TEST PROCEDURES

SLUMP CONE 1. Purpose : The slump cone is used for determining the workability of concrete where the nominal maximum size of aggregate does not exceed 38 mm. 2. Procedure as per IS 1199 Methods of sampling and analysis of concrete a. b. c. d.
e.

f. g.

h.

Firstly decide the frequency of slump value to be taken during concreting. Oil the interior surface of the slump cone with mould releasing oil to prevent adhesion of the concrete. Place the slump cone on a leveled surface. Collect the sample in a wheelbarrow after mixing the concrete properly in the transit mixture. Remix the sample thoroughly in wheelbarrow with sampling scoop. After remixing immediately fill the slump cone in layers approximately one quarter of the height of the cone. Each layer shall be compacted with the tamping rod by 25 strokes distributed in a uniform manner over the cross-section of the cone and for the second and subsequent layers tamping rod shall penetrate into the underlying layer. After compacting the top layer the concrete shall be struck off level with the top of the slump cone, using a _______. Any mould which may have leaked out between the mould and the base plate shall be cleaned away.

i.

Unscrew the slump cone from the base plate and remove it immediately from the concrete by raising it slowly and carefully in a vertical direction. After the concrete subsides place the slump cone on the base plate in reverse position and place a scale on it. Measure the height between the top of the mould and the highest point of the concrete specimen being tested.

j.

3. Reporting of slump value The slump measured shall be reported in terms of millimeters.

VIBRATING TABLE 1. Purpose Vibrating table is used for proper compaction of concrete (as per IS 516-Methods of tests for strength of concrete) while casting specimens for compressive strength determination. 2. Procedure i. ii. iii. After preparing the concrete mix, put moulds on the vibration table platform. Fill concrete in the mould in layers of 50 mm deep. In placing each scoopful of concrete, move the scoop around the top edge of the mould as the concrete slides from it, in order to ensure a symmetrical distribution of the concrete within the mould. Let each layer compact by vibration. After compacting concrete in 3 layers, finish the surface of the concrete level with the top of the mould. Stop the table and remove the mould from it.

iv. v. vi.

TEST PROCEDURES
BULK DENSITY MEASURE (For Density of Concrete) 1. Purpose The bulk density measure is used for determining the weight per cubic meter of freshly mixed concrete (density) from which the yield of concrete per cubic meter can be calculated. 2. Procedure as per IS 1199 methods of sampling and analysis of concrete i.
ii.

iii.
iv.

v. vi. vii. viii.

ix.

Take freshly mixed concrete from transit mixer by using wheel borrow. Fill the cylindrical measure with concrete as soon as practicable after mixing. Fill the cylindrical measure with concrete in layers approximately 5 cm deep and each layer shall be compacted. While compacting the concrete the standard tamping bar shall be distributed in uniform manner over the cross section of the measure. The number of strokes per layer is 60 for 10 litres cylinder and 120 for 20 litres cylinder. The exterior surface of the cylinder shall be tapped 10 to 15 times or until no large bubbles of air appear on the surface of the compacted layer. Strike-off the top surface and finish it smoothly with a flat cover plate. Clean all excess concrete from the exterior and weigh the filled measured. Density of concrete (W1): The weight per cubic meter of concrete shall be calculated by dividing the

x. xi.

weight of fully compacted concrete in the cylindrical measure by the capacity of measure in kg/cu.m (W1). Yield of concrete (V2) : The volume of concrete produced per cum. shall be calculated as follows. V2 = Wc + Wf + Wca + Ww W1 Wc = Wf = Wca = Ww = Weight of cement, kg Weight of fine aggregate, kg Weight of coarse aggregate, kg Weight of water, kg

TEST PROCEDURES
150 x 150MM Cube Moulds 1. Purpose The moulds are used for making of concrete cubes as per IS : 516 1959 Methods of tests for strength of concrete. 2. Apparatus Wheel barrow, sampling scoop, trowel cube moulds of 15 x 15 x 15 cm size and tamping bar 16 mm in diameter, 0.6 m long and bulleted point at the lower end. 3. Procedure as per IS 516 a. Firstly decide the number of samples to be taken during concreting. b. Oil the interior surface of the mould with mould releasing oil to prevent adhesion of the concrete. c. Collect the sample in a wheelbarrow after mixing the concrete properly in the transit mixer. d. Remix the sample thoroughly in wheelbarrow with sampling scoop. e. After remixing immediately fill the mould in layers approximately 5 cm deep. f. During filling the mould, the scoop shall be moved around the top edge of the mould as the concrete slides from it, in order to ensure a symmetrical distribution of the concrete within the mould. g. Each layer shall be compacted with the tamping rod (of 16 mm dia 60 cm long and rounded at one end) by

minimum 35 strokes distributed in a uniform manner over the cross-section of the mould. h. After compacting the tip layer, top surface of the concrete shall be finished level with the top of the mould, using a trowel. i. Store the cube moulds in a place which is free from vibration and cover the surface of the concrete with a piece of damp sacking for initial 16 to 24 hours. j. After this period, mark the specimen and remove it from the mould by dismantling and submerge it clean water at a temperature of 27 +2oC and keep it till the time of testing for compressive strength.

TEST PROCEDURES
PENETRATION RESISTANCE APPARATUS 1. Purpose Penetration resistance apparatus : (Penetrometer) is used to find out initial and final setting time of concrete as per IS 8142Method of test for determining setting time of concrete by penetration resistance. 2. Procedure a. b. c. d. e.
f.

g.

h.

Select a representative sample of concrete of known proportion. Oil the interior surface of the cube mould with mould releasing oil to prevent adhesion of the concrete. Remove all of the mortar from the sample by sieving it through a 4.75 mm IS sieve into a mortar pan. Remix the sample thoroughly and fill it in a 15 cm cube mould in two layers, leaving a space of 13 mm (1/2 inch) at top. Compact each layer with tamping rod by tamping each layer 25 times. For each test, a set of three cube moulds should be filled. Keep the moulds covered with a water impermeable cover and under shed for the duration of test. Prior to making each penetration resistance test, remove bleeding water by using a pipette. For easy removal of water, tilt the mould by placing a 3 cm block under one of the edges and allow water to collect at the shallow portion for 2 minutes. Select 65 mm2 and 16 mm2 removable needles for initial and final setting time respectively. After removing the bleed water, insert the penetrometer vertically into the mortar. Push the apparatus gradually

i.

j. k. l.
m. n.

until the needle (65 mm2) penetrates the mortar upto scribe mark, in about 10 seconds. The force required is indicated by the white ring. Record the force required and the elapsed time after adding water to the mix. Make penetration test at hourly intervals, initial test being made after 3 hours. Leave a space of 20 mm from previous impression in subsequent penetration test. Initial setting time is read off against a penetration resistance corresponding to 35 kg f/cm2. Change the needle dia i.e. 16mm2 and final setting time is read off against a penetration resistance corresponding to 275 kgf/cm2

ACCELERATED CURING METHOD

1. Purpose :

To find out 28 days compressive strength of concrete in 28 hours by accelerated curing method. (As per IS 9013-1978Method of making, curing and determining compressive strength of accelerated cured concrete test specimens) Procedure :
1.

2. 3.
4. 5.

6.

7. 8.

After the test specimens (whose 28 days strength to be determined) have been made, store it in moist air of at least 90 percent humidity for 23 hours + 15 min. Cover the specimens with flat steel cover plate to avoid distortion during the use. Carefully and gently lower the specimens into the curing tank and shall remain totally immersed for a period of 3 Hours + 15 min. The temperature of water in the curing tank shall be at boiling (100 oC) when the specimens are placed. After curing for 3 hours in boil water, the specimen shall be carefully removed from the boiling water and cooled by immersing in cooling tank at 27 +2oC for 2 hrs. After cooling remove the specimens from the mould and tested for its accelerated compressive strength (Ra) in N/mm2. The 28 days can be found out using following formula. Predicted 28 days compressive strength = R28 = 8.09 + 1.64 Ra, where Ra is accelerated compressive strength and R28 is predicted compressive strength at 28 days.

TEST PROCEDURES
DIGITAL COMPRESSION TESTING MACHINE 1. Purpose : The digital compression testing machine is used to determine the compressive strength of hardened concrete specimens. Procedure as per IS 516 Methods of tests for strength of concrete 1. Keep the specimen to be tested centrally on the clean lower platen so that small clearance is left between the upper platen and the top the specimen under test. 2. Close the pressure release valve. 3. Make the digital display to read Zero by adjusting the zero knob. 4. Put the display unit on Peak Hold mode to hold the maximum load reading. 5. Start applying the load at the specified pace rate, which could be maintained by adjusting the slow fast knob. 6. If the pace rate is on higher side the indicator displays red colour and the pace rate is on lower side the indicator will display yellow colour. 7. If the pace rate is exactly equal to set rate then the indicator will display green colour. 8. As soon as sample fails, release the pressure slowly by opening valve. 9. The digital display will be holding the maximum load reading at which sample has failed. Note down the pattern of failure and calculate the compressive strength in N/mm2 or kg/cm2. 10. Pace rate for 15 cm cube is 5.15 kN/s. 11. Before starting another test, clean the lower platen and bring the digital display to Zero position by depressing the Reset switch.

TEST PROCEDURES
VICAT APPARATUS (Standard Consistency) 1. Purpose :

It is used to determine the standard consistency, initial and final setting of cement (As per IS 4031 Methods of physical tests for hydraulic cement) Procedure for determination of standard consistency : a. Take the Vicat apparatus and fit the standard consistency plunger (Cylindrical one). Lower the stem and check if the reading is zero when the plunger touches the non-porous resting plate (glass plate). If not adjust it to zero. The temperature of cement and water and that of testing room shall be preferably within the range of 27 +2oC. Coat the non-porous resting plate (glass plate) with petroleum jelly. Place the mould after coating it lightly with petroleum jelly on the non-porous resting plate (glass plate). Take 300 g of cement. Prepare a past with weighed quantity of water (30% of weight of cement = 90ml). The time from adding water to the dry cement till starting to fill the Vicat mould should be within 3 to 5 minutes. Fill the Vicat mould completely with the cement past made and smooth off the surface of the paste, make it level to the top of the mould. Place the mould under the plunger together with non-porous resting plate. Lower the plunger gently to touch the surface of the block and release quickly. Make sure that the dash pot works properly. Measure and note down the penetration. Clean the mould and plate. If the value obtained is below 5 mm then try with lesser quantity of water (say 29%, 28%, etc.) repeat steps c to k above with the lesser water.

b.

c. d. e. f. g. h. i. j. k. l.

m.

n.

o.

If the value obtained is above 7 mm then try with more quantity of water (say 31%, 32% etc.) repeat steps c to k above with more water. Keep doing above tests with varying percentages of water until the amount of water for the required penetration of 5 to 7mm value is found. Standard consistency : Express the amount of water as a percentage by weight of the dry cement.

TEST PROCEDURES
VICAT APPARATUS (Initial setting time of cement) 1. Procedure as per IS 4031 Methods of physical tests for hydraulic cement
a.

b.

c.

d.
e.

f. g.

h.

Take the Vicat apparatus and fit the standard consistency plunger (Needle type). Lower the stem and check if the reading is zero when the plunger touches the non-porous resting plate (glass plate). If not adjust it to zero. The temperature of cement and water and that of testing room shall be preferably within the range of 27 + 2oC. Coat the non-porous resting plate (glass plate) with petroleum jelly. Place the mould after coating it lightly with petroleum jelly, on the non-porous resting plate (glass plate). Take 300 g of cement. Prepare a neat cement paste mixed with water which is 0.85 times that of standard consistency (i.e. If standard consistency = 30%; water for initial setting time = 0.30 x 300 x 0.85 = 25.5 ml). The time from adding water to the dry cement until starting to fill the Vicat mould should be within 3 to 5 minutes. Start the stop watch as soon as you start adding water and mixing the cement past. The mixing should be done using a stainless steel trowel called gauging trowel which is available with lab equipment dealers. Fill the Vicat mould completely with the cement paste made and smooth off the surface of the paste, make it level to the top of the mould.

i. j.
k.

l.

Place the mould under the needle (1 mm square) together with non-porous resting plate and cement paste. Lower the needle gently to touch the surface of the block and release quickly. Make sure that the dash pot works properly. Initially the needle will pierce completely into the test block. Repeat this procedure until the needle fails to penetrate into the test block by 5 + 0.5 mm from the bottom of the mould. Initial setting time : The time started from mixing of water to the cement to the time when the needle fails to penetrate the test block by 5 + 0.5 mm is described as the initial setting time.

TEST PROCEDURES
VICAT APPARATUS (Final setting time of cement) 1. Procedure as per IS 4031 Method of physical tests for hydraulic cement
a. After determining the initial setting time replace the

needle of Vicat apparatus by the needle with annular attachment. b. Lower the attachment gently to touch the surface of the block and release. Use the dash pot. c. Repeat this procedure at regular intervals until the time to find the needle makes an impression on the surface of the block and the circular impression is not seen. d. Final Setting time : The time elapsed from mixing of water to the cement and the time till step c is the final setting time of cement.

TEST PROCEDURES
VIBRATING MACHINE (Compressive strength of cement) 1. Procedure as per IS 4031 Methods of physical test for hydraulic cement
a. Take 200 g of cement and 600 gms of standard sand

b. c. d. e.

f. g.
h.

i.

conforming to IS : 650 1966. The 600g of standard sand will be made up o 200g each of grade I, Ii & III Sand purchased from TAMIN, Manali, Chennai. Mix it dry with a trowel for one minute on a non-porous mixing plate. Take water @ (P/4 + 3)% of combined weight of cement and sand (800g) where P is the standard consistency of cement paste. Mix the dry mixture with the quantity of water specified above for 3 to 4 minutes. Place the 50 cm2 ( 7.07 x 7.07 x 7.07 cm) mould on the vibration table and clamp it to hold it firmly in position. Attach a hopper of suitable size on the top of the mould to facilitate filling. Immediately after mixing the mortar place it in the cube mould and tamp it with the poking rod for 20 times in about 8 seconds. Place the remaining quanitity of mortar place it in the cube mould and tamp it again as specified for the first layer. Compact the mortar further by means of vibration for two minutes. At the end of vibration remove the mould from the machine and finish the top surface of the cube with the blade of a trowel.

j. Keep the filled moulds preferably at a temperature of

27 + 2oC and atleast 90 percent relative humidity for 24 hours after completion of vibration. k. After 24 hours remove the cubes from the moulds and immediately submerge in clean water for curing. l. Temperature of the curing water should be preferably 27 + 2oC. m. Cast twelve such cubes so that we can find the compressive strength for 3 cubes each at 1 day, 3 days, 7 days and 28 days. Report average of compressive strength of three cube results to the nearest 5 kg/cm2.

TEST PROCEDURES
SCHMIDT CONCRETE TEST HAMMER 1. PURPOSE It is used for estimation of compressive strength of concrete by rebound hammer method. (As per IS 13311 part 2Non destructive testing of concrete methods of test) 2. PROCEDURE a. For testing, smooth, clean and dry surface preferably bottom of the slab is to be selected. b. If loosely adhering scale is present, this should be rubbed of with grinding stone. c. Release the impact bolt by applying pressure to it. d. Place test hammer perpendicular to the test surface. e. Press housing against the test surface at moderate speed until impact is triggered. f. The rebound value is arrested and read by means of the push-button. g. Each test point should be tested with at least 8 to 10 impacts. h. Minimum distance between impact points 20 mm. i. Rebound values, which are abnormally high or low, must be eliminated. j. After using the hammer the impact bolt is to be arrested by means of the push-button after the initiation of an impact. k. Plot the average rebound value in the conversion curve to determine the compressive strength of concrete. l. The strength determined from the curve is to be corrected by using correction factors (as per manual of manufacture).

m. The test can be conducted horizontally on vertical surfaces like column or vertically upward or downward on horizontal surfaces like slabs and beams. n. The correlation between compressive strength of concrete cubes and its rebound number is to be established for most satisfactory results.

TEST PROCEDURES
SIEVE ANALYSIS FOR FINE AGGREGATE
1.

Purpose :

The sieves are used for the determination of particle size distribution of fine aggregate by sieving. (As per IS 2386 part 1 Methods of test for aggregates for concrete)
2.

Sizes of sieves :

Sieves of the sizes 10mm, 4.75 mm, 2.36 mm, 1.8mm, 6000 mic., 300 mic., and 150 mic.
3.

Procedure : a. Take known weight of dry sample. b. Sieve the sample progressively starting from the largest sieve i.e. 10 mm c. On completion of sieving weigh the material retained on each sieve. d. Calculate the percentage of sand retained in each sieve and cumulative percentage retained on each sieve. e. Calculate cumulative percentage passing through each sieve. f. Calculate the fineness modulus of sand by summing up the cumulative percentage of sand retained on 10 mm, 4.75 mm, 1.18 mm, 600 mic., 300 mic., and 150 mic., sieves and dividing the sum by 100. g. Find out which grading zone the sand conforms to by checking with the table 1 given below.

Table 1 : Grading zones (I.S. 383) 1978

I. S. Sieve 10mm 4.75mm 2.36mm 1.18mm 600 micron 300 micron 150 micron 75 micron Cumulative percentage passing IS sieves for grading zone (natural sand) I II III IV 100 90-100 60-95 30-70 15-34 5-20 0-10 0-3 100 90-100 75-100 55-90 35-59 8-30 0-10 0-3 100 90-100 85-100 75-100 60-79 12-40 0-10 0-3 100 90-100 95-100 90-100 80-100 15-50 0-15 0-3 Crushed Sand 100 90-100 75-100 55-100 35-79 8-40 0-20 0-15

TEST PROCEDURES
SIEVE ANALYSIS FOR COARSE AGGREGATE
1. Purpose :

The sieves are used for the determination of particle size distribution of coarse aggregate by sieving (As per IS 2386 part I Methods of test for aggregates for concrete) 2. Sizes of sieves required for nominal size coarse aggregate Balance and I.S. sieves sizes as following : Nominal size of aggregate 40 mm 20 mm 12.5 mm 10 mm Sieve size (mm) 80 mm, 63 mm, 40 mm, 20 mm, 10 mm, 4.75 mm 40 mm, 25 mm, 20 mm, 10 mm, 4.75 mm 20 mm, 16 mm, 12.5 mm, 10 mm, 4.75 mm, 600 mic., 150 mic. 12.5 mm, 10 mm, 4.75 mm, 2.36 mm, 600 mic., 150 mic.

3. Procedure : a. b. c. d. e. f. Take a known weight 9 2kg) of dry aggregate. Sieve the aggregate progressively starting from the largest sieve. Note down the weight of the material retained in each sieve. Calculate the percentage of aggregate retained in each sieve. Calculate the cumulative percentage of aggregate retained in each sieve. Calculate the cumulative percentage of aggregate passing through each sieve.

g.

Check the values of percentage passing with the limits specified in IS 383 and record it.

Grading requirement of coarse aggregate (IS : 383) 25 mm 20 mm 12.5 mm 10 mm 4.75 mm

TEST PROCEDURES
SILT CONTENT OF FINE AGGREGATE (BY VOLUME METHOD)

1. Purpose :

The 250 ml capacity glass-measuring cylinder is used for determination of silt and clay content in sand on volume basis. 2. Procedure : a. Fill the glass-measuring cylinder with sample of sand upto 100 ml mark. b. Add clean water upto 150 ml and shake the contents well. c. Allow contents to settle for 15 to 20 min. d. Clay and silt will be seen as a separate layer over sand. e. Measure the total height of material (A). f. Measure the height of sand layer (B). g. Find out height of silt and clay layer (A-B). h. Calculate the percentage of silt and clay in the total sand layer. i. Calculation : Silt & Clay %, (A-B) /B* 100

SIEVE SHAKER
1.

Purpose : Sieve shaker is used for the process of sieving easier and quicker as per IS 2386 part I Methods of test for aggregates for concrete.

2.

Procedure : a.
b.

c.

d. e. f. g.
h.

Unbolt the nuts of the sliding retaining plate, raise it to a suitable height and tighten the nuts. Select the required group of sieves for the sieve analysis. On the base of the sieve holder mount the sieves in order of decreasing opening size from top to bottom, together with a receiver fitted below the bottom sieve. Keep the material on the top sieve. Place the lid on the sieve. Unbolt the nuts of the clamping plate, slide it down to pass the whole sieve assembly and tighten the nuts. Start the sieve shaker by switching on the motor, and continue the sieving operation for specified time say 10 minutes. At the end of sieving operation, dismantle the sieve assembly and collect separately the material retained on each sieve and on the receiver for weighin

TEST PROCEDURES
AIR OVEN

1.

Purpose Air oven is used to dry the material for finding out moisture content present in aggregate. Moisture content of aggregate is the percentage of weight of water in the aggregate sample to the total dry weight of the aggregate sample. The procedure is the same for both coarse and fine aggregate.

2.

Procedure a.
b.

c. d.

Take the moist or wet sample weigh (W1) Dry it in a hot air oven for 10-15 min. at the temperature of 100oC. Take the sample out of air oven and cool it. Take the weight of dry sample (W2).

3. Calculation Moisture content of aggregate is calculated as follows : M=(W1-W2) / W2 x 100 Where M = Moisture content of aggregate, % W1=weight of moist sample, gm W2= weight of dry sample, gm

TEST PROCEDURES
SPECIFIC GRAVITY TEST FOR AGGREGATE 1. Purpose : The pycnometer is used to determine the specific gravity of aggregate as per IS 2386 part III Methods of test for aggregates for concrete. 2. Procedure a. b. c. d. e. Weight an empty pycnometer (W1) Fill up half of the pycnometer with dry aggregate sample and weigh. Add water to the sample, fill the pycnometer with water, roll it on a flat surface and then fill it completely with water and weigh (W3). Empty the contents of the pycnometer, refill it with water only and weigh. (W4). Calculate the specific gravity using this formula. Specific Gravity = (W2 W1) / [(W4-W1)-(W3-W2)] weight of empty pycnometer, g. weight of pycnometer and dry aggregate, g. weight of pycnometer with aggregate and water, g weight of pycnometer filled with only water, g

Where W1 = W2 = W3 = W4 =

TEST PROCEDURES CYLINDRICAL METAL MEASURE (For Density of Aggregate) 1. Purpose : The cylindrical metal measures are used for determining unit weight or bulk density of aggregate. 2. Procedure as per IS 2386 part III- Methods of test for aggregates for concrete A. Rodded or Compacted Density
a. Fill the measure about 1/3rd height with thoroughly

b. c. d. e.

mixed aggregate. Tamp it with 25 strokes of the rounded end of tamping rod. Again fill the measure with approx. same quantity & tamp it with 25 strokes. Overflow the measure with aggregate, tamp it 25 times & struck off surplus aggregate with tamping rod. Determine the net weight of aggregate by knowing empty weight of measure and calculate Bulk density in Kg/cu.m.

B. Loose Density a. Fill the measure to overflow with aggregate by discharging from height not more than 5 cm above the top of measure. b. Level the sample with a straight edge. c. Determine the net weight of aggregate by knowing empty weight of measure and calculate Bulk density in Kg/cu.m.

TEST PROCEDURES
LENGTH GAUGE 1. Purpose The length gauge is used to determine the Elongation index of coarse aggregate (As per IS 2386 part 1 Method of test for aggregates for concrete) 2. Procedure
a. Take enough quantity of dry blended sample so that b.

c.

d. e. f.

atleast 200 pieces of any fraction is present. Sieve the blended sample through all the sieves mentioned above starting from the largest sieve i.e. 63 mm. Separate all the individual fractions 63 mm to 50 mm, 50 mm to 40 mm, 40 mm to 25 mm, 31.5 mm to 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mm 10 mm to 6.3 mm. Take all the fraction separately, gauge them one by one through the corresponding shot provided in the gauge. Keep the particles retained by the length separately. Weigh the particles retained on length gauge. Elongation index is the total weight of the material retained on the various length gauges, expressed as a percentage of the total weight of the sample gauged.

3.

Calculation Elongation index of aggregate in % is calculated as follows: Ei = (W1/W2) x 100% Where W1 = Weight of particles retained in length gauge, g W2 = Weight of total sample taken for test, g

TEST PROCEDURES
THICKNESS GAUGE 1. Purpose : Thickness gauge is used to find out flakiness index of coarse aggregate. (As per IS 2386 part 1 Methods of test for aggregates for concrete). 2. Procedure :
i.

ii.
iii.

iv.

v. vi.

Take enough quantity of dry blended sample so that atleast 200 pieces of any fraction is present. This is not applicable for the biggest and smallest size. Sieve the blended sample through all the sieves mentioned above starting from the largest sieve i.e. 63 mm. Separate all the individual fractions 63 mm to 50 mm, 50 mm to 40 mm, 40 mm to 31.5mm, 31.5 mm to 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mm and 10 mm to 6.3 mm. Take all the fraction separately, gauge them one by one through the corresponding slot provided in the gauge. Keep the particles passing through the slot of the gauge and retained in gauge separately. Note the number of particles passing and not passing through the corresponding slot in the gauge for each fraction. Calculate for each fraction the following : a. Percentage of number of particles passing the slot to the total number of particles in fraction. This is noted as X. b. Percentage of weight of particles in fraction taken for testing to the total weight of particles in fraction taken for the test (total qty.). This is noted as Y.

3.

Calculation : Flakiness Index = Fi = X (Xi Yi)/100% i=1 to n Where Xi = Percentage of number of particles passing the slot to the total number of particles in that fraction, % Yi = Percentage of weight of particles in fraction to the total weight of particles in all fraction, %

IMPACT VALUE TEST FOR 10 mm AGGREGATE 1. Purpose : The impact test machine is used to determine the aggregate impact value of coarse aggregate as per IS 2386 Part IV 1963 Methods of test for aggregates for concrete 2. Procedure : 1. 2. 3. 4. 5. Take about 1000 g of dry sample passing through 12.5 mm IS sieve and retained on 10 mm IS sieve. Fill the cylindrical metal measure with the dried sample. The sample should be placed in three increments, each increment being rodded 25 times with the tamping rod. Strike off the excess sample using the tamping rod as a straight edge. Take the weight of sample in the measure (W1). Now drop the hammer in the testing machine 15 times on the sample test in the cup. Height of the fall of the hammer should be 380 mm. The interval between each blow should be about one second. Remove the sample from the cup and sieve it on 2.36 mm IS sieve until no more sample passes through the sieve. Find the weight of sample retained on 2.36 mm sieve (W2). Repeat the test for another sample from the same lot and calculate the average of the two values. Calculation : Aggregate impact value, % = (W1 W2) W1 x 100 Where W1 = weight of dry sample passing through 12.5 mm IS sieve and retained on 10 mm IS sieve, g W2 = weight of dry sample retained on 2.36 mm IS sieve, g Report the aggregate impact value in percentage and as the mean of two determinations rounded off to the nearest whole number.

6. 7. 8. 9.

10.

TEST PROCEDURES
SIEVES FOR COARSE AGGREGATE Sieve analysis of Coarse Aggregate Coarse aggregate consists of material above 4.75mm size. It may be crushed aggregate of natural gravel of different sizes. Apparatus Balance and I.S. sieves sizes as following : Nominal size of aggregate 40 mm 20 mm 12.5 mm 10 mm Sieve size (mm) 80 mm, 63 mm, 40 mm, 20 mm, 10 mm, 4.75 mm 40 mm, 25 mm, 20 mm, 10 mm, 4.75 mm 20 mm, 16 mm, 12.5 mm, 10 mm, 4.75 mm, 600 mic., 150 mic. 12.5 mm, 10 mm, 4.75 mm, 2.36 mm, 600 mic., 150 mic.

Procedure : a. b. c. d.
e.

f.

Take a known weight (2 kg) of dry aggregate reduced by quartering. Sieve the aggregate progressively starting from the largest sieve. Note down the weight of material retained in each sieve. Calculate the percentage of aggregate retained in each sieve. Calculate the cumulative percentage of aggregate retained in each sieve. Calculate the cumulative percentage of aggregate passing through each sieve.

g. h.

Check the values of percentage passing with the limits specified in IS 383 and enter the values. If the grading deviates from limit specified, it can be corrected by blending it to coarser of finer size fractions available to make it according to the limit specified in IS 383 (Grades Coarse Aggregate).

TEST PROCEDURES
ELONGATION TEST 1. Elongation Index Elongation index of an aggregate is the percentage by weight of particles whose greatest dimension (length) is greater than one and four-fifth times their mean dimension. It is measured on particles passing through mesh size of 63 mm and retained on mesh size 6.3 mm. 2. Apparatus Balance, Elongation gauge (Length gauge) and IS sieves of the following mesh sizes 63 mm, 50 mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5 mm 10 mm and 6.3 mm 3. Procedure a. b. c. Take enough quantity of dry blended sample so that atleast 200 pieces of any fraction is present. This is not applicable for the biggest and smallest size. Sieve the blended sample through all the sieves mentioned above starting from the largest sieve i.e. 63 mm. Separate all the individual fractions 63 mm to 50 mm, 50 mm to 40 mm, 40 mm to 25 mm, 31.5 mm to 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mm and 10 mm to 6.3 mm. Take all the fraction separately, gauge them one by one through the corresponding slot provided in the gauge. Keep the particles retained by the length separately. The aim should be to retain as much as possible to avoid testing bias. Weigh the particles retained on length gauge. Elongation index is the total weight of the material retained on the various length gauges, expressed as a percentage of the total weight of the sample gauged.

d.

e. f.

Calculation Elongation index of aggregate in % is calculated as follows: Ei = (W1/W2) x 100% Where W1 = weight of particles retained in length gauge,g W2 = weight of total sample taken for test, g Reporting Report the elongation index in percentage rounded off to the nearest whole number.

TEST PROCEDURES
FLAKINESS TEST
1. Flakiness Index :

Flakiness index of an aggregate is the percentage by weight of particles in it whose least dimension (thickness) is less then threefifth of their mean dimension. It is measured on particles passing through mesh size of 63 mm and retained on mesh size 6.3 mm.
2. Apparatus :

Balance, Flakiness gauge (thickness gauge) and GI sieves of the following mesh sizes 63 mm, 50 mm, 40 mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5 mm, 10 mm and 6.3 mm.
3. Procedure :

a. b. c.

d.

e.

Take enough quantity of dry blended sample so that atleast 200 pieces of any fraction is present. This is not applicable for the biggest and smallest size. Sieve the blended sample through all the sieves mentioned above starting from the largest sieve i.e. 63 mm. Separate all the individual fractions 63 mm to 50 mm, 50 mm to 40 mm, 40 mm to 31.5 mm, 31.5 mm to 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mm and 10 mm to 6.3 mm. Take all the fraction separately, gauge them one by one through the corresponding slot provided in the gauge. Keep the particles passing through the slot of the gauge and retained in gauge separately. The aim should be to pass as many as possible through the slot to avoid testing bias. Calculate for each fraction the following : a. Percentage of number of particles passing the slot to the total number of particles in fraction. This is noted as X.

b. Percentage of weight of particles in fraction taken for testing to the total weight of particles in all fractions taken for the test (total qty.). This is noted as Y. Calculation Flakiness Index = Fi = (Xi Yi)/100% Where Xi = Percentage of number of particles passing the slot to the total number of particles in the fraction, %. Yi = Percentage of weight of particles in fraction to the total weight of particles in all fraction, % Reporting Report the flakiness index in percentage rounded off to the nearest whole number.

TEST PROCEDURES
PENETROMETER 1. Initial setting time of concrete by penetration resistance

Initial setting time of concrete is the time interval required for the mortar sieved from the concrete mixture to reach a penetration resistance of 3.43 N/mm2 (35 kgf/cm2) after the initial contact of cement and water. 2. Apparatus

Concrete cube moulds of 15 cm x 15 cm size, penetrometer graduated from 0 kgf to 60 kgf in increments of 2 kgf, pipette, tamping rod of 16 mm in diameter and 600 mm length rounded at one end. Procedure a. b. c. d. e. f. g. Select a representative sample of concrete of known proportion. Oil the interior surface of the cube mould with mould releasing oil to prevent adhesion of the concrete. Remove all of the mortar from the sample by sieving it through a 4.75 mm IS sieve into a mortar pan. Remix the sample thoroughly and fill it in a 15 cm cube mould in two layers, leaving a space of 13 mm (1/2 inch) at top. Compact each layer with tamping rod by tamping each layer 25 times. For each test, a set of three cube moulds should be filled. Keep the moulds covered with a water impermeable cover and under shed for the duration of test. Prior to making each penetration resistance test, remove bleeding water by using a pipette. For easy removal of water, tilt the mould by placing a 3 cm block under one of the edges and allow water to collect at the shallow portion for 2 minutes. After removing the bleed water, insert the pocket penetrometer vertically into the mortar. Push the apparatus

h.

i. j. k.
l.

gradually until the needle penetrates the mortar upto the scribe mark, in about 10 seconds. The force required is indicated by the white ring. Record the force required and the elapsed time after adding water to the mix. Make penetration tests at hourly intervals, initial test being made after 3 hours. Leave a space of 20 mm from previous impressions in subsequent penetration tests. Plot the penetration resistance against time. Initial setting time is read off against a penetration resistance corresponding to 35 kgf/Cm2.

Reporting : Average value of elapsed time of three tests shall be reported as initial setting time. Report the type and proportion of cement, fine aggregate, coarse aggregate and the water-cement ration with ambient temperature during test period with the result.

TEST PROCEDURES CASTING OF CONCRETE CUBE MOULDS 1. MAKING AND CURING CONCRETE CUBES: This method covers the procedure for making and curing of concrete cubes as per IS : 516 1959.
2.

APPARATUS : Wheel barrow, sampling scoop, trowel, cube moulds of 15 x 15 x 15 cm size and tamping bar 16 mm in diameter, 0.6 m long and bulleted point at the lower end.

3.

PROCEDURE : a. Firstly decide the number of samples to be taken during concreting. b. Oil the interior surface of the mould with mould releasing oil to prevent adhesion of the concrete. c. Collect the sample in a wheelbarrow after mixing the concrete properly in the transit mixer. d. Remix the sample thoroughly in wheelbarrow with sampling scoop. e. After remixing immediately fill the mould in layers approximately 5 cm deep. f. During filling the mould, the scoop shall be moved around the top edge of the mould as the concrete slides from it, in order to ensure a symmetrical distribution of the concrete within the mould. g. Each layer shall be compacted with the tamping rod by minimum 35 strokes distributed in a uniform manner over the cross-section of the mould.

h. After compacting the top layer, top surface of the concrete shall be finished level with the top of the mould, using a trowel. i. Store the cube moulds in a place which Is free from vibration and cover the surface of the concrete with a piece of damp sacking for initial 16 to 24 hours.

TEST PROCEDURES SLUMP TEST 1. SLUMP TEST This method of test specifies the procedure to be adopted, either in the laboratory or in the field during work, for determining the workability of concrete where the nominal maximum size of aggregate does not exceed 38 mm. 2. APPARATUS Metal slump cone of at least 1.6 mm thickness provided with suitable base plate and also handles for lifting it from the moulded concrete test specimen vertically. Internal dimension of the cone should have the following sizes : Bottom diameter 20 cm Top diameter 10 cm Height 30 cm Tamping rod of 16 mm diameter, 0.6 m long and rounded at one end. 3. PROCEDURE : a. Firstly decide the frequency of slump value to be taken during concreting. b. Oil the interior surface of the slump cone with mould releasing oil to prevent adhesion of the concrete. c. Place the slump cone on a leveled surface. d. Collect the sample in a wheelbarrow after mixing the concrete properly in the transit mixer. e. Remix the sample thoroughly in wheel barrow with sampling scoop. f. After remixing immediately fill the slump cone in layers approximately one quarter of the height of the cone. g. Each layer shall be compacted with the tamping rod by 25 strokes distributed in a uniform manner over the crosssection of the cone and for the second and subsequent layers tamping rod shall penetrate into the underlying layer.

h. After compacting the top layer, the concrete shall be struck off level with the top of the slump cone, using a trowel. Any mortar, which may have leaked out between the mould and the base plate, shall be cleaned away. i. Unscrew the slump cone from the base plate and remove it immediately from the concrete by raising it slowly and carefully in a vertical direction. j. After the concrete subsides place the slump cone on the base plate in reverse position and place a scale on it. Measure the height between the top of the mould and the highest point of the specimen being tested. 4. REPORTING OF SLUMP VALUE :

The slump measured shall be reported in terms of millimeters of subsidence of the specimen during the test. Any slump specimen, which collapses or shears off laterally, shall be repeated with another sample. If, in the repeat test also, the specimen shears, the slump shall be measured and the fact that the specimen sheared, shall be reported. Take corrective action to make the mix cohesive.

TEST PROCEDURES DENSITY CYLINDER FOR AGGREGARE (Coarse and Fine) 1. Bulk density of aggregate This method of test covers the procedure for determining unit weight or bulk density of aggregate 2. Apparatus Balance cylindrical metal measure with handle and tamping rod of 16 mm dia. And 60 cm long, rounded at one end. Sizes of metal measures for different sizes of aggregate are given in table 1. A straight tamping rod of cylindrical c/s 16 mm in diameter, 60 cm long and rounded at one end. Table 1 : Size of container for Bulk density test
Size of largest particles 4.75 mm and under Over 4.75 mm to 40 mm Over 40 mm Nominal Capacity Litre 3 15 30 Inside diameter cm 15 25 35 Inside Height cm 17 30 31 Thickness of Metal Min mm 3.15 4.00 5.00

3. Procedure Rodded or Compacted weight

a.

b. c.

Fill the measure about 1/3rd height with thoroughly mixed aggregate. Tamp it with 25 strokes of the rounded end of tamping rod. Again fill the measure with approx. same quantity & tamp it with 25 strokes.

d. e.

Overflow the measure, tamp it 25 times and struck off surplus aggregate with tamping rod. Determine the net weight of aggregate and calculate Bulk density in Kg/lit.

Loose Density a. b. c. Fill the measure to overflow with aggregate by discharging from height not more than 5 cm above the top of measure. Level the sample with a straight edge. Determine the net weight of aggregate and calculate Bulk density in Kg/lit.

TEST PROCEDURES PYCNOMETER 1. Specific gravity of aggregates

This method cover the procedure for finding the specific gravity of aggregate using glass pycnometer. 2. Apparatus

Pycnometer (glass bottle with conical cap) and balance. 3. a. b. c. d. e. Procedure Weigh an empty pycnometer. Fill up half of the pycnometer with dry aggregate sample and weigh. Add water to the sample, fill the pycnometer with water, roll it on a flat surface and then fill it completely with water and weigh. Empty the contents of the pycnometer, refill it with water only and weigh. Calculate the specific gravity using this formula, Sp. Gravity = (W2-W1) [(W4-W1)-(W3-W2)] Where W1 Where W1 = W2 = W3 = W4 = weight of empty pycnometer, g. weight of pycnometer and dry aggregate, g. weight of pycnometer with aggregate and water, g weight of pycnometer filled with only water, g

TEST PROCEDURES AIR OVEN 1. Moisture Content of Aggregate Moisture content of aggregate is the percentage of weight of water in the aggregate sample to the total dry weight of the aggregate sample. The procedure is the same for both coarse and fine aggregate. 2. Apparatus One hot plate or over, tray and balance 3. Procedure a. b. c. 4. Take the weight of moist or wet sample Dry it in a hot plate or oven Take the weight of dry sample

Calculation Moisture content of aggregate is calculated as follows : M=(W1 W2)/W2 x 100 Where M = Moisture content of aggregate, % W1 = Weight of moist sample, g W2 = Weight of dry sample, g

TESTING METHOD OF IMPACT TEST MACHINE (As per IS 2386 Part IV) 1963 Purpose : This method is used to determine the aggregate impact value of coarse aggregate Procedure : a. Take about 1000 g of dry sample passing through 12.5 mm IS sieve and retained on 10 mm sieve. b. Fill the cylindrical metal measure with the dried sample. The sample should be placed in three increments, each increment being rodded 25 times with the tamping rod. c. Strike off the excess sample using the tamping rod as a straight edge. d. Take the weight of sample in the measure (W1) e. Now drop the hammer in the testing machine 15 times on the sample kept in the cup. Height of the fall of the hammer should be 380 mm. The interval between each blow should be about one second. f. Remove the sample from the cup and sieve it one 2.36 mm IS sieve until no more sample passes through the sieve. g. Find the weight of the sample retained on 2.36 mm sieve (W2). h. Repeat the test for another sample from the same lot and calculate the average of the two values. i. Calculation : Aggregate impact value, % = (W1-W2)/W1 x 100 Where W1 = weight of dry sample passing through 12.5mm IS sieve and retained on 10 mm IS sieve, g W2 = weight of dry sample retained on 2.36 mm IS sieve, g j. Report the aggregate impact value in percentage and as the mean of two determinations rounded off to the nearest whole number.

TEST PROCEDURES Air Oven for Aggregate (Coarse and Fine) 1. Moisture content of Aggregate Moisture content of aggregate is the percentage of weight or water in the aggregate sample to the total dry weight of the aggregate sample. The procedure is the same for both coarse and fine aggregate. 2. Apparatus One hot plate or oven tray and balance 3. Procedure a. Take the weight of moist or wet sample b. Dry it in a hot plate or oven c. Take the weight of dry sample 4. Calculation

Moisture content of aggregate is calculated as follows : M=(W1-W2) / W2 x 100 Where M = Moisture content of aggregate, % W1 = Weight of moist sample, g W2 = Weight of dy sample, g

TEST PROCEDURES ELONGATION GAUGE COARSE AGGREGATE 1. Elongation Index : Elongation index of an aggregate is the percentage by weight of particles whose greatest dimension (length) is greater than one and four-fifth times their mean dimension. It is measured on particles passing through mesh size of 63 mm and retained on mesh size 6.3 mm. 2. Apparatus : Balance, Elongation gauge (Length gauge) and IS sieves of the following mesh sizes 63 mm, 50 mm, 40 mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5 mm, 10 mm and 6.3 mm. 3. Procedure : a. b. c. Take enough quantity of dry blended sample so that atleast 200 pieces of any fraction is present. This is not applicable for the biggest and smallest size. Sieve the blended sample through all the sieves mentioned above starting from the largest sieve i.e. 63 mm. Separate all the individual fractions 63 mm to 50 mm, 50 mm to 40 mm, 40 mm to 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mm and 10 mm to 6.3 mm. Take all the fraction separately, gauge them one by one through the corresponding slot provided in the gauge. Keep the particles retained by the length separately. The aim should be to retain as much as possible to avoid testing bias. Weigh the particles retained on length gauge. Elongation index is the total weight of the material retained on the various length gauges, expressed as a percentage of the total weight of the sample gauged.

d.

e.
f.

4.

Calculation : Elongation index of aggregate in % is calculated as follows : Ei = (W1 / W2) x 100, % Where W1 = weight of particles retained in length gauge, g W2= weight of total sample taken for test, g

5.

Reporting : Report the elongation index in percentage rounded off to the nearest whole number.

TEST PROCEDURES FLAKINESS GAUGE FOR COARSE AGGREGATE 1. Flakiness Index Flakiness index of an aggregate is the percentage by weight of particles in it whose least dimension (thickness) is less then three-fifth of their mean dimension. It is measure on particles passing through mesh size of 63 mm and retained on mesh size 6.3 mm. Apparatus Balance, Flakiness gauge (thickness gauge) and GI sieves of the following mesh sizes 63 mm, 50 mm, 40 mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5 mm, 10 mm and 6.3 mm. Procedure a. Take enough quantity of dry blended sample so that atleast 200 pieces of any fraction is present. This is not applicable for the biggest and smallest size. b. Sieve the blended sample through all the sieves mentioned above starting from the largest sieve i.e. 63 mm. c. Separate all the individual fractions 63 mm to 50 mm, 50 mm to 40 mm, 40 mm to 31.5 mm, 31.5 mm to 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mm and 10 mm to 6.3 mm. d. Take all the fraction separately, gauge them one by one through the corresponding slot provided in the gauge. Keep the particles passing through the slot of the gauge and retained in gauge separately. The aim should be to pass as many as possible through the slot to avoid testing bias. e. Note the number of particles passing and not passing through the corresponding slot in the gauge for each fraction.

2.

3.

f.

Calculate for each fraction the following : 1. Percentage of number of particle passing the slot to the total number of particles in fraction. This is noted as X. 2. Percentage of weight of particles in fraction taken for testing to the total weight of particles in all fractions taken for the test (total qty.). This is noted as Y.

Calculation : Flakiness Index = Fi = X (Xi Yi)/100% i=1 to n Where Xi = Percentage of number of particles passing the slot to the total number of particles in that fraction, % Yi = Percentage of weight of particles in fraction to the total weight of particles in all fraction, % Reporting : Report the flakiness index in percentage rounded off to the nearest whole number.

TEST PROCEDURES SIEVES FOR FINE AGGREGATE 1. Purpose : The sieves are used for the determination of particle size distribution of fine aggregate by sieving. Sieve analysis of Fine Aggregate : Fine aggregate consists of material mostly between 4.75 mm and 150 micron. It may be natural sand or crushed stone dust. Sand based on sieve analysis is classified into four zones conforming to zone-I, zone-II, zone-III and zone-IV as per IS383. Sizes of sieves : Sieves of the sizes 10 mm, 4.75 mm, 2.36 mm, 1.18 mm, 600 mic., 300 mic., and 150 mic. And weighing balance. Procedure : a. Take known weight of dry sample (about 1 kg min.) b. Sieve the sample progressively starting from the largest sieve i.e. 10 mm. c. On completion of sieving weigh the material retained on each sieve. d. Calculate cumulative percentage of sand retained in each sieve and cumulative percentage retained on each sieve. e. Calculate cumulative percentage passing through each size. f. Calculate the fineness modulus of sand by summing up the cumulative percentage of sand retained on 10 mm, 4.75 mm, 1.18mm, 600 mic., 300 mic., and 150 mic. Sives and dividing the sum by 100. g. Find out which grading zone the sand conforms to by checking with the table 1 given below :

2.

3.

4.

Table 1 : Grading zones (I.S. 383) 1978

I. S. Sieve 10mm 4.75mm 2.36mm 1.18mm 600 micron 300 micron 150 micron 75 micron Cumulative percentage passing IS sieves for grading zone (natural sand) I II III IV 100 90-100 60-95 30-70 15-34 5-20 0-10 0-3 100 90-100 75-100 55-90 35-59 8-30 0-10 0-3 100 90-100 85-100 75-100 60-79 12-40 0-10 0-3 100 90-100 95-100 90-100 80-100 15-50 0-15 0-3 Crushed Sand 100 90-100 75-100 55-100 35-79 8-40 0-20 0-15