Introduction To Sprayed Concrete

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C 2571 , MPSEZL
TEST PROCEDURE FOR COMPRESSIVE STRENGTH TEST

OF CONCRETE SPECIMENS
PURPOSE OF TESTING:
 This test is done to determine compressive strength of concrete specimens.
IS REFERANCE :
 IS 516 : Methods of test for strength of concrete
 IS 1199 : Method of sampling and analysis of concrete
TEST EQUIPMENTS :
 Compression Testing Machine 3000 kN

 Cube (15x15x15) & (10x10x10) cm3 & Cylinder (15x300)
Above Testing Machine should regularly calibrate at every three month intervals.
AGE AT TEST :
 Test is conducted at recognized ages of the test specimens, the more common being 7&28 days.
 The age is calculated from the time of addition of water to the dry ingredients.
NUMBER OF SPECIMENS:
 At least three specimens is required for testing at each specified age.
TEST PROCEDURE :
 Specimens stored in water should test immediately on removal from the water & should maintain the wet
condition until testing .
 Bearing surface of testing machine should wipe clean & the loose materials from the surface of
specimens also removed.
 Cube specimens should be placed in such manner that the load shall be applied to opposite sides as it
cast.
 The axis of the specimens shall be carefully aligned with the center of the thrust.
 The pace rate is to be set to 5.2 kN/Sec for 15cm cube & 4.0 kN/Sec for 15 cm dia cylinder.
 The maximum load applied to the specimen shall be recorded.
CALCULATIONS :
 The measured compressive strength of the specimen = P/A ( Kg/cm2,N/mm2or MPa)
a. P = Max load applied to the specimen during the test
b. A = Cross sectional area of the specimen
 Average of three values is taken as representative of the batch.
 Individual variation should not be more than + 15 % of the Average.
ACCEPTANCE CRITERIA :
 The mean strength determined from any group of four consecutive test results is higher than
a. For M-15 grade of concrete :- fck + 0.825x S or fck + 3.0 MPa Which ever is greater.
b. For M-20 grade & above of concrete :- fck + 0.825x S or fck + 4.0 MPa Which ever is
greater
c. Any individual result should greater than fck - 3.0 MPa for M-15 grade of concrete.
d. Any individual result should greater than fck - 4.0 MPa for M-20 grade & above of
concrete.
e. For Cylinder strength shall not be less than 75% of the cube strength .
Where fck = Characteristic strength of concrete & S = Standard deviation in MPa .
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C 2571 , MPSEZL
TEST PROCEDURE FOR FLEXTURAL STRENGTH TEST

OF CONCRETE SPECIMENS
PURPOSE OF TESTING:
 This test is done to determine flexural strength of concrete specimens.
IS REFERANCE :
 IS 516 : Methods of test for strength of concrete .
 IS 1199 : Method of sampling and analysis of concrete .
 IS 456 : Code of practice for plain & reinforced concrete .
TEST EQUIPMENTS :
 Flexural Testing Machine 100 KN capacity.

 Concrete beam (150x150x700)
 Scale
 Pencil or Marker
Above Testing Machine should regularly calibrate at every six month intervals.
TEST SPECIMENS :
 The test specimen shall be 15x15x70 cm concrete beam .
 Specimen shall be cured by submerging in clean water up to time of testing .
AGE AT TEST :
 Test is conducted normally 28 days after the casting date .
 At least three specimens require for testing at each specified age.
TEST PROCEDURE :
 Specimens stored in water should be tested immediately on removal from the water & should maintain
the wet condition until testing .
 The bearing surface of the supporting & loading rollers shall be wiped clean & the loose materials from
the surface of specimens also removed.
 Mark two lines on the supporting surface, measuring 50mm from the both edge. & another two lines on
the loading surface, measuring 250mmfrom the both edge .
 The specimen shall then be placed in such manner that the load shall be applied to the uppermost surface
as it cast .
 The load shall be applied by increasing continuously at a rate so that extreme fiber stress increase at
approximately 7Kg/cm 2 /min that is, 4 kN/min for 150mm specimen.
 The load shall increase until the specimen fails.
CALCULATIONS :
 The flexural strength shall be expressed as the modulus of rapture F b,
Fb = Px L ( MPa)
B x D2
a. P = Max load applied to the specimen in N
b. L = Length of specimen on which it is supported in mm
c. B = Width of specimen in mm
d. D = Depth of the specimen
 As per IS 456- 2000 it should not be less than 0 .7√fck .
 Where fck = Characteristic strength of concrete.
C 2571 , MPSEZL
2
TEST PROCEDURE FOR SPLIT TENSILE STRENGTH TEST
OF CONCRETE CYLINDERS
PURPOSE OF TESTING:
 This test is done to determine Split tensile strength of concrete specimens.
IS REFERANCE :
 IS 516 : Methods of test for strength of concrete .
 IS 1199 : Method of sampling and analysis of concrete .
 IS 5816 : Methods of test for splitting tensile strength of concrete cylinders .
TEST EQUIPMENTS :
 Cylinder (15x300)
 2 No 3mm plywood stripe (30cm long & 2.5cm wide)
TEST SPECIMENS :
 Test specimen shall be cylindrical with diameter not less than 15cm & length is not less than the &not
more than twice of the dia, but more common being it is used (15x30) cm cylinder .
AGE AT TEST :
 Test shall be conducted normally 28 days after the casting date .
 At least three specimens shall be made for testing at each specified age.
TEST PROCEDURE :
 Specimens stored in water shall be tested immediately on removal from the water & should maintain the
wet condition until testing.
 Marking shall be drawn through the diameter line to ensure the same axial plane .
 The specimen shall be placed in the testing machine in such manner that the axial plane of the specimen
should be coincide with center of the bearing surface .
 Then two plywood stripe should placed in both bearing & loading face of the specimen.
 The rate of loading maintains for 15cm dia &30cm length cylindrical works out 1.62 to 2.43kN/Sec.
 The maximum load applied to the specimen shall be recorded .
CALCULATIONS :
 The measured splitting tensile strength Tsp shall be calculated as following,
Tsp = 2P ( MPa)
3.14xDL
a. P = Max load applied to the specimen in N
b. D = Dia of the specimen
c. L = Length of the specimens
Min 0.63*fck N/mm2

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINING MODULUS OF ELASTICITY

OF CONCRETE BY MEANS OF COMPRESSOMETER
PURPOSE OF TESTING:
 This test is done to determine the modulus of elasticity of concrete by means of an extensometer.
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IS REFERANCE :
 IS 1199 : Method of sampling and analysis of concrete
TEST EQUIPMENTS :
 Compressometer along with a dial gauge .
 Cylinder (150x300)
 Scale
 Sulpher (For capping the loading face)
 Capping instrument
 Stove (For melting the sulpher )
AGE AT TEST :
 Test is conducted normally 28 days after the casting date .
PREPARATION OF TEST SPECIMEN :

 At least three specimens is required ready for testing.
 First capping is done by means of sulpher on the loading surface of the test specimens .
 Next mark 75mm from the both vertical edge along the whole periphery of the cylinders for fixing the
compressometer.
 Adjust compressometer screw along the marking line & lock them in position.
 Adjust dial gauge pivot for its free movement & remove the spacer frames .
TEST PROCEDURE :
 Test specimen with compressometer place centrally along the bearing surface of the testing machine.
 The pace rate of loading is to be maintain 4 kN/Sec until an average stress of ( C+0.5)N/mm2 is reached .
 Where C ,is one-third of the average compressive strength of cube.
 Maintain the above load at least one minute & then reduced gradually.
 Again apply the same load at same pace rate &note the compressometer dial reading at every 25kN load
until an average stress of ( C+0.5)N/mm2 is reached.
 Observed reading of the dial gauge are to be divided by two.
 The individual value should not be more than 15% of the average value.
CALCULATIONS :
 Then the above reading is plotted graphically against the stress.
 Then draw the straight line through the each reading & calculate the slope of any consecutive two values
touching the line, is expressed as the modulus of elasticity ( E ) of the test specimen.
Average stress of the two consecutive reading X 150
E=
Average strain of the above two consecutive results
 As per IS 456- 2000 it should not be less than 5000 Sqrt of fck .
 Where fck = Characteristic strength of concrete

C 2571 , MPSEZL
TEST PROCEDURE FOR TESTING WATER PERMEABILITY ON

CONCRETE
PURPOSE OF TESTING:
 This test is done to determine the Water tightness or Permeability of concrete .
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APPLICABLE STANDARDS : ( For this project )
 GOST : 12730.5-84 : Methods for determination of water tightness .
 IS : 10080
 IS : 10086
TEMPARATURE & HUMIDITY:

 The specimen is kept in normal hardening chamber at temperature of 20 +_ 20 C.
 Relative humidity of the laboratory should 95%.
TEST EQUIPMENTS :
 Permeability cell – Contains six specimen cylindrical mould
 Cylinder moulds – Six nos ( 15 X 15)
 Gauging trowel
 Rosin ( For sealing )
 Air pressure cylinder
 Compressor
 Stove
 Compression testing machine
 Marker
AGE AT TEST :
 Test shall be conducted normally 28 days after the casting date.
PREPARATION OF TEST SPECIMEN :

 At least six specimens is required for testing.
 Chip or scratch the top surface of the cylinder around 130mm dia.
 Place the specimen accommodated in the holder into the test set-up & secure water tightening by using
rosin for avoiding water seepage through sides .
 Ensure pressure should applied on top scratched surface only.
 Tightening the upper cover of the test set-up.
TEST PROCEDURE :
 Raise the pressure in step of 0.2 MPa within 1 to 5 minute.
 For the concrete grade W6 the pressure will be raised up to 0.6MPa
 For the concrete grade W8 the pressure will be raised up to 0.8MPa.
 This above pressure should be hold step by step (0.2MPa to .06/0.8MPa) as following –
a. Specimen height in mm : 150 100
b. Time duration in hrs : 16 12
 After testing released the pressure.
 Then remove the packing material by external heating of mould & keep out the specimen.
 After that clean the specimens & break it axially in compression testing machine.
 Measure the water penetration mark & record it.
 Water should not penetrate more than 20mm from the top surface of the test specimens .
Simplex Infrastructures Ltd. Page: 01 OF 01

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINING SETTING TIME OF CONCRETE BY

PENETRATION RESISTANCE
PURPOSE OF TESTING:
 This test is done to determine the initial & final setting time of concrete .
IS REFERANCE :
 IS : 8142 : Method of test for determining setting time of concrete by penetration resistance.
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 IS : 1199 : Method of sampling & analysis of concrete.
TEST EQUIPMENTS :
 Containers for mortar specimen :- Min lateral dim-150mm & height-150mm (Commonly 150x150 cube
mould are used).
 Penetration Resistance Apparatus :-
a. Spring Reaction type apparatus, graduated from 5kg to 60kgf in step 1kgf.
b. Bearing area of the penetration needles are respectively 645, 323,161,100,65,32 &16mm2.
c. Generally for initial setting time 32 mm2 & for final setting time 16mm2 needles are used.
 Tamping Rod.
 4.75mm sieve.
PREPARATION OF MORTER SPECIMEN:

 Collect some freshly concrete sample & first sieve it by 4.75mm IS sieve.
 Collect the sieving sample on a non-absorptive surface.
 Again remix the mortar properly, then pour it into the container in layers of 50mm each, and compact
with tamping rod 25 times in each layers.
 The mortar surface shall be at least 13mm below the top edge of the container (for collection & removal
of bleeding water).
 Then store the container in such place so that excess evaporation shall be restricted.
 At least one specimens shall be taken for each concrete mix.
TEST PROCEDURE :
 First remove bleed water from the surface just prior to penetration test by means of pipette.
 Insert the above designated needle by applying uniformly downward force to a depth 25mm in approx
10sec.
 Continue the above procedure at hourly intervals, initial setting time test being made after an elapsed
time of 3 to 4 hrs.
 After 3hrs generally test is done at 30 min intervals.
 Initial setting time of concrete is equal to the time elapsed to achieve the penetration resistance
35kg/cm2 or 3.5MPa from the time of added water to the cement..
 Final setting time of concrete is equal to the time elapsed to achieve the penetration resistance
275kg/cm2 or 27.5MPa from the time of added water to the cement.
 Record the force required to produce 25mm penetration & the time of inserting from the time of added
water to the cement.
CALCULATIONS :
 Penetration resistance can be calculated by dividing recorded force by the bearing area of the needle.
 Plot a graph of penetration resistance as ordinate & elapsed time as abscissa.
 Setting time of concrete should satisfy the time limit required

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINING BLEEDING OF CONCRETE IN PLASTIC

CONDITION
PURPOSE OF TESTING:
 This test is done to determine the bleeding of concrete .
IS REFERANCE :
 IS : 9103 : Specification of admixture of concrete.
TEST EQUIPMENTS:
 A cylindrical container of approximately 0.10 m3 capacity.
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 Tamping bar
 Wt balance sensitive to 0.001kg.
 Pipette
 A graduated jar (100ml capacity)
PREPARATION OF TEST SPECIMEN:

 Sample is taken from different points of a fresh concrete batch, while it is discharge from the mixer.
 Then it is thoroughly mixing on a non-absorbent metal tray to form a composite sample.
 Fill the concrete in the container in layers approx 50mm & compact by means of tamping bar, with not
less than 60 strokes.
 Then finish the top surface smoothly by the trowel .
 Leave at least 15mm gap between top edge of the container & top surface of the concrete for
accumulation of bleeding water.
 Then keep the test specimen on a level surface free from vibration, at a temperature of 27 +- 20 C.
 Cover the specimen with a lid.
TEST PROCEDURE :
 Immediately after troweling the surface of the specimen, measure the weight of the specimen along with
the container.
 Drawn off the accumulated water at the top surface of the specimen by means of pipette , at 10min
intervals during the first 40min & at 30min intervals subsequently till the bleeding occurs.
 To facilitate the easy collection of bleeding water , place a 50-mm cover block under one side of the
container.
 Then keep the accumulated water into a graduated jar & record the quantity.
CALCULATIONS :
 Accumulated bleeding water expressed as a percentage of the net mixing water & it calculated as follow:
Bleeding water % =
Vw X W X 100
W1 X S
a. Vw = total mass of bleeding water, kg.
b. W = net mass of water in the concrete batch, kg.
c. W1 = total mass of batch , kg.
d. S = the mass of the sample,kg.
ACCEPTANCE CRITERIA:
 5% over the control mix.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINING OF

UNIT WEIGHT OFREESHLY MIXED CONCRETE
PURPOSE OF TESTING:
 This test is done to determine the weight per cubic meter of freshly mixed concrete .
IS REFERANCE :
TEST EQUIPMENTS:
 A cylindrical container of approximately 0.10 m3 capacity.
 Tamping bar
 Wt balance (sensitive to 0.01kg)
 A non-absorbent metal tray of 1 sq.m.
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 Fill the concrete in the container in layers approx 50mm & compact by means of tamping bar, with not
less than 60 strokes.
 For achieve successfully compaction, malleting the exterior surface of the container by means of wooden
hammer.
 Then finish the top surface smoothly by the trowel .
TEST PROCEDURE :
 Immediately after troweling the surface of the specimen, measure the weight of the specimen along with
the container.
 Before pouring the container, weigh the empty-dry-container accurately.
CALCULATIONS :
 The unit wt of concrete shall be calculated by dividing the wt of fully compacted concrete in the measure
by the capacity of the measure.
Unit wt of concrete = W1- W2 kg/m3

V
a. W1 = Weight of concrete + Wt of empty container, kg

b. W2 = Weight of empty container, kg.
c. V = Volume of the container in m3
 Should not be less than the approved mix design.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINING THE AIR CONTENT OF FREESHLY

MIXED CONCRETE
PURPOSE OF TESTING:
 This test is done to determine of Air Content of freshly mixed concrete.
IS REFERANCE :
 Operating manual supplied along with instrument.
TEST EQUIPMENTS:
 Air meter (this instrument simplifies the application of Boyl’s law for the precision determination of the
air entrained concrete it has the capacity exact .25 cut & accuracy measure of entrained air to 22%).
 Tamping bar.
 Rubber bulb.
 A non absorbent metallic tray.
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 Fill the concrete in the container in three layers & compact by means of tamping bar, with not less than
25 strokes.
 Then remove excess concrete by sliding-off bar across the top flange until the container is just level-full.
TEST PROCEDURE :
 First close the main air valve on top of the air receiver.
 Then open both pet cock on the top of lid .
 Place the lid properly on the material container & close the four toggle clamps.
 Pour water into funnel until water comes out petcocks in the center of the lid & close the both petcock.
 Close both petcocks & air bleeder valve in end of air receiver .
 Then gently pump air into receiver until gauge hand comes to the vicinity of the ‘zero’ line.
 Tap gauge gently with one hand & catch bleeder valve in end air receiver until gauge hand reset exactly
on the starting point & then quickly close the bleeder valve.
 Then open the air valve between air receiver & air container.
 Jar the container slightly when pressure is on ,to allow for possible re-arrangement of particles.
 Tap gauge gently until gauge hand comes to rest.
 Now record the reading of present of air entrained.

C 2571 , MPSEZL
PROCEDURE FOR CASTING THE CUBE,CYLINDER & BEAM MOULD
SCOPE:
 This procedure covers the methods of casting the standard size of cube, cylinder & beam moulds at
production & placement point for determining the properties of hardened concrete.
IS REFERANCE :
 IS 1199 : Method of sampling and analysis of concrete.
 IS 10086 specification of moulds for use in test of cement & concrete.
 IS 456 : Sequence of sampling.
CASTING EQUIPMENTS:
 Standard cube moulds 150X150X150 mm.
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 Standard cylinder moulds 150 (dia) X300 mm
 Standard beam moulds 150X150X700 mm.
 Tamping bar.
 Trowel.
 Table vibretor.
PREPARATION OF SAMPLING:
 Random sampling of fresh concrete is to be taken from transit miller at batching plant & site.
 Some quantity of sample allows to fall down before collecting the sample.
 Sample should be collect on a non-absorbent metal tray/wheel barrow.
 Then thoroughly mix it to have the uniform properties.
 For every 50m3of concrete minimum six cube should be cast.
PROCEDURE:
 Cube moulds : Pour the concrete into the mould in three layers approx 5cm deep & compact it by means
of hand or table vibrator. When compacted by hand each layer shall be tamped with 35 stroke by
standard tamping bar, uniformly distributed over the throughout cross-section of the cube.
 Cylinder moulds : Pour the concrete into the mould in three layers approx 5cm deep & compact it by
means of hand or table vibrator. When compacted by hand each layer shall be tamped with 30 stroke by
 Beam moulds: Pour the concrete into the mould in three layers approx 5cm deep & compact it by means
of hand or table vibrator. When compacted by hand each layer shall be tamped with 35 stroke by
 In all above cases penetrate the number of strokes into the underlying layer & the bottom layer
throughout its depth.
 Before pouring the concrete into the above mould, mould realize oil should apply properly.
 After compaction of the top layer struck off the excess concrete & level it smoothly by means of trowel.
STORAGE OF THE SPECIMENS:

 Keep the specimen at a level surface, free from any kind of vibration , in moist air of at least 90%
humidity & at a temperature of 27 +- 20 C for 24hrs +- ½ hour from the time of adding water to the dry
ingredient.
 After this time period realize the cube from the moulds and submerge in the clean & fresh water under
the controlled temperature of 27 +- 20 C.

C 2571 , MPSEZL
1. TEST PROCEDURE FOR SAMPLING & TESTING OF CHEMICAL ADMIXTURE FOR

CONCRETE
PURPOSE OF TESTING:
 This test is done for the sampling & testing of chemical admixture for normal concrete (M-10 to M-50)
& for admixture band qualification & subsequent batch qualification.
IS REFERANCE :
 IS : 8142 : Method of test for determining setting time of concrete by penetration resistance.
 IS : 9103 : Specification for chemical admixture.
 ASTM-C-494 : Standard specification for chemical admixture for concrete.
TEST EQUIPMENTS:
 Same as compressive, flexural , setting time & bleeding test of concrete.
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SEQUENCE OF SAMPLING:
 For 25 MT once sampling & testing is to be done for same band of admixture.
 Grab sample is taken from each batch of manufacturer .
 Before sampling admixture should be thoroughly agitated.
PREPARATION OF SAMPLING:
 Concrete ingredient for the admixture batch qualification:
a. Cement: Conforming to IS 8112/ IS 1489 .
b. Aggregate: Grading conforming to IS 383-1970 (Max size of aggregate 20mm down).
c. Water : Conforming to IS 456-2000.
 Proportioning of concrete mix (for one cubic meter):
Weight in (kg/m3)
Slump
Sl No Grade Remarks
Admixture (mm)
Cement
Dosage
1 M10 to M40
307 NIL 90 +- 15
(Control Mix)
The concrete mix is
2 M10 to M40
307 1.75% 90 +- 15 required to satisfy
( With admixture)
plastic & hardened
3 M50
307 NIL 90 +- 15 test requirements as
(Control Mix)
specify in ASTM-C
4 M50 494 / IS 9103
(With admixture) 307 2.0% 90 +- 15
NOTE: Minor adjustment in the proportioning of the mix may be carried out to meet the workability requirements
without affecting the performance of concrete.
 Trial is conducted with reduced water content & adjusting the mix proportion to get required yield &
workability.

C 2571 , MPSEZL
TEST PROCEDURE:
 Following test has to be done on plastic & hardened concrete in both control & using the samples of
admixture for a Product band qualification.
a. Slump test.
b. Water reduction.
c. Initial & Final setting time test
d. Bleeding test
e. Compressive strength of concrete at 1,3,7 & 28 days.
f. Flexural strength at 3,7 & 28 days.
 Following test has to be done on plastic & hardened concrete in both control & using the samples of
admixture for a admixture batch qualification.
1. Slump test.
2. water reduction.
3. Initial & Final setting time test
4. Bleeding test
5. Compressive strength of concrete at 1,3,7 & 28 days.
 Require manufacturer test certificates / reports duly authenticated by their authorized functionary
required.
 Admixture should be meet following requirements.
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Description of Tests Acceptance values as per ASTM-C-494 Type G
Water reduction (% of Control Mix) 12% Minimum
Initial setting time At least 1 hrs latter
(Deviation from control) Not more than 3:30 hrs latter
Final setting time At least -
(Deviation from control)
Not more than 3:30 hrs latter
Compressive strength
( % Over control mix) Minimum
1 days 125%
3 days 125%
7 days 115%
28 days 110%
Flexural strength
( % Over control mix) Minimum
3 days 110%
7 days 100%
28 days 100%
Bleeding ( % Over control mix) 5% Maximum
1.If the product is not meeting the requirements during the brand qualification stage, then the item may
only be taken for testing after a gap of six months & on due improvement of the product to meet the
specified limit.
2. The validation period shall be six months from the date of collection of sample or one month before the
date of expiry.
3. If the product is not meeting the requirements during the batch qualification stage, additional test has to
be done to identify the abnormal behavior.
4. In case of anomaly in these two observations, batch shall not be accepted.
SAMPLES FOR TESTS AT EXTERNAL LABORATORY:
 Sample from each lot of 25MT is sent to tests at any approved external laboratory for the following tests:
1. Specific gravity test at 250C.
2. Solid contents.
3. pH Value.
4. water Soluble Chloride & sulphate.
5. Infra red Spectroscope.
C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF CONSISTENCY OF STANDARD CEMENT

PASTE
PURPOSE OF TESTING:
 This test is done for determining the quantity of water required to produce a cement paste of standard
consistency.
IS REFERANCE :
 IS : 4031, Part-4 : Method of Physical testing for hydraulic cement, Determination of consistency of
standard cement paste of hydraulic cement.
 IS : 5513, Specification of Vicat apparatus.
TEST EQUIPMENTS:
 Vicat apparatus with plunger.
 Graduated Jar to measure water.
 Weight balance.
 Trowel.
TEST PROCEDURE:
 The Standard Consistency of a cement paste is defined as that consistency which will permit the Vicat
plunger to penetrate to a point 5mm to 7mm from the bottom of the vicat mould.
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 Take 400 gm cement & add water 25% of the weight of cement to make the standard cement paste.
 The time of gauging should not less than 3 minute & not more than 5 minute, the time period from the
time adding water to the dry cement until commencing to fill the mould.
 Place the test mould on a non-porous testing plate made off glass.
 After filling the mould place it on the base plate of the Vicat apparatus with the glass plate, for making it
level with the top of the mould.
 Then slightly shake the mould to expel the air.
 Now lower the plunger just near the top surface of the cement paste & realize quickly it to sink into the
paste.
 The above operation should be carried out immediately after filling the mould.
 Continue the same process with the varying percentage of water in the range of 25% to 30% until the
desired limit not achieved.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF INITIAL & FINAL SETTING TIME

OF CEMENT
PURPOSE OF TESTING:
 This test is done for determining the initial & final setting time of cement
IS REFERANCE :
 IS : 4031, Part-5 : Method of Physical testing for hydraulic cement, Determination of initial & final
setting time of cement
 IS : 3535 Method of sampling cement.
 IS : 5513, Specification of Vicat apparatus.
 IS: 10086: Specification for moulds for use in test of cement & concrete.
TEST EQUIPMENTS:
 Vicat apparatus with setting time needles.
 Graduated Jar to measure water.
 Weight balance of permissible variation + 1.0gm.
 Gauging Trowel.
TEMPERATURE & HUMIDITY:

 The temperature of the gauging room , dry materials & water should be maintained at 27+ 20 C &
relative humidity required 65+ 5%.
TEST PROCEDURE:
 For preparation of a neat cement paste, take 400gm cement gauging with 0.85 times of the water
required to make a cement paste of standard consistency.
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Time limit for the above operation is 3 to 5minute, starts from adding water with the dry cement to fill
the cement paste into the mould.
 Place the test mould on a non-porous testing plate made off glass.
 After filling make the top surface smooth & level.
 Determination of initial setting time of cement: -
a. Place the test specimen under the rod, bearing the initial setting time needle.
b. Now lower the needle gently until it comes contact with surface of the cement paste & realize
quickly it to sink into the paste.
c. Repeat the process several time until the needle penetrate to a point 5 + 0.5 mm measured from
the bottom of the vicat mould.
d. The period elapsing between the time of adding water to the cement & the time at which the
needle successfully penetrate into the cement paste to a point 5 + 0.5 mm measured from the
bottom of the vicat mould is known as initial setting time.
e. Record the time.
 Determination of final setting time of cement: -
a. After initial setting time test, replace the initial setting time needle by the final setting time
needle with an annular attachment.
b. Now lower the needle gently until it comes contact with surface of the cement paste & realize
quickly it.
c. When the needle drops on the test sample it makes a point impression along with a circular
mark due to cutting edge of annular attachment thereon.
d. Repeat the process several times until the impression of annular attachment shall be vanished.
e. The period elapsing between the time of adding water to the cement & the time at which the
impression of annular attachment is being vanished is known as final setting time.
f. Now record the time.
 Initial setting time in minute should not be less than 30 minute
 .Final setting time in minute should not be more than 600 minute.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF SPECIFIC GRAVITY OF CEMENT
PURPOSE OF TESTING:
 This test is done for determining the specific gravity of cement
IS REFERANCE :
 IS : 4031, Part-11 : Method of Physical testing for hydraulic cement, Determination of specific gravity
of cement.
TEST EQUIPMENTS:
 Le Chatelier Flask
 Analytical balance
 Kerosene oil.
TEST PROCEDURE:
 First fill kerosene oil into the flask to a point on the stem between zero & 1-ml mark.
 Then wt of Flask + kerosene oil (W1).
 Then pour a known quantity (65gms) of cement into the flask up to a predetermined volume, marked
(20).
 At the time of pouring cement into the flask make it roll simultaneously to remove the entrapped air.
 Care should be taken to see that the cement dose not adhere to the inside of the flask above the liquid.
1
 After introducing the cement stopper should be placed at the top of the flask & roll it properly until no
further air bubble rise to the surface of the liquid.
 Note the final reading of the
 Again take wt of Flask + Kerosene oil + Cement (W2).
CALCULATION:
 The difference between the first(V1)& the final (V2) reading represent the volume of the liquid
displaced by the mass of the cement.
The specific gravity of cement = W2 - W1

V2 - V1

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF SOUNDNESS OF CEMENT BY

LECHATLIER METHOD
PURPOSE OF TESTING:
 This test is done for determining the Soundness of cement.
IS REFERANCE:
 IS : 4031, Part-3: Method of Physical testing for hydraulic cement, Determination of specific gravity
of cement.
 IS : 5514 Specification for the apparatus used in lechatelier sp gr test cement.
 IS : 9459 : Specification for the apparatus to measure the length change of hardened cement paste,
mortar & concrete.
TEST EQUIPMENTS:
 Le Chatelier mould
 Wt balance.
 Water bath.

 The temperature of the gauging room, dry materials & water should be maintained at 27+ 20 C & relative
humidity required 65+ 5%.
TEST PROCEDURE:
1
 First prepare a cement paste by gauging 100gm of cement with 0.78 times of water required to make a
cement paste of standard consistency.
 Place a lightly oiled Le Chatelier mould on a glass plate & pour the cement paste into the mould .
 Take care; the edge of the mould should keep together.
 Cover the mould with another piece of lightly oiled glass sheet, place a small wt piece on the covering
glass sheet.
 Then immediately immerse the mould into the water in a water bath at a temperature 27+ 20 C & keep it
24 hrs.
 Measure the distance between two indicator points to the nearest 0.5 mm.
 Then submerge the mould again in water and boil it for three hours.
 Remove the mould from the water, allow it to cool and measure the distance between the indicator points
.
 The distance between these two measurements indicates the expansion of the cement.
CALCULATION:
 Calculate the mean of two values to the nearest 0.5 mm to represent the expansion.
 Not more than 10mm
NOTE : By this method we ca n identify only presence of free excess lime in the cement, but Autoclave method
is sensitive to identify the presence of both free excess lime & magnesia in cement.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF COMPRESSIVE STRENGTH OF

CEMENT
PURPOSE OF TESTING:
 This test is done for determining the Compressive strength of cement.
IS REFERANCE:
 IS : 4031, Part-6: Method of Physical testing for hydraulic cement, Determination of Compressive
strength Compressive strength hydraulic cement.
 IS : 650 Specification for the standard sand for testing cement.
 IS: 10086: Specification for gauging trowel.
 IS: 10080 : Specification for the apparatus to measure the length change of hardened cement
paste, mortar & concrete.
TEST EQUIPMENTS:
 Vibration machine should be conformed IS : 10080.
 Poking rob.
 Three types standard Ennore sand conforming IS : 650
 Cube moulds of size 70.7 mm, conforming IS : 10080.
 Gauging trowel.
 Wt balance.
 Graduated cylindrical glass jar.
 Poking rod (made of rubber).
1
 Compression Testing Machine 500 kN

 The temperature of the gauging room, dry materials & water should be maintained at 27+20 C & relative
humidity required 65+-5%.
 Humidity chamber should be maintained at 27+ 20 C & relative humidity required not less than 90%.
PREPARATION OF TEST SAMPLE:

 The material for each cube is to be mixed separately & the quantity of cement, standard sand & water
required as bellow: -
a. Cement : 200 gm
b. Standard sand 600 gm ( 200gm of each grade )
c. Water = ( P +3 ) X weight of cement & standard sand , gms
4 100
Where P is the % of water required to produce a paste of standard consistency.
 Place the cement & sand mixer on a non-porous plate & mix it dry with a gauging trowel for one minute
properly.
 Then mix the water of above described quantity, with the cement to make a uniform mortar.
 The mixing time should not be less than 3 min & should the time taken to obtain a uniform colour
exceed four minute.
 Three samples are required for each period of curing 3,7 &28days.
MOULDING THE SPECIMEN:

 In the time of assembling the moulds ready for use, the joints is to be coated by thin petroleum jelly.
Apply thin coating of mould oil at the interior faces of the mould.
 Then place the mould on the table of vibration machine & hold it firmly in position by means of
suitable clamp.
 Attach a suitable size hopper at the top of the mould to restrict falling of the mortar in outside at the
time of vibration.
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Simplex Infrastructures Ltd.
C 2571 , MPSEZL
 Immediately after mixing start the vibration machine & the mortar place in the cube in layer & prod 20
times by means of poking rob in about 8 sec to ensure the elimination of entrapped air & honey comb.
 The period of vibration should not be less than 2 minute & the specified speed 12000 + 400 times per
minute.
 At the end of the vibration, remove the mould then finish &make smoothing the top surface of the
specimen by a trowel.
CURING THE SPECIMEN :

 Keep the filled mould 24 hrs in the humidity chamber.
 At the end of that period remove the specimen from the mould & immediately submerge in clean fresh
water & keep there until testing.
 Curing tank of the cement specimen should be cleaned & changed the water at 7 days intervals.
TESTING OF THE CEMENT CUBE:

 Test three cubes for compressive strength for each period of curing of 3,7 & 28 days.
 Bearing surface of testing machine should wiped clean & the loose materials from the surface of
 Cube specimens should be placed in such manner that the load shall be applied to opposite sides as it
cast.
 The axis of the specimens should be carefully aligned with the center of the thrust.
 The pace rate is to be set to 2.9 kN/Sec for 10cm cube.
 Record the maximum load applied to the specimen.
1
CALCULATIONS :
 The measured compressive strength of the specimen = P/A ( Kg/cm2,N/mm2or MPa)
c. P = Max load applied to the specimen during the test
d. A = Cross sectional area of the specimen
 Average of three values is taken as representative of the batch .
 Individual variation should not be more than + 15 % of the Average.
 For compressive strength of cement (OPC)
At 3 days it should not be less than 23 (MPa).
 At 7 days it should not be less than 33 (MPa).
 At 28 days it should not be less than 43 (MPa).

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF COMPRESSIVE STRENGTH OF CEMENT

BY ACCELERATED- CURING METHOD
PURPOSE OF TESTING:
 This test is done for determining the Compressive strength of cement.
IS REFERANCE:
 IS : 9013, Part-6: Method of making, curing & determining the cement compressive strength by
accelerated cured concrete test specimen.
 IS : 4031 Method of physical test for hydraulic cements , determination of compressive
strength of hydraulic cement.
 IS : 650 Specification for the standard sand for testing cement.
 IS: 10086: Specification for gauging trowel.
TEST EQUIPMENTS:
 Mould conform to IS : 516-1959 of size 7.07 X 7.07 X 7.07 cm.
 Accelerated curing testing apparatus.
TEST PROCEDURE:
 Prepare twelve numbers of cement specimens as per procedure describe in compressive strength test of
cement, for each band of cement & insert a hook of binding wire in three specimens at the time of
casting, for easy handling in boil water.
 Place the specimen at such position, free from vibration, in moist air at least 90% relative humidity & at
a temperature of 27+ 20 C after casting , for 23 + ¼ hrs.
1
 At the end of that period remove the specimen from the mould & immediately submerge three specimen
into the curing tank for a period of 3 ½ hrs + 5 min at boiling condition.
 After that above time period remove the specimen & immerse into the cooling tank at a temperature of
27+ 20 C for one hr.
 Compressive strength test of the accelerated cured specimen is to be done as per procedure & specified
age at the time of 28 ½ hrs + 15 min. remaining specimen shall be test at 3 ,7 & 28 days.
 Minimum 30 set required for each brand of cement, to develop a relation between compressive strength
at 3,7 & 28days versus accelerated strength to derive a regression equation.
 If the calculated compressive strength of cement at 3,7 & 28 days based on accelerated curing test is
meeting the requirement then allow the cement to use for work.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF SPECIFIC SURFACE BY BLAINE AIR

PERMEABILITY METHOD
PURPOSE OF TESTING:
 This test is done for determining the specific surface area of cement in cm2/gm.
IS REFERANCE:
 IS : 4031, Part-2 Method of physical test for hydraulic cements , determination of specific surface area of
cement by Blain’s air permeability method.
 IS : 5516 Specification for blain air permeability apparatus.

The temperature of the gauging room, dry materials & water should be maintained at 27+20 C.
TEST EQUIPMENTS:
 Blain’s air permeability apparatus conforming to IS : 5516.
 Timer (Stop watch).
 Electronic balance.
CALIBRATION OF APPARATUS:
 Calibration of the air permeability apparatus is to be done by using National Council for Cement and
Building Materials standard cement.
 Bulk volume of compacted bed of cement: It can be determined by mercury displacement method.
PROCEDURE:
 Place two Whatman No.4 filter paper in the permeability cell, pressing down the edge with a rod having
slightly smaller dia than cell dia until the filter discs are fall on the perforated metal disk.
1
 Use tong to handling the cell.
 Then fill the cell with the mercury, removing all the air bubble adhering the cell wall.
 Level the mercury with top of the cell by means of small glass plate.
 Now remove the mercury from the cell, weight & record the mass of the mercury (M1).
 Then remove one filter paper & place a trial quantity of cement 2.80gms of cement into the cell by
compressing one filter paper at bottom & one at top of cell with mercury.
 Fill the remaining space in the cell with mercury.
 Then again remove the mercury from the cell, weight & record the mass of the mercury (M2).
 The bulk volume occupied by the cement shall be calculated to the nearest 0.005 cm3.
Bulk volume of cement, V = M1 –M2

D
M1= gms of mercury required to fill cell, when there is no cement

M2= gms of mercury required to fill the portion of cell not occupied by the bed of cement.
D = Mass density of mercury at temperature of test in g/ cm3.
At least two determination of test should be made.
DENSITY OF MURCURY AT DEFFERENT TEMPERETURE
Room temperature Mass density of mercury ( g/cm3)
20 13.55
22 13.54
24 13.54
26 13.53
28 13.53
30 13.52
32 13.52
34 13.51

C 2571 , MPSEZL
 Preparation of sample: The contents of the standard cement sample enclose in a 125g jar & shaken
vigorously for 2 min to break-up the lumps.
 Mass of the sample M = PV ( 1-E)
P = Mass density of test sample ( for OPC 3.15)
V= Bulk volume of bed of cement in cm3.
E = desired porosity of cement (0.500 +0.005).
PERMIABILITY TEST PROCEDURE:
 First attach the permeability cell to the Manometer tube, making such an airtight arrangement.
 Evacuate the air slowly from one arm of the Manometer (U- Tube) until liquid reaches the top mark of
the bottle & then close the valve tightly.
 Then start the timer as the bottom of the meniscus of the manometer liquid reaches the second mark
(next to the top) & when the bottom of meniscus of liquid reaches the third mark (next to the bottom)
stop the timer & note the time in second.
CALCULATIONS:
 Specific surface of the cement then be calculated as bellow:
S = K sqrt of T
Where S = specific surface area of cement cm2/gm.
T = time of flow in second.
K = calibration constant ( it is determined at time of calibration with taking the value of specific surface
area of the standard cement ).
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C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF FINENESS OF CEMENT BY

SIEVING
PURPOSE OF TESTING:
 This test is done for determining the fineness of cement in %.
IS REFERANCE:
 IS : 4031, Part-1 Method of physical test for hydraulic cements , determination of fineness of cement by
Dry sieving method.

 The temperature of the gauging room, dry materials & water should be maintained at 27+20 C.
TEST EQUIPMENTS:
 IS sieve no 9 (90 micron).
TEST PROCEDURE:
 Take 100gm (A) of cement sample in a 90-micron sieve.
 Then sieve it properly by shacking all the specified direction for period of 2 minute.
 Weight the residue left on the sieve ( B )
CALCULATIONS:
 Fineness of the cement F = B X100 (%)
A
2
 It should not be more than 10% .

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF SOUNDNESS OF CEMENT BY AUTOCLAVE

METHOD
PURPOSE OF TESTING:
 This test is done for determining the Soundness (presence of free lime & magnesia) of cement.
IS REFERANCE:
 IS : 4031, Part-3: Method of Physical testing for hydraulic cement, Determination of soundness of
cement.
 IS : 9459 : Specification for the apparatus to measure the length change of hardened cement paste,
mortar & concrete.
 The temperature of the gauging room, dry materials & water should be maintained at 27+ 20 C & relative
humidity required 65+ 5%.
TEST EQUIPMENTS:
 Moulds of size 25 X 25 mm size & 282 mm internal length & other accessories conforming IS : 10086.
 Autoclave apparatus is complying with:
 It mainly consist of a high pressure steam boiler equipped with suitable safety device.
 It’s capacity of heating should be such that with max load (water plus specimen),saturated steam
pressure may be raised to a gauge pressure 21 kg/cm2 in 1 to 1 ¼ hrs& corresponding temperature
of 215.7+ 1.70C.
 It is designed in such way that the pressure can reduce from 21 kg/cm2 to less than 0.7 kg/cm2 in
1hr.
 The pressure gauge having nominal dia 115mm & graduated from 0 to 41 kg/cm2.
 It is consist also a length compactor to measure the change of length conforming IS 9459.
2
PREPARATION OF TEST SAMPLE:
 First apply a thin oil layer at inner side of the mould.
 Then make a cement paste of standard consistency by mixing 500gm cement & sufficient quantity of
water.
 Immediately after mixing pour the sample into the mould in two layers of same depth & compacted with
thumb carefully.
 Then make smooth the top of the surface with a few strokes.
 Keep the sample in same condition in a humidity chamber for one hr.
TEST PROCEDURE:
 After 24 hrs remove the specimen from the mould & place into the autoclave at room temperature on the
rack in such manner that the four side of the sample expose to saturated steam.
 The autoclave should have contained enough water to maintain the saturated vapor condition.
 Keep open the air vent valve to escape the air until steam begins to escape.
 Then close the air valve & raise the temperature at such a rate that it can bring the gauge pressure of the
steam to 21 kg/cm2 in 1 to 1 ¼ hrs.
 After 3hrs period, it should be cool in such a rate that within 1hr pressure become less than 1 kg/cm 2 .
 If some pressure remaining realize by partially opening the valve, until atmospheric pressure is attained.
 Then open the Autoclave & place the specimen into the water at a temperature more than 90 0 C.
 Then cool the above water by adding such quantity of cool water that it reach at 27+ 20 C in 15min.
 At last remove the specimen from the water & measure the length.
CALCULATIONS:
 The difference of the length measured before & after autoclaving indicate presence of free lime &
magnesia in the cement sample.
 The difference between initial & final reading should not be more than 10%.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF MOISTURE ABSORPTION OF

SOIL
PURPOSE OF TESTING:
 This test is done for determining the moisture absorption of soil.
IS REFERANCE:
 IS : 2720 Part 2 Method for sampling soil.
 IS : 2720 Part II Determination of water content of soil.
TEST EQUIPMENTS:
 Suitable non-corrodible container.
 Balance
 Hot air oven accurate to 10 C.
 Non-absorbent tray.
 Steel rule
 Steel straight edge etc.
TEST PROCEDURE:
 Take wt of the sample as per size of sample tested as per IS 2720- Part II.
 Clean the container & take wt (W1).
 Then place the sample loosely in it.
 Take wt of sample + container (W2).
 Keep the sample on a oven at 110 + 50 C for 24hrs.
2
 At end of drying keep the sample out from the container & allow to cool at room temperature.
 Then take wt of final mass (W3).
CALCULATIONS:
 The water content is calculated as W = W2 – W3 X100 (%)
W3 – W1
Simplex Concrete Piles (I) Ltd Page: 01 OF 01

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF DRY DENSITY OF SOIL BY CORE

CUTTER METHOD
PURPOSE OF TESTING:
 This test is done for determining the dry density of soil by core cutter method.
IS REFERANCE:
 IS : 2720 Part -XXIX Determination of dry density of soil in place by core – cutter method.
TEST EQUIPMENTS:
 Cylinder core cutter : Seamless steel tube of 130mm long, 100mm internal dia & 3mm thick with bottom
end open & cutting edge at bottom.
 Steel Dolly: 25mm high, 100mm dia & 10cm thickness.
 Steel rammer : 140mm dia & 75 mm height base connected with 900mm length stuff of having dia
25mm, weight of these whole arrangement approx 9kg.
 Weight balance accurate to 1gm.
 Hot air oven accurate to 10C / Moisture meter to check the moisture content of the sample.
 One non-absorbent tray.
 Steel rule for remove sample from the core.
 Steel straight edge.
CALIBRATION OF CORE:
 Check the dimension of the core.
 Measure the volume of core.
 Measure the weight of empty core(Wc).
TEST PROCEDURE:
2
 Select the place first, where the compaction of soil layer is to be tested.
 Place the core cutter along with dolly on the selected soil layer & penetrate it by ramming with the
rammer.
 Take three samples for a particular layer.
 Then the cutter is dug out from the soil test area.
 Remove carefully the extra soil on both face of the core cutter by using the steel straight edge .
 Weight the core-cutter with soil sample (Ws).
 Then remove the soil sample carefully & keep on a tray.
 Check the moisture content (Wm) either by moisture meter or by thermostatically hot air oven .
CALCULATIONS:
The bulk density is calculated as Bd= Ws – Wc in g/cm3
Vc
The dry density is calculated as Db= 100 x Bd in g/cm3

100+w
Where , Ws= weight of core-cutter + soil in gm.
Wc= weight of empty core- cutter.
Vc = volume of empty core.
W = water content of the of the soil
 As per tender document.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF DRY DENSITY OF FINE, MEDIUM &

COARSE-GRAINED SOILS BY SAND REPLACEMENT METHOD
PURPOSE OF TESTING:
 This test is done for determining of the dry density (in g/cm3) of fine, medium & coarse- grained soils by
sand replacement method.
IS REFERANCE:
 IS : 2720 Part -XXVIII Determination of dry density of soil in place by core – cutter method.
TEST EQUIPMENTS:
 Large sand pouring cylinder, conforming to IS : 2720 Part –XXVIII.
 Tools for excavating holes.
 Cylinder calibrating container.
 Wt balance.
 Metal containers.
 Metal tray of 450sq mm area & 50mm deep with a 200mm dia hole at center.
 Uniformly graded natural sand passing 1.0mm sieve & retained on 600micron IS Sieve.
CALIBRATION OF APPARATUS:
 First measure volume of the calibrating container (V) in cc.
 Measure the wt of calibrating container.
 Close the shutter of the container & pour the above described sand into the cone at the bottom of the
container.
 Then remove the sand from the cone & take wt (W2).
 Pour sand into the poring cylinder & take wt of both, sand + pouring cylinder (W1).
 Then place the cylinder on the known volume-calibrating container & open the shutter to allow to run
out the sand into the cylinder.
2
 After fully pouring the container close the shutter & remove it carefully.
 Then take wt of the cylinder & sand after pouring (W3).
 Weight the sand to fill the calibrating container (Wa).
 So bulk density of sand Bds= (Wa/V) X 1000 kg/cum.
PROCEDURE OF SAMPLING:
 Choose a flat & level area approximately 60 cm2, at the place where the soil is to be tested.
 Then the metal tray with central hole place on the prepare surface.
 Then excavate a hole using the hole on the tray as the pattern, to the depth of the layer to be tested upto a
maximum of 250mm.
 Collect carefully the soil sample from the hole & Keep the soil sample in a poly pack for further
moisture testing.
 Remove the metal tray & place the pouring cylinder just over the excavated hole.
 First Pour a known wt of sand into the cylinder & measure the wt of sand & cylinder before pouring.
 Then open the shutter & allow to running out the sand into the hole.
 Close the shutter when no further movement of sand takes place.
 Continue this process at least twice more.
TEST PROCEDURE:
 First weight the soil sample collects from the hole (Ww).
 Measure the wt sand + cylinder after pouring.
 Check the moisture content (Wm) by thermostatically hot air oven .

C 2571 , MPSEZL
CALCULATIONS:
 Weight of wet soil from the hole (Ww), in gm.
 Weight of sand (+ cylinder) before pouring (W1), in gm.
 Weight of sand ( + cylinder) after poring (W4), in gm.
 Weight of sand in hole ( Ws = W1 – W4 – W2), in gm.
 Bulk density Bd= ( Ww/Ws ) x Bds , in kg/m3 .
 Water content container No.
 Weight of soil for water content determination (Wa), in gm.
 Weight of oven dried soil (Wb), in gm.
 Water content w = Wa – Wb x 100 (%)
Wa
 Dry density Db= 100 Bd kg/cum
100+w
 As per tender document.
2
C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF MAXIMUM DRY DENSITY OF THE SOIL

AT OPTIMUM WATER CONTENT BY STANDARD PROCTOR COMPACTION
METHOD
PURPOSE OF TESTING:
 This test is done for determining of the maximum dry density in( g/cm3) at optimum moisture content of
the soil.
IS REFERANCE:
 IS : 2720 Part -VII Determination of moisture content & dry density relation by using light compaction
method.
TEST EQUIPMENTS:
 Cylinder metal mould having dia 10cm , internal height 117cm & capacity 0.945lit.
 Detachable base plate.
 Collar 50mm height.
 Rammer, having wt 2.5kg & 362mm ht.
TEST PROCEDURE:
 Take about 3kg of air-dried & pulverized soil, passing 4.75 mm IS Sieve.
 Mix it thoroughly over a big tray.
 Then the mixer keep cover with a wet cloth & left it for 30min to proper absorption of water.
 First add water 2% of the wt of the soil with the soil sample.
 Then mix it properly again for few minute.
 Pour the soil sample into the mould in layer at a 1/3 height of mould & compacted by uniformly
distributed 25 blows of the rammer over the surface.
 Before putting second installment scratch the top surface of the first compacted layer.
 Second & third layer are similarly compacted & last layer should not project more than 6mm.
 Take wt of the mould, base plate & the compacted soil.
 Then de -mould the soil & collect representative sample from the center.
 Check the moisture content (Wm) either by moisture meter or by thermostatically hot air oven. `
 Then increase the % of water adding with the sample & continue the process at least 6 to 7 times.
2
 The water content corresponding to maximum dry density is called optimum moisture content.
 Plot a curve between water content as abscissa & dry density as ordinate.
 Mark the max dry density & corresponding water content in the graph.
CALCULATIONS:
 Water added in cc.
 Weight of compacted soil + mould (W1), in gm.
 Weight of empty mould (W2), in gm.
 Volume of mould (V), in cc.
 Weight of compacted soil (W1 – W2), in gm.
 Wet density (Bd ) in gm/ cc.
 Water content container No.
 Weight of soil for water content determination (Wa), in gm.
 Weight of oven dried soil (Wb), in gm.
 Water content w = Wa – Wb x 100 (%)
Wa
 Dry density Db= 100 Bd gm/cc
100+w
 Mark max dry density from the graph.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF ELONGATION INDEX OF COARSE

AGGREGATE
PURPOSE OF TESTING:
 This test is done for determining the elongation index of coarse aggregate.
IS REFERANCE:
 IS : 2386 Part 1 Method of test of aggregate for concrete, Particle shape & size.
 IS : 2430 : Method of sampling of aggregate for concrete.
 IS : 460 : Specification of test sieve.
TEST EQUIPMENTS:
 Wt balance accuracy to0.1 % of the wt of the test sample.
 Metal length gauge conforming to IS 2386 Part 1.
 IS Sieves.
IS Sieve size
Length of gauge
Passing through Retained on
63mm 50mm -
50mm 40mm 81.0
40mm 25mm 58.50
31.5mm 25mm -
25mm 20mm 40.50
20mm 16mm 32.40
16mm 12.5mm 25.60
12.5mm 10mm 20.20
10mm 6.3mm 14.70
PROCESS OF SAMPLING:
 Approx wt of 40mm down aggregate sample = 50kg.
 Minimum 200 pieces of each fraction is to be tested.
TEST PROCEDURE:
 First sieving the test sample properly in accordance with the method described in IS 2386 Part 1
2
 Take wt of the sample retained on each sieve (C3i).
 Then calculate the percentage retained on each sieve & cumulative percentage retained on all sieve.
 Collect 200 nos of pieces from the aggregate retained on each sieve (Wi).
 Then each fraction is to be gauged through length on the standard metal length gauge & then aggregate
retained on gauge for each fraction then separately weighted (W1i).
CALCULATIONS:
 Elongation index is calculated by using the following formula :
EI = cumulative summation of (W1i / Wi) X C3i. (expressed in %).
 As per IS 25% maximum.
 As per project specification 15% maximum.

C 2571 , MPSEZL
TEST PROCEDURE FOR DETERMINATION OF FLAKINESS INDEX OF COARSE

AGGREGATE
PURPOSE OF TESTING:
 This test is done for determining the flakiness index of coarse aggregate.
IS REFERANCE:
 IS : 2386 Part 1 Method of test of aggregate for concrete, Particle shape & size.
 IS : 2430 : Method of sampling of aggregate for concrete.
 IS : 460 : Specification of test sieve.
TEST EQUIPMENTS:
 Wt balance accuracy to0.1 % of the wt of the test sample.
 Metal thickness gauge conforming to IS 2386 Part 1.
 IS Sieves.
IS Sieve size
Thickness gauge
Passing through Retained on
63mm 50mm 33.90
50mm 40mm 27.00
40mm 25mm 19.50
31.5mm 25mm 16.95
25mm 20mm 13.50
20mm 16mm 10.80
16mm 12.5mm 8.55
12.5mm 10mm 6.75
10mm 6.3mm 4.89
PROCESS OF SAMPLING:
 Minimum 200 pieces of each fraction is to be tested.
TEST PROCEDURE:
 First sieving the test sample properly in accordance with the method described in IS 2386 Part 1
 Take wt of the sample retained on each sieve (C3i).
 Then calculate the percentage retained on each sieve & cumulative percentage retained on all sieve.
 Collect 200 nos of pieces from the aggregate retained on each sieve (Ni).
2
 Then each fraction is to be gauged through thickness on the standard metal thickness gauge & then
aggregate passing on gauge for each fraction then separately counted (N1i).
CALCULATIONS:
 Elongation index is calculated by using the following formula :
F.I = cumulative summation of (N1i / Ni) X C3i. (Expressed in %).
 As per IS 25% maximum.
 As per project specification 15% maximum.

C 2571 , MPSEZL
FOLLOWING TEST OF COARSE & FINE AGGREGATE DONE AT OUTSIDE QUALIFIED

LABORATORY
TEST DESCRIPTION (For Coarse Aggregate) LIMITS AS PER IS : 383-1970.

Deleterious Material : -
Coal & Lignite (% by wt) 1.00 max(observation : Traces)
Clay content (% by wt) 1.00 max(observation : Traces)
Material finer than 75micron (% by wt) 3.00 max(observation : Traces)
Shale (% by wt) 1.00 max (observation : Traces)
Organic Impurities (% by wt) Not Specified (observation : Traces)
Alkali aggregate reactivity: -
1. Reduction in alkalinity of 1N NaOH Not Specified (observation : 180)
(milimole/lit)
Not Specified (observation : 70)
2. Silica dissolved (milimole/lit)
Water soluble chlorides as ‘Cl’ (% by wt) Not Specified (observation : 0.01)
Water soluble sulphates as ‘So4’ (% by wt) Not Specified (observation : <0.05)
Moisture Content (% by wt) Not Specified (observation : 0.09)
Ferric Oxide (% by wt) Not Specified (observation : 6.52)
Specific Gravity Not Specified (observation : 2.93)
Water absorption (% by wt) Not Specified (observation : 0.1)
TEST DESCRIPTION (For Fine Aggregate, crusher

LIMITS AS PER IS : 383-1970.
sand)
Deleterious Material : -
Coal & Lignite (% by wt) 1.00 max(observation : Traces)
Clay content (% by wt) 1.00 max(observation : 0.18)
Material finer than 75micron (% by wt) 3.00 max(observation : 0.03 )
Shale (% by wt) 1.00 max (observation : Traces)
Organic Impurities (% by wt) Not Specified (observation : Traces)
Alkali aggregate reactivity: -
1. Reduction in alkalinity of 1N NaOH Not Specified (observation : 150)
(milimole/lit)
Not Specified (observation : 50)
2. Silica dissolved (milimole/lit)
Petrographic test As per IS : 2386- Part VIII
3
Soundness test (5 Cycles in Na2So4 sol) 10%
Legends : Observation are given as per one Geological & meteorological Ltd (GML) test report for coarse & fine
aggregate .

C 2571 , MPSEZL
TEST PROCEDURE FOR CHEMICAL ANALYSIS ON WATER
PURPOSE OF TESTING:
 This test is done for determining the pH value, Chloride & Sulphate content present in water.
IS REFERANCE:
 IS : 3025 – 1964 Method of chemical analysis on water.
TEST EQUIPMENTS:
 PH Meter
 Beaker (50ml)
 Burette with stand.
 Flask.
 Chloride content identifying kits.
 Testing kits for sulphate content.
TEST PROCEDURE FOR IDETIFY pH VALUE OF WATER:

 The pH of water is determined by using electronic pH Meter provided with a glass electrode .
 First calibrate the electrode by using standard buffer solution .
 Then the electrode washed with distilled water & then sample water.
 The sample is taken in resistant glassware & the pH value then noted.
TEST PROCEDURE FOR IDETIFY CHLORIDE VALUE OF WATER:

 Chemical reagents required :-
 N/ 35.5 Silver Nitrate.
 N/ 35.5 Sodium Chloride.
 5% Potassium Chromate.
 Preparation of chemicals :
a. N/ 35.5 Silver Nitrate : Dissolve 1.2gm of silver nitrate in 250cc distilled water.
b. N/ 35.5 Sodium Chloride: Dissolve 0.41gm of sodium chloride in 100cc-distilled water.
c. 5% Potassium Chromate : Dissolve 5gm of Potassium Chromate in 50cc of water & then raise
the volume to its final volume to 100cc with distilled water.
d. Standardization of silver nitrate:
Take 50 cc of N/35.5 NaCl in a titration flask, and then add 5 drops of
potassium chromate indicator then it is titrated against standardized Silver Nitrate
solution to a brick red end point. The volume of AgNO3 used is noted & again repeat this
experiment at least thrice.
CALCULATION:
 Amount of chloride content present in the sample
3
= Volume of AgNO3 x Normality of AgNO3 x 1000 x equivalent wt of chlorine
Volume of water sample taken
TEST PROCEDURE FOR IDETIFY SULPHATE CONTENT OF WATER:

 Fill the easy test jar with the water sample up to 10ml mark.
 Alkalinity titration as follows before proceeding for actual sulphaite test.
 Add two drops of alkalinity Reagent ‘A’.
 Then if pink color is appearing add alkalinity Reagent ‘B’ until blue end point is not coming, count no of
drops of alkalinity reagent ‘B’.
 If the pink color does not appear again add a pinch of sulphite reagent ‘A’.
 Then shake the jar 30sec & add sulphite reagent ‘B’ drop by drop, count the number of drops added.
 Shake the jar after each drop till blue end point is observed.

C 2571 , MPSEZL
CALCULATION:
 Amount of sulphite content present in the water sample is equal to
Each drop of sulphite reagent ‘B’ = 5 ppm of sulphite as Na2So3 .
 PH Value should not be less than 6.0.
 Sulphate content should not more than 250mg/lit.
 Chloride content should not more than 250mg/lit.
3
C 2571 , MPSEZL
FOLLOWING TEST OF WATER DONE AT OUTSIDE QUALIFIED LABORATORY
TEST DESCRIPTION LIMITS AS PER IS : 456-2000.

Organic Solid 200 Max
Inorganic Solid 3000 Max
Suspended Matter 2000 Max
Phenolphthalein Acidity It shall not required more than 5ml of 0.02N NaOH
Neutralization of water by mixed indicator It shall not required more than 5ml of 0.02N H2So4
pH Shall not be less than 6
3
C 2571 , MPSEZL
TEST PROCEDURE FOR MECHANICAL TESTING OF METALS TENSILE STRENGTH
PURPOSE OF TESTING:
 This test is done for determining the pH value, Chloride & Sulphate content present in water.
IS REFERANCE:
 IS :1608: 1995 Mechanical testing of Metals – Tensile Testing.
 IS : 1828 Part 1 Metallic Material Verification of Static uniaxial testing machine.
 IS : 3803 Part 1 Steel - Conversions of elongation values (carbon & low alloy steels).
 IS : 3803 Part 1 Steel - Conversions of elongation values (Austentic steels).
 IS : 12872 : 1990 Metallic materials : Verification of extensometer used in an axial testing.
PRINCIPLE:
 This test starts by applying tensile force to a test piece, generally to fracture, for the purpose of
determining one or more mechanical properties of the test piece.
TEMPERATURE:
 The test should be carried out at ambient temperature between 100C to 350C .
TEST EQUIPMENTS:
 Universal testing machine (UTM) conforming to IS: 1828 Part 1.
 Griping plate for plane MS plate & different dia reinforcement bar.
 Extensometer.
 Digital measuring gauge.
 Punch for marking.
TEST PROCEDURE:
 Take a sample of specified heat no, having length minimum 600mm.
 Calculate the cross sectional area from the measurement from the appropriate dimension.
 Mark the original gauge length (Lo) from the following formula: Lo = 5.65 sqrt of (c/s area).
 The original gauge length should not be less than 25mm.
 Mark the grip length on both ends of the specimen of minimum 150mm.
 Fix the specimen between the grip plates both in top & bottom by suitable means such as pin holder &
ensure that the test piece are held in such a way that force is applied axially.
 Apply force in such manner so as to strain the test piece in a non-decreasing manner, without shock or
sudden vibration.
 Rate of stressing:
1. Modulus of Elasticity of the material < 150000 N/ mm2 ………. 2 to 10 N/ mm2/sec
2. Modulus of Elasticity of the material > 150000 N/ mm2 ………. 6 to 30 N/ mm2/sec
 Strain rate shall not exceed 0.0025mm/sec.
 Measure the gauge length after fracture (Lu) by keeping two broken pieces carefully fitted back.
 Calculate the Elongation (%) : (Lu – Lo)/ Lo X 100.
 Calculate the 0.2% Proof stress, Yield stress from the load vs extension graph.
 Calculate the Ultimate stress from load vs displacement graph.
Ultimate stress = (Peak Load / cross sectional area) in MPa.
SOME IMPORTENT TERMINOLOGY:
3
 Gauge Length: Length of the cylindrical or prismatic portion of the test piece on which elongation is
measured at any moment during testing.
 Original Gauge Length(Lo): Gauge length before application force.
 Final Gauge Length (Lo): Gauge lengths after fracture takes place, the two pieces are carefully fitted
back carefully so that their axes lies in a straight line.
 Percentage Permanent Elongation: Increase in the original gauge length of a test piece after removal
of specified stress, expressed as % of the original gauge length.

Simplex Infrastructures Ltd Page : 01 OF 01

C 2571 , MPSEZL
TEST PROCEDURE FOR COMPRESSIVE STRENGTH TEST OF BRICK

PURPOSE OF TESTING:
 This test is done to determine compressive strength of Bricks
IS REFERANCE :
 IS 3495 Part-1 : Methods of test of Burnt Clay Bricks –Determination of Com. Strength
 IS 5454 : Method of sampling of Clay Bricks
TEST EQUIPMENTS :
 Compression Testing Machine 3000 KN

 Measuring Scale of 300 mm in length
Above Testing Machine should regularly calibrate at every three month intervals.
SAMPLE PREPARATION:
 Unevenness in the bed faces of Bricks to be tested & removed. After that the Bricks immersed in cold
Water for 24 hrs. After that any surplus water should be removed .
The frog of the Brick shall be filled by 1:1 cement sand mortar and it store in a damp area for 24 hrs followed by
immersion in water for 3 days. The Bricks shall be taken out and wiped away the water.
 At least ten specimens is required
TEST PROCEDURE :
 The length and width of brick shall be taken in millimeters for calculating area before testing.
 Bearing surface of testing machine should wipe clean & the loose materials from the surface of
 The specimens should be placed in machine on flat faces in horizontal and mortar filled face facing
upward between two plywood sheets each of 3mm thick.
 The load should be increased at uniform rate of 140kg/sq cm/minutes till the failure occurs.
CALCULATIONS :
 The compressive strength of the specimen = P/A ( Kg/cm2,N/mm2)
e. P = Max load applied to the specimen during the test
f. A = Cross sectional area of the specimen
 Average of three values is taken as representative of the batch .
 According to IS-1077 the minimum strength should not be less than 40 kg/cm2
3
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Introduction To Sprayed Concrete

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Simplex Infrastructures Ltd Page : 01 OF 01

TEST PROCEDURE FOR COMPRESSIVE STRENGTH TEST

 Compression Testing Machine 3000 kN

TEST PROCEDURE FOR FLEXTURAL STRENGTH TEST

 Flexural Testing Machine 100 KN capacity.

Min 0.63*fck N/mm2

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TEST PROCEDURE FOR DETERMINING MODULUS OF ELASTICITY

PREPARATION OF TEST SPECIMEN :

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TEST PROCEDURE FOR TESTING WATER PERMEABILITY ON

TEMPARATURE & HUMIDITY:

PREPARATION OF TEST SPECIMEN :

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TEST PROCEDURE FOR DETERMINING SETTING TIME OF CONCRETE BY

PREPARATION OF MORTER SPECIMEN:

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TEST PROCEDURE FOR DETERMINING BLEEDING OF CONCRETE IN PLASTIC

PREPARATION OF TEST SPECIMEN:

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TEST PROCEDURE FOR DETERMINING OF

Unit wt of concrete = W1- W2 kg/m3

a. W1 = Weight of concrete + Wt of empty container, kg

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TEST PROCEDURE FOR DETERMINING THE AIR CONTENT OF FREESHLY

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PROCEDURE FOR CASTING THE CUBE,CYLINDER & BEAM MOULD

STORAGE OF THE SPECIMENS:

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1. TEST PROCEDURE FOR SAMPLING & TESTING OF CHEMICAL ADMIXTURE FOR

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TEST PROCEDURE FOR DETERMINATION OF CONSISTENCY OF STANDARD CEMENT

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TEST PROCEDURE FOR DETERMINATION OF INITIAL & FINAL SETTING TIME

TEMPERATURE & HUMIDITY:

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TEST PROCEDURE FOR DETERMINATION OF SPECIFIC GRAVITY OF CEMENT

The specific gravity of cement = W2 - W1

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TEST PROCEDURE FOR DETERMINATION OF SOUNDNESS OF CEMENT BY

TEMPERATURE & HUMIDITY:

Simplex Infrastructures Ltd. Page: 01 OF 02

TEST PROCEDURE FOR DETERMINATION OF COMPRESSIVE STRENGTH OF

TEMPERATURE & HUMIDITY:

PREPARATION OF TEST SAMPLE:

MOULDING THE SPECIMEN:

CURING THE SPECIMEN :

TESTING OF THE CEMENT CUBE:

Simplex Infrastructures Ltd. Page: 01 OF 01

TEST PROCEDURE FOR DETERMINATION OF COMPRESSIVE STRENGTH OF CEMENT

Simplex Infrastructures Ltd. Page: 01 OF 01

TEST PROCEDURE FOR DETERMINATION OF SPECIFIC SURFACE BY BLAINE AIR

TEMPERATURE & HUMIDITY:

Bulk volume of cement, V = M1 –M2

M1= gms of mercury required to fill cell, when there is no cement

Simplex Infrastructures Ltd. Page: 01 OF 01

PERMIABILITY TEST PROCEDURE:

 Specific surface of the cement then be calculated as bellow:

TEST PROCEDURE FOR DETERMINATION OF FINENESS OF CEMENT BY

TEMPERATURE & HUMIDITY:

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TEST PROCEDURE FOR DETERMINATION OF SOUNDNESS OF CEMENT BY AUTOCLAVE

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