MINIMUM QUANTITIES REQUIRED TO BE SENT TO LABORATORIES FOR TESTING OF MATERIALS SR .No. Name of Test CEMENT 1. 2.

Fineness Specific Gravity Test samples of cement shall be made up of a 15 Kg. Cement approximately taken from each of number of bags on the site Minimum Quantities of Material Required for testing

3. 4. 5. 6.

Standard Consistency Setting Time (Initial & Final) Compressive Strength Soundness COARSE AGGREGATE Size of metal 60 mm 40 mm 25 mm 20 mm 12.5 mm 10 mm 6.3 mm Quantity 100 Kg 50 kg 50 Kg 25 Kg 12 kg 6 Kg 3 Kg

7. 8. a) b) 9.

Sieve Analysis Water absorption & Specific Gravity Water Absorption Specific Gravity Impact Value

10. Abrasion Value 11. Crushing Value 12. Flakiness Index FINE AGGREGATE 13. Fineness Modulus (Sieve Analysis) 14. Silt & Clay Content (Weight Seiving) BRICKS 15. Water Absorption 16. Compressive Strength 17. Efflorences FLOORING TILES 18. Flexural Test 19. Water Absorption

One bag of 25 Kg.

Five Bricks Five Bricks Five Bricks Six Tiles Six Tiles

20. Resistance to wear MANGLORE TILES 21. Water Absorption 22. Flexural Test 23. Permeability Test GLAZED TILES 24. Water Absorption CONCRETE

Six specimen of size 70 x 70 mm

Six Tiles Six Tiles Six Tiles Five Tiles

25. Compressive Strength Three Nos of C. C. Cubes Size of C. C. Cube 15 x15x 15 cm. Per Set 26. Concrete Mix Design with all tests on basic materials 27. Concrete mix design only for mix (tests on basic materials have already been taken MORTOR 28. Compressive Strength Three Nos of MorterCubes Size 7.07x 7.07x 7.07 CmsPer Set STONE 29. Crushing Value 30. Water Absorption & Specific Gravity 31. Compressive Strength Six dressed Samples of Size (Dressing of Stone already Done) 10x 10x 10 Cms 32. Compressive Strength Six Samples from which six with dressing of stone specimen of dressed stone of in Laboratory Size 10 x10 x10 Cms can be achieved SOIL/ MURUM 33. Field moisture Content 34. Liquid limit & Plastic Limit 50 Kg. One full bag of each Aggregate , Sand & Cement for Mix Design of each Grade

35. Compaction Test (Proctor Density) 36. C.B.R. Test (Lab.) 37. Field Density by sand replacement method BITUMEN 38. Extraction Test 39. Marshall stability & flow measurements a)Moulds Testing 40. Preparation of Marshall moulds & Testing 41. Penetration

One bag of 50 Kg.

Two Kg. Bituminus Mix One Set of Three Standard MarshallMoulds of size Diametre 10 cm ,Height 6.5 cm. 4 Kg. Mix

Two Kg Bitumen

42. Asphaltic concrete Job One full bag of each Mix Design with all Aggregate , filler- 5 Kg.,Grit-10 tests on basic materials Kg., Bitumen-5 Kg. for DBM/SDBC/AC 43. Bituminus Macadam Job Mix Design for each Mix Design

HOLLOW BLOCKS 44. Density test 45. Compressive Strength 46. Water Absorption Test SOLID BLOCKS 47. Density Test 48. Compressive Strength 49. Water Absorption Test

Three Blocks Eight Blocks Three Blocks

Three Blocks Eight Blocks Three Blocks

S.N.

Name of Test

Minimum Quantities of Materials required for testing

COARSE AGGREGATE

1 2 3 4 5 6

Soundness Bulk Density FINE AGGREGATE CL2 & Sulphate Content Moisture Content Bulkage of sand CONCRETE Flexural Strength of beam SOIL/ MURUM Sulphate & Chloride content Mechanical analysis BITUMEN Softening point Viscosity Flash & fire point Specific gravity Ductility Mastic Hardness No. WATER PH value Sulphate & Chloride content WOOD Density Moisture content STEEL ANTI CORROSIVE TEST Resistance to applied voltage (1 Hr.test) Resistance to applied voltage (30 days.test) Thickness of coating Chemical resistance Test

20 kg 25 kg 2 kg 2 kg 5 kg One set of three beams 2 kg 60 kg (IS 2720 Pt.4)

7 8 9 10 11 12 13 14 15 16 17 18

5 kg Bitumen

5 Moulds 1 Litre of Water

3 Samples of 450 x 300 mm Two bars of 90 cm. length of required diameter Eight bars of 30 cm. length of required diameter Two bars of 30 cm. length of required diameter

19 20 21 22

23

Hardness of coating Test

Control Tests & their frequency & specified limits for various construction materials: Sr.No Material & Tests. Specified Limit. Frequency.

1.

CEMENT (OPC) 1) Initial setting time. 2) Final setting time. 3) Fineness by dry sieving. 4) Specific gravity. Not less than 30 minutes. Not more than 600 minutes. Residue not more than 10% on 90micron sieve. 3.10 to 3.15 For each consignment of 50 M.T. or part thereof.

5) Compressive strength. 33 Grade. 43 Grade 53 Grade (in Kg/cm2.) a) 3 days ( +/- 1 hours ) 6) Soundness by Lechatelier apparatus. 2) SAND 1) Particle size. 2) Silt content. 3) Fineness modulus. a) 160 230 270 Expansion not more than 10 mm. b) 7 days. ( + /-2 hours. ) b) 220 330 370

100% passing through 4.75 mm I.S. sieve. Not more than 4% 1) For concrete 2.6 to 3.6 Tests should be carried out in the beginning and if 2)For masonry and 1st coat of plaster. there is a change in source Not more than 3. 3) For pointing & IInd coat of plaster shall Not exceed 1.6

4) Bulkage.

Bulkage will have to be determined for applying correction to the qty. of sand as and when necessary. Will have to be determined to find quantity of free water in sand.

5) Moisture content.

Sr.No Material & Tests. 3. COARSE AGGREGATE 1) Gradation. Size of metal.

Specified Limit.

Frequency.

80 mm. 60mm 50mm 40mm

100 % Passing through sieve size 100mm 80mm 60mm 63mm

100% Retained on sieve size 50 mm 50 mm 40 mm 63 mm ( 0%)

One test for per 100 Cubic metre

40mm 35 to 70% 12.5mm 0 to 5 % 40mm to50mm. For Bituminus Works 40mm Crushed Metal 25mm Crushed Metal 20mm Crushed Metal 12.5 mm Crushed Metal 10mm Crushed Metal 6.3 mm Crushed Metal 63 mm 50mm 40 mm 25 mm 20 mm 12.5 mm 10 mm For concrete 2)Impact Value. Crushing value 4) Los Angles abrasion value 3. Shall not exceed 45% shall not exceed. 45% shall not exceed 16%.

40mm (30 to 65%) 12.5mm (95 to 100%) 25 mm 25 mm 20 mm 12.5mm 10 mm 6.3 mm 4.75 mm For Road work (Heavy traffic) Shall not exceed 30% shall not exceed. 17 % shall not exceed. At the beginning & if 50% (for WBM) there is change in shall not exceed. source. 17%(B.T.works) shall not exceed. 15%

5) Flakiness Index

Shall not exceed 35%

6) Water absorption

7) Specific Gravity

shall not exceed 5% shall not exceed 5% for WBM shall not exceed 1% for BT work Not specified Not specified

Sr. No 4

Tests. BRICKS 4. Water absorption shall not exceed

Specified Limit. I class II class 20% 22%

Frequency.

 Compressive Strength 32.8 kg/cm2 29.52 kg/cm2 (wet condition ) minimum 3)Efflorescence NIL - when there is no percephible deposit of efflorescence Slight when not more than 10% area is covered with deposit Serious when there is heavy deposit of salt accompanied by powdering 1) Compressive Strength for 28 days Propotion 28 days Strength 1:3 127 to 211 Kg/cm2 1:4 84 to 126 Kg/cm2 1 :5 56 to 84 Kg/cm2 1:6 35 to 56 Kg/cm2 6 CEMENT CONCRETE CUBE 1) Compressive Strength Grade 7days 28 days (Min kg/cm2) (Min kg/cm2) M100 70 100 M150 105 150 M200 135 200 M250 170 250 M300 200 300 M350 235 350 M400 270 400

A set of 15 bricks for 50000 consignment or part there of.

Quantity Min. No Of Concrete of Samples Cum. 151 6 15 2 16 30 3 31 50 4 50 & Above 4 plus additional samples for each addition 0f 50 m3 or part there of 1 Sample = 6 Cubes

MANGALORE TILES 1) Water absorption shall not exceed Class AA Class A 19% 24%

2) Breaking Load kg (minimum)

For Average For Average 100 (410 x 235) 80(410x235) 110(420x250) 90(420x250) 110(425x260) 90(425x260) Individual Individual 90(410x235) 68(410x235) 100(420x250) 78(420x250) 100(425x260) 78(425x260)

1 set of 18 tiles for every 2000 tiles or part thereof.

3) Permeability Test

The tile shall be considered as satisfying the test, if not water has coazed from the bottom at the tile after the test.

CEMENT FLOORING TILES 5. Water absorption 6. Transverse strength Shall not exceed 10% Average wet shall not be less than 3 N /mm2 (30 kg/cm2) tiles or part there of. 6 tiles shall be tested or every test for every 2000

SOIL/MURUM 7. Proctor Density 1.44 gm/cc Embankment upto 3 mtr. Shall not be less Height than 1.5 to gm/cc for Embankment exceeding 3 mtr. Height 1.65 gm/cc for top 0.5 mtr. Height of Embankment 8. C.B.R. Value The Embankment shall be designed on ascertaining the CBR value 95% passing through 80 mm seive One test for compaction of size 2% passing through 25 mm seive 1 layer in one km. and size Below 4 every change in source or type of murum. One test per 1000 m3 or soil.

10

HARD MURUM 9. Gradation 2) Plasticity Index

11

SOFT MURUM 1) Plasticity Index Below 8

One test for compaction of 1 layer in one km. and every change in source or type of murum.

1 Sr. No Tests. 12 STONE 10. Water Absorption 11. Compressive Strength 12. Specific Gravity GLAZED TILES 1) Water Absorption Specified Limit. Frequency.

Maximum 5% 1530 kg/cm2 minimum Not less than 3

13

Not more than 10%

One set of 5 tiles for every 5000 tiles or part thereof.

14

BITUMEN 1) Penetration To ascertaion the correct grade of bitumen Two samples per lot to be subjected to all some tests as directed by the Engineer.

15

BITUMINI0U MIX 13. Extruction To check correct binder content as per 2 test for each 100 tonnes the tender of mix subject to a minimum of two tests per day per plant.

Minimum stability 820 kg 2) Marshall Stability & Flow measurments Flow 2-4 mm

For each 100 tonnes of mix produced , a set of 3 marshall moulds to be prepared and tested as per MOST

CONTROL TESTS AND THEIR FEQUENCY AND SPECIFIED LIMITS FOR VARIOUS CONSTRUCTION MATERIALS

S.N. 1

Name of Test COARSE AGGREGATE Soundness

Specified Limit

Frequency

2 3 4 5

Bulk Density FINE AGGREGATE CL2 & Sulphate Content Moisture Content Bulkage of sand CONCRETE Flexural Strength of beam

Loss with Before approving the Sodium 12% Max. aggregates and every Magnesium Sulphate 18% Max. month subsequently Sulphate content 500 mg/Lt Cl 2 content 2000 mg/Lt. For P.C.C. 1000 mg/Lt. For R.C.C. Grade Modules of rupture Of By beam test min. Concrete 3 days 7 days N/mm2 N/mm2 M-10 1.2 1.7 M-15 1.5 2.1 M-20 1.7 2.4 M-25 1.9 2.7 M-30 2.1 3.0 M-35 2.3 3.2 M-40 2.5 3.4 Sulphate content 500 mg/Lt Chloride content 2000 mg/Lt. for P.C.C. 1000 mg/Lt. for R.C.C. 2 beams/150 m3 or part there of (one for 7 days and other for 28 days) or minimum 6 beams per days work whichever is more

SOIL/ MURUM Sulphate & Chloride content

8 9 10 11 12 13 14

Mechanical analysis BITUMEN Softening point Viscosity Flash & fire point Specific gravity Ductility Mastic Hardness No.

40 to 550C 2 sample/lot to be subjected to all or some tests as directed 1750C by the Engineers 0.99 minimum 75 cm. Minimum 60 to 80 at 250C without coarse aggregate 10 to 20 at 250C after adding coarse aggregate Not less than 6 Sulphate content 500 mg/Lt Chloride content 2000 mg/Lt. for P.C.C. 1000 mg/Lt. for R.C.C. Once for approval of source of supply subsequently in case of doubt

WATER 15 16 PH value Sulphate & Chloride content

WOOD 17 18 Density Moisture content Roof and floors/weather Boards 20% Joinery beams/staircase 16% floors 12% At least 3 samples from lots containing upto 200 pieces

19

STEEL ANTI CORROSIVE TEST Resistance to applied voltage (1 Hr.test)

20

Resistance to applied voltage (30 days.test)

21

Thickness of coating

There was no sign of any coating failure at cathode, due to evaluation of hydrogen gas of any lasting at anode No under cutting of coating shall occur at any holiday that develops during testing. If no holiday developed during 30 days single intentional hole of 6 mm. shall be made in both cathod in anode then test shall be continued for additional 24 hours in which no under cutting shall occur Minimum thickness CECRI 200 400 Mic. FBEC 100 300 Mic. CPCC 125 Mic. Min.

Coating thickness shall be tested at a frequency of not less than one full length bar every twenty bars for each size.

22

Chemical resistance Test

23

Hardness of coating Test

The coating shall not blister, soften, lose bond, nor development holiday during 45 days. The intentionally made holes shall exhibit no under cutting during the 45 days period. Hardness of coating when measured using a pencil hardness tester shall be around 54 to 74.

TYPICAL LETTER FOR SAMPLE DESPATCH Date To,

Sub.:- Testing of construction material Please find enclosed herewith the samples collected from the below mentioned work site and it is requested to please test the materiasl and communicate the test results to this office at an early date. 1. 2. 3. 4. 5. Name of Work : ----------------------------------------------------------------------------Estimates cost of work :---------------------------------------------------------------------Tender No. & Cost :-------------------------------------------------------------------------Scheme of Work :-----------------------------------------------------------------------------Name of Agency :-----------------------------------------------------------------------------

6. Details of sample as below.

A. Aggregate/ Murum/ Bituminious mix. Sr.No. 1) Material its location chainage LHS/RHS 60 mm metal km 1/500 (RHS) No. of samples 1 No. Tests to be conducted 1)Water Absorption 2) Impact Value 3) Gradation

B. C. Bricks/Tiles (Flooring/Manglore) /CC Blocks etc Sr.No 1 Material & its identification mark Bricks No. of sets 1 set 1 set=10 bricks Tests to be conducted 1)Water Absorption 2) Compressive strength

D. E. CC Cube/Moter Cube/ Hallow Block/Soil Block :Sr.No Grade of concrete / member 1 M-20 Beam No.B-4 Date of Casting 12-5-2000 Mark Size in cm B-1 B-2 B-3 No. of sets Test Compressive Strength

15x15x15 2 sets 1 set= 3 No. cube

G. Concrete Mix Design 1. Grade of Concrete ----------------------------------------------------2. Size of Aggregate to be used ------------------------------------3. Details of fine Aggregate -------------------------------------------

4. Cement company and Grade ------------------------------------5. Maximum size of Aggregate --------------------------------------6. Required character stic strength --------------------------------7. Degree of workability ------------------------------------------------8. Type of exposer -------------------------------------------------------9. Degree of quality control --------------------------------------------10. Water cement ratio ----------------------------------------------------11. Required slump --------------------------------------------------------12. Minimum cement content specified -----------------------------E) Job Mix Design for Bituminus Work (SDBC/DBM/BC/BM) 1. 2. 3. 4. 5. Wearing surface type -------------------------------------------------Thickness as per tender ---------------------------------------------Details of material to be used --------------------------------------Details of filler ------------------------------------------------------------Details of binder ---------------------------------------------------------

Identification slip as described below duly signed with seal shall be kept in the sample bag. Identification Slip 1) Name of Sub Dn. : ---------------------------------------------------------2) Name of work ---------------------------------------------------------------3) Date of sample ------------------------------------------------------------- dispacted to Laboratory 4) Details of sample --------------------------------------------------------Testing charges for the above tests will be paid by the agency in cash or Demand Draft. It is requested to send the results to the Executive Engineer ----------------Dn. Encl: Samples as Deputy Engineer, Mentioned above P.W/NH/ZP Sub Dn. Copy submitted to the Executive Engineer, P.W. Dn. ---------------------- for information Copy to Agency ---------------------------------------- for information & necessary action.

REGISTER OF QUALITY CONTROL TESTS A. Guidelines for maintaining the Register of Quality Control Tests. 1) On every work, this Register shall be maintained.

2) The Junior Engineer, in charge of the work, should maintain this Register under the guidance of his Deputy Engineer. 3) The entries in the register should be signed by the Deputy Engineer for authentication. 4) Register should be available on the site of work during the inspection and should be kept up-to-date. 5) This register shall form a part of the permanent record of work and its pages should not be torn off and erasured, changed etc. should be authenticated. 6) For special type of works involving large scale construction in Bituminous Macadam and Asphaltic concrete etc. a separate register may be kept for dayto-day tests. A. Samples of Materials of Testing 1) Samples should be adequately representative and should be takenafter receipt of each new consignment. 2) The number of samples to be tested and the quality of each sample etc. as also the frequency of the testing shall be as per the Standard Specification. 3) Samples should be properly identified by giving due identification marks and sent to the Laboratory carefully so that they do not get damaged in transit. A. Standard Results The prescribed standards and frequency are shown in separate chapter. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) Cement. ... Sand. Bricks. Stone. Aggregates. Concrete. Steel. Welded Joints/Electrodes. Flooring Tiles. Mangalore Tiles. Cement Mortar. Soils Bitumen Hume pipes.

PERFORMA FOR TESTING OF CEMENT

Sr. Date of No. Sampling

Age of Date of Sample identification cement at Testing No. including Name the time of of Factory, Lot Not. testing No. etc.

FINENESS

% of Residue Specific surface by by weight on Air Permeability 90 micron method cm2/gm. sieve. 6 7

Soundness

Setting Time Initial Final (Minutes) (Minutes)

10

Compressive Strength Name of Lab. Dated Remarks Age of Compressive & No. & Date Signature of letter No. of the cube strength in under which Deputy Kg/cm 2 the results are Engr. received. 11 12 13 14 15

PROFORMA FOR TESTING OF SAND Sr. No. 1 Date 2 Silt contents % 3 Sieve Analysis Sieve size in mm. % Retained by weight 4 5

Fineness Condition of Modulus sand

Moisture content %

% Bulkage observed

Action taken for reduction in silt content /F.M. Bulkage 10

Dated Signature of D.E. 11

Remarks

12

PROFORMA FOR TESTING OF BRICKS Sr. No. No. of Bricks in one consignment 2 No. of samples selected for testing 3 Size of brick 4 Identification No. on sample 5 Date of testing 6 % of water absorption 7

Compressive strenth Kg/cm2 Dry. Wet. 8 9

Efflorance Test.

Reference No. from laboratory 11

Dated Signature of the Dy. Engineer 12

Remarks.

10

13

PROFORMA FOR TESTING MASONRY STONES. Sr. No. Date of Testing Source & details of Samples Specific gravity Water Absorption Compre- Name of Dated ssive Lab. No.& Signature strength Dt. Under of Dy. Kg/cm2 which the Engr Kg/cm2 results received. 6 7 8 Remarks

PROFORMA FOR TESTING OF STONE AGGREGATE Sr. No. Nominal size of Date of testing metal 1 2 3 Impact value 4 Crushing value 5 Los Angles abrasing value test 6

Water Stripping SIEVE ANALYSIS Absorbtion value I.S. sieve % passing by weight 7 8 9 10

% No. & Dt. Under Dated flakiness which the results Signature Index are received from of the Dy. the laboratory Engr. 11 12 13

Remarks

14

PROFORMA FOR TESTING OF CEMENT CONCRETE CUBES Sr. Date of No. concreting. Grade of concrete. Total Nos. of cubes Location Quantity of & where concrete laid identification concrete during the there on used. day. 4 5 6 Water cement ratio Slump observed.

Date of Age Dimension Weight Testing of of cube of of Cube cube. Cube 9 10 11 12

Observed comp. Strength Kg/cm2 13

Calculated Ref. No. Dated Comp. from Signature of strength Laboratory the Dy. Engr. 728 14 15 16

Remarks

17