JB

DARSHAN INSTITUTE
OF
ENGINEERING & TECHNOLOGY
RAJKOT
HIGHWAY ENGINEERING
(2150601)
LAB MANUAL
DEGREE CIVIL ENGINEERING
SEMESTER –V
Name of student
Roll No
Enrollment No
Class
A.Y. 2018-2019
Department of Civil Engineering Semester-V Highway Engineering Lab Manual
INDEX
Sr.
No.
Name of Experiment Date Page Marks Sign.
SECTION-A –TEST ON AGGREGATES
1 Shape Test (Flakiness Index + Elongation Index) (IS:2386 part-1)
2 Aggregate Impact Test (IS:2386 part-4)
3 Aggregate Crushing Test (IS:2386 part-4)
4 Aggregate Los Angeles Abrasion Test (IS:2386 part-5)
5 Specific Gravity and Water Absorption Test (IS:2386 part-3)
6 Gradation and Blending of Aggregate (IS:383-2016)
SECTION-B –TEST ON SOIL (Subgrade)
7 California Bearing Ratio Test-CBR (IS:2720 PART-16)
8 Dynamic Cone Penetrometer Test-DCP (IRC:SP:72-2015)
SECTION-C –TEST ON BITUMEN AND BITUMINOUS MIX DESIGN
CONSISTENCY TESTS OF BITUMEN
9 Penetration test (IS:1203-1978)
10 Softening point test (IS:1205-1978)
11 Introduction of tar viscometer (IS:1206-1978)
12 Viscosity test- Absolute Viscosity (IS:1206 part 2 -1978)
13 Viscosity test – Kinematic Viscosity (IS:1206 part 3 -1978)
AGING TESTS ON BITUMEN
14 Introduction on Thin film oven test(ASTM-D-1754/IS:9283)
SAFETY TESTS ON BITUMEN
15 Flash and Fire point test (IS: 1209-1978)
OTHER TESTS
16 Specific Gravity test on bitumen (IS: 1202-1978)
17 Ductility test (IS: 1208-1978)
SECTION-D –TEST ON BITUMINOUS MIX
18 % Bitumen content in Paving mixture (ASTM-D-2172)
19 Stripping value test (IS:6241)
20 Marshal Stability Test-Determination of O.B.C. (MS-2)
SECTION-E DESIGN OF CONCRETE MIX FOR PAVEMENT
21 Design of concrete Mix for PQC(IRC:44-)1976
SECTION-F- A STUDY ON TRAFFIC PARAMETERS
22 Spot speed study (IRC:SP:19-2001)
23 Traffic Volume Study (IRC:SP:19-2001)
24 Accident Study (IRC:SP:19-2001)
SECTION-G- HIGHWAY GEOMETRIC DESIGN- STUDY MATERIAL
25 Highway Geometric Design(Study) (IRC:73,86-2015)
SECTION-H- FIELD VISIT AND FIELD TESTS ON PAVEMENT LAYERS
26 Hot Mix Plant Visit (Prepare report) (IRC:90-1985)
27 Ready Mix Concrete Plant visit (Report) (IRC:90-1985)
28 Determination of Field Density of Pavement Layer2720-29,28
29 Introduction of Plate Bearing Test (IS:1888-1982)
30 Introduction of Benkelman Beam Deflection (IRC:81-1997)
Introduction Unevenness Measurement by Bump Integrator and MERLIN
31 (IRC:SP:82-2015)
Darshan Institute of Engineering and Technology-Rajkot Page 1

Laboratory Instructions
1. Study the experiment and read in detail aim, apparatus, and
procedure of each experiment before coming to the lab. The lab
teachers are instructed to take a brief written test on last experiment about
5-10 minutes before the commencement of the experiment.
2. After the test, the lab teacher will give instruction to start the experiment.
Do the experiment, and note the readings as a group.
3. After you complete the experiment, you have to do the calculations and
discussion of results by yourself before leaving the lab.
4. Ensure that lab teacher have checked your results and get the lab mark
entered in the report and get their signature.
5. Follow all the safety instructions given by the Lab staff. Kindly wear shoes
inside the laboratory
6. Absenting from the lab will be taken very seriously including fail grade as
per rules. No compensatory experiments will be allowed.
7. Tests shall be done in groups. However, observation table, calculation,
Discussion of the result, etc. should be individual and should be completed
on the same day.
8. Return the equipment after the test to the lab teacher and ensure that the
lab teacher gives the mark along with his signature.
9. L a b t e a c h e r shall supervise the experiment and marks will be
awarded based on the participation in the experiments, and the report.
Signature of the Student

HIGHWAY ENGINEERING
SCOPE OF STUDY
FLEXIBLE RIGID
PAVEMENT PAVEMENT
DESIGN DESIGN
THICKNESS MIXTURE DESIGN THICKNESS MIXTURE

DESIGN DESIGN DESIGN
Data Required: DETERMINATION OF Data Required: (CONCRETE MIX
Traffic census OPTIMUM BITUMEN Traffic census DESIGN)- Pavement
Subgrade CBR CONTENT Modulus of Sub grade/ Quality Concrete
Axle load spectrum CBR (PQC)
Vehicle damage factor Axle load spectrum
As per IRC: 44-
As per ASHTO Manual
As per IRC:37-2012 As per IRC:58-2011 2008
(MS-2)
( PQC)
SOFTWARE: IIT
SOFTWARE:IITRIGID
PAVE
SOIL TEST –
Atterber’s limit, [AGG.&CEMENT
[BITUMEN&AGG.TEST
CBR TEST
REQUIRED]
Soil Classification REQUIRED]
UCS
Rigid Pavement Flexible Pavement

Load distribution concept

HIGHWAY ENGINEERING
TESTING OF MATERIAL (Pavement making material)
SOIL AGGREGATE BITUMEN CEMENT

(SUBGRADE/GSB)
(Geotech Lab/ Soil
Egg. Lab)
• Atterberg’s limit • Specific Gravity • Specific Gravity • Consistency

(LL, PL, PI) • Water Absorption • Penetration • Initial Setting Time
• Impact Value • Viscosity • Final Setting Time
• Soil • Abrasion Value • Ductility • Soundness
Classification • Crushing Value • Flash & Fire Point • Compressive Strength
• 10% Fines Value • Softening Point • Fineness
• CBR (California • Shape Test –
Bearing Ratio) Flakiness Index &
Elongation Index
• UCS(Unconfined
Compressive
Strength)
• Sieve Analysis
• OMC & MDD

(Optimum Moisture
Content and
Maximum Dry
Density)
FOR BITUMINOUS PAVEMENT FOR RIGID PAVEMENT

BITUMINIOUS MIX DESIGN- Marshal CONCRETE MIX DESIGN (PQC-Pavement
Method- As per AASHTO-Manual MS-2. Quality Concrete) (As per IRC-44-2008)
Test on Mix
• Stability Test on Mix:
• Flow • Flexural Strength.
• Density • Compressive strength
• Bitumen content
• Stripping value
• Resilient Modulus

Typical C/S of Flexible Pavement

Typical Cross section of
Rigid pavement
Road component


AGGREGATE TEST VALUE ACCEPTANCE CRITERIA
AGGREGATE SPECIFICATION FOR VARIOUS TYPE OF ROAD CONSTRUCTION ACTIVITIES ( As per IS/ IRC/ MORT&H 5th Rev.)
Granular Sub-Bases, Base courses requirement as per MORT&H 5th Rev. Bituminous Base & Wearing Courses requirement as per MORT&H 5th Rev.
Cement Concrete Cement Concrete
Sr.
Property Name of Test IS Code BASE COURSE/ SURFACE COURSE/ Pavement (Other than Wearing
No Base Course,
Sub Base, Base Course, BINDER COURSE WEARING CORSE (Wearing surfaces) surfaces)
Base Course, WBM Crusher Run
GSB Crushed WMM
Macadam BM DBM SDBC BC
Deleterious Organic Matter
IS-2386
1.00% Max 1.00% Max 1.00% Max 1.00% Max Nil Nil Nil Nil Nil Nil
Materials and (Part-2)
1
Organic Sodium Sulphate
IS-2386
0.20% Max 0.20% Max 0.20% Max 0.20% Max NIl Nil NIl NIl NIl NIl
Impurities (Part-2)
Max 5% Max 5% Max 5%
IS-2386 Max 5% Passing
2 Cleanliness Grain size Analysis - - - - Passing Passing Passing - -
Part – 1 75 µ sieve
75 µ sieve 75 µ sieve 75 µ sieve
Los Angeles IS-2386 Not Specified
Part – 4
Max 40 % Max 40 % Max 40 % Max 40 % Max 35 % Max 35 % Max 30 % 30 % Max 16 % Max
Abrasion in MORT&H
IS-2386
Crushing value Part – 4
Max 45% Max 45% Max 45% Max 45% Max 45% Max 45% Max 30 % Max 30 % 30 % Max 45 % Max
IS-2386- 4) or
3 Strength Agg. Impact value IS-5640
Max 40 % Max 30 % Max 30 % 30 % Max Max. 30% Max. 27 % Max. 27% Max. 24 % 30 % Max 45 % Max
IS-2386 Part -
10 % Fines Value IV or BS 812- 50 Kn. -Min. - - - - - - - - -
111
IS-2720
4 Days Soaked CBR (Part-16) Min 30% - - - - - - - - -
Aggregate Max 12% Max 12% Max 12% Max 12%
- - - - - -
Soundness test* *(If IS-2386 Part – ( Na₂SO₄) ( Na₂SO₄) ( Na₂SO₄) ( Na₂SO₄)
4 Durability W.A. greater than V Max 18% Max 18% Max 18% Max 18%
2%) - - - - - -
( MgSO₄) ( MgSO₄) ( MgSO₄) ( MgSO₄)
IS-2386 35 % Max. 35 % Max. 35 % Max. 35 % Max. 30 % Max. 30 % Max.
Flakiness Index Part –I 35 % Max. 15% 15%
Not (Combined (Combined (Combined (Combined (Combined (Combined
IS-2386 (Combined FI + EI)
5 Shape Elongation Index Part –I Mentioned FI + EI) FI + EI) FI + EI) FI + EI) FI + EI) FI + EI) 15% 15%
IS-2386 in MORT&H
Angularity Index Part – 1 0 to 11 0 to 11 0 to 11 0 to 11 0 to 11 0 to 11 0 to 11 0 to 11 0 to 11
6 Liquid Limit 25% Max NA NA 25% Max - - - - -

Determination of
IS-2720
Liquid Limit and (Part-5)
Plasticity Index Non
7 Plasticity Index 6% Max 6% Max 6% Max 6% Max Non Plastic Non Plastic Non Plastic - -
Plastic
IS-2386
8 Water Absorption Water Absorption 2 % Max. 2 % Max. 2 % Max. 2 % Max. 2 % Max. 2 % Max. 2 % Max. 2 % Max. 2 % Max. 2 % Max.
Part – 3
IS-2386
9 Specific Gravity Specific Gravity N.A. 2.6 to 2.9 2.6 to 2.9 2.6 to 2.9 2.6 to 2.9 2.6 to 2.9 2.6 to 2.9 2.6 to 2.9 2.6 to 2.9 2.6 to 2.9
Part - 3
Min.
Bitumen Min. retaind Min. retaind Min. retaind retaind
10 Strippting Value IS-6241 NA NA NA NA - -
Adhesion coating 95% coating 95% coating 95% coating
95%
Retained Tensile AASHTO
11 Water Sensitivity - - - - Min. 80% Min. 80% Min. 80% Min 80% - -
Strength 283
Aggregate Stone Polishing BS :

12 - - - - - - Min 55 Min 55 - -
Softness Value 812-114

SECTION-A
TEST ON AGGREGATES
Sr. No. Name of Test Relevant IS code

1 Shape test (Flakiness Index+Elongation Index) IS:2386 PART-1
2 Aggregate Impact Test IS:2386 PART-4
3 Aggregate Crushing Test IS:2386 PART-4
4 Aggregate Los Angeles Abrasion Test IS:2386 PART-5
5 Specific Gravity and Water Absorption Test IS: 2386 PART-3
6 Gradation and Blending of Aggregate IS 383-2016

EXPERIMENT NO: 1 DATE:
SHAPE TEST (IS: 2386 PART -1)
OBJECTIVE: To determine the value of Flakiness and Elongation Index of

Coarse aggregates. Combined Index = FI+EI
INTRODUCTION:
The shape of aggregate particles is determined by the percentage of flaky and elongated
particles contained in it. In the case of gravel, it may be expressed in terms of the
angularity number. Presence of flaky and elongated particles in the coarse aggregates
used for the construction of base and surface courses of road pavements is considered
undesirable, as these may cause inherent weakness with possibilities of breaking down
during compaction as well as under heavy traffic loads. Rounded aggregates are
preferred in cement concrete road construction as the workability of concrete improves.
Angular shapes of particles are desirable for granular base course due to increased
stability derived from the better interlocking. Thus, evaluation of shape of the particles,
particularly with reference to flakiness index and elongation index is necessary.
FLAKINESS INDEX:
The flakiness index of aggregates is the percentage by weight of particles whose

least dimension (thickness) is less than three fifths (0.6) of their mean dimension. The
test is not applicable to sizes smaller than 6.3 mm.
APPARATUS:
The apparatus consists of a standard thickness gauge shown in fig. 1. IS sieves of sizes
63, 50, 40, 31.5, 25, 20, 16, 12.5, 10 and 6.3 mm and a balance to weigh the samples.
PROCEDURE:
In order to calculate the flakiness index of the entire sample of aggregates, first the weight
of each fraction of aggregate passing and retained on the specified set of sieves is noted.
As an example, note down the weight of 200 pieces of aggregates passing 50 mm sieve
and retained on 40 mm sieve. Each of the particle for this fraction of aggregate is tried to
be passed through the slot of the specified thickness, in this example, the 27 mm
thickness slot. Similarly, let the weight of 200 pieces of aggregates retained on the
specified sieves be W, W2, W3 etc. and the total weight W1+W2+W3 is found. Then the
flakiness index is the total weight of the material passing the various thickness gauges,
expressed as a percentage of the total weight of the sample gauged.

Fig 1. Thickness gauge
IRC RECOMMENDATIONS:
Sr. Maximum limit

No. Type of Construction of Flakiness
Index i n %
1 Water bound macadam 15%
2 Bituminous surface dressing penetration macadam 25%
3 Bituminous bound macadam bituminous concrete 15%

Fig 2. Length Gauge
(B) ELONGATION INDEX:

The elongation index of an aggregate is the percentage by weight of particles
whose greatest dimension (length) is greater than one and fifth times (1.8 times) their
mean dimension. The elongation test is not applicable to sizes smaller than 6.3 mm
APPARATUS:
The apparatus consists of the length gauge shown in fig 2., IS sieves of sizes 50,
40, 25, 20, 16, 12.5, 10 and 6.3 mm and a balance.
PROCEDURE:
The sample is sieved through the IS sieves as mentioned above. A minimum of 200
pieces of each fraction is taken and weighted. As an example, note down the weight of
200 pieces of aggregates passing 50 mm sieve and retained on 40 mm sieve. Each of the
particle for this fraction of aggregate is tried to be passed through the slot of the specified
length in this example, the 81 mm length slot. Similarly, let the weight of 200 pieces of
aggregates retained on the specified sieves be W, W2, W3 etc. and the total weight
W1+W2+W3 is found, then the elongation index is the total weight of the material retain
on the various length gauges, expressed as a percentage of the total weight of the sample
gauged.

APPLICATION O F SHAPE TEST:

In pavement construction flaky and elongated particles are to be avoided,
particularly in surface course. If flaky and elongated aggregates are present in appreciable
proportions, the strength of pavement layer would be adversely affected with possibility
of breaking down under loads. In cement concrete the workability is also reduced.
However, the reduction is strength in cement concrete depends on the cement content.
Indian Roads Congress has been recommended the maximum allowable limits of
flakiness index values for various types of construction, as given below:
PERMISSIBLE LIMITS - Requirement as per MORT&H
Property Granular Sub-Bases (GSB),

Bituminous Base &Wearing Courses
Cement Concrete (Other

than Wearing surfaces)
Base courses
Pavement (Wearing
Cement concrete
SURFACE
Base Course, Crusher
BASE COURSE/
surfaces)
Crushed WMM
COURSE/
Sub Base GSB
Run Macadam
Base Course,
Base Course
BINDER
WEARING
WBM
COURSE
COURSE
BM DBM SDBC BC
SHAPE
TEST 35% 35% 35% 35% 35% 30% 30%
- 40%
CI = Max. Max. Max. Max. Max. Max. Max. 15%
Max
FI+EI

OBSERVATION TABLE:
Weight of the Aggregate taken for the test (W) = _______________gms
FLAKINESS INDEX ELONGATION INDEX

Passing Retained on Weight of Weight of Weight of Weight of
through IS IS sieve Aggregate aggregate in Non- Flaky the
Sr. sieve (mm) taken in each each fraction Aggregate aggregate in
No. (mm) fraction (gms) passing the taken each each fraction
thickness fraction (gms) not passing
Gauge (gms) the length
Gauge (gms)
1 63 50 - -
1 50 40
2 40 25
3 31.5 25 - -
4 25 20
5 20 16
6 16 12.5
7 12.5 10
8 10 6.3
W= w= W1 = w1 =
(w/W)x100 = (w1/ W1)x100 =
Flakiness Index:
Elongation Index:
Combined Index:
RESULT
CONCLUSION:
(Faculty Advisor)
Date:

EXPERIMENT NO: 2 Date :
DETERMINATION OF AGGREGATE IMPACT VALUE

(IS: 2386 PART-4)
OBJECTIVE:
To determine the impact value of given sample using Aggregate Impact Testing Machine.
INTRODUCTION:
Toughness is the property of a material to resist impact. Due to traffic loads the
road stone are subjected to the pounding action of impact and there is possibility of
breaking into smaller pieces. The road stone should therefore be tough enough to resists
fracture under impact. A test designed to evaluate the toughness of stones i.e. the
resistance of the stones to fracture under repeated impacts may be called an impact test
for road stones.
The aggregate impact value indicates a relative measure of the resistance of an
aggregate to a sudden shock or an impact, which differs from its resistance to a slow
gradually increasing compressive load. The method of test covers the procedure for
determining the aggregate impact value of course aggregate.
APPARATUS:
The apparatus consists of an impact testing machine, a cylindrical measure,
tamping rods, IS sieves, balance and oven.
• Impact Testing Machine :
The machine consists of a metal base with a plain lower surface, supported well
on firm floor, without rocking. A detachable test cylindrical steel cup of internal diameter
10.2 cm and depth 5 cm is rigidly fastened centrally to the base plate A metal hammer
cylindrical m shape, 10 cm in diameter and 5 cm long, with 2 mm chamfer at the lower
edge is capable of sliding freely between vertical guides and fall concentric over the cup.
There is an arrangement for raising the hammer and allowing it to fall freely between
vertical guides from a height of 38+ cm on the test sample in the cup, A key is provided
for supporting the hammer while fastening or removing the cup. Refer Figure.
• Measure:
A cylindrical metal measure having internal diameter 7.5 cm and depth 5 cm for
measuring aggregate.
• Tamping Rod :
A straight metal tamping rod of circular cross section 1 cm diameter and 25 cm
long, rounded at one end.

• Sieve:
IS sieve of sizes 12.5 mm, 10 mm, and 2.36 mm for sieving the aggregates
• Oven:
A thermostatically controlled drying oven capable of maintaining constant
temperature between 100° C and 110° C.
• Balance:
A balance of capacity not less than 500 gm to weight accurate to 0.1 gm
Fig 1. Aggregate Impact Testing Machine
SAMPLE QUANTITY:
The test sample shall consist of aggregate passing through 12.5 mm IS
sieve and retained on a 10 mm IS sieve.
The metal measure shall be filled about one third full with the aggregate
and tamped with 25 strokes of the rounded and of the tamping rod. A further
similar quantity of aggregate shall be added and procedure is repeated. The
measure shall finally be filled to overflowing capacity and after tamping surface
material is struck off using tamping rod weight of aggregate in the measure is
determined and same weight is taken for duplicate test.

PROCEDURE:
The test sample consists of aggregates passing 12.5 mm sieve and retained on 10
mm sieve and dried in an oven for four hours at a temperature 100° C to 110° C, and
cooled.
The Impact machine is placed with its bottom plate flat on the floor so that the
hammer guides columns are vertical. The cup is fixed firmly in position of the base of
the machine and the whole of the test sample from the cylindrical measure is transferred
to the cup and compacted by tamping rod with 25 strokes.
The hammer is raised until its lower face is 38 cm above the upper surface of
the aggregates in the cup, and allowed to fall freely on the aggregates. The test
sample is subjected to a total of 15 such blows, each being delivered at an interval of
not less than one second. The crushed aggregates are than removed from the cup
and the whole of its sieved on the 2.36 mm sieve until on further significant
amount passes. The fraction passing the sieve is weighted accurate to 0.1 g. The
weight of the fractions passing and retained on the sieve is added and it should not be
less than the original weight of the specimen by more than one gram, if the total
weight is less than original by over one gram the result should be discarded and a
fresh test is to be performed again, else the aggregate impact value is total weight of
the material passing 2.36 mm sieve, expressed as a percentage of the total weight of
the sample taken. The mean of the two or more results is reported as the aggregate
impact value of the specimen to the nearest whole number.
OBSERVATIONS:
TABLE NO: 1 Aggregate observation Table
Sr. Description Sample - I Sample–II
No.
1. Original weight of the aggregate passing through
12.5 mm IS sieve and retained on 10 mm IS sieve
i.e. weight ->W1
2. Weight of the aggregate passing through 2.36
mm IS sieve after the test
i.e. weight -> W2
3. Weight of the aggregate retained on 2.36 mm IS
sieve after the test
i.e. weight ->W3 = W1 - W2
4. W2 + W3
5. Impact Value = 𝑊2 100 %
𝑊1
Aggregate Impact Value = _______ % =

SPECIFICATIONS:
Table no: 2 Aggregate Impact Values
Sr. Aggregate Impact Value Type of aggregate
No.
1. Up to 10 % Exceptionally strong (Too strong)
2. 10% to 20% Strong
3. 20% to 30% Satisfactory for road surface
4 > 35 % Weak for road surface
Table No: 3 Max. Permissible Aggregates Values for the different types of
pavements
For deciding the suitability of soft aggregates in base course construction, this test
has been commonly used. A modified impact test is also often carried out in the case of
soft aggregates to find the wet impact value after soaking the rest samples Based on work
reported by different agencies, the following recommendations have been made assess the
suitability soft aggregates for road construction.
IRC RECOMMENDATIONS:
Sr. Types of Pavements Max. Aggregate Impact
No. Value
(IRC Recommendations)
1. Granular sub base 40%
2. Base course (WBM) 30%
3. Base course (WMM) 30%
Bituminous Macadam (B.M.) 30%
4. Bituminous binder Dense bituminous Macadam 27%
course (D.B.M.)
6. Bituminous wearing course - SDBC 27%
7. Bituminous concrete - BC 24%

DISCUSSION:
Chief advantages of aggregate impact test are that it determines the
resistance of stones to impact, simulating field condition. The test can be
performed in a short time even at construction site or at stone quarry, as the
apparatus is simple and portable.
Well shaped cubical stones provided higher resistance to impact when
compared with flaky and elongated stones.
CONCLUSION:
(Faculty Advisor)
Date:

DETERMINATION OF AGGREGATE CRUSHING VALUE

(IS: 2386 PART- 4)
OBJ ECTIVE: To determine the crushing value of the given sample of aggregate with the
help of compression testing machine.
INTRODUCTION:
The principal mechanical properties required in road stones are:
• Satisfactory resistance to crushing under the roller during construction and
• Adequate resistance to surface abrasion under traffic. Also surface under rigid type of
heavily loaded drawn vehicles are high enough to consider the crushing
strength of road aggregates as an essential requirement in India
Crushing strength of road stone may be determine either on aggregates or on
cylindrical specimen cut out of rocks. The two tests are quite different not only in the
approach but also in the expression of the results. Aggregate used in road construction,
should be strong enough to resist crushing under traffic wheel loads. If the aggregates are
weak the stability of the pavement structure is likely to be adversely affected. The
strength of coarse aggregates is assessed by aggregate crushing test. The aggregate
crushing value provides a relative measure of resistance to crushing under a
gradually applied compressive load. To achieve a high quality of pavement,
aggregates possessing low aggregate crushing value should be preferred.
APPARATUS:
• Steel Cylinder with open ends, and internal diameter 15.2 cm, circular base plate,
plunger having a piston of diameter 15 cm with a hole provided across the stem of
the plunger so that a rod could be inserted for lifting or placing the plunger in the
cylinder.
• Cylindrical measure having internal diameter of 11.5 cm and height 18 cm
• Steel tamping rod with one rounded end, having a diameter of 1.6 cm and length 45 to
60cm
• Balance of capacity 3 kg with accuracy up to 1 g.
• Compression testing machine capable of applying load of 40 tones, at a uniform
rate of loading of 4 tones per minute.

150 mm dia Mould 75 mm dia Mould
Fig. Aggregate Crushing Value Test apparatus
Fig . Aggregate Crushing Test Machine (Compression testing machine- 2000 KN Cap)

SAMPLE QUANTITY:
The aggregate comprising the test sample shall be dried in an oven at a

temperature 100°C - 110°C for four hours and cooled. The aggregates should pass the
12.5 mm IS sieve and retained on the 10 mm IS test sieve. The measure shall be filled
about one third full of aggregate and temped with 25 strokes of the tamping rod. A further
similar quantity of aggregate shall be taken and a further tamping of 25 strokes is given,
the measure shall finally be filled to overflowing, temped 25 times and the surplus
aggregate stuck off. The net weight of the aggregate in the measure shall be determined
and this weight of sample shall be used for duplicate on the same material.
PROCEDURE:
The aggregate passing 12.5 mm IS sieve and retained on 10 mm IS sieve is

selected for standard test. The aggregate should be in surface dry condition before testing.
The aggregate may be dried by heating at a temperature 100° С to 110° С for a
period of 4 hours and is tested after being cooled to room temperature.
The cylindrical measure is filled by the test sample of aggregate in three layers of
approximately equal depth, each layer being tamped 25 times by the rounded end of the
tamping rod. After the third layer is tamped, the aggregates at the top of the cylindrical
measure are leveled off by using the tamping rod as a straight edge. About 6.5 kg of
aggregate is required for preparing two test samples. The test sample thus taken is then
weighted. The same weight of the sample is taken in the repeat test.
The cylinder of the test apparatus is placed in position on the base, one third of the
test sample is placed in this cylinder and tamped 25 times by the tamping rod similarly,
two parts of the test specimen is added, each layer being subjected to 25 blows. The total
depth of the material in the cylinder after tamping shall however be 10 cm. The surface of
the aggregates is leveled and the plunger inserted so that it rests on this surface in level
position. The cylinder with the test sample and plunger in position is placed on
compression machine. Load is then applied though the plunger at a uniform rate of 4
tons per minute until the total load is 40 tons. Aggregates including the crushed
portion are removed from the cylinder and sieved on a 2.36 mm IS sieve. The
material which passes through the sieve is collected.
The above crushing test is repeated on second sample of the same weight in
accordance with above test procedure. Thus two tests are made for the same specimen for
taking an average value
Table No: 1 Recommended Aggregate crushing value.
Sr. No. Description Maximum crushing value

1. Sub grade course 45%
2. Sub base + base course 45%
3. Bituminous base course + Wearing course 30%

OBSERVATION TABLE
Sr. No. Description Test -1 Test-2
1. Weight of oven drying aggregate passing 12.5

mm IS sieve and retain on 10 mm IS sieve.
W1
2. Weight of sample passes 2.36 mm IS sieve
after test W2
3. Weight sample retain 2.36 mm IS sieve after
test W3
4. Aggregate crushing value
𝑊2
= x 100%
𝑊1
5. W1=W2+ W3
6. Avg. aggregate crushing value in %
RESULTS:
The mean of the crushing value obtained in the two tests is reported as the aggregate
crushing value.
DISCUSSION:
In general, larger size of aggregates used in the test, results in higher aggregate crushing
value. The relationship between the aggregate sizes and the crushing values will however
vary with the type of specimens tested.
CONCLUSION:
(Faculty Advisor)
Date:

ABRASION VALUE OF ROAD AGGREGATE (IS: 2386 PART - 5)
OBJECTIVE:
To determine the hardness of the sample aggregate by testing for abrasion value
using Los Angles Testing Machine.
INTRODUCTION:
Due to the movement of traffic, the road stones and used in the surfacing course
are subjected to wearing action at the top Resistance to wear or hardness is hence an
essential property of road aggregate, especially when used in wearing course. Thus road
stones should be hard enough to resist the abrasion due the traffic. When fast moving
traffic fitted with pneumatic tyres move on the road, the sod particles present between the
wheel and road surface causes abrasion on the road stone. Steel tyres of the animal drawn
vehicles which rub against the stones can cause considerable abrasion of the stones on the
road surface Hence in order to tests are carried out in the laboratory.
LOS ANGELES ABRASION TEST:
The principle of Los Angeles Abrasion Test is to find the percentage wear
due to the relative rubbing action between the aggregate and steel balls used as
abrasive charge, pounding action of these balls also exist while conducting the test.
Some investigators believe this test to be more dependable as rubbing and pounding
action simulate the field conditions where both abrasion and impact occur. Los Angeles
Abrasion Test has been standardized by the ASTM, AASHTO and also by the ISI
Standard specifications of Los Angeles Abrasion Values are also available for various
types of pavement constructions.
APPARATUS:
(i). Los Angeles Machine should have essential characteristics as under: The
machine has hollow steel cylinder 700 mm in dia, and 500 mm in side length. A
steel self-88 x 25 x 500 mm is projecting radially. It can be mounted on inside of
the cover plate.
(ii). Sieve 1.70 mm and as given in Table 1. for different grades of aggregates
(iii). Abrasive charge: It consists of cast iron spheres or steel sphere app 48 mm in dia
and weighing 390 to 446 gm No of spheres are chosen from Table - 2 as per the
grade of aggregates.
(iv). Oven and accurate balance.

Fig. Loss Angeles Abrasion Testing Machine
SAMPLE QUANTITY:
Sieve the sample of aggregate and refer to the "Grades of Test sample" to decide
the grade and the weight of the aggregate to be taken. Take little пюге than the required
quantity in the oven at 105 °C to 110 °C for 24 hours for drying. Allow it to cool to room
temperature. From this sample, weigh the required quantity for the test.
PROCEDURE:
Clean aggregate dried in oven at 105° С to 110 °C to constant weight, confirming

to any one of the grading A, to G, as per Table 1 is used for the test. The grading or
grading used in the test should be nearest to the grading to be used in construction
Aggregates weighing 5 kg for grading А, В, С or D and 10 kg for grading E, F or G may
be taken as test specimen and placed in the cylinder. The abrasive charge is also chosen in
accordance with Table 1 depending on the grading of the aggregate and is placed m the
cylinder of the machine. The cover is then fixed dust sight. The machine is rotated at a
speed of 30 to 33 revolutions per minute. The machine is rotated for 500 revolutions for
grading А, В, С and D. For grading E, F and G, it shall be rotated for 1000
revolutions. The machine should be balanced and driven in such a way as to maintain
uniform peripheral speed.
After the desired number of revolutions, the machine is stopped and the material is
discharged from the machine taking care to take out entire stone dust. Using a sieve
coarser than 1.70 mm IS sieve, the material is first separate into two parts and the finer
portion is taken out and sieved further on a 1.7 mm IS sieve. The portion of material
coarser than 1.70 mm size is washed and dried in an oven at 105 °C to 110 °C to constant
weight and correct to one gram

OBSERVATION
TABLE: 1 Specification for Los Angeles Test
Grad Weight in grams of each lest sample in the size range mm No. of Weight of
-ing (passing and retained on square holes) spheres charge
gms.
80-63 63-50 50-40, 25-20 20- 12.5- 10- 6.3- 4.75-
40-25 12.5 10 6.3 4.75 2.36
A - - - 1250 1250 1250 1250 - - - 12 5000±25
В - - - - - 2500 2500 - - - 11 4584±25
С - - - - - - - 2500 2500 - 8 3330±20
D - - - - - - - - - 5000 6 2500+15
E 2500' 2500 5000 - - - - - - - 12 5000+25
»
F - - 5000 5000 - - - - - 12 5000±25
" *
G - - - 5000 5000 - 1- - - 12 5000+25
*
• Tolerance of ±2 percent is permitted
• Let the original weight of aggregate = W1gm
• Weight of aggregate retained on 1.70 mm IS sieve after the test = W2 gm
• Loss in weight due to wear = (Wl- W2) gm
𝑊1−𝑊2
• Percentage wear = x 100
𝑊1
TABLE: 2
Sr. No. Description Sample -1 Sample - II
1. Original weight of aggregate W1gms.
Weight of material retain on 1.70 mm IS-sieve after
2.
test W2
3. Weight of passing (W1 - W2) gms.
Abrasion Value in % =
4. 𝑊1−𝑊2
x 100
𝑊1
5 Avg. Abrasion value in %
APPLICATIONS OF LOS ANGELES ABRASION TEST:
Los Angeles Abrasion test is very widely accepted as suitable test to assess the
hardness of aggregate used in pavement construction. Many agencies have specified the
desirable limits of the test, for different methods of pavement construction. The maximum

allowable Los Angeles Abrasion values of aggregates as specified by Indian Roads

Congress for different methods of construction are given below:
Sr. Type of surface Max. Los Angeles
No. Abrasion Value %
1. Water Bound Macadam and surface treated 40
WBM (Wear at 500 revolutions)
2. Bituminous surface dressing - BM 40
3. Bituminous dam macadam 35
4. DBM,SDBC 35
5. Bituminous concrete 30
6. Cement Concrete 16
The difference between the original and final weights of the sample expressed as a
percentage of the original weight of the sample is reported as the percentage wears.
DISCUSSION:
It may seldom happen that the aggregates desired for a certain construction project
has the same grading as any one of the specified grading In all cases the standard grading
or grading nearest to the gradation of the selected aggregates may be chosen
Different specification limits may be required for grading E, F and G when

compared with А, В and D. Further investigations are necessary before any such
specifications could be made.
Los Angeles Abrasion Test is very commonly used to evaluate the quality of road
aggregates, especially to decide the hardness of stones. However, this test may be
considered as one in which resistance to both abrasion and impact of aggregate may be
obtained simultaneously, due to the presence of abrasive charge. Also the test condition is
considered more representatives of field conditions. The result obtained on stone
aggregates is highly reproducible.
CONCLUSION:
(Faculty Advisor)
Date:

SPECIFIC GRAVITY AND WATER ABSORPTION TEST

(IS: 2386 PART-3-1963)
OBJECTIVE:
To determine the specific gravity and water absorption of aggregates by perforated

basket.
INTRODUCTION:
The specific gravity of an aggregate is considered to be a measure of strength or

quality of the material. The specific gravity test helps in the identification of stone. Water
absorption gives an idea of strength of aggregate. Aggregates having more water
absorption are more porous in nature and are generally considered unsuitable unless they
are found to be acceptable based on strength, impact and hardness tests.
1) Specific gravity = (dry weight of the aggregate / Weight of equal volume of water)
2) Apparent specific gravity = (dry weight of the aggregate / Weight of equal volume
of water excluding air voids in aggregate)
Pycnometer Bottle Perforated Basket Apparatus

APPARATUS:
• A wire basket of not more than 6.3mm mesh or a perforated container of

convenient size with thin wire hangers for suspending it from the balance.
• A thermostatically controlled oven to maintain temperature of 100° to 110°C.
• A container for filling water and suspending the basket.
• An airtight container of capacity similar to that of the basket.
• A balance of capacity about 5 kg. to weigh accurate to 0.5 g. and of such a type
and shape as to permit weighing of the sample container when suspended in
water.
• A shallow tray and two dry absorbent clothes, each not less than 750 X 450 mm.
PROCEDURE:
(i) About 2 kg of aggregate sample is washed thoroughly to remove fines, drained and
placed in wire basket and immersed in distilled water at a temperature between 22- 32º C
and a cover of at least 5cm of water above the top of basket.
(ii) Immediately after immersion the entrapped air is removed from the sample by lifting
the basket containing it 25 mm above the base of the tank and allowing it to drop at the
rate of about one drop per second. The basket and aggregate should remain completely
immersed in water for a period of 24 hour afterwards.
(iii) The basket and the sample are weighed while suspended in water at a temperature of
22° – 32°C. The weight while suspended in water is noted =W1g.
(iv) The basket and aggregates are removed from water and allowed to drain for a few
minutes, after which the aggregates are transferred to the dry absorbent clothes. The
empty basket is then returned to the tank of water jolted 25 times and weighed in water=
W2 g.
(v) The aggregates placed on the absorbent clothes are surface dried till no further
moisture could be removed by this cloth. Then the aggregates are transferred to the
second dry cloth spread in single layer and allowed to dry for at least 10 minutes until the
aggregates are completely surface dry. The surface dried aggregate is then weighed =W3
g.
(vi) The aggregate is placed in a shallow tray and kept in an oven maintained at a
temperature of 110° C for 24 hrs. It is then removed from the oven, cooled in an air tight
container and weighted=W4 g.

OBSERVATIONS:
By using pycnometer bottle:
The specific gravity of the aggregate sample is calculated as given belowIS:2386 (Part 3-
1963):
𝑅
Specific gravity =
𝑄1−(𝑄2−𝑆)
𝑅
Apparent specific gravity =
𝑅−(𝑄2−𝑆)
(𝑄1− 𝑅)
Water absorption by per cent weight of aggregates = x 100
𝑅
Where,
Q1= weight of saturated surface-dry aggregate
Q2= total weight of pycnometer filled with saturated aggregates and water
S = weight of surface-dry pycnometer filled with water
R =weight of oven dried aggregates
By using perforated wire basket:
1) Empty weight of wire bucket = W1 gm

2) W1 + Weight dry aggregate = W2 gm
3) W2 in water = W3 gm
4) W1 in water = W4 gm
CALCULATION:
𝑊2−𝑊1
1) Specific gravity =
(𝑊2−𝑊1)−(𝑊3−𝑊4)
FOR WATER ABSORPTION:

1) Dry weight of aggregate = W1 =

2) Weight of aggregate immersed in water = W2 =
𝑊2−𝑊1
3) Water absorption = X 100 =
𝑊1
RECOMMENDED VALUE:
The size of the aggregate and whether it has been artificially heated should be indicated.
ISI specifies three methods of testing for the determination of the specific gravity of
aggregates, according to the size of the aggregates. The three size ranges used are
aggregates larger than 10 mm, 40 mm and smaller than 10 mm. The specific gravity of
aggregates normally used in road construction ranges from about 2.5 to 3.0 with an
average of about 2.68. Though high specific gravity is considered as an indication of high
strength, it is not possible to judge the suitability of a sample road aggregate without
finding the mechanical properties such as aggregate crushing, impact and abrasion values.
Water absorption shall not be more than 2% per unit by weight.
DISCUSSION
In case in Water absorption is higher than 2% than soundness test is required.
RESULT:
CONCLUSION:
(Faculty Advisor)
Date:

GRADATION AND BLENDING OF AGGREGATE:
Proportioning of Mineral Aggregate:

Methods of proportioning
Graphical methods Using formula Iterative methods

1. Triangular chart method P = Aa+Bb+Cc+Dd+… 1.Trial and error method
2. Rothfutch’s method 2.Simple iterative or
genetic algorithm based
Using Formula and trial and error method
❖ Aggregate blending:
P = Aa + Bb + Cc + Dd + …………
Where, P = Total percentage of aggregates A,B,C,D,…
passing from a given sieve
A,B,C,D,….=% of aggregate A,B,C,D,…..
passing from a given sieve
a,b,c,d,…=Proportion of aggregate A,B,C,D,…..
(1) Two Aggregate blending:
P = Aa + Bb and a + b = 1
Hence, a = 1 – b
∴ P = A (1 – b) + Bb
∴ P = A – Ab + Bb
∴ P = A + b (B – A)
∴ P – A = b (B – A)
P−A
∴b=
B−A
∴a=1–b
P−A
=1-
B−A
B−A−P
=
B−A
B−P P−B
= a=
B−A A−B

❖ Calculate the blending proportion for two aggregate by using the following data to meet
the given specifications:
10.0 4.75 2.36

Sieve size 12.5 mm 600 µ 300 µ 150 µ 75 µ
mm mm mm
Specification 80-100 70-90 50-70 30-50 18-29 13-23 8-16 4-10

% passing
100 60 30 10 2 0 0 0
Aggregate A
% passing
100 100 100 85 52.5 42.5 30 15
Aggregate B
Mid value, P 90 80 60 40 23.5 18 12 7
For 2.36 mm sieve

P=40, A=10, B=8
𝑃−𝐴 40−10 30
∴ b = 𝐵−𝐴 = 85−10 = 75 = 0.4
∴ a = 1 – b = 0.6
First Iteration:
10.0 4.75 2.36 600 300 75

Sieve size 12.5 mm 150 µ
mm mm mm µ µ µ
Specification 80-100 70-90 50-70 30-50 18-29 13-23 8-16 4-10

% passing 60 36 18 6 1.2 0 0 0
Aggregate A
% passing 40 40 40 34 21 17 12 6
Aggregate B
Total 100 76 58 40 22.2 17 12 6
Now, Reduce proportion of aggregate by 2% = a = 0.58

Increase proportion of aggregate by 2% = b = 0.42

Second iteration:
10.0 4.75 2.36 600 300 75
Sieve size 12.5 mm 150 µ
mm mm mm µ µ µ
Specification 80-100 70-90 50-70 30-50 18-29 13-23 8-16 4-10

% passing 58 34.8 17.4 5.8 1.16 0 0 0
Aggregate A
% passing 42 42 42 35.7 22.05 17.8 12.6 6.3
Aggregate B
Total 100 76.8 59.4 41.5 23.2 17.8 12.6 6.3
Hence proportion of aggregate A = 58%

Proportion of aggregate B = 42%
Graphical Method for 2 Aggregates ( Refer attach chart)
Steps
1) Take suitable scale on graph mark 0 to 100% of Aggregate A on X axis at bottom of
graph and on top of graph % of aggregate B aggregates as opposite direction of A
aggregate
2) On Y axis Left hand side (LHS)of graph mark 0 to 100 % for % passing of aggregate B
and on Right hand side (RHS)of graph mark 0 to 100% for % passing of aggregate A.
3) Now see the % passing of aggregate A and aggregate B in respective size of sieve
(i) For 12.5 mm sieve size aggregate A is passing 100% and B is also passing
100% so mark on X axis on top of graph on the side of % passing of aggregate A
and B
(ii) For 10 mm sieve size aggregate A is passing 60% and B is passing 100% so
mark point on 60% -Y axis of graph (% passing of aggregate A) –RHS and mark
point on 100% -Y axis of graph –LHS(% passing of aggregate B) ,…now join the
line between 60% of A and 100% of B
(iii) For 4.75 mm sieve size aggregate A is passing 30% and B is passing 100% so
mark point on 30% -Y axis of graph(% passing of aggregate A) –RHS and mark
point on 100% -Y axis of graph –LHS (% passing of aggregate B) ,…now join the
(iv) For 2.36 mm sieve size aggregate A is passing 10% and B is passing 85% so
mark point on 10% -Y axis of graph(% passing of aggregate A) –RHS and mark
point on 85% -Y axis of graph –LHS (% passing of aggregate B) ,…now join the
In similar style make a line for % passing of Aggregate A and B
4) Now see the specification e.g. 10.0 mm sieve has % passing 70 to 90 %. Mark the
point on line which we have join as per step 3(ii) on 70% passing of aggregate A –RHS
and 90% passing of aggregate B-LHS.

In similar style make a point on each line which we have prepared from step 3
5) Now Find the mid of both the line inner and out and make a line ending ox bottom X
and axis and top of X axis
6) See the end of line on bottom of X axis % of aggregate A and top of X axis % of
aggregate B…that suggest the desirable proportion of aggregate A and B
Graphical solution for proportioning of two aggregate
( 2 ) Three Aggregate blending: -
Using Formula and trial and error method
P = Aa + Bb + Cc ; a + b + c = 1
❖ Calculate the blending proportion for three aggregate by using following data to meet
the given specifications.

10.0 4.75 2.36 1.18 600 300 150 75

Sieve size 12.5 mm
mm mm mm mm µ µ µ µ
Specification 100 70-90 45-65 30-60 25-50 19-36 8-25 4-12 3-6
% passing 100 62 8 2 0 0 0 0 0
Aggregate A
% passing 100 100 100 91 73 51 24 4 0
Aggregate B
% passing
100 100 78 52 36 29 24 20 18
Aggregate C
Mid value 100 80 55 45 37.5 27.5 16.5 8 4.5
For 75µ sieve

P = Aa + Bb + Cc
4.5=0(a)+0(b)+18(C)
∴ C=0.25
a+b+c=1
a + b + 0.25 = 1
a + b = 0.75
a = 0.75 – b
For 2.36mm sieve
P=Aa + Bb + Cc
P=A (b + 0.75) + Bb + C(0.25)
P=0.75A – Ab + Bb + 0.25C
𝑃−0.75𝐴−0.252𝐶
b=
𝐵−𝐴
45−0.75(2)−0.25𝐶
=
𝐵−𝐴
0.45−0.75(2)−0.25(52)
=
91−2
b = 0.34
∴a+b+c=1
a + 0.34 + 0.25 = 1
∴ a = 0.41

First Iteration:
12.5 10.0 4.75 2.36 1.18 600 300 150 75
Sieve size
mm mm mm mm mm µ µ µ µ
19-
Specification 100 70-90 45-65 30-60 25-50 8-25 4-12 3-6
36
Aggregate A 41 25.42 3.28 0.82 0 0 0 0 0
Aggregate B 34 34 34 30.94 24.82 17.34 8.16 1.36 0
Aggregate C 25 25 19.5 13 9 7.25 6 5 4.5
Total 100 83.42 56.78 44.76 33.82 24.59 14.16 6.36 4.5
Now, Reduce proportion of aggregate A by 2% = a = 0.39

Increase proportion of aggregate B by 1% = b = 0.35
Increase proportion of aggregate C by 1% = b = 0.26
Second Iteration:
12.5 10.0 4.75 2.36 1.18 600 300 75
Sieve size 150 µ
mm mm mm mm mm µ µ µ
Specification 100 70-90 45-65 30-60 25-50 19-36 8-25 4-12 3-6
Aggregate A 39 24.18 3.12 0.78 0 0 0 0 0
Aggregate B 35 35 35 31.85 25.55 17.85 8.4 1.4 0

Aggregate C 26 26 20.28 13.52 9.36 7.54 6.24 5.2 4.68
Total 100 85.18 58.4 46.15 34.91 25.39 14.64 6.6 4.6
Ideal gradations for maximum packing of aggregate particles have been suggested
by many researchers. However, the so-called Fuller´s curve is quite well known. The
following is the equation for Fuller´s maximum density curve:
n
P=100(d/D)
Where,
d= diameter of the sieve size in question
P=total percent passing or finer than the sieve
D=maximum size of the aggregate
n=exponent
Graphical Method for 3 Aggregates ( Refer attach chart)

Chart for three aggregate blends

PROPORTIONING OF AGGREGATES
Size A B C D LL UL MID GRADATION SE
Stone
20 mm 12.5 mm 6 mm dust
26.5 100 100 100 100 100 100 100 100 0.00
19 75.08 100 100 100 79 100 90 92 5.18
13.2 1.48 100 100 100 59 79 69 67 2.28
9.2 0.00 90.00 100 100 52 72 62 65 7.84
4.75 0.00 5.00 100 100 35 55 45 46 1.21
2.36 0.00 0.00 70.50 100 28 44 36 32 13.58
1.18 0.00 0.00 50.55 100 20 34 27 24 10.65
0.6 0.00 0.00 40.50 100 15 27 21 19 2.51
0.3 0.00 0.00 30.00 100 10 20 15 15 0.01
0.15 0.00 0.00 16.54 100 5 13 9 9 0.01
0.075 0.00 0.00 6.00 97.00 2 8 5 5 0.23
Solution Bar 43.51
Proportion 0.3300 0.2200 0.4300 0.0200 0.0000 Total Proportion 1.00
Percent 33.00 22.00 43.00 2.00 0.00 Total Percent 100
Experiment :
Size A B C D LL UL MID GRADATION SE
Solution Bar
Proportion Total Proportion 1.00
Percent Total Percent 100

Calculation:
(Faculty Advisor)
Date:

Comparison table of aggregate test
Name of test
Specificati
on Crushing Shape Specific gravity and
Impact Abrasion
value Elongation Flakiness water absorption
Measure Toughness Hardness Strength Shape Shape Quality
Impact Loss angles

Pycnometer bottle or
Instrument testing abrasion Mould Length gauge Thickness gauge
Wire bucket
machine machine
Hammer- Steel
13.5-14 kg sphere Mould
15.2 9 5
Specific gravity range
Brief 25 stock 48mm dia. Dimension< Dimension< 2.2 to 3.2
Free fall Wt. 390 to cm 5 8
specification 15 cm 200 Pieces 200 Pieces Water absorption max.
380mm 446 gm allowable 2.0 %
Piston
height
12.5 mm Grading 12.5 mm
Test on minimum 200 Test on minimum 200 pieces
passing, A,B,C,D=5 Kg passing,
Sample size
10 mm E F and G =10 10 mm
pieces passing and retain passing and retain on -
Kg
on respective sieve size respective sieve size
retain* retain
Sieve size
Particle size smaller than Particle size smaller than 6.3
used
Limiting
2.36 mm 1.7 mm 2.36 mm 6.3 mm elongation test is mm elongation test is not -
not applicable applicable
criteria
*For smaller size of aggregate impact test can be done refer IS 2386 part IV

Specifications for Road - Earth Work, Sub-grade, Sub-Base and Base Course As per MORTH (Fifth Revision)
Earth work, Embankment and Subgrade
Sub-Bases, Base Course and Shoulders (Non-Bituminous)
Construction Requirement
Grading Requirements
Density Requirement Wet Mix
Granular Sub-Base Materials (GSB) Water Bound Macadam (WBM)
Macadam (WMM)
Max. Lab Dry Unit Weight
Type of Work
when tested as per IS:2720 (Part 8)
Percent by Weight Passing the IS Sieve Coarse Aggregates Screening Aggregates IS Sieve % by Weight
Embankments up to 3m height, not Grading IS Sieve % by Weight Grading Size of IS Sieve % by Weight Size Passing
Not less than 15.2 kN/cu. m. IS Sieve Grading Class Size Range
subjected to extensive flooding No. Size Passing Class Screenings Size Passing
Size
Embankments exceeding 3m height
or embankments of any height Not less than 16 kN/cu. m. I II III IV V VI 75 mm 100 13.2 mm 10 53 mm 100
subject to long periods of inundation
Subgrade and earthen
shoulders/verges,backfill
Not less than 17.5 kN/cu. m. 75.0 mm 100 - - - 100 - 63 mm 90-100 11.2 mm 95-100 45 mm 95-100
63 mm
53.0 mm 80-100 100 100 100 80-100 100 1 to 53 mm 25-75 A 13.2 mm 5.6 mm 15-35 26.5 mm -
Compaction Requirements 45 mm
26.5 mm 55-90 70-100 55-75 50-80 55-90 75-100 45 mm 0-15 22.4 mm 60-80
180
Relative Compaction as % of Max. 0-10
Type of work/material Lab Dry Density 9.50 mm 35-65 50-80 - - 35-65 55-75 22.4 mm 0-5 micron 11.20 mm 40-60
as per IS:2720 (Part 8)
Subgrade and earthen shoulders Not less than 97% 4.75 mm 25-55 40-65 10-30 15-35 25-50 30-55 63 mm 100 11.2 mm 100 4.75 mm 25-40
Embankment Not less than 95% 2.36 mm 20-40 30-50 - - 10-20 10-25 53 mm 95-100 9.5 mm 80-100 2.36 mm 15-30
53 mm
2 to B 11.2 mm 600
Expansive Clays (Free swell index ≥ 50 %) 0.85 mm - - - - 2-10 - 22.4 mm 45 mm 65-90 5.6 mm 50-70 8-22
micron
a) Subgrade and 500 mm portion
just below the subgrade
Not allowed 0.425 mm 10-15 10-15 - - 0-5 0-8 22.4 mm 0-10 180
5-25 75 micron 0-5
b) Remaining portion of micron
embankment
90-95% 0.075 mm <5 <5 <5 <5 - 0-3 11.2 mm 0-5
Department of Civil Engineering, Darshan Institute of Engineering & Technology, Rajkot

I.S. SOIL CLASSIFICATION ( IS 1498-1970)

G= Gravel, S=Sand, C= Clay, M=Silt, W=Well graded, P= Poorly graded,L= Low compressibility, I= Intermediate compressibility, H=High compressibility,
O=Organic.
Major Division Group Typical names Classification criteria Dual classification
symbol
Well graded gravels, Gravel sand mixtures with little
Less than 5% GW Cu>4 , Cc -1 to 3
or no fines % Passing between 5%
passing through
Gravel -More 75 μ sieve Poorly graded gravel, Gravel sand mixtures with little to 12%
GP Not meeting above criteria
than 50% or no fines GW-GM
retained on 4.75 Silty gravels, Gravel, sand and silt mixtures, poorly GW-GC
Coarse grained mm sieve More than 12 % GM PI<4 PI between GP-GM
soil
graded
passing through 4 and 7 GP-GC
More than 50% 75 μ sieve Clayey gravels, Gravel, sand and silt mixtures, poorly GM-GC
GC PI>7
retained on 75μ graded
sieve Sand -More Less than 5% % Passing between 5%
SW Well graded sand, Gravelly sands little or no fines Cu>6 , Cc -1 to 3
than 50% passing through to 12%
passing from 75 μ sieve SP Poorly graded sand, Gravelly sand, little or no fines Not meeting above criteria SW-SM
4.75 mm and More than 12 % PI between SW-SC
retained on
SM Silty sand, poorly graded sand-silt mixtures PI<4
SP-SM
passing through 4 and 7
75 μ sieve 75 μ sieve SC Clayey sand, poorly graded sand-clay mixtures PI>7 SM-SC SP-SC
In organic silt, silty or clayey fine sand, with low CLASSIFICATION BASED ON PLASTICITY CHART
ML
plasticity,
With low compressibility In organic clay, sand ,silty and clay mixtures with low
CL
WL < 35 plasticity,
In organic silt
OL
of low plasticity
In organic silt, silty or clayey fine sand of medium
MI
Fine grained
plasticity
soil With Intermediate compressibility In organic clay, sandy clay, silty clayey of medium
CI
More than 50% WL > 35 and WL < 50 plasticity
passing from Organic silts and organic silty clay
OI
75μ sieve of medium plasticity
In organic silts, silty soil
MH
of high compressibility
In organic clay
With high compressibility CH
WL > 50
Organic clay
OH
Highly organic soil Highly organic soil
Pt

SECTION-B
TEST ON SOIL
7 California bearing ratio test (CBR test) IS:2720 part-16
8 Dynamic cone penetrometer (DCP) test IRC:SP:72-2015
CBR TEST CLASSIFICATION
Lab Test Field CBR Test

(Disturbed sample /Undisturbed sample)
Light Compaction Heavy Compaction

(Standard Procter) (Modified Procter)
Static compaction /Dynamic Compaction Static compaction/Dynamic Compaction
Socked Unsocked Socked Unsocked

CBR CBR CBR CBR
Light compaction Heavy compaction

Mould Vol 2210 cc 2210 cc
Hammer 2.6 kg 4.9 kg
Height of fall 31 cm 45 cm
No. of blow 55 55
No. of layer 3 5

CALIFORNIA BEARING RATIO TEST (CBR TEST)

(IS: 2720 PART-16)
OBJECTIVE:
➢ To determine the California bearing ratio by conducting a load penetration test in the
laboratory.
NEED AND SCOPE:

➢ The California bearing ratio test is penetration test meant for the evaluation of
subgrade strength of roads and pavements. The results obtained by these tests are used
with the empirical curves to determine the thickness of pavement and its component
layers. This is the most widely used method for the design of flexible pavement.
➢ This instruction sheet covers the laboratory method for the determination of C.B.R. of
undisturbed and remoulded /compacted soil specimens, both in soaked as well as
unsoaked state.
EQUIPMENTS AND TOOLS REQUIRED:
1. Cylindrical mould with inside dia 150 mm and height 175 mm, provided with a
detachable extension collar 50 mm height and a detachable perforated base plate 10 mm
thick.
2. Spacer disc 148 mm in dia and 47.7 mm in height along with handle.
3. Metal rammers:- Weight 2.6 kg with a drop of 310 mm (or) weight 4.89 kg a drop 450
mm.
4. Weights:- One annular metal weight and several slotted weights weighing 2.5 kg each,
147 mm in dia, with a central hole 53 mm in diameter.
5. Loading machine:- With a capacity of at least 5000 kg and equipped with a movable
head or base that travels at an uniform rate of 1.25 mm/min. Complete with load
indicating device.
6. Metal penetration piston 50 mm dia and minimum of 100 mm in length.
7. Two dial gauges reading to 0.01 mm.
8. Sieves. 4.75 mm and 20 mm I.S. Sieves.
9. Miscellaneous apparatus, such as a mixing bowl, straight edge, scales soaking tank or
pan, drying oven, filter paper and containers.
DEFINITION OF CBR:
➢ It is the ratio of force per unit area required to penetrate a soil mass with standard
circular piston at the rate of 1.25 mm/min. to that required for the corresponding
penetration of a standard material.
Test load
➢ C.B.R. = x 100
Standard load
➢ The following table gives the standard loads adopted for different penetrations for the
standard material with a C.B.R. value of 100%

Penetration of plunger
Standard load (kg)
(mm)
2.5 1370
5.0 2055
7.5 2630
10.0 3180
12.5 3600
The test may be performed on undisturbed specimens and on remoulded specimens
which may be compacted either statically or dynamically.
PREPARATION OF TEST SPECIMEN:

1. Undisturbed specimen
➢ Attach the cutting edge to the mould and push it gently into the ground. Remove the
soil from the outside of the mould which is pushed in . When the mould is full of soil,
remove it from weighing the soil with the mould or by any field method near the spot.
DETERMINE THE DENSITY:

2. Remoulded Specimen
➢ Prepare the remoulded specimen at Proctors maximum dry density or any other
density at which C.B.R. is required. Maintain the specimen at optimum moisture
content or the field moisture as required. The material used should pass 20 mm I.S.
sieve but it should be retained on 4.75 mm I.S. sieve. Prepare the specimen either by
dynamic compaction or by static compaction.
(a) Dynamic Compaction

Take about 4.5 to 5.5 kg of soil and mix thoroughly with the required water.
Fix the extension collar and the base plate to the mould. Insert the spacer disc over the
base (See Fig.38). Place the filter paper on the top of the spacer disc.
• Compact the mix soil in the mould using either light compaction or heavy
compaction. For light compaction, compact the soil in 3 equal layers, each layer
being given 55 blows by the 2.6 kg rammer. For heavy compaction compact the
soil in 5 layers, 56 blows to each layer by the 4.89 kg rammer.
• Remove the collar and trim off soil.
• Turn the mould upside down and remove the base plate and the displacer disc.
• Weigh the mould with compacted soil and determine the bulk density and dry
density.
• Put filter paper on the top of the compacted soil (collar side) and clamp the
perforated base plate on to it.
(b) Static Compaction (IRC prefer static compaction)

Calculate the weight of the wet soil at the required water content to give the desired
density when occupying the standard specimen volume in the mould from the expression.

W = desired dry density * (1+w) V

Where W = Weight of the wet soil
w = desired water content
V = volume of the specimen in the mould = 2250 cm3 (as per the mould available
in laboratory)
• Take the weight W (calculated as above) of the mix soil and place it in the mould.
• Place a filter paper and the displacer disc on the top of soil.
• Keep the mould assembly in static loading frame and compact by pressing the
displacer disc till the level of disc reaches the top of the mould.
• Keep the load for some time and then release the load. Remove the displacer disc.
• The test may be conducted for both soaked as well as unsoaked conditions.
• If the sample is to be soaked, in both cases of compaction, put a filter paper on the top
of the soil and place the adjustable stem and perforated plate on the top of filter paper.
• Put annular weights to produce a surcharge equal to weight of base material and
pavement expected in actual construction. Each 2.5 kg weight is equivalent to 7 cm
construction. A minimum of two weights should be put.
• Immerse the mould assembly and weights in a tank of water and soak it for 96 hours.
Remove the mould from tank. Note the consolidation of the specimen.
Procedure for Penetration Test

• Place the mould assembly with the surcharge weights on the penetration test
machine. Fig. 1.
• Seat the penetration piston at the center of the specimen with the smallest possible
load, but in no case in excess of 4 kg so that full contact of the piston on the
sample is established.
• Set the stress and strain dial gauge to read zero. Apply the load on the piston so
that the penetration rate is about 1.25 mm/min.
• Record the load readings at penetrations of 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 4.0, 5.0, 7.5,
10 and 12.5 mm. Note the maximum load and corresponding penetration if it
occurs for a penetration less than 12.5 mm.
• Detach the mould from the loading equipment. Take about 20 to 50 g of soil from
the top 3 cm layer and determine the moisture content.

Fig 1 CBR test setup
Figure -2 Correlation load penetration curves

Observation and Recording
For Dynamic Compaction

• Optimum water content (%) :____________________________
• Weight of mould + compacted specimen g :____________________________
• Weight of empty mould g :____________________________
• Weight of compacted specimen g :____________________________
• Volume of specimen cm3 :____________________________
• Bulk density g/cc :____________________________
• Dry density g/cc :____________________________
For Static Compaction

Dry density g/cc : ___________________________
Moulding water content % : ___________________________
Wet weight of the compacted soil, (W)g : ___________________________
Period of soaking 96 hrs. (4days) : ___________________________
For Penetration Test

Calibration factor of the proving ring :
Surcharge weight used (kg) : 2.0 kg per 6 cm construction
Water content after penetration test % :
Least count of penetration dial : 1 Div. = 0.01 mm
If the initial portion of the curve is concave upwards, apply correction by drawing a
tangent to the curve at the point of greatest slope and shift the origin (Fig. 2). Find and
record the correct load reading corresponding to each penetration.
C.B.R. = PT/PS *100

Where, PT = Corrected test load corresponding to the chosen penetration from the load
penetration curve.
PS = Standard load for the same penetration taken from the table .

Proving ring capacity: ________ KN

Proving ring calibration factor: ________ KN/division
Observation Table:
Readings on
Penetration in-
proving ring* Load in KN Load (Kg) Corrected load
mm
( Ring division)
0
0.5
1.0
1.5
2.0
2.5
3.0
4.0
5.0
7.5
10.0
12.5
Interpretation and recording

C.B.R. of specimen at 2.5 mm penetration =
C.B.R. of specimen at 5.0 mm penetration =
Important Notes
The C.B.R. values are usually calculated for penetration of 2.5 mm and 5 mm.
Generally the C.B.R. value at 2.5 mm will be greater that at 5 mm and in such a
case/the former shall be taken as C.B.R. for design purpose. If C.B.R. for 5 mm
exceeds that for 2.5 mm, the test should be repeated. If identical results follow, the
C.B.R. corresponding to 5 mm penetration should be taken for design.
Calculation:
Conclusion:
(Faculty Advisor)
Date:

DYNAMIC CONE PENETROMETER (DCP) TEST
INTRODUCTION
➢ The Dynamic Cone Penetrometer is a simple device developed in UK for rapid in situ
strength evaluation of subgrade and other unbound pavement layers. Essentially, a
DCP measures the penetration of a standard cone when driven by a standard force,
the reported DCP value being in terms of the penetration of a standard cone, in mm
per blow of the standard hammer.
➢ Basically, the penetration (in mm) per blow is inversely proportional to the strength
the material. Thus, higher the CBR value of a material being tested, lower will be the
DCP value in mm/blow.
OBJECTIVE
➢ To evaluate strength of subgrade and other unbound pavement layers on site.
APPARATUS
➢ DCP test apparatus consists of steel cone with an angle of 60o having diameter of 20
mm, standard 8 kg drop hammer slides over a 16 mm diameter steel rod with a fall
height of 575 mm.
NEED AND SCOPE
➢ This test is needed to measure the subgrade strength, also to determine the boundaries
between pavement layers with different strengths and their thicknesses. The
measurements can be taken up to 1.2m depth with an extension rod.
PROCEDURE
➢ One person holds the DCP instrument in a vertical position; another person carefully
drops the weight and third takes the readings of penetration.
➢ The penetration of the cone can be measured on a graduated scale. The readings are
taken with each blow of the weight.
➢ The field data is reduced in terms of penetration versus corresponding number of
blows. The number of blows and depth readings are recorded on the DCP test form.
➢ The cone is case-hardened but requires replacing. When used on subgrade materials
the cone can be expected to last 30 to 40 tests before replacement.

The DCP test is especially useful for bituminous pavement rehabilitation design and is
being used extensively in several countries.
The following charts show the relationship between DCP (mm/blow) and CBR.


OBSERVATION TABLE:
Cumulative
No. of blow penetration CBR value
penetration
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
For all soils except for CL and CH soils having CBR value less than 10 %,
292
CBR = where, DCP is the penetration per blow.
(𝐷𝐶𝑃)1.12
292
For CL soils with CBR< 10, CBR =
(0.017019∗𝐷𝐶𝑃)
292
For CH soils, CBR =
(0.002871∗𝐷𝐶𝑃)
CALCULATIONS:

RESULTS:
CONCLUSION:
(Faculty Advisor)
Date:

Specifications for Road - Bases and Surface Courses (Bituminous) As per IRC/MORTH - Fifth Revision
Working and Testing
Temperature of Bitumen/Mix Gradation Requirement Requirements of Mixture for
Mixing, Laying and Rolling Dense Graded
Working with Temp. Tests on Bituminous Concrete Dense Graded Bituminous
Requirements for Paving Bitumen Bituminous Mix °C Bitumen/Mix Temperatures for Bituminous Macadam
(BC)
(DBM) Macadam (DBM) &
Bituminous Mixes °C
- 200 -
Nominal
Agg. Size
37.5
mm
26.5
mm
Nominal
Agg. Size
19 mm 13.2 mm Bituminous Concrete (BC)
Bitumen Mixed
Minimum Flash Bitumen Aggregate Laying *Rolling Layer 75-100 50-75 Layer 30-40 Viscosit Modified
Bitumen Grade - 175
Point
Viscosity
Temperature Temperature
Material
Temperature Temperature Thickness mm mm Thickness
50 mm
mm Bitumen
Bitumen Grade Temperature y Grade Test
Properties
Properties Mixing Temperature
Cumulative % by Cumulative % by Paving Hot Cold Method
VG 10 VG 20 VG 30 VG 40 Range (150 to 177)
163 TFO & RTFO tests VG 40 160-170 160-175 160-170 150 Min. 100 Min. IS Sieve weight of total IS Sieve weight of total
Bitumen Climate Climate
aggregate passing aggregate passing
Absolute Viscosity at Compaction Kinematic Viscosity

60° C, Poises, Min. 800-1200 1600-2400 2400-3600 3200-4800 Temperature
135
test
VG 30 150-165 150-170 150-165 140 Min. 90 Min. 45 mm 100 - 45 mm - - Compaction level 75 blows on each face of the specimen
Kinemaic viscosity at Minimum Rolling Minimum stability AASHTO

135°C,cSt,Min. 250 300 350 400 Temperature
100 - VG 20 145-165 145-170 145-165 135 Min. 85 Min. 37.5 mm 95-100 100 37.5 mm - -
(kN at 60 °C)
9.0 12.0 10.0
T245
Static Viscosity,
Marshall flow AASHTO
Flash point,°C, Min. 220 220 220 220 60 Marshall Stability & VG 10 140-160 140-165 140-160 130 Min. 80 Min. 26.5 mm 63-93 90-100 26.5 mm 100 -
(mm)
2-4 2.5-4 3.5-5
T245
Float tests
Solubility in
Ductility & Specific *Rolling must be completed before the mat cools to these Marshall Quotient MS-2 and
trichloroethylene, 99 99 99 99 27
Gravity test
19 mm - 71-95 19 mm 90-100 100
(Stability/Flow)
2-5 2.5-5
ASTM D2041
Min. % minimum temperatures
Penetration at 25°C, Needle Rate of Application
100g, 5s, 0.1 mm 80 60 45 35 Working Range of 25
Penetration test
Rate of Application of Prime Coat 13.2 mm 55-75 56-80 13.2 mm 59-79 90-100 % Air voids 3-5
Bituminous of Tack Coat
Pavements in Rate of % Voids Filled
Softening Point, India (60 to -10) Needle Bitumen Type of
°C, Min. 40 45 47 50 4
Penetration test Emulsion
Bitumen Cutback
Surface
Spray 9.5 mm - - 9.5 mm 52-72 70-88 with Bitumen 65-75
Type of (kg/sq. m.) (VFB)
Surface Rate of Rate of Coating of
Type of Bituminous
Test on Residue from Thin Film Oven Tests (TFOT) / RTFOT 0 Direct tensile and Spray Spray 0.20-0.30 4.75 mm 38-54 38-54 4.75 mm 35-55 53-71 Aggregate 95% Minimum IS:6241
Cutback surfaces
Frass break point (kg/sq. m.) (kg/sq. m.) Particle
Granular
Viscosity ratio at tests, Min. Frass Tensile Strength AASHTO
60°C, Max.
4 4 4 4 -10
breaking point for
WMM/WBM 0.7-1.0 MC 30 0.6-0.9 surfaces treated 0.25-0.30 2.36 mm 28-42 28-42 2.36 mm 28-44 42-58 80% Minimum
with primer Ratio T283
Indian conditions Cement
Stabilized soil
Ductility at = - 4 to -10
25°C, cm, Min
75 50 40 25 - -36 bases/Crusher 0.9-1.2 MC 70 0.9-1.2 Concrete 0.30-0.35 1.18 mm - - 1.18 mm 20-34 34-48 % Voids in
Run Macadam Pavement Minimum percent voids in mineral aggregate
Mineral
Permissible Variations in the Actual Mix from the (VMA) are set out in table below*
Aggregate
Selection of Binder for Bituminous Mixes & its Applications in India 0.6 mm - - 0.6 mm 15-27 26-38
Job Mix Formula (JMF)
Viscosity Grade
Equivalent
Penetration
Maximum
average air Traffic (CVPD)
Bituminous
General Applications
Description Base/Binder Course 0.3 mm 7-21 7-21 0.3 mm 10-20 18-28 *Minimum Percent Voids in
Course
Grade temperature °C Aggregate passing 19 mm sieve or larger ± 8% Mineral Aggregate (VMA)
BM, DBM and Spraying applications, paving applications in 0.15 mm - - 0.15 mm 5-13 12-20
VG 10 80/100 ≤ 30 °C ≤ 1500 CVPD Aggregate passing 13.2 mm, 9.5 mm sieve ± 7%
BC cold regions. Nominal
BM, DBM and Paving applications in cold climatic conditions of Minimum VMA Percent Related to
VG 20 60/80 ≤ 30 °C ≤ 1500 CVPD Aggregate passing 4.75 mm sieve ± 6% Maximum
BC North India and in high altitude region. Design Percentage Air Voids
0.075 mm 2-8 2-8 0.075 mm 2-8 4-10 Particle Size
For all types of BM, DBM, Aggregate passing 2.36 mm, 1.18 mm, 0.6 mm ± 5% (mm)
VG 30 60/70 ≤ 40 °C Paving applicaions for most part of India.
traffic SDBC and BC
Aggregate passing 0.3 mm, 0.15 mm sieve ± 4% Bitumen Bitumen 3.0 4.0 5.0
Heavy loads, Content % Content %
DBM,SDBC Use in high stressed area like intersections, toll Aggregate passing 0.075 mm sieve ± 2% Min. 4.0 Min. 4.5 Min. 5.2 Min. 5.4 26.5 11.0 12.0 13.0
VG 40 30/40 ≥ 40 °C Expressways, by mass of by mass of
and BC plazas, truck terminals. Binder content & Mixing temperature ± 0.3% & ± 10°C 37.5 10.0 11.0 12.0
MSA > 30 total mix total mix
Department of Civil Engineering, Darshan Institute of Engineering & Technology, Rajkot

SECTION-C
TEST ON BITUMEN AND BITUMINOUS MIX DESIGN

CONSISTENCY TESTS OF BITUMEN
9 Penetration test IS: 1203-1978
10 Softening point test IS: 1205-1978
11 Introduction of tar viscometer IS: 1206-1978
12 Viscosity test- Absolute Viscosity IS: 1206-1978
13 Viscosity test – Kinematic Viscosity IS: 1206-1978
AGING TESTS ON BITUMEN
14 Introduction on Thin film oven test ASTM-D-1754/IS: 9382
SAFETY TESTS ON BITUMEN
15 Flash and Fire point test IS: 1209-1978
OTHER TESTS
16 Specific Gravity test on bitumen IS: 1202-1978
17 Ductility test IS: 1208-1978

About bitumen
Bitumen is a thermoplastic material and its stiffness is dependent on temperature. The

temperature-vs-stiffness relationship of bitumen is dependent on the source of crude oil
and the method of refining.
The Bureau of Indian Standards (BIS) introduced paving grade bitumen

specifications (IS: 73-1950) for the first time in the year 1950 and classified it on
penetration. The specifications were revised in the years 1962 and 1992. To improve the
quality of Bitumen, BIS revised IS-73-1992specifications based on Viscosity (Viscosity
at 60oC) in July 2006. As per these specifications, there are four grades VG-10, VG-20,
VG-30 & VG-40. A few qualification tests like specific gravity, water content, ductility,
loss on heating & Farass breaking point were removed from IS:73-1992 specifications as
these tests do not have any relationship either with the quality or performance of the
product.
Indian Oil commenced marketing of Bitumen as per Viscosity Grade specifications

conforming to IS: 73-1992 from all its refineries from Aug 2009. Therefore, the
Penetration grades have been replaced by Viscosity grade Bitumen. According to
viscosity (degree of fluidity) grading, higher the grade, stiffer the Bitumen. Tests are
conducted at 600 C and 135o C, which represent the temperature of road surface during
summer (hot climate, similar to northern parts of India) and mixing temperature
respectively. The penetration at 25o C, which is annual average pavement temperature, is
also retained.
Different Grades of Bitumen marketed by Indian Oil :
VG-10 BITUMEN: VG-10 is widely used in spraying applications such as surface-

dressing and paving in very cold climate in lieu of old 80/100 Penetration grade. It
is also used to manufacture Bitumen Emulsion and Modified Bitumen products.
VG-20 BITUMEN: VG-20 is used for paving in cold climate & high altitude
regions
VG-30 BITUMEN: VG-30 is primarily used to construct extra heavy duty Bitumen
pavements that need to endure substantial traffic loads. It can be used in lieu of
60/70 Penetration grade.
VG-40 BITUMEN: VG-40 is used in highly stressed areas such as intersections,

near toll booth sand truck parking lots in lieu of old 30/40 Penetration grade. Due
to its higher viscosity, stiffer Bitumen mixes can be produced to improve
resistance to shoving and other problems associated with higher temperature and
heavy traffic loads.

VISCOSITY GRADE (VG) BITUMEN SPECIFICATION AS PER IS 73:2006

Characteristics VG-10 VG-20 VG-30 VG-40
Sr. Paving Grades Method

Characteristics of Test,
no. VG 10 VG 20 VG 30 VG 40 Ref to
Penetration at 25°C, 100 g, 5
i) 80 60 45 35 IS 1203
s, 0.1 mm, Min
Absolute viscosity at 60°C, IS 1206
ii) 800-1200 1600-2400 2400-3600 3200-4800
Poises (Part-2)
Kinematic viscosity at IS 1206
iii) 250 300 350 400
135°C, cSt, Min (Part-3)
Flash point (Cleveland open IS 1448
iv) 220 220 220 220
cup), °C, Min [P : 69]
Solubility in
v) trichloroethylene, percent, 99.0 99.0 99.0 99.0 IS 1216
Min
Softening point (R&B), °C,
vi) 40 45 47 50 IS 1205
Min
Tests on residue from rolling
vii)
thin film oven test:
a) Viscosity ratio at 60°C, IS 1206
4.0 4.0 4.0 4.0
Max (Part 2)
b) Ductility at 25°C, cm, Min 75 50 40 25 IS 1208
VISCOSITY GRADED (VG) BITUMENS AND THEIR GENERAL

APPLICATIONS
Viscosity
General Applications
Grade (VG)
Use in highly stressed areas such as those in intersection, near toll
VG – 40
booths, and truck parking lots in lieu of old 30/40 penetration grade
VG – 30 Use for paving in most of India in lieu of old 60/70 penetration grade
VG – 20 Use for paving in cold climatic, high altitude regions of North India
Use in spraying applications such as surface dressing and for paving in
VG - 10
very cold climate in lieu of old 80/100 penetration grade

SELECTION CRITERIA BFOR VISCOSITY- GRADED(VG) PAVING BITUMENS

BASED ON CLIMATIC CONDITIONS
Highest daily mean air temperature, C

Lowest daily Less than 20 C 20 to 30 C More than 30 C
mean air
temperature, C
More than -10 C VG-10 VG-20 VG-30
-10 C or lower VG-10 VG-10 VG-20
GRADES
Bitumen shall be classified into four grades based on the viscosity, and suitability
recommended for maximum air temperature as given below:
Grade Suitable for 7 day Average

Maximum Air Temperature
°C
VG10 < 30
VG20 30-38
VG30 38-45
VG40 > 45
NOTE — this is the 7 day average maximum air temperature for a period not less than 5
years from the start of the design period.

Working Temperature (⁰C) with bitumen

and Bituminous pavement

CONSISTENCY TESTS
PENETRATION TEST (IS: 1203-1978)
OBJECTIVE: To determine the penetration value of given bitumen sample.
INTRODUCTION:
Bituminous materials are available in variety of types and grades. The
penetration test determines the hardness of these materials by measuring the depth in
tenth of a millimeter to which a standard needle will penetrate vertically under specified
conditions of standard load, time and temperature. The sample is maintained at the
standard temperature of 25 °C. The total load on needle is l00 gm. The penetration test
set-up is illustrated in fig. The softer the bitumen, the greater will be its number of
penetration unit. Indian Standards Institution has standardized the equipment and test
procedure vide IS 1203-1958 Penetration test is widely used world ever for classifying
the bituminous materials into different grades Even though it is recognized recently that
the empirical tests like penetration, softening point etc are incompetent to qualify the
paving binder for its temperature susceptibility characteristics, its quickness and
simplicity of operations cannot be ignored. Correlations are also established between
penetration test and absolute viscosity test values.
APPARATUS:
It consists of items like container, needle, water bath, penetrometer, stopwatch etc.
Following are standard specifications as per 1SI for the above apparatus
a) Container: A flat bottomed cylindrical metallic container 55 mm in diameter and

35 mm or 57 mm in height
b) Needle: A straight, highly polished cylindrical hard steel needle with conical end,
having the shape and dimensions as shown in fig. Needle is provided with a shank
appropriately 3 mm in diameter into which it is immovably fixed.
c) Water Bath: A water bath is maintained at 25 + 1 °C containing not less than 10

liters of water, the sample is immersed to depth not less than 100 mm from the top
and supported on a perforated shelf not less than 50 mm from the bottom of the
bath.
d) Penetrometer: It is an apparatus which allows the needle to penetrate without

appreciable friction. It is accurately calibrated to yield results in hundreds of
centimeters "These days automatic Penetrometers (electrically operated) are also
available. Typical sketch of Penetrometer is shown in figure.

e) Transfer Tray: A small tray which can keep the container fully immersed in
water during the test
Fig 1.Bitumen Penetrometer
Penetration Measurements

PROCEDURE:
The bitumen is softened to a pouring consistency between 75 °C and 100 °C

above the approximated temperature at which bitumen softens The sample material is
thoroughly stirred to make it homogenous and free from air bubbles and water The
sample material is then poured into the container to a depth at least 15 mm more than the
expected penetration The sample containers are cooled in atmosphere of temperature
not lower than 18°C for one hour. Then they are placed in temperature controlled water
bath at a temperature of 25 °C for a period of one hour.
The sample container is placed in the transfer tray with water from the water bath
and is placed under the needle of the penetrometer. The weight of needle, shaft and
additional weight are checked. The total weight of this assembly should be 100 gm.
The needle is now arranged to make contact with the sample surface. This is done by
placing a lamp to the rear of the apparatus in such a way that the image of the needle can
be checked to make surface contact. Zero reading of the penetrometer dial is taken
before-releasing the needle. The needle is released-for- 5 seconds and-the final reading
is taken on the dial. At least three measurements are made on this sample by testing at
distance not less than 10 mm apart. After each test, the needle is disengaged and wiped
with benzene and carefully dried. The sample container is also transferred in the water
bath before next testing is done so as to maintain a constant temperature of 25 °C. The
test is repeated with sample in the other containers.
I.R.C. RECOMMANDETIONS:
The depth of penetration is reported in hundreds of a centimeter. The mean value

of three consistent measurements is reported as the penetration value. It is further
specified by I SI that results of each measurements should not vary from the mean value
reported above by more than the following:
Penetration at 25°C, Grade of
Penetration Grade Repeatability 100 g, 5 s, 0.1 mm, bitumen
Min value
0-80 4% 80 VG 10
80- 225 5% 60 VG 20
Above 225 7% 45 VG 30
35 VG 40
DISCUSSION:
It may be noted that the penetration value is largely influenced by an inaccuracy
as regards factors,
i. Pouring Temperature
ii. Size of needles
iii. Weight placed on the needle
iv. Test Temperature

It is obvious to obtain high values of penetration if the test temperature and/or

weight (placed over the needle) are/is increased. Higher pouring temperatures than the
specified may result into hardening of bitumen and may give lower penetration values.
Higher test temperatures have given considerably higher penetration values. It is also
necessary to keep the needle clean before testing in order to get consistent results. The
penetration needle should not be placed more than 10 mm from the side of the dish
OBSERVATIONS:
I Pouring Temp °C =
II Bath material =
III. Period of air cooling at 30 °C temp. =
IV Period of water bath at constant temp, of 25 °C =
V Room Temp. =
VI Depth of Sample =
OBSERVATION TABLE:
Sr. Penetration Value Mean Penetration

Sample
No. Initial Final Difference Value
CALCULATIONS:
RESULT:
CONCLUSION:
(Faculty Advisor)
Date:

SOFTENING POINT TEST (IS: 1205-1978)
OBJECTIVE: To determine the softening point of a given sample of bituminous

material with the help of Ring and Bali apparatus.
INTRODUCTION:
Bitumen does not suddenly change from solid to liquid state, but as the
temperature increases, it gradually becomes softer until it flows readily. All semi-solid
state bitumen grades need sufficient fluidity before they are used for application with the
aggregate mix. For this purpose, bitumen is sometimes cut back with solvent like
kerosene. The common procedure however is to liquefy the bitumen by heating.
The softening point is the temperature at which the substance attains
particular degree of softening under specified condition of test. For bitumen, it is
usually determined by Ring and Ball Test. A brass ring containing the test sample of
bitumen is suspended in liquid like water or glycerin at a given temperature. A steel ball
is placed upon the bitumen and liquid medium is then heated at a specified rate. The
temperature at which the soften bitumen touches the metal plate placed at a
specified distance below the ring is recorded as the softening point of a particular
bitumen. The apparatus and test procedure are standardized by ISI. It is obvious that
harder grade bitumen possess higher softening point than softer grade bitumen.
APPARATUS:
It consists of Ring and Ball apparatus.
a) Steel Balls: They are two in number. Each has a diameter 9.5 mm and weighs
2.5+0.5 gm
b) Brass Rings: There are two rings of the following dimension:
Depth : 6.4 mm
Inside diameter at bottom : 15.9mm
Inside diameter at top : 17.5 mm
Outside diameter : 20.6mm
Brass rings are also placed with ball guides as shown m fig. 8.2.
c) Support: The metallic support is used for placing pair of ring.
The upper surface of the rings is adjusted to be 50mm below the surface of water
or liquid contained in the bath. A distance of 25 mm between the bottom of the
rings and top surface of the bottom plate of support is provided It has a housing
for suitable thermometer.
d) Bath and Stirrer: A heat resistant glass container of 85 mm diameter and 120
mm depth is used. Bath liquid is water for materials having softening point above
80 °C, and glycerin for materials having softening point above 80 °C. Mechanical
stirrer is used for ensuring uniform heat distribution at all times throughout the
bath.

Fig 1. Ring and Ball Apparatus
PROCEDURE:
Sample material is heated to a temperature between 75 °C TO 100 °C above the

approximate softening point until it is completely fluid and is poured in heated rings
placed on metal plate. To avoid sticking of the bitumen to metal plate, coating is done to
this with a solution of glycerin and dextrin. After cooling the rings in air for 30 minutes,
the excess bitumen is trimmed and rings are placed in the support as discussed in item (c)
above. At this time, the temperature of distilled water is kept at 5 °C. This temperature
is maintained for 15 minutes after which the balls are placed in position. The
temperature of water is raised at a uniform rate of 5 °C per minute with a controlled
bottom plate by sinking of balls. At least two observations are made. For material
whose softening point is above 80 °C. Glycerin is used in heating medium and the starting
temperature is 35 °C instead of5°C.
I.R.C. RECOMMENDATIONS:
The temperature at the instant when each of the ball and sample touches the
bottom plate of support is recorded as softening point value. The mean of duplicate
determinations is noted. It is essential that the mean value of the softening point
(temperature) does not differ from individual observation by more than the following
limits:

Softening
Softening Point Repeatability Reproducibility Grade of Bitumen
point (min.)
4 °C
Below 30 °C 2 °C VG 10 40
30 °C to 80 °C 1 °C 2 °C VG 20 45
Above 80 °C 2 °С 4 °C VG 30 47
VG 40 50
DISCUSSION:
As in the other physical tests on bitumen, it is essential that the specifications

discussed above are strictly observed. Particularly, any variation in the following points
would affect the result considerably:
Factors affect the test results:
i. Quality and type of liquid
ii. Weight of Balls
iii. Distance between bottom of Ring and bottom base plate
iv. Rate of heating
Impurity in water or glycerin lies been observed to affect the result considerably.
It is logical, lower will be the softening point, if the weight of balls is excessive. On the
other hand, increased distance between bottom of ring and bottom plate, increases the
softening point.
APPLICATION OF SOFTENNING POINT TEST:
Softening point is essentially the temperature at which the bituminous binders
have an equal viscosity. The softening point of a tar is therefore related to the equiviscous
temperature (e.v.t.). The softening point found by the ring and ball apparatus is
approximately 20°C lower than the e.v.t.
Softening point, thus gives an idea if the temperature at which the
bituminous material attains a certain viscosity. Bitumen with higher softening point
may be preferred in warmer places. Softening point is also sometimes used to specify
bitumen and pitches.
OBSERVATIONS:
I. Grade of Bitumen : _________________________
II. Approx. Softening point of Bitumen : _________________________
III. Bath Liquid : _________________________
IV. Period of Air Cooling : _________________________
V. Period of cooling in water bath at 5°C : _________________________
VI. Rate of heating : _________________________
VII. Room Temp. : _________________________

OBSERVATION TABLE:
Sr. Test Property Test I Test II Mean Value

No.
1 Temp, at which Sample
touches bottom base
plate
CALCULATIONS:
RESULT:
CONCLUSION:
(Faculty Advisor)
Date:

INTRODUCTION OF TAR VISCOMETER (for penetration grade of

bitumen using tar viscometer) (IS: 1206-1978)
OBJECTIVE: To determine the Viscosity of given bitumen sample for penetration grade
of bitumen.
INTRODUCTION:
Viscosity is defined as inverse of fluidity. Viscosity thus defines the fluid

property of bituminous material. The degree of fluidity at the application temperature
greatly influences the strength characteristics of the resulting paving mixes. High or low
fluidity at mixing and compaction has been observed to result in lower stability values
There is an optimum value of fluidity or viscosity for mixing and compacting for each
aggregate gradation of the mix and bitumen grade. At high fluidity or low viscosity, the
bituminous binder simply "lubricates" the aggregate particles instead of providing a
uniform film thickness for binding action. Similarly low fluidity or high viscosity also
resists the compactive effort and the resulting mix is heterogeneous in character
exhibiting stability values. ISI specifies a test procedure for liquid binders like outback
bitumen, emulsion and liquid tar. One of the method by which viscosity is measured is by
determining the time taken by 50 CC of the material to flow from a cup through specified
orifice at a given temperature. This is illustrated in fig 1 Specification vide IS : 1206 -
1958 describe the details of equipment and procedure. In the range of consistency of
bituminous materials when neither orifice viscometer test nor penetration test could be
conducted, float test may be carried out. Equipment like sliding plate micro viscometer
and Brook field viscometer are however in use for defining the viscous characteristics of
the bitumen of all grades irrespective of testing temperature.
APPARATUS:
Ten millimeter orifice viscometer is specified for road tar and is called tar
viscometer. Fig. shows the details of this apparatus. The apparatus consists of main parts
like cup, valve, water bath, sleeves, stirrer and thermometers etc.

VISCOMETER FOR PENETRATION

GRADE OF BITUMEN
Fig 1. Viscometer for TAR viscosity
Difference between Tar and Bitumen
Tar Bitumen
A dark, thick flammable liquid distilled A black viscous mixture of hydrocarbons
from wood or coal, consisting of a mixture obtained naturally or as a residue from
of hydrocarbons, resins, alcohols, and other petroleum distillation.
compounds. It is used in road-making and
for coating and preserving timber.
Available by destructive distillation Available by fractional distillation
It is used in road-making and for coating It is used for road surfacing and roofing.
and preserving timber.
More temperature susceptible Less temperature susceptible
PROCEDURE:
The tar cup is properly leveled and water in the bath is heated to the temperature
specified for the test and is maintained throughout the test. Stirring is also continued The
sample material! is heated at the temperature 20°C above the specified test temperature
and the material is allowed to cool. During this, the material is continuously stirred, when
material reaches slightly above test temperature, the same is poured in the tar cup, until
the leveling peg on the valve rod is just immersed. In the graduated receiver (cylinder),
20ml of mineral oil or one percent by weight solution of soft soap is poured This receiver
is placed under the orifice. When the sample material reaches the specified testing

temperature within + 0.1°C and is maintained for 5 minutes, the valve is opened. The
stopwatch is started, when the cylinder records 25ml. The time is recorded for flow up to
a mark of 75ml. (i.e. 50ml of test sample to flow through the orifice).
I.R.C RECOMMANDETIONS:
The time in seconds for 50ml of the sample material to flow through the orifice is
defined as the viscosity at a given test temperature The standard test temperatures have
been specified for the various grades of cutback and tar. The viscosity values of repeat
test on the same sample should not vary by more than 4 percent from the mean value.
DISCUSSION:
The working range of tar viscometer for 10 mm orifice is 10 to 140 seconds. For
cutback bitumen, the orifice size specified is 4mm for lower grades and 10mm for higher
grades with higher viscosity. Viscosity is the resistance to flow and the absolute unit of
viscosity is dyne sec./cm' or poise.
APPLICATIONS OF VISCOSITY TEST:
Orifice viscosity test gives an indirect measure of viscosity of tars and cutbacks in
second. Higher the time, more viscous is the binder material. Float test also measures the
viscosity in tune units (seconds)
OBSERVATIONS:
1. Grade of Bitumen
2. Specified test temp
3. Test temp
4. Room Temp.
5. Size of Orifice
6. Repeatability
OBSERAVATION TABLE:
Tests
Test Property Mean Value
Sample 1 Sample 2
Viscosity in terms of time (seconds)
taken by 50 ml of bitumen to flow
through 10 mm orifice at 70°C
CONCLUSION:
(Faculty Advisor)
Date:

VISCOSITY TEST - ABSOLUTE VISCOSITY (IS: 1206-1978)
❖ INTRODUCTION:
Viscosity of a liquid is a measure of resistance to flow of the liquid. Higher the viscosity
slower the movement of rate of flow. Lower the viscosity Higher the movement of rate of
flow.
As the bitumen binders are mixed with aggregates for road work at different temperature
, It is necessary to determine viscosity at different temperature before its' use.
Viscosity of bitumen can be measured by capillary tube viscometer.
❖ DETERMINATON OF ABSOLUTE VISCOSITY:
➢ A vacuum capillary tube viscometer is generally used to measure the absolute

viscosity of bitumen at 60˚C.
➢ The viscometer is mounted in a digitally controlled constant temperature bath at
uniform test temperature of 60˚C.
➢ At this temp. the paving grade bitumen is highly viscous and cannot flow freely
through the capillary tube and therefore vacuum is applied to measure the flow.
➢ The time taken in second for the liquid bitumen to flow through a known distance
through the capillary tube is measured and expressed as the absolute viscosity.
➢ Depending on the type of fluid, different diameter tubes are taken and hence
calibration factors are required to calculate viscosity.
➢ Generally canon manning vacuum viscometer is used to find out absolute
viscosity of bitumen.
❖ APPARATUS:
Following items are used to carry out the test:

1. Cannon manning Viscometer size no.13 with calibration factor.
2. Thermometer to measure the test temperature of 60˚C ± 0.1˚C.
3. Constant temperature bath digitally controlled..., having viewing glass panel and
illuminating light to maintain test temperature of 60 deg. C with an accuracy of
0.1˚C.
4. Hot Air Oven to operate at 135˚C.
5. Vacuum pump unit with regulator to maintain vacuum of 300 mm Hg ± 0.5 mm
Hg.
6. A stop Watch to measure timing accurate to 0.1 second.

TO VACUUM
PUMP
TIMING
MARKS
FILLING LINE
Fig. Absolute viscosity tube
❖ PROCEDURE:
➢ The bitumen sample is heated to a pouring temperature not exceeding 90˚C.

➢ About 20 ml. of sample is transferred to a glass beaker 50 ml. and is placed in the
oven maintained at 135 ± 5 ˚C. to allow entrapped air to escape.
➢ The prepared sample is poured in to the filling tube of the viscometer until the sample
touches the fill line.

➢ The charged viscometer is placed in the oven at 135˚C for 10 minutes to allow large
air bubbles to escape.
➢ The viscometer is now transferred to digitally controlled constant temperature bath
maintained at 60 ± 0.1˚C.
➢ The temperature is maintained for 30 to 35 minutes.
➢ Now the vacuum of 300 ± 0.5 mm hg is applied and liquid bitumen is allowed to
flow through bulb B and Bulb C and time taken from start timing mark to end timing
mark is noted in both the bulbs separately.
❖ RESULT:
The measured time in second is multiplied with calibration factor to obtain the value of
viscosity in poise for each bulb.
That is, Viscosity P = Calibration factor K x Measured time t

FOR EXAMPLE:
Calibration factor for bulb B=59.3615 and flow time T =49 seconds then
Viscosity for bulb B = 59.3615 x 49
= 2908.71 poise
Now Calibration factor for bulb C=19.7521 and flow time T =147 seconds then
Viscosity for bulb C = 19.7521 x 147
= 2903.55 poise
The final absolute viscosity of sample = Consider the fine of bitumen flow for bulb B and
C, which is higher than 60 sec that time will be multiply by its constant that is absolute
viscosity on sample.
OBSERVATION AND RESULT
Sr. No Flow Time B Flow Time C Remarks
Time in Sec
Calibration Factor 59.3615 19.7521
Viscosity in Poise
(B+C)/2 =
Consider viscosity which time > 60 sec.

❖ NOTE:
➢ While reporting the viscosity test temperature 60˚C and vacuum 300mm hg
should be mentioned.
➢ After completion of test remove the viscometer from the bath and place it in an
inverted position in an oven maintained at 135 ± 5˚C, until asphalt is drained off
thoroughly.
➢ Clean the viscometer by rinsing with appropriate solution like acetone or benzene.
➢ Dry the tube by passing a flow of filtered air through the capillary for 2 minutes.
➢ Periodically tube can be cleaned by chromic acid to remove organic deposits.
✓ The basic unit of viscosity is the Pascal seconds (Pa s).

✓ The absolute or dynamic viscosity of bitumen measured in Pascal seconds
✓ It is the shear stress applied to a sample of bitumen in Pascal divided by the
shear rate per second;
✓ 1Pa s = 10 p (Poise).
(Faculty Advisor)
Date:

VISCOSITY TEST - KINEMATIC VISCOSITY (IS: 1206-1978)
Kinematic viscosity is the measure of resistance to flow of bitumen under gravity.
In CGS unit kinematic viscosity is expressed as Cm²/second and is called a STOKE. In

SI unit Kinematic Viscosity is expressed as mm²/second and is called a centi-stoke,
i.e..cSt.
If kinematic viscosity (In stoke) is multiplied by the specific gravity of bitumen, the
absolute viscosity (in poise) can be obtained.
Kinematic viscosity of bitumen can be carried out in reverse flow viscometer at test
temperature of 135˚C.
❖ APPARATUS:
Following items are used to carry out the test:

1. Viscometer No. 6 with calibration factor.
2. Calibrated thermometer to measure the temperature of 135˚C with least count of
0.1˚C.
3. Constant temperature bath, digitally controlled, having viewing glass panel and
illuminating light to maintain test temperature of 135˚C with an accuracy of 0.1˚C.
4. High temperature Silicon oil.
5. A stop Watch to measure timing accurate to 0.1 second.
❖ PROCEDURE:
➢ The bitumen sample is heated to a pouring temperature not exceeding 90˚C. The
sample is stirred thoroughly and about 20 ml sample is transferred in glass beaker.
➢ The viscometer is placed in the oil bath and held in vertical position with the help
of viscometer holder.
➢ Pour the sample through filling tube to a point just about filling mark.
➢ Now arrest the flow of the sample by inserting the cork in tube.
➢ Add more sample if necessary to bring the upper meniscus slightly above filling
mark.
➢ Remove excess sample above filling mark G by inserting the special pipette.
➢ Maintain the bath temperature of 135 deg. C ± 0.1 deg. C for 30 minutes.
➢ Remove the cork from tube H and allow the sample to flow by gravity.
➢ Observe the flow and start stop watch at start timing mark A and stop at Stop
timing mark B. Record the seconds nearest to 0.1 S. value

FILLING LINE
TIMING MARKS
Viscosity Bath
Kinematic Viscosity Apparatus and Tube
❖ CALCULATIONS:
Viscosity cSt = Calibration factor K (Centi-stoke per second) x flow time in seconds t
Always report test temperature along with the temperature.
As per BIS, The repeatability of Kinematic viscosity test result should not differ by
1.8%of their mean value.
The reproducibility of Kinematic viscosity test result should not differ by more than 8.8%
of their mean value.

OBSERVATION AND RESULT
Flow Time From A to B Remarks

Data
Time in Sec
Calibration Factor 18.40277

Viscosity in cSt
(Centi-stoke per second )
CONCLUSION:
(Faculty Advisor)
Date:

AGING TESTS
INTRODUCTION TO THIN FILM TEST (ASTM D 1754 or IS: 9382)
Figure: Thin film test
❖ PROCEDURE:
The thin film oven (TFO) test is conducted by placing a 50g sample of bitumen
in a cylindrical flat-bottom pan (5.5 inches inside diameter and 3/8 inch
deep).The bitumen layer in the pan is about 1/8 inch deep. The pan containing the
bitumen sample is transferred to a shelf in a ventilated oven maintained at 160°C
(325°F) the shelf rotates at 5 to 6 revolutions per minute (RPM).The sample is
kept in the oven for 5 h, and then transferred to a suitable container for measuring
penetration or viscosity of the aged bitumen. The test method is described in
ASTM D 1754 or IS:9382.The aged bitumen is usually required to meet specified
maximum viscosity ratio at 60°C which is four in case of IS:73-2013.A loss or
gain in weight of the test sample is also measured and reported.
(Faculty Advisor)
Date:

SAFETY TESTS
FLASH AND FIRE POINT TEST (IS: 1209-19780)
OBJECTIVE: To determine the Flash and Fire point of a given sample of bituminous
material with the help of Pensky-Martins apparatus.
INTRODUCTION: This test is done to determine the flash point and the fire point of
asphaltic bitumen and fluxed native asphalt, cutback bitumen and blown type bitumen as
per IS: 1209 – 1978. The principle behind this test is given below:
Flash Point – The flash point of a material is the lowest temperature at which the
application of test flame causes the vapours from the material to momentarily catch fire in
the form of a flash under specified conditions of the test.
Fire Point – The fire point is the lowest temperature at which the application of test
flame causes the material to ignite and burn at least for 5 seconds under specified
conditions of the test.
APPARATUS:
The apparatus required for this test
i) Pensky-Martens apparatus
ii) Thermometer-
Low Range: -7 to 110oC, Graduation 0.5ᵒC
High Range: 90 to 370ᵒC, Graduation 2ᵒ
Fig 1.Pensky-Martens apparatus
PROCEDURE:
• FLASH POINT
i) Soften the bitumen between 75 and 100oC. Stir it thoroughly to remove air bubbles and
water.

ii) Fill the cup with the material to be tested up to the filling mark. Place it on the bath.
Fix the open clip. Insert the thermometer of high or low range as per requirement and also
the stirrer, to stir it.
iii) Light the test flame, adjust it. Supply heat at such a rate that the temperature increase,
recorded by the thermometer is neither less than 5oC nor more than 6oC per minute.
iv) Open flash point is taken as that temperature when a flash first appears at any point on
the surface of the material in the cup. Take care that the bluish halo that sometimes
surrounds the test flame is not confused with the true flash. Discontinue the stirring
during the application of the test flame.
v) Flash point should be taken as the temperature read on the thermometer at the time the
flash occurs.
• FIRE POINT
i) After flash point, heating should be continued at such a rate that the increase in
temperature recorded by the thermometer is neither less than 5oC nor more than 6oC per
minute.
ii) The test flame should be lighted and adjusted so that it is of the size of a bead 4mm in
dia.
OBSERVATIONS
Sr.
Test Property Test I Test II Mean Value
No.
1 Flash point
2 Fire point
REPORTING OF RESULTS
i) The flash point should be taken as the temperature read on the thermometer at the time
of the flame application that causes a distinct flash in the interior of the cup.
ii) The fire point should be taken as the temperature read on the thermometer at which the
application of test flame causes the material to ignite and burn for at least 5 seconds
DISCUSSION:
CONCLUSION:
(Faculty Advisor)
Date:

OTHER TESTS
SPECIFIC GRAVITY TEST OF BITUMEN (IS: 1202-1978)
OBJECTIVE: To determine the specific gravity of given bitumen sample.
INTRODUCTION:
The specific gravity of bitumen binder is a fundamental property frequently used as an aid
to classify the binders for use in paving jobs.in most applications, the bitumen is weighed,
but finally in use with aggregate system, the bitumen content is converted on volume
basis. Thus an accurate determination of specific gravity value is required for conversion
of weight to volume. The specific gravity is influenced by the chemical compaction of
binder. Increased quantity of aromatic type compounds increases the specific gravity. The
test procedure has been standard by the BIS.
The specific gravity is defined by BIS as the ratio of the mass of a given volume of the
bituminous material to the mass of an equal volume of water, the temperature of both
being specified as 27°±0.1°.
Figure: Specific gravity bottle

APPARATUS:
There are two methods (1) Pycnometer method (2) Balance method. For Pycnometer
method, the apparatus are specific gravity bottle of 50 ml capacity, ordinary capillary type
with 6 mm diameter neck or wide mouthed capillary type bottle with 25 mm diameter
neck can used. For balance method an analytical balance equipped with a pan straddle is
used.

PROCEDURE:
Method-1, Pycnometer method

The specific gravity bottle cleaned, dried and weight along with the stopper. It is filled
with fresh distilled water, stopper placed and the same is kept in water container for at
least half an hour at temperature 27°±0.1°. The bottle is then removed and cleaned from
outside. The specific gravity bottle containing distilled water is now weight.
The bituminous material is heated to a pouring temperature and is pouring in the above
empty bottle taking all the precautions that it is clean and dry before filling sample
materials. The material is filled up to the half taking care to prevent entry of air
temperature cooled to 27° and then weighed. The remaining space in the specific gravity
bottle is filled with distilled water at 27°, stopper placed and is placed in water container
at 27°. The bottle containing bituminous material and containing water is removed,
cleaned from outside and is again weighed.
Method-2, Balance method

In the balance method, the bitumen test specimen is cube shaped, about 12 mm on each
edge. It is prepared by pouring the liquefied bitumen sample in a brass to provide the
sample of required dimensions and later cooled. The sample is weighted in air and then in
distilled water maintained at 27°±0.1° to the nearest 0.1 mg.
CALCULATION:
The specific gravity of the material is calculated as follows:
(1)Pycnometer method
Specific gravity = (weight of bituminous material)/(weight of equal volume of water)
(𝑐−𝑎)
=
(𝑏−𝑎)−(𝑑−𝑐)
Where,
a=weight of the specific gravity bottle, g
b= weight of the specific gravity bottle filled with distilled water, g
c= weight of the specific gravity bottle about half filled with bituminous material, g
d= weight of the specific gravity bottle about half with the material and the rest with
distilled water, g
(2)Balance method
𝑒
Specific gravity =
(𝑒−𝑓)
Where,
E=weight of the dry specimen, g
F=weight of the specimen when immersed in distilled water, g

OBSERVATIONS:
Results of specification gravity test on bitumen by Pycnometer method
(1) Grade of bitumen=………. (2) Test temperature=……….
Weight of Weight of Weight of bottle +

Weight of bottle + bottle + half- half-filled
Specific
Sample No. bottle, g distilled filled material, material +
gravity
water, g g distilled water, g
a b C D
Average value
Specific gravity value=……….
Results of specification gravity test on bitumen by balance method
(1) Grade of bitumen=………. (2) Test temperature=……….
Weight of sample in
Weight dry sample
Sample No. distilled water, g Specific gravity
E F
1
2
3
Average value
Specific gravity value=……….
(Faculty Advisor)
Date:

DUCTILITY TEST (IS: 1208-1978)
OBJECTIVE: To determine Ductility of given bitumen sample.
INTRODUCTION:
In the flexible pavement construction where bitumen binders are used, it is of

significant importance that the binders form ductile thin films around the aggregates. This
serves as a satisfactory' binder in improving the physical interlocking of the
aggregates. The binder material which does not possess sufficient ductility would crack
and thus provides pervious pavement surface. This in turn results in damaging effect to
the pavement structure. It has been stated by some agencies that the penetration and
ductility properties go together; but depending upon the chemical composition and the
type of crude source of the bitumen, sometimes it has been observed that the above
statement is incorrect. It may hence be mentioned that the bitumen may satisfy the
penetration valve, but may fail to satisfy the ductility requirements. Bitumen paving
engineer would however want that both test requirements are satisfied in the field jobs.
Ductility is expressed as the distance centimeters to which a standard briquette of bitumen
can be stretched before the thread breaks. See fig. 1. The test is conducted at 27 + 0.5° С
and at a rate of pull of 50 + 2.5 mm per minute. The test has been standardized by the
IS1.
APPARATUS:
It consists of items Use sample (briquette) moulds, water bath, square-end trowel
or putty knife sharpened on end and ductility machine Following are standard
specifications as per ISI for the above items:
a) Briquette Mould:
Mould is made of brass metal with shape and dimensions as indicated in fig. 10 2.
Both ends called lips possess circular holes to grip the fixed and movable ends of the
testing machine, sidepieces when placed together form the briquette of the following
dimensions:
Length 75 mm
Distance between clips 30 mm
Width at mouth of clip 20 mm
Cross section at minimum width 10 mm x 10 mm
b) Ductility Machine:
It is an equipment which functions as constant temperature water bath and a pulling
device at a pre calibrated rate. The central rod of the machine is threaded and through

gear system provides a movement to one end where the clip is fixed during initial
pavement. The other clip end is hooked at the fixed end of the machine. Two clips are
thus pulled apart horizontally at a uniform speed of 50 + 2.5 mm per minute.
Fig . Ductility Testing Apparatus
PROCEDURE
The bitumen sample is melted to a temperature of 75 to 100°C above the

approximate softening point until it is fluid It is strained through IS sieve 30, poured in
the mould assembly and placed on a brass plate, after a solution of glycerin and dextrin is
applied at all surfaces of the mould exposed to bitumen
Thirty to forty minutes after the sample is poured into the moulds, the plate
assembly along with the sample is placed m water bath maintained at 27°C for 30
minutes. The sample and mould assembly are removed from water bath and excess
bitumen material is cut off by leveling the surface using hot knife. After trimming the
specimen, the mould assembly containing sample is replaced in water bath maintained at
27°C for 85 to 95 minutes. The sides of the mould are now removed and the clips are
carefully hooked on the machine without causing any initial strain. The pointer is set to
read zero. The machine is started and the two clips are thus pulled apart horizontally
while the test is in operation, it is checked whether the sample is immersed in water at
depth of at least 10 mm. The distance at which the bitumen thread breaks is recorded
in cm to report as ductility value.
Fig. Prepared Briquette with bitumen

Fig. Bitumen Filled brequettes
Fig. Briquette assembly started pulling.
Fig Bitumen thread breaks

Fig: Ductility Measurements
I.R.C. RECOMMANDETIONS:
The distance traveled up to the point of breaking of thread measured in

centimeters is recorded as ductility value. It is recommended by ISI that results should not
differ from mean value by more than the following:
Grade of bitumen Ductility value in cm-

Repeatability Reproducibility
Minimum
VG 10 15
VG 20 50
5 percent- 10 percent
VG 30 40
VG 40 25
DISCUSSION:
The ductility value gets seriously affected if any of the following factors are
varied
i) Pouring temperature.
ii) Dimensions of briquette.
iii) Improper level of briquette placement.
iv) Rate of pulling.
v) Test temperature
Increase m minimum cross section of 10mm would record increased ductility.
APPLICATIONS OF DUCTILITY TEST:
A certain minimum ductility is necessary for a bitumen binder. This is because of

the temperature changes in the bituminous mixes and the deformations that occur in
flexible pavement. If the bitumen has low ductility, cracking may occur especially in
cold weather. The ductility values of bitumen vary from 5 to over 100. Several

agencies have specified the minimum ductility values for various types of bituminous
pavement. Often a minimum ductility value of 50cm is specified for bituminous
construction.
OBSERVATIONS:
1. Grade of Bitumen =
2. Pouring temp =
3. Test temp. =
4. Period of air cooling =
5. Rate of cooling =
OBSERAVATION TABLE:
Test Property Briquette final length in cm Mean ductility

Ductility Value in cm to which standard 1 2 3 Value
2
briquette mould having 10x10 cm cross- In cm.
section in center can stretch where thread just
break
CALCULATIONS:
RESULT:
CONCLUSION:
(Faculty Advisor)
Date:

SECTION-D
TEST OF BITUMINOUS MIX

18 % Bitumen content in paving mixture ASTM-D-2172
19 Stripping value of road aggregate IS: 6241-1971
Marshal stability test-determination of
20 MS-2
optimum bitumen content

% BITUMEN CONTENT IN PAVING MIXTURE(ASTM-D-2172)
OBJECTIVE: To determine the percentage of bitumen in paving mixture.
INTRODUCTION:
This method of test is intended for the determination, by cold solvent extraction,
of the percentage of bitumen (Not, in a paving mixture, the aggregate in which all passing
through 25 mm sieve. It is not intended for use in recovering the bitumen for further
testing). The mineral matter recovered from this test can be used for sieve analysis.
Note: Although "Bitumen" by definition is material soluble I carbon disulfide, benzene is

recommended for use in this method for safety reasons, and it normally produces the
same results within the precision of the method. Other solvents, such as carbon
tetrachloride, trichloroethylene, etc. may be substitute for benzene or carbon disulfide in
this method and similar results may be obtained, but the relationship of such results to
these obtained with benzene or carbon disulfide cannot be predicted or assumed.
If volatile distillates are desired, they may be obtained by the method of test for
Moisture or volatile distillates m Bituminous Paving Mixtures.
APPARATUS:
It consists of following:
a) Extraction Apparatus: consisting of a bowl approximating that shown m fig.1
and an apparatus in which the bowl may be revolved at controlled variable speeds
up to 3600 rpm The apparatus shall be provided with a shell for catching the
solvent thrown from the bowl and a drain for removing the solvent. The
apparatus preferably shall be provided with explosion proof features and installed
under a hood to provide ventilation
b) Filter Rings: to fit the nm of the bowl.
c) Oven: capable of being maintained at 240 °F.
d) Steam Bath
e) Balance: of 5000 g capacity, sensitivity to 0.1 g
f) Analytical Balance
g) Graduate: 2000 ml capacity
h) Ignition Dish: 125 ml capacity
l) Maker Burner, Stands; Large Flat Pan, Beakers etc.

Fig . Centrifugal Extractor
REAGENTS:
i. Benzene, confirming to the Standard specifications for Industrial Grade Benzene.
ii. Ammonium Carbonate Solution- Prepare a saturated solution of (NH4)2СОз.
iii. Cresol, crystal-free, confirming to the standard specifications for Cresol for
priming coat with coal-tar pitch in damp proofing and water proofing
PREPARATION OF SAMPLE:
a. If the mixture is not sufficiently soft to separate with a spatula or towel, place
2000 to 5000 g in a large, fiat pan and warm in oven at 240°F, only until it can be
so handled Separate the particles of the sample as uniformly as possible, using
care not to fracture the mineral particles, and weigh a representative 1000 g
portion in to the bowl, distributing it uniformly around the bowl. For routine
testing, smaller samples may be used when the maximum size aggregate therein is
less than 6.3 mm. The precision of the method becomes less as the aggregate size
increases, due to variations in samples. It may, however be used on mixtures
containing aggregate larger than 25 mm by using samples weighing at least 3000
g. They may be tested by extracting 1000 g at a tune
b. Cover the sample in the bowl with benzene and allow sufficient time for the solvent
to disintegrate the sample before testing (not over 1 hr.)
с. At the time, weigh 500 g of the sample to a metal still confirming to section 3 (b)
of the test for water in Petroleum Products and other Bituminous Materials

PROCEDURE:
i. Place the bowl containing the sample and solvent in the machine. Dry and weight
the filter ring and fit it around the edge of the bowl. Clamp the cover over the
bowl tightly in place and place the beaker under the drain to collect the extract.
ii. Start the machine revolving slowly, gradually increasing speed to a maximum of
3600 rpm or until solvent ceases to flow from the drain. Allow the machine to
stop, add 200 ml of benzene, and repeat the above procedure. Use sufficient 200
ml solvent and repeat the above procedure. Use sufficient 200 ml solvent
additions (not less than three) so that the extract is clear and not darker than and
light straw color when a portion is viewed in a separate container.
iii. Remove the filter ring from the bowl, dry in air and then to constant weight in
oven at 240°F and weigh. The increase in weight of this ring during the extraction
procedure is mineral matter. Evaporate the contents of the bowl to dryness on the
steam bath and then heat in an oven at 240°F to constant weight after cooling.
iv. Collect all extract in a 2000ml graduate and measure the total volume. Agitate the
contract thoroughly and measure 100 ml in to a previously weighed ignition dish.
Evaporate the extract in the dish to dryness on a steam bath and ash the residue at
a dull red heat. Ash the bituminous material at a dull red heat (500 to 600°C) cool,
and add 5 ml or saturate ammonium carbonate (NH4CO3) solution per gram of
ash. Digest at room temp, for 1 nr. and then dry in an oven at 110°C to constant
weight, cool in a desiccators, and weigh. Calculate the weight of ash in the entire
volume of extract.
v. Determine the water content of the sample in the metal still (section 4(c) in
accordance with method D95).
CALCULATIONS:
Calculate the percentage bitumen in the sample as follows:
Bitumen content of dry sample percent = (W1- W2)( W3+ W4 + W5) x 100 /(W1- W2)
Where
W1 weight of sample, in gm.
W2 weight of water in sample
W3 weight of extracted mineral matter
W4 weight of ash in extract, and
W5 Increase in the weight of the filter ring

OBSERVATIONS:
I. Solvent used:
II. Initial wt. Of sample in gms.= W1
III. Weight of aggregate after being centrifuged =
OBSERVATION:
Bitumen content =
CALCULATIONS:
RESULT:
CONCLUSION:
(Faculty Advisor)
Date:

STRIPPING VALUE TEST ON ROAD AGGREGATE (IS: 6241-1971)

OBJECTIVE: To determine the stripping value of road aggregate.
APPARATUS:
The apparatus consists of:
• Thermostatically controlled water bath
• Beaker
• Mixer, etc.
PROCEDURE:
This method covers the procedure for determining the stripping the stripping value
of coarse aggregates by static immersion method, when bitumen and tar binders are used.
200g of dry and clean aggregate passing 20 mm IS sieve and retained on 12.5 mm are
heated up to 150°C when these are to be mixed with bitumen and the aggregates are
heated 100°C when these are to be mixed with tar. Five percent by weight of bitumen
binder is heated to 160°C (110°C in the case of tar binder). The aggregate and binder are
mixed thoroughly till they are completely coated and mixture is transferred to a 500ml
beaker and allowed to cool at room temperature for about two hours. Distilled water is
then added to immerse the coated aggregate to cool at room temperature for about two
hours. Distilled water is then added to immerse the coated aggregates. The beaker is
covered and kept in a water-bath maintained at 40°C taking care that the level of water in
the water-bath is at least half the height of the beaker. After 24 hours the beaker is taken
out, cooled at room temperature and the extent of stripping is estimated visually while the
specimen is still under water.
OBSERVATION:
Results of stripping test on road aggregates
(1) Type of aggregate
(2) Type of binder
(3) percentage binder used
(4) Total weight of aggregate
(5) total weight of binder
(6) Temperature of water-bath

Observation Number Uncovered area/Stripping,

percentage
1
2
3
𝑈𝑛𝑐𝑜𝑣𝑒𝑟𝑒𝑑 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑎𝑔𝑔𝑟𝑒𝑔𝑎𝑡𝑒 𝑏𝑦 𝑣𝑖𝑠𝑢𝑎𝑙 𝑒𝑥𝑎𝑚𝑖𝑛𝑎𝑡𝑖𝑜𝑛

Stripping value = x 100
𝑇𝑜𝑡𝑎𝑙 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑎𝑔𝑔𝑟𝑒𝑔𝑎𝑡𝑒
(Faculty Advisor)
Date:

MARSHAL STABILITY TEST DETERMINATION OF OPTIMUM

BITUMEN CONTENT (MS-2)
OBJECTIVE: To determine the Optimum Bitumen content of given sample using

Marshall Stability Test.
INTRODUCTION:
The Marshall Stability and flow test provides the performance prediction measure
for the Marshall Mix design method. The stability portion of the test measures the
maximum load supported by the test specimen at a loading rate of 50.8 mm/minute. Load
is applied to the specimen till failure, and the maximum load is designated as stability.
During the loading, an attached dial gauge measures the specimen's plastic flow
(deformation) due to the loading. The flow value is recorded in 0.25 mm (0.01 inch)
increments at the same time when the maximum load is recorded.
Desirable properties of mix:

1. Stability
2. Durability
3. Surface flask
APPARATUS:
The apparatus consists of:
• Marshall Stability testing machine
• Cylindrical mould – 10 cm. diameter and 7.5 cm. height
• Rammer – 4.5 kg. weight with free fall of 45.7 cm
• Compacting Machine
• IS Sieves
MATERIALS:
The materials consist of:
• Coarse Aggregate
• Fine Aggregate
• Filler
• Bitumen

SPECIFICATION AS PER MORTH FOR DBM & BC
PHYSICAL REQUIREMENTS FOR COARSE AGGREGATE FOR BITUMINOUS

CONCRETE PAVEMENT LAYERS (BC)& DENSE GRADED BITUMINOUS MACADAM
PAVEMENT LAYERS (DBM)
Property Test Specification Specification
(BC) (DBM)
Cleanliness (dust) Grain size analysis1 Max. 5% passing Max. 5% passing
0.075mm sieve 0.075mm sieve
Particle shape Flakiness and Elongation Index Max. 30% (combined)2 Max. 30% (combined)2
Strength* Los Angeles Abrasion value3 Max. 30% Max. 35%
Aggregate Impact value4 Max. 24% Max. 27%
Polishing Polished stone value5 Min. 55 -
Durability Soundness:6
Sodium sulphate Max. 12% Max. 12%
Magnesium sulphate Max. 18% Max. 18%
Water absorption Water absorption7 Max. 2% Max. 2%
Stripping Coating and stripping of Minimum retained Minimum retained
Bitumen aggregate mixtures9 Coating 95% Coating 95%
Water sensitivity** Retained tensile strength8 Min. 80% Min. 80%
COMPOSITION OF DENSE GRADED BITUMINOUS MACADAM PAVEMENT LAYERS

(DBM) & BITUMENOUS CONCRETE PAVEMENT LAYER (BC)
DBM BC
Grading 1 2 1 2
Nominal aggregate size 40mm 25mm 40mm 25mm
Layer Thickness 80-100mm 50-75mm 80-100mm 50-75mm
IS sieve1 (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 95-100 100
26.5 63-93 90-100 100
19 - 71-95 79-100 100
13.2 55-75 56-80 59-79 79-100
9.5 - - 52-72 70-88
4.75 38-54 38-54 35-55 53-71
2.36 28-42 28-42 28-44 42-58
1.18 - - 20-34 34-48
0.6 - - 15-27 26-38
0.3 7-21 7-21 10-20 18-28
0.15 - - 5-13 12-20
0.075 2-8 2-8 2-8 4-10
Bitumen content % by mass of total mix2 Min 4.0 Min 4.5 5.0-6.0 5.0-7.0
Bitumen grade (pen) 65 or 90 65 or 90 65 65

REQUIREMENT FOR BITUMENOUS PAVEMENT LAYERS (BC) & DENSE

GRADED BITUMINOUS MACADAM (DBM)
BC DBM
0
Minimum stability(kn at 60 C) 9.0 9.0
Minimum flow (mm) 2 2
Maximum flow (mm) 4 4
Compaction level 75 blows on each of the 75 blows on each of the
(Number of blows) two faces of the specimen two faces of the specimen
Percent air voids 3-6 3-6
Percent voids in mineral
See Table Below See Table Below
aggregate (VMA)
Percent voids filled with
65-75 65-75
bitumen (VFB)
Loss of stability on immersion
Min. 75 percent retained
in water at 600C (ASTMD -
strength
1075)
MINIMUM PERCENT VOIDS IN MINERAL AGGREGATE (VMA)

Nominal Maximum Minimum VMA, per cent related to design air voids, per cent2
particle size1 (mm) 3.0 4.0 5.0
9.5 14 15 16
12.5 13 14 15
19.0 12 13 14
25.0 11 12 13
37.5 10 11 12
Fig . Phase diagram of a bituminous mix

Density and voids analysis

Basic properties of compacted bituminous mix
The compacted specimen of bitu + minous mix consists of mineral aggregate (coarse and
fine aggregate and mineral filler), bituminous binder and some air voids. The volumetric
composition of compacted bituminous mix is shown diagrammatically in Fig. The
volumes are represented as given below:
PROPERTIES OF THE MIX:

The properties that are of interest include the theoretical specific gravity Gt, the
bulk specific gravity of the mix Gm, percent air voids Vv, percent volume of bitumen Vb,
percent void in mixed aggregate VMA and percent voids filled with bitumen VFB. These
calculations are discussed next.
Fig 1. Marshall Test Setup

Theoretical specific gravity of the mix Gt
Theoretical specific gravity Gt is the specific gravity without considering air voids, and is
given by:
(1)
where, W1is the weight of coarse aggregate in the total mix, W2is the weight of fine
aggregate in the total mix, W3is the weight of filler in the total mix, Wbis the weight of
bitumen in the total mix, G1is the apparent specific gravity of coarse aggregate, G2is the
apparent specific gravity of fine aggregate, G3is the apparent specific gravity of filler and
Gbis the apparent specific gravity of bitumen,
Bulk specific gravity of mix Gm
The bulk specific gravity or the actual specific gravity of the mix Gmis the specific
gravity considering air voids and is found out by:
(2)
where, Wmis the weight of mix in air, Wwis the weight of mix in water, Note that Wm-Ww
gives the volume of the mix. Sometimes to get accurate bulk specific gravity, the
specimen is coated with thin film of paraffin wax, when weight is taken in the water.
This, however requires to consider the weight and volume of wax in the calculations.
Air voids percent Vv

Air voids Vv is the percent of air voids by volume in the specimen and is given by:
(3)
in %
Where Gt is the theoretical specific gravity of the mix, given by equation 26.1. and Gmis
the bulk or actual specific gravity of the mix given by equation 26.2.
Percent volume of bitumen Vb
The volume of bitumen Vbis the percent of volume of bitumen to the total volume and
given by:
(4)
OR
Vb = Gm * (Wb/Gb)

where, W1 is the weight of coarse aggregate in the total mix,W2 is the weight of fine
aggregate in the total mix,W3is the weight of filler in the total mix, Wb is the weight of
bitumen in the total mix, Gb is the apparent specific gravity of bitumen, and Gmis the bulk
specific gravity of mix given by equation 26.2.
Voids in mineral aggregate VMA
Voids in mineral aggregate VMA is the volume of voids in the aggregates, and is the sum
of air voids and volume of bitumen, and is calculated from
(5)
in %
where, Vv is the percent air voids in the mix, given by equation 26.3. and Vb is percent
bitumen content in the mix, given by equation 26.4. (4).
Voids filled with bitumen VFB
Voids filled with bitumen VFB is the voids in the mineral aggregate frame work filled
with the bitumen, and is calculated as:
(6)
where, Vb is percent bitumen content in the mix, given by equation 26.4. and VMA is the
percent voids in the mineral aggregate, given by equation 26.5.
PROCEDURE:
• Specimen preparation
Approximately 1200gm of aggregates and filler is heated to a temperature of 175-
190oC. Bitumen is heated to a temperature of 121-125oC with the first trial percentage of
bitumen (say 3.5 or 4% by weight of the mineral aggregates). The heated aggregates and
bitumen are thoroughly mixed at a temperature of 154-160oC. The mix is placed in a
preheated mould and compacted by a rammer with 50 blows on either side at temperature
of 138oC to 149oC. The weight of mixed aggregates taken for the preparation of the
specimen may be suitably altered to obtain a compacted thickness of 63.5+/-3 mm. Vary
the bitumen content in the next trial by +0:5% and repeat the above procedure. Numbers
of trials are predetermined. The prepared mould is loaded in the Marshall Test setup as
shown in the figure 1.
• Determine Marshall stability and flow

Marshall Stability of a test specimen is the maximum load required to produce
failure when the specimen is preheated to a prescribed temperature placed in a special test
head and the load is applied at a constant strain (5 cm per minute). While the stability test
is in progress dial gauge is used to measure the vertical deformation of the specimen. The

deformation at the failure point expressed in units of 0.25 mm is called the Marshall flow
value of the specimen.
• Apply stability correction
It is possible while making the specimen the thickness slightly vary from the
standard specification of 63.5 mm. Therefore, measured stability values need to be
corrected to those which would have been obtained if the specimens had been exactly
63.5 mm. This is done by multiplying each measured stability value by an appropriated
correlation factors as given in Table below:
Table 1. Correction factors for Marshall Stability values

Volume of specimen –cm3 Thickness of specimen(mm) Correction factor
457 -470 57.1 1.19
471 -482 68.7 1.14
483 -495 60.3 1.09
496 -508 61.9 1.04
509 -522 63.5 1.00
523 -535 65.1 0.96
536 -546 66.7 0.93
547 -559 68.3 0.89
560 -573 69.9 0.86
OBSERVATIONS AND CALCULATION:
BLENDING OF AGGREGATES for DBM OR BC
Seive size % Passing of aggregates – for different size Required
% of Agg.
45
37.5
26.5
19
13.2
9.5
4.75
2.36
1.18
0.6
0.3
0.15
0.075

Mix Proportion
Size of aggregate % of Aggregate Remarks
TRIAL 1
Bitumen % :________
Sr.
Parameter Specimen-1 Specimen-2 Specimen-3 Specimen-4
No.
1. Stability value
(kg.)
2. Flow value, 0.25
mm unit
PREPARE GRAPHICAL PLOTS:
The average value of the above properties is determined for each mix with
different bitumen content and the following graphical plots are prepared:
1. Binder content versus corrected Marshall Stability.
2. Binder content versus Marshall Flow.
3. Binder content versus percentage of void (Vv) in the total mix

4. Binder content versus voids filled with bitumen (VFB)
5. Binder content versus unit weight or bulk specific gravity (Gm).
Fig 3. Marshall Graphical Plots

DETERMINE OPTIMUM BITUMEN CONTENT:
Determine the optimum binder content for the mix design by taking average value
of the following three bitumen contents found form the graphs obtained in the previous
step.
1. Binder content corresponding to maximum stability
2. Binder content corresponding to maximum bulk specific gravity (Gm)
3. Binder content corresponding to the median of designed limits of percent air voids (Vv)
in the total mix (i.e. 4%)
The stability value, flow value, and VFB are checked with Marshall mix design
specification chart given in Table below.
CALCULATIONS:
CONCLUSION:
(Faculty Advisor)
Date:

Comparison table of bitumen test
Name of test
Specification Viscosity Flash & fire Specific
Penetration Ductility Softening point
Absolute Kinematic point gravity
Hardness Temperature at
Affecting on Resistant to Resistant to Hazardous
Measure 1/10 tn on which bitumen Quality
bitumen with flow flow temp.
penetration soften
Test temp. 25 C° 27 C° 60 C° 135 C° - - 27 C°
Viscosity bath + Viscosity bath +

Ductility Ring & ball Pensky Specific gravity
Instrument Penetrometer Canon manning Canon manning
martens
machine apparatus bottle
tube tube
Needle 1 9.5 mm dia.

Briquette area-1
sq.m mm. 2.5g ± 0.05gm
Brief cm2
100 gm wt.
Rate -50
Canon manning tube wt. of ball - -
specification Penetration Start heating
for 5 sec mm/min rate
from 5°C

SECTION-E
DESIGN OF CONCRETE MIX FOR PAVEMENT

DESIGN OF CONCRETE MIX FOR PQC (IRC:44-1976)
EXAMPLE – 1 IILLUSTRATIVE EXAMPLE ON CONCRETE MIX

PROPORTIONING
C-0 An example illustrating the mix proportioning for a concrete of M40 grade is given
below.
C-l STIPULATIONS FOR PROPORTIONING
(a) Grade designation M40
(b) Type of cement OPC 43 grade conforming to 18:8112
(c) Maximum nominal size of aggregate 20mm
(d) Minimum cement content 325 kg/m3
(e) Maximum water-cement ratio 0.50
(f) Workability 20 ± 5 mm (slump)
(g) Degree of supervision Good
(h) Type of aggregate Crushed angular aggregate
(i) Maximum cement content 425 kg/m3
g) Chemical admixture type Super plasticizer
C-2 TEST DATA FOR MATERIALS

(a) Cement used OPC 43 grade conforming to IS:8112
(c) Specific gravity
Cement 3.15
Coarse aggregate 2.74
Fine aggregate
2.62
(d) Water absorption
(1) Coarse aggregate 0.5 per cent
(2) Fine aggregate
1.0 per cent
(d) Free (surface) moisture
(I) Coarse aggregate Nil (absorbed moisture also nil)
(2) Fine aggregate
Nil

(e) Sieve Analysis of Coarse Percentage

analysis Aggregate passing for
Fraction, % Percentage Passing of Different graded 1"
IS Sieve Passing Fractions aggregate
sizes as per
(1)Coarse mm Table I
aggregate I II I II Combined
20 to 10 10mm 60 40 100
down Percent Percent Percent
20 100.00 100.00 60.00 40.00 100.00 95-100
10 2.80 78.30 1.68 31.30 32.98 25-55
(2)Fine 4.75 Nil 8.70 - 3.48 3.48 0-10
aggregate Conforming to grading Zone II of Table 2
C-3 DESIGN COMPRESSIVE STRENGTH FOR MIX PROPORTIONING

f'ck= fck+ 1.65 x s
Where, f'ck = target average compressive strength, N/mm2 at 28 days.
fck = characteristic compressive strength, N/mm2 at 28 days.
s = standard deviation, N/mm2
Table 3. Assumed Standard Deviation (IRC:44-2008)
Sr. No. Grade of Concrete Assumed Standard Deviation (N/mm2)
1 M25 4.0
2 M30
3 M35
4 M40
5 M45 5.0
6 M50
7 M55
8 M60
From Table 3, Standard Deviation = 5.0 N/mm2

Therefore, design compressive strength = 40 + 1.65 x 5.0 = 48.25 N/mm2
Design flexural strength using IS: 456 relationships = 4.86 N/mm2
C-4 SELECTION OFWATER-CEMENT RATIO
Table No.4 Preliminary Selection of Water-Cement Ratio for the Given Grade (IRC:44-2008)
Sr. No. Grade of Concrete Approximate Water/cement ratio
1 M25 0.50
2 M30 0.45
3 M35 0.42
4 M40 0.38
5 M50 0.34
6 M60 0.28

From Table 4, preliminary water-cement ratio = 0.38

0.38 < 0.50, hence OK.
C-5 SELECTION OFWATER CONTENT
Table 5. Approximate Water Content per Cubic Meter of Concrete for Nominal Maximum
Size of Aggregate (without Plasticizer/Super plasticizer) (IRC:44-2008)
Nominal Maximum Size of Aggregate (mm) Suggestive water content (kg)
20 208
10 186
40 165
From Table 5, water content for 20 mm aggregate = 186 kg/m3 at W/C = 0.5
As super plasticizer is proposed to be used, the water content can be reduced maximum
up to 30%. For the purpose of present trial exercise, a reduction of water content of 15%
has been assumed by adjusting suitably the doses of the super plasticizer. The designer
can use this reduction as per his requirement of the availability of the grade of cement and
quality of super plasticizer. With 15% reduction in water content at water-cement ratio
of0.38, the reduced water content equals to186 x 0.85=158.1 kg, say 158 kg.
C-6 CALCULATION OF CEMENT CONTENT

Water-cement ratio = 0.38
Water content = 158 kg/m3
Cement content = 158/0.38 = 415.80 kg/rn3, say 416.0 kg/rn3
Check for minimum and maximum cement content as per IRC: 15
Minimum cement content as per IRC: 15,325 kg/m3<416 kg/m3 Hence, OK
Maximum cement content as per IRC: 15,425 kg/m3>416 kg/m3 Hence, OK
C-7 PROPORTIONOFVOLUMEOFCOARSEAGGREGATEAND
FINEAGGREGATE
Table No.6 Volume of Coarse Aggregate Per Unit Volume of Total Aggregate for
Different Zones of Fine Aggregate as per IS:383 (IRC:44-2008)
Nominal Maximum Volume of Coarse Aggregate Per Unit Volume of Total Aggregate
Size of Aggregate for Different Zones of Fine Aggregate
(mm) Zone IV Zone III Zone II Zone I
10 0.50 0.48 0.46 0.44
20 0.66 0.64 0.62 0.60
40 0.75 0.73 0.71 0.69
From Table 6, volume of coarse aggregate corresponding to 20 mm size aggregate and

fine aggregate grading Zone II == 0.62 per unit volume of total aggregate. This is valid
for water-cement ratio of0.50. As water-cement ratio is actually 0.38, the ratio is taken as
0.64 to reduce sand content (as per Note 3 of Table 6).
Volume of fine aggregate content = 1 - 0.64 = 0.36perunit volume of total aggregate

C-8 MIX CALCULATIONS

(a) Volume of concrete = 1 m3
(b)Volume of cement = (Mass of cement/Specific gravity of
cement) x (1/1000)
= (416/3.15) x (1/1000)
= 0.132 m3
(c)Volume of water = (Mass of water/Specific gravity of water) x
(l/100)
= (158/1) x (1/1000)
= 0.158 m3
(d)Volume of chemical =(Mass admixture/Specific gravity of
admixture (super plasticizer) admixture) x (1/1000)
[@ 0.6% by mass of cementations material] = (2.50/1.2) x (111000)
=0.002 m3
(e)Volume of all in aggregate = {a - (b+c+d)}
= {1-(0.132+0.158+0.002)}
= 0.708 m3
(f) Mass of coarse aggregate = (e) x 0.64 x Specific gravity of coarse
aggregate x 1000
= 0.708 x 0.64 x 2.74 x 1000
= 1241.5 Say 1242 kg/m3
(g) Mass of fine aggregate =(e) x 0.36 x Specific gravity of fine
aggregate x 1000
= 0.708 x 0.36 x 2.62 x 1000
= 667.8 Say 668 kg/m3
C-9.1 MIX PROPORTIONS FOR TRIAL NUMBER 1 BASED ON AGGREGATE

IN SSD CONDITION
Cement = 416 kg/m3

Water = 158 kg/rrr3
Fine Aggregate = 668 kg/m3
Coarse Aggregate = 1242 kg/m3
Chemical Admixture = 2.50 kg/rm3

IN DRY CONDITION
Cement = 416 kg/m3
Water =158+6.68+6.21 =170.9 kg/ m3
Chemical Admixture = 2.50 kg/ m3
Fine Aggregate = 661.3 kg (668-1 % of 668)
Coarse Aggregate = 1235.8 kg (1242-0.5% of 1242)

C-10 The slump shall be measured and the water content and dosage of admixture shall
be adjusted for achieving the required slump based on trial, if required. The mix
proportions shall be reworked for the actual water content and checked for
durability requirements.
C-11 Two more trials having variation of ±10percentofwater-cementratio in C-10 shall

be carried out and a graph between three water-cement ratios and their
corresponding strengths shall be plotted to work out the mix proportions for the
given target strength for field trials. However, minimum arid maximum cement
content requirements should be met.
C-12 Adjustment due to higher slump requirements for use of RMC can be made as
follows:
Based on initial trials, it has been established that for expected 1 hour transit time
initial slump requirement is 100 mm for 20 mm slump at the time of placement.
Based on trials dosage of admixture may be increased from 0.6 per cent to 1.0 per cent by
mass of cement to achieve required workability (accordingly all other calculations can be
modified).
C-13 IN CASE IT IS PROPOSED TO USE FLY ASH IN THE CONCRETE
C-13.1 CALCULATION OF CEMENT AND FLYASH CONTENTS

Cement content 158/0.38 = 416 kg/m3
Now, to proportion a mix containing fly ash the following steps are suggested:
(i) Decide percentage of fly ash to be used based on project requirement and quality of
materials
(ii) *Increase the cementitious material content by 10% of total cementitious material
content of control mix calculated as above, to account for fly ash reactivity.
Cementitious material content = 416 x 1.10 = 457.6 kg/m3, say 458 kg/m3
* In certain situations increase in cementitious material content may be warranted. The

decision on increase in cementitious material and its percentage may be based on
experience and trial. This illustrative example is with increase of 10 per cent cementitious
material content.
Water Content = 158 kg/m3
So, water-cementitious material ratio = 158/458 = 0.345
Fly ash @ 20 per cent of total cementitious content = 458 x 20%
= 91.6 kg/m3
Say = 92 kg/m3
Cement (OPC) = 458 - 92 = 366 kg/m3
Check for maximum cement content Maximum cement (OPC) content as per IRC: 15,425
kg/m3> 366 kg/m3 Hence, OK

3 3 3
Check for minimum cementitious content, 325kg/m <458kg/m (366kg/m OPC+ 92
kg/m3 fly ash) Hence, OK
C-13.2 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE

AGGREGATE CONTENT

fine aggregate Zone II= 0.62 per unit volume of 'total aggregate. This is valid for water-
cement ratio of 0.50. As water-cement ratio is actually 0.345, the ratio is taken as 0.65 to
reduce sand content.
Volume of fine aggregate content =1-0.65=0.35per unit volume of total aggregate
C-13.3 MIX CALCULATIONS

(a) Volume of concrete = 1m3
(b) Volume of cement = (Mass of cement/Specific gravity of
cement) x (1/1000)
=(366/3.15)x 1/1000
3
=0.1l6m
(c) Volume of fly ash = (Mass of fly ash/Specific gravity of fly
ash) x1/1000
= (92/2.2) x 1/1000
= 0.042 m3
(d) Volume of water = (Mass of water/Specific gravity of water)
x 1/1000
= (158/1) x 1/1000
= 0.158 m3
(e) Volume of chemical = (Mass of chemical admixture/Specific
[@ 0.8% by Mass of gravity of admixture(super plasticizer)
cementitious material] admixture) x (l/1000)
= (3.66/1.2) x 1/1000
= 0.003 m3
(f) Volume of all-in aggregate = {a-(b+c+d+e)}
= {1-(0.116+0.042+0.158+0.003)
= 0.681 m3
(g) Mass of coarse aggregate = (f) x volume of coarse aggregate x
Specific gravity of coarse aggregate x 1000
= 0.681 x 0.65 x 2.74 x 1000
= 1212.9 Say 1213 kg/m3
(h) Mass of fine aggregate = (f) x volume of fine aggregate x Specific
gravity of fine aggregate x 1000
= 0.681 x 0.35 x 2.62 x 1000
= 624.5 Say 625 kg/rn3

C-13.4.1 MIX PROPORTIONS FOR TRIAL NUMBER 1 ON AGGREGATE IN

(SATURATED SURFACE DRY) SSD CONDITION
Cement = 366 kg/m3

Fly Ash = 92 kg/ m3
Water = 158 kg/ m3
Fine Aggregate =625 kg/ m3
Coarse Aggregate = 1213 kg/ m3
Chemical Admixture = 3.66 kg/ m3
Water-cementitious material ratio = 0.345

DRY CONDITION
Cement = 366 kg/m3

Fly Ash = 92 kg/ m3
Water = 158+6.3+6.1 = 170.4 kg
Fine Aggregate =618.7 kg/m3 (625-1% of 625)
Coarse Aggregate =1206.9 kg/m3 (1213-0.5% of 1213)
Chemical Admixture = 3.66 kg/rn3
Water-cementitious material ratio = 0.345
All other steps will remain same as C-10 to C-12.
EXAMPLE -2 IILLUSTRATIVE EXAMPLE ON CONCRETE MIX

PROPORTIONING
C-0 An example illustrating the mix proportioning for a concrete of M30 grade is given
below.
C-l STIPULATIONS FOR PROPORTIONING
(a) Grade designation M30
(b) Type of cement
(c) Maximum nominal size of aggregate
(d) .Minimum cement content
(e) Maximum water-cement ratio
(f) Workability
(g) Degree of supervision
(h) Type of aggregate
(i) Maximum cement content
g) Chemical admixture type

C-2 TEST DATA FOR MATERIALS

(a) Cement use OPC 43 grade conforming to IS:8112
(e) Specific gravity
Cement
Coarse aggregate
Fine aggregate
(f) Water absorption
(1) Coarse aggregate
(2) Fine aggregate
(d) Free (surface) moisture
(I) Coarse aggregate
(2) Fine aggregate
(e) Sieve Analysis of Percentage
analysis Coarse Aggregate passing for
Fraction, % Percentage Passing of Different graded 1"
IS Passing Fractions aggregate as
Sieve per Table I
(1)Coarse sizes I II I II Combined
aggregate mm 20 to 10 10mm 60 40 100
down Percent Percent Percent
20
10
4.75
(2)Fine Conforming to grading Zone II of Table 2

aggregate
C-3 DESIGN COMPRESSIVE STRENGTH FOR MIX PROPORTIONING

f'ck= fck+ 1.65 x s
Where, f'ck = target average compressive strength, N/mm2 at 28 days.
fck = characteristic compressive strength, N/mm2 at 28 days.
s = standard deviation, N/mm2
From Table 3, Standard Deviation = 5.0 N/mm2
Therefore, design compressive strength = ……. + 1.65 x 5.0 = ……N/mm2
Design flexural strength using IS: 456 relationships = ……… N/mm2
C-4 SELECTION OFWATER-CEMENT RATIO

From Table 4, preliminary water-cement ratio = ……..
…….. < 0.50, hence OK.
C-5 SELECTION OFWATER CONTENT
From Table 5, water content for 20 mm aggregate = …….. kg/m3 at W/C = ……..
As super plasticizer is proposed to be used, the water content can be reduced maximum
up to 30%. For the purpose of present trial exercise, a reduction of water content of 15%

has been assumed by adjusting suitably the doses of the super plasticizer. The designer
can use this reduction as per his requirement of the availability of the grade of cement and
quality of super plasticizer. With 15% reduction in water content at water-cement ratio of
……, the reduced water content equals to 186 x…..=…….. kg.
C-6 CALCULATION OF CEMENT CONTENT
Water-cement ratio =……
Water content = ……. kg/m3
Cement content =………. kg/rn3
Check for minimum and maximum cement content as per IRC: 15
Minimum cement content as per IRC: 15, 325 kg/m3<416 kg/m3 Hence, OK
Maximum cement content as per IRC: 15,425 kg/m3>416 kg/m3 Hence, OK
C-7 PROPORTIONOFVOLUMEOFCOARSEAGGREGATEAND
FINEAGGREGATE
fine aggregate grading Zone…….. per unit volume of total aggregate. This is valid for
water-cement ratio of …... As water-cement ratio is actually ……,the ratio is taken as
…….. to reduce sand content (as per Note 3 of Table 6).
Volume of fine aggregate content = 1-…… = ……. Per unit volume of total
aggregate
C-8 MIX CALCULATIONS

(a) Volume of concrete = 1 m3
(b)Volume of cement = (Mass of cement/Specific gravity of
cement) x (1/1000)
= (………/…….) x (1/1000)
= ……… m3
(c)Volume of water = (Mass of water/Specific gravity of water) x
(l/100)
= (……/……) x (1/1000)
= ……. m3
(d)Volume of chemical =(Mass admixture/Specific gravity of
admixture (super plasticizer) admixture) x (1/1000)
[@ 0.6% by mass of cementations material] = (……/…..) x (1/1000)
=……… m3
(e)Volume of all in aggregate = {a - (b+c+d)}
= {1-(………+……..+……)}
= …….. m3
(f) Mass of coarse aggregate = (e) x ……. x Specific gravity of coarse
aggregate x 1000
= ……… x ……… x ……. x 1000
= ……. Say …….. kg/m3
(g) Mass of fine aggregate =(e) x ……. x Specific gravity of fine

aggregate x 1000
= ……. x ……. x ……. x 1000
= …….. Say…….. kg/m3

IN SSD CONDITION
Cement = …….. kg/m3

Water = ……… kg/m3
Fine Aggregate = …….. kg/m3
Coarse Aggregate = ……… kg/m3
Chemical Admixture = ………. kg/rm3
Water-cement ratio = ……….

IN DRY CONDITION
Cement = ……… kg/m3
Water =………. kg/ m3
Chemical Admixture = …….. kg/ m3
Fine Aggregate = ……. kg
Coarse Aggregate = ……. kg
C-10 The slump shall be measured and the water content and dosage of admixture shall
be adjusted for achieving the required slump based on trial, if required. The mix
proportions shall be reworked for the actual water content and checked for
durability requirements.
C-11 Two more trials having variation of ± 10 percent of water-cement ratio in C-10
shall be carried out and a graph between three water-cement ratios and their
corresponding strengths shall be plotted to work out the mix proportions for the
given target strength for field trials. However, minimum arid maximum cement
content requirements should be met.
C-12 Adjustment due to higher slump requirements for use of RMC can be made as
follows:
Based on initial trials, it has been established that for expected 1 hour transit time initial
slump requirement is 100 mm for 20 mm slump at the time of placement.
Based on trials dosage of admixture may be increased from 0.6 per cent to 1.0 per cent
by mass of cement to achieve required workability (accordingly all other calculations
can be modified).

C-13 IN CASE IT IS PROPOSED TO USE FLY ASH IN THE CONCRETE
C-13.1 CALCULATION OF CEMENT AND FLYASH CONTENTS

Water-cement ratio = …….
Cement content = ……… kg/m3
Now, to proportion a mix containing fly ash the following. steps are suggested:
(i) Decide percentage of fly ash to be used based on project requirement and quality of
materials.
(ii) *Increase the cementitious material content by 10% of total cementitious material
content of control mix calculated as above, to account for fly ash reactivity.
Cementitious material content = ………..kg/m3
* In certain situations increase in cementitious material content may be warranted. The
decision on increase in cementitious material and its percentage may be based on
experience and trial. This illustrative example is with increase of 10 per cent cementitious
material content.
Water Content == ……… kg/m3
So, water-cementitious material ratio = …………
Fly ash @ 20 per cent of total cementitious content = …….kg/m3
Cement (OPC) = ………..kg/m3
Check for maximum cement content Maximum cement (OPC) content as per IRC: 15,425
kg/m3> ……… kg/m' Hence, OK
3 3 3
Check for minimum cementitious content, ………kg/m <458kg/m (366kg/m OPC+ 92
kg/m3 fly ash) Hence, OK
C-13.2 PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE

AGGREGATE CONTENT

fine aggregate Zone ………= …….per unit volume of 'total aggregate. This is valid for
water-cement ratio of …….. As water-cement ratio is actually ……., the ratio is taken as
…….. to reduce sand content.
Volume of fine aggregate content =1-……. = ……… per unit volume of total aggregate
C-13.3 MIX CALCULATIONS
(a) Volume of concrete = 1m3

(b) Volume of cement = (Mass of cement/Specific gravity of
cement) x (1/1000)
=(……../……)x 1/1000
3
= ……..m
(c) Volume of fly ash = (Mass of fly ash/Specific gravity of fly
ash) x1/1000
= (……./……) x 1/1000
= ……. m3

(d) Volume of water = (Mass of water/Specific gravity of water)

x 1/1000
= (……./…..) x 1/1000
= …….. m3
(e) Volume of chemical = (Mass of chemical admixture/Specific
[@ 0.8% by Mass of gravity of admixture(super plasticizer)
cementitious material] admixture) x (l/1000)
= (……../…….) x 1/1000
= ……… m3
(f) Volume of all-in aggregate = {a-(b+c+d+e)}
= {1- (……..+……..+………+………)
= …….. m3
(g) Mass of coarse aggregate = (f) x volume of coarse aggregate x
Specific gravity of coarse aggregate x 1000
= ……. x ……. x …… x 1000
= ……… Say ……. kg/m3
(h) Mass of fine aggregate = (f) x volume of fine aggregate x Specific
gravity of fine aggregate x 1000
= …….. x ……. x …….. x 1000
= ……. Say ……. kg/rn3

(SATURATED SURFACE DRY) SSD CONDITION
Cement = ……. kg/m3
Fly Ash = …….. kg/ m3
Water =…….kg/ m3
Fine Aggregate =……. kg/ m3
Coarse Aggregate = …….. kg/ m3
Chemical Admixture = ………kg/ m3
Water-cementitious material ratio = ……..
DRY CONDITION
Cement = ……. kg/m3
Fly Ash = ……. kg/ m3
Water = ………kg
Fine Aggregate =……… kg/ m3
Coarse Aggregate =………..kg/m3
Chemical Admixture = ………..kg/rn3
Water-cementitious material ratio = ……….
All other steps will remain same as C-10 to C-12.
(Faculty Advisor)
Date:

SECTION-F
A STUDY ON TRAFFIC PARAMETERS
SECTION-F- A STUDY ON TRAFFIC PARAMETERS

22 Spot speed study (IRC:SP:19-2001)
23 Traffic Volume Study (IRC:SP:19-2001)
24 Accident Study (IRC:SP:19-2001)

Dimension
Weight STATIC
Max. Turning angle
Speed
Accleration
Braking System DYNAMIC
VEHICULAR
Lighting system
CHARACTRISTICS
Tyres
Vision
Hearing Permanent
Strength
PHYSICAL
Fatigue CHARACTRISTIC
Alcohol Temporary S
Illness
Department of Civil Engineering
Knowledge
Skill MENTAL
Intelligence CHARACTRISTIC
Experience S
Literacy
Attentiveness
Fear PSYCHOLOGICA
TRAFFIC CHARACTRISTICS
Anger L
Superstition CHARACTRISTIC
Darshan Institute of Engineering and Technology-Rajkot

S
Traffic stream ENVIRONMENTA
ROAD USER CHARACTRISTICS
L
Facilities to traffic atmospheric
CHARACTRISTIC
S
TRAFFIC VOLUME
Semester-V
ORIGIN AND DESTINATION STUCDY

TRAFFIC FLOW CHARACTRISTICS
TRAFFIC CAPACITY STUDY
Spot speed study TRAFFIC
SPEED
Speed and Delay study
STUDY
On street parking PARKING
AND ANALYSYS
Off street parking STUDY

TRAFFIC ENGINEERING -SCOPE OF STUDY
TRAFFIC STUDIES
ACCIDENT STUDY
TRAFFIC OPERATION AND CONTROL DESIGN
PLANNING AND ANALYSYS
GEOMETRIC DESIGN*
ADMINISTRATION AND MANAGEMENT

Highway Engineering Lab Manual
Page 120
SPOT SPEED STUDY (IRC:SP:19-2001)
General:
Spot speed is referred to as the instantaneous speed of a vehicle at a point or cross
section; however there are two distinctly different methods of determination of spot
speeds. In the first method, the time , t (sec) taken by the vehicle to travel a short distance,
d(m) is determined. There for the speed, v= (d/t) m/sec. In the case second method, the
instantaneous speed is measured by a pre-calibrated ‘radar’ equipment which displays or
records the speed in desired units, such as kmph.
In view of these two methods, there are two definitions for the average of a series of spot
speed measurement viz. ‘space-mean speed’ and ‘time-mean speed’.
Space-mean speed represents the average speed of vehicles in a certain road length at any
time. This is obtained from the observed travel time of the vehicles over a stretch of the
road. Space-mean speed is calculated from the relation:
Vs = ∑3.6𝑑
𝑛
𝑛
𝑡𝑖
𝑖=1
Where,
Vs = space-mean speed, kmph
d = length of road or the distance considered, m
n = number of individual vehicle observations
ti = observed travel time, (sec) for ith vehicle to travel the distance d, m
the average travel time of all vehicle is obtained from the reciprocal of space-mean speed.
Time-mean speed represent the speed distribution of vehicle at a point on the roadway
and it is the average of instantaneous of observed vehicles at the spot. Time-mean speed
is calculated from the relation:
∑𝑛
𝑖=𝑙 𝑉𝑖
Vt = 𝑛
Where,
Vt = time-mean speed
Vi = observed instantaneous speed of ith vehicle, kmph
n = number of vehicles observed
The space-mean speed is slightly lower than tome-mean speed under typical speed
condition on rural highways.

Frequency distribution and cumulative frequency diagram of spot speeds
Aim
Apparatus
Procedure

Observations and calculations
Result
Discussion of the result
(Faculty Advisor)
Date:

SPOT SPEED STUDY

NAME OF ROAD : TYPE OF ROAD: DATE:
DIRECTION : REF. DISTANCE: m TIME:
TIME TAKEN TO COVER REF. DISTANCE

Sr
2W 3W 4W BUS LCV/HCV NMT BICYCLE
No.
Time Speed Time Speed Time Speed Time Speed Time Speed Time Speed Time Speed
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
NAME OF ENUMERATOR: SIGNATURE:

Darshan Institute of Engineering and Technology-Rajkot

CIVIL ENGINEERING DEPARTMENT
Highway Engineering
SPOT SPEED STUDY
NAME OF ROAD : TYPE OF ROAD: DATE:
DIRECTION : REF. DISTANCE: m TIME:
TIME TAKEN TO COVER REF. DISTANCE

Sr
2W 3W 4W BUS LCV/HCV NMT BICYCLE
No.
Time Speed Time Speed Time Speed Time Speed Time Speed Time Speed Time Speed
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
NAME OF ENUMERATOR: SIGNATURE:

TRAFFIC VOLUME STUDY (IRC:SP:19-2001)

Definition: Traffic volume is a measure to quantify the traffic flow. Traffic volume or
traffic flow is expressed as the number of vehicles that pass across a given transverse
line of the road during unit time. As the carriageway width of the roads may vary, the
traffic volume is generally expressed as number of vehicles per hour or per day, per
traffic lane.
Measurement Unit: PCU, Vehicle/hr and Vehicle per day
Aim
Apparatus
Procedure

Result
(Faculty Advisor)
Date:

ACCIDENT STUDY (IRC:SP:19-2001)
Aim
Apparatus
Procedure

COLLISION DIAGRAM

CONDITION DIAGRAM
Result
(Faculty Advisor)
Date:

SECTION-G
HIGHWAY GEOMETRIC DESIGN- STUDY MATERIAL
Highway Geometric Design (Study Material) (IRC:73,86-2015)

HIGHWAY GEOMETRIC DESIGN ELEMENTS

(FIVE ELEMENTS)
1 2 3 4 5
CROSS SECTION SIGHT HORIZONTAL VERTICAL INTERSECTION

ELEMENTS DISTANCE ALIGNMENT ALIGNMENT ELEMENTS
❖ Pavement ❖ Stopping ❖ Horizontal • Gradien ❖ Intersection
surface sight curve t at grade
characterist distance
ic (SSD)
→ Friction ❖ PIEV ❖ Super • Summit 1. Unchannelize
(Skid and theory elevation curve
Slip)
→ Pavement ❖ Overtaking ❖ Widening • Valley 2. Channelize
unevenness sight of curve
distance pavement
(OSD)
→ Light ❖ Sight ❖ Horizontal 3. Rotary
reflecting distance at transition intersection
characteristi intersection curve
c
❖ Camber / ❖ Set-back ❖ Grade
Cross slope distance on separated
horizontal intersection
curve
❖ Carriage ❖ Curve
way resistance
❖ Median
❖ Kerb
❖ Road
margin
❖ ROW
❖ Formation
width

HIGHWAY GEOMETRIC DESIGN - STUDY MATERIAL
HIGHWAY GEOMETRIC DESIGN (STUDY MATERIAL) (IRC:73,86-2015)
Highway Geometric Design

❖ Elements Of HGD (GTU Dec. 2010)
1) Cross-section Elements
2) Sight Distance Consideration
3) Horizontal Alignment Details
4) Vertical Alignment Details
❖ Factor Affecting HGD

1) Design Speed
2) Topography
3) Traffic Factors
4) Design Hourly Volume & Capacity
5) Environmental Factors
❖ Topography Classification
➢ Based on the cross slope of the country, the terrains are classified as under:
Terrain Classification Cross slope of the country (%)
PLAIN 0-10%
ROLLING 10-25%
MONTAINOUS 25-60%
STEEP >60%
❖ Cross-section Elements Of Road
1) Carriage Way
2) Formation Width
3) Right Of Way
4) Road Shoulders
5) Side Slope
6) BERM
7) Boundary Stone
8) Side Drain
9) Building Line (B.L)
10) Control Line(C.L.)
11) Spoil Bank
12) Borrow Pits

13) Krebs (Low, semi-barrier, barrier)

14) Pavement Surface Characteristics
(i) Friction (ii) Unevenness of Pavement (iii) Light Reflecting Characteristics
❖ Cross-Section Of Roads As Per IRC: (JUNE 2011)
1) C/S Of NH Or SH In Rural Area In Embankment:
2) C/S Of MDR In Rural Area In Embankment:
3) C/S Of Divided Highway In Urban Area:
❖ Difference Of SKID & SLIP

SKID SLIP
It occurs when the wheels of the vehicle slide It occurs when a wheel revolves more than
without revolving the corresponding longitudinal distance along
OR the roads
When the wheels partially revolve
Distance travelled is greater than the Distance travelled is less than the
circumferential moment of the wheel circumferential movement of the vehicle

❖ CAMBER
➢ CAMBER is the slope provided to the road surface in the transverse direction to
drain off the rain water from the road surface
➢ CAMBER can be provided in three ways:
(1) Parabolic Camber (2) Straight Camber
(3) Combination Of Straight & Parabolic
Camber
❖ CAMBER For Different Road Surface

Sr. No. Types Of Road surface Range of CAMER in Area
of Rainfall Range
HIGH to LOW
1 Cement Concrete/High type
bituminous surface 1 in 50 (2%) 1 in 60 ( 1.7%)
2 Thin Bituminous surface 1 in 40
1 in 50( 2 %)
(2.5%)
3 Water Bound Macadam
(WBM)/ Gravel pavement 1 in 33 (3%) 1 in 40( 2.5%)
4 Earth
1 in 25 (4%) 1 in 33 ( 3.0%)

❖ Stopping Sight Distance (SSD)

SSD = Lag Distance + Breaking Distance
❖ Factors Affecting SSD
1) Speed Of Vehicle
2) Efficiency Of Break
3) Total Reaction Time Of Driver
4) Frictional Resistance betn The Road & Tyres
5) Gradient of The Road
❖ PIEV Theory : (GTU Dec. 2010)

➢ According to PIEV theory the total reaction time of the driver is split into four
parts
I. Perception Time
II. Intellection Time
III. Emotion time
IV. Volition time

❖ Stopping Sight Distance (SSD)

SSD = Lag Distance + Breaking Distance
v2
SSD = 0.278vt + ( In kmph)
254f
v2
SSD = vt + ( In m⁄sec)
2gf
❖ Break Efficiency When Given:

v2
SSD = vt + (In m⁄sec)
2g(f × Break efficiency in fraction)
v2
SSD = 0.278vt + (In kmph)
254(f × Break efficiency in fraction)
❖ SSD:
1) When road is with ascending gradient
v2
SSD = vt + n
(In m⁄sec)
2g (f + 100)
2) When road is with descending gradient
v2
SSD = vt + n
(In m⁄sec)
2g (f − 100)
1) For One Way Traffic:
SSD = SSD × 2
2) For A Two Way Traffic On A Single Lane Road:
SSD = 2 × SSD
3) For Two Way Traffic On A Two Lane Road:
SSD = 1 × SSD
❖ Overtaking Sight Distance (OSD):

➢ The minimum distance open to the vision of the driver of a vehicle intending to
overtake slow vehicle ahead with safety against the traffic of opposite direction is
known as the OSD.

OSD = d1+d2+d3
➢ What is d1 , d2 & d3 we see ahead.
d1 = Vb t Where, b = Vb T
b = distance travelled by slow moving vehicle B.
S = 0.7Vb + 6
d2 = b + 2S S = Spacing of vehicle
4S
= Vb T + 2S T=√
a
d3 = V. T (V > Vb )V = Speed Of Overtaking Vehicle
T = Overtaking time
t = Reaction time (sec)
a = Acceleration of overtaking vehicle
Vb= Speed of slow vehicle B (m/s)
OSD = d1 + d2 + d3
OSD = Vb . t + (Vb . T + 2S) + V. T

➢ As per IRC, minimum length of OSD = 3 × OSD
➢ As per IRC, desirable length of OSD = 5 × OSD
❖ Design Speed:
➢ The maximum safe speed of vehicles used for highway geometric design is known
as DESIGN SPEED.
➢ Factors affecting design speed are:
1) Class Of Road
2) Class Of Terrain
3) Curves On The Road

4) Type Of Road Surface

5) Intensity And Nature Of Traffic
6) Condition Of Road Surface
Types Design Speed in kmph for various terrains

Sr. of PLAIN ROLLING MOUNTAINOUS STEEP
No. Roads Ruling Min. Ruling Min. Ruling Min. Ruling Min.
1 NH OR SH 100 80 80 65 50 40 40 30
2 MDR 80 65 65 50 40 30 30 20
3 ODR 65 50 50 40 30 25 25 20
4 VR 50 40 40 35 25 20 25 20
❖ SUPERELEVATION:
➢ The amount by which the outer edge of the road surface is raised is known as
super elevation or cant or banking.

Rotating About Center Line Rotating About The Inner Edge
❖ FORMULA FOR SUPERELEVATION:

v2
e+f= Where, e = tan θ
gR
= Rate of super elevation
2
V
e+f= f
127R
= design lateral friction co − efficient
= 0.15
➢ If f = 0 then
v2
e= v = speed of vehicle m⁄sec
gR
R = Radius of horizontal curve (m)
➢ When e=0
v2
f= V = speed of vehicle in kmph
gR
v = √fgR g = 9.8 m⁄s 2
➢ As per IRC, e should not exceed 0.067 ≅0.07 or 6.7%.
➢ The value of f should not exceed 0.15.
❖ ADVANTAGE OF SUPER ELEVATION:

➢ Transportation made safely on the road.
➢ Vehicle can traverse the horizontal curve with more speed.
➢ Traffic volume is increased.
➢ The maintenance of road on curved is decreased.
There is no need to construct drain at the outer edge of the road & water drain off the
road surface quickly.

❖ TRANSITION CURVE:
It is a curve which is provided betn straight and circular curve or between two
compound curves or between two reverse curves.
❖ OBJECTIVES OF TRANSITION CURVE:
TRANSITION CURVE
Objectives Of TRANSITION
CURVE:
1. To enable gradual introduction of
the designed Super elevation.
2. To enable gradual introduction of
the extra winding of pavement.
3. To introduce gradually the
centrifugal force between the
tangent point & the beginning of
the circular curve, avoiding a
sudden jerk on the vehicle.
4. To improve the aesthetic
appearance of road.
5. To prevent the possibility of
overturning of vehicles on
horizontal curves.
6. There is no need to decrease the
speed of the vehicle entering the
curve.
❖ Requirements Of TRANSITION CURVE:

1) The radius of transition curve should gradually decrease from infinite at the point
of tangency (T.P.) to the radius of curve (R) near the circular curve.
2) The rate of increase of curvature should be equal to the rate of increase of super
elevation.
3) The length of transition curve (Ls) should be such that full super elevation is
obtained where transition curve meet the circular curve.

4) The length of transition curve should be inversely proportion to the radius of the
curve
1
LS ∝ R LS . R = Constant
❖ Length Of TRANSITION CURVE:

➢ The length of the transition curve is designed to fulfill three condition :
1) The rate of change of centrifugal acceleration should be developed gradually:
0.0215v 3
Ls = Ls = LengthOfTransitionCurve(m)
CR
v = SpeedOFvehicle(kmph)
R = RadiusOfCircularCurve(m)
➢ The min. & max. value of C are limited to 0.5 & 0.8 respectively.
80
C= m⁄sec 3
75 + V
2) The Rate of change of super elevation should gradual:
V2
e= e should be less than o. 7 E
225R
= e .B Where ,
E = Rise Of Outer Edge Of Road
EN If Road Is Rotated
Ls = [ ] B = 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑅𝑜𝑎𝑑[
2 From The Center
If Road Is Rotated From

Ls = EN [ ]
The Inner Edge
N = Rate of super elevation → If 1 in N = 1 in 150
N = 150
3) Minimum length as per IRC:
2.7V2
I. For Plain & Rolling terrain:Ls = V in kmph
R
V2
II. For Mountainous terrain:Ls = R
LS 2
4) SHIFT OF CURVE:S = 24R

❖ GRADIENT:
➢ The Rate Of Rise Or Fall Along The Length Of The Road With Respect To The
Horizontal Is Called GRADIENT.
❖ TYPES OF GRADIENT:
1) Average Gradient
2) Ruling Gradient
3) Limiting Gradient
4) Exception Gradient
5) Minimum Gradient
6) Floating Gradient
❖ FACTORS AFFECTING GRADIENT:
1) Nature Of Traffic
2) Drainage Of Water
3) Appearance
4) Access To Adjoining Property
5) Obligatory Points like Bridge, Canal, Railway Crossing etc.
❖ GRADE COMPENSATION :
➢ The Reduction in gradient at the horizontal curve is called GREDE
30+R
COMPENSATION.GRADE COMPENSATION (%) = R
➢ According to IRC the grade compensation is not necessary for gradient flatter than
4%.
❖ WIDENING OF CURVES:
Total widening
= Mechanical Widening(WM ) + Psychological Widening(WPS )
nl2 V
= + Where,
2R 9.5√R
n = No. of lane
18n 0.1V
= + l
R √R
= length of wheel base(m)
R = Mean radius of curve(m) V = Design speed in kmph

❖ EXTRA WIDENING AT HORIZONTAL CURVES (AS PER

IRC):
Radius of Up to 20 21 to 40 41 to 60 61 to 100 101 to 300 Above
curve (m) 300
Extra
widening(m)
Two-lane 1.5 1.5 1.2 0.9 0.6 Nil
Single lane 0.9 0.6 0.6 Nil Nil Nil
VERTICAL CURVES
Summit Curves Valley Curve
➢ Length of summit curve for SSD: ➢ Length of Transition curve (Ls) for
1) When L > 𝑆𝑆𝐷 comfort condition:
1
NS 2 LS = 0.19(NV 3 ) ⁄2
L= 2 1⁄
[√2H + √2h] L = 2LS = 0.38(NV 3 ) 2
1⁄
Put H = 1.2 m & ℎ = 0.15𝑚 Nv 3 2
L = 2LS = 2 [ ]
NS 2 C
L= Where, S = SSD
4.4 1
= 0.38(𝑁𝑉 3 ) ⁄2
➢ The minimum radius of the valley
2) When L < 𝑆𝑆𝐷 curve for the cubic parabola
2
[√2H + √2h] LS L
L = 2s − R= =
N N 2N
Put H = 1.2 m & ℎ = 0.15𝑚 Where, V = Speed in kmph
4.4 v = speed in m⁄sec
L = 2s − C = allowable rate of
N change of centrifugal
Where, L = length of summit curve acceleration
S = stopping sight C = 0.6 m sec 3
distance(SSD) R = Radius of valley curve

N = deviation Angle LS = Length of transition

H = Height of eye level of Curve
driver above roadway
surface (m) ➢ Length of valley curve for head light
h = height of object above sight distance:
the pavement surface I. When L > 𝑆𝑆𝐷
NS 2
➢ Length of summit curve for a safe L=
[2h1 + 2S tan α]
OSD: Put h1 = 0.75 m & 𝛼 = 1°
NS 2
I. When L > 𝑂𝑆𝐷 L=
[1.5 + 0.035 S]
NS 2
L= 2
[√2H + √2h] Where, L = total length of valley
Put H = h = 1.2 m curve(m)
NS 2 S = SSD(m)
L= Where, S N = deviation Angle
9.6
N = (n1 + n2 )with slopes
= OSD −n1 and + n2
II. When L < 𝑆𝑆𝐷

II. When L < 𝑂𝑆𝐷 (2h1 + 2S tan α)
L = 2s −
9.6 N
L = 2s − Put h = 0.75m & 𝛼 = 1°
N
1.5 + 0.035S
L = 2S − ( )
N
❖ STEPS FOR SUPER ELEVATION DESIGN :

1) The super elevation for 75% of design speed
(0.75 v)2 (0.75v)2
e= OR
gR 127R
2
v
e=
225R
2) If e exceeds 0.07 than provide max. super elevation 0.07 & go through step (3) &
(4)
V2 V2 V2
3) f = gR − e = gR − 0.07 = 127R − 0.07
➢ If the value of f is < 0.15, the super elevation of 0.07 is safe for the design speed .
➢ If not the go to step (4)
Vs 2 V 2
s
4) e + f = 0.07 + 0.15 = 0.22 = = 127R
gR
vs = √0.22gR = √2.156R m⁄sec OR vs = √27.94R kmph

❖ SUMMIT CURVES:
❖ VALLEY CURVE:

SECTION-H
FIELD VISIT
AND
FIELD TESTS ON PAVEMENT LAYERS
26 Hot Mix Plant Visit (Prepare report) (IRC:90-1985)
27 Ready Mix Concrete Plant visit (Report) (IRC:90-1985)
28 Determination of Field Density of Pavement Layer (IS:2720-29,28-1975)
29 Introduction of Plate Bearing Test (IS:1888-1982)
30 Introduction of Benkelman Beam Deflection (IRC:81-1997)
Introduction Unevenness Measurement by Bump Integrator and (IRC:SP:82-2015)
31
MERLIN
HOT MIX PLANT-and STONE CRUSHER VISIT REPORT

HOT MIX PLANT VISIT REPORT (IRC:90-1985)

Draw line diagram of STONE CRUSHER operation as seen on site
Draw line diagram of HOT MIX PLANT as seen on site
(Faculty Advisor)
Date:

READY MIX CONCRETE PLANT (RMC PLANT) - VISIT

REPORT
READY MIX CONCRETE PLANT (STUDY) (IRC:90-1985)
Draw line diagram of READY MIX CONCRETE PLANT as seen on

site
(Faculty Advisor)
Date:

FIELD TESTS ON PAVEMENT LAYERS

INTRODUCTION OF DETERMINATION OF FIELD DENSITY OF

PAVEMENT LAYER (IS:2720-29,28-1975)
Introduction:
It is often necessary to determine the field dry density or in-place
Dry density of: (i) natural soil (ii) compacted soil layers of the embankment and subgrade
and (iii) pavements layers, in road construction projects. The dry density of natural soil is
useful to estimate the quantity of borrow soil required to complete a construction project
and is also useful in other application in civil engineering.
The dry density of compacted soil or pavement layer is a common measure of the amount
of the compaction achieved during the field compaction in road construction in road
construction works. The determination of dry density is done in three stages, (i)
determination of the field density or in-place density by a suitable method and (ii)
determination of filed density moisture content and field dry density are important field
control tests during the compaction of soil or dry other pavement layer.
Determination of field density by sand replacement method:

A simple and most common method of determination of in-place field density of soil and
other compacted pavement layer is the ‘sand pouring cylinder method’. The basic
principal of sand replacement method is to measure the in-place volume of a hole from
which the material was excavated, by filling-in the hole with dry sand of known density.
The sand poring cylinder apparatus is used for this purpose. The in-place density of
material is given by the weight of the excavated material collected from the hole, divided
by the in-place volume of the hole. In-place dry density is determined by finding the
moisture content in the soil collected from the field.
Fig. Sand pouring Cylinder

Equipment:
1. Sand pouring cylinder
2. Metal tray with hole
3. Tools for travelling and excavating
4. Container
5. Calibrating container
6. Plane surface
7. Balance
8. Sand
Procedure:
The determination of field density of the compacted soil or pavement layer by sand
replacement method is carried out in following stages:
• Calibration of the apparatus by determination the density of the sand used
• Finding the weight of the soil/pavement material excavated from the hole
• Finding the weight of test sand filling the hole
• Calculating the volume of the hole by making use of the weight of the sand filling
the hole and the density of the sand used
• Calculating the field density by dividing the weight of the excavated material from
the hole by the volume of the hole
• Determination of the field moisture content or the average moisture content in the
excavated soil/pavement material
• Calculation of dry density of the soil/pavement material, making use of the
density and moisture content values.
Determination of field density by core cutter method:
Equipment:
1. Cylindrical core cutter
2. Steel dolly
3. Steel rammer
4. Extractor
5. Other apparatus
Procedure:
The internal diameter and length of the core cutter are measured at two or more locations
in order to determine the internal volume, Vc if the core cutter. The weight of the core
cutter, Wc is determined.
300 mm square area is cleaned and leveled at the location where the field density is to be
determined. The core cutter is placed on the desired location with the cutting edge at the
bottom and the steel dolley or ring is placed on the top of the core cutter and is rammed
down vertically into the soil using the steel rammer. The soil around the core cutter is dug
and removed and the core cutter with the soil inside is taken out carefully, causing least
possible disturbance to the soil sample inside the core cutter. The ends of the soil core are
trimmed flat (flush with the top and bottom edges of the core cutter) using a straight edge.
The weight of the core cutter along with the wet soil taken the field is determined = W s .
The soil core is removed from the core cutter and one or more reprensentive soil samples
are taken for determination of moisture content in the soil sample. The soil samples
collected from the sample are placed in moisture content dishes, wet weight determined,
dried in oven at 110˚C and the dry weight determined in order to find the mean moisture
content. Any other rapid test method for determination of field moisture content as
method as earlier may also be adopted earlier may also be adopted as per the requirement.

CORE CUTTER METHOD SAND REPLACEMENT METHOD

Observations Volume of calibrating cylinder (cm3),
V1 = ______________
Internal diameter of core cutter (cm) = Mass of sand for filling the calibrating
cylinder and cone (g),
______________
W1= ______________
3
Height of cutter (cm) =______________ Bulk density of sand (g/cm ),
Volume of cutter, V cm3) =___________ =_______

Mass of sand for filling only the cone (g),
W2=______________
Mass of sand in the calibrating cylinder (g)
W3 = W1 - W2 =______________
Field Test No. 1 Field Test No. 1

Mass of pouring cylinder +
Mass of core cutter (g), W1 sand before pouring in hole
(g), W4
Mass of pouring cylinder +
Mass of cutter + soil (g), W2 sand after pouring in hole
(g), W5
Mass of sand used in the
Mass of moist soil (g), (W2-
hole (g), W6 = W4 - W5 -
W1)
W2
Volume of excavated hole
Average water content, W
(%)
(cm3),
Field bulk density (g/cm3),
Mass of excavated soil (g),
W
Field dry density (g/cm3), Average water content, w
(%)
Field bulk density (g/cm3),
Field dry density (g/cm3),
(Faculty Advisor)
Date:

INTRODUCTION OF PLATE BEARING TEST (IS:1888-1982)
Introduction: The tests used to evaluate the strength properties of soils may be broadly
divided into three groups, namely. (1) shear tests (2) bearing tests and (3) penetration
tests. The shear strength parameters are determined in terms of cohesion, C and angle of
internal friction, Ø by conducting shear tests on soil specimens. Bearing test is carried out
on the soil in-place by applying loads on a relative large size plate and observing the
settlement values. Plate bearing test is an example of bearing test. Penetration tests are
carried out on soil by applying loads through a plunger of small diameter.
In plate bearing test, compressive loads are applied on the soil or pavement layer in-place
through rigid plates of relatively large size and the deflection values are measured for
increasing load values. The deflection level is generally limited to a low value, in the
order of 1.25 to 5 mm and so the deformation caused may be partly elastic and partly due
to compaction of the stressed mass with very less plastic deformation. The plate bearing
test has been devised to evaluate the supporting power of a prepared subgrade or any
other pavement layer in-place by using plates of large diameter.
The plate bearing test was originally devised to find the modulus of subgrade reaction
of prepared subgrade soil in the Westergaard’s analysis for wheel load stresses in
cement concrete pavements. The procedure for determining modulus of subgrade
reaction, K of a soil in-place to evaluate strength of subgrade for subgrade for design of
road and airfield pavement structure is presented in this test. Various organizations
including BIS have specified standard test procedure to conduct plate bearing test for the
determination of K-value. The subgrade modulus is defined as the intensity ‘p’ applied on
the standard plate per unit deflection i.e. K = p / d, where the value of deflection d=1.25
mm or 0.125 mm.

Fig. Plate bearing set-up

Equipment:
• Bearing plate consists of a mild steel plate of diameter 750 mm and thickness 25
mm. Smaller bearing plates of diameter 450 or 300 mm and thickness 25 mm may
also be used. Stiffening plates of diameter 600, 450, 300 and 225 mm and
thickness 25 mm are used to prevent bending of the large plate of diameter 750
mm during application of heavy loads.
• Loading equipment consists of a reaction frame or a dead load and a hydraulic or
screw jack of capacity 15000 kg. The reaction frame may suitably be loaded to
give the reaction load of about 15 tonnes on the plate. The load applied may be
measured either by a proving ring with dial gauge assembly or a load cell.
• Settlement measurements may be by means of three or four dial gauges with an
accuracy of 0.01 mm, fixed on the periphery of the bearing plate from an
independent datum frame/bar. The datum frame should the supported far from the
loaded area.
Procedure:
Preparation of test area and seating
The test site prepared and loose material is removed so that the 750 mm diameter plate
rests horizontally in full contact with the surface of soil subgrade. If the modulus of
subgrade reaction of natural ground is needed, the top soil is stripped off and removed up
a depth of about 250 mm or up to the elevation of the proposed subgrade, for an area
twice that of the plate. If the test is to be conducted on the compacted fill or subgrade,
care is taken that test is conducted at the dry density and moisture content of the soil that
are likely to exist subsequent to the construction. In order to ensure full contact of the
plate, oil is applied on the bottom of the plate and the plate is rotated to mark the
irregularities and high spots of the seating surface to be trimmed. In the case of granular
soil with gravel particles, after initial levelling of the surface by a straight edge, it may be
necessary to apply a thin layer of plaster of paris and allow the same to same to set before
applying the load. The level surface of the plate is checked using a bubble tube placed on
the plate in different positions.
Test set up

The bearing plate is seated on the prepared surface and the stiffening plates are placed
one above the other in the decreasing order of the diameter. The reaction load frame is
set up above the centre of the plate. The loading jack is places centrally above the top of
the set of plates and the proving ring with dial gauge or any other type of load cell is
inserted between the loading jack and reaction load frame in order to measure the load
applied. Additional spacer discs or cylinders may be required to be placed between the
jack/load measuring device and the reaction load frame. Three or four dial gauges are to
be uniformly spaced and set up near the rim of the bearing plate from an independent
datum frame or bar in order to measure the settlement readings due to load application.
The supports of this datum bar are placed away from the loading plate as well as the
supports of the loading frame such that they are not affected by the loading operations.
After seating the bearing plate and setting up the loading and settlement measuring
device, a seating load of 310 kg is applied on the 75 cm diameter plate, equivalent to a
pressure of 0.07 kg/cm2 in the case of pavements meant for light loads. For heavy duty
pavements, a seating load of 620 kg or a seating pressure of 0.14 kg / cm 2 is applied. The
seating load may be held till there is no significant settlement and then it is released,
Cyclic loading under seating load may be applied if required, to obtain good seating.
Loading procedure Method-1

The seating load applied is released and the load reading is set to zero. All the settlement
dial gauge readings are either set to zero or the initial dial readings are noted
corresponding to zero load. The load is applied by means of the jack and it is increased to
sufficient magnitude to cause an average settlement of about 0.025 mm and the jack and
the load is retained, observing the settlement dial reading. When there is no perceptible
increase in settlement or when the rate of settlement is less than 0.025 mm per minute, the
load dial reading and the settlement dial reading of the individual dial gauges are noted.
The average of the taken as the average settlement of the palate corresponding to the
applied load.
The load is then increased till the average settlement increase till further amount of about
0.25 mm, and the load and the settlement dial readings are noted as before. The procedure
is repeated till the total average settlement of the plate is not less than 1.75 mm.
A graph is plotted with the mean settlement values of the plate on the X- axis versus load
per unit area or the bearing pressure, p on the Y-axis. The pressure p (kg/m2)
corresponding to a settlement, d=0.125 cm obtained from this graph. The modulus of
subgrade reaction, K is calculated from the relation:
𝑝 𝑝
K= = kg/cm2/ cm, or kg/cm3
𝑑 0.125
Loading procedure Method-2
After the application of seating load and holding it for sufficient time, without releasing
the seating load, the settlement dial gauges are set to zero and an additional load 3100 kg
is applied. If the plate bearing test is conducted on relatively weak cohesive soils (which
is indicated by average settlement exceeding 1.25 mm under 3100 kg load on the plate),
the applied load is held until the rate of settlement is less than 0.05 mm per minute and
after that the reading are noted.
If the plate bearing test is conducted on granular soils or on relatively strong cohesive
soils (which is indicated by average settlement reading much lower than 1.25 mm under
the applied load of 3100 kg on the plate), additional load of 1550 kg is applied on the
plate (without releasing the applied load already applied) and the settlement observations
are recorded when the rate of settlement is lower than the specified rate. This process of

applying the load increments are continued until the total load applied on the plate is 9300
kg .This load is held for 15 minutes or until the rate if settlement is less than 0.02 mm per
minute.
The average settlement, d under an unit load of 0.7 kg/cm2 (0.07Mpa) is noted from the
graph and the modulus of subgrade reaction, K is calculated from the relation:
0.70 0.70
K= kg/cm3 = Mpa/cm
𝑑 𝑑
Observation and calculation:
(Faculty Advisor)
Date:

INTRODUCTION OF BENKELMAN BEAM DEFLECTION

STUDIES AND ANALYSIS (IRC:81-1997)
Introduction:
The principle of this method of pavement evaluation is that the flexible pavement surface
deflects under an applied wheel load and the amount of deflection under a saturated wheel
load depends upon the stability of the pavement structure. The stability of pavement
structure depends upon (a) thickness and quality of various pavement layer (b0 subgrade
soil type and degree of compaction (c) drainage condition and field moisture content in
the subgrade soil at the time of load application and (d) pavement surface temperature (in
case the case of bituminous pavement layers of total thickness above 40 mm). A weak
pavement surface structure will deflection will deflect to a greater extent under a standard
wheel load whereas a strong pavement structure will deflect pavement to a lesser extent
under the same load. After a number of repeated applications of wheel loads will be
elastic and therefore on removal of the load (or when load moves forward) the deflected
pavement structure will bounce back to original shape or the deflected surface will
‘rebound’. The magnitude of ‘rebound deflection’ due to removal of a standard wheel
load is measured using this simple equipment, ‘Benkelman Beam’.
Fig. Benkelman Beam

Fig. Benkelman Beam

Equipment:
• Benkelman Beam
• Loaded Truck
• Accessories-30 m tape, chalk, glycerol, thermometer to measure temperature up to
100°C with 1°C accuracy, spanners, tools to dig the pavement layers, pressure
gauge.
Procedure:
On the selected road sub-grade with uniform surface condition, minimum of ten points
should be marked at equal intervals along the outer lane of the traffic for measurement of
the deflection values. It is desirable that the distance between the points should not be
than 50 m. If the carriageway has more than two lanes, the deflection observation points
marked on the adjacent lanes are staggered. The deflection observation points are marked
along of 3.5 m and 0.90 m if the lane width is more than 3.5 m. In case of divided four
lane highways, the deflection measurement points should be 1.5 m from the pavement
edge.
The loaded truck is made to stand parallel to the pavement edge such that the rear dual
wheel is centrally placed over the first deflection observation point. The probe of the
Benkelman beam is inserted in between the dual wheels from the rear side of the truck
such that the end of the probe rest exactly over the marked deflection observation point,
in between the dual wheels. The legs of the beam are adjusted and the beam is checked,
so that there is no possibility of the probe touching any part of the tyre, the dial gauge
spindle is checked foe appropriate contact and run of the spindle. The initial dial gauge
reading D0 is noted after the dial gauge reading shows no further change or when the rate
of deflection of the pavement is less than 0.025 mm per minute. The truck is moved
forward at a slow and uniform speed of 8 to 10 m/sec to a distance of 2.70 m and stopped
and the intermediate dial gauge reading Di is noted when the rate of change in reading is
less than 0.025 mm per minute.
The truck is further moved forward to the final location by a further distance of 9.0 m
from the intermediate location and the final dial gauge reading Df is noted when the rate
of change in deflection is less than 0.025 mm per minute.
(Faculty Advisor)
Date:

INTRODUCTION OF UNEVENNESS MEASUREMENT BY BUMP

INTEGRATOR AND MERLIN (IRC:SP:82-2015)
Introduction:
The undulations or unevenness of pavement surface may be classified in to three

categories:
• Rough surface profile with minor corrugation which cause some discomfort and
vibrations, especially in small automobiles or light vehicles.
• Uneven surface with large number of undulations such as small depressions and
humps or a wavy surface which result in considerable discomfort to the
passengers and drivers due to the oscillations and also increase in vehicle
operation cost for all categories of automobiles. The magnitude of discomfort in
riding quality depends on the vehicle type, its weight, tyre size, suspension details
and the operating speed.
• Surface with large size depressions on some stretches (which may be due to the
settlement of embankment or its foundation), without noticeable minor
undulations, in such case the undulations cannot be measures under a straight edge
of 3.0 m length, but such profile will be of very adversely affect high speed
movement of vehicles on expressways and movement if aircrafts on runways.
It is therefore desirable to provide an even or plane road surface with least undulations or
unevenness. The evaluation of undulations or unevenness in the pavements may be
divided in to three board classifications:
• Methods which are based on certain physical measurement of the surface
undulations
• Methods which are based on indirect measurement in terms of human response to
surface undulations during riding
Methods which are based on subjective assessment or rating of the surface characteristics
and no measurement is involved
There are large numbers of equipment developed by various organizations based on the
principal of moving straight edge or moving datum resting on two pairs of wheel which
rolls or traverse along the pavement surfaces and this vertical movement with respect to
the temporary datum is utilized to indicate or to measure unevenness
Bump integrator (BI) is a single-wheel trailer unit hauled by a tractor unit or a suitable
vehicle at the specified uniform speed. The vertical oscillations of the BI are integrated
with the help of an attached ‘integrator unit’. In India the undulations or unevenness
values of pavement surface are generally measured using the ‘Fifth Wheel Bump
Integrator’ and are expressed in terms of ‘Unevenness Index’ in mm per km road length
or m/km. The Bump Integrator is a response type road roughness measuring equipment.

Measurement of unevenness index by Bump Integrator
Fig. Bump Integrator
Equipment
The Bump Integrator (BI) is a trailer unit comprising of a single automobile wheel with
rubber type of specified size mounted on a heavy chassis through suitable bearings and a
suspension system which is hauled at a uniform speed of 30 kmph by a towing vehicle.
Procedure
The stretch of road to be tested is identified and the start end points are marked by bold
lines drawn across the pavement width. Usually unevenness measurements are made
along the normal paths, by making the test runs such that wheel of the bump integrator
runs along the desired wheel path. While conducting the tests on undivided roads, the first
test run is made along the wheel path on the onward trip from the starting point the end.
In the return trip, the test wheel is run along the other wheel path.
The digital units / counters, one indicating the cumulative value of
undulations and the indicating the number of revolutions of the test wheel may be set to
read zero when the test wheel crosses the starting line, or else the initial reading may be
noted down. When the test wheel of the BI unit crosses the ending line, the readings of
both the counters are noted and recorded. The hauling vehicle and the BI unit are final
readings. Similarly total three to four test runs are made along each wheel path so as to
determine the mean value of unevenness. In the case of divided highways with multiple
lanes, the study may be planned to cover each wheel path during each test run in each
direction and the required number of test runs may be made along each wheel path.
It is preferable that the hauling vehicle with the bump integrator starts from a location 30
to 50 m before actual starting line of the test stretch so that by the time the vehicle reaches
the starting line, a uniform speed of 30 kmph can be maintained; when the test wheel just
crosses the starting point, both the counters are set to zero. When the test wheel crosses
the ending line, the readings are noted and recorded, while maintaining the uniform speed
of the test run and the vehicle and the trailer unit may be slowed down and turned after a
further distance of about 30 to 50 m, at a convenient location.

Measurement of unevenness by merlin
Fig. Merlin
Equipment
MERLIN has two feet which are spaced at 1.8 m and a probe that rest on the wheel track.
The probe lies mid- way between the two feet. The equipment is fitted with a bicycle tyre
for ease of operation in the front leg. A rigid metal road is fitted in the rear leg. A
stabilizer leg is fitted at the rear to prevent the equipment from falling. The probe is
attached with a moving arm with a pointer at one end which moves over a prepared data
sheet. The arm has a mechanical amplification of ten, so that a movement of the probe of
one mm will produce a movement of the pointer of ten mm. The chart consists of
columns, each 5 mm wide and divided into boxes.
Procedure
The wheel path along which the readings are to be taken is marked. The MERLIN is
moved and kept at the starting point. The location of the pointer on the chart is recorded
with a cross at the appropriate column and to keep a record of the totl number of
observations, a cross mark is also made in a ‘tally box’ in the chart. The handle of the
MERLIN is raised, so that only the wheel is in contact with the road surface and moved
forward to the next measuring point and the process is repeated. The next point is located
after each revolution of the wheel of the MERLIN. A mark is painted on the rim of the
wheel and the measurement is taken every time, the wheel rotates and the mark comes to

the road surface. It is desirable to have at least 200 readings at regular intervals or 200
wheel revolutions.
When 200 observations are made, the chart is removed from MERLIN. The numbers of
cross marks are counted from either end. The position mid-way between the tenth and
eleventh cross marks from either end are marked on the chart. If needed, the position may
be interpolated between the tenth and eleventh readings. The spacing between the two
marks; D is measured in millimeters and taken as the roughness on the ‘MERLIN Scale’.
(Faculty Advisor)
Date:

JB

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DARSHAN INSTITUTE

Darshan Institute of Engineering and Technology-Rajkot Page 1

Signature of the Student

Darshan Institute of Engineering and Technology-Rajkot Page 2

THICKNESS MIXTURE DESIGN THICKNESS MIXTURE

Rigid Pavement Flexible Pavement

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TESTING OF MATERIAL (Pavement making material)

SOIL AGGREGATE BITUMEN CEMENT

• Atterberg’s limit • Specific Gravity • Specific Gravity • Consistency

• OMC & MDD

FOR BITUMINOUS PAVEMENT FOR RIGID PAVEMENT

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Typical C/S of Flexible Pavement

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AGGREGATE TEST VALUE ACCEPTANCE CRITERIA

6 Liquid Limit 25% Max NA NA 25% Max - - - - -

Aggregate Stone Polishing BS :

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Sr. No. Name of Test Relevant IS code

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EXPERIMENT NO: 1 DATE:

SHAPE TEST (IS: 2386 PART -1)

OBJECTIVE: To determine the value of Flakiness and Elongation Index of

The flakiness index of aggregates is the percentage by weight of particles whose

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Fig 1. Thickness gauge

Sr. Maximum limit

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Fig 2. Length Gauge

(B) ELONGATION INDEX:

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APPLICATION O F SHAPE TEST:

PERMISSIBLE LIMITS - Requirement as per MORT&H

Property Granular Sub-Bases (GSB),

Cement Concrete (Other

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Weight of the Aggregate taken for the test (W) = _______________gms

FLAKINESS INDEX ELONGATION INDEX

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EXPERIMENT NO: 2 Date :

DETERMINATION OF AGGREGATE IMPACT VALUE

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Fig 1. Aggregate Impact Testing Machine

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EXPERIMENT NO: 3 DATE:

DETERMINATION OF AGGREGATE CRUSHING VALUE

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150 mm dia Mould 75 mm dia Mould

Fig. Aggregate Crushing Value Test apparatus

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The aggregate comprising the test sample shall be dried in an oven at a

The aggregate passing 12.5 mm IS sieve and retained on 10 mm IS sieve is

Table No: 1 Recommended Aggregate crushing value.

Sr. No. Description Maximum crushing value

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1. Weight of oven drying aggregate passing 12.5

6. Avg. aggregate crushing value in %