PROCEDURES/OBSERVATION BOOK

CE 3410 - Construction Materials Laboratory

(Experiments on Cement, Concrete, Aggregates, Bricks/Tiles, & Steels)

Student’s Name

Student’s Roll Number

Building Technology & Construction Management Division

Dept. of Civil Engineering
Indian Institute of Technology Madras
Chennai 600 036, India

July-November 2016
 TABLE OF CONTENTS

1 CEMENT LAB ........................................................................................................................ 5

2 CONCRETE LAB ................................................................................................................. 11

3 AGGREGATE LAB .............................................................................................................. 17

4 BRICK-TILE LAB ................................................................................................................ 29

5 STEEL LAB .......................................................................................................................... 37

 1 CEMENT LAB
1.1 AIM
i) To determine the specific gravity of cement
ii) To determine the normal consistency and initial/final setting time of cement
iii) To determine the specific surface of cement by using Blaine’s air permeability test
iv) To determine the soundness of cement
v) To determine the compressive strength of cement

1.2 REFERENCED CODES

a) IS 4031: 1999 Methods of physical tests for hydraulic cement: Part 2 Determination of
fineness by specific surface by Blaine air permeability method
b) IS 4031: 1988 Methods of physical tests for hydraulic cement: Part 3 Determination of
soundness
c) IS 4031: 1988 Methods of physical tests for hydraulic cement: Part 4 Determination of
consistency of standard cement paste
d) IS 4031: 1988 Methods of physical tests for hydraulic cement: Part 5 Determination of
initial and final setting times
e) IS 4031: 1988 Methods of physical tests for hydraulic cement: Part 6 Determination of
compressive strength of hydraulic cement

1.3 APPARATUS
1.3.1 Specific gravity of cement
 Le-Chatelier’s standard flask  Holder
 Kerosene, free of water  Water bath
 Balance
1.3.2 Consistency, Initial and final setting time of cement
 Vicat apparatus  Weighing balance
 Split mould  Stop clock
 Glass plate
1.3.3 Fineness (by Blaine’s air permeability test)
 Blaine's air permeability apparatus  Filter paper
 Standard cement  Mercury
 Glass plate
1.3.4 Soundness test
 Small split
 Brass cylinder of 0.5 mm thickness, forming  Small Glass plates and weight
a mould with 30 mm internal diameter and  Measuring scale
30 mm height
1.3.5 Compressive strength
 Weights and weighing device.  Testing machine
 Glass Graduate  Mortar mixer
 Specimen molds: Three cubes of (50mm)  Tamper and trowel
side.

Page 5 of 40
1.4 PROCEDURES
NOTE 1: Write brief description of the test procedures and provide small photograph(s) of apparatus/equipment/test
specimens to aid the description. Important elements in the photograph must be labeled properly. A caption should
be given for each photograph.
1.4.1 Specific gravity of cement
1.4.1.1 Fill the flask with Kerosene to a point on the stem between 0 and 1 ml mark.
1.4.1.2 Put the flask in the water bath at a constant temperature for a sufficient period
of time in order to avoid flask temperature variations greater than 0.2 °C
between the initial and final readings.
1.4.1.3 Record the final reading on the flask.
1.4.1.4 Prepare (64) g of cement weighed to the nearest (0.05) gm and place it in the
flask in small increments. Take care to avoid splashing and see that the cement
dose not adheres to the inside of the flask above the liquid.
1.4.1.5 After all the cement has been introduced, place the stopper in the flask and roll
the flask in an inclined position so as to free the cement from air until no
further air bubbles rise to the surface of the liquid.
1.4.1.6 Put the flask in the water bath as in Step 1.4.1.2.
1.4.1.7 Take the final reading.

1.4.2 Consistency Initial and final setting time of cement

1.4.2.1 500 grams of cement is taken on a glass plate and 25 % by weight (of cement)
of water is added
1.4.2.2 The Vicat mould is filled with this paste by keeping the mould over a non-
porous plate. After completely filling the mould, the top is levelled and is
placed under the Vicat plunger (10 mm diameter)
1.4.2.3 The settlement of the plunger is read directly from the graduated scale. If it is
between 5 and 7 mm from the bottom, then the water added is correct.
Otherwise, test is to be repeated as above by preparing pastes with varying
percentages of water, until the amount of water necessary to produce the
required penetration of 5 to 7 mm.
1.4.2.4 500 grams of cement is taken and to it 85% (by weight) of water required for
normal consistency, as determined earlier is added.
1.4.2.5 Initial setting time is defined as the period of time elapsing between the time
when water is added to the cement and the time at which the 1 mm square
Vicat needle fails to pierce the paste by about 5 ±0.5 mm from the bottom of
the mould.
1.4.2.6 The final setting time is the time interval between the time when water is added
to the cement and the time at which the annul attachment of the particular
needle fails to make an impression on the surface of the test block of cement
paste

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1.4.3 Fineness (by Blaine air permeability test)
1.4.3.1 Calculate the volume of the compacted bed of cement, V,
V = (WA - WB) / ρ
where,
WA = mass of the mercury required to fill the permeability cell
WB = mass of the mercury to fill the portion of the cell not occupied by
the bed of cement formed by 2.8 gm of standard cement sample.
ρ= Density of mercury at the temperature of test
1.4.3.2 Determine the mass of sample W required to produce a bed having porosity of
(e = 0.5) as follows
W = SG x V x (1 - e)
1.4.3.3 Evacuate the air until the fluid moves above the upper line without pulling if
over the top of the side outlet close the valve and note the time Ts taken by
manometer liquid to fall from 2nd mark (from top) to the 3rd mark on the
manometer when the air allowed to permeate though the compacted bed of
standard cement sample.
1.4.3.4 Weigh an amount of cement sample equal to that determined in Step 1.4.3.2,
and the calibration.
1.4.3.5 Place the perforated disc in the permeability cell, and then add a filter paper,
followed by the sample and another filter paper
1.4.3.6 Evacuate the air until the fluid moves above the upper line without pulling it
over the top of side tube. Close the valve of manometer and note the time T it
takes for the fluid to drop from the 2nd mark to the 3rd mark on the manometer
when the air is allowed to permeate through the compacted bed of cement
1.4.3.7 Calculate the specific surface S in sq. cm/gm of the tested cement by using the
following formula with the temperature at the calibration and at the time of test
are within ±3% of each other.
S = (Ss x √T) / √Ts; where Ss = Specific surface of standard cement used in
calibration; Ts= Measured time (seconds) required for the fluid to fall the
middle interval for standard sample; T = Measured time (seconds) required for
the fluid to drop over the middle interval.
1.4.4 Soundness test
1.4.4.1 Place the mould on a glass sheet and fill it with cement paste formed by
gauging cement with 0.78 times the water required to give a paste of standard
consistency.
1.4.4.2 Cover the mould with another piece of glass sheet, place a small weight on this
covering glass sheet and immediately submerge the whole assembly in water at
a temperature of 27 ± 2 ºC and keep there for 24 hours.
1.4.4.3 Measure the distance separating the indicator points.
1.4.4.4 Submerge the mould again in water at the temperature prescribed above.
1.4.4.5 Bring the water to boiling, with the mould kept submerged, in 25 to 30
minutes, and keep it boiling, for 3 hours.
1.4.4.6 Remove the mould from the water, allow it to cool and measure the distance
between the indicator points. The difference between these two measurements
represents the expansion of the cement

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1.4.5 Compressive strength
1.4.5.1 Weigh 300 gm of cement and prepare the corresponding weights of standard
sand and water
1.4.5.2 Place the dry paddle and the dry bowl in the mixing position in the mixer. Then
introduce the materials for a batch into the bowl and mix as follows
1.4.5.3 Place all the mixing water in the bowl.
1.4.5.4 Add the cement to the water, then start the mixer and mix at the low speed
(140±5 rpm) for 30 s.
1.4.5.5 Add the entire quantity of sand slowly over a (30 s) period , while mixing at
slow speed.
1.4.5.6 Stop the mixer and let the mortar stand for 1.5 min . During the first (15 s) of
this interval, quickly scrape down into the batch any mortar that may have
collected on the side of the bowl.
1.4.5.7 Finish by mixing for 1min, at medium speed.
1.4.5.8 After 7 days of curing under water, take the specimen and clean it with cloth
and test.
Note: In the field, compressive strength on 28th day is typically used. However, due to time constraints, only the
7-day compressive strength will be determined, experimentally. The 28-day compressive strength will be estimated,
analytically. Also, if you miss this lab on your assigned date, then make special arrangement with the HTTA for
conducting the experiments before the make-up class.

1.5 OBSERVATIONS AND CALCULATIONS

1.5.1 Specific gravity

Trial Weight in g Initial Reading Final Reading Specific gravity

No.

1.5.2 Consistency, initial and final setting time

Trial water Penetration

Sl. No. Trial Initial Setting time, min Final setting time, min

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1.5.3 Fineness test
Weight of mercury when no cement in the plunger Wa =
Weight of mercury when cement is in the plunger Wb =
Density of mercury =
Porosity = 0.5
Specific surface of standard cement = m2/kg
Specific gravity =
Bulk volume of cement, V = cm3
Time for standard cement = sec
Weight of sample required = g
Time for sample = sec
Fineness of given cement = m2/kg

1.5.4 Soundness test

Table 1-1 Observations from soundness test

Sl. No. Sample Before Boiling, cm After Boiling, cm

1.5.5 Compressive strength

Table 1-2 Observations from compressive strength tests

Specimen detail Load, kN Stress, MPa Average strength (MPa)

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Page 10 of 40
 2 CONCRETE LAB
2.1 AIM
To make concrete with a given mixture proportion and then determine its fresh and hardened
properties
2.1.1 Fresh properties
i) To determine the workability of concrete by slump test.
ii) To determine the unit weight of fresh concrete
iii) To determine air content of fresh concrete
2.1.2 Hardened properties
iv) To determine compressive strength of concrete cubes
v) To determine the tensile strength of concrete by conducting the split tensile test on
concrete cylinder
vi) To determine the modulus of rupture of concrete by conducting flexural test on prismatic
concrete test specimen

2.2 REFERENCED CODES

a) IS 1199 – 1959; Methods of sampling and analysis of concrete (Slump Test)
b) ASTM C 138/C 138M-10b Standard Test Method for Density (Unit Weight), Yield, and
Air Content (Gravimetric) of Concrete
c) ASTM C 231- 91 Standard Test Method for Air Content of Freshly Mixed Concrete by
the Pressure Method
d) IS 516 – 1959; Methods of test for strength of concrete
e) IS 5816 – 1999; Splitting tensile strength of concrete

2.3 APPARATUS
 Pan mixer  Weighing balance
 Weighing balance  Air meter (Type B)
 Sieves  Cover assembly
 Scoop  Spray tube
 Showel  Trowel
 Mallet
 Strike off bar
 Mould for slump test: The mould shall be in the form of a frustum of a cone open
at both top and bottom having the following internal dimensions:
 Bottom diameter - 200 mm
 Top diameter - 100 mm
 Height - 300 mm
 Tamping rod: The tamping rod shall be of steel or other suitable material, 16 mm
in diameter, 0.6 m long and rounded at one end.
 Universal Testing Machine

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2.4 PROCEDURES
2.4.1 Concrete mixing
2.4.1.1 Butter the mixer with cement slurry.
2.4.1.2 Introduce the coarse and fine aggregates and dry mix for 2 minutes.
2.4.1.3 Add 20±5 %of water into the mixer and mix on and mix for 2 minute.
2.4.1.4 Give a rest period of 4 minutes (it is done so that the aggregate can reach the
SSD condition)
2.4.1.5 Add the cementitious material (cement and mineral admixture) into the mixer
and mix it for 1 minute.
2.4.1.6 Add the rest 80% of the water and mix it for 2 minutes
2.4.1.7 Clean and dry the mixer for the later use.
2.4.2 Fresh Properties - Slump test
The internal surface of the mould shall be thoroughly cleaned and should be free from
superfluous moisture, before commencing the test. The mould shall be placed on a smooth,
horizontal, rigid and non-absorbent surface, such as a carefully levelled metal plate, the mould
being firmly held in place while it is being filled. The mould shall be filled in three layers, each
approximately one-third of the height of the mould. Each layer shall be tamped with twenty five
strokes with the rounded end of the tamping rod. The strokes shall be distributed in uniform
manner over the cross section of the mould and for the second and subsequent layers shall
penetrate into the underlying layer. The bottom layer shall be tamped throughout its depth. After
the top layer has been rodded, the concrete shall be struck off level with a trowel or the tamping
rod, so that the mould is exactly filled. Any mortar which may have leaked out between the
mould and base plate shall be cleaned away. The mould shall be removed from the concrete
immediately by raising it slowly and carefully in a vertical direction. This allows the concrete to
subside and difference between the height of the mould and that of the highest point of the
specimen being noted down. The above operations shall be carried out at a place free from
vibration or shock, and within a period of two minutes after sampling. The slump measured shall
be recorded in terms of millimeters of subsidence of the specimen during the test. Any slump
specimen which collapses or shears off laterally gives incorrect result and if this occurs the test
shall be repeated with another sample. If, in the repeat test also, the specimen should shear, the
slump shall be measured and the fact that the specimen sheared shall be recorded.

2.4.3 Fresh Properties - Unit weight test

Take a cylindrical measure of known volume (V). The measuring bowl of the air content meter
itself can be used. Note down the weight of the cylinder (W1). Place the freshly mixed concrete
in three layers of equal volume with 25 strokes of tamping rod. Tamping should be done
uniformly over the cross section. Strike off the excess concrete and note down the weight (W2).

2.4.4 Fresh Properties - Air content test

Thoroughly clean the flanges or rims of the bowl and the cover assembly so that when the cover
is clamped in place a pressure-tight seal will be obtained. Close the air valve between the air
chamber and the measuring bowl and open both petcocks on the holes through the cover. Using a
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rubber syringe, inject water through one petcock until water emerges from the opposite petcock.
Jar the meter gently until all air is expelled from this same petcock. Close the air bleeder valve
on the air chamber and pump air into the air chamber until the gage hand is on the initial pressure
line. Allow a few seconds for the compressed air to cool to normal temperature. Stabilize the
gage hand at the initial pressure line by pumping or bleeding-off air as necessary, tapping the
gage lightly by hand. Close both petcocks on the holes through the cover. Open the air valve
between the air chamber and the measuring bowl. Tap the sides of the measuring bowl smartly
with the mallet to relieve local restraints. Lightly tap the pressure gage by hand to stabilize the
gage hand. Read the percentage of air on the dial of the pressure gage. Failure to close the main
air valve before releasing the pressure from either the container or the air chamber will result in
water being drawn into the air chamber, thus introducing error in subsequent measurements. In
the event water enters the air chamber it must be bled from the air chamber through the bleeder
valve followed by several strokes of the pump to blow out the last traces of water. Release the
pressure by opening both petcocks before removing the cover.
2.4.5 Hardened properties – Compressive strength test on cube
Test specimens cubical in shape shall be 15 × 15 × 15 cm. If the largest nominal size of the
aggregate does not exceed 2 cm, 10 cm cubes may be used as an alternative.
Specimens stored in water shall be tested immediately on removal from the water and while they
are still in the wet condition. Surface water and grit shall be wiped off the specimens and any
projecting fins removed. The specimen shall be placed in the machine in such a manner that the
load shall be applied to opposite sides of the cubes as cast, that is, not to the top and bottom. The
axis of the specimen shall be carefully aligned with the centre of thrust of the spherically seated
platen. No packing shall be used between the faces of the test specimen and the steel platen of
the testing machine. The load shall be applied without shock and increased continuously at a rate
of approximately 140 kg/sq.cm/min until the resistance of the specimen to the increasing load
breaks down and no greater load can be sustained. The maximum load applied to the specimen
shall then be recorded and the appearance of the concrete and any unusual features in the type of
failure shall be noted.
2.4.6 Hardened properties – Split tensile strength test on cylinder
The specimens shall be cylinder of 150 mm in diameter and 300 mm long. Tests shall be made
at the recognized ages of the test specimens, the most usual being 7 and 28 days.
Surface water and grit shall be wiped off the specimens and any projecting fins removed from
the surfaces which are to be in contact with the packing strips. Central lines shall be drawn on
the two opposite faces of the cube using any suitable procedure and device that will ensure that
they are in the same axial plane. The mass and dimensions of the specimen shall be noted before
testing. The sides of the specimen, lying in the plane of the pre-marked lines, shall be measured
near the ends and the middle of the specimen and the average taken to the nearest 0.2 mm. The
length of the specimen shall be taken to the nearest 0.2 mm by averaging the two lengths
measured in the plane containing the pre-marked lines. The bearing surfaces of the testing
machine and of the loading strips shall be wiped clean. The test specimen shall be placed in the
centering jig with packing strip and/or loading pieces carefully positioning along the top and
bottom of the plane of loading of the specimen. The jig shall then be placed in the machine so
that the specimen is located centrally. The load shall be applied without shock and increased

Page 13 of 40
continuously at a nominal rate within the range 1.2 N/(mm2/min) to 2.4 N/(mm2 /min). Maintain
the rate, once adjusted, until failure. The maximum load applied shall then be recorded.
2.4.7 Hardened properties - Flexural test on beam
The standard specimen size shall be 15 × 15 × 70 cm. Alternatively, if the largest nominal size of
the aggregate does not exceed 19 mm, specimens 10 × 10 × 50 cm may be used.
The bearing surfaces of the supporting and loading rollers shall be wiped clean, and any loose
sand or other material removed from the surfaces of the specimen where they are to make contact
with the rollers. The specimen shall then be placed in the machine in such a manner that the load
shall be applied to the uppermost surface as cast in the mould, along two lines spaced 20.0 or
13.3 cm apart. The axis of the specimen shall be carefully aligned with the axis of the loading
device. No packing shall be used between the bearing surfaces of the specimen and the rollers.
The load shall be applied without shock and increasing continuously at a rate such that the
extreme fiber stress increases at approximately 7 kg/sq cm/min, that is, at a rate of loading of 400
kg/min for the 15.0 cm specimens and at a rate of 180 kg/min for the 10.0 cm specimens. The
load shall be increased until the specimen fails, and the maximum load applied to the specimen
during the test shall be recorded. The appearance of the fractured faces of concrete and any
unusual features in the type of failure shall be noted.

2.5 OBSERVATIONS AND CALCULATIONS

2.5.1 Concrete making

Mix Details :

Water cement ratio :

Volume of concrete : m3

Give Volume Calculation:

Weight of cement : kg

Weight of fine aggregate : kg

Weight of coarse aggregate : kg

Weight of water : kg

Page 14 of 40
2.5.2 Fresh Properties – Slump/Unit weight/air content of concrete
Slump = mm

Unit weight of concrete

Volume of the cylindrical measure, V = m3
Weight of the empty cylinder, W1 = kg
Weight of cylinder with compacted concrete, W2 = kg

Unit weight of concrete =

= kg/m3
Air content of concrete (as % of air on the pressure gage dial) = %

2.5.3 Hardened properties – 7 and 28-day compressive strengths of concrete

Date of casting :
Date of testing :
Table 2-1 Observations on 77-day compressive strength of concrete
Compressive
strength Compressive strength (MPa)
Sl. measured using Failure
No. Impact Hammer load (kN) Standard
Individual Average
(kN) deviation
1.
2
3

Estimated 28-day compressive strength =

2.5.4 Hardened properties - split tensile strength of concrete

Diameter of the specimen, d = mm
Length of the specimen, l = mm
Load at failure, P = N

Tensile strength, fct =

= MPa

Page 15 of 40
2.5.5 Hardened properties - Flexural strength of concrete by test on beams
The flexural strength of the specimen shall be expressed as the modulus of rupture fb,
which, if ‘a’ equals the distance between the line of fracture and the nearer support,
measured on the centre line of the tensile side of the specimen, in cm, as follows:

when ‘a’ is greater than 20.0 cm for 15.0 cm specimen, or greater than 13.3 cm for a 10.0
cm specimen, or

when ‘a’ is less than 20.0 cm but greater than 17.0 cm for 15.0 cm specimen or less than
13.3 cm but greater than 11.0 cm for a 10.0 cm specimen, where,
b = measured width in cm of the specimen,
d = measured depth in cm of the specimen at the point of failure,
l = length in cm of the span on which the specimen was supported, and
p = maximum load in kN applied to the specimen.

If ‘a’ is less than 17.0 cm for a 15.0 cm specimen, or less than 11.0 cm for a 10.0 cm
specimen, the results of the test shall be discarded.

Distance between the line of fracture

and the nearer support, a = cm

Measured width of the specimen = cm

Clear span = cm

Maximum load applied = kN

Modulus of rupture (use appropriate formula) =

2.6 RESULTS
2.6.1 The workability of the concrete in terms of slump = mm
2.6.2 Unit weight of fresh concrete = kg/m3
2.6.3 Air content of fresh concrete = %
2.6.4 Mean compressive strength of concrete = MPa
2.6.5 Split tensile strength of concrete = MPa
2.6.6 Modulus of rupture of concrete = MPa

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 3 AGGREGATE LAB
3.1 AIM
i) To determine the specific gravity of coarse aggregate
ii) To determine the specific gravity of fine aggregate
iii) To determine bulk density (by compacted weight) and void content (%) of fine
aggregates
iv) To determine bulk density (by compacted weight) and void content (%) of coarse
aggregates
v) To determine the bulking of sand
vi) To determine the flakiness index, elongation index and angularity of coarse aggregates
vii) To determine the impact value of coarse aggregate
viii) To determine the abrasion value of coarse aggregate by the use of Los Angeles Machine
ix) To determine the crushing value of coarse aggregate

3.2 REFERENCED CODES

f) IS 2386-1963 Methods of test for aggregates for concrete; Part III: Methods of test for
aggregates for concrete
g) IS 2386–1963; Methods of test for aggregates for concrete; Part IV: Mechanical
properties
h) IS 383–1970; Specification for coarse and fine aggregates from natural sources for
concrete

3.3 APPARATUS
3.3.1 Specific gravity test
 Balance
 Oven
 Pycnometer
 Tray
NOTE: The vessel used for this test shall be capable of holding 1 kg of material and capable of being filled with
water to a constant volume. Either of the following two vessels is suitable. a) Glass vessel (called pycnometer) of
1 litre capacity having a metal conical screw top with a 6 mm diameter hole at its apex. The screw top shall be
watertight. (b) A wide mouth glass vessel of 1.25 litres capacity with a flat ground lip and a plane ground glass to
cover it, giving virtually a watertight fit.
3.3.2 Bulk density and void content tests
 Balance
 Cylindrical metal measure
 Tamping rod
NOTE: The cylindrical metal measure shall be water tight and of sufficient rigidity to retain its form under rough
usage. The measure shall be of 3 litres capacity, for the aggregates of size 4.75 mm and less and 15 litres capacity
for the aggregates of size over 4.75 mm to 40 mm. Tamping rod is a straight metal rod of cylindrical cross section
16 mm in diameter and 60 cm long, rounded at one end.

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3.3.3 Bulking of Sand
 Measuring jar 250 c.c.
 Weighing balance
3.3.4 (a) Flakiness Index, (b) Elongation Index and (c) Angularity

3.3.4.1 For flakiness and elongation tests

 Balance - Should have an accuracy of 0.1 percent of the weight of the test sample
 Metal Gauges of particular pattern
 Sieves

Figure 1 Flakiness thickness gauge

Figure 2 Elongation length gauge

3.3.4.2 For Angularity test

 Metal Cylinder: A metal cylinder closed at one end and of about 3 litre capacity, the diameter and height of
which shall be approximately equal, for example 15 cm and 15 cm. The cylinder shall be made from metal
of thickness not less than3 mm and shall be of sufficient rigidity to retain its shape under rough usage.
 Tamping Rod: A straight metal tamping rod of circular cross-section of 16 mm diameter and 60 cm long,
rounded at one end.
 Balance: Balance or scale of capacity 10 kg readable to one gram.
 Scoop: A metal scoop approximately 20 x 12 x 5 cm

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3.3.5 Aggregate Impact Value
 An impact-testing machine with a cylindrical steel cup of internal diameter 102 mm and depth of 50 mm
and not less than 6.34 mm thick
 A metal hammer weighing 13.5 to 14.0 kg.
 The IS Sieves of sizes 12.5, 10 and 2.36 mm.
 A straight metal tamping rod of circular cross-section 10 mm in diameter and 230 mm long, rounded at one
end.
 A balance of capacity not less than 500 g, readable and accurate to 0.1 g.
3.3.6 Aggregate Abrasion Value
 Los Angles machine consists of a hollow steel cylinder, closed at both ends, having an inside diameter of
700 mm and an inside length of 500mm
 Steel charges.
 The 1.70 mm IS Sieve.
 A balance of capacity not less than 500 g, readable and accurate to 0.1 g.
3.3.7 Crushing Value of Coarse Aggregate
 A 15 cm diameter open-ended steel cylinder, with plunger and base-plate.
 A straight metal tamping rod of circular cross-section 16 mm in diameter and 45 to 60 cm long, rounded at
one end.
 A balance of capacity 3 kg, readable and accurate to one gram.
 IS Sieves of sizes 12.5, 10 and 2.36 mm.
 A compression testing machine capable of applying a load of 40 tones and which can be operated to give a
uniform rate of loading so that the maximum load is reached in 10 minutes.

3.4 PROCEDURES
NOTE: Write brief descriptions of the test procedures and provide small photograph(s) of apparatus/equipment/test
specimens to aid the description. Important elements in the photograph must be labelled properly. A caption should
be given for each photograph.
3.4.1 Specific gravity tests (fine and coarse aggregates)
3.4.1.1 Prepare a saturated surface dry sample of the given aggregate as detailed
below:
3.4.1.2 Place a sample of 500 gm in a tray and cover it with distilled water.
3.4.1.3 Remove the air entrapped by gentle agitation. The sample shall remain for
24 hours. Drain the water from the sample by decantation through a filter
paper. Expose the aggregates to a gentle current of warm air to evaporate the
surface moisture with gentle stirring until no free surface moisture can be seen.
The material is now in a saturated surface dry condition. [Note: This Step
relates to preparation of saturated surface dry aggregates. However, due to time
shortage, the waiting time will be reduced (say, 30 minutes)]
3.4.1.4 Determine the empty weight of the pycnometer (Weight A).
3.4.1.5 Place the saturated surface dry sample in the pycnometer so that it occupies
about three-fourths of the volume of the pycnometer, and obtain the weight of
the pycnometer with the sample (Weight B).
3.4.1.6 Fill the pycnometer containing the aggregate, with distilled water up to the
brim taking care to see that no air bubbles are entrapped.
3.4.1.7 Weigh the pycnometer with aggregate and water as filled (Weight C).

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 3.4.1.8 Empty the pycnometer and dry the sample in an oven for 24 hours and
determine its dry weight (Weight D).
3.4.1.9 Clean the inside of the pycnometer and fill it up with distilled water up to the
brim eliminating any entrapped air bubbles.
3.4.1.10 Determine the weight of pycnometer with water (Weight E).
3.4.2 Bulk density and void content tests (fine and coarse aggregates)
3.4.2.1 Collect a sample of dry aggregate materials.
3.4.2.2 Fill the measure about one-third full with thoroughly mixed aggregate and
tamp it with 25 strokes of the rounded end of the tamping rod.
3.4.2.3 The measure shall be filled in another two layers and given tamping of
25 strokes for each layer. The net weight of the aggregate in the measure shall
then be determined.
3.4.2.4 Calculate the bulk density in kilogram per litre.
3.4.2.5 Calculate the percentage of voids from specific gravity and bulk density of the
aggregate.
3.4.3 Bulking (sand/fine aggregates)
3.4.3.1 Select a sand sample and dry it to constant weight.
3.4.3.2 Weigh exactly 200 gm of dry sand and pour it in a measuring jar
3.4.3.3 Find out its volume and transfer the sand from the measuring jar to a clean
mixing tray
3.4.3.4 Add 1 percent of water based on the weight of sand.
3.4.3.5 Mix thoroughly the water with the sand and pour the damp sand into the jar and
find its volume
3.4.3.6 Find the volume of sand with varying percentage of water increasing in steps of
1 percent
3.4.3.7 Observe the changes in volume of sand with increase in water content.
3.4.3.8 Verify whether the bulking increases in the initial stages and then starts
decreasing, to attain zero value at some moisture content
3.4.3.9 Draw a graph connecting the percentage of water and bulking of sand
(expressed as percentage increase in its volume).
3.4.4 Flakiness Index
3.4.4.1 The sample shall be sieved in accordance with the standard method with the
specified sieves
3.4.4.2 Each fraction shall be gauged in turn for thickness on a metal gauge of the
pattern or in bulk on sieves having elongated slots. The width of the slot used
in the gauge or sieve shall be of the dimension in col. 3 of Table 1 for the
appropriate size of material.
3.4.4.3 The total amount passing the gauge shall be weighed to an accuracy of at least
0.1 percent of the weight of the test sample

Page 20 of 40
3.4.5 Elongation Index
3.4.5.1 The sample shall be sieved in accordance with the standard method with the
specified sieves
3.4.5.2 Each fraction shall be gauged individually for length on a metal length gauge.
The gauge length used shall be that specified in column 4 of Table-1 for the
appropriate size of material.
3.4.5.3 The total amount retained by the length gauge shall be weighed to an accuracy
of at least 0.1 percent of the weight of the test sample.

3.4.6 Angularity Number

3.4.6.1 The amount of aggregate available shall be sufficient to provide, after
separation on the appropriate pair of sieves, at least 10 kg of the predominant
size, as determined by the sieve analysis on the 20 mm, 16 mm, 12.5 mm,
10 mm, 6.3 mm and 4.7 mm IS Sieves. The test sample shall consist of
aggregate retained between the appropriate pair of IS Sieves (square mesh)
from the following sets:
20.0 mm and 16.0 mm
16.0 mm and 12.5 mm
12.5 mm and 10.0 mm
10.0 mm and 6.3 mm
6.3 mm and 4.75 mm
3.4.6.2 The scoop shall be filled and heaped to overflowing with the aggregate, which
shall be placed in the cylinder by allowing it to slide gently off the scoop from
the least height possible. The aggregate in the cylinder shall be subjected to
100 blows of the tamping rod at a rate of about 2 blows per second.
3.4.6.3 Each blow shall be applied by holding the rod vertical with its rounded end 5
cm above the surface of the aggregate and releasing it so that it falls freely. No
force shall be applied to the rod. The 100 blows shall be evenly distributed
over the surface of the aggregate.
3.4.6.4 The process of filling and tamping shall be repeated exactly as described above
with a second and third layer of aggregates; the third layer shall contain just
sufficient aggregate to fill the cylinder level with the top edge before tamping.
After the third layer has been tamped, the cylinder shall be filled to
overflowing, and the aggregate struck off level with the top using the tamping
rod as a straight edge.
3.4.6.5 Individual pieces shall then be added and 'rolled-in' to the surface by rolling the
tamping rod across the upper edge of the cylinder, and this finishing process
shall be continued as long as the aggregate does not lift the rod off the edge of
the cylinder on either side.
3.4.6.6 The aggregate shall not be pushed in or otherwise forced down, and no
downward pressure shall be applied to the tamping rod, which shall roll in
contact with the metal on both side of the cylinder. The aggregate in the
cylinder shall than be weighed to the nearest 5 grams.

Page 21 of 40
 3.4.6.7 Three separate determinations shall be made, and the mean weight of aggregate
in the cylinder calculated. If the result of any one determination differs from
the mean by more than 25 grams, three additional determinations shall
immediately be made on the same material and the mean of all the six
determinations calculated.

3.4.7 Aggregate Impact Value

3.4.7.1 The test specimen shall consist of aggregates passing through a 12.5 mm IS
Sieve and retained on a 10 mm IS Sieve. The aggregate comprising the test
specimen shall be dried in an oven for a period of four hours at a temperature
of 100 to 110 0 C and cooled. The measure shall be filled to about one third full
with the aggregate and tamped with 25 strokes of the tamping rod. A similar
quantity of aggregates shall be added and tamped for 25 times. The measure
shall finally be filled to brim, tamped 25 times and leveled, using the tamping
rod as a straight-edge. The net weight of aggregate in the measure shall be
determined to the nearest gram (weight A). Two tests with different aggregate
samples shall be conducted.
3.4.7.2 Transfer the measured aggregates to the container in the impact machine. The
impact machine shall rest without wedging or packing upon the level plate,
block or floor, so that it is rigid and the hammer guide columns are vertical.
3.4.7.3 The cup shall be fixed firmly in position on the base of the machine and the
whole of the test sample placed in it. The hammer shall be raised until its lower
face is 380 mm above the upper surface of the aggregate in the cup, and
allowed to fall freely on to the aggregate.
3.4.7.4 The test sample shall be subjected to a total of 15 blows each being delivered at
an interval of not less than one second. The crushed aggregate shall then be
removed from the cup and the whole of it sieved on the 2.36 mm IS Sieve until
no further significant amount passes in one minute.
3.4.7.5 The fraction passing the sieve shall be weighed to an accuracy of 0.1 g (weight
B). The fraction retained on the sieve shall also be weighed (weight C) and, if
the total weight (B+C) is less than the initial weight (weight A) by more than
one gram, the result shall be discarded and a fresh test made.

Page 22 of 40
3.4.8 Aggregate Abrasion Value
3.4.8.1 Collect test sample consisting of clean aggregates and conforming to one of the
grading shown in Table 3-1.
3.4.8.2 Collect abrasive charges consisting of cast iron spheres or steel spheres
approximately 48 mm in diameter and each weighing between 390 and 445 g.
The abrasive charge, depending upon the grading of the test sample shall be as
given in Table 3-2.
3.4.8.3 Place the test sample and the abrasive charge into the Los Angles abrasion
testing machine
3.4.8.4 Rotate the machine at a speed of 20 to 33 rev/min. [For grading A,B,C and D,
the machine shall be rotated for 500 revolutions; for grading E, F and G, it
shall be rotated for 1000 revolutions.
3.4.8.5 The machine shall be so driven and so counter-balanced as to maintain a
substantially uniform peripheral speed.
3.4.8.6 At the completion of the test, discharge the material from the machine
3.4.8.7 Separate the sample made on sieve coarser than the 1.70 mm IS Sieve. The
finer portion shall then be sieved on a 1.70 mm IS Sieve. Dry (at 105 to
110O C) and weigh (gram) the aggregate coarser than the 1.70 mm IS Sieve.

Table 3-1 Standard Grading of Test Samples

Table 3-2 Abrasive charge for different grading of the test sample (from IS 2386)

Page 23 of 40
3.4.9 Crushing Value of Coarse Aggregate
3.4.9.1 Preparation of Test Sample: The material for the standard test shall consist of
aggregate passing a 20 mm IS Sieve and retained on a 12.5 mm IS Sieve, and
shall be thoroughly separated on these sieves before testing. For other sizes, the
material shall be separated on the appropriate sieves given in Table 3-3.
Table 3-3 Details of aggregate crushing test for non-standard sizes of aggregate

3.4.9.2 About 6.5 kg of natural aggregate is required to provide the two test samples
for the 15 cm cylinder. The aggregate shall be tested in a surface-dry condition.
The quantity of aggregate shall be such that the depth of material in the
cylinder, after tamping as described shall be 10 cm.
3.4.9.3 The appropriate quantity may be found conveniently by filling the cylindrical
measures in three layers of approximately equal depth, each layer being
tamped 25 times with the rounded end of the tamping rod and finally levelled
off, using the tamping rod as a straight-edge.
3.4.9.4 The weight of material comprising the test sample shall be determined (weight
A) and the same quantity of sample from the same aggregate stockpile shall be
taken for the duplicate test.
3.4.9.5 Test Procedure: The cylinder of the test apparatus shall be put in position on
the base-plate and the measured aggregates transferred to the cylinder. The
surface of the aggregate shall be carefully levelled and the plunger inserted so
that it rests horizontally on this surface, care being taken to ensure that the
plunger does not jam in the cylinder.
3.4.9.6 The apparatus, with the test sample and plunger in position, shall then be
placed between the platens of the testing machine and loaded at as uniform a
rate as possible so that the total load is reached in 10 minutes.
3.4.9.7 The total load shall be 40 tones. The load shall be released and the whole of the
material removed from the cylinder and sieved on a 3.35 mm IS Sieve for the
standard test, or the appropriate sieve given in Table I. The fraction passing the
sieve shall be weighed (weight B). In all these operations, care shall be taken to
avoid loss of the fines.

Page 24 of 40
3.5 OBSERVATIONS AND CALCULATIONS
3.5.1 Specific gravity tests (fine and coarse aggregates)
Table 3-4 Observations/calculations for specific gravity test on fine and coarse aggregates
Parameter Fine aggregate Coarse aggregate
Empty weight of the pycnometer (A)
Weight of the pycnometer with the sample
(about 3/4 filled in pycnometer) (B)
Weight of the pycnometer with aggregate and
water as filled (C)
Weight of the aggregate taken above in oven dry
condition (D)
Weight of pycnometer with water (E)
Weight of the saturated surface dry aggregate (g)
Formula:= B – A
Weight of water in equal volume to that of
aggregate (g)
Formula: = (E- A) – (C – B)
Actual Specific gravity of the aggregate
Formula: = D/ (E- A) – (C – B)
Approx. Specific gravity of the aggregate
Formula: = (B-A)/ ((E-A) - (C-B))
Note: Within the time allotted for class work, the weight of the oven dry sample (Weight D) cannot be
determined. Hence, it is assumed that the given sample is in oven dry condition and the absorption capacity
is 2%.. Then the specific gravity may be calculated as = (B-A)/ ((E-A) - (C-B)).

3.5.2 Bulk density and void content tests (fine and coarse aggregates)
Table 3-5 Observations/calculations for bulk density/void content tests on aggregates
Parameter Fine aggregate Coarse aggregate
Weight of empty vessel (A)
Weight of vessel with aggregate (B)
Volume of the vessel (C)
Weight of aggregate sample (kg)
Bulk Density (kg/m3)
Formula:= B/C
Percentage of voids (%)
Formula: = (SG – Bulk density)/ SG

Page 25 of 40
3.5.3 Bulking of sand

Parameter Fine aggregate Coarse aggregate

Weight of empty vessel (A)
Weight of vessel with aggregate (B)
Volume of the vessel (C)

3.5.4 Flakiness Index, Elongation Index and Angularity

Parameter Flakiness test Elongation test

Mass of particles passing the
appropriate gauge in given
sieve fraction (x1)

Mass of particles retained the

appropriate gauge in given
sieve fraction (x2)

Mass of total number of pieces

in given sieve fraction (y)

Flakiness Index = Total weight of the material passing the various thickness gauges or
sieves, expressed as a percentage of the total weight of the sample
gauged
=

Elongation Index = Total weight of the material retained on the various length gauges,
expressed as a percentage of the total weight of the sample gauged
=

Angularity number = 67 - (100 x W) / (C x SGagg)

=
where,
W = mean weight in g of the aggregate in the cylinder,
C = weight of water in g required to fill the cylinder, and
SGagg= specific gravity of aggregate.

Page 26 of 40
3.5.5 Aggregate impact value
Table 3-6 Observation table for aggregate impact value tests
Sample Weight of fraction Weight of oven Aggregate Average
passing through IS dried sample in Impact Impact
No.
sieve 2.36 mm in grams (A) Value value
grams (B) (B/A)x100
1
2

Aggregate impact value = , where,

B = weight of fraction passing IS 240 Sieve size, and A = weight of oven-dried sample.

The ratio of the weight of fines formed to the total sample weight in each test shall be
expressed as a percentage, the result being recorded to the first decimal place.

3.5.6 Aggregate Abrasion Value

Weight of the sample in grams, W1 =

Weight of the sample retained on the appropriate sieve in grams, W2 =

Aggregate abrasion Value =

3.5.7 Crushing Value of Coarse Aggregate

Table 3-7 Observation table for crushing value of aggregate tests
Sample Weight of fraction Weight of surface- Crushing Value of Average
No. passing the dry sample in Aggregate Crushing
appropriate sieve in grams(A) Value of
grams(B ) Aggregate

1
2.

Aggregate crushing value = , where,

B = weight of fraction passing the appropriate sieve, and
A = weight of surface-dry sample.

The ratio of the weight of fines formed to the total sample weight in each test shall be
expressed as a percentage, the result being recorded to the first decimal place.
Page 27 of 40
3.6 RESULTS

Table 3-8 Results from physical and mechanical tests on fine and coarse aggregates
Parameter Unit Fine aggregate Coarse aggregate
Specific gravity

Bulk density

Percentage of voids

Bulking of sand

Flakiness Index

Elongation Index

Angularity Number

Impact value

Abrasion value

Crushing value

Page 28 of 40
 4 BRICK-TILE LAB
4.1 AIM
(i) To determine efflorescence of burnt clay bricks
(ii) To determine warpage (to the nearest 0.5 mm) of burnt clay bricks
(iii) To determine dimensional tolerances of burnt clay bricks when exposed to moisture
(iv) To determine the compressive strength of bricks
(v) To determine the water absorption of bricks
(vi) To determine wet transverse strength of tiles
(vii) To determine wear resistance of tiles

4.2 REFERENCED CODES

a) IS 3495-1976 Methods of tests of burnt clay building bricks
b) IS 5454-1976 Method for sampling of clay building bricks
c) IS 1077-1992 Common Burnt Clay Building Bricks – Specification
d) IS 1237-1980 Specification for cement concrete flooring tiles

4.3 APPARATUS
4.3.1 Efflorescence test
 A tray made of glass or porcelain (size: 180 mm x 180 mm and 40 mm depth)
 A cylinder made of glass or porcelain (size: 200 mm dia. x 40 mm depth)
4.3.2 Warpage test
 A steel rule graduated from one end in 0.5 mm divisions. Alternatively, a steel measuring wedge 60 mm in
length, 15 mm in width and 15 mm in thickness at one end and tapered, starting at a line 15 mm from one
and to zero thickness at the other end. The wedge shall be graduated in 0.5 mm divisions and numbered to
show the thickness of the wedge between the base and the slope.
 A flat surface of steel or glass, not less than 300 x 300 mm in area
4.3.3 Dimensional tolerance test
 Measuring scale/ruler
4.3.4 Compressive Strength test
 A compression testing machine, the compression plate of which shall have a ball seating in the
form of portion of a sphere the centre of which coincides with the centre of the plate, shall be
used.
4.3.5 Water absorption test
 A sensitive balance capable of weighing within 0’1 percent of the mass of the specimen
 Ventilated oven.
4.3.6 Wet transverse strength test
 Flexure testing apparatus with simple end-supports (bearers) for the tile and facility for applying and
measuring a centrally located line load on the tile acting as a beam,
 10 kg balance for measuring weight of tile, and
 Measuring scale

Page 29 of 40
4.3.7 Wear resistance test
 Apparatus for abrasion-testing of tiles
 Thickness measuring instrument
 A suitable instrument capable of measurements to an accuracy of 0.01 mm

4.4 PROCEDURES
4.4.1 Efflorescence test
4.4.1.1 Place the end of the bricks in the dish, the depth of immersion in water being
25mm.
4.4.1.2 Place the whole arrangement in a warm well ventilated room until all the water
in the dish is absorbed by the specimens and the surplus water evaporates.
4.4.1.3 Cover the dish containing the brick with suitable glass cylinder so that
excessive evaporation from the dish may not occur.
4.4.1.4 When the water has been absorbed and bricks appear to be dry, place a similar
quantity of water in the dish and allow it to evaporate as before.
4.4.1.5 Examine and report the bricks for efflorescence after the second evaporation.
The liability to efflorescence shall be reported as 'nil', 'slight', 'moderate,
`heavy' or `serious' in accordance with the definitions in Table 4-1.
Table 4-1 Standard definitions for various efflorescence levels on bricks
a) Nil When there is no perceptible deposit of efflorescence

b) Slight When not more than 10% of the exposed area of the brick is covered with
a thin deposit of salts
c) Moderate When there is a heavier deposit than under ‘slight’ and covering upto
50% of the exposed area of the brick surface but unaccompanied by
powdering or flaking of the surface
d) Heavy When there is a heavy deposit of salts covering 50% or more of the
exposed area of the brick surface but unaccompanied by powdering or
flaking of the surface

e) Serious When there is a heavy deposit of salts accompanied by powdering and/or

flaking of the exposed surfaces

4.4.2 Warpage test - concave

4.4.2.1 Remove any dirt adhering to the surface of brick
4.4.2.2 Place the flat surface along the surface to be measured, selecting the location
that gives the greatest departure from straightness.
4.4.2.3 Measure the greatest distance of the brick surface from the edge of straightness
by a steel rule or wedge.
4.4.3 Warpage test - convex
4.4.3.1 Place the brick on the flat surface with the convex surface in contact with the
flat surface.
4.4.3.2 Mark the four corners of the brick as Corners A, B, C, and D
4.4.3.3 Measure the distance from flat surface to the Corners A, B, C, and D of the
brick and identify the minimum of four measurements.

Page 30 of 40
4.4.4 Dimensional tolerance test
4.4.4.1 Select twenty (or more according to the size of stack) whole bricks, at random
from the sample selected.
4.4.4.2 Remove all the blisters, loose particles of clay and small projections from the
brick surface
4.4.4.3 Linearly, arrange the bricks on a levelled surface
4.4.4.4 Measure the total length of the assembled bricks. [NOTE: Use a steel tape or
other suitable inextensible measure that is sufficiently long to measure the
whole row at one stretch. Measurement by repeated applications of short rule
or measure shall not be permitted.]
4.4.4.5 If, for any reason, it is found impracticable to measure bricks in one row of
20 bricks, then divide the sample into rows of 10 bricks. Then, measure the
length of each row separately to the nearest millimeter. All these dimensions
shall be added together.
4.4.4.6 Compare the dimensions with the standard dimensions and tolerances given in
Table 4-2

Table 4-2 The standard modular size and tolerances of some common bricks (IS 1077-1992)
Modular type Parameter Standard size of Tolerance for a row
one brick (mm) of 20 bricks (mm)
Standard Length (L) 190 3800 ± 80 mm
Width (W) 90 1800 ± 40 mm
Height (H) 90 1800 ± 40 mm
Standard Length (L) 190 3800 ± 80 mm
Width (W) 90 1800 ± 40 mm
Height (H) 40 800 ± 40 mm
Non-standard Length (L) 230 4600 ± 80 mm
Width (W) 110 2200 ± 40 mm
Height (H) 70 1400 ± 40 mm
Non-standard Length (L) 230 4600 ± 80 mm
Width (W) 110 2200 ± 40 mm
Height (H) 30 600 ± 40 mm

Page 31 of 40
4.4.5 Compressive strength test for bricks
4.4.5.1 Immerse the specimen in water at room temperature for 24 hours.
4.4.5.2 Remove the specimen from water and drain out any surplus water. No mortar
shall be filled in perforations and no mortar capping shall be provided.
4.4.5.3 Place the specimen with flat faces horizontal, and mortar filled face
facing upwards between two 3-ply plywood sheets each of 3 mm
thickness and carefully centred between plates of the testing machine.
4.4.5.4 Apply load axially at a uniform rate of 14 N/mm2 ( 140 kgf/cm2 ) per
minute till failure occurs and note the maximum load at failure.
4.4.5.5 The load at failure shall be the maximum load at which the specimen
fails to produce any further increase in the indicator reading on the
testing machine.
4.4.6 Water absorption test for bricks
4.4.6.1 Dry the specimen in a ventilated oven at a temperature of 105 to 115°C
till it attains substantially constant mass. Cool the specimen to room
temperature and obtain its weight ( M1 ).
4.4.6.2 Immerse completely dried specimen in clean water at a temperature of
270C + 2°C for 24 hours.
4.4.6.3 Remove the specimen and wipe out any traces of water with a damp
cloth and weigh the specimen. Complete the weighing 3 minutes after
the specimen has been removed from water ( M2 ).
4.4.7 Wet transverse strength test for tiles
4.4.7.1 Collect 6 full-size tile specimens and immerse the tiles in water for 24 hours.
4.4.7.2 Then, remove the tiles from water and wipe to dry.
4.4.7.3 Place the specimen horizontally on bearers with its wearing surface uppermost
and its sides parallel to the bearers.
4.4.7.4 Place a plywood packing (3mm thick and 25mm wide) between the tile and the
bearers and also between the tile and the loading bar.
4.4.7.5 Apply load to mid-span starting from zero and increase it steadily and
uniformly at a rate not exceeding 200kg per metre width (measured along the
bearer) per minute until the specimen fails.
4.4.7.6 Record the breaking load.
4.4.7.7 Repeat the experiment on the remaining specimens and calculate the average
wet transverse strength.
4.4.7.8 Compare the average wet transverse strengths with the limits in Table 4-3.
Table 4-3 IS Specifications for wet transverse strength of cement concrete flooring tiles of various sizes
Size of Tile Span
Minimum specified wet transverse strength (MPa)
(mm) (mm)
200 x 200 150
250 x 250 200 3
300 x 300 205

Page 32 of 40
4.4.8 Wear resistance test for tiles
4.4.8.1 The test specimens shall be square in shape and of size 7.06 x 7.06 cm (i.e. 50
cm2 in area) with an accuracy of ± 2%. They shall be sawn off, only one from
each tile, preferably from the central part of the tile. The surface to be tested
shall be ground smooth, if necessary.
4.4.8.2 The specimens shall be dried at 110° ± 5°C for 24 hours and then weighed to
the nearest 0.1 g. The specimen after initial drying and weighing shall be
placed in the thickness-measuring apparatus with its wearing surface upwards
and the reading of the measuring instrument taken.
4.4.8.3 The grinding path of the disc of the abrasion testing machine shall be spread
evenly with 20 g of the abrasive powder.
4.4.8.4 The specimen shall then be fixed in the holding device with the surface to be
ground facing the disc, and loaded at the centre with 300 N (30 kgf).
4.4.8.5 The grinding disc shall be put in motion at a speed of 30 rpm and the abrasive
powder is continuously fed back on to the grinding path so that it remains
uniformly distributed in a track corresponding to the width of the test piece.
4.4.8.6 After every 22 revolutions, the disc shall be stopped, the abraded tile powder
and the remainder of the abrasive powder shall be removed from the disc, and
fresh abrasive powder in quantities of 20 g applied each time.
4.4.8.7 After every 22 revolutions the specimen shall be turned about the vertical axis
through an angle of 90° in the clockwise direction and it should be repeated 9
times thereby giving total number of revolutions of 220.
4.4.8.8 The disc, the abrasive powder and the specimen shall be kept dry throughout
the duration of the test.
4.4.8.9 After the abrasion is over, the specimen shall be reweighed to the nearest 0.1 g.
It shall then be placed in the thickness measuring apparatus once again in an
identical manner and the reading taken with the same position and setting of
the dial gauge as for the measurement before abrasion.

4.5 OBSERVATIONS AND CALCULATIONS

4.5.1 Efforescence test
Liability of efflorescence =

4.5.2 Warpage test – concave

The maximum distance of the brick surface from the edge of straightness = mm

4.5.3 Warpage test - convex

Distance from the flat surface to the corner A of the brick = mm
Distance from the flat surface to the corner B of the brick = mm
Distance from the flat surface to the corner C of the brick = mm
Distance from the flat surface to the corner D of the brick = mm
Minimum distance from the flat surface to any of the corners = mm

Page 33 of 40
4.5.4 Dimensional tolerance test

Modular Parameter Standard size Allowable tolerance Measured length of

type of one brick for a row of a row of 20 bricks
(mm) 20 bricks (mm) (mm)
Length (L)
Width (W)
Height (H)
Length (L)
Width (W)
Height (H)

4.5.5 Compressive strength test for bricks

Sl.No. Size of brick Maximum Area of the Compressive Average

(mm) load at brick (mm2) strength Compressive
failure(N) (N/mm2) strength
1.
2.
3.

4.5.6 Water absorption test for bricks

Sl.No. Size of brick Weight of Weight of Water absorption Average

(mm) dry wet (M2--Ml ) x100 water
specimen specimen /M1 absorption
(M1) (M2)

1.
2.
3.

Page 34 of 40
4.5.7 Wet transverse strength test for tiles
Table 4-4 Observations from wet transverse strength test
Sl.No. Size of tile (mm) Span Proving ring dial gauge calibration
(mm) 1 Division = kg
Dial gauge Breaking load Wet flexural
reading (N) strength
(Divisions) (MPa)
1.
2.
3.

Average wet transverse strength of tiles = MPa

4.5.8 Wear resistance test for tiles

Table 4-5 Observations from wear resistance test
Corner
Sl. No. Initial Reading Final Reading Difference (mm)
Identification
A
B
C
D

The wear determined using the differences in readings obtained by the measuring
instrument before and after the abrasion of the specimen = mm

Initial weight, W1 = g

Final weight, W2 = g

Initial volume, V1 = cm3

Surface area of specimen, A = cm2

Average loss in thickness, t = (10(W1-W2)V1)/(W1.A) =

= mm

Page 35 of 40
Page 36 of 40
 5 STEEL LAB
5.1 AIM
To obtain stress-strain diagram and the following properties of a mild steel (MS) bar, TMT bar,
and high strength steel (center king-wire of a pre-stressing strand):
vii) Yield strength/ proof stress
viii) Ultimate strength
ix) Percent elongation at rupture
x) Modulus of elasticity

5.2 REFERENCED CODES

a) IS 432 (Part-1 and 2)-1982: Specification for mild steel and medium tensile bars for
concrete reinforcement
b) IS 1786-1979: Specification for cold worked steel high strength deformed bars for
c) concrete reinforcement (Fe 415)
d) IS 14268 - 1995: Indian Standard Uncoated Stress Relieved Low Relaxation Seven-ply
strand for prestressed concrete- specifications
e) IS 1608 - 2005 : Metallic materials – Indian Standard Tensile testing at ambient
temperature

5.3 APPARATUS
 Universal testing machine  Dot Punch
 Extensometer – 50mm Gauge length  Hammer
 Scale  Hacksaw blade
 Vernier caliper
5.4 PROCEDURES
5.4.1 7-wire strand testing
5.4.1.1 Take 15.2 mm diameter 7-wire strand and measure/record the diameter, gauge
length, gap length, pitch length of the strand.
5.4.1.2
Place the strand between the grips/ wedges and apply the load at a rate of not
less than 70 MPa/min or at the strain rate of 10-5 to 10-1 s-1
5.4.1.3 Apply an initial load of 10 % of the required minimum breaking strength to the
specimen, attach the extensometer and adjust it to a reading of 0.1 % of gauge
length.
5.4.1.4 Monitor the distance between the gripping jaws and increase the load until the
extensometer indicates an extension of 1 %.
5.4.1.5 Record the extensometer reading until it reaches the yield strength, at every
10 kN increment in the applied load.
5.4.1.6 The extensometer may be removed from the specimen after the yield strength
has been determined. The distance between the gripping jaws is measured. The
total percent elongation is calculated as a percentage of the change in the
jaw-to-jaw distance and adding this value to the value obtained by the
extensometer.
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 5.4.1.7 Continue loading to determine the maximum load at which one or more wires
of the strand are fractured. Record this load as the breaking strength of the
strand.

5.4.2 Solid reinforcement testing

5.4.2.1. Measure the length and diameter of the given specimen.
5.4.2.2. Mark the centre of the specimen using dot punch.
5.4.2.3. Mark two points P and Q at a distance of 25mm on either side of the centre mark so
that the distance between P and Q will be equal to 50mm. Place the extensometer at
P and Q
5.4.2.4. Insert the specimen in the middle cross head and top cross head grip of the machine
so that the two points A and B coincide with the tip of grips.
5.4.2.5. Mark two point A and B at the tip of the grip, and measure the length of A & B,
where distance between A and B is the spacing between the upper and lower grips.
5.4.2.6. Apply the load gradually at a rate of 70 MPa/min and continue the application of
load. After sometime, there will be slightly pause in the increase of load. The load
at this point is noted as yield point.
5.4.2.7. Apply load continuously till the specimen fails and note down the ultimate load and
breaking load from the digital indicator.
5.4.2.8. Remove the specimen from the machine and join the two pieces of the specimens.
5.4.2.9. Measure the distance between the two points A and B. This distance is known as
final gauge length of the specimen.
5.4.2.10. Measure the diameter of the rod at neck.
5.4.2.11. Determine the yield stress, ultimate stress, percentage elongation in length,
Modulus of elasticity and using the formula.

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5.5 OBSERVATIONS AND CALCULATIONS
5.5.1 Solid Reinforcement specimens
Note: All the calculations must be provided inside each cell in this table.
Table 5-1 Observations on the testing of solid reinforcement specimens
Steel Type Mild steel TMT steel Prestressing
steel (king-wire)
Nominal diameter (mm)

Nominal cross-sectional area (mm2)

Effective diameter after cutting the

circular groove at the center (mm)
Effective cross-sectional area (mm2)

Gauge length of the extensometer

(mm)
Gauge length [say, ] to calculate
the elongation (mm)
Formula =
Length of after testing (mm);

Remarks, if any

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NOTES

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