t Rev s on) (Amendment No.1) Method of Test for Determ n ng Str pp ng Value of r
oad aggregates IS : 6241- 1971 Part cle S ze and Shape IS : 2386 (Part 4) –1963
Est mat on of Deleter ous Mater als and Organ c Impur t es, IS 2386 (Part 2) – 1
963 Spec f c Grav ty, Dens ty, Vo ds, Absorpt on and Bulk ng IS : 2386 (Part 3)
– 1963 Mechan cal Propert es (Crush ng Value, Aggregate Impact Value, Abras on,
Pol shed Stone, Crush ng Strength) IS : 2386 (Part 4) – 1968 Soundness IS : 2386
(Part 50 – 1963 Measur ng Mortar mak ng propert es of F ne Aggregates IS : 2386
(Part 6) – 1963
Append x-1/2
9
Alkal Aggregate React v ty IS : 2386 (Part 7) – 1963 Tests on Flyash
10
Method of test for Pozzolan c Mater al IS : 1727-1967 Covers the follow ng a) Ch
em cal g) Compress ve Strength b) Flak ness h) Transverse Strength c) Soundness
) Dry ng Shr nkage d) Sett ng t me j) Permeab l ty e) L me React v ty k) Reduct
on n Alk n ty and S l ca release f) Compress ve Strength l) Spec f c grav ty P
ulver sed Fuel Ash – Spec f cat ons , Part – 1 for use as pozzolana n cement, c
ement mortar and concrete IS : 3812 (Part 1) – 2003 BITUMINOUS CONSTRUCTION Test
s on B tum nous Macadam / Emuls ons
11 Sect on 500
1 2 3 4 5 6 Sect on 600
Sampl ng IS : 1201-1978 Determ nat on of Penetrat on IS : 1203-1978 Determ nat o
n of Soften ng Po nt IS : 1205 – 1978 Determ nat on of Duct l ty IS : 1208-1978
Determ nat on of Str pp ng Value of Road Aggregates IS : 6241-1971 Ind an Standa
rd Methods for test ng tar and b tum nous mater al IS : 1201-1978 BRICK WORK FOR
STRUCTURES Tests on Cement
1 2 3 4 5 6 7
Determ nat on of F neness of Cement by dry s ev ng IS : 4031 (Part 1) – 1996 (Se
cond Rev s on) Determ nat on for F neness of Cement by Bla ne’s A r Permeab l ty
Method IS : 4031 (Part 2) -1999 (Second Rev s on) Determ nat on of Soundness IS
: 4031 (Part 3) – 1988 (F rst Rev s on) Determ nat on of Cons stency of Standar
d Cement Paste IS : 4031 (Part 4) – 1988 Determ nat on of In t al and F nal Sett
ng t mes IS : 4031 (Part 5) – 1988 (F rst Rev s on) Determ nat on of Compress v
e Strength of Hydraul c Cement other than masonry cement IS : 4031 (Part 6) – 19
88 (F rst Rev s on) Determ nat on of False Set IS : 4031 (Part 15) – 1991 Tests
on Br cks
8 9 10 11
Determ nat on of Compress ve Strength of Br cks IS : 3495 (Part 1) – 1992 Determ
nat on of Water Absorpt on of Br cks IS : 3495 (Part 2) – 1992 Determ nat on of
Efflorescence of Br cks IS : 3495 (Part 3) – 1992 Determ nat on of Warpage IS :
3495 (Part 4) – 1992 Tests on Sand / Stone Dust
12 13 14
Rev s on)
Append x-1/3
Append x - 1
Tests on Stones 15 Method of test for determ nat on of water absorpt on, apparen
t spec f c grav ty and poros ty of natural bu ld ng stones IS : 1124 – 1974 (F r
st Rev s on) Tests on Cement Sand Mortar 16 17 18 19 20 21 Sect on 700 Determ na
t on of Cons stency of Masonry Mortar IS : 2250 – 1981 Measurement of Water Rete
nt v ty of Masonry Mortar IS : 2250 – 1981 Determ nat on of Compress ve Strength
of Masonry Mortars IS : 2250 – 1981 Code of Pract ce for Preparat on and Use of
Masonry Mortars IS : 2250-1981 (F rst Rev s on) Code of Pract ce for Br ckwork
IS : 2212-1991 (F rst Rev s on) Code of Pract ce for Jack-Arch Type of bu lt up
floor or roof IS : 2118-1991 (F rst Rev s on) STONES MASONRY FOR STRUCTURES Test
s on Cement Sand Mortar 1 2 3 4 Determ nat on of Cons stency of Masonry Mortar I
S : 2250 – 1981 Measurement of Water Retent v ty of Masonry Mortar IS : 2250 – 1
981 Determ nat on of Compress ve Strength of Masonry Mortars IS : 2250 – 1981 Co
de of Pract ce for Preparat on and Use of Masonry Mortars IS : 2250-1981 (F rst
Rev s on) Tests on Stones 5 6 Sect on 800 Method of test for determ nat on of wa
ter absorpt on, apparent spec f c grav ty and poros ty of natural bu ld ng stone
s IS : 1124 – 1974 (F rst Rev s on) Construct on of Stone Masonry – Code of Prac
t ce Part –I rubble stone masonry IS : 1597 (Part 1) – 1992 (F rst Rev s on) CON
CRETE FOR STRUCTURES Tests on Cement 1 2 3 4 5 6 7 Determ nat on of F neness of
Cement by dry s ev ng IS : 4031 (Part 1) – 1996 (Second Rev s on) Determ nat on
for F neness of Cement by Bla ne’s A r Permeab l ty Method IS : 4031 (Part 2)199
9 (Second Rev s on) Determ nat on of Soundness IS : 4031 (Part 3) – 1988 (F rst
Rev s on) Determ nat on of Cons stency of Standard Cement Paste IS : 4031 (Part
4) – 1988 Determ nat on of In t al and F nal Sett ng t mes IS : 4031 (Part 5) –
1988 (F rst Rev s on) Determ nat on of Compress ve Strength of Hydraul c Cement
other than masonry cement IS : 4031 (Part 6) – 1988 (F rst Rev s on) Determ nat
on of False Set IS : 4031 (Part 15) – 1991 Tests on Sand / Stone Dust 8 9 10 San
d for masonry mortars IS : 2116- 1980 (F rst Rev s on) Measur ng Mortar mak ng p
ropert es of f ne aggregate IS : 2386 (Part 6) – 1963 (Amendment No.2) Coarse an
d F ne Aggregates from natural sources from concrete IS : 383 – 1970 (Second Rev
s on)
Append x-1/4
Tests on Aggregates / WBM / Base / Sub-base 11 12 13 14 15 16 17 18 19 Spec f ca
t ons for Coarse Aggregate for Water bound Macadam IS : 6579-1981 (F rst Rev s o
n) (Amendment No.1) Method of Test for Determ n ng Str pp ng Value of road aggre
gates IS : 6241- 1971 Part cle S ze and Shape IS : 2386 (Part 4) –1963 Est mat o
n of Deleter ous Mater als and Organ c Impur t es, IS 2386 (Part 2) – 1963 Spec
f c Grav ty, Dens ty, Vo ds, Absorpt on and Bulk ng IS : 2386 (Part 3) – 1963 Me
chan cal Propert es (Crush ng Value, Aggregate Impact Value, Abras on, Pol shed
Stone, Crush ng Strength) IS : 2386 (Part 4) – 1968 Soundness IS : 2386 (Part 50
– 1963 Measur ng Mortar mak ng propert es of F ne Aggregates IS : 2386 (Part 6)
– 1963 Alkal Aggregate React v ty IS : 2386 (Part 7) – 1963 Tests on Concrete
20 21 Method of tests for strength of concrete (compress ve Strength, Flexural S
trength, Modulus of Elast c ty) IS : 516 –1959 Code of Pract ce for pla n and re
nforced concrete IS : 458-1988 (Th rd Rev s on) Tests on Water Sect on 900 1 2
Sect on 1000 1 2 3 4 5 Sect on 1100 1 2 Sect on 1200 FORWORK AND SURFACE FINISH
FOR STRUCTURES Code of Pract ce for pa nt ng of ferrous metals n bu ld ngs IS :
1477-1971 (Part 1 & 2) (F rst Rev s on) Code of Pract ce for Pa nt ng Concrete,
Masonry and Plaster Surfaces IS : 2395 (Part 1 & 2) – 1994 (F rst Rev s on) TES
TS ON STRUCTURAL STEEL Spec f cat on for h gh strength deformed steel bars and w
res for concrete re nforcement IS : 1786-1985 M ld steel and med um tens le ste
el bars IS : 432 (Part 1) – 1982 (Th rd Rev s on) Code of Pract ce for nspect o
n of welds IS : 822-1970 H gh stress deformed steel bars and w res for concrete
re nforcement IS : 1786 – 1985 (Th rd Rev s on) Steel for general structural pur
pose – Spec f cat ons PIPE CULVERTS Precast Concrete P pes (W th and w thout re
nforcement) IS : 458-1988 (Th rd Rev s on) Concrete P pes – Methods of Tests IS
: 3597 1998 (Second Rev s on) RCC SLAB CULVERTS AND MINOR BRIDGES Tests on Cemen
t 1 2 3 4 Determ nat on of F neness of Cement by dry s ev ng IS : 4031 (Part 1)
– 1996 (Second Rev s on) Determ nat on for F neness of Cement by Bla ne’s A r Pe
rmeab l ty Method IS : 4031 (Part 2)-1999 (Second Rev s on) Determ nat on of Sou
ndness IS : 4031 (Part 3) – 1988 (F rst Rev s on) Determ nat on of Cons stency o
f Standard Cement Paste IS : 4031 (Part 4) – 1988
Append x-1/5
Append x - 1
5 6 7
Determ nat on of In t al and F nal Sett ng t mes IS : 4031 (Part 5) – 1988 (F rs
t Rev s on) Determ nat on of Compress ve Strength of Hydraul c Cement other than
masonry cement IS : 4031 (Part 6) – 1988 (F rst Rev s on) Determ nat on of Fals
e Set IS : 4031 (Part 15) – 1991 Tests on Sand / Stone Dust
8 9 10
Rev s on) Tests on Aggregates / WBM / Base / Sub-base
11 12 13 14 15 16 17 18 19
(Part 6) – 1963 Alkal Aggregate React v ty IS : 2386 (Part 7) – 1963 Tests on
Concrete
20 21
Method of tests for strength of concrete (compress ve Strength, Flexural Strengt
h, Modulus of Elast c ty) IS : 516 –1959 Code of Pract ce for pla n and re nforc
ed concrete IS : 458-1988 (Th rd Rev s on) Tests on Flyash
22
Method of test for Pozzolan c Mater al IS : 1727-1967 Covers the follow ng (a) C
hem cal (g) Transverse Strength (b) Flak ness (h) Dry ng Shr nkage (c ) Soundnes
s ( ) Permeab l ty (d) Sett ng t me (j) Reduct on n Alk n ty and s l ca release
(e) L me React v ty (k) Spec f c grav ty (f) Compress ve Strength Pulver sed Fu
el Ash – Spec f cat ons , Part – 1 for use as pozzolana n cement, cement mortar
and concrete IS : 3812 (Part 1) – 2003 PROTECTION WORK AND DRAINAGE Ready m xed
pa nt, brush ng for road mark ng, to Ind an Standard Color No.356 Golden Yellow
, Wh te and Black IS : 164-1981 Spec f cat ons for Galvan sed steel barked w re
for fenc ng IS : 280-1978 (Th rd Rev s on Spec f cat ons for hot appl ed seal ng
compounds for jo nts n concrete IS : 1834-1984 (F rst Rev s on) Code of Pract
ce for Pa nt ng of ferrous metals n bu ld ngs IS : 1477 (Part 1 & 2)
23 Sect on 1300 1 2 3 4
Append x-1/6
Sect on 1400
CEMENT CONCRETE CAUSEWAYS Tests on Cement
1 2 3 4 5 6 7
Method IS : 4031 (Part 2)-1999 (Second Rev s on) Determ nat on of Soundness IS
: 4031 (Part 3) – 1988 (F rst Rev s on) Determ nat on of Cons stency of Standard
Cement Paste IS : 4031 (Part 4) – 1988 Determ nat on of In t al and F nal Sett
ng t mes IS : 4031 (Part 5) – 1988 (F rst Rev s on) Determ nat on of Compress ve
Strength of Hydraul c Cement other than masonry cement IS : 4031 (Part 6) – 198
8 (F rst Rev s on) Determ nat on of False Set IS : 4031 (Part 15) – 1991 Tests o
n Sand / Stone Dust
8 9 10
11 12 13 14 15 16 17 18 19
Concrete
20 21
ed concrete IS : 458-1988 (Th rd Rev s on) Tests on Flyash
22
Method of test for Pozzolan c Mater al IS : 1727-1967 Covers the follow ng (a) C
hem cal (g) Transverse Strength (b) Flak ness (h) Dry ng Shr nkage (c ) Soundnes
s ( ) Permeab l ty (d) Sett ng t me (j) Reduct on n Alk n ty and s l ca release
(e) L me React v ty (k) Spec f c grav ty (f) Compress ve Strength
Append x-1/7
Append x - 1
23 Sect on 1500
Pulver sed Fuel Ash – Spec f cat ons , Part – 1 for use as pozzolana n cement,
cement mortar and concrete IS : 3812 (Part 1) – 2003 CEMENT CONCRETE / ROLLER CO
MPACTED PAVEMENTS Tests on Cement
1 2 3 4 5 6 7
Method IS : 4031 (Part 2)-1999 (Second Rev s on) Determ nat on of Soundness IS
: 4031 (Part 3) – 1988 (F rst Rev s on) Determ nat on of Cons stency of Standard
Cement Paste IS : 4031 (Part 4) – 1988 Determ nat on of In t al and F nal Sett
ng t mes IS : 4031 (Part 5) – 1988 (F rst Rev s on) Determ nat on of Compress ve
Strength of Hydraul c Cement other than masonry cement IS : 4031 (Part 6) – 198
8 (F rst Rev s on) Determ nat on of False Set IS : 4031 (Part 15) – 1991 Tests o
n Sand / Stone Dust
8 9 10
11 12 13 14 15 16 17 18 19
Concrete
20 21
ed concrete IS : 458-1988 (Th rd Rev s on)
Append x-1/8
Tests on Flyash 22 Method of test for Pozzolan c Mater al IS : 1727-1967 Covers
the follow ng (a) Chem cal (g) Compress ve Strength (b) Flak ness (h) Transverse
Strength (c) Soundness ( ) Dry ng Shr nkage (d) Sett ng t me (j) Permeab l ty (
e) L me React v ty (k) Reduct on n Alk n ty and s l ca release (f) Compress ve
Strength (l) Spec f c grav ty Pulver sed Fuel Ash – Spec f cat ons , Part – 1 fo
r use as pozzolana n cement, cement mortar and concrete IS : 3812 (Part 1) – 20
03 Spec f cat ons for preformed f llers for expans on jo nts n concrete pavemen
ts and structures (non-
22 23
Append x-1/9
Append x -2
LIST OF TESTS
TEST Accelerated Cur ng Test of Concrete Aggregate Impact Value (Dry and Wet) Al
kal Aggregate React v ty Ava lable L me as CaO B nder Content CBR on Remoulded
and Soaked So l Samples Cement for Stone Masonry for Dra ns Character st c Stren
gth of Steel Compacted Th ckness Compress ve Strength of Br cks Compress ve Stre
ngth of Cement Compress ve Strength of Concrete Cubes (150mm x 150mm x 150mm) at
28 days Compress ve Strength of Mortar Cons stency of Mortar Consumpt on of Mor
tar n Stone Masonry Crush ng Strength Deleter ous Mater als and Organ c Impur t
es Dev at on from Draw ngs Dev at ons of Pre-Spl t Face from Plane Pass ng Thro
ugh Adjacent Holes. D mens onal Tolerances of Stones D mens onal Tolerances of B
r cks Duct l ty of B tumen Edge Bear ng Tests on P pes Efflorescence of Br cks E
last c Recovery Test Equ pment for Central Laboratory Equ pment for F eld Labora
tory Equ pment for Laboratory at D str ct Level F neness of Cement F n sh ng Fla
k ness Index SECTION NO. 800.25 401.5 800.11 403.1 504.10 302.7 800 1000.1 401.1
0 600.4 800.3 800.26 600.12 600.10 307.24 800.8 800.6 1200.8,1300.8,1400.12 304.
1 700.1 600.1 504.1 (c ) 1100.10 600.3 504.2 (c) 121 119 120 409.1 600.15 402.3
Append x-2/1
Append x - 2
Flexural Strength of Concrete Free Swell Index Gradat on Analys s of Aggregates
Gra n S ze Analys s Hor zontal Al gnment In t al and F nal Sett ng T me of Cemen
t Jo nt F lters and Crack Sealers L me React v ty L qu d L m t and Plast c L m t
Loss of Ign t on Measurements of Length, Internal D ameter, Barrel Th ckness Mo
sture Content of So l – Oven Dry ng Method Nuclear Dens ty Gauge Method Organ c
Mater al Content Pa nts for H ghways Uses Penetrat on Test Placement Mo sture C
ontent and Degree of Compact on Plaster F n sh – Tolerance Proctors’ Dens ty Qua
l ty of b nder Stra ght run B tumen (Penetrat on, Soften ng Po nt and Duct l ty)
Qual ty of B nder Mod f ed B tumen (Penetrat on, Soften ng Po nt, Elast c Recov
ery and Separat on) Qual ty of B nder B tumen Emuls on (V scos ty, Res due on 60
0 m cron s eve and Storage Stab l ty Rate of Spread of B nder Rebound Hammer Tes
t Sand Bath Method Soften ng Po nt of B tumen Soluble Sulphate Content Soundness
by Autoclave Expans on Soundness by Le Chatel er Method Soundness of Cement Sou
ndness w th Magnes um Sulphate Soundness w th Sod um Sulphate Spec f c Grav ty a
nd Water Absorpt on of Aggregate Standard Cons stency of Cement Storage Stab l t
y Tests on Emuls on
800.27 301.4 401.1 301.1 301.9 800.1 1501.7,1501.8 409.3 301.2 301.5 1100.16 301
.7 (a) 301.8 (c ) 301.5 1700 504.1 (a) 301.8 600.15 301.3 504.1 504.2 507.2 503.
6 800.23 301.7 (b) 504.1 (b) 301.6 409.4 409.5 800.2 402.6 402.5 402.4 800.1 502
.4
Append x-2/2
Str pp ng of B tumen Aggregate M xture Su tab l ty of Water for Construct on Sur
face Levels Surface Regular ty Temperature of B nder Res due on 600 M cron Tests
to Cert fy Su tab l ty of Water for Construct on Th ckness Compacted Layer Th c
kness of Jo nts for General Br ck Work – Tolerance Th ckness of Jo nts for Arche
s – Tolerance Tolerances n Formwork Ult mate Tens le Strength and Elongat on Ul
trason c Pulse Veloc ty Test Unconf ned Compress ve Strength of Stab l zed So l
Samples V scos ty of B nders Water Absorpt on of Br cks Water Absorpt on of Ston
es Water Retent v ty of Mortar Workab l ty of Concrete by Compact on Test Workab
l ty of Concrete by Slump Test
504.5 600.8 301.10 301.11 503.5 502.3 600.8 401.10 600.13 600.14 904 1000.1 800.
24 403.5 501.2 600.2 700.2 600.11 800.20 800.19
Append x-2/3
Append x - 3
LIST OF FORMS
DESCRIPTION EARTHWORKS S eve Analys s of So l Atterberg L m ts Test Proctor Dens
ty Free Swell Index Determ nat on of Organ c Matter Content Determ nat on of So
luble Sulphate Content Mo sture Content of So l by Oven Dry ng Method Mo sture C
ontent of So l by Sand Bath Method F eld Dens ty of So l (Sand replacement metho
d) F eld Dens ty of the So l (Core Cutter Method) Determ n ng Swell Index CBR Te
st of So l GRANULAR CONSTRUCTION Gradat on Analys s of Aggregates Aggregate Impa
ct Value Flak ness Index Water Absorpt on Soundness w th Sod um Sulphate Soundne
ss w th Magnes um Sulphate Determ nat on of F neness of Cement BITUMINOUS CONSTR
UCTION Storage Stab l ty Test Flash Po nt of B tumen Determ nat on of Temperatur
e of B nder Rate of Spread of B nder Penetrat on of B tumen Soften ng Po nt of B
tumen Duct l ty of B tumen Elast c Recovery Test FORM NO. SECTION 300 EW-1 EW-2
EW-3 EW-4 EW-5 EW-6 EW-7 EW-8 EW-9 EW-10 EW-11 EW-12 SECTION 400 SB-1 SB-2 GB-1
GB-2 GB-3 GB-4 GB-5 SECTION 500 BC-1 BC-2 BC-3 BC-4 BC- 5 BC-6 BC-7 BC-8
Append x-3/1
Append x - 3
Str pp ng Test of Aggregate Percentage of B nder BRICKWORK FOR CONSTRUCTION Wate
r Absorpt on of Br cks Compress ve Strength of Br cks Compress ve Strength of Mo
rtar STONE MASONRY FOR STRUCTURES Water Absorpt on of Stones CONCRETE FOR STRUCT
URES Sett ng T me of Cement Soundness of Cement by Le-Chatel er Method Compress
ve Strength of Cement Crush ng Strength of Coarse Aggregate Workab l ty of Concr
ete Compress ve Strength of Concrete Cubes
BC–9 BC-10 SECTION 600 BR-1 BR-2 BR-3 SECTION 700 ST-1 SECTION 800 CC-1 CC-2 CC-
3 CC-4 CC-5 CC-6
Append x-3/2
Append x - 4
LIST OF PHOTOGRAPHS
DESCRIPTION EARTHWORKS S eve for Gra n S ze Analys s Motor sed S eve Shaker L qu
d L m t Dev ce Un versal Automat c Compactor Electr c Oven D g tal Balance Sand
Pour ng Cyl nder Apparatus Nuclear Dens ty Gauge Laboratory CBR Test Apparatus
GRANULAR CONSTRUCTION S eves for Aggregates Impact Tester Th ckness Gauge BITUMI
NOUS CONSTRUCTION Saybolt V scometer R ng and Ball Apparatus Duct l ty Test Appa
ratus Centr fuge Apparatus CONCRETE FOR STRUCTURES Le Chatel er Mould V brat ng
Mach ne for Cement Cubes Hand Operated Compress on Test ng Mach ne Length Compar
ator Bar Mould Rebound Hammer Ultreson c Pulse Veloc ty Tester Accelerated Cur n
g Tank Hand Operated Compress on Test ng Mach ne Moulds Flexure Test Apparatus P
HOTO NO. SECTION 300 1 2 3 4 5 6 7 8 9 SECTION 400 1 2 3 SECTION 500 1 2 3 4 SEC
TION 800 1 2 3 4 5 6 7 8 9 10 11
Append x-4/1
Append x - 5
LIST OF TABLES
DESCRIPTION EARTHWORKS Mass of Var ous S zed Mater als to be Taken for S eve Ana
lys s Max mum We ght of Mater al to be Reta ned on Each S eve Perm ss ble Max mu
m Mass of Sample on 200mm D ameter Typ cal values of max mum dry dens ty and opt
mum water content Tolerances n Surface Levels Standard Loads for the CBR Test
GRANULAR CONSTRUCTION Des rable S zes and Grad ng of Coarse Aggregates for Granu
lar Construct on Des rable S zes and Grad ng of F ne Aggregates (or Screen ngs)
So l Pulver sat on Requ rements of L me Stab l sat on BITUMINOUS CONSTRUCTION No
m nal Rates of Spread for B nder and Ch pp ngs BRICK WORK FOR STRUCTURES Perm ss
ble L m ts of Sol ds n Construct on Water CONCRETE FOR STRUCTURES L m ts of De
leter ous Mater als Grad ng of F ne Aggregates for Alkal Aggregate React v ty T
est Ultrason c Pulse Veloc ty and Qual ty of Concrete RCC SLAB CULVERTS AND MINO
R BRIDGES Tolerances n var ous d mens ons and levels TABLE NO. SECTION 300 301.
1.1 301.1.2 301.1.3 301.3.1 301.10.1 302.7.1 SECTION 400 401.1.1 401.1.2 403.6.1
SECTION 500 502.8.1 SECTION 600 600.8.1 SECTION 800 800.6.1 800.11.1 800.24.1 S
ECTION 1200 1200.35.1
Append x-5/1
Append x - 6
LIST OF FIGURES
DESCRIPTION EARTHWORKS Typ cal Gra n S ze D str but on D agram Determ nat on of
L qu d L m t Mod f ed Proctor Test Curve (Dry dens ty Vs Mo sture content) Compa
ct on Curves for a Range of So l types Set up for Rap d Determ nat on of Mo stur
e Content Correlat on Load Penetrat on Curve (CBR Test) BRICK WORK FOR STRUCTURE
S Standard Cone Apparatus Apparatus Assembly for Water Retent on M x ng Bowl A M
xer Blade PIPE CULVERTS Three Edge Bear ng FIGURE NO. SECTION 300 F gure 1 F gu
re 2 F gure 3 F gure 4 F gure 5 F gure 6 SECTION 600 F gure 7 F gure 8 F gure 9
F gure 10 SECTION 1100 F gure 11
Append x-6/1
Append x-7
Measurement Convers on Factors
To convert from the un t n the f rst column to the un t n the second column, m
ult ply by the factor n the th rd column.
SI Un t Length M ll meters Cent meters Meters K lometers Area Square m ll meters
Square meters Square meters Hectares Square k lometers Volume L ters Cub c mete
rs Cub c meters Mass Grams K lograms Megagrams Illum nat on Lux Candelas per squ
are meter Force and Pressure or Stress Newtons K lopascals Temperature To conver
t Cels us temperature (oC) to Fahrenhe t temperature (oF), use the follow ng for
mula :oF = (oC x 1.8) + 32 Poundforce Poundforce per square nch 0.225 0.145 Foo
tcandles Footlamberts 0.093 0.292 Ounces Pounds Short tons 0.035 2.205 1.102 Gal
lons Cub c feet Cub c yards 0.264 35.314 1.308 Square nches Square feet Square
yards Acres Square m les 0.00155 10.764 1.196 2.471 0.386 Inches Inches Feet M l
es 0.039 0.394 3.281 0.621 Customary Un t Factor
Append x-7/1
Append x - 7
Convers on between the Imper al and SI systems 1 bar = 106 dynes / cm2 = 105 N /
m2 = 105 Pa = 0.1 Mpa = 1kg / cm2 1 atm = 1.013 bars =14.7 ps =2116 lbf / ft 2
= 1.03125 x 10 5 Pa = 1.03125 kg / cm2 1 slug = 1 lbf - s2/ft = 14.59 kg 1 sna
l = 1 lbf-s 2 / n 1 grav ty = 9.81 m / s2 1 g = 9.81 N
Append x-7/2

Quality Assurance Hand Book For Rural Roads VolumeII

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Quality Assurance Hand Book For Rural Roads VolumeII

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Ministry of Rural Development Government of India

Quality Assurance Handbook for Rural Roads

Procedure 1. 2. 3. 4. 5. 6. 7.Take a representative

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