RMC - QUALITY LAB MANUAL

CQRA PVT. LTD, PUNE.

 INDEX
I - General

1. Table-1- List of tests to be conducted at RMC Lab

2. Table-2.- List of tests to be conducted at External Lab. (Third Party)
3. Table-3.- List of lab equipment’s for RMC Lab
4. Table-4.- List of reference IS codes
5. Table-5.- Acceptance Criteria for material Tests
6. Acceptance Criteria Graph ‘Zone wise’ for Sand

II - Procedures :

1. Area of Laboratory Required

2. Precautionary measures for testing equipment’s.
3. Procedure for Sampling of Material
4. Slump test
5. RMC Inspection/testing for Concrete
6. Cube filling from fresh concrete
7. Compressive strength of concrete
8. Procedure for Standard deviation
9. Field Test for Silt Content in Sand
10. Sieve Analysis of Fine aggregate
11. Sieve analysis of coarse aggregate
12. Specific Gravity and water Absorption of Aggregates
13. Flakiness Index
14. Elongation Index
15. Aggregate Crushing Value
16. Aggregate Impact Value
17. Bulk Density of Aggregates.
18. Moisture Content in Aggregates.
19. Bulking of Fine aggregates.
20. Consistency of Cement.
21. Initial and Final Setting time of Cement.
22. Compressive Strength of Cement.
23. Fineness of Cement by dry Sieving. .
24. Fineness of M Sand by Wety Sieving.(Deleterious Material)

III - Calibration of Test Equipments:

1. General
2. Calibration Plan
3. Procedure for Verification of Equipment’s
4. Calibration of Batching Plant
5. List of Abbreviations
6. Definitions
PART – I

GENERAL
 TABLE – 1

List of Tests to be Conducted at Site Laboratory :

Sr. Material to be Tests to be Conducted

No tested Related IS Codes

1. Concrete 1199 (1959), 456 (2000), 10262  Compressive strength

(1982), 8112 (1989)  Slump Test
a. Coarse Agg. 2430(1986)  Sieve Analysis
2386 part-1-3-4 (1963)  Aggregate Crushing /Impact
383 (1970) Value.
b. Fine aggregate 1542 (1992)  Flakiness & Elongation Index
2116 (1980)  Specific Gravity
383 (1972)  Water absorption
 Silt Content (Wet Sieving)
 Specific Gravity
 Bulk density
 Fineness modulus.
 Bulking of fine aggregates.
2. Cement 8112 (1989), 4031 (1988)  Consistency
 Initial and Final setting Time
 Fineness (Dry Sieving)
 Compressive Strength
3 GGBS 12089:1987  45 micn Retention
 TABLE – 2

List of the Material / Tests to be Conducted at External Laboratory :

*Note: External Laboratory shall be as per requirement of the project or as

approved by Client.

Sr. Material to Tests to be conducted Requirements

No. be Tested
1. Construction Portability, Sulphates, As per Requirements of IS :
Water Chlorides 456.
2. Cement As per respective IS codes for
OPC, PPC, PSC and for
Grades 43 /53
a. Physical Strength, Fineness, Initial / For every batch if MTC is not
Final setting Time, Standard available. If MTC is available at
Consistency, Soundness by Random frequency.
Le-chatelier method
b. Chemical Loss on ignition, Insoluble In case cement is old or for
residue new brand along with above
tests
3. Concrete Compatibility with cement- New admixture or admixture is
Admixtures Marsh cone testing giving performance problems.
4. Aggregate
a. Physical Routine tests If required.
Abrasion value Critically for road works
5. Concrete Mix Design As per Client requirement.
Non Destructive Tests like When cube strengths are below
Ultra sonic or Rebound acceptance criteria or as
hammer required by client.
Core Test As specified by IS : 456 or as
per Client requirement
 TABLE – 3
List of Laboratory Equipment’s :

Sr. Equipments Capacity/ Size Make

No
1. Compression Testing 2000 KN
machine
2. Cube Moulds 150x150x150 mm, ISI Mark
100 x 100x100 mm, (Contass)
70.6x70.6x70.6 mm,
3. Slump Cone Top Diameter – 100 mm,
Bottom Diameter – 200
mm,Height – 300 mm,
SheetThickness – 1.6 mm
min.
4. G.I.Coarse Aggregate 40,20,16,12.5,10,6.32,4.75,2.3 ISI Mark
Sieves- 300 mm dia 6 mm (Contass)
5. Brass Fine Aggregate 10mm & 4.75, 2.36, 1.18mm, ISI Mark
sieves- 200 mm dia 600mcn, 300mcn,150mcn (Contass)
6. Electronic Weigh Balance Battery backup ISI Mark (sico)
10kg,150 kg Platform 345x 225mm
a C.I. Weights 20 kg, 01 kg, 500g, etc. Duely calibrated
and stamped by
Weight and
Measure Dept.
7. Flakiness Index Gauge --
8. Elongation Gauge --
9. Measuring Cylinders 250 ml
a) Plastic Height 335mm
10. Pycnometer Bottle Capacity 1 litre approx.
11. Aggregate Crushing test --
apparatus
12. Aggregate Impact test --
apparatus
13. Oven with Thermostat 45x45cm size (2 tray)
aluminium chamber
14. G.I. Trays Large / med
15. Thermometer 200 deg range (Indian Glass) ISI Mark
16. Vernier Caliper -- ISI Mark
17. Wire gauge -- ISI Mark
18. Accelerator curing tank --
19. Vibrating table --
20. Vicat Apparatus --
21. Misc.- Brush, duster,
Trowel, scoop, Spanners,
Sample metal containers,
gunny bags, wheel
barrows, trays,

Table – 4

LIST OF REFERENCE IS CODES:

IS: 383 - Specifications for Coarse and Fine aggregate

IS: 516 - Method of tests for strength of Concrete
IS: 1199 - Method of Sampling & analysis of Concrete
IS: 2386-I - Method of test for aggregates – Particle size , shape
IS: 2386-III - Method of test for aggregates – Sp. Gr, Density
IS: 2386-IV - Method of test for aggregates- Mechanical properties
IS: 2430 - Method of Sampling Aggregates
IS: 269 - Specifications for 33 Grade Ordinary Portland cement. (For Ref)
IS: 8112 - Specifications for 43 Grade Ordinary Portland cement. (For Ref)
IS: 12269 - Specifications for 53 Grade Ordinary Portland cement. (For Ref)
IS: 10262 - Guidelines for Concrete Mix Design. (For Ref)
IS: 456 - Specification for Plain and Reinf. Cement Concrete. (For Ref)
IS : 9103 - Concrete Admixture : Specification
IS : 3812 - Specification for Fly Ash for use as pozzolana and admixture
IS : 9013 - Accelerated Cured – Concrete.
IS : 4031 - Physical test for Hydraulic cement.
IS : 4032 - Chemical test for Hydraulic Cement.
IS : 3025 - Method and Sampling of Test for Water.
 TABLE – 5
ACCEPTANCE CRITERIA FOR VARIOUS MATERIAL

Material Test Required Relevant IS Code Acceptance Criteria

IS : 12269 -1989 ; IS :
CEMENT Initial Setting Time Not Less Than 30 minutes
4031 ( Part -5 ) -1988
IS : 12269 -1989 ; IS :
Final Setting Time Not More Than 600 minutes
4031 ( Part -5 ) -1988
IS : 12269 -1989 ; IS : Specific Surface of cement shall not be less
Fineness Test
4031 ( Part -2 ) -1988 than 225 m2/kg
IS : 12269 -1989 ; IS : Expansion shall not be more than 10 mm or
Soundness Test
4031 ( Part -3 ) -1988 0.8%
;33 grade – 33 Mpas , 43 grade - 43 Mpa ; 53
Compressive Strength IS : 12269 -1989 ;IS - 516
grade – 53 Mpa for 28 days
90 Mic Retention IS 4031 : 1988 Max 10 %
IS:1727 : 1967 ;IS
GGBS 45 Mic Retention Max. 20 %
4031(Part I & VI)
IS:1727 : 1967 ;IS Specific Surface of cement shall not be less
Fineness Test
4031(Part I & VI) than 320 m2/kg

IS:1727 : 1967 ;IS Not less than 80% of the strength of

Compressive Strength
4031(Part I & VI) corresponding plain cement mortar cubes.

MTC

Fine Aggregate IS : 383 - 1970 90-100% passing through 4.75mm and 20-
Sieve analysis
(C.Sand) IS :2386-I- 1963 40% passing through 600 mic. IS sieve

IS : 383 - 1970
Bulk Density As Actual
IS :2386-III- 1963
IS : 383 - 1970
Fineness Modulus 2.6 -3.5
IS :2386-I- 1963
IS : 383 - 1970
Water Absorption As Actual
IS :2386-III- 1963
IS : 383 - 1970
Specific Gravity As Actual
IS :2386-III- 1963
Silt Content IS : 383 / 2116/1542 0-10 % passing through 75 mic. Is sieve

Coarse
Sieve analysis IS : 383 -1970 IS : 2386 - I 100% retained on 4.75 mm Sieve
Aggregate
IS : 383 -1970 IS : 2386 -
Crushing Value 45% for concrete; 30% for road concrete
v
IS : 383 -1970 IS : 2386 -
Impact value 45% for concrete; 30% for road concrete
v
IS : 383 - 1970 IS : 2386-
Bulk Density As Actual
III
 IS : 383 - 1970
Water Absorption As Actual
IS :2386-III- 1963
IS : 383 - 1970
Specific Gravity As Actual
IS :2386-III- 1963
Flakiness & Elongation
IS : 383 -1970 IS : 2386 - I Flakiness-10 %, Elongation - 15 %
Index
Low - 25 to 75 mm, Medium - 50-100 mm,
Concrete Slump IS : 1199, IS : 456
High - 100-150
Compressive Strength IS : 516 - 1969, IS : 456 As per IS : 456
Suitability for pH value not < 6; sulphates - 400 mg/l max,
Water IS : 456, IS : 3025
Construction Chlorides- 500 mg /l max for RCC

Admixture Relative Density IS : 456, IS : 9103 within 2% of value stated by manufacturer

MTC
 Acceptance Criteria Graph ' Zone Wise ' for Sand

600 mcn % passing

Lower Limit Upper limit ZONE DESIGNATION FOR FINE AGGREGATES

Zone-I 15 34
Zone-II 35 59 100
Zone-III 60 79 90

% PASSING 600 MCN SIEVE

Zone-IV 80 100 80
70
60
50
40
30
20
10
600 mcn %
0
passing

Zone-II

Zone-III
Zone-I

Zone-IV
Upper limit

600 mcn %
ZONES passing
Lower Limit

ZONE - I GRADING
ZONE-I GRADING CURVE
Sieves % Passing

10 mm 100 100 120

4.75 mm 90 100 100
% PASSING

2.36 mm 60 95 80
60
1.18 mm 30 70
40
600 mcn 15 34 20
300 mcn 5 20 0
1.18 mm

2.36 mm

4.75 mm

10 mm
150 mcn

300 mcn

600 mcn

150 mcn 0 10 % Passing

Lower
SIEVES SIZES % Passing
Upper

ZONE - II GRADING
Sieves % Passing ZONE -II GRADING CURVE
Lower Limit Upper limit
10 mm 100 100 120
4.75 mm 90 100 100
% PASSING

2.36 mm 75 100 80
1.18 mm 55 90 60
600 mcn 35 59 40
300 mcn 8 30 20
150 mcn 0 10 0
1.18 mm

2.36 mm

4.75 mm

10 mm
150 mcn

300 mcn

600 mcn

% Passing
Lower
% Passing
SIEVE SIZES
Upper
 ZONE - III GRADING
Sieves % Passing ZONE -III GRADING CURVE
Lower Limit Upper limit
10 mm 100 100 120
4.75 mm 90 100
100
2.36 mm 85 100
1.18 mm 75 100

% PASSING
80
600 mcn 60 79
60
300 mcn 12 40
150 mcn 0 10 40

20

0 % Passing

1.18 mm

2.36 mm

4.75 mm

10 mm
150 mcn

300 mcn

600 mcn
Lower
% Passing
Upper
SIEVE SIZES

ZONE - IV GRADING
Sieves % Passing
Lower Limit Upper limit ZONE -IV GRADING CURVE
10 mm 100 100
4.75 mm 95 100 120
2.36 mm 95 100 100
1.18 mm 90 100
% PASSING

80
600 mcn 80 100
60
300 mcn 15 50
40
150 mcn 0 15
20
% Passing
0
Lower
1.18 mm

2.36 mm

4.75 mm

10 mm
150 mcn

300 mcn

600 mcn

% Passing
Upper
SIEVE SIZES

GRADING OF AGGREGATES :

Seives used for Coarse Aggregate : 80mm, 40mm, 20mm, 10mm, 4.75mm.

Seives used for Fine Aggregate : 10mm, 4.75mm, 2.36mm, 1.18mm, 600micron, 150micron.
 PART – II

PROCEDURES
 CHAPTER – 1

Area of laboratory Required:

To have convenient working and storage of records and equipment area is required
more than 12 sq. m. Working platform of approx 3 m long and 700 mm wide will be
required. 2-15Amp / 2-5 Amp electric points other than regular lighting /fan points are
required.

Curing tank :
Size of Tank is depending upon number of cube sets taken at decided frequency.
Cubes to be arrange in stack of three and day wise. Tank should have separate
compartments for 7 days and 28 days cubes. Thus for daily avg 3 sets
( 18 cubes ) of cubes, tank will have plan dimensions 1250x900 for 7 day
compartment and 3000x1250 for 28 days compartment. Clear Depth of tank shall be
fixed one at 750 mm which includes free board. For any increase and decrease of
sampling size can be alter considering cube stacking arrangements.Water tank should
be kept clean and free from dust particles & micro organisms growth. Water should be
changed every 7th day.Curing tank should be covered with a lid.
 CHAPTER – 2

PRECAUTIONERY MEASURES FOR TESTING EQUIPMENTS / TESTING

Certain work Culture and precautions are required to upkeep equipment’s and
samples :
1. Cube Moulds :
 Shall be always used in whole set. ( 1 set of 6 nos of moulds along with
spanner )
 Components of mould sets shall not be interchanged.
 All bolts shall be checked for threading and shall be oiled from time to time after
cleaning.
 Only fixed spanners shall be used for bolts.
 Moulds shall be checked for dimensional correctness & diagonal check every
time before use.
 Moulds shall be thoroughly cleaned after the use and lightly oiled.
2. Slump Cone :
 Shall be always ready in complete set including tamping rod and trowel.
 Shall be cleaned and lightly oiled from inside after the use. Before use oil shall
be wiped out.
 Cone shall be well fitted with base so as no leakage of slurry takes place.
3. Compression Testing machine :
 Have authentic calibration report handy.
 Always use designated oil in machine
 Keep platens in clean condition.
 CTM shall be properly fixed in position and shall be in level.
 Keep adequate clear working area in front of CTM.
 Check dial gauge pointer is on zero before testing.
 Max. Loading on CTM shall be 85-90% of Rated Capacity.
4. Curing Tank :
 Water in tank shall be clean and change at frequent intervals. The water shall
not be allowed to use for any other purpose.
 Water shall always cover top of cube by at least 50-75 mm.
 Water temperature must be controlled during winter.
5. Concrete Cubes :
 Casting of cubes shall be done at well designated place and level / hard
platform.
 Freshly cast cubes shall be away from any vibrations and shocks. They will be
covered by wet gunny bags immediately after casting.
 Cubes shall be correctly mkd for number / location , mix, date etc.
 Cubes shall be placed in tank in correct sequential manner so as to locate them
easily.
 While handling cubes, utmost care to be taken not to damage edges / corners.
 Always cast extra cubes to deal with serious situation.
6. Sieves :
 Sieves shall be always kept in set in proper sequence and vertically arranged.
 Fine sieves can get damaged due to incorrect use. Always clean sieves by
brush and remove stuck particle by forceps or needle. Do not bang on the
mesh.
 Sieves shall be kept clean and dry.
.
7. Weighing Balance :
 Keep balance in clean condition. De-dust it frequently.
 Always cover electronic balance when not in use.
 Balance shall be loaded to max 90% of rated capacity.
 Balance shall be kept on level platform. Remove the pan when not in use.
 Do not weigh with Fan on. Breeze affects the accurate weighing.
8. Samples :
 All samples shall be kept at laboratory in designated area in proper pack,
container.
 All samples shall be tagged for name, sources and collection points and dated.
 CHAPTER – 3

PROCEDURE FOR SAMPLING

FOR AGGREGATES ( IS : 2430 ) :

Sample from Stock Pile of the Coarse / Fine aggregate:
 Samples from stock piles should be made up of at least 10 increments; taken
equally from top third , midpoint and bottom third.
 Outer layer of sampling point shall be removed and the sample is taken from
the material beneath.
 Gross Sample – the sample thus collected will be the gross sample. Qty of
gross sample is depends on the aggregate size :
Aggregate Size , mm 2.36 / 4.75 12.5 20 40
Min wt. Of
Gross sample, kg 10 15 25 80
 Reduction of Gross Sample : Will be done as per method of Quartering to
required sample size for testing.
Quartering Method :
 Take the gross sample on plain platform. For Fine aggregate use Tray so that
residual fines can be collected by brushing.
 The aggregate shall be mixed and then scooped into a cone shape pile.
 After the cone is formed, it shall be flattened by pressing the top.
 Then it is divided in four quadrants diagonally.
 The bulk of the sample is reduced by rejecting any two diagonally opposite
quarters.
 This method is repeated till sample size is approximately achieved for given
testing.
FOR FRESH CONCRETE IN THE FIELD ( IS : 1199 )
Sample from Mixer :
 At least three approximate equal samples totaling 0.02 m3 ( equivalent to fill 6
cube moulds ) shall be taken from a batch.
 For collection a scoop shall be used. No tool with flat edges ( like pawra) shall
be used.
 3 samples are taken at about the time interval when ¼, ½ and ¾ of concrete is
discharged.
Sample from Place and Time of Deposition :
 Sample shall be taken immediately after or during discharge at site.
 Samples shall be collected from not less than 5 well distributed points avoiding
the edges of the mass where segregation may have occurred.
Mixing of Sample :
 Sample thus received shall be immediately remixed on non-absorbent platform
and made ready for testing.
Frequency of Sampling :
 The minimum frequency of sampling of concrete of each grade shall be as
below:
Qty of Concrete in the No of Samples *
Work , m3
1-5 1
6-15 2
16-30 3
31-50 4
51 & Above 4+1 additional sample for each
Addl 50 m3 or part thereof.
Note – At least one sample taken from each shift.
Where concrete is produced at continuous production unit such as RMC
plant, frequency of sampling may be agreed upon mutually.
Note – Three specimens shall be made for each sample for testing at 28 days.
Additional samples may be required for determining strength at 7 days or at the
time of striking formwork.
Remarks – Sample* means qty of concrete required to fill one set of cubes
(3nos / 6 nos ) for testing. Hence number of sample is equivalent to number of
cube sets (3 / 6 nos. ). 3 cubes are drawn when only cube testing is done at 28
days. 6 cubes are drawn for tests at 7 / 28 days required.
 CHAPTER – 4

PROCEDURE FOR SLUMP TEST FOR FRESH CONCRETE ( IS : 1199)

Aim : To check Workability of Freshly mixed Concrete by Standard Slump Cone

Method. This method is suitable for max size of aggregate up to 38 mm only.
Apparatus :
Slump cone with base plate and cone having bottom dia 20 cms , top dia 10 cms and
height 30 cms.
Smooth Tamping rod 16 mm dia and 600 mm long with one rounded edge.
Scoop , Trowel, Collection pan, measuring scale ( Tamping rod also have marking ).
Smooth / leveled platform for working.
Procedure :
 Sample is collected as per the sampling procedure given earlier.
 Internal surface of the cone shall be cleaned and freed from extra moisture and
any layer of set cement slurry.
 Conical mould shall be fixed tight on the base with screw arrangement ensuring
that no cement slurry will leak from the joint.
 Assembly shall be placed on smooth and truly horizontal surface rigidly.
 Mould shall be filled up in 4 layers. Each layer shall be tamped with tamping
rod for 25 times evenly. Tamping shall penetrate in layer below.
 The top level shall be struck off by trowel or rod flush to the top of cone.
 The Cone shall loosen at the base and shall be lifted carefully vertically without
disturbing concrete mass.
 The subsidence shall be measured immediately.
 Above operations shall be carried out at place free from vibrations and shock.
 The whole exercise is to be done within two minutes from sampling.
 In any test in which specimen collapses or shears the test will be repeated.
Record:
 Slump shall be recorded in mm.
 If in repeat test the slump shears, it is to be recorded.

Format Used: It shall be recorded in Cube Register.

 CHAPTER – 5

PROCEDURE FOR SAMPLING / INSPECTION / TESTING RMC CONCRETE

Aim:
To Check, Inspect Conformity of RMC Concrete which is manufactured outside and
supplied at site.
Pre-requisites:
RMC supplier shall be given prior information by the site regarding following:
1. Grade of Concrete.
2. Minimum Cement or cementetious material contents. ( Client Approval required )
3. Slump required and tolerances in slump. (Guidelines IS: 4926. Client Approval
required)
4. W/C ratio.
5. Method of Concreting ( Manual, Bucket or Pumping )
6. Control of temperature if required shall be specified in case of Mass concreting.
7. Quantity of Concrete required – Total, Phase wise, day wise.
8. Supplier shall know site condition , distance and shortest route to the site from his
plant
9. Decision shall be made between Supplier and Site regarding tests and method to
be adopted. ( Client Approval required )
10. Frequency and Acceptance criteria of each testing shall be decided before start. (
Client Approval required )

RMC Supplier shall give following Information to Site:

1. Mix design details including admixtures / additives and cement used. ( To be
approved by Customer )
2. Material testing results for Cement, Admixtures / Additives, water , Coarse and
Fine aggregate.
3. Transit mixer Capacity & time to travel from RMC plant to site.
4. Minimum and maximum quantity that can be supplied in a single pour.
5. Supplier’s In-house testing facilities.
6. Method of concreting which Supplier can undertake for the pours.
7. Communication system which Supplier adopts.
8. Name of Important Plant Personnel.

Site Planning for RMC Concrete Laying :

1. Concrete Volume shall be planned for various grades. Concreting shall be
released possibly in multiple of Transit mixer capacities with concrete pumps at
site.
2. Readiness for receiving concrete shall be assured for given pours. Pour shall be
completed at the earliest after receiving transit mixer on the site. ( As per IS : 4926
entire operation of pouring in place shall be completed within 1 ½ hours water is
mixed in mix when retarder is not mixed.)
3. If multiple suppliers are planned to supply concrete in a given pour or concreting
plan, it shall be at well-defined locations for each supplier and not mixed up.
Procedure :
a) Slump Test : Shall be carried out for each Transit mixer as per procedure –1 and
sampling procedure.
b) Filling Cubes from Freshly mixed concrete : Shall be carried out as per Procedure
–2 in presence of Supplier’s representative or by Supplier as decided. Sample
shall be taken at the earliest when transit mixer is received on the site.
c) Inspection of Coarse Aggregate in Mix ( Site Trial Method ) :
This shall be done on random basis to check coarse aggregate proportion and
quality in mix.
 Take sample from transit mixer as per sampling procedure weighing around 15
kgs. Put the sample in tray, remix thoroughly and select 8 kgs of sample by
quartering method so as correct representative sample is collected.
 Place the test sample on sieves 20 mm /10 mm/ 4.75 mm and wash same in
running water and simultaneously sieving through the sieves.
 Air dry the portion separately and weigh the same. Check the total weight of the
fractions vis –a –vis arrived from mix design calculations. These shall be more
or less conforming without major deviations.
 Check the quality of aggregate vis –a –vis the samples collected from the Plant.
d) Cube testing shall be done at Site laboratory or as decided.

Reports:
 Maintain all reports like slump tests, cube tests and random inspection of
coarse aggregate etc challanwise and date / time wise.
 Mention location , layer of pour on challan. Mention challan no in cube register
along with location. Mention name of Supplier in all records.
 CHAPTER – 6

PROCEDURE FOR FILLING CUBES FROM FRESHLY MIXED CONCRETE

Aim : To prepare specimens for the test of Compressive Strength of concrete.

Apparatus :
Cube moulds fitted tightly on base plate (size in mm 150x150x150) in required set (
One set comprises of 6 moulds.)
Smooth Tamping rod of size 16 mm dia and length of 600 mm with one rounded edge.
Trowels small and large.
Collection pan, scoop, measuring scale etc.
Flat working platform of adequate size.

Procedure of Cube Casting:

 Cube moulds shall be verified for dimensions and tight fitting assembly. They
shall be lightly oiled and have clean surfaces.
 Cube moulds shall be arranged in sets on working platform.
 Sample is collected as per the procedure given earlier.
 Concrete is filled in cubes one by one in three layers. Each layer is tamped 35
times with tamping rod evenly. Tamping shall penetrate the layer below. Care
to be taken particularly at corners. Small trowel can be used at the sides to
ensure proper surface of sides and allow entrapped air to escape.
 Cubes shall be filled slightly above top surface of mould.
 The top extra layer shall be struck off by large trowel, flush to the top.
 Cubes shall not be disturbed till at least 6 hours after the casting.
 Cube concrete surface shall be marked with Cube I.D. , Mix, location of use,
date, source of concrete ( additional) when adequately set.
 Cubes thus cast, shall be covered with wet gunny bags till they are replaced in
curing tank.
 After about 10-12 hours cubes can be opened and place them in curing tank.
  Cubes shall be checked for surface correctness, sharp edges and incorrect
filling. Such defective cubes may be rejected there itself. In such case
Corrective /Preventive actions shall be taking.

Procedure for Tank Curing:

 Cubes shall be arranged in the curing tank sequentially as per ID mark, date
wise.
 Cubes shall be sorted out for 7 days , 28 days tests. Cubes shall be placed in
the tank in layer of three cubes with marked top upside.
 Cubes once placed in tank shall not be handled, disturbed frequently so that
edges are not broken.
 Water in tank shall cover cubes by at least 50-75 mm all the time.
 Water temperature must be maintained in winter.

Procedure for In-Situ Curing:

This method is deployed to decide stripping time of shuttering when shuttering
stripping is planned earlier than given as per IS: 456. This method shall not be
deployed for the cubes to be tested for compressive strength of concrete at 28 days.

Record:
Details of Cubes thus sampled shall be entered serially in Cube Register maintained
for testing compressive strength.
The number of cube samples cast shall also be entered in pour card with proper
traceability to cube register.

Format to be Used: It shall be recorded in Cube register

 CHAPTER – 7

PROCEDURE FOR COMPRESSIVE STRENGTH TESTING FOR CONCRETE

Aim : To establish Compressive strength of concrete sample for acceptance

Apparatus :
Compressive Testing machine having adequate capacity.
Weighing Balance.
Measuring Scale.
Procedure :
 Remove the cubes required for testing from curing tank wipe clean of water and
air dry them to surface dryness.
 Stack cubes in sequence as per mix, dates, locations etc.
 Record the actual surface area ( Sq cm)of the cube which will be in contact with
platen of CTM ( A in cm2 or mm2 ).
 Weigh the cubes and record the weights in the register in gm.
 Place the cube on platen centrally keeping trowelled side in front.
 Position the top platen on cube surface. See that there is no gap left between
cube top and platen.
 Load the CTM at desired speed without any shocks.( Pointer and needle shall
move together)
 When crushing takes place in the specimen, needle will start falling back but
pointer will remain at maximum reading.
 Record the reading shown by pointer viewing perpendicular to the face of dial.
( Load applied in kN or tonne- W)
 Relieve the load from CTM. Remove the cube. Clean the platens.
 Check the features of cube failure. Good failure is that cube mass retained
shall have concavity on sides. If failures are occurring consistently by crack
developing only on one side it means cubes are eccentrically loaded. If cracks
are always developed centrally means point load is getting applied due to
convexity of platens. Remedial measures are required to be taken for this.
Calculations:
 Compressive Stress ( c ) in N / mm2 or Kg / cm2 as below :

c = Wx1000 /A in N/mm2 or Kg /cm2

Average of the set of Three or more cubes to be recorded (c’ ).
 When three or more cubes from single batch/lot is tested, max variation is
allowed +/- 15%. If any cube is showing more variation, result of that cube is
discarded and average of two or more is to be taken.

Recording :
 Record is generated as per the sample format given in chronological order.

Format to be Used : To be recorded in Cube Register.

\
 CHAPTER – 8

STANDARD DEVIATION FOR CONCRETE CUBE RESULTS AT 28 DAYS

( As per SP-23 )

A. Initial Set of 30 Readings :

1 List down 28days cube result of one concrete grade taking Averages of 3 cube samples ( Xi )

2 Std Dev shall first calculated for minimum 30 nos of results, n = No of results considered

3 Calculate Average of Xi = X bar

4 Calculate value of ( Xi - Xbar ) for each result and Calculate square of ( Xi -Xbar )

5 Add all values of ( Xi -Xbar ) ^2 = Xn

6 Calculate Std Deviation by Formula

S.D. = ( Xn / n-1 ) ^ 1/2

7 After first 30 results, SD to be updated on decided frequency ( say Monthly )

Site : Name of Client :

Concrete Grade : Period :

Individual Avg Result of Xi- Xbar ( Xi- Xbar ) ^2
Sr. No Cube strength 3 Cubes
in N/mm2 Xi
1
2
3

30
Total Xi = Total Xn = (I)

Xbar n = 30

S.D. = (I)
 UPDATING THE SD FOR SUBSEQUENT SETS
OF RESULTS

Site : Name of Client :

Concrete Grade : Period :

Individual Avg Result ofXi- Xbar ( Xi- Xbar ) ^2
Sr. No Cube strength
3 Cubes
in N/mm2 Xi
31
32
33

55
Total Xi = Total Xn = ( II )

Xbar n = 25

S.D. = ( II )

To Calculate SD upto date Result 55

Total Xn = Xn( I ) + Xn ( II )

Total ( n-1 ) = 29 + 24

Therefore S.D. = ( Total Xn / Total ( n -1 ) ) ^ 1/2

Note : Do not calculate Average of SD ( I ) & SD ( II ).

 CHAPTER – 9

PROCEDURE FOR FIELD TEST FOR SILT CONTENT IN SAND

( Ref : A. M. Neville )
Aim : To determine Silt content in Sand by volumetric method field test.
Apparatus :
Measuring cylinder 250 ml
Common Salt.
Procedure :
 Prepare 1% solution by mixing 10gms of common salt in 1litre of water.
 Put this solution in measuring cylinder up to the mark of 50 ml.
 Add Sand as received in the cylinder till its level reaches 100 ml.
 Add Solution again so that the mixture reaches the level of 150 ml.
 Cylinder top is now covered with the palm of hand and shake vigorously by
turning upside down.
 Then allow it to stand undisturbed for 3 hours.
 Take reading for top layer of Silt ( A ) and layer of Sand ( B ).
Calculations :
Silt content % Volumetric = (A / B ) x100
Reporting :
% Silt contain (Volumetric ) shall be reported in whole number.
Note : This method is approximate and conversion to weight basis ( which is
acceptance criteria ) is dependent on fineness of material. However 8% volumetric
content is treated as reliable. It was suggested that weight ratio is obtained by
multiplying volumetric ratio by ¼ for natural sand and ½ for Crushed sand.
Accurate test when 8% limit of silt contain is exceeded can be done as per IS method
of Sedimentation if required.

Format to be Used :
It shall be recorded in Sieve Analysis for Fine aggregate. Alternatively separate
register for silt contents.
 CHAPTER – 10

PROCEDURE FOR SIEVE ANALYSIS OF FINE AGGREGATES

( I.S. : 2386-I )

Aim : To determine the properties of Fine aggregate for size and distribution by
calculating Fineness modulus and deciding Grading Zone.
Apparatus :
Drying Oven
IS Sieves 10 mm, 4.75mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron, 150 mm,
pan.
Weigh scale to the accuracy of 1g.
Brush , Metal trays etc.
Procedure:
 Sample of sand shall be collected as given earlier.
 Sieves shall be cleaned and arrange in sequence in descending order. Pan
shall at the lower most end and Lid on top.
 Take around 1 kg of sample and dry it in oven at temp of 100-110 deg C.
 Dried sample shall be then weighed ( 1 kg preferably) and sieved successively
on sieves starting with 10mm and then through 150 micron.
 Each sieve shall be shaken at least for two minutes on clean tray until no more
trace passes.
 Motion shall be varied like back and forth, left to right, circular clockwise and
anti-clockwise and with frequent jarring.
 Material shall not be forced through the mesh. Lumps in fines shall be broken
against the wall of sieve.
 Sieves shall be brushed from underneath of mesh and pass on to the next.
 On completion of sieving, material retained on each sieve is to be weigh
separately.
Calculations:
Fineness Modulus: Add values of Cumulative % Retained on each sieves and
divide by 100. (Normally accepted limit of FM is value between 2.2 to 3.2.
Higher value of FM indicates coarser sand whereas lesser value indicates
Finer one. )
Grading Zone of Fine Aggregate – Value is shown between I to IV. Where
zone- I is associates with Coarser Fine aggregate and Zone IV is Finer. Zones
are decided from values of 600 micron passing % in sieve analysis. (Refer
Table-4 of IS: 383)
Zone –I – 15-34%, Zone-II – 35-59 %, Zone-III- 60-79%, Zone-IV- 80-100%
Reporting:
 The cumulative % by weight of the total sample passing each sieves, to the
nearest whole number.
Or
 The % by weight of the total sample passing one sieve and retained on the next
smaller sieve to the nearest 1 decimal.
 Calculate F.M. of the material and decide Grading Zone of material.

Format to be Used :
Format of Sieve Analysis of Fine Aggregate shall be used.
 CHAPTER – 11

PROCEDURE FOR SIEVE ANALYSIS OF COARSE AGGREGATES

(I.S.: 2386-I)

Aim: To determine the properties of Coarse aggregate for size and grading
distribution (Nominal 20mm/12.5or10 mm metal).
Apparatus :
Drying Oven
IS Sieves 40 mm, 20 mm,16 mm, 12.5 mm, 10mm, pan. – for Analysis of 20 mm
metal
IS Sieves 20 mm, 16 mm,12.5 mm, 10 mm, 4.75 mm ,2.36mm pan - for Analysis of
10/12.5 metal.
Weigh scale to the accuracy of 1g.
Brush , Metal trays etc.
Procedure:
 Sample of aggregate shall be collected as given earlier.
 Sieves shall be cleaned and arrange in sequence in descending order. Pan
shall at the lower most end and Lid on top.
 Take around 5 kg of sample and dry it in oven at temp of 100-110 deg C.
 Dried sample shall be then weighed ( 5 kg preferably) and sieved successively
on sieves starting with 40mm and then through 4.75mm( For 20 mm down
aggregate size ) and through 2.36 mm (For 12.5/10 mm down aggregate size) .
 Each sieve shall be shaken at least for two minutes on clean tray until no more
trace passes.
 Motion shall be varied like back and forth, left to right, circular clockwise and
anti-clockwise and with frequent jarring.
 Material shall not be forced through the mesh. But for coarser than 20mm
particles, placing is permitted (passing particles through sieve opening
manually).
 Sieves shall be brushed from underneath of mesh and pass on to the next.
 On completion of sieving, material retained on each sieve is to be weigh
separately.
Reporting:
 The cumulative % by weight of the total sample passing each sieves, to the
nearest whole number.
Or
The % by weight of the total sample passing one sieve and retained on the next
smaller sieve to the nearest 1 decimal.
 Check for permissible limits for passing.

Format to be used:
Format of Sieve Analysis for Coarse Aggregate shall be used.
 CHAPTER – 12

DETERMINATION OF SPECIFIC GRAVITY AND WATER ABSORPTION OF

AGGREGATES
(IS: 2386 – part-III)
Aim :
To determine the Specific Gravity of Coarse Aggregate (Smaller than 10 mm) and
Fine Aggregate by using Pychnometer Bottle.
Apparatus:
Balance of Capacity not less than 3 Kgs and accuracy of 0.5 g.
Thermostatically controlled Oven
Pychnometer Bottle
G.I. Tray, Air Tight Containers around 1kg capacity, Filter Paper and Funnel.
Sample :
1 kg sample of 10mm sieve passing and retained on 4.75 mm sieve for Coarse
Aggregate
500 g sample of 4.75 mm sieve passing for River or Crushed Sand.

A. PROCEDURE FOR COARSE AGGREGATE –

 A sample passing 10mm sieve and retained on 4.75 mm sieve is to be
collected and placed in the tray and covered with distilled water; gently rodded
to remove entrapped air.
 The sample shall be kept for 24 hrs +/- ½ hrs
 The water shall be then carefully drained from the sample by decantation
through filter paper and any material retained being returned to the sample.
 The sample is then air-dried with help of air drier or fan gently until no free
surface moisture is seen.
 The saturated and surface-dry sample shall be weighed. ( Weight ‘A’ g )
 The aggregate shall then be placed in pychnometer bottle which shall be filled
with distilled water. Any trapped air shall be removed by rotating bottle on its
sides and covering hole in the cone portion with finger.
 The pychnometer bottle shall be topped with water full to the surface of hole in
metallic cone.
 The pychnometer bottle shall be dried from outside and weighed (Weight ‘B’ g )
  The contents of Pychnometer bottle shall be then emptied in the tray ensuring
all aggregate is transferred properly.
 Pychnometer bottle shall be then rinsed and filled up with distilled water fully,
dried from outside as above and then weighed ( Weight ‘C’ g )
 The sample of aggregate as collected above shall be drained and decanted
through filter paper and retained material on filter paper shall be returned to the
sample.
 The sample then shall be placed in oven at 100 to110 deg C for 24 +/- ½ hrs.
During this period it shall be stirred occasionally to facilitate drying.
 It shall be cooled in air-tight container and weighed ( Weight ‘D’ g )
 Such two tests shall be made
Calculations :
Specific Gravity = D/A–(B–C)
Water Absorption = 100 (A – D) / D
(% of Dry weight)
Reporting :
Individual and mean results shall be reported and grading of the aggregate shall be
stated.

B. PROCEDURE FOR FINE AGGREGATE :

Procedure is similar to the above but only sample size shall be 500g.

Format to be Used :
Format of Determination of Specific Gravity shall be used.( For Sp. Gravity )
Format of Determination of Water Absorption of Coarse and Fine Aggregates
shall be used. (Water Absorption)
FORMAT FOR DETERMINATION OF WATER ABSORPTION OF COARSE & FINE
AGGREGATE
( IS : 2386-III )

NAME OF PROJECT : DATE OF TESTING:

Name of Client :

Name Of Consultant :

Type of Aggregate : Date of sample

Collected :
Source :

Name of Supplier : Sample size : grams

Sr.No Description Sample-1 Sample-2

.
1. Weight of material after fan drying for
4-5 hrs to Surface Saturated Dry
condition ( A, g )
2. Weight of Oven dry material for 24 hrs
( D, g )

3. % Water absorption in SSD condition

100 x ( A – D ) / D
4. Average of % Water Absorption

SAMPLE ACCEPTED / REJECTED

Tested by : Checked by :

Date Date
 FORMAT FOR DETERMINATION OF SPECIFIC GRAVITY
( IS 2386- III )

NAME OF PROJECT : DATE OF TESTING:

Name of Client :

Name of Consultant :

Size of CA : mm Date of sample

Collected :
Source :
Name of Supplier : Sample size : grams

Sr Description Sample
I II
1. Weight of Saturated
Surface-dry sample, A in
g
2. Weight of Pychn. Bottle
+ Sample + Water , B in
g
3. Weight of Pychn. Bottle
+ Water, C in g
4. Weight of Oven Dried
Sample, D in g
5. Sp. Gravity = D / A – ( B
–C)

6. Average Sp. Gravity

Tested By : Checked By :

Date Date
 CHAPTER – 13

PROCEDURE FOR DETERMINATION OF FLAKINESS INDEX OF AGGREGATE

(IS: 2386 – I)

Aim:
To determine the Flakiness of particles of Coarse Aggregate greater than 6.3 mm
size.
Apparatus :
Balance with accuracy of 0.1% of weight of sample
Flakiness Index Gauge
All other as per Sieve analysis.
Sample :
It shall be taken from retained material from Sieve analysis preferably and should
have at least 200 pieces of any fraction.
Procedure :
 Each sample of 20 mm and 10mm shall be taken from retained fraction.
 Each fraction shall be gauged in turn for thickness on metal gauge.
 The total amount passing the gauge shall be weighed.
Report :
 The flakiness Index is the total weight of the material passing the various
thickness gauges; expressed as a % of the weight of total sample gauged.

Format to be Used :
Format for Flakiness Index shall be used.
 FORMAT FOR FLAKINESS INDEX OF COARSE AGGREGATE

NAME OF PROJECT : DATE OF TESTING:

Name of Client :

Name Of Consultant :

Size of CA : mm Date of sample

Collected :
Source :
Name of Supplier : Sample size : grams

Size of Aggregate Individual wt of Weight of

aggregates Aggregate
retained between passing through
sieves , g respective slot of
the gauge , g
63 – 50 mm W1 = w1 =
50- 40 mm W2 = w2 =
40 – 31.5 mm W3 = w3 =
31.5 – 25 mm W4 = w4 =
25 – 20 mm W5 = w5 =
20 – 16 mm W6 = w6 =
16 – 12.5 mm W7 = w7 =
12.5- 10 mm W8 = w8 =
10- 6.3 mm W9 = w9 =

Actual Flakiness Index = 100 x ( w1 +w2 + w3 + ----- / W1 + W2 + W3 --- )

Actual Flakiness Index =

Acceptable Flakiness Index =

SAMPLE ACCEPTED / REJECTED

Tested by : Checked By :

Date Date
 CHAPTER – 14

PROCEDURE FOR DETERMINATION OF ELONGATION INDEX OF

AGGREGATE
(IS: 2386 – I)
Aim:
To determine the Elongated shape of particles of Coarse Aggregate greater than 6.3
mm size.
Apparatus:
Balance with accuracy of 0.1% of weight of the sample
Elongation Index Gauge
All other as per Sieve analysis.
Sample:
It shall be taken from retained material from Sieve analysis preferably and should
have at least 200 pieces of any fraction.
Procedure :
 Each sample of 20mm and 10mm metal shall be taken from retained fraction.
 Each fraction shall be gauged in turn for thickness on metal gauge.
 The total amount passing the gauge shall be weighed.
Report :
 The Elongation Index is the total weight of the material passing the various
thickness gauges; expressed as a % of the weight of total sample gauged.

Format to be used:
Format for Elongation Index shall be used.
 FORMAT FOR ELONGATION INDEX OF COARSE AGGREGATE

NAME OF PROJECT : DATE OF TESTING:

Name of Client :

Name Of Consultant :

Size of CA : mm Date of sample

Collected :
Source :
Name of Supplier : Sample size : grams

Size of Aggregate Individual wt of Weight of

aggregates Aggregate
retained between passing through
sieves , g respective slot of
the gauge , g
63 – 50 mm W1 = w1 =
50- 40 mm W2 = w2 =
40 – 31.5 mm W3 = w3 =
31.5 – 25 mm W4 = w4 =
25 – 20 mm W5 = w5 =
20 – 16 mm W6 = w6 =
16 – 12.5 mm W7 = w7 =
12.5- 10 mm W8 = w8 =
10- 6.3 mm W9 = w9 =

Elongation Index = 100 x ( w1 +w2 + w3 + ----- / W1 + W2 + W3 --- )

Actual Elongation Index =

Acceptable Elongation Index =

SAMPLE ACCEPTED / REJECTED

Tested by : Checked By :

Date Date
 CHAPTER – 15

PROCEDURE FOR DETERMINATION OF AGGREGATE CRUSHING VALUE

(I.S: 2386-IV)

Aim:
To calculate aggregate Crushing value by testing aggregate passing 12.5 mm sieve
and retained on a 10 mm sieve. ( This is Alternative method to Aggregate Impact
Value.)
Apparatus:
15 cm dia steel cylinder with plunger and base plate
Tamping rod 16 mm dia and 600 mm long with one end rounded.
Weighing balance of accuracy 1 g
I.S sieves 12.5 mm, 10 mm & 2.36 mm.
Drying Oven, CTM
Procedure:
 Take sample of aggregates by sieving through 12.5mm and retained on 10mm.
 The aggregate shall be tested in surface dry condition. If dried by heating, the
period of drying shall not exceed 4 hours and temp shall be 100-110 deg C.
 Sample shall be cooled down to room temperature before testing. Take
approximately 6 kgs of sample.
 The quantity of the sample shall be such that the depth of material in the
cylinder after tamping shall be 10cms.
 Cylinder shall be filled up in 3 layers and each layer shall be tamped 25 times
with tamping rod and finally leveled off.
 The weight of material comprising the test sample shall be determined. ( A ), g
 The plunger shall be placed in position and the apparatus shall be then placed
between the platens of CTM.
 Load shall be applied at uniform rate so that load of 40t is reached in 10
minutes.
 The load shall be removed from the cylinder and sieved through 2.36 mm
sieve. The fraction passing sieve 2.36 mm shall be weighed to nearest 1g
(B,g )
 Such two tests shall be taken.
Reporting:
 Aggregate Crushing Value, % = ( B / A ) x100
 The mean of the two results shall be reported to the nearest whole number.

Format to be Used:
Format for Aggregate Crushing value to be used.
 FORMAT FOR AGGREGATE CRUSHING VALUE

NAME OF PROJECT : DATE OF TESTING:

Name of Client :

Name of Consultant :

Size of CA : mm Date of sample

Collected :
Source :
Name of Supplier : Sample size : grams

Description Sample
I II
Weight of Oven Dried
Sample ‘A’ , g
Weight of Sample
passing 2.36 mm
sieve after Loading ,
‘B’ , g
Aggregate Crushing
Value
= 100x B/A
Average

Acceptable Limit

SAMPLE ACCEPTED / REJECTED

Tested By : Checked By :
Date Date
 CHAPTER – 16

DETERMINATION OF IMPACT VALUE FOR COARSE AGGREFATE

(I.S: 2386-IV)

Aim:
To calculate aggregate Crushing value by testing aggregate passing 12.5 mm sieve
and retained on a 10 mm sieve.

Apparatus:
IS sieve: 12.5mm , 10mm , 2.36mm, Weight balance : capacity 500gm accuracy
0.1gm oven temperature 100 c to 110 c, tamping rod : 230mm long and 10mm dia,
cylindrical steel cup internal dia : 102mm cylindrical steel cup depth : 50mm ,impact
machine.

Procedure:

 Take a sample from the various places sieve it from 12.5mm to 10mm retained.
 Samples retained on 10mm collect it and wash well and put it into oven at
temperature from 100c to 110c up to 4 hrs.
 Remove the sample from oven and cool it well.
 Fill the sample in standered manner in 3 layers with 25 strokes each uniformly
in impact value cup.
 Fall the hammer freely from height of 38 cm /-0.5 cm.
 Total no of blows should be 15 with not less than 1 sec.
 Then the sample sieve through 2.36 mm sieve .
 Weight the sample retained on 2.36 mm sieve and passing separately.

Calculation :

Impact value in % = wt of passing gms

Total wt of sample

Reporting :
 Aggregate Impact Value, % = ( B / A ) x100.
 The mean of the two results shall be reported to the nearest whole number

Format to be used:
Format for Aggregate Impact value to be used.
 FORMAT FOR AGGREGATE IMPACT VALUE

NAME OF PROJECT : DATE OF TESTING:

Name of Client :

Name of Consultant :

Size of CA : mm Date of sample

Collected :
Source :
Name of Supplier : Sample size : grams

Description Sample
I II
Weight of Oven Dried
Sample ‘A’ , g
Weight of Sample
passing 2.36 mm
sieve after blows ,
‘B’ , g
Aggregate Crushing
Value
= 100x B/A
Average

Acceptable Limit

SAMPLE ACCEPTED / REJECTED

Tested By : Checked By :
Date Date
 CHAPTER – 17

DETERMINATION OF BULK DENSITY OF AGGREGATE

A LOOSE BULK DENSITY
(AS PER IS 2386 PART III)

Aim : To determination of bulk density of aggregate

Apparatus:

1.) Weight balance – a balance sensitive to 0.5 percent of the weight of the
sample to be weighed
2.) Container for bulk density size is as follows.

Size of largest Nominal Inside Inside Thickness of

particles capacity liter diameter(cm) height(cm) metal (mm)

4.75 mm and under 3 15 17 3.15

over 4.75 mm to 40 mm 15 25 30 4.00
over 40 mm 30 35 31 5.00

Procedure:

 Take a dry sample of aggregate

 The cylindrical measure is filled loosely in container .
 Measure the weight of the aggregate just enough to fill the calibrated
container
 The measure is carefully struck off level using tamping rod as a straight
edge.
 Note the volume of the calibrated container .

Calculation: The net weight of the aggregate on the measure is determined and the
bulk density is calculated in kg/ltr as follows:-

Bulk density = Net weight of the aggregate kg

Capacity of the container 1 ltr

% of voids = Gs – y x 100
Gs

Gs = specific gravity of aggregate

y = bulk density in kg/1tr
 CHAPTER – 18

DETERMINATION OF MOISTURE CONTENT OF AGGREGATE

( AS PER IS 2386 PART III )

Aim :
To determine the moisture content of aggregate

Apparatus:-

1.) Weigh balance - capacity not less than 2kg accuracy should be less
than 0.5gm.
2.) Hot air oven.

Procedure:-

 Take the moist or wet sample and weigh (w1)

 Dry it using an oven or hot plate and then weigh, (w2)
 Then calculate the moisture content

Calculation :- w1 – w2 x 100
w2

Moisture content of the aggregate is the percentage of the weight of water in

aggregate sample to the total of sample.
 CHAPTER – 19

DETERMINATION OF BULKING OF FINE AGGREGATE

( AS PER IS 2386 PART III )

Aim :
To Determine the Bulking of Fine aggregate.

Apparatus:-

 Measuring cylinder (1000ml )

Procedure:

 Fill the moist sand up to 800ml in a 1000ml capacity glass measuring

cylinder.
 Remove the sand and fill the measuring with water up to the 500ml mark.
 Put back measured sample of moist sand into the measuring cylinder.
 Shake the content well after topping with some more waterif required to
inundate the sand.
 Allow it to settel.
 Note down the level of the to of sand in the graduated measuring cylinder
(H)
 Calculate the level difference of the sand layers before and after adding
water (h)

Calculation = hx100
H
 CHAPTER – 20

DETERMINATION OF CONSISTANCY OF CEMENT PASTE

( AS PER IS 4031 , 12269 & 8112)

Aim : To determine the consistency of cement paste.

Apparatus: -
1.) Vicats apparatus ( is : 5513-1976)
2.) Weighing balance accuracy – 0.01gm.
3.) Gauging trowel ( is : 10086 – 1982 ) – shall have steel blade of
100 to 150mm in length with straight edges weighing 210+/-10g
Procedure:-
 The sample of cement to be taken = 400gm.
 The temperature of room shall be maintained at 27. c
 Prepare a paste of weighed qty of cement sample by
taking water 29% that of cement qty (400gm x 0.29)
 The care should be taken that the time of gauging is not
less than 3 to 5 min. gauging should be completed before
any sign of setting occurs.
 Fill the vicats mould by this paste the mould place on non
porous plate.
 After completely filling the mould, smoothen the surface of
the paste making it level with the top of the mould
 The mould be slightly shaken to expel the air.
 Under the rod bearing plunger lower the plunger gently to
touch the surface of the test block, and quickly release,
allowing it to sink into the paste.
 Penetration should be between 5 to 7mm from the bottom
of the vicats mould when the cement paste tested. if not
repeat the procedure by increasing the water by : 0.5%

Calculation:

Example:-

Weight of Weight of % of w.t. Temp. c Penetration

cement water
400 gm 120 ml 30 % 27.4 c 7 mm
 CHAPTER – 21

DETERMINATION OF INITIAL & FINAL SETTING TIME OF CEMENT

( AS PER IS 4031, IS 122695 IS 8112)

A.DETERMINATION OF INITIAL SETTING TIME OF CEMENT

Aim:
To Determine the Initial setting time of Cement.

Apparatus :
1) Vicats apparatus ( is : 5513-1976)
2) Weighing balance accuracy – 0.01gm
3) Gauging trowel ( is 10086 - 1982 ) - shall have steel blade of 100 to
150mm in length with straight edges weighing 210+/-10g
Procedure:-
 Prepare a neat cement paste by gauging cement paste by gauging the cement
with 0.85 times the water required to give a paste of std consistency
 Portable or distilled water should be used in preparing the paste
 The sample of cement to be taken = 400g
 The temperature of room shall be maintained at 27 c.
 The care should be taken that the time of gauging is not less than 3 to 5 min .
gauging should be completed before any sign of setting occurs
 Fill the vicats mould by this paste the mould place on non porous plate.
 After completely filling the mould, smoothen the surface of the paste , making it
level with the top of the mould
 The mould be slightly shaken to expel the air.
 Immediately after the moulding, place the test block in the moist closer or moist
room and allow it to there except when determinations of time of setting are
being made.
 Under the rod bearing plunger lower the plunger gently to touch the surface of
the test block and quickly
 Release allowing it to sink into the paste initially the needle will complete pierce
the test block
 Repeat this procedure until the needle , when brought in contact with test block
and released as described above, fails to pirce the block beyond 5.0 +/- / 0.5
mm measured from the bottom of the mould
 The period elapsing between the time at which the needle fails to pierce the
test block to a point .0+/- 0.5mm measured from the bottom of the mould shall
be the initial set.
B.DETERMINATION OF FINAL SETTING TIME OF CEMENT

Aim:
To Determine the Initial setting time of Cement.

Apparatus :
1) Vicats apparatus ( is : 5513-1976)
2) Weighing balance accuracy – 0.01gm
3) Gauging trowel ( is 10086 - 1982 ) - shall have steel blade of 100 to
150mm in length with straight edges weighing 210+/-10g

Procedure:-

 Replace the needle of the vicats apparatus by the needle with an anular
attachment.
 The cement shall be considered as finally set when upon applying the
needle gently to the surface of the test block , the needle makes an
impression theron , white the attachment fails to do so.
 The period elapsing between the time at which the water added to the
cement and the time at which the needle makes an impression on the
surface of test block while the attachment fails to do so shall be the final
setting time.

Calculation :

W.T. of cement W.T.. of water Initial setting Final setting

time (Min) time(Min)

Note: - W.T. of water = 0.85 x w.t. of water taken for consistency

 CHAPTER – 22

DETERMINATION OF COMPRESSIVE STRENGTH OF CEMENT

( AS PER IS 4031 , IS 12269 & IS 8112 )
Aim:
To determine the compressive strength of cement.

Apparatus: -

1.) Vibration machine ( is : 10080-1982)

2.) Poking rod ( is : 10080-1982)

3.) Cube mould - shall be 70.6mm size

confirming to is : 10080 – 1982

4.) Gauging trowel - Gauging trowel shall have steel blade 100 to
150mm in length with straight edges weighing 210+/-10
5.) Balance - The permissible variation at a load of 1000g
shall be +/-1g

6.) Graduated glass - Cylinders of 150 to 200ml

Cylinders capacity

Material:-

Standard sand :- 600g (grade 1,2,3 each 200gms)

Cement :- 200g

Water :- (p/4+3.0) percent of combined mass of cement

and sand whether p is the percentage of water required to produce a paste of
standard consistency determined as described in is : 4031 ( part 4)

Procedure:-

 Take a mixture of cement & sand on non porous plate mix it dry with
trowel for one min then with water untill the mixture is of uniform colour.
 The qty of water to be used shall be as above
 The time of mixing shall be not less than 3 min, if the time exceed 4 min
repeated their after by taking fresh cement
 Moulding specimens:-

 The joints between the halves of mould cover with thin film of petroleum jelly
and apply a similar coating on the contact surfaces of bottom of mould to
ensure that no water escapes during vibration .
 Placed the assembled mould on the table of the vibration machine and hold
it firmly in position by means of suitable clamps.
 Immediately after mixing the mortar shall be placed in the cube mould by
rodding 20 times to elimination of entrained air and honeycombing place the
remaining qty mortar in the hopper of the mould and rodd again as specified
above for the first layer and then by compaction .
 The period of vibration shall be two min at the specified of 12000+/- 400
rpm.
 At the end of vibration remove the mould with the base plate from the
machine and finish the top surface with the blade of a trowel.

Curing specimen.

 The specimen should be cured in moist condition for 24 hrs then submerge
in the clean fresh water temp. shall be maintained at 27 c +/-2 c

Testing :

 Test three cubes for compressive strength for each period of curing.
 The load shall be uniformly and steadily applied starting from 0 to 35
n/mm2/min.
 CHAPTER – 23

DETERMINATION OF FINENESS OF CEMENT BY DRY SIEVING

(AS PER IS 4031, IS 12269 & IS 8112)

Aim :
To determine fineness of cement by dry sieving

Apparatus :-

 Test sieve – cylindrical frame of 150-200mm dia with 90 micron mesh sieve of
woven stainless steel. as per is : 460 ( part i)

 A tray fitting beneath the sieve frame with lid fitting above it shall be provided to
avoid loss during sieving.

 Weight balance – capable of weighing up to 10g to the nearest 10mg.

 Brush

Procedure :

 Take a 100g of cement and place it on the 90micron sieve being careful
to avoid loss.
 Fit the lid over the sieve.
 Agitate the sieve by swirling and linear movement untill no more finer
material pass to it.
 Remove and weigh the residue, as a percentage. ri.
 Gently brush all the fine material off the base into the tray.
 Repeat the same procedure using fresh 10g sample
 Let the percentage be r2.
 Take the mean of two.
 If the result differ by 1 percent carry out 3rd test as r3. and finally take
mean of three.

Test result as per is : 12269

The fineness of cement by dry sieve analysis is max 10%

 CHAPTER – 24

DETERMINATION OF MATERIALS FINER THAN 75 – MICRON BY WET SIEVING

( AS PER IS : 2386 PART II AND IS 383 )

Aim :
To determine fineness of Manufactured sand (CRF) by wet sieving.

Apparatus :-
 WEIGHT BALANCE - THE PERMISSIBLE
VARIATION AT A LOAD OF
1000g ACCURACY SHALL BE
0.5gms

 SIEVE - LOWER THAN 75 MICRON

1.18mm

 CONTAINER: HOT AIR OVEN OF SUFFICIENT SIZE CAPABLE OF

MAINTAINING AN UNIFORM TEMP OF110 C +/- 5 C

PROCEDURE:-

 THE SAMPLE SHALL BE DRIED TO CONSTANT WEIGHT AT A TEMP 110 C

+/- 5 C
 THE TEST SMAPLE AFTER BEING DRIED AND WEIGHED SHALL BE
PLACED IN THE CONTAINER AND SUFFICIENT WATER ADDED TO
COVER IT THE CONTENTS OF THE CONTAINER SHALL BE AGITATED
VIGOROUSLY
 THE AGITATION SHALL BE SUFFICIENTLY VIGOROUS TO RESULT IN
THE COMPLETE SEPARATION FROM THE COARSE PARTICALS OF ALL
PARTICALS FINER THAN 75- MICRON AND FINE MATERIAL INTO
SUSPENSION.
 THE OPERATION SHALL BE REPEATED UNTIL THE WASH WATER IS
CLEAR .
 THE WASH WATER CONTAINING THE SUSPENDED AND DISSOLVED
SOLIDS SHALL BE IMMEDIATELY POURED OVER THE NESTED SIEVES
ARRANGED WITH THE COARSER SIEVE ON THE TOP
 ALL MATERIAL RETAINED ON THE NESTED SHALL BE RETURNED TO
THE WASHED SAMPLE THE WASHED AGGREGATE SHALL BE DRIED TO
CONSTANT WEIGHT AT A TEMP. NOT EXCEEDING 110 C

Procedure & Test results as per IS 2386 PART II AND IS 383

CALCULATION :-
s
A= B – C X100
B

WHERE

A=% OF MATERIAL FINER THAN 75MIC

B= ORIGINAL DRY WEIGHT.
C= DRY WEIGHT AFTER WASHING

LIMITS OF DELETERIOUS MATERIAL IS 383

SL DELETERIOUS METHOD OF FINE AGGREGATE COARSE AGG

TEST
N SUBSTANCE % BY WEIGHT % BY WEIGHT
O. UNCRUSHED CRUSHED UNCRUSHED
CRUSHED CRUSHED
SAND SAND
1. MATERIAL IS : 2386
FINER THAN 75 3.00 15.00 3.00
MICRON ( PART 1 )
 PART – 3

CALIBRATION OF TEST
EQUIPMENTS
 1- GENERAL

Scope :
The scope of this Calibration Plan is pertaining to Marvel Procedure – .
This Plan deals with Calibration & /or Verification of test equipments and measuring
equipments used in testing and production.

Requirements :
All test equipments in lab shall be in proper condition of use. They shall be verified at
some defined frequency to achieve correct results and consistent performance.
Measuring equipments and Test equipments are required to be calibrated to show that
these equipments give correct results within the tolerances specified by BIS. This shall
be done at defined frequency or as required.

Refer Calibration Plan

 2 - PROCEDURE FOR VERIFICATION OF EQUIPMENTS
(In House Test)
VERIFICATION OF CUBE MOULD
Aim : To check Cube Mould assembly for dimensional correct ness.
Apparatus : Platform flat and leveled, Set of spanners, Metallic scale, Vernier Caliper
Procedure :
 Put Sr No on Cube moulds and base plates ( All plates )
 Cube set assembly shall be kept on platform.
 Check the joints which shall be tight and uniform. Thickness shall be hairline
thick.
 Check the bolts for tight fitting and cleanliness.
 Remove the bolts and dis –assemble the side plates and bottom plate.
 Check for cleanliness and straightness with help of straight edge.
 Re-fit the assembly and again and check for dimensional accuracy.
 Check for diagonals for right angles in plan.
 Remove bottom plate if attached and check diagonals between top and
bottom.
 Put cube assembly on base plate and check level of adjacent plates.
 Tolerances ( IS : 516 ) :
 Dimensional tolerances shall not be more than 150 + /- 0.2 mm.
 Angular Tolerances shall be 90 deg + /- 0.5 deg. ( +/- 0.2 mm ).
Reports :Keep records of verifications of dimensions Date and Serial wise.
VERIFICATION OF SIEVES
Aim : To visually inspect the sieves for condition
Procedure :
Check the sieves are properly secure at frame and no gap is seen between frame and
sieve when pressed little on sieve center by palm.
Check the sieve wires /flats for straightness, ruptures etc.
Records : Rejected sieves shall be marked and then dispose suitably.

VERIFICATION OF PAN BALANCE

Aim : To check the sensitivity of pan balance.
Apparatus : Weight of least count.
Procedure :
Check proper level of balance and cleanliness.
Keep the pan on balance and check for pointer.
Then apply slight pressure on pan and keep the balance in swing. Watch for any
abrupt stoppage of swing.
Then keep the least count weight lightly without shock in pan and check if it record
swing. Remove the weight lightly with forceps without shock and watch if pointer
returns back to original.
If it does not respond to the least count weight, use next higher weight and observe.
Conclusion : Weight to which balance responds and visually seen shall be the least
count of the balance.

VERIFICATION OF MECHANICAL WEIGH BALANCE

Aim : To check condition and sensitivity of weighing mechanism.
Apparatus : Weight of 3kgs. ( This will give tolerance of about 2% in weighing as
against 3% specified ).
Procedure :
Put weigh balance on level ground. Empty the buckets completely.
Check weighing mechanism is showing zero reading.
Add 3 kg load in bucket and check the reading.
Add 20 kg weight and check the reading.
Add 3kg weight and check the reading and so on.
Conclusion :
If it shows the reading around 3 kgs for each increment , it is OK. If not check
weighing mechanism which may have jammed bearing. Clean, change and repeat
procedure. If still error persists then it is time to calibrate equipment which only can be
done by manufacturer or approved agency. ( One common problem with arm type
weigh batcher is slotted weights. If they get interchanged then weighing will show
variation.)

VERIFICATION OF COMPRESSION TESTING MACHINE OIL LEAKAGE

Aim : To check performance of loading. This can be tested while performing above
test also.
Apparatus :
Test Cube for higher grade than normally tested.
Procedure :
Test method is same as Cube Testing but cube is not to be loaded till crushing.
Place the cube in machine and load the cube till first crack appears on surface.
Stop the loading.
Watch the black needle whether remains in position. This needle may come back
slightly as cube is getting strained but then remains in position.

Conclusions :
If the needle traced back slowly it means there is leakage in system particularly Oil
seal inside cylinder. Or visible leakage in line connecting dial gauge and cylinder.

Report :
Report the load applied and observation and file in Calibration File.
Consult manufacturer for Repairs if required.
VERIFICATION OF COMPRESSION TESTING MACHINE PLATEN FLATNESS
Aim : To check the condition of CTM for its performance- platen Flat ness.
Apparatus :
Test Cubes of grade at least M: 20 ( Extra Conc. Cubes which are not listed for
checks of work )
Plain Paper and New Carbon Paper- 2each
Procedure :
For carrying out this test, cube is required to load partially only say up to 25-30 kN and
cube shall be retrieve in whole piece. Method is same as Cube testing.
Check cube surface which will be contact with platens for flatness by straight edge.
Put carbon paper on bottom platen, carbon side facing top and then put plain paper
( Mark “Bottom Side” on the paper ) on top of carbon paper.

Slide the cube and center it correctly so that whole cube surface shall be in contact
with plain paper. Mark the cube edges on the paper by pen.
Slide one more plain paper ( Mark “ Top Side on the paper )on top surface of cube.
Put carbon paper on top of plain paper with carbon side touching plain paper. Mark
the cube edges on paper by pen after tightening platen on cube by jack.
Load the CTM partially say up to 25-30 kN. This should not break the cube.
Remove the load. Retrieve the cube and plain papers watch the carbon marks on the
papers. Complete the cube size marking with straight edge to show area of cube with
respect to carbon mark ( which will appear circular in shape).
Results :
Refer to the top side paper first. Match the diagonals of cube size and check if carbon
mark is concentric with center of cube dimensions. If this is not concentric then cubes
are getting loaded eccentrically and failures are occurring only on one side mostly.
Check the carbon marking on the paper with respect to size of cube. If this marking is
less than 75 mm in diameter, it means cube is getting loaded only as point load
thereby most of the cubes are getting cracks centrally. Refer to the Bottom side paper.
On this side carbon marking will on more area than top side. Check the consistency of
shade of marks. It shall not be varying too much in shade or blank spaces in between.
Conclusions:
If top markings are showing point or eccentric loading, it means top platen is bent (
Usually this occurs in 100t CTM as per our experience).If bottom marking have large
shade variance, bottom platen surface has irregularities. Consult the Manufacturer for
replacement or repairs of platens.

4 - CALIBRATION OF BATCHING PLANT

(In House Test)

Aim : To calibrate the weighing mechanism of batch plant to conform within weighing
tolerances.

Apparatus :
Calibrated Weight blocks of various designations 50 / 20 kgs / 10 kgs ( As decided
and required ).

Procedure :
 Clear the bucket of all loose and any sticking material shall be removed.
 Set the reading at zero on display for no load.
 Load the bucket with weights starting from 20 kg and increase at the increment of
50 kgs.
 At start and each increment record the load on dial or display ( Loading Condition
).
 Reach the total load up to 1.2 times the operating weight of material being used or
to the 0.9 times of capacity.
 After this remove 50 kg load every time and record these decrement values as
above ( Unloading Condition )
 Check the report for tolerances to + /- 3 %. If it is exceeding the same weighing
mechanism shall be adjusted suitably to give minimum errors.

Report :
Keep report of variance of actual weights and recorded weights. Give correction
factors to plant operator.
 BATCHING PLANT CALIBRATION REPORT

Site : Date of Calibration :

Make and capacity of Batching Plant :

SP Code No :

Testing Condition : LOADING / UNLOADING

Actual Readin Readin Error% Error% Remarks

Weight g g before After
before After correct correct
correct Corret
n
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500

Calibration Done By : Checked By :

 5 - LIST OF ABBREVIATION

Amp : Ampere
Avg : Average
C : Centigrade
C.C. : Cement Concrete
CA : Coarse Aggregate
cc : Cubic Centimeter
cl. : Clause
CM : Cement Mortar ( Proportion )
cm : Centimeter
cm2 : Square Centimeter
cm3 : - do –
CTM : Compression Testing Machine
deg : Degree ( Temperature)
Dia : Diameter
DLBD : Dry Loose Bulk Density.
g : Gram
G.I. : Galvanized Iron
Hrs : Hours
IS : Indian Standard
ISI : Indian Standard Institution now BIS ( Bureau of Indian Standards )
Kg : Kilogram
kN : Kilo-Newton ( Weight measure. 1kN = 1000 N = 100 kg )
LL : Live Load
M.S. : Mild Steel
m3 : Cubic meter
Max : Maximum
mcn : Micron ( 1000 micron = 1 mm )
MDD : Maximum Dry Density
Min : Minimum
mm : Millimeter
mm2 : Square Millimeter
Mpa : Mega Pascal ( Unit of Stress/ Pressure )
MT : Metric Ton ( 1 MT = 1000 Kgs)
MTC : Manufacturer’s Test Certificate
N : Newton ( weight measure 10 N = 1 Kg approx )
No : Number
O.P.C : Ordinary Portland Cement
OMC : Optimum Moisture Content
Pg : Page
PPC : Portland Pozzolana Cement
PSC : Portland Slag Cement
Qty : Quantity
RMC : Ready Mix Concrete
S.D. : Standard Deviation
Sp.Gr. : Specific Gravity
Sr. : Serial
Std : Standard
UTS : Ultimate Tensile Stress
wt : Weight
 6 - DEFINITIONS
Newton : It is measure of weight in S.I. ( International Standard ) Unit. 10 N = 1kg.
Approximately.
Mpa : It is unit of Stress or Pressure in S.I. ( International Standard ) Unit. Equivalent
to N/mm2.
Gross Sample : Sample collected from stack of material which is representative and
it is further divided to make specimen for testing by specific method.
Characteristic Strength ( of Concrete ) , Fck : This is the designated strength ( in
N/mm2 or kg /cm2 ) of cube cured for 28 days for given Grade of the concrete, below
which not more than 5% of the test results are expected to fall. This value shall not be
considered as accepted value of strength directly. Concrete strength acceptance
criteria is based on value of ‘Fck’.
Mean Target Strength (of Concrete ) : This value is targeted when designing the
mix of concrete under strict control at laboratory. Hence under site conditions lower
values will be attained without any compromise on acceptance criteria.
.
Batch of Cement : This is displayed on cement bags as a week number of the year.
It shows Week of production ( Whole year is divided in weeks and serial no of week is
given. E.g.- 4th week means 4th week of Jan. 9th week means 1st week of Mar ) along
with Month and year is also shown. The display is ‘ 9 / 03’ or

W M Y
9 3 2003