Kdmtl testing manual

Krishna Digital Material Testing Laboratory
02, Bhawani Nagar Near J.K.Road Bhopal Madhya Pradesh Telephone No. 0755-4228147 Fax No. 07554246045 e-mail info@ktcpl.org
TESTING MANUAL
Kdmtl testing manual
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Construction Material Testing

TRAINING
SPONSORED BY
MADHYA PRADESH RURAL ROAD DEVELOPMENT AUTHORITY

GIVEN BY
KRISHNA DIGITAL MATERIAL TESTING LABORATORY (AN NABL ACCREDITED LABORATORY)
BHOPAL
TO TRAINEE
NAME OF THE SDO

DATE OF TRAINING
INDEX
ABOUT NABL ABOUT OUR LABORATORY TRAINING COURSE o 1.SOIL TESTING
Grain Size Analysis Consistency Limits Classification of Soils Compaction Test California Bearing Ratio Free Swelling Index Sand Replacement Test
o 2. COARSE AGGREGATE TESTING

SIEVE ANALYSIS IMPACT VALUE CRUSHING VALUE ABRASION VALUE SPECIFIC GRAVITY &WATER ABSORPTION BULK DENSITY
3. FINE AGGREGATE TESTING

SIEVE ANALYSIS SILT CONTENT SPECIFIC GRAVITY
4. CEMENT TESTING FINENESS OF CEMENT STANDARD CONSISTENCY OF CEMENT SOUNDNESSOF CEMENT INITIAL & FINAL SETTING TIME OF CEMENT SPECIFIC GRAVITY OF CEMENT COMPRESSIVE STRENGTH OF MORTAR CUBES
5. CONCRETE TESTING COMPRESSIVE STRENGTH REBOUND HAMMER Concrete Mix Design As Per Indian Standard Code SLUMP CONE
National Accreditation Board for Testing and Calibration Laboratories
National Accreditation Board for Testing and Calibration Laboratories (NABL) is an autonomous body under the aegis of Department of Science & Technology, Government of India, and is registered under the Societies Act 1860. NABL has been established with the objective to provide Government, Industry Associations and Industry in general with a scheme for third-party assessment of the quality and technical competence of testing and calibration laboratories. Government of India has authorised NABL as the accreditation body for Testing and Calibration Laboratories. In order to achieve this objective, NABL provides laboratory accreditation services to laboratories that are performing tests / calibrations in accordance with ISO/IEC 17025:2005 and ISO 15189:2007 for medical laboratories. These services are offered in a non-discriminatory manner and are accessible to all testing and calibration laboratories in India and abroad, regardless of their ownership, legal status, size and degree of independence. NABL accreditation system complies with ISO/IEC 17011:2004 and Asia Pacific Laboratory Accreditation Cooperation (APLAC) MR001. Based on evaluation of NABL operations by APLAC in 2000, NABL has been granted signatory member status by APLAC and International Laboratory Accreditation Cooperation (ILAC) under their Mutual Recognition Arrangements (MRAs). Under these MRAs, the reports issued by NABL accredited laboratories are considered to be equivalent to reports issued by laboratories accredited by (currently) 76 accreditation bodies in 64 economies. NABL has undergone re-evaluation by four member APLAC evaluation team in July 2008. APLAC/ILAC has recommended NABLs Mutual Recognition Arrangement (MRA) status for further four years with extension of scope for Medical Testing laboratory as per new international standard ISO 15189:2007. Recently, NABL also added a new dimension in the area of accreditation as a new program on "Accreditation of PT Providers" based on international standard ISO/IEC 17043 Conformity Assessment - General Requirements of Proficiency Testing and strive to obtain ILAC / APLAC Mutual Recognition Arrangement (MRA) Signatory Status for international acceptability also. The users have access to information regarding accredited laboratories through web-based directory of NABL accredited laboratories. NABL website is updated continuously with respect to status of accredited laboratories and their scope of accreditation. The list of laboratories which are either suspended or their scope of accreditation is partially or fully withdrawn is also available for the benefit of the users. The laboratories will be able to acquire the necessary NABL documents through the website thereby eliminating postal delays. Suggestions are welcome from users of the website for further improvement
SCOPE OF LABORATORY
I - COARSE AGGREGATE
S. No.
Name of Test
Minimu m Period Require d for Testing

2 Days 2 Days 2 Days 2 Days 3Days 3 Days 2 Days 15 Days 2 Days 2 Days 5 Days 2 Days
Minimum Quantity of Sample Required for One Test

20 Kg 5 Kg 20 Kg 20 Kg 5 Kg 5 Kg 30 Kg 15 Kg 20 Kg 20 Kg 5 Kg 20 Kg 60mm - 30 Kg 20mm 60 Kg 12.5mm 60mm-30 Kg
1 2 3 4 5 6 7 8 9 10 11 12
Impact Value Sieve Analysis( Gradation) Crushing Value Abrasion Value Water Absorption/Surface Moisture Specific Gravity Bulk Density Soundness Flakiness Index Elongation Test Deleterious material* 10% fine value
13
WMM Mix Design(as per MORT& H)*
6 Days
II FINE AGGREGATE/SAND
S. No.
Name of Test

2 Days 2 Days 3 Days 2 Days 2 Days 2 Days 2 Days 2 Days

10 Kg 10 Kg 10 Kg 10 Kg 10 Kg 10 Kg. 5 Kg. 2 Kg.
1 2 3 4 5 6 7 8
Sieve Analysis( Gradation) Bulk Density Bulking* Specific Gravity Silt Content* (inclusive Gradation) Fineness Modulus* (inclusive Gradation) Organic Impurities/Deleterious Material* Surface Moisture Contents*
9 10
Water Absorption Soundness
2 Days 8 Days
5 Kg. 10 Kg
III CEMENT
S. No.
Name of Test

3 Days 3 Days Cubes (including 30 Days

5Kg 5Kg 1 Full Bag
A 1 2 3
PHYSICAL TESTING
Fineness (Dry Sieving test) Consistency & Setting Time Compressive Strength of Cubes (3 Cement preparation of sample)
CONSISTENCY WITH IST

4 Soundness (Lechatelier's test) Density 3 Days 3 Days 2Kg 5Kg
IV CEMENT CONCRETE
S. No.
Name of Test

7 Days/ 28 Days

Set of 3 Cubes 8 Paver blocks 1 Bag Cement 4 Bags Aggregate 2 Bag Sand Cement- 1 bag Sand-1 bag Agg. -1 bag *
Compressive strength (Cement / Cement concrete cubes / Paver Blocks)
Concrete Mix design including lab. Testing in normal conditions. *
14 Days /30 days
3 4
Casting of C.C. cube and determination of Compressive Strength (Normal Condition)
10 days at field 3 days
Slump test / Compaction Factor Test
5 6
Core Cutting From the Structure / Pavement . Rebound Hammer test (NDT)
V-- BRICKS
S. No.
Name of Test

2 Days 3 Days 6 Days 4 Days 2 Days

20 Nos. 5 Nos. 9 Nos. 5 Nos. 6 Nos.
1 2 3 4 5
Dimension tolerance* Water Absorption Compressive strength Efflorescence Visual Examination *
VI-SOIL LABORATORY TEST
S. No.
Name of Test

3 Days 3 Days 3 Days 3 Days

1kg 1Kg 5 Kg 20 Kg
1 2 3 4
Natural Moisture content Specific Gravity Liquid Limit/Plastic Limit Proctor test (OMC & Max. Dry Density) for Light / heavy Compaction CBR test (i) Excluding of OMC / MDD) in Soaked / Unsoaked conditions (ii) Including OMC/MDD Wet Sieve Analysis Bulk Density* Permeability of soil (Lab.) * Free Swelling Index Triaxial Test Direct Shear Test Swelling Pressure
8 Days 9 Days 3 Days 2 Days 4 Days 3 Days 7 Days 5 Days 3 Days
25 Kg. 26 Kg. 5 Kg 5 Kg 30 Kg 5 Kg 10 Kg 10 Kg 10 Kg
6 7 8 9 10 11 12
VII - BITUMEN Kdmtl testing manual

S. No.
Name of Test

3 Days 3 Days 3 Days 3 Days 3 Days 3 Days 3 Days 3 Days

5 Kg 5 Kg 5 Kg 5 Kg 5 Kg 5 Kg 5 Kg 2 Kg 2 full bag of each Aggregate 20mm, 13.2mm 11.2mm,6.0 mm stone dust filler (5Kg.) Bitumen (5 Kg) 3 Kg 5 Kg Bituminous mix
1 2 3 4 5 6 7 8
Specific gravity* Softening point Penetration value Viscosity Ductility Flash Point/Fire Point Loss on heating % by weight* Spot Test*
Job mix formula by Marshall Stability Test * (a)B.M./DBM/SDBC
15 Days
10 11
Striping values * Bitumen Content*
2 Days 2 Days
VIII - CERAMIC TILES
S. No.
Name of Test

3 Days 1 Days 3 Days 7 Days 2 Days 3 Days

6 Nos. 6 Nos. 6 Nos. 6 Nos. 6 Nos. 6 Nos.
1 2 3 4 5 6
Water Absorption Dimension Abrasion Chemical Resistance Hardness MOR
IX-CONCRETE TILES
S. No.
Name of Test

3 Days 3 Days 3 Days

6 Nos. 6 Nos. 6 Nos.
1 2 3
Water Absorption Abrasion Dimension & Surface Regularity X - FIELD TESTS
S. No.
1 2 3 4 5
Name of Test
Field density testing by core cutter method. Field density testing by sand replacement method / by DCPT method (excluding transportation) Standard penetration test (spt) Core Cutting From the Structure / Pavement . Rebound Hammer test (NDT)
XI - STEEL
S. No.
1
Name of Test
Steel all Physical & Chemical Test
Rate per Test

4000/-
XII - PAVER BLOCK
S. No.
1 2 3 Water Observation Compressive Strength Abrasion Resistence XIII- SAMPLING
Name of Test
S. No.
1
Name of Test
Collection of Sample from Field excluding Transporation
TEST1-Grain Size Analysis

Theory: The soil is sieved through a set of sieves. The material retained on different sieves is determined. The percentage of material retained on any sieve is given by
Where
= mass of soil retained on sieve n
M= total mass of the sample. The cumulative percentage of the material retained
Where sieve n
etc are the percentages retained on sieve 1, 2 etc which are coarser than sieve n. The percentage finer than the
Equipment: 1. Set of fine sieves, 2mm, 1mm, 600micron, 425, 212, 150, and 75 micron. 2. Set of coarse sieves, 100mm, 80mm, 40mm, 10mm, and 4.75mm. 3. Weighing balance with accuracy of 0.1% of the mass of the sample. 4. Oven 5. Mechanical shaker 6. Trays 7. Mortar with a rubber covered pestle. 8. Brushes 9. Riffler
Part-I: Coarse Sieve Analysis Procedure: 1. Take the required quantity of the sample. Sieve it through a 4.75mm Is sieve. Take the soil fraction retained on 4.75mm IS sieve for the coarse sieve analysis (Part-I) and that passing through the sieve for the fine sieve analysis (Part-II). 2. Sieve the sample through the set of coarse sieves by hand. While sieving through each sieve, the sieve should be agitated such that the sample rolls in irregular motion over the sieve, the material retained on the sieve may be rubbed with the rubber pestle in the mortar, if necessary. Care shall be taken so as not to break the individual particles. The quantity of the material taken for
sieving on each sieve shall be such that the maximum mass of material retained on each sieve does not exceed the specified value. 3. Determine the mass of the material retained on each sieve. 4. Calculate the percentage of soil retained on each sieve on the basis of the total mass of the sample, taken in step (1). 5. Determine the percentage passing through each sieve. Part-II: Fine Sieve Analysis. 6. Take the portion of the soil passing 4.75 mm IS sieve. Oven dry it at 105 to 110 0C. Weigh it to 0.1% of the total mass. 7. Sieve the soil trough the nest of fine sieves, the sieves should be agitated so that the sample rolls in irregular motion over the sieves. However, no particles should be pushed through the sieve. 8. Take the material retained on various sieves in a mortar. Rub it with rubble pestle, but do not try to break individual particles. 9. Reserve the material through the nest of sieves. A minimum of 10min of shaking is required if a mechanical shaker is used. 10. Collect the soil fraction retained on each sieve in a separate container. Take the mass. 11. Determine the percentage retained, cumulative percentage retained, and the percentage finer, based on the total mass taken in step (1).
TEST2-Consistency Limits THE LIQUID LIMIT OF SOIL TEST

TO DETERMINE THE LIQUID LIMIT OF A SOIL SPECIMEN Theory:
The liquid limit of a soil is the water content at which the soil behaves practically like a liquid, but has small shear strength. It flows to close the groove in just 25 blows in Casagrandes liquid limit device. As it is difficult to get exactly 25 blows in a test, 3 to 4 tests are conducted and the number of blows (N) required in each test is determined. A semi-log plot is then drawn between log N and the water content (w). The liquid limit is the water content corresponding to N=25, as obtained from the plot. Equipment 1. Casagrandes liquid limit device 2. Grooving tolls of both standard and ASTM types 3. Oven 4. Evaporating dish or glass sheet 5. Spatula 6. 425 IS sieve
7. Weighing balance accuracy 0.01g. 8. Wash bottle.
Fig: Casagrandes Liquid Limit Apparatus
Fig:
Casagrandes Apparatus Details and Tools
Procedure: 1. Adjust the drop of the cup of the liquid limit device by releasing the two screws at the top and by using the handle of the grooving tool or a gauge. The drop should be exactly 1cm at the point of contact on the base. Tighten the screw after adjustment. 2. Take about 120g of the air-dried soil sample passing 425 IS sieve.
3. Mix the sample thoroughly with distilled water in an evaporating dish or a glass plate to form a uniform paste. Mixing should be continued for about 15 to 30 min, till a uniform mix is obtained. 4. Keep the mix under humid conditions for obtaining uniform moisture distribution for sufficient period. For some fat clays. This maturing time may be upto 24 hours. 5. Take a portion of the matured paste and remix it thoroughly. Place it in the cup of the device by a spatula and level it by a spatula or a straight edge to have a minimum depth of the soil as 1cm at the point of the maximum thickness. The excess soil, if any should be transferred to the evaporating dish. 6. Cut a groove in the sample in the cup by using the appropriate tool. Draw the grooving tool through the paste in the cup along the symmetrical axis, along the diameter through the centre line of the cup. Hold the tool perpendicular to the cup. 7. Turn the handle of the device at a rate of 2 revolutions per second. Count the number of blows until the two halves of the soil specimen come in contact at the bottom of the groove along a distance of 12mm due to flow and not by sliding. 8. Collect a representative sample of the soil by moving spatula width-wise from one edge to the other edge of the soil cake at right angles to the groove. This should include the portion of the groove in which the soil flowed to close the groove. 9. Remove the remaining soil from the cup. Mix it with the soil left in evaporating dish. 10. Change the water content of the mix in the evaporating dish either by adding more water if the water content is to be increased or by kneading the soil, if the water content is to be decreased. In no case the dry soil should be added to reduce the water content. 11. Repeat the steps 4 to 10 and determine the number of blows (N) and the water content in each case. 12. Draw the flow curve between log N and w, and determine the liquid limit corresponding to N=25.
TEST 3-DETERMINATION OF PLASTIC LIMIT OF SOIL

Theory: The plastic limit of a soil is the water content of the soil below which it ceases to be plastic. It begins to crumble when rolled into threads of 3mm diameter. Equipment: 1. Porcelain evaporating dish about 120mm diameter or a glass plate 450mm square and 10mm thick. 2. Ground glass plate about 200mm x 150mm 3. Metallic rod 3mm dia and 100mm long 4. Oven 5. Spatula or plate knife 6. Moisture content can Procedure: 1. Take about 30g of air dried soil from a thoroughly mixed sample of the soil passing 425 sieve.
2. Mix the soil with distilled water in an evaporating dish or on a glass plate o make it plastic enough to shape into a small ball. 3. Leave the plastic soil mass for some time for maturing. For some fat clay, this period may be even upto 24 hours. 4. Take about 8g of the plastic soil, and roll it with fingers on a glass plate. The rate of rolling should be about 80 to 90 strokes per minute to form a thread of 3mm diameter counting one stroke when the hand moves forward and backward to the starting point. 5. If the diameter of the thread becomes less than 3mm without cracks, it shows that the water content is more than plastic limit. Knead the soil to reduce the water content and roll it again into thread. Repeat the process of alternate rolling and kneading until the tread crumbles and the soil can no longer be rolled into thread. Note: If the crumbling occurs when the thread has a diameter slightly greater than 3mm it may be taken as plastic limit, provided the soil had been rolled into a thread of 3mm diameter immediately before kneading. Do not attempt to produce failure exactly at 3mm diameter.
6. Collect the pieces of the crumbled soil thread in a moisture content container. 7. Repeat the procedure at least twice more with a fresh samples of plastic soil each time.
Fig: Determination of Plastic Limit
TEST-3 Classification of Soils

Classification systems are used to group soils according to their order of performance under given set of physical conditions. Soils that are grouped in order of performance for one set of physical conditions will not necessarily have the same order of performance under some other physical conditions. Therefore, number of classification systems have been developed depending on the intended purpose of the system. Soil classification has proved to be a very useful tool to the soil engineer. It gives general guidelines in an empirical manner for making use of the field experience of others. Soil may be broadly classified as follows:
1. 2. 3. 4. Classification based on grain size Textural classification AASHTO classification system Unified soil classification system
INDIAN STANDARD CLASSIFICATION SYSTEM: Indian Standard Classification System (ISC) was adopted by Bureau of Indian Standards is in many respect similar to the Unified Soil Classification (USC) system. Soils are divided into three broad divisions:
1. Coarse grained soils, when 50% or more of the total material by weight is retained on 75 micro IS sieve.
2. 3.
For fine grained soils, when more than 50% of the total material passes through 75 micron IS sieve. If the soil is highly organic and contains a large percentage of organic matter and particles of decomposed vegetation, it is kept in a separate category marked as peat (Pt).
In all there are 18 groups of soils: 8 groups of coarse grained, 9 groups of fine grained and one of peat. GW well graded gravel GP poorly graded gravel GM silty gravel SW well graded sand SP poorly graded sand SM silty sand SC clayey sand CL clay of low plastic CI clay of medium plastic CH clay of higher plastic ML silt of medium plastic MI silt of medium plastic MH silt of higher plastic OL organic silt and clays of low plastic OI organic silt and clays of medium plastic OH organic silt and clays of high plastic
Fig.2: Indian Standard Classification Plasticity Chart
TEST 4 COMPACTION OF SOIL PROCTORS TEST

Theory: Compaction is the process of densification of soil by reducing air voids. The degree of compaction of a given soil is measured in terms of its dry density. The dry density is maximum at the optimum water content. A curve is drawn between the water content and the dry density to obtain the maximum dry density and the optimum water content.
Dry density
Where M = total mass of the soil, V= volume of soil, w= water content. Equipment: 1. Compaction mould, capacity 1000ml. 2. Rammer, mass 2.6 kg. 3. Detachable base plate. 4. Collar, 60mm high.
5. IS sieve, 4.75 mm. 6. Oven 7. Desiccator 8. Weighing balance, accuracy 1g. 9. Large mixing pan 10. Straight edge. 11. Spatula 12. Graduated jar 13. Mixing tools, spoons, trowels, etc. Procedure: 1. Take about 20kg of air-dried soil. Sieve it through 20mm and 4.7mm sieve. 2. Calculate the percentage retained on 20mm sieve and 4.75mm sieve, and the percentage passing 4.75mm sieve. 3. If the percentage retained on 4.75mm sieve is greater than 20, use the large mould of 150mm diameter. If it is less than 20%, the standard mould of 100mm diameter can be used. The following procedure is for the standard mould. 4. Mix the soil retained on 4.75mm sieve and that passing 4.75mm sieve in proportions determined in step (2) to obtain about 16 to 18 kg of soil specimen. 5. Clean and dry the mould and the base plate. Grease them lightly. 6. Weigh the mould with the base plate to the nearest 1 gram. 7. Take about 16 18 kg of soil specimen. Add water to it to bring the water content to about 4% if the soil is sandy and to about 8% if the soil is clayey. 8. Keep the soil in an air-tight container for about 18 to 20 hours for maturing. Mix the soil thoroughly. Divide the processed soil into 6 to 8 parts. 9. Attach the collar to the mould. Place the mould on a solid base. 10. Take about 2.5kg of the processed soil, and hence place it in the mould in 3 equal layers. Take about one-third the quantity first, and compact it by giving 25 blows of the rammer. The blows should be uniformly distributed over the surface of each layer.
The top surface of the first layer be scratched with spatula before placing the second layer. The second layer should also be compacted by 25 blows of rammer. Likewise, place the third layer and compact it. The amount of the soil used should be just sufficient to fill the mould ad leaving about 5 mm above the top of the mould to be struck off when the collar is removed. 11. Remove the collar and trim off the excess soil projecting above the mould using a straight edge. 12. Clean the base plate and the mould from outside. Weigh it to the nearest gram. 13. Remove the soil from the mould. The soil may also be ejected out. 14. Take the soil samples for the water content determination from the top, middle and bottom portions. Determine the water content. 15. Add about 3% of the water to a fresh portion of the processed soil, and repeat the steps 10 to 14.
(a)MOULD
b) Rammer Fig: Standard Proctor Test (Compaction Test)
Plot a curve between w as abscissa and
as ordinate.
Fig: Compaction Curve
TEST5-CALIFORNIA BEARING RATIO TEST

AIM:To determine the California Bearing Ratio value of the subgrade soil. APPARATUS:Loading machine-any compression machine can operate at constant rate of 1.25mm per minute can be used. Cylindrical moulds- moulds of 150mm diameter and 175mm height provided with a collar of about 50mm length and detachable perforated base. Compaction rammer, surcharge weight-annular weights each of 2.5kg and 147mm diameter. IS sieve 20mm, Coarse filter paper, balance etc. THEORY:The California Bearing Ratio(CBR) test was developed by the California Division of Highways as a method of classifying and evaluating soil- subgrade and base course materials for flexible pavements. CBR is a measure of resistance of a material to penetration of standard plunger under controlled density and moisture conditions. CBR test may be conducted in remoulded or undisturbed sample. Test consists of causing a cylindrical plunger of 50mm diameter to penetrate a pavement component material at 1.25mm/minute. The loads for 2.5mm and 5mm are recorded. This load is expressed as a percentage of standard load value at a respective deformation level to obtain CBR value. PROCEDURE: Sieve the sample through 20mm IS sieve. Take 5kg of the sample of soil specimen. Add water to the soil in the quantity such that optimum moisture content or field moisture content is reached. Then soil and water are mixed thoroughly. Spacer disc is placed over the baseplate at the bottom of mould and a coarse filter paper is placed over the spacer disc. The prepared soil water mix is divided into five. The mould is cleaned and oil is applied. Then fill one fifth of the mould with the prepared soil. That layer is compacted by giving 56 evenly distributed blows using a hammer of weight 4.89kg. The top layer of the compacted soil is
scratched. Again second layer is filled and process is repeated. After 3 rd layer, collar is also attached to the mould and process is continued. After fifth layer collar is removed and excess soil is struck off. Remove base plate and invert the mould. Then it is clamped to baseplate. Surcharge weights of 2.5kg is placed on top surface of soil. Mould containing specimen is placed in position on the testing machine. The penetration plunger is brought in contact with the soil and a load of 4kg(seating load) is applied so that contact between soil and plunger is established. Then dial readings are adjusted to zero. Load is applied such that penetration rate is 1.25mm per minute. Load at penetration of 0.5,1,1.5,2,2.5,3,4,5,7.5,10 and 12.5mm are noted. Standard Load Values
Standard Penetration(mm) Load(kg)
Unit Standard Load(kg/cm2)
2.5
1370
70
2055
105
7.5
2630
134
10.0
3180
162
12.5
3600
183
TEST 6-
FREE SWELLING INDEX

Free swell or differential free swell, also termed as free swell index, is the increase in volume of soil without any external constraint when subjected to submergence in water. The apparatus used :
i) IS Sieve of size 425m ii)Oven iii)Balance,withanaccuracyof0.01g iv) Graduated glass cylinder- 2 nos., each of 100ml capacity Procedure to determine Free Swell Index Of Soil i) Take two specimens of 10g each of pulverised soil passing through 425m IS Sieve and oven-dry.
ii) Pour each soil specimen into a graduated glass cylinder of 100ml capacity.
iii) Pour distilled water in one and kerosene oil in the other cylinder upto 100ml mark.
iv) Remove entrapped air by gently shaking or stirring with a glass rod.
v) Allow the suspension to attain the state of equilibrium (for not less than 24hours).
vi) Final volume of soil in each of the cylinder should be read out.
TEST 7 IN-SITU DRY DENSITY BY SAND REPLACEMENT METHOD

Theory:A hole of specified dimensions is excavated in the ground. The mass of the excavated soil is determined. The volume of the hole is determined by filling it with clean, uniform sand whose dry density ( ) is determined separately by
calibration. The volume of the hole is equal to the mass of the sand filled in the hole divided by its dry density. The dry density of the excavated soil is determined as
Where M= mass of the excavated soil, V= volume of the hole and w= water content. Equipment: 1. Sand pouring cylinder 2. Calibrating container, 100mm diameter and 150mm height 3. Soil cutting and excavating tools, such as scrapper tool, bent spoon 4. Glass plate, 450mm square, 9mm thick 5. Metal container to collect excavated soil 6. Metal tray, 300mm square and 40mm deep with a hole of 100mm in diameter at the centre 7. Weighing balance 8. Moisture content cans
9. Oven 10. Desiccator Clean, uniform sand passing 1mm IS sieve and retained on 600micron IS sieve in sufficient quantity. Part-I: Calibration Procedure: 1. Determine the internal volume of the calibrating container by filling it with water and determining the mass of water required. The mass of water in grams is approximately equal to the volume in mililitres. The volume may also be determined from the measured dimensions of the container. 2. Fill the sand-pouring cylinder with sand, within about 10mm of its top. Determine the mass of the cylinder (M 1) to the nearest gram. 3. Place the sand-pouring cylinder vertically on the calibrating container. Open the shutter to allow the sand run out from the cylinder. When there is no further movement of the sand in the cylinder, close the shutter. 4. Lift the pouring cylinder from the calibrating container and weigh it to the nearest gram (M3). 5. Again fill the pouring cylinder with sand, within 10mm of its top. 6. Open the shutter and allow the sand to run out of the cylinder. When the volume of the sand let out is equal to the volume of the calibrating container, close the shutter. 7. Place the cylinder over a plane surface, such as a glass plate. Open the shutter. The sand fills the cone of the cylinder. Close the shutter when no further movement of sand takes place. 8. Remove the cylinder. Collect the sand left on the glass plate. Determine the mass of sand (M 2) that had filled the cone by weighing the collected sand. 9. Determine the dry density of sand, as shown in the data sheet, part-I. Part-II: Dry density Procedure: 1. Expose an area of about 450mm square on the surface of the soil mass. Trim the surface down to a level surface using a scrapper tool. 2. Place the metal tray on the leveled surface.
3. Excavate the soil though the central hole of the tray, using the hole in the tray as a pattern. The depth of the excavated hole should be about 150mm. 4. Collect all the excavated soil in a metal container, and determine the mass of the soil (M). 5. Remove the metal tray from the excavated hole. 6. Fill the sand pouring cylinder within 10mm of its top. Determine its mass (M1). 7. Place the cylinder directly over the excavated hole. Allow the sand to run out the cylinder by opening the shutter. Close the shutter when the hole is completely filled and no further movement of sand is observed. 8. Remove the cylinder from the filled hole. Determine the mass of the cylinder (M 4). 9. Take a representative sample of the excavated soil. Determine its water content.
COARSE AGGREGATE TESTING
TEST 1GRAIN SIZE ANALYSIS

AIM: To determine the particle size distribution of the given COARSE aggregate and to determine ,the THEORY Coarse aggregate is the broken stone used in concrete .The coarse aggregate unless mixed with fine aggregate serves no purpose in cement works .the size of fine aggregate is limited to a maximum of 4.75 mm gauge beyond which it is known as coarse aggregate . EFFECTIVE SIZE Effective size (in microns) is the maximum particle size of the smallest 10% of the aggregate or it is the sieve opening corresponding to 10% finer and is designated by the symbol D10. APPARATUES Indian standard test sieves, weighing balance ,sieve shaker etc . Size of sieves to be used
(I) For coarse aggregate-25mm,20mm 12.5mm, 10mm, 4.75mm
PROCEDURE . (i)Take one kg of coarse aggregate (ii)Arrange the sieves one over the other in relation to their size of opening.(25mm,20mm,12.5mm10mm,4.75mm) (iii) Carry out the sieving for the specified time (iv) Find the weight of agggregate retained on each sieve taken in order and tabulate in table.
GRADING LIMITS FOR AGGREGATES

GRADING LIMIT FOR SINGLE SIZED AGGREGATES (Clause 4.1 and 4.2 of IS: 383- 1970) IS Sieve 80 mm 63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm 4.75 mm 2.36 mm 63 mm 100 85 100 0 30 05 05 Percentage passing for single sized aggregates of nominal size(mm) 40 mm 20 mm 16 mm 12.5 mm 100 85 100 0 20 05 100 85 100 0 20 05 100 85 100 0 30 05 100 85 100 0 45 0 10 10 mm 100 85 100 0 20 05
GRADING LIMITS FOR FINE AGGREGATES

(Clause 4.3 of IS: 383 1970) Grading Zone I 100 90 100 60 95 Grading Zone II 100 90 100 75 100 Percentage Passing Grading Zone III 100 90 100 85 100 Grading Zone IV 100 95 100 95 100
IS Sieve Designation 10 mm 4.75 mm 2.36 mm
1.18 mm 600 micron 300 micron 150 micron
30 70 15 34 5 20 0 10
55 90 35 59 8 30 0 10
75 100 60 79 12 40 0 10
90 100 80 100 15 50 0 15
TEST2-Aggregate Impact Value

Impact testing machine conforming to IS: 2386 (Part IV)- 1963,IS Sieves of sizes 12.5mm, 10mm and 2.36mm, A cylindrical metal measure of 75mm dia. and 50mm depth, A tamping rod of 10mm circular cross section and 230mm length, rounded at one end and Oven. Preparation i) The Passing test sample through should 12.5mm of conform IS to the Sieve following Sample grading: 100%
- Retention on 10mm IS Sieve 100% ii) The sample should be oven-dried for 4hrs. at a temperature of 100 to 110oC and cooled. iii) The measure should be about one-third full with the prepared aggregates and tamped with 25 strokes of the tamping rod.
A further similar quantity of aggregates should be added and a further tamping of 25 strokes given. The measure should finally be filled to overflow, tamped 25 times and the surplus aggregates struck off, using a tamping rod as a straight edge. The net weight of the aggregates in the measure should be determined to the nearest gram (Weight A).
Procedure
to
determine
Aggregate
Impact
Value
i) The cup of the impact testing machine should be fixed firmly in position on the base of the machine and the whole of the test sample placed in it and compacted by 25 strokes of the tamping rod.
ii) The hammer should be raised to 380mm above the upper surface of the aggregates in the cup and allowed to fall freely
onto the aggregates. The test sample should be subjected to a total of 15 such blows, each being delivered at an interval of not less than one second. TEST-AGGREGATECRUSHINGVALUE This test helps to determine the aggregate crushing value of coarse aggregates as per IS: 2386 (Part IV) 1963. The apparatus used is Cylindrical measure and plunger, Compression testing machine, IS Sieves of sizes 12.5mm, 10mm and 2.36mm Procedure to determine Aggregate Crushing Value
i) The aggregates passing through 12.5mm and retained on 10mm IS Sieve are oven-dried at a temperature of 100 to 110oC for 3 to 4hrs.
ii) The cylinder of the apparatus is filled in 3 layers, each layer tamped with 25 strokes of a tamping rod. iii) The weight of aggregates is measured (Weight A).
iv) The surface of the aggregates is then leveled and the plunger inserted. The apparatus is then placed in the compression testing machine and loaded at a uniform rate so as to achieve 40t load in 10 minutes. After this, the load is released. v) The sample is then sieved through a 2.36mm IS Sieve and the fraction passing through the sieve is weighed (Weight B). vi) Two tests should be conducted. Aggregate crushing value = (B/A) x 100%.
TEST4-AGGREGATEABRASIONVALUE
This test helps to determine the abrasion value of coarse aggregates as per IS: 2386 (Part IV) 1963. The apparatus used in this test are Los Angles abrasion testing machine, IS Sieve of size 1.7mm, Abrasive charge 12 nos. cast iron or steel spheres approximately 48mm dia. and each weighing between 390 and 445g ensuring that the total weight Sample of charge is 5000 +25g and Oven. Preparation
The test sample should consist of clean aggregates which has been dried in an oven at 105 to 110oC to a substantially constant weight and should conform to one of the gradings shown in the table below:
Procedure
to
determine
Aggregate
Abrasion
Value
The test sample and the abrasive charge should be placed in the Los Angles abrasion testing machine and the machine rotated at a speed of 20 to 33 revolutions/minute for 1000 revolutions. At the completion of the test, the material should be discharged and sieved through 1.70mm IS Sieve.
Reporting
of
Results
i) The material coarser than 1.70mm IS Sieve should be washed, dried in an oven at a temperature of 100 to 110 oC to a constant weight and weighed (Weight B).
ii) The proportion of loss between weight A and weight B of the test sample should be expressed as a percentage of the original weight of the test sample. This value should be reported as, Aggregate abrasion value = (A-B)/B x 100%.
TEST5-SPECIFIC GRAVITY OF CORSE AGGREGATES

AIM:To determine the specific gravity of given sample of fine and coarse aggregates. Apparatus
1. A balance or scale of capacity not less than 3 kg, readable and accurate to 0.5 g and of such a type and shape as to permit the basket containing the sample to be suspended from the beam and the weighed in water. 2. 3. 4. 5. 6. 7. A well ventilated oven thermostatically controlled to maintain a temperature of 100oC to 110oC. A wire basket of not more than 6.3 mm mesh or a perforated container of convenient size. A stout water tight container of convenient size. Two dry soft absorbent cloths each not less than 7545 cm A shallow tray of area no less than 650 cm2 An air tight container of capacity similar to that of the basket.
Procedure (I) Take 2 kg of aggregate. Sample larger than 10mm (ii)Wash the sample thoroughly to remove finer particle and dust. (iii) Place the sample in a wire basket and immerse it in distilled water at a temperature between 22oC and 32oC with a cover of at least 5 cm of water above the top of the basket. (iv) Remove the entrapped air by lifting the basket containing the sample 25 mm above the base of the tank and allowing it to drop per second, care being taken to see that the sample is completely immersed in water during the operation. (v) With the sample in water at a temper of 220C-32oC (W). (vi) Remove the basket and aggregate from water and allow To drain for a few minutes. (vii) Empty the aggregate from the basket to a shallow tray. (viii) Immerse the empty basket in water jolt 25 times and than the weight in water (w2). (ix) Place the aggregates in oven at a temperature of 100oC to 110oC for 24+- 0.5 hours. (x) Remove it from the oven and cool it and find the weight. (w2)
TEST 6-BULK DENSITY AND PERCENTAGE VOIDS OF AGGREGATES

Aim:To determine the bulk density and percentage voids of aggregate . Apparatus (I)Balance -A balance sensitive to 0.5% of the weight of the sample to be weighed . (ii) Cylindrical Metal Measure- The measure shall be of 3,15 or 30 liters capacity and shall comply with the requirements given below. . . . Size of largest particle 4.75mm and under Over 4.75 mm to 40mm Over 40mm Nominal capacity 3 liters 15 liters 30 liters
4. Tamping Rod- A straight metal tamping rod of cylindrical cross section 16 mm in diameters 60 cm long , rounded at one end .
Procedure Take the weight of empty measure (W) (ii) Fill the measure with aggregates sample for about one third height and tam evenly with 25 strokes of the rounded end of the tamping rod (iii) Add a similar quantity of aggregate as second layer and tamp it evenly with 25 strokes. (iv) Fill the measure with a third layer of aggregate up to over following and tamp it with 25 strokes
(v) Strike off the surplus aggregate using the tamping rod as a straight edge. (vi) Take the weight (w1) (vii) Empty the measure and fill it again to over flowing by means of a shovel, the aggregate being discharged from a height not exceeding 5 cm above the top of the measure. (viii)Level the surface of the measure and weight it (w2). r = Bulk density of aggregate in kg / liter.
3. FINE AGGREGATE TESTING
GRAIN SIZE ANALYSIS

AIM To determine the particle size distribution of the given fine aggregate and to determine ,the fineness modulus,the effective . THEORY Fine aggregate is the sand used in mortars.the size of fine aggregate is limited to a maximum of 4.75 mm gauge beyond which it is known as coarse aggregate . FINENESS MODULUS. Fineness modulus is only a numerical index of fineness, giving some idea of the mean size of the particle s in the entire body of the aggregate. To a certain extent it is a method of standardization of the grading of the aggregate. It is obtained by adding the percentage weight of material retained in each of the standard sieves and dividing it by 100. To object of finding the fineness modulus is to grade a given aggregate for the most economical mix and workability with minimum quantity of cement .Certain limits of fineness modulus for fine coarse aggregates are given in the table below and a sample under test should satisfy these results so that the aggregate may give good workability under economical conditions. LIMIT OF FINENESS MODULUS
Maximum size of aggregate Fine Aggregate Coarse aggregate 20mm
Fineness modulus Minimum Maximum 2 6 3.5 6.9
Coarse aggregate 40mm Coarse aggregate 75mm
6.9 7.5
7.5 8.0
APPARATUES Indian standard test sieves, weighing balance ,sieve shaker etc . Size of sieves to be used. (I) for fine agggregate- 4.75mm, 2.36mm, 1.18mm, 600 microns, 300microns ,150microns . .
PROCEDURE FINE AGGREGATE (i)Take one kg of sand from the laboratory sample (ii)Arrange the sieves in order of IS sieves nos 480, 240, 120, 60, 30 and 15, Keeping sieve no.480 at the top and 15 at the bottom and cover the top. (iii)Keep the sample in the top sieve no.480. (iv) Carry out the sieving in the set of sieves for not less than 10 minutes . (v) find the weight of sample retained in each sieve. (vi) Tabulate the values in given tabular column . 4. Effective size =..micron
5. Uniformity coefficient = 6. Fineness modulus =
TEST 2-SILT CONTENT
TEST3- SPECIFIC GRAVITY OF FINE AGGREGATES

AIM To determine the specific gravity of given sample of fine aggregates. 1.A balance of capacity not less than 3kg ,readable and accurate to 0.5 gm and of such a type as to permit the weighing of the vessel containing the aggregate and water . 2.A well ventilated oven to maintain a temperature of 100C to 110C 3.Pyconometer of about 1 littre capacity having a metal conical screw top with a 6mm hole at its apex . The screw top shall be water tight . 4.a means supplying a current warm air . 5.A tray of area not less than 32cm. 6.An air tight container large enough to take the sample. 7.Filter papers and funnel.
Procedure (I) Take about 500g of sample and place it in the pycnometer. (II) Pour distilled water into it until it is full.
(III) Eliminate the entrapped air by rotating the pycnometer on its side ,the hole in the apex of the cone being covered with a finger. (IV) Wipe out the outer surface of pycnometer and weigh it (W) (V) Transfer the contents of the pycnometer into a tray , care being taken to ensure that all the aggregate is transferred . (VI) Refill the pycnometer with distilled water to the same level . (VII) Find out the weight (W1) (VIII) drink water from the sample through a filter paper . (IX) Place the sample in oven in a tray at a temperature of 100C to 110 C for 240.5 hours ,during which period ,it is stirred occasionally to facilitate drying . (X) Cool the sample and weigh it (W2)
PROPERTIES OF AGGREGATES
1. AGGREGATES: BULK DENSITY, SPECIFIC GRAVITY AND VOIDS BULK DENSITY River sand Fine Medium Coarse 1.44 1.52 1.60
Beach or river shingle Broken stone Stone screenings Broken Granite
1.60 1.60 1.44 1.68
SPECIFIC GRAVITY Trap Granite Gravel Sand 2.9 2.8 2.66 2.65
VOIDS, PERCENT, AVERAGE River sand
Fine Coarse
43 35
Mixed and moist Mixed and dry
38 30
Broken stone, graded 25 mm maximum size 50 mm maximum size 63 mm maximum size 46 45 41
Stone screenings
48
Note: Above values are indicative only
2. AGGREGATES: LIMITING VALUES OF MECHANICAL PROPERTIES LIMITING VALUES (PERCENTAGE) OTHERTHAN FOR PROPERTIES FOR WEARING SURFACES SURFACES Crushing value Impact value Abrasion value (Los Angeles) Soundness (Average loss of weight after 5 cycles) Fine aggregates Coarse aggregates *Source- IS: 383 1970 30 30 30 When tested with Na2SO4 10 12 45 45 50 When tested with MgSO4 15 18
WEARING
3. APPROXIMATE WATER ABSORPTION OF AGGREGATES, BY WEIGHT Average sand 1.0 percent Pebbles and crushed limestone 1.0 percent Trap rock and granite 0.5 percent Porous sandstone 0.5 percent Very light and porous aggregates may absorb as much as 25 percent by weight
Note: The coarser the aggregate, the less free water it carries.
4. LIMITS OF DELETERIOUS MATERIALS (Percentage by weight, maximum) (Clause 3.2.1 of IS: 383 1970) FINE AGGREGATES DELETERIOUS SUBSTANCES Uncrushed Crushed Coal and lignite Clay lumps Materials finer than 75 micron sieve Shale Total of percentages of all deleterious materials ** 1.00 1.00 2.00 1.00 1.00 1.00 15.00 -
COARSE AGGREGATES Uncrushed Crushed 1.00 1.00 3.00 1.00 1.00 3.00 -
5.00
2.00
5.00
5.00
5. SURFACE WATER CARRIED BY AGGREGATES APPROXIMATE QTY OF SURFACE WATER AGGREGATES Percent by mass Ltr./cu.m Very wet sand Moderately wet sand Moist sand Moist gravel or crushed rock 7.5 5.0 2.5 1.25 2.5 120 80 40 20 40
Note: Coarser the aggregate, less the water it will carry Source: Table 10 of IS: 456 2000
4. CEMENT TESTING
TEST1FINENESS So we need to determine the fineness of cement by dry sieving as per IS: 4031 (Part 1) 1996.The principle of this is that we determine the proportion of cement whose grain size is larger then specified mesh size.
The apparatus used are 90m IS Sieve, Balance capable of weighing 10g to the nearest 10mg, A nylon or pure bristle
brush,
preferably
with
25
to
40mm,
bristle,
for
cleaning
the
sieve.
Sieve shown in pic below is not the actual 90m seive.Its just for reference.
Procedure i) Weigh
to approximately 10g of
determine cement to the
fineness nearest 0.01g and
of place it on the
cement sieve.
ii) Agitate the sieve by swirling, planetary and linear movements, until no more fine material passes through it. iii) Weigh the residue and express its mass as a percentage R1,of the quantity first placed on the sieve to the nearest 0.1 percent. iv) Gently brush all the fine material off the base of the sieve.
v) Repeat the whole procedure using a fresh 10g sample to obtain R2. Then calculate R as the mean of R1 and R2 as a percentage, expressed to the nearest 0.1 percent. When the results differ by more than 1 percent absolute, carry out a third sieving and calculate the mean of the three values.
TEST2- STANDARD CONSISTENCY OF CEMENT

To determine the quantity of water required to produce a cement paste of standard consistency. The standard consistency is that consistency, which will permit the vicat plunger to penetrate to a point 5 to 7mm from the bottom of the vicat mould when tested as described below. APPARATUS 1. VICAT APPARATUS The vicat apparatus consists of a frame having a movable rod with a cap at one end and at the other end any one of the following attachment, which are interchangeable. i) Needle for determining the initial setting time ii) Needle for determining the final setting time iii) Plunger for determining the standard consistency 2.NEEDLES NEEDLE FOR INITIAL SETTING TIME
The needle is having a cross sectional area of 1mm2. The end of the needle is flat. NEEDLE FOR FINAL SETTING TIME The needle is circular having a cross sectional area of 1mm2. The needle is fitted with a metal attachment. The end of the needle projects beyond the cutting edge of the hollowed out metal attachment.
1. PLUNGER FOR STANDARD CONSISTANCY
It is of polished brass 10 0.05mm in diameter with a projection at the upper end for insertion into the movable rod. The lower end is flat. MOVABLE ROD Movable rod carries an indicator which moves over a graduated scale attached to the frame (certain models have an additional attachment of dash pot, which facilitates lowering of movable rod slowly). 4. GRUADUATED SCALE Graduated scale is 40mm in length and the smallest division of scale is 1mm. 5. VICAT MOULD Single mould: The vicat mould is in the foam of a frustum of a cone having an internal diameter of 60+/-0.5mm at the top, 70 +/- 0.5mm at the bottom and height 40 +/_ 0.5mm. 1.1.2.2.2 Split type vicat mould:- The split type vicat mould is used as an alternative to single mould. This mould consist of a split ring having an internal diameter 80+/- 0.1mm and a height 40+/_0.5mm. A non-porous base plate is provided. The split mould is provided with a suitable clamping ring. PROCEDURE
1. Keep the vicat apparatus on a level base (when using vicat apparatus with dash pot, keep the bearing movable rod to its highest position and pin it.) Unscrew the top of the dash pot. Half fill the dash pot with any suitable oil of viscosity and screw the top. Work the plunger a number of times. 2. Attach the plunger for determining standard consistency to the movable rod. Work the plunger a number of times.
Take 400 gm of cement in a pan and a weighed quantity of water in a beaker. 3. Prepare a paste with the water added to cement. Start a stop watch at the time of adding water to cement. 4. Keep the vicat mould on a non porous plate and fill the cement paste in it. 5. After completely filling the mould, shake it slightly to expel the air. Smooth off the surface of the paste making it level with the top of the moulder. The cement paste thus prepared is the test block.
6. Place the test block resting on the non porous plate under the movable rod, bearing the needle. 7. Lower the plunger gently to touch the surface of the cement paste and quickly release; (when vicat apparatus with dash pot is used, place the mould filled with cement paste and the non absorbent plate on the base plate of the vicat apparatus. Raise the plunger of the dash pot, bring it in contact with the top cap of the movable bearing rod. Remove the pin holding the movable bearing rod to the surface of the cement paste and quickly release by pushing down the plunger to sink in to the paste). This operation shall be done immediately after filling the mould. 8. Prepare trial test specimens with varying percentages of water until plunger penetrates to a point 5 to 7mm from the bottom of the vicat mould, which is read on the scale. Express the water required as percentage by weight of the dry cement. POINTS TO BE NOTED 1. The time of gauging should not be less than 3 minutes and not more than 5 minutes. Gauging time is the time elapsing from the time of adding water to the dry cement until commencing to fill the mould. 2. The test should be conducted at room temperature 27 oC +/- 2oC 3. There should be no vibration on the working table. 4. The plunger should be cleaned during every repetition.
TEST3-SOUNDNESS
Soundness of cement is determined by Le-Chatelier method as per IS: 4031 (Part 3) 1988. Apparatus The apparatus for conducting the Le-Chatelier test should conform to IS: 5514 1969 Balance, whose permissible variation at a load of 1000g should be +1.0g and Water bath.
Procedure
to
determine
soundness
of
cement
i) Place the mould on a glass sheet and fill it with the cement paste formed by gauging cement with 0.78 times the water required to give a paste of standard consistency.
ii) Cover the mould with another piece of glass sheet, place a small weight on this covering glass sheet and immediately submerge the whole assembly in water at a temperature of 27 2 oC and keep it there for 24hrs. iii) Measure the distance separating the indicator points to the nearest 0.5mm (say d 1 ).
iv) Submerge the mould again in water at the temperature prescribed above. Bring the water to boiling point in 25 to 30 minutes and keep it boiling for 3hrs.
v) Remove the mould from the water, allow it to cool and measure the distance between the indicator points (say d 2 ). vi) (d2 d1 ) represents the expansion of cement.
TEST-4 INITIAL SETTING TIME OF CEMENT (IS 4031, IS 269)

AIM To find the initial setting time of cement APPARATUS Vicat apparatus, needle for initial setting time, stop watch. PROCEDURE Take 400 gm of cement in a pan. Prepare a neat cement paste by adding 0.85 times the water required to give a paste of standard consistency by the previous test. Start a stop watch at the instant when water is added to the cement. Keep the vicat mould on a non porous plate and fill the cement paste in it. After completely filling the mould, it should be shaken slightly to expel the air. Smooth off the surface of the paste making it level with the top of the mould. Place the test block and the non porous plate under the rod bearing the needle having 1sq.mm.cross section. Lower the needle gently till in contact with the surface of the test block and quickly release allowing it to penetrate in to the test block.(When vicat apparatus with dash pot is used, place the mould filled with cement paste and the non absorbent plate on the base of the vicat apparatus .Raise the in the beginning the needle will completely pierce the block. Repeat the procedure until the needle fails to pierce block for 5+-0.5mm measured from the bottom of the mould. The period elapsing between the time when water is added to the cement and the time at which the needle fails to pierce the test block by 5+-0.5mm is the initial testing time.
TEST5-
SPECIFIC GRAVITY OF CEMENT
AIM To determine the specific gravity is normally defined as the ratio between the weight of a given volume of material and weight of an equal volume of water.To determine the specific gravity of cement, kerosene which doe snot recent with cement is used.
APPARATUES Le Chaterliers flask, weighing balance, kerosene (free from water). Le Chaterliers flask, is made of thin glass having a bulb at the bottom. The capacity of the bulb is nearly 250 ml. The bulb is 7.8 cm in mean diameter. The stem is graduated in millimeters. The zero graduation is at a distance of 8.8 cm from the top of the bulb. At 2 cm from the zero, there is another bulb is of length 3.5cm and capacity 17 ml. At 1 cm from bulb, the stem is marked with 18 ml and is grated up to 24 ml. The portion above 24ml mark is in the form of a funnel of diameter 5cm.
PROCEDURE (I) Dry the flask carefully and fill with kerosene or naphtha to a point on the stem between zero and 1 ml. (II) Record the level of the liquid in the flask as initial reading. (III) Put a weighted quantity of cement (about 60 gm) into the flask so that level of kerosene rise to about 22 ml mark, care being taken to avoid splashing and to see that cement does not adhere to the sides of the above the liquid. (IV) After putting all the cement to the flask, roll the flask gently in an inclined position to expel air until no further air bubble rise3s to the surface of the liquid. (V) Note down the new liquid level as final reading.
TEST6- COMPRESSIVE STRENGTH OF MORTAR CUBES

AIM To find the compressive strength of standard cement sand mortar cubes. APPARATUS 7.06cm cubes moulds (50cm2 face area), apparatus for gauging and mixing mortar, vibrator, compression testing maching etc.
PROCEDURE Take 200gm of cement and 600gm of standard sand in the proportion 1:3 by weight) in a pan. (The standard sand shall be of quartz, of light, gray or whitish variety and shall be free from silt. The sand grains shall be angular, the shape of grains approximating to the spherical form, elongated and flattened grains being present only in very small quantities. Standard sand shall pass through 2mm IS sieve and shall be retained on 90 microns IS sieve with the following particle size distribution.
Mix the cement and sand in dry condition with a trowel for 1minitues and then add water. The quantity of water shall be (p/4+3)% of combined weight of cement and sand where, p is the % of water required to produce a paste of standard consistency determined earlier. Add water and mix it until the mixture is of uniform colour. The time of mixing shall not be < 3 minutes & not > 4 minutes. Immediately after mixing the mortar, place the mortar in the cube mould and prod with the help of the rod. The mortar shall be prodded 20 times in about 8 sec to ensure elimination of entrained air. If vibrator is used, the period of vibration shall be 2minitues at the specified speed of 12000+-400 vibrations /minutes. Then place the cube moulds in temperature of 272o C and 90% relative humidity for 24 hours. After 24 hours remove the cubes from the mould and immediately submerge in clean water till testing. Take out the cubes from water just before testing. Testing should be done on their sides without any packing. The rate of loading should be 350 kg/cm2/minute and uniform. Test should be conducted for 3 cubes and report the average value as the test result for both 7day and 28 day compressive strength.
PHYSICAL & CHEMICAL PROPERTIES OF OPC OF VARIOUS GRADES

Physical and Chemical Properties of Ordinary Portland Cement (OPC) of Various Grades
33 Grade 43 Grade (IS: 269- (IS:81121989) 1989) PHYSICAL PROPERITES 53 Grade (IS: 122691987)
Type of Cement
Minimum Compressive Strength, N/mm2 3 day 16 23
27
7 day 28 day Fineness
22 33
33 43
37 53
Minimum specific surface (Blaines air permeability) m2/kg 225 Setting times (minutes) Initial, minimum 30 Final,maximum 600 Soundness, expansion (Le Chatelier Test, mm), maximum 10.0 Autoclave test for MgO, percent, maximum 0.8
225 30 600
225 30 600
10.0
10.0
0.8
0.8
CHEMICAL PROPERTIES Loss on ignition, percent, maximum 5 5 Insoluble residue, percent, maximum 4 2 Magnesia Mgo, percent maximum 6 6 SO3 , percent, maximum for: C3A>5 percent 2.5 C3A<5 percent 3 Lime saturation 0.66 to 1.02 factor (LSF)
4 2 6
2.5 3
2.5 3
0.66 to 1.02
0.8 to 1.02
5. CONCRETE TESTING TEST1-COMPRESSIVE STRENGTH OF CONCRETE CUBES TEST 2-REBOUND HAMMER
TEST 3-Concrete Mix Design As Per Indian Standard Code

.
Concrete Mix Design

Introduction
The process of selecting suitable ingredients of concrete and determining their relative amounts with the objective of producing a concrete of the required, strength, durability, and workability as economically as possible, is termed the concrete mix design. The proportioning of ingredient of concrete is governed by the required performance of concrete in 2 states, namely the plastic and the hardened states. If the plastic concrete is not workable, it cannot be properly placed and compacted. The property of workability, therefore, becomes of vital importance. The compressive strength of hardened concrete which is generally considered to be an index of its other properties, depends upon many factors, e.g. quality and quantity of cement, water and aggregates; batching and mixing; placing, compaction and curing. The cost of concrete is made up of the cost of materials, plant and labour. The variations in the cost of materials arise from the fact that the cement is several times costly than the aggregate, thus the aim is to produce as lean a mix as possible. From technical point of view the rich mixes may lead to high shrinkage and cracking in the structural concrete, and to evolution of high heat of hydration in mass concrete which may cause cracking. The actual cost of concrete is related to the cost of materials required for producing a minimum mean strength called characteristic strength that is specified by the designer of the structure. This depends on the quality control measures, but there is no doubt that the quality control adds to the cost of concrete. The extent of quality control is often an economic compromise, and depends on the size and type of job. The cost of labour depends on the workability of mix, e.g., a concrete mix of inadequate workability may result in a high cost of labour to obtain a degree of compaction with available equipment. Requirements of concrete mix design The requirements which form the basis of selection and proportioning of mix ingredients are : a ) The minimum compressive strength required from structural consideration b) The adequate workability necessary for full compaction with the compacting equipment available. c) Maximum water-cement ratio and/or maximum cement content to give adequate durability for the particular site conditions
d) Maximum cement content to avoid shrinkage cracking due to temperature cycle in mass concrete.
Types of Mixes
1. Nominal Mixes In the past the specifications for concrete prescribed the proportions of cement, fine and coarse aggregates. These mixes of fixed cementaggregate ratio which ensures adequate strength are termed nominal mixes. These offer simplicity and under normal circumstances, have a margin of strength above that specified. However, due to the variability of mix ingredients the nominal concrete for a given workability varies widely in strength. 2. Standard mixes The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and may result in under- or over-rich mixes. For this reason, the minimum compressive strength has been included in many specifications. These mixes are termed standard mixes. IS 456-2000 has designated the concrete mixes into a number of grades as M10, M15, M20, M25, M30, M35 and M40. In this designation the letter M refers to the mix and the number to the specified 28 day cube strength of mix in N/mm2. The mixes of grades M10, M15, M20 and M25 correspond approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and (1:1:2) respectively. 3. Designed Mixes In these mixes the performance of the concrete is specified by the designer but the mix proportions are determined by the producer of concrete, except that the minimum cement content can be laid down. This is most rational approach to the selection of mix proportions with specific materials in mind possessing more or less unique characteristics. The approach results in the production of concrete with the appropriate properties most economically. However, the designed mix does not serve as a guide since this does not guarantee the correct mix proportions for the prescribed performance. For the concrete with undemanding performance nominal or standard mixes (prescribed in the codes by quantities of dry ingredients per cubic meter and by slump) may be used only for very small jobs, when the 28-day strength of concrete does not exceed 30 N/mm2. No control testing is necessary reliance being placed on the masses of the ingredients. Factors affecting the choice of mix proportions Kdmtl testing manual
The various factors affecting the mix design are: 1. Compressive strength It is one of the most important properties of concrete and influences many other describable properties of the hardened concrete. The mean compressive strength required at a specific age, usually 28 days, determines the nominal water-cement ratio of the mix. The other factor affecting the strength of concrete at a given age and cured at a prescribed temperature is the degree of compaction. According to Abrahams law the strength of fully compacted concrete is inversely proportional to the water-cement ratio. 2. Workability The degree of workability required depends on three factors. These are the size of the section to be concreted, the amount of reinforcement, and the method of compaction to be used. For the narrow and complicated section with numerous corners or inaccessible parts, the concrete must have a high workability so that full compaction can be achieved with a reasonable amount of effort. This also applies to the embedded steel sections. The desired workability depends on the compacting equipment available at the site. 3. Durability The durability of concrete is its resistance to the aggressive environmental conditions. High strength concrete is generally more durable than low strength concrete. In the situations when the high strength is not necessary but the conditions of exposure are such that high durability is vital, the durability requirement will determine the water-cement ratio to be used. 4. Maximum nominal size of aggregate In general, larger the maximum size of aggregate, smaller is the cement requirement for a particular water-cement ratio, because the workability of concrete increases with increase in maximum size of the aggregate. However, the compressive strength tends to increase with the decrease in size of aggregate. IS 456:2000 and IS 1343:1980 recommend that the nominal size of the aggregate should be as large as possible. 5. Grading and type of aggregate The grading of aggregate influences the mix proportions for a specified workability and watercement ratio. Coarser the grading leaner will be mix which can be used. Very lean mix is not desirable since it does not contain enough finer material to make the concrete cohesive. The type of aggregate influences strongly the aggregate-cement ratio for the desired workability and stipulated water cement ratio. An important feature of a satisfactory aggregate is the uniformity of the grading which can be achieved by mixing different size fractions. 6. Quality Control
The degree of control can be estimated statistically by the variations in test results. The variation in strength results from the variations in the properties of the mix ingredients and lack of control of accuracy in batching, mixing, placing, curing and testing. The lower the difference between the mean and minimum strengths of the mix lower will be the cement-content required. The factor controlling this difference is termed as quality control.
Mix Proportion designations

The common method of expressing the proportions of ingredients of a concrete mix is in the terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of proportions 1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or the mix contains one part of cement, two parts of fine aggregate and four parts of coarse aggregate. The proportions are either by volume or by mass. The water-cement ratio is usually expressed in mass Factors to be considered for mix design The grade designation giving the characteristic strength requirement of concrete. The type of cement influences the rate of development of compressive strength of concrete. Maximum nominal size of aggregates to be used in concrete may be as large as possible within the limits prescribed by IS 456:2000. The cement content is to be limited from shrinkage, cracking and creep. The workability of concrete for satisfactory placing and compaction is related to the size and shape of section, quantity and spacing of reinforcement and technique used for transportation, placing and compaction.
Procedure
1. Determine the mean target strength ft from the specified characteristic compressive strength at 28day fck and the level of quality control. ft = fck + 1.65 S where S is the standard deviation obtained from the Table of approximate contents given after the design mix. 2. Obtain the water cement ratio for the desired mean target using the emperical relationship between compressive strength and water cement ratio so chosen is checked against the limiting water cement ratio. The water cement ratio so chosen is checked against the limiting water cement ratio for the requirements of durability given in table and adopts the lower of the two values. 3. Estimate the amount of entrapped air for maximum nominal size of the aggregate from the table. 4. Select the water content, for the required workability and maximum size of aggregates (for aggregates in saturated surface dry condition) from table. 5. Determine the percentage of fine aggregate in total aggregate by absolute volume from table for the concrete using crushed coarse aggregate. Kdmtl testing manual
6. Adjust the values of water content and percentage of sand as provided in the table for any difference in workability, water cement ratio, grading of fine aggregate and for rounded aggregate the values are given in table. 7. Calculate the cement content form the water-cement ratio and the final water content as arrived after adjustment. Check the cement against the minimum cement content from the requirements of the durability, and greater of the two values is adopted. 8. From the quantities of water and cement per unit volume of concrete and the percentage of sand already determined in steps 6 and 7 above, calculate the content of coarse and fine aggregates per unit volume of concrete from the following relations:
where V = absolute volume of concrete = gross volume (1m3) minus the volume of entrapped air Sc = specific gravity of cement W = Mass of water per cubic metre of concrete, kg C = mass of cement per cubic metre of concrete, kg p = ratio of fine aggregate to total aggregate by absolute volume fa, Ca = total masses of fine and coarse aggregates, per cubic metre of concrete, respectively, kg, and Sfa, Sca = specific gravities of saturated surface dry fine and coarse aggregates, respectively 9. Determine the concrete mix proportions for the first trial mix. 10. Prepare the concrete using the calculated proportions and cast three cubes of 150 mm size and test them wet after 28-days moist curing and check for the strength. 11. Prepare trial mixes with suitable adjustments till the final mix proportions are arrived at. EXAMPLE M-20 Mix Designs as per IS-10262-2009
M-20 CONCRETE MIX DESIGN
As per IS 10262-2009 & MORT&H A-1 Stipulations for Proportioning 1 Grade Designation 2 Type of Cement 3 Maximum Nominal Aggregate Size 4 5 6 Workability (MORT&H 1700-4) 7 Exposure Condition 8 Degree of Supervision 9 Type of Aggregate Crushed Angular Aggregate 10 Maximum Cement Content (MORT&H Cl. 1703.2) 540 kg/m3 11 Chemical Admixture Type A-2 Test Data for Materials 1 Cement Used 2 Sp. Gravity of Cement 3 Sp. Gravity of Water 4 Chemical Admixture Not Used 1.00 3.15 Coromandal King OPC 53 grade Superplasticiser Confirming to IS9103 Good Normal 25 mm (Slump) Minimum Cement Content (MORT&H 1700-3 A) 20 mm 250 kg/m3 M20 OPC 53 grade confirming to IS12269-1987
Maximum Water Cement Ratio (MORT&H 1700-3 A) 0.5
5 Sp. Gravity of 20 mm Aggregate 6 Sp. Gravity of 10 mm Aggregate 7 Sp. Gravity of Sand 8 Water Absorption of 20 mm Aggregate 9 Water Absorption of 10 mm Aggregate 10 Water Absorption of Sand 11 Free (Surface) Moisture of 20 mm Aggregate 12 Free (Surface) Moisture of 10 mm Aggregate 13 Free (Surface) Moisture of Sand 14 Sieve Analysis of Individual Coarse Aggregates 15 Sieve Analysis of Combined Coarse Aggregates 15 Sp. Gravity of Combined Coarse Aggregates 16 Sieve Analysis of Fine Aggregates A-3 Target Strength for Mix Proportioning 1 Target Mean Strength (MORT&H 1700-5) 30N/mm2 2 Characteristic Strength @ 28 days A-4 Selection of Water Cement Ratio 1 Maximum Water Cement Ratio (MORT&H 1700-3 A) 0.5
2.884 2.878 2.605 0.97% 0.83% 1.23% nil nil nil Separate Analysis Done Separate Analysis Done 2.882 Separate Analysis Done
20N/mm2
2 Adopted Water Cement Ratio A-5 Selection of Water Content 1 Maximum Water content (10262-table-2) 2 Estimated Water content for 25 mm Slump 145 Lit. 3 Superplasticiser used A-6 Calculation of Cement Content 1 Water Cement Ratio 2 Cement Content (145/0.5) 290 kg/m3 Which is greater then 250 kg/m3 0.5 nil 186 Lit. 0.5
A-7 Proportion of Volume of Coarse Aggregate & Fine Aggregate Content 1 Vol. of C.A. as per table 3 of IS 10262 2 Adopted Vol. of Coarse Aggregate Adopted Vol. of Fine Aggregate ( 1-0.65) A-8 Mix Calculations 1 Volume of Concrete in m3 2 Volume of Cement in m3 (Mass of Cement) / (Sp. Gravity of Cement)x1000 3 Volume of Water in m3 (Mass of Water) / (Sp. Gravity of Water)x1000 4 Volume of Admixture @ 0% in m3 (Mass of Admixture)/(Sp. Gravity of Admixture)x1000 Kdmtl testing manual nil 0.145 0.09 1.00 65.00% 35.00% 62.00%
5 Volume of All in Aggregate in m3 Sr. no. 1 (Sr. no. 2+3+4) 6 Volume of Coarse Aggregate in m3 Sr. no. 5 x 0.65 7 Volume of Fine Aggregate in m3 Sr. no. 5 x 0.35 1 Mass of Cement in kg/m3 2 Mass of Water in kg/m3 3 Mass of Fine Aggregate in kg/m3 4 Mass of Coarse Aggregate in kg/m3 Mass of 20 mm in kg/m3 Mass of 10 mm in kg/m3 5 Mass of Admixture in kg/m3 6 Water Cement Ratio 0.5 nil 1429 1029 400 696 145 290 0.267 0.496 0.763
A-9 Mix Proportions for One Cum of Concrete (SSD Condition)
TEST 4-SLUMP CONE

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