Concrete Lab Manual

CONCRETE AND HIGH WAY ENGINEERING LABORATORY
1. OBJECTIVE & RELEVANCE

The objective of concrete laboratory is to determine the physical properties of building
construction materials like cement, fine and coarse aggregate and strength characteristics of
cement mortar, plain cement concrete and reinforced cement concrete. The tests include
determination of specific gravity, fineness, normal consistency, setting times, workability
and soundness of cement, fineness modulus of fine and coarse aggregate, strength of cement
mortar, cement concrete and bricks, , and non destructive test on concrete. The students will
be able to infer the suitability of these materials for construction. They can design the mix,
make the specimens and test the same for the strength for comparison with design strength.
This laboratory course will help the students to understand the theoretical concepts learned
in the course building materials.
The objective of highway materials laboratory is to determine some of the properties of

coarse aggregates and bitumen. Experiments include tests for impact , abrasion , attrition test
and crushing strength for coarse aggregate and tests for penetration, ductility, viscosity,
softening point and flash and fire point for bitumen. The students will be able to infer the
suitability of these materials for construction of road. This laboratory course will help the
students to understand the theoretical concepts learned in this course
2.OUTCOME
At the end of this section of the course, the student will be capable of
• Selecting the appropriate materials for use in different road layers
• To evaluate the quality and performance of unbound and bound road materials
• Perform road pavement design and analysis
• Drawing up an appropriate road monitoring and maintenance programme
• Interpret geometric design fundamentals, in relation to safety and driver comfort, focusing
on horizontal and vertical alignment
• Design the geometric curves of a road pavement
1
DEPARTMENT OF CIVIL ENGINEERING ASTRA
3. CODE OF CONDUCT
1. Students should report to the labs concerned as per the timetable.
2. Students who turn up late to the labs will in no case be permitted to perform the
experiment scheduled for the day.
3. After completion of the experiment/program, certification of the staff in-charge
concerned in the observation book is necessary.
4. Students should bring a notebook of about 200 pages and should enter the
readings/observations/results into the notebook while performing the experiment.
5. The record of the program(s) executed, results along with the description and
algorithm performed in the immediate previous session should be submitted and
certified by the staff member in-charge.
6. Before occupying the system students must enter appropriate information into the Log
book kept in the respective lab.
7. After completion of the lab work students should shut down the system properly.
8. Any damage of the equipment or burnout of components will be viewed seriously either by
putting penalty or by dismissing the total group of students from the lab for the semester/year.
9. Students should be present in the labs for the total scheduled duration.
10. Students are expected to prepare thoroughly to perform the experiment/program before
coming to Laboratory.
11. Horseplay will not be tolerated and will constitute grounds for dismissal from the
course.
2
4. PRECAUTIONS
1 Among some of the more commonly mentioned precautions are: proper grounds on
electric equipment, proper using, suitable extension cords where their use is necessary,
and adequate lighting.
2 Provide suitable enclosures for moving parts of machines, particularly belts and gears.
Laboratory personnel have been badly injured by contact with exposed gears or by being
caught in a machine while testing specimens while alone in a laboratory. In a latter case,
the operator managed to kick the switch off with his foot; this he could not have done if
the switch had been located at a distance. Keep hands out of moving machinery, and do
not touch revolving shafts or rolls, or even the ends of the moving shafts, even though the
parts may be polished and smooth. It is particularly dangerous to touch such moving parts
with rags or gloves
3 . Contact with cement powder or fresh (unhardened) cementitious mixtures can cause skin
irritation, severe chemical burns, or serious eye damage. Avoid contact with eyes and
skin. Wear waterproof gloves, a fully buttoned long sleeve shirt, full-length trousers, and
tight fitting eye protection when working with these materials. Wash cement powder or
fresh (unhardened) cementitious mixtures from your skin with fresh, clean water
immediately after contact. Indirect contact through clothing can be as serious as direct
contact, so promptly rinse out cement powder or fresh (unhardened) cementitious
mixtures from clothing. Seek immediate medical attention if you have persistent or severe
discomfort. In case of eye contact, flush with plenty of water for at least 15 min. Consult a
physician immediately.
4 When mixing or testing fresh concrete, wear safety glasses, goggles, or face shields to
keep concrete from splashing into the eyes. When working around noisy equipment such
as crushers or screening plants, use ear plugs. Use dust masks in dusty areas. Safety shoes
are always advised.
5 A protective screen or curved shield of perforated metal should be used to surround

concrete test specimens that are expected to shatter at high load. Such a shield can rest
loosely upon the machine platen a small distance from the specimen.
The operator should wear goggles, safety glasses, or a face shield if the material scatters
enough to warrant such precaution. The clutch on the gears of the screw-loaded testing
3
Machine should be kept in proper adjustment so that it will not fall into gear unexpectedly
while preparations are being made for test of a specimen.
Be cautious about flying fragments.
6. Remember that dry cement splashes like water and that eye protection is necessary,
particularly if the cement is hot. Provide collectors for such dust as may be produced in
dry grinding, sawing, or otherwise finishing or cutting concrete specimens.
7. Some materials now in use in the concrete laboratory warrant special precautions, for
example, sulfur, sodium hydroxide, mercury, sulfur cements, benzol, alcohol, and carbon
tetrachloride. An emergency eye wash station is advisable.
Safety showers and eye wash fountains should be at hand for students in some lines of
work, and these should be in working order.
8. Most of these safety admonitions have been prompted by recollections of actual

happenings and they should not be treated lightly. Most of all, use common sense.
4
5. LIST OF THE EXPERIMENT AS PER JNTUH
S.No List of the Experiment
1 Introduction to C&HM lab

2 Aggregate Crushing value
3 Aggregate Impact Test.
4 Specific Gravity and Water Absorption.
5 Attrition Test
6 Abrasion Test.
7 Shape tests
8 Penetration Test.
9 Ductility Test.
10 Softening Point Test.
11 Flash and fire point tests.
12 Normal Consistency of fineness of cement.
13 Initial setting time and final setting time of cement.
14 Specific gravity and soundness of cement.
15 Compressive strength of cement.
16 Workability test on concrete by compaction factor, slump and Vee-bee.
17 compressive strength of concrete.
18 Bulking of sand.
19 Non-Destructive testing on concrete
20 Blaine's Air Permeability Test
5
6. SYLLABUS ANALYSIS
SNO Name of the Experiment Unit Text /Reference

No Books
1 Introduction to C&HM lab 1-8 --
2 Normal Consistency of fineness of cement. 1 T1:48,T3-1.29,1.30
3 Initial setting time and final setting time of 1 T1:52,53,T3-(1.31-

cement. 1.33)
4 Specific gravity and soundness of cement. 1 T1:54, T3-1.35
5 Compressive strength of cement. 1 T1:421,T3-1.33
6 Bulking of sand. 2 T1:80,T3-2.21
7 Aggregate Crushing value 2 T1:113,75,T3-2.27,
T4-7.6
8 Aggregate Impact Test. 2 T1:114-115,T3-2.29,
T4-7.6
9 Specific Gravity and Water Absorption. 2 T1:78,T3-2.25,T4-

7.6
10 Attrition Test 2 T1:76,T4-7.8
11 Abrasion Test. 2 T1:77,T3-2.32,T4-

7.7
12 Shape tests 2 T1:70,T4-7.5
13 Workability test on concrete by compaction factor, 4 T1:227,222,232,

slump and Vee-bee.
T3-3.82,3.83,3.80
14 Penetration Test. 5 T2:182-183,T4-7.18
15 Ductility Test. 5 T2:190-192,T4-7.19
16 Softening Point Test. 5 T2:184-185,T4-7.19
17 Flash and fire point tests. 5 T2:192,T4-7.18
18 compressive strength of concrete. 5 T1:421,T4-5.1
6
19 Non-Destructive testing on concrete (for 6 T1:437-44,T4-5.7

demonstration
20 Blaine's Air Permeability Test 6 T3-1.29,T5-1
21 Bituminous Mix Design By Marshall Method 7 T4-7.24,T6-7.22
22 Split Tensile Strength Of 8 T3-5.4,T7-181

Concrete
7)Text Books:
T1 -Concrete Technology, by M.S.SHETTY. S.Chand and Company Ltd., New Delhi.
T2-Pavement Design by R.Srinivasa kumar
T3-Concrete technology by Mahaboob Basha
T4. -High way engineering by S.P.Bindra
.T5-Methods Of Physical Tests For Hydraulic Cement
T6.- The hand book of highway engineering BY T.F.FWA
T7- Concrete technology fifth edition published by MCGRAW HILL EDUCATION
Reference Books:
1. Indian Standard Methods of Test for Aggregate for concrete IS: 2386 Part-IV, Indian
Standards Institution.
2. Indian Standard Specifications for Coarse and Fine Aggregate from Natural Sources for
Concrete, IS: 383 Indian Standards Institution.
3. S.K. Khanna, C.E.G. Justo, Highway Material Testing Laboratory Manual, Nem Chand
& Bros., Roorkee.
4.Relevant IS Codes and IRC Codes.

Highway Material Testing Laboratory Manual – Nemi Chand & Bros.
7
8
8)SESSION PLAN
1 1-8 Introduction to C&HM lab Prerequisite
2 1 Shape tests
JNTUH
3 1 Normal Consistency of fineness of cement.
JNTUH
4 1 Initial setting time and final setting time of
cement. JNTUH
5 1 Specific gravity and soundness of cement. JNTUH
6 1 Compressive strength of cement.

JNTUH
7 2 Aggregate Crushing value
JNTUH
8 2 Aggregate Impact Test.

JNTUH
9 2 Specific Gravity and Water Absorption.

JNTUH
10 2 Attrition Test
JNTUH
11 2 Abrasion Test.
JNTUH
12 3 Bulking of sand.
JNTUH
13 4 Workability test on concrete by compaction

factor, slump and Vee-bee. JNTUH
9
14 5 . Penetration Test.
JNTUH
15 5 . Ductility Test. JNTUH

16 5 Softening Point Test.
JNTUH
17 5 Flash and fire point tests.

JNTUH
18 5 compressive strength of concrete.

JNTUH
19 6 Non-Destructive testing on concrete

JNTUH
20 6 Blaine's Air Permeability Test

CBS
21 7 Bituminous Mix Design By Marshall Method

CBS
22 8 Split Tensile Strength Of

Concrete
CBS
10
9. Experiment Write Up
9.1. Introduction to concrete and highway materials lab
Equipments used in the lab:
1.PENETRO METER As Per IS 1203
Bitumen Penetration Test Apparatus are used for testing bitumen, tar, cement and soils. A
Chosen force is applied over a given area for a known period of time and the depth of
penetration or the depression made in the sample is measured in tenths of a millimeter which
is expressed as a penetration number. An accurately machined aluminium base with in- set
spirit level in these bitumen penetration test apparatus has been designed to facilitate
penetration tests to be made over a wide surface area of sample, Adjustable feet are provided
in the base for leveling and a head support, mounted on a vertical rod which can be adjusted
for head, a rack & pinion and pointer assembly provides for fine adjustments of needle or
cone tip to sample incorporated a slipping clutch mechanism which makes reading of
penetration and subsequent resetting a simple and accurate operation. Each Penetrometer is
supplied with a Plunger and Needle weighing 50g for testing bituminous products, one of
each 50gm & 100gm weights, and one of each aluminium sampling containers 55mm dia x
53mm ht & 55mm dia x 35mm ht.
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2. Ring & Ball (Softening Point) Test Apparatus

Quality Standard : As Per IS 1205
Specification:
Ring & Ball (Softening Point) test apparatus is used for determination of softening point of
bituminous materials. Softening point is that temperature at which the specimen under test
becomes soft enough to allow a steel ball of specific dimensions to fall a required distance
under test conditions.
A) MANUALLY OPERATED
Ring and Ball apparatus (Softening Point) test apparatus manually operated with Borosil
Beaker 600ml capacity, tapered rings, ball centering guides, steel balls (9.5mm dia).
B) ELECTRICALLY OPERATED
Ring and Ball apparatus (Softening Point) test apparatus electrically operated (Stirring
Arrangement) with Borosil Beaker 600ml capacity, tapered rings, ball centering guides, steel
balls (9.5mm dia), Stirring Rod and Heater.Suitable for Operation on 220V, Single Phase,
50Hz, AC Supply.
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3. NAME : Flash & Fire Point Test Apparatus

Specification :
Flash & Fire Point Apparatus used for determining the flash point of fuel oils and lubricating
oil, bitumen other than cutback bitumen and suspension of solids in liquids, having a flash
point above 49°C. The apparatus consists of brass test cup with handle removable cup cover
with the spring operated rotated shutter having oil test jet flame device, stirrer with flexible
shaft. The assembly rests in Air Bath which is covered with dome shape metal top. The cup
assembly is positioned in a cast iron air bath, fitted with a chrome plated brass top having
electric heater with temperature controller. Suitable for operation on 220V, 1Ph, 50Hz AC -
Supply.
Suitable for Operation on 220V, Single Phase, 50Hz, AC Supply.
4. Ductility Testing Machine

Specification:
Ductility Testing Machine Electrically Operated for determining the ductility of asphalt and
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bitumen. The ductility of bitumen is expressed as the distance in centimeters to which a

standard briquette can be elongated before the thread thus formed breaks under specified
conditions. The ductility testing machine is designed to test three specimens simultaneously,
and consists of a bath thermostatically controlled with inlet and outlet taps and is equipped
with an electric pump circulator & heater and carriage moving over a lead screw. Fixed and
movable brackets are so positioned that specimen is submerged in water throughout. A clutch
arrangement is made to stop the movement of the movable bracket when rapture of the
specimen is noticed. An electric motor driven reduction gear unit ensures smooth constant
speed and continuous operation and provides two rates of pull / travel, i.e., 50mm/min and 10
mm/min in the machine.
The ductility testing machine is fitted with ½ HP motor. Suitable for Operation on 220V,
Single Phase, 50Hz, AC Supply.
Aggregate crushing value test
Consists of M.S.Cylindrical container 150mm ±0.5mm dia x 130mm to 140mm high with base plate
200 to 230 mm.sqr x 6mm thick.
A plinger of 148mm ± 0.5mm dia x 100 to 115mm high. Supplied complete with tamping rod, 16mm
dia x 600mm long, one end rounded. And 1 No. Metal measure 115 ± 0.5mm dia x 180 0.5mm high
The instrument consists of a circular base with two vertical guides. The hammer of weight 13.75
±0.25 kg can be raised to fall freely down the vertical guides. The height of fall can be adjusted
through 380 ± 5mm. The hammer is provided with a locking arrangement. The hammer falls freely to
the base and is removable for emptying. Supplied complete with metal measures 75mm dia x 50mm
high (for specimen preparation) and tamping rod 230mm long x 10mm dia.
Aggregate impact test:
14
The apparatus as per IS: 2386 (Part IV) – 1963 consists of:
(i) A testing machine weighing 45 to 60 kg and having a metal base with a painted lower
surface of not less than 30 cm in diameter. It is supported on level and plane concrete floor of
minimum 45 cm thickness. The machine should also have provisions for fixing its base.
(ii) A cylindrical steel cup of internal diameter 102 mm, depth 50 mm and minimum
thickness 6.3 mm. .
(iii) A metal hammer or tup weighing 13.5 to 14.0 kg the lower end being cylindrical in
shape, 50 mm long, 100.0 mm in diameter, with a 2 mm chamfer at the lower edge and case
hardened. The hammer should slide freely between vertical guides and be concentric with the
cup. Free fall of hammer should be within 380±5 mm.
(iv) A cylindrical metal measure having internal diameter 75 mm and depth 50 mm
for measuring aggregates.
(v) Tamping rod 10 mm in diameter and 230 mm long, rounded at one end.
(vi) A balance of capacity not less than 500g, readable and accurate up to 0.1 g.
Specific gravity test:
15
(a) A· balance of capacity about 3 kg, t weigh accurate to 0.5 g, and of such a type and
shape as t- permit weighing of the sample container when suspended in water~
(b) A thermostatically controlled oven to maintain temperature of 100° to 110°C.
(c) A wire basket of not more than 6.3 rom mesh or a perforated container of convenient
size witb thin
wire hangtlTS for suspending it from the balance.
(d) A container for filling water and suspending the basket.
(e) An air tight container ofcapacity similar to that of tile basket (referred to in 'c' above)
{f) A shallow tray and two dry absorbent clothes, each not less than 75 x 45 cm.
Water absorption test:
16
Wire basket – perforated, electroplated or plastic coated with wire hangers for suspending it
from the balance, Water-tight container for suspending the basket, Dry soft absorbent cloth –
75cm x 45cm (2 nos.), Shallow tray of minimum 650 sq.cm area, Air-tight container of a
capacity similar to the basket and Oven
Abrasion test:
 The machine comprises of a hollow cylinder, which is horizontally mounted on a

strong frame on ball bearings.
17
 The machine is supplied with abrasive charges consisting of a set of 12 hardened steel
balls having approximately 48 mm diameter.
 The cylinder has an opening, which can be closed with a dust tight cover to promote
charging and discharging the cylinder with the material under test.
 It consists of a detachable extension that extends throughout the interior of the
cylinder and prevents it from falling on the cover.
 The cylinder is rotated by an electric motor through a heavy reduction gear.
 A revolution counter is attached to the frame and provided with tray for collection of
materials at the end of the test.
Shape test:
Flake pore width: 3,5.2,7.2,9,11.3,14.3mm

Flake pore interval: 18,31.2,43.2,54,67.8,85.8mm
Flakiness index:
it consists of a frame with a sliding panel. The panel has lots of different standard lengths
and widths accurately cut
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Elongation index:
Consists of a hard wood base with vertically mounted metal studs as specified in the
IS 2386 (Part-I)
TESTS ON CEMENT
Normal consistency of fineness
of cement:
19
The standard consistency is attained when the 10 mm plunger of the apparatus penetrates
the material to a pre-determined depth under free-fall. A new sample is prepared and tested
with initial and final needles in accordance with the procedure described in various
specifications. Vicat Apparatus consists of a frame bearing a movable rod with a cap at top
and a Vicat mould in the form of the frustum of a cone, (80+5)/70 + 5mm dia at the
base,(70mm+5mm) /60 mm at the top and 40 mm high, and with a glass base plate of
minimum 2.5 mm thickness with various models of Vicat apparatus as per standard
specification
Initial setting time and final setting time:
20
TESTS ON CONCRETE
Workability test on concrete by compaction factor:
21
It consists of two rigid conical hoppers and a cylinder mounted on a rigid metal frame. The lower
openings of the hoppers are fitted with hinged trap-doors having quick release catches. A circular
metal plate is provided to cover the top of the cylinder. Supplied complete with one plaster's trowel
and one tamping rod, 16mm dia x 600mm long, one end rounde
Slump test
22
The Apparatus consists of one slump cone with handles and foot pieces. The slump cone has
internal dimensions 20cm. dia at base 10cm. top dia. and 30cm height. Foot pieces can be
fixed to the clamps on the base plate.
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3. LIST OF EXPERIMENTS
Experiment as per the curriculum
I.TESTS ON CEMENTS:
1. Normal Consistency of cement.
2. Initial setting time and final setting time of cement.
3. Fineness of cement
4. Specific gravity of cement.
5. Soundness of cement
6. Compressive strength of cement.
II. TEST ON AGGREGATES:
1. Aggregate Crushing value
2. Aggregate Impact Test.
3. Attrition Test
4.. Abrasion Test.
5. Specific Gravity and Water Absorption
6. Shape test (flaki ness index)
7. Shape test (elongation index)
8. Bulking of sand.
9. Sieve analysis and gradation charts
10. Bulk and compact densities of fine and coarse aggregates
III.TEST ON FRESH CONCRETE
1. Workability test on concrete by compaction factor.
2. Workability test on concrete by, slump cone test
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3. Workability test on concrete by Vee-bee test for stiff mixes
IV. TEST ON FRESH SCC
1. L box Test
2. Slump cone
3. V funnel test
IV.TEST ON HARDEND CONCRETE
1. Young’s modulus and compressive strength of concrete for cubes and cylinders.
2. Splitting tensile strength of concrete
3. Flexural tests on prisms
V. NON-DESTRUCTIVE TESTING ON CONCRETE
1.Rebound hammer
2. ultra sonic pulse velocity (USPV)
VI. BITUMINOUS MATERIALS :
1. Penetration Test.
2. Ductility Test.
3. Softening Point Test.
4. Flash and fire point tests.
CONTENT BEYOND THE SYLLABUS
25
4. TEXT AND REFERENCE BOOKS
Text Books:
1. Shetty, M.S., Concrete Technology, S.Chand and Company Ltd., New Delhi.
2. Khanna and Justo, Highway Material Testing Laboratory Manual, New Chand and
Brothers
Reference Books:
1. Relevant IS Codes and IRC Codes.

2. Highway Material Testing Laboratory Manual – Nemi Chand & Bros.
3. M. L. Gambhir : Concrete Manual : Dhanpat Rai & sons New – Delhi.
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6. EXPERIMENTAL DETAILS
6.3.CEMENT AND CONCRETES

TESTS ON CEMENTS
6.3.1.NORMAL CONSISTENCY OF CEMENT
Aim: To determine the percentage of water required for preparing cement paste of standard
consistency, used for other tests.
Apparatus: Vicat apparatus with plunger, I.S. Sieve No. 9, measuring jar, weighing balance
Procedure: The vicat apparatus consists of a D- frame with movable rod. An indicator is
attached to the movable rod, which gives the penetration on a vertical scale. A plunger of 10
mm diameter, 50 mm long is attached to the movable rod to find out normal consistency of
cement. Take 300 gm of cement sieved through I.S. Sieve No. 9 and add 30% by weight (90
ml) water to it. Mix water and cement on a non-porous surface thoroughly with in 3 to 4
minutes. The cement paste is filled in the vicat mould and top surface is leveled with a
trowel. The filled up mould shall be placed along with its bottom non-porous plate on the
base plate of the vicat apparatus centrally below the movable rod. The plunger is quickly
released into the paste. The settlement of plunger is noted. If the penetration is between 33
mm to 35 mm from top (or) 5 mm to 7 mm from the bottom, the water added is correct. If the
penetration is less than required, the process is repeated with different percentages of water
till the desired penetration is obtained.
S.No. Amuont of water Penetration of Remark

mixed Plunger from top
27
Result: The normal consistency of cement =
Vicat Apparatus
28
6.3.2. INITIAL AND FINAL SETTING TIME OF CEMENT
Aim: To find initial and final setting times of cement.
Apparatus: Vicat apparatus with mould, I.S. sieve No. 9, Initial and final setting time
needles, measuring jar, weighing balance, etc.
Procedure:
Initial setting time: Initial setting time is defined as the time elapsed between the moment
that the water is added to the cement, to the time that the paste starts loosing its plasticity i.e.
the initial setting time needle fails to penetrate the cement paste kept in the mould by about
33-35 mm from the top or 5-7 mm from bottom of the indicator is called initial setting time.
Take a cement sample weighing 300 gm, sieved through I.S. sieve No. 9 and mixed with
percentage of water as determined in normal consistency test. Stopwatch should be started at
the instant when water is added to the cement. Now the prepared cement paste is filled in
vicats mould and leveled with trowel. This mould filled with cement paste kept on the non
porous plate is now placed under the movable rod with initial setting time needle of cross
section 1mm x 1mm The needle is quickly released and it is allowed to penetrate the cement
paste. In the beginning the needle penetrates completely. It is then taken out and dropped at a
fresh place. This procedure is repeated at regular intervals till the needle does not penetrate
the block for about 5 mm measured from the bottom of indicator. Note the time for initial
setting of cement. The initial setting time of an ordinary Portland cement shall not be less
than 30 minutes.
Final setting time:

After noting the time for initial setting of cement, the needle shall be replaced by the final
setting time needle. The movable
rod is slowly released on to the cement paste. In the initial stages he needle and collar may
pierce through the paste. But after some time the same procedure is followed. Such trials
shall be carried out until the needle only makes as impression on the top surface of the
cement paste and the collar of the needle fails to do so. Note the time for final setting time of
29
cement. The final setting time of an ordinary Portland cement shall not be more than 10
hours.
Result: 1. Initial setting time of cement=

2. Final setting time of cement=
Vicat Apparatus
Viva Voce:
1. What is normal or standard consistency of a cement paste?
2. What are the factors affecting the result of the test?
3. What do you understand by the term flash setting?
30
Reference:
1. Indian Standard Methods of Physical Tests for cements IS: 4031, Indian Standards
Institution.
2. Indian Standard Specifications for ordinary and low heat Portland cement IS: 269, Indian
3. Neville. A. M, Properties of concrete, 3rd edition, Pitman publishing company, 1981.
31
SPECIFIC GRAVITY OF CEMENT
REF: I.S 4031 - 1988
AIM: To determine the specific gravity of cement

DEFINITION: Specific gravity of cement is defined as the ratio of weight of a given volume
of cement at a given temperature to the weight of an equal volume of distilled water at the
same temperature both weights being taken in air.
APPARATUS: Specific gravity bottle, weighing balance
MATERIAL: Kerosene free of water, naphtha having a specific gravity not less than 0.7313
shall be used in the specific gravity determination.
PROCEDURE:
1. Wt. of empty dry specific gravity bottle = W1
2. Wt. of bottle + Cement (filled 1/4 to 1/3 ) = W2
3. Wt. of bottle + Cement (Partly filled ) + Kerosene = W3
4. Wt. of bottle + Kerosene (full). = W4
5. Wt. of bottle + water (full) = W5
Specific gravity of kerosene Sk = (W4 – W1) / (W5 – W1) (W2 –W1) x Sk
Specific gravity of Cement = --------------------------- (W4 – W1) – (W3 – W2)
RESULT: Specific Gravity of cement =
SPECIFICATIONS:
INFERENCE:
32
6.3.3. SOUNDNESS OF CEMENT

Soundness of Cement
Unsoundness of cement means, that the cement having excess lime, magnesium
sulphates, etc. due to excess of these items there will be volume changes and large
expansions, there by reduces the durability of the structures.
AIM :- To find out the soundness of cement.
APPARATUS :- Le-Chatelier Apparatus Cement, Water , Glass plate.
Procedure :-
i) The cement is gauged with 0.78 times the water required for standard consistency
(0.78P) in a standard manner and filled in to the Le-Chatelier mould kept on the glass
plate.
ii) The mould is covered on the top with another glass plate.
iii) The whole assembly is immersed in water at temperature of 27oC to 32oC and kept
there for 24 hrs.
iv) Measure the distance between the indicator points.
v) Submerge the mould again in water, heat the water up to boiling point in 30 minutes
and keep it boiling for 3 hrs.
vi) Remove the mould from hot water and allow it to cool and measure the distance
between the indicator points.
vii) The distance between these two measurements gives the expansion of cement.
33
viii) This must not exceed 10mm for OPC, RHC, LHC, etc.
ix) If the expansion is more than 10mm, the cement is unsound.
34
35
6.3.4a COMPRESSIVE STRENGTH OF CEMENT
Theory and Scope: The compressive strength of cement mortar is determined strength of
cement mortar is determined in order to verify whether the cement conforms to IS
specification (IS: 269-1976) and whether it will be able to develop the required compressive
strength of concrete. According to IS: 269-1976, the ultimate compressive strength of cubes
of cement sand mortar of the ratio 1:3, containing (P/4+3.0) percent of water should be as.
Aim: To determine the compressive strength of 1:3 Cement sand mortar cubes after 3 days and
7 days curing.
Apparatus: Universal Testing Machine or Compression Testing Machine, cube moulds,

vibrating machine, crucible for mixing cement and sand measuring cylinder,
trowels, non-porous plate and balance with weight box.
Procedure:
 Calculate the material required. The material for each cube shall be mixed separately
and the quantities of cement and standard sand shall be as follows:
Cement = 200 gm.
Standard Sand = 600 gm.
Water = (P/4+3.0) percent = 84 gm.
The time of mixing (gauging) in any event shall not be less than 3 minutes and if the
time taken to obtain a uniform colour exceeds 4 minutes the mixture shall be rejected and
the operation is repeated with a fresh quantity of cement, sand and water.
 Place the assembled mould on the table of the vibrating machine and firmly hold it in
the vibrating machine and firmly hold it in position by means of suitable clamps.
36
Securely attach the hopper at the top of the mould to facilitate filling and this hopper
shall not be removed until completion of the vibration period.
 Immediately after mixing the mortar as explained above, fill the entire quantity of
mortar
 in the hopper of the cube mould and compact by vibration. The period of vibration
shall be 2 minutes at the specified speed of 12000+400 cycles per minute.
 Remove the mould from the machine and keep it at a temperature of 27+ 2 0C in an
atmosphere of at least 90 percent relative humidity for 24 hours after completion of
vibrations.
 The cubes are removed from the mould and immediately submerge it in clean and
fresh water and keep there until taken out just prior to breaking. The water is which
the cubes are submerged shall be renewed after every 7 days and be maintained at a
temperature of 27+ 20C, keep the cubes wet till they are placed in machine for testing.
 Test the specimens at the required periods, test three cubes at the periods mentioned
below, the periods being reckoned from the completion of vibration. The compressive
strength shall be the average of the strengths of the three cubes for each period.
a) Ordinary Portland Cement: 3 and 7days.
b) Rapid Hardening Portland Cement: 1 and 3 days.
c) Low Heat Portland Cement: 3, 7 and 28 days.
The cubes shall be tested on their sides, the load being applied at the rate of 35
N/mm2/ minute.
Observation and Calculations:
Ordinary Portland Cement
3-day strength 7-day strength

S.No. Strength in Strength in
Load in KN Load in KN
N/mm2 N/mm2
37
Average
Rapid Hardening Cement

N/mm2 N/mm2
Average
Rapid Hardening Cement

N/mm2 N/mm2
Average
38
Viva Voce:
1. What you understand by term ultimate strength of cement?

2. What precautions do you take during determination of compressive strength?
3. What is the significance of this test?
References:
1. Neville A.M, properties of concrete, 3rd Edn. Pitman Publishing Company, 1981.
2. Gambhir .M.L, Concrete Manual, 4th Edn., Dhanpat Rai Sons, Delhi
39
1. ROAD AGGREGATES
6.1.1. AGGREGATE CRUSHING STRENGTH TEST
Theory and Scope:

This is one of the major Mechanical properties required in a road stone. The test
evaluates the ability of the Aggregates used in road construction to withstand the stresses
induced by moving vehicles in the form of crushing. With this the aggregates should also
provide sufficient resistance to crushing under the roller during construction and under rigid
tyre rims of heavily loaded animal drawn vehicles.
The crushing strength or aggregate crushing value of a given road aggregate is
found out as per IS-2386 Part- 4.
The aggregate crushing value provides a relative measure of resistance to crushing
under a gradually applied compressive load. To achieve a high quality of pavement
aggregate possessing low aggregate crushing value should be preferred.
The aggregate crushing value of the coarse aggregates used for cement concrete
pavement at surface should not exceed 30% and aggregates used for concrete other than for
wearing surfaces, shall not exceed 45% as specified by Indian Standard (IS) and Indian
Road Congress (IRC).
Aim: To determine crushing strength of a given aggregate as per IS: 2386 part - IV
Apparatus:
 A steel cylinder of internal diameter 15.2 cm (Steel cylinder with open ends)
 A square base plate, plunger having a piston diameter of 15 cm.
 A cylindrical measure of internal diameter of 11.5 and height 18 cms.
 Steel tamping rod having diameter of 1.6 cms length 45 to 60 cms.
 Balance of capacity 3 kg with accuracy up to 1 gm.
 Compression testing machine capable of applying load of 40 tonnes at a loading rate
40
of 4 tonnes per minute
41
Procedure:
 The aggregate in surface-dry condition before testing and passing 12.5 mm sieve and
retained on 10 mm sieve is selected.
 The cylindrical measure is filled by the test sample of the aggregate in three layers of
approximately equal depth, each layer being tamped 25 times by the rounded end of the
tamping rod.
 After the third layer is tamped, the aggregates at the top of the cylindrical measure are
leveled off by using the tamping rod as a straight edge. Then the test sample is weighed.
Let that be w1 gm.
 Then the cylinder of test apparatus is kept on the base plate and one third of the sample
from cylindrical measure is transferred into cylinder and tamped 25 times by rounded end
of the tamping rod.
 Similarly aggregate in three layers of approximately equal depth, each layer being tamped
25 times by rounded end of the tamping rod.
 Then the cylinder with test sample and plunger in position is placed on compression
testing machine.
 Load is then applied through the plunger at a uniform rate of 4 tonnes per minute until the
total load is 40 tonnes and the load is released.
 Aggregates including the crushed position are removed from the cylinder and sieved on a
2.36mm IS. sieve and material which passes this sieve is collected and weighed. Let this
be w2 gm.
 The above step is repeated with second sample of the same aggregate. The two tests are
made for the same specimen for taking an average value.
 Total weight of dry sample taken is w1 gm weight of the portion of crushed material
passing 2.36mm IS sieve be w2 gm.
Then the aggregate crushing value is defined as the ratio of weight of fines passing the
specified IS sieve to the total weight of the sample (w1).
Aggregate crushing value = 100*w2/w1%
42
Aggregate Crushing Test Apparatus
Crushing Test in Progress
43
Observation and Calculation:
Weight of fines
Total Weight of Aggregate Average aggregate
passing
Trials dry aggregate crushing value crushing strength
2.36mm IS
sample 10 gm % value
sieve, w2gm
1
2
Aggregate crushing value = 100*w2/w1.
Result:
The mean (average) of the crushing value aggregate is __________________%
Viva voce:
1. What do you understand by the term "Ten percent Fines value"?
2. Define aggregate crushing value and how crushing strength test is carried out on
cylindrical stone specimen explain.
3. What is the use or application of the aggregate crushing test?
Reference:
2. Indian Standard Specifications for Coarse and Fine Aggregate from Natural Sources
for Concrete, IS: 383 Indian Standards Institution.
& Bros., Roorkee.
44
45
6.1.2. AGGREGATE IMPACT TEST
Theory and Scope:

Toughness is the property of a material to easiest impact. Due to moving loads the
aggregates are subjected to pounding action or impact and there is possibility of stones
breaking into smaller pieces. Therefore a test designed to evaluate the toughness of stones
i.e., the resistance of the stones to fracture under repeated impacts may be called Impact
test on aggregates. The test can also be carried on cylindrical stone specimen known as Page
Impact test. The aggregate Impact test has been standardized by Indian Standard Institution.
The aggregate impact test is conducted as per IS-2386 Part IV.
The aggregate Impact value indicates a relative measure of the resistance of aggregate
to a sudden shock or an Impact, which in some aggregates differs from its resistance to a
slope compressive load in crushing test. A modified Impact test is also often carried out in
the case of soft aggregates to find the wet Impact value after soaking the test sample.
Various agencies have specified the maximum permissible aggregate Impact values
for the different types of pavements. IRC has specified the following values.
The maximum allowable aggregate Impact value for water bound Macadam; Sub-
Base coarse 50% where as cement concrete used in base course is 45%. WBM base course
with Bitumen surface in should be 40%. Bituminous Macadam base course should have
A.I.V of 35%. All the surface courses should possess an A.I.V below 30%.
Aim: To determine the aggregate impact value of given aggregate as per I.S-2386 Part IV.
Apparatus: The apparatus consists of an

 Impact testing machine: The machine consists of a metal base. A detachable
cylindrical steel cup of internal diameter 10.2cm and depth 5cm. A metal hammer of
weight between 13.5 to 14Kg, 10cm in diameter and 5cm long. An arrangement for
raising the hammer and allow it to fall freely between vertical guides from a height of
38cm on the test sample in the cup.
46
 A cylindrical metal measure having 7.5cm and depth of 5cm for measuring
aggregates.
 A tamping rod of circular cross section, 1cm in diameter and 23cm long, rounded at
one end.
 I.S. sieve of sizes 12.5mm, 10mm and 2.36mm.
 Balance of capacity not less than 500gm to weigh accurate up to 0.01gm.
Procedure:
 The test sample consists of aggregates passing 12.5mm sieve and retained on 10mm
sieve and dried in an oven for 4 hours at a temperature of 100 C to 110 C.
 The aggregates are filled upto about 1/3 full in the cylindrical measure and tamped 25
times with rounded end of the tamping rod.
 The rest of the cylindrical measure is filled by two layers and each layer being
tamped 25 times.
 The overflow of aggregates in cylindrically measure is cut off by tamping rod using it
has a straight edge.
 Then the entire aggregate sample in a measuring cylinder is weighted nearing to
0.01gm.
 The aggregates from the cylindrical measure are carefully transferred into the cup
which is firmly fixed in position on the base plate of machine. Then it is tamped 25
times.
 The hammer is raised until its lower face is 38cm above the upper surface of
aggregates in the cup and allowed to fall freely on the aggregates. The test sample is
subjected to a total of 15 such blows each being delivered at an interval of not less
than one second. The crushed aggregate is than removed from the cup and the whole
of it is sieved on 2.366mm sieve until no significant amount passes. The fraction
passing the sieve is weighed accurate to 0.1gm. Repeat the above steps with other
fresh sample.
47
 Let the original weight of the oven dry sample be w1gm and the weight of fraction
passing 2.36mm I.S sieve be w2gm. Then aggregate Impact value is expressed as the
% of fines formed in terms of the total weight of the sample.
Aggregate Impact Value = 100 * w2 %

.
w
1
Aggregate Impact Testing Machine
48
Sl
Details of Sample Trail 1 Trail 2 Average
No.
Total Weight of aggregate sample filling the
1
cylinder measure = W1 g
Weight of aggregate passing 2.36 mm sieve
2
after the test = W2 g
Weight of aggregate retained 2.36 mm sieve
3
after the test =W2 g
4 (W1-W2 + W2)
Aggregate Impact Value =(W2/W1)*100

5
Percent
Result:
The mean A.I.V is _____________________%.
Viva voce:
1. How is aggregate Impact expressed?
2. What do you understand by dry and wet Impact value?
3. Aggregate Impact value of material A is 15 and that of B is 35. Which one is better for
surface course?
49
Reference:
& Bros., Roorkee.
50
6.1.4. ATTRITION TEST
AIM:
Determination of the percentage of deleterious material in ice control sands by carrying out
the Attrition test.
APPARATUS
DRYING OVEN: A thermostatically controlled drying oven capable of being maintained

continuously at a temperature of 110 ± 5°C.
BALANCE: Sensitive to 0.1 g and having a capacity of 1000 g.
SIEVE: 75 µm.
CONTAINERS: Suitable for drying test samples.
ATTRITION MACHINE: Conforming in all its essential characteristics to the design shown
The machine shall consist of a vertical shaft with paddles attached at one end. The other end
shall be attached to an electric motor capable of rotating the shaft at a speed of 390 ± 10 rpm
under load.
TEST SAMPLE
Samples for attrition are to be obtained from materials to be tested by use of a sample splitter
or the method of quartering. The test sample shall be the end result of the sampling method
and, when dry, should weigh between 490 and 520 g. Under no circumstances should an
attempt be made to select samples of an exact predetermined mass.
PROCEDURE
 Oven dry the test sample to constant mass. Weigh to the nearest 0.1 g and record the
mass as the original mass.
 Set the Attrition test sample tank so that there is a clearance of 5 mm between the
51
bottom of the attrition shaft and the bottom of the tank.

 Place the test sample in the tank and add 175 mL of water and cover with the lid. Run
the attrition machine at 390 rpm for 10 min
 Lower the tank, wash the material on the lid and paddles into the tank with a wash
bottle and wash the sample onto a 75 µm sieve
 Wash the sample over the 75 µm sieve as described in MTO Test Method LS-602 and
oven dry the material retained to constant mass
 Weigh the oven-dry sample to the nearest 0.1 g
CALCULATION
Calculate the percentage of deleterious material (loss by attrition and washing) as follows
A = mass of pass 75 µm sieve W1- W2
mass of original sample x 100 = W1 x 100
where: A = loss by attrition and washing, percent
W1= original mass of sample, g
W2 = mass of retained 75 µm sieve after washing, g
REPORTING OF RESULTS
Report the percentage of deleterious material to the nearest 0.1 percent
GENERAL NOTES
 Care should be taken to ensure that there is no loss of material or water by splashing
in the Attrition machine and that all material is washed from the attrition paddles into
the sample tank.
 Tap water at room temperature may be used in the test. It is important that exactly
175 mL of water is used since smaller or greater values may have a significant affect
on the test result.
 This test includes the pass 75 µm material in the original sample as deleterious
material.
 Since a 500 g sample is used, the washing procedure after test may not remove all the
pass 75 µm material from very fine sands. If this is suspected, the oven dry sample,
after test, should be re-sieved. Any additional pass 75 µm material should be
52
discarded, and the oven dry sample mass (retained) used for calculation purposes. A
note should be made on the data card.
PRECISION
Two test results on a sample of sand should not have a difference of greater than one percent.
If a greater difference than one percent is obtained, the sample should be re-tested
ATTRITION TEST
ORIGINAL MASS AFTER PERCENT

Lab No. LOGG g
MASS g TEST g LOSS
Date : Operator :
Remarks
53
6.1.5. ABRASION TEST
Theory and Scope:

Abrasion is a measure of resistance to wear or hardness. It is an essentially property for road
aggregates especially when used in wearing coarse. Due to the movements of traffic, the
road stones used in the surfacing course are subjected to wearing actions at the top. When
traffic moves on the road the soil particle (sand) which comes between the wheel and road
surface causes abrasion on the road stone. The abrasion test on aggregate is found as per
I.S.-2386 part-IV.
Abrasion tests on aggregates are generally carried out by any one of the following
methods-
1. Los Angeles abrasion test.
2. Deval abrasion test.
3. Dorry abrasion test.
Los Angeles Abrasion Test: - The principle of Los Angeles abrasion test is to find the
percentage wear due to the relative rubbing action between the aggregates and steel balls
used as abrasive charge pounding action of these balls also exist while conducting the test.
Maximum Allowable Los Angeles Abrasion Values of Aggregates in Different
types of pavement layers as per Indian Road Congress (IRC) are:-
For sub-base course a value of 60%. For base course such as WBM, Bituminous
Macadam (B.M.), Built - Up spray grout base course and etc. value of 50%.
For surface course such as WBM, BM, Bituminous Penetration Macadam, Built-
Up spray grout binder course and etc. a value of 40%.
If aggregates are used in surface course as Bituminous carpet, Bituminous surface
dressing, single or two coats, cement concrete surface coarse and etc. a value of 35%.
If aggregates are used for Bituminous concrete, Cement concrete pavement as

surface coarse than aggregate abrasion value of 30% maximum.
54
Aim: To determine the abrasion value of given aggregate sample by conducting Los
Angeles abrasion Test.
Apparatus:
 Los Angeles machine with inside diameter 70cm and inside length of
50%.Abrasive charges.
 I.S Sieve with 1.7mm opening.
 Weighting Balance of 0.1gm accuracy.
Procedure:
 Clean and dry aggregate sample confirming to one of the grading A to G is
used for the test. (Refer table no. 1)
 Aggregates weighing 5Kg for grading A, B, C or D and 10Kg for
gradings E, F or G may be taken as test specimen and placed in the
cylinder.
 The abrasive charge is also chosen in accordance with table no.1 and
placed in the cylinder of the machine, and cover is fixed to make dust
tight. The machine is rotated at a speed of 30 to 33 revolutions per minute.
 The machine is rotated for 500 revolutions for gradings A, B, C and D,
for gradings E, F and G, it shall be rotated for 1000 revolutions.
 After the desired number of revolutions, the machine is stopped and the
material is discharged from the machine taking care to take out entire
stone dust.
 Using a sieve of size larger than 1.70mm I.S sieve, the material is first
separated into two parts and the finer position is taken out and sieved
further on a 1.7mm I.S sieve.
 Let the original weight of aggregate be w1gm, weight of aggregate
55
retained on 1.70mm I.S sieve after the test be w2gm.
Los Angeles abrasion value %= w1  w2 x100 .
w1
Schematic Diagram of Los Angeles Abrasion Testing Machine
56
Sl No. Details of Sample Trail 1 Trail 2 Average

1 Weight of Specimen = W1 g
2 Weight of Specimen after abrasion test,
coarser than 1.70mm IS sieve = W2 g
3 Percentage wear = ((W1 – W2)/W1) * 100
Table
Weight in grams of each test sample in the size range, mm Abrasive

(Passing and retained on Square holes) Charge
No. Weight
25- 20- 20-5- 10- 6.3- 4.75- of of
Grading
80-63 63-50 50-40 40-25

20 12,5 10 6.3 4.75 2.36 Sph- Charge,
eres g
A 5000+2
1250 1250 1250 1250 12
5
B 4584+2
2500 2500 11
5
C 3330+2
2500 2500 8
0
D 2500+1
2500 6
5
E 5000+2
2500 2500 5000 12
5
F 5000+2
5000 5000 12
5
G 5000+2
5000 5000 12
5
57
Result:
The average value of two Los Angeles abrasion test is __________________%
Viva voce:
1. The abrasion value found from Los Angeles test for two aggregates A and B are 50% and
38% respectively. Which aggregate is harder? Why? For what types of constructions
are these suitable?
2. Why Los Angeles abrasion test is considered superior to the other form of tests which are
used to determine the hardness of aggregates?
3. Two materials have abrasion values 3 and 10 respectively. Which one is harder and why?
Reference:
& Bros., Roorkee.
58
6.1.3. SPECIFIC GRAVITY AND WATER ABSORPTION TEST
AIM: To find out the specific gravity and water absorption of the given aggregate
APPARATUS:
1. Balance
2. Oven to maintain temp of 100oC to 110oC
3. Wire basket
4. Container with water
5. Trays
PROCEDURE:
About 2 Kg of the aggregate sample is washed thoroughly and placed in the wire
basket when immersed in distilled water. The basket and the sample are then weighed (W 1)
while suspended in water at a temp of 22oC to 32oC. The aggregatges are then placed on the
absorbent clothes and should be cleaned. The surface dry aggregates is then weighed (W2).
The aggregate is placed in a shallow tray and kept in an oven maintained at a temp of 110 oC
for 24 hours. It is then removed from the oven, cooled in an air tight container and weighted
(W4).
OBSERVATIONS:
Weight of saturated aggregate suspended in water with the basket = W1
Weight of basket above suspended in water = W2
Weight of saturated aggregate in water = (W1 -W2)
Weight of saturated surface dry aggregate in air = W3
Weight of Water equal to the volume of the aggregate = W3 –W5
59
CALCULATIONS:
W4
Specific Gravity= dry weight of aggregate/ weight of equal volume of water =
W3  W5
Water Absorption, % = Percentage by weight of water absorbed in terms of oven dried

weight of aggregate
W3  W4
= x100
W4
INTERFERENCE:
The specific gravity of aggregates normally used in road construction ranges from about 2.5
to 3.0 with an average value of 2.68. Water absorption value ranges from 0.1 to 2.0 % for
aggregates normally used in road surfacing IRC has specified the maximum water absorption
valves as 10 percent for aggregate used in bituminous surface dressing and built up spray
grow.
60
6.1.6a. SHAPE TEST (Flakiness Index)

Theory and Scope:
The particle shape of aggregate is determined by the percentages of flaky and
elongated particles contained in it. In case of gravel it is determined by its Angularity
Number. Flakiness and Elongation tests are conducted on coarse aggregates to assess the
shape of aggregates. Aggregates which are flaky or elongated are detrimental to the higher
workability and stability of mixes. They are not conducive to good interlocking and hence the
mixes with an excess of such particles are difficult to compact to the required degree. For
base coarse and construction of bituminous and cement concrete types, the presence of flaky
and elongated particles are considered undesirable as they may cause inherent weakness with
probabilities of breaking down under heavy loads. Rounded aggregates are preferred in cement
concrete road construction as the workability of concrete improves. Angular shape of
particles are desirable for granular base coarse due to increased stability derived from the
better interlocking when the shape of aggregates deviates more from the spherical shape, as
in the case of angular, flaky and elongated aggregates, the void content in an aggregate of any
specified size increases and hence the grain size distribution of the graded aggregates has to
be suitably altered in order to obtain minimum voids in the dry mix or the highest dry
density. It is determined according to the procedure laid down in IS-2386 (PART- I).
FLAKINESS INDEX: The flakiness index of aggregates is the percentage by particles

whose least dimension (thickness) is less than 3/5th (0.6) of their mean dimension. The test
is not applicable to sizes smaller than 6.3mm.
ELONGATION INDEX: The elongation index of an aggregate is the percentage by weight

of particles whose greatest dimension (length) is greater than 1 and 4/5th times (1.8 times)
their mean dimensions. The elongation test is not applicable to sizes smaller than 6.3mm.
61
ANGULARITY NUMBER: The angularity number of an aggregate is the amount by which

the percentage voids exceeds 33 after being compacted in a prescribed manner. The
minimum allowable combined index of aggregates used in surface course in different types of
pavement is 30%.
Aim: - To determine the flakiness Index of a given aggregates sample.
Apparatus: - The apparatus consists of a standard thickness gauge, I.S. sieves of sizes 63,
50, 40, 31.5, 25, 20, 16, 12.5, 10 and 6.3mm and a balance to weigh the samples.
Procedure:
 The sample is sieved with the sieves mentioned in the table.
 A minimum of 200 pieces of each fraction to be tested are taken and weighed
(w1gm).
 In order to separate flaky materials, each fraction is then gauged for thickness on
 thickness gauge, or in bulk on sieve having elongated slots as specified in the
table.
 Then the amount of flaky material passing the gauge is weighed to an accuracy of
atleast 0.1% of test sample.
 Let the weight of the flaky materials passing the gauge be w1gm. Similarly the
weights of the fractions passing and retained on the specified sieves be w1, w2,
w3, etc. are weighed and the total weight w1+w2+w3+. = wg is found. Also
the weights of the materials passing each of the specified thickness gauge are
found = W1, W2, W3 and the total weight of the material passing the different thickness
gauges = W1+W2+W3+. =Wg is found.
 Then the flakiness index is the total weight of the flaky material passing the
various thickness gauges expressed as a percentage of the total weight of the
sample gauged
Flakiness Index w1 w2
62
w3 ....... x100
W1 W2 W3
.......
w x100 %
W
Thickness Gauge
Flakiness Index Test in Progress
63
SIZE OF AGGREATE Weight of

THICKNESS Weight of the
aggregates in
GAUGE faction
PASSING RETAINED each fraction
(O.6 TIMES consisting of
THROUGH I.S ON I.S. passing
THE MEAN atleast 200
SIEVE mm SIEVE mm thickness
SIEVE)mm pieces in gm.
gauge,gm.
63 50 33.90
50 40 27.00
40 25 19.50
31.5 25 16.95
25 20 13.50
20 16 10.80
16 12.5 8.55
12.5 10.0 6.75
10 6.3 4.89
Result: The flakiness index of the given sample of aggregates is _______________%.
64
6.1.6b. SHAPE TEST (Elongation Index)
Aim: To determine the Elongation Index of the given aggregate

sample.
Apparatus: Length gauge, I.S-sieves as given in the table and a balance of accuracy
0.01 Gm.
Procedure:
 The sample is sieved through I.S-sieves specified in the table. A minimum of 200
aggregate pieces of each fraction is taken and weighed.
 Each fraction is thus gauged individually for length in a length gauge. The gauge
length is used should be those specified in the table for the appropriate
material.
 The pieces of aggregates from each fraction tested which could not pass through
the specified gauge length with its long side are elongated particles and they are
collected separately to find the total weight of aggregate retained on the length
gauge from each fraction.
 The total amount of elongated material retained by the length gauge is weighed to
an accuracy of atleast 0.1% of the weight of the test sample.
 The weight of each fraction of aggregate passing and retained on specified sieves
 sizes are found - W1, W2, W3, . And the total weight of sample determined
= W1+W2+W3+. = Wg. Also the weights of material from each fraction
retained on the specified gauge length are found = x1, x2, x3 and the total weight
retained determined = x1+x2+x3+ = x gm.
 The elongation index is the total weight of the material retained on the
various length gauges, expressed as a percentage of the total weight of
the sample gauged.
65
Elongation Index x1 x2 x3
=
........ x100 .
W1 W2 W3 .....
Length Gauze
Elongation Index Test in Progress
66
SIZE OF AGGREATE Weight of

LENGTH Weight of the
aggregates in
GAUGE (1.8 faction
PASSING RETAINED each fraction
TIMES THE consisting of
THROUGH I.S ON I.S passing
MEAN atleast 200
SIEVE mm SIEVE mm thickness
SIEVE)mm pieces in gm.
gauge,gm.
63 50 -
50 40 81.00
40 25 58.50
31.5 25 -
25 20 40.50
20 16 32.40
16 12.5 25.60
12.5 10.0 20.20
10 6.3 14.70
Result: The elongation index of a given sample of aggregate is ________________%.
67
6.1.6c SHAPE TEST (Angularity Number)
Aim: To determine the Angularity Number of the given aggregate sample.
Apparatus:
1. The apparatus consists of a metal cylinder closed at one end and of about 3 liter capacity.
The diameter and height of this being approximately equal i.e., about 15.64cms diameter
and 15.64cms height.
2. A metal tamping rod of circular cross section 1.6cms in diameter and 60cms in length
rounded at one end.
3. I.S. sieves of sizes 20, 16, 5, 10, 6.3 and 4.75mm and balance of capacity 10kg to weigh
upto 0.1gm.
Procedure:
 Metal cylinder is calibrated by determining the weight of water at 27ºC required to fill
it, so that no meniscers is present above the rim of the container.
 The sample of single size aggregate retained between the specified pair of sieves is
dried in an oven at a temperature 100ºC to 110ºC for 24 hours and cooled prior to
testing.
 The aggregates are placed in the cylinder and subjected to 100 blows of the tamping
rod at a rate of about 2 blows per second. Each blow is applied by holding the rod
vertically with its rounded end 5cms above the surface of the aggregates and releasing
it so that it falls vertically and no force is applied to the rod.
 The process of filling and tamping is repeated exactly as described above with a
second and third layer of aggregate.
 After the third layer is tamped, the cylinder is filled to over flowing and the
aggregates are struck off level with the top using a tamping rod as a straight edge. The
aggregate with cylinder is then weighed accurately.
 All the above steps are repeated on another sample and averages of two are represented.
68
 The angularity number is calculated from the formula,
Angularity Number = 67  100W where,

CG
W = Mean weight of aggregates in the cylinder, gm.
C = Weight of water required in the cylinder, gm. G = Specific gravity of
aggregate.
Details of Sample Trail 1 Trail 2 Average
Weight of aggregate Filling the cylinder to the

nearest five grams
Result: The angularity number of given aggregate sample =

__________________.
Viva Voce:
1. Explain what is meant by flaky and elongated particles?
2. Explain Angularity Number. How is it found?
3. What do you understand by the term Combined Index?
Reference:
1. Indian Standard Methods of Test for Aggregate for concrete IS: 2386 Part-I, Indian
69

& Bros., Roorkee.
70
.3.7. BULKING OF SAND
The volume of fine aggregate may increase by 1% to 5% due to presence of moisture.

This property of increase in volume of fine aggregate due to moisture is called bulking.
AIM :- To find out the bulking factor of fine aggregate.
APPARATUS :- Container, Sand, Water, Mixing Pan.
Procedure :-
i) Take about 6 liters of dry compacted sand and weigh it and dump it into a mixing pan.
ii) Add a certain known percentage of water by weight of dry sand.
iii) Mix rapidly and thoroughly till a uniform colour is obtained and fill the container with
the wet sand with out any tamping.
iv) Now strike off the top surface and weigh and thus find the weight of wet sand.
v) Repeat the experiment No. of times increasing in water content from 1% to 20%.
vi) Calculations :-
W1=Wt. of 1m3 of compacted dry sand.
W2=Wt. of dry sand contained in 1m3 of wet loose sand.
W3=Wt. of 1m3 of wet sand
X = Percentage of water added
W3=Wt. of dry sand + Wt. of water

71
x
W3= W2 (1+ )
100
w3
W2=
1  X 100
 % of bulking =
W1  W2
x100
W1
W1
Bulking factor =
W2
72
BULKING OF SAND by LAB. METHOD
AIM: To ascertain the bulking Phenomena of given sample of sand.
APPARATUS: Special Vessel for unit volume, tray, balance and weights,
THEORY: Increase in volume of sand due to presence of moisture is known as Bulking of

sand. Bulking is due to the formation of thin film of water around the sand grains and the
interlocking of air in between the sand grains and the film of water.
When more water is added a sand particles got submerged and volume again becomes equal
to dry volume of sand. To compensate the bulking effect extra sand is added in the concrete
so that the ration of coarse to fine aggregate will not change from the specified value
. Fine sands shown greater percentage of bulking than coarse sands with equal percentage of
moisture.
PROCEDURE: Compact the sand in three layers in the vessel, each layer being given 25
strokes, and strike level at top. Weigh it and dump it into a tray.
Add a certain percent of water by weight (say 2%) of dry compacted tray. Add a certain
percent of water by weight (say 2%) of dry compacted sand. Mix, well till uniformly moist.
Fill the container with the wet sand without any tamping strike tip surface level, and find
weight of the wet loose sand.
Repeat this with moisture contents of 4,6,8,10,12,14,16,18 and 20%.
OBSERVATIONS: S. No. % of water added (X%)
Wt. of wet sand W2 gm
Wt. of dry sand in wet sand
W3 gm. = W2 / (1+0.01 x) Bulk Factor = W1 / W3
73
CALCULATIONS: Weight of unit volume of dry compacted sand = W1
Weight of loose wet sand of unit volume = W2
If moisture content be x% in sand, and
if W3 is weight of dry sand in W2 of loose wet sand
, Then W2 = W3 + (0.01) x W3 W3 = W2/ (1+0.01 X).
Bulking factor (B.F.) = W1 /W3.
Bulking percentage = (W1 – W3) X 100 / W3.
Or
(B.F. –1) X 100.
GRAPH: Plot graph between B.F. on (Y- axis) and water content on (X- axis). RESULT: 1.
Moisture content at maximum bulking = 2. Percentage of maximum bulking =
SPECIFICATION: INFERENCE:
74
6.3.5. WORKABILITY TESTS ON CEMENT CONCRETE (FRESH CONCRETE)
B). COMPACTION FACTOR TEST
Aim: To determine the workability of cement concrete by compaction factor test.

Apparatus: Compaction factor apparatus, tamping rod, ingredients of cement concrete.
Procedure:
 Initially a known volume of cement concrete is prepared by required proportion of

ingredients and water-cement ratio.
 The compaction factor apparatus is cleaned and the cylinder is properly oiled. The
sample freshly prepared is put into the top hopper with the shutter closed.
 Then the clamp is released and the shutter is opened and thus the sample falls into the
second hopper whose shutter is closed.
 Then the shutter of the second hopper is also opened to allow the concrete sample into
the cylinder.
 Then the cylinder is weighed and the weight of the partially compacted concrete is
found by deducting the weight of the cylinder.
 The density of the partially compacted concrete mix is calculated by knowing the
volume of the cylinder.
 Then the same sample is filled into the cylinder in 3 layers and each layer is
compacted for 25 blows by using a standard tamping rod.
 Then the weight of the fully density of the fully compacted sample is found out as in
the above case.
 Then the compaction factor for the given sample of cement concrete is found out by
 using the formula,
Compaction Factor = Density of partially compacted cement concrete x100

.
Density of fully compacted cement
concrete
75
76
Mass of Cylinder W1:
Mass Mass
Mass Mass C.F=(W2-
Water partially partially
fullycompacted fullycompacted W1)
S.l. No cement compacted compacted
concrete concrete
ration concrete concrete
(W3) (W3-W1) (W3-W1)
(W2) (W2-W1)
1
2
3
Result: The compaction factor of the given sample of concrete is _______________%.
77
Value of Compaction factor Standard of Workability
0.95 Good
0.92 Medium
0.85 Low
78
A). SLUMP TEST
Theory and Scope:

The workability of fresh concrete is a composite property which includes the diverse
requirements of stability, mobility, compatibility, placeability and finishability. There are
different methods for measuring the workability. Each of them measures only particular
aspects of it and there is really no unique test which measures workability of concrete in its
totality. The test measures the relative effort required to change a mass of concrete from one
definite shape to another by means of vibration. The amount of effort called remoulding effort
is taken as the time in seconds required to complete the change.
Aim: To determine the workability of the cement concrete by slump

test.
Apparatus: Ingredients for the cement concrete, slump mould, IS standard tamping rod,
non-
porous base plate, etc.
Procedure:
 Initially, a known volume of cement concrete is prepared with a required proportion
of ingredients and water - cement ratio.
 The slump mould is cleaned for any remaining cement particles or impurities and is
properly oiled at the inner surface.
 Then the prepared concrete sample is put into the mould which is placed on a non-
porous plate, in 3 layers with a tapping of 25 times for each layer by a standard tamping
rod. The extra heap of concrete present on the top of the mould is cut off or leveled off.
79
 Then the mould is lifted up vertically by taking care not to disturb the cast cement in
the mould.
 The nature of slump is analyzed to get the workability of the given cement concrete
sample.

Result: The total slump observed for given sample = ____________cm.
Degree of
Place of work Slump in mm
workability
Blinding concrete, Shallow sections, pavements Very Low

using pavers
Mass Concrete, Slabs, Beams, Walls, Columns, Low 25-75

Floors, Canal Lining, Strip Footing
Heavily reinforced sections, Slabs, Beams, Medium 50-100

Columns, etc.
Trench filling, insitu pilling High 100-150
80
81
C). VEE-BEE CONSISTOMETER
Aim: To determine the workability of freshly mixed concrete by the use of Vee-Bee
consistometer.
Apparatus: Vee-Bee apparatus, a cylindrical container and a sheet metal slump cone,
standard iron rod, weighing balance and trowels.
Procedure:
 Place the sheet metal slump cone in the cylindrical container of the consistometer. Fill
the cone in four layers, each approximately one quarter of the height of the cone.
 Tamp each layer with twenty five strokes of the rounded end of the tamping rod. The
strokes are distributed in a uniform manner over the cross-section uniform manner
over the cross-section of the cone and for the second and subsequent layers the
tamping bar should penetrate into the under laying layer. After the top layer has been
tamped, struck off level the concrete with trowel so thst the cone is exactly filled.
 Move the glass disc attached to the swivel arm and place it just on the top of the
slump cone in the cylinder container. Adjust the glass disc so as to touch the top of the
concrete cone, and note the initial reading on the graduated rod.
 Remove the cone from the concrete immediately by raising it slowly and carefully in
the vertical direction. Lower the transparent disc on the top of concrete. Note down
the reading on the graduated rod.
 Determine the slump by taking the difference between the readings on the graduated
rod recorded in the steps (2) and (3) above.
 Switch on the electrical vibrations and start the stop watch. Allow the concrete to
remould by spreading out in the cylindrical container. The vibrations are continued
until the concrete is completely remoulded, i.e., the surface becomes horizontal and the
whole concrete surface adheres uniformly to the transparent disc.
 Record the time required for complete remoulding seconds which measures the
workability expressed as number of Vee-Bee seconds.
Initial reading on the graduated rod, a
82
Final reading on the graduated rod, b
Slump (b) - (a), mm
Time for complete remoulding, seconds
Results: The consistency of the concrete is _______________________ sec.
Viva Voce:
1. Describe the factors affecting the choice of the method of test.
2. What are the advantages and disadvantages of Vee-Bee method of test over the other
methods?
References:
1. Neville. A. M, Properties of concrete, 3rd edition,
Pitman publishing company, 1981. 2. Gambhir. M. L,
Concrete manual, 4th edition, Dhanpat Rai and Sons, Delhi
83
TEST ON FRESH SELF COMPACTING CONCRETE

3.7.1 Slump flow test and T50cm test:
(a) Introduction
The slump flow is used to assess the horizontal free flow of SCC in the absence of
obstructions. It was first developed in Japan for use in assessment of underwater concrete.
The test method is based on the test method for determining the slump. The diameter of the
concrete circle is a measure for the filling ability of the concrete.
(b) Assessment of test
This is a simple, rapid test procedure, though two people are needed if the T50 time is to be
measured. It can be used on site, though the size of the base plate is somewhat unwieldy and
level ground is essential. It is the most commonly used test, and gives a good assessment of
filling ability. It gives no indication of the ability of the concrete to pass between
reinforcement without blocking, but may give some indication of resistance to segregation. It
can be argued that the completely free flow, unrestrained by any boundaries is not
representative of what happens in practice in concrete construction, but the test can be
profitably be used to assess the consistency of supply of ready-mixed concrete to a site from
load to load.
Fig 3.2 Slump flow equipment and measuring of slump flow
84
(c) Equipment
The apparatus is shown in figure
 Mould in the shape of a truncated cone with the internal dimensions 200 mm diameter
at the base, 100 mm diameter at the top and a height of 300 mm.
 Base plate of a stiff non absorbing material, at least 900 x 900 mm square, marked
with a circle marking the central location for the slump cone, and a further concentric
circle of 500mm diameter.
 Trowel
 Scoop
 ruler
 Stopwatch
(d) Procedure
 About 6 liter of concrete is needed to perform the test, sampled normally. Moisten
the base plate and inside of slump cone, Place base plate on level stable ground and
the slump cone centrally on the base plate and hold down firmly.
 Fill the cone with the scoop. Do not tamp, simply strike off the concrete level with
the top of the cone with the trowel.
 Remove any surplus concrete from around the base of the cone.
 Raise the cone vertically and allow the concrete to flow out freely.
 Simultaneously, start the stopwatch and record the time taken for the concrete to
reach the 500mm spread circle. (This is the T50 time).
 Measure the final diameter of the concrete in two perpendicular directions.
85
 Calculate the average of the two measured diameters. (This is the slump flow in
mm).
(e) Interpretation of result
The higher the slump flow (SF) value, the greater its ability to fill formwork under its own
weight. A value of at least 650mm is required for SCC. There is no generally accepted advice
on what are reasonable tolerances about a specified value, though ± 50mm, as with the related
flow table test, might be appropriate.
3.7.2 V-Funnel test and V-Funnel test at T5 minutes:
(a) Introduction
The test was developed in Japan and used by Ozawa et al. The equipment consists of a V-
shaped funnel, shown in Fig. An alternative type of V-funnel, the O funnel, with a circular
section is also used in Japan. The described V-funnel test is used to determine the filling
ability (flowability) of the concrete with a maximum aggregate size of 20mm. The funnel is
filled with about 12 liter of concrete and the time taken for it to flow through the apparatus
measured. After this the funnel can be refilled concrete and left for 5 minutes to settle. If the
concrete shows segregation then the flow time will increase significantly.
Though the test is designed to measure flowability, the result is affected by concrete
properties otherthan flow. The inverted cone shape will cause any liability of the concrete to
block to be reflected in the result- if, for example there is too much coarse aggregate. High
flow time can also be associated withlow deformability due to a high paste viscosity, and
with high inter-particle friction.While the apparatus is simple, the effect of the angle of the
funnel and the wall effect on the flow ofconcrete is not clear.
86
Fig 3.3 V-Funnel equipment
(c) Equipment
 V-funnel
 Bucket ( 12 ± 2 liter )
 Trowel
 Scoop
 Stopwatch
(d) Procedure flow time
 About 12 liter of concrete is needed to perform the test, sampled normally.
 Set the V-funnel on firm ground. Moisten the inside surfaces of the funnel Keep the
trap door open to allow any surplus water to drain. Close the trap door and place a
bucket underneath.
 Fill the apparatus completely with concrete without compacting or tamping, simply
strike off the concrete
 Level with the top using trowel.
 Open within 10 sec after filling the trap door and allow the concrete to flow out under
gravity.
 Start the stopwatch when the trap door is opened, and record the time for the
discharge to complete (the flow time). This is taken to be when light is seen from
above through the funnel.
87
 The whole test has to be performed within 5 minutes.
Procedure flow time at T5 minutes
 Do not clean or moisten the inside surfaces of the funnel again.
 Close the trap door and refill the V-funnel immediately after measuring the flow time.
Place a bucket underneath.
 Fill the apparatus completely with concrete without compacting or tapping, simply
strike off the concrete level with the top with the trowel.
 Open the trap door 5 minutes after the second fill of the funnel and allow the concrete
to flow out under gravity.
 Simultaneously start the stopwatch when the trap door is opened, and record the time
for the discharge to complete (the flow time at T 5 minutes). This is taken to be when
light is seen from above through the funnel.
This test measures the ease of flow of the concrete; shorter flow times indicate greater
flowability. For SCC a flow time of 10 seconds is considered appropriate. The inverted cone
shape restricts flow, and prolonged flow times may give some indication of the susceptibility
of the mix to blocking. After 5 minutes of settling, segregation of concrete will show a less
continuous flow with an increase in flow time.
3.7.3 L-box test method:
(a) Introduction
This test, based on a Japanese design for underwater concrete, has been described by Peterson
.The test assesses the flow of the concrete, and also the extent to which it is subject to
blocking by reinforcement. The apparatus is shown in figure.
The apparatus consists of a rectangular-section box in the shape of an ‘L’, with a vertical and
horizontal section, separated by a moveable gate, in front of which vertical lengths of
reinforcement bar are fitted. The vertical section is filled with concrete, and then the gate
88
lifted to let the concrete flow into the horizontal section. When the flow has stopped, the
height of the concrete at the end of the horizontal section is expressed as a proportion of that
remaining in the vertical section (H2/H1 in the diagram). It indicates the slopeof the
concrete when at rest. This is an indication passing ability, or the degree to which the passage
of concrete through the bars is restricted.
The horizontal section of the box can be marked at 200mm and 400mm from the gate and the
times taken to reach these points measured. These are known as the T20 and T40 times and
are an indication for the filling ability.
The sections of bar can be of different diameters and spaced at different intervals: in
accordance with normal reinforcement considerations, 3x the maximum aggregate size might
be appropriate. The bars can principally be set at any spacing to impose a more or less severe
test of the passing ability of the concrete.
This is a widely used test, suitable for laboratory, and perhaps site use. It assesses filling and
passing ability of SCC, and serious lack of stability (segregation) can be detected visually.
Segregation may also be detected by subsequently sawing and inspecting sections of the
concrete in the horizontal section. Unfortunately there is no agreement on materials,
dimensions, or reinforcing bar arrangement, so it is difficult to compare test results. There is
no evidence of what effect the wall of the apparatus and the consequent ‘wall effect’ might
have on the concrete flow, but this arrangement does, to some extent, replicate what happens
to concrete on site when it is confined within formwork. Two operators are required if times
are measured, and a degree of operator error is inevitable.
89
Fig 3.4 L –box equipment
(c) Equipment
 L-box of a stiff non absorbing material see in figure
 Trowel
 Scoop
 Stopwatch
(d) Procedure
 About 14 liter of concrete is needed to perform the test, sampled normally.
 Set the apparatus level on firm ground, ensure that the sliding gate can open freely
and then close it.
 Moisten the inside surfaces of the apparatus, remove any surplus water
 Fill the vertical section of the apparatus with the concrete sample.
 Leave it to stand for 1 minute.
 Lift the sliding gate and allow the concrete to flow out into the horizontal section.
 Simultaneously, start the stopwatch and record the times taken for the concrete to
reach the 200 and 400 mm marks.
90
 When the concrete stops flowing, the distances “H1” and “H2” are measured.
Calculate H2/H1, the blocking ratio.
If the concrete flows as freely as water, at rest it will be horizontal, so H2/H1 = 1. Therefore
the nearer this test value, the ‘blocking ratio’, is to unity, the better the flow of the concrete.
The EU research team suggested a minimum acceptable value of 0.8. T20 and T40 times can
give some indication of ease of flow, but no suitable values have been
generally agreed. Obvious blocking of coarse aggregate behind the reinforcing bars can be
detected visually.
3.7.4 U-box test method:
(a) Introduction
The test was developed by the Technology Research Centre of the Taisei Corporation in
Japan. Sometimes the apparatus is called a “box-shaped” test. The test is used to measure the
filling ability ofself-compacting concrete. The apparatus consists of a vessel that is divided by
a middle wall into twocompartments, shown by R1 and R2 in Fig.
An opening with a sliding gate is fitted between the two sections. Reinforcing bars with
nominal diameters of 13 mm are installed at the gate with centre-to-centre spacings of 50
91
mm. This creates a clear spacing of 35 mm between the bars. The left hand section is filled
with about 20 litre of concrete then the gate lifted and concrete flows upwardsinto the other
section. The height of the concrete in both sections is measured.
This is a simple test to conduct, but the equipment may be difficult to construct. It provides a
good direct assessment of filling ability – this is literally what the concrete has to do –
modified by anUnmeasured requirement for passing ability. The 35mm gap between the
sections of reinforcement may be considered too close. The question remains open of what
filling height less than 30 cm. is still acceptable.
Fig 3.5 U–box equipment
(c) Equipment
92
 U-box of a stiff non absorbing material see in figure

 Trowel
 Scoop
 Stopwatch
(d) Procedure
 About 20 litre of concrete is needed to perform the test, sampled normally.

 Set the apparatus level on firm ground, ensure that the sliding gate can open
freely and then close it.
 Moisten the inside surfaces of the apparatus, remove any surplus water.
 Fill the one compartment of the apparatus with the concrete sample.
 Leave it to stand for 1 minute.
 Lift the sliding gate and allow the concrete to flow out into the other
compartment.
 After the concrete has come to rest, measure the height of the concrete in the
compartment that has been filled, in two places and calculate the mean (H1).
 Measure also the height in the other compartment (H2) Calculate
H1- H2, the filling height.
If the concrete flows as freely as water, at rest it will be horizontal, so H1 - H2 = 0. Therefore

the nearer this test value, the ‘filling height’, is to zero, the better the flow and passing ability
of the concrete.
4.3 Acceptance criteria for SCC
S.No Method Unit Typical range of values
93
Minimum Maximum
1 Slump flow by Abrams cone mm 650 800
2 T 50 Slump flow sec 2 5
3 J-ring mm 0 10
4 V-Funnel sec 6 12
5 V-Funnel @ T 5min sec 0 +3
6 L-box (h2/h1) 0.8 1
7 U-box (h2/h1)mm 0 30
8 Fill box % 90 100
9 GTM Screen stability test % 0 15
10 Orimet sec 0 5
HARDENED CONCRETE
CUBE COMPRESSIVE STRENGTH OF CONCRETE
AIM: To determine the compressive strength of concrete using 15 x 15 x 15 cm concrete

cubes.
APPARATUS: Compressive testing machine, Balance, Trays, Weights, Moulds and

Trowels.
PROCEDURE:
94
1. Place the cube at the centre of the lower platen of the compression testing machine in such a
manner that the load shall be applied to opposite sides of the cube as cast, that is, not to the
top and bottom.
2. The axis of the specimen shall be carefully aligned with the centre of the 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.
3. The load shall be applied without shock and increased continuously at a rate of approximately
140kg/cm2/min. until the resistance of the specimen to the increasing load breaks down and
no greater load can be sustained.
4. The maximum load applied to the specimen shall then be recorded.
OBSERVATIONS: Measured side of cube = cm

Weight of the cube = kg.
Load at first crack = kg.
Load at ultimate failure = kg.
95
CALCULATIONS:
Load at first crack__

Initial crack strength of concrete =
c/s area of the specimen
Maximum Load __.

Ultimate cube compressive strength of the concrete =
c/s area of the specimen
Ultimate strength
Safe compressive strength of concrete =
Factor of safety
Ultimate strength
=
3
Trails Mean Value

Specimen
1 2 3 N/MM2
Load on Cubes, KN
RESULT:
INFERENCE:
1. How does strength correlate with other properties of hardened

concrete?
2. What are the requirements for curing the specimens?
3. What is the rate of loading in flexure test?
Reference:
1. Indian Standard, Recommended Guidelines for Concrete Mix Design, IS: 10262
3. Gambhir. M. L, Concrete manual, 4th edition, Dhanpat Rai and Sons, Delhi.
96
2 Test for splitting tensile strength of concrete
Immediately after removal of cylinder specimens were kept on the surface, water, and grit
shall be removed from the surfaces, which are to be in contact with the packing strips and the
bearing surfaces of the testing machine was wiped clean.
The cylinder specimen was placed horizontally in the centering with packing skip (wooden
strip)/or loading pieces carefully positioned along the top and bottom of the plane of loading
of the specimen. The wooden pieces were placed on top of the cylinder and bottom of the
cylinder, so that the specimen is located centrally, all these arrangements are shown in
fig.The load was applied without shock and increased continuously at a normal rate with the
range 1.2N/mm2/min to 2.4N/mm2/min until failure of the specimen. The maximum load
applied was recorded at failure and the appearance of concrete and unused features in the type
of failure was observed. The test results are presented in table.
Then the splitting tensile strength of the specimen was calculated by using the following
formula.
2P
fct = -----------------------
πxLxD
Where, P = Maximum load in Newton’s applied to the specimen.
L = Length of the specimen in mm.
D= Cross sectional dimension of the specimen in mm.
97
3.8.3 Test for flexural strength of concrete
The prism specimens were removed from the water tank on 7th and 28thday and placed for 10
minutes to wipe off the surface water. The dimensions of each specimen were noted before
testing. The test specimen was marked for third point load as shown in fig. Before placing in
the specimen in the testing machine the bearing surfaces of the supporting and loading
rollers were wiped off clean and any loose sand or other material was removed from the
surfaces of the specimen.
The specimen was placed in the machine in such a manner that the load was applied to the
uppermost surface as cast in the mould, along two lines spaced 13.33cm apart. The axis of
the specimen was carefully aligned with the axis of the loading device. The load was applied
through two similar steel rollers, 38mm in diameter, mounted at the third points of the
supporting span that is spaced at 13.33cm centre to centre. This arrangement was presented
in plate. The load was applied without shock and increased continuously at a rate of
180kg/min until the specimen failed. The appearance of the fractured faces of concrete and
unused features in the type of failure was noted. The test results are presented in the table.
The flexural strength of the specimen is expressed as the modulus of rupture “fb”
(1) If a>13.33cm
fb=(pxl)/(bxd2)
(2) If a<13.33cm
But a>11.0cm fb=(3pxa)/(bxd2)
Where, b = measured width in cm of 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, and
p = maximum load in kg applied to the specimen.
98
If a<11.0cm, the results of the test were discarded.
6.2. BITUMINOUS MATERIALS
6.2.1. PENETRATION TEST

Theory and Scope:
The consistencies of bituminous materials vary depending upon several factors such
as constituents, temperature, etc. As temperature ranges between 25º and 50ºC most of the
paving bitumen grades remain in semi solid or in plastic states and their viscosity is so high
that they do not flow as liquid.
Determination of absolute viscosity of bituminous material is not so simple.
Therefore the consistency of these materials is determined by indirect methods. The
consistency of bitumen is determined by penetration test which is a very simple test. Various
types and grades of bituminous materials are available depending on their origin and
refining process. The penetration test determines the consistency of these materials foe the
purpose of grading them, by measuring the depth (in units of one tenth of a millimeter or one
hundredth of a centimeter) to which a standard needle will penetrate vertically under
specified conditions of standard load, duration and temperature. Thus the basic principle of
the penetration test is the measurement of the penetration (in units of one tenth of a mm) of
a standard needle in a bitumen sample maintained at 25C during five seconds, the total
weight of the needle assembly being 100gm. The softer the bitumen, the greater will be the
penetration. The test is conducted as per IS-1203 for paving bitumen.
Aim: To determine the grade of a given binder.
Apparatus: It consists of items like container, needle, water bath, penetrometer, stop watch
etc. Container is 55mm in diameter and 35mm to 57mm height. The needle is provided
with a shank approximately 3.0mm in diameter into which it is immovably fixed.
Procedure:
 The bitumen is softened to a paving consistency between 75º and 100ºC above the
99
approximate temperature at which bitumen softens.

 The sample material is thoroughly stirred to make it homogeneous and free from air
bubbles and water.
 The sample containers are cooled in atmosphere of temperature not lower than 13ºC
for one hour. Then they are placed in temperature controlled water bath at a
temperature of 25ºC for a period of one hour.
 The weight of needle, shaft and additional weight are checked. The total weight of
this assembly should be 100gm.
 Using the adjusting screw, the needle assembly is lowered and the tip of the needle is
made to just touch the top surface of the sample.
 The needle assembly is clamped in this position. The contact of the tip of the needle is
checked using the mirror placed on the rear of the needle.
 The initial reading of the penetrometer dial is either adjusted to zero or the initial
reading is noted.
 Then the needle is released by pressing a button and a stop watch is started. The needle
is released exactly for a period of 5.0secs.
 At least 3 measurements are made on this sample by testing at distance of not less
than 100mm apart.
 The difference between the initial and final penetration readings are taken as the
penetration value.
Penetration Test Concept
100
Penetrometer
Trails
Readings Mean Value
1 2 3
Penetrometer Dial Initial Reading
Penetrometer Dial Final Reading
Penetration Value
Result:
The average penetration value of a given bitumen sample is ________________ and the grade
of bitumen is ___________________.
Viva Voce:
1. What are the applications of penetration test?
2. What do you understand by the term 30/40 bitumen?
3. What are the precautions to be taken while conducting a penetration
test?
References:
1. Indian Standard Method for Tar and Bitumen, Determination of Penetration of Bitumen,
IS: 1203, Indian Standards Institution.
101
2. Indian Standard Specification for Paving Bitumen, IS: 73.

3. S.K. Khanna and C.E.G Justo, Highway Materials Testing Laboratory Manual, Nem
Chand Bros. Roorkee.
6.2.2 DUCTILITY TEST

Theory and Scope:
A certain minimum ductility is necessary for a bitumen binder. This is because of the
temperature changes in bituminous mixes and the repeated deformations that occur in
flexible pavements due to the traffic loads. It is of significant importance that the binders
form ductile thin films around the aggregates. The binder material which does not possess
sufficient ductility would crack and thus provide previous pavement surface. This is in turn
results in damaging effect to the pavement structure. The ductility is expressed as the
distance in centimeters to which a standard briquette of bitumen can be stretched before the
thread breaks. The test is standardized by the IS: 1208. The test is conducted at 27º±0.5ºC and
a rate of pull of 50±2.5 mm per minute.
Aim: To conduct ductility test on given bitumen sample.
Apparatus: Briquette mould, (length - 75mm, distance between clips - 30mm, width at
mouth of clips - 20mm, cross section at minimum width - 10mm x 10mm), Ductility
machine with water bath and a pulling device at a precaliberated rate, a putty knife,
thermometer.
Procedure:
The bitumen sample is method to a pouring temperature (75ºC to 100ºC) and poured
into the mould assembly and placed on a brass plate, where a solution of glycerin or
soap solution is applied at all surfaces of briquette mould exposed to bitumen.
After the sample is poured to the mould, thirty to forty minutes the entire assembly is
placed in a water bath at 27ºC.
Then the sample is removed from the water bath maintained at 27ºC and excess
bitumen material is cutoff by leveling the surface using hot knife.
After trimming the specimen, the mould assembly containing sample is replaced in
water bath maintained at 27ºC for 85 to 95 minutes. Then the sides of mould are
removed and the clips are carefully booked on the machine without causing any initial
strain. Two or more specimens may be prepared in the moulds and clipped to the
102
machine so as to conduct these test simultaneously.

The pointer is set to read zero. The machine is started and the two clips are thus
pulled apart horizontally.
While the test is in operation, it is checked whether the sample is immersed in water
at depth of atleast 10mm. The distance at which the bitumen thread of each specimen
breaks is recorded (in cm) to report as ductility value.
Ductility Test Concept
103
Sample Prepared in Briquette Mould and Ductility Apparatus
Table
Trails
Test Property Mean Value
1 2 3
Ductility Value
Result: The ductility value of the given bitumen sample is _________________ cm.
Viva Voce:
1. List the factors that affect the result of a ductility test.
2. What do you understand by the term repeatability and
reproducibility? 3. Explain the significance of ductility test.
References:
1. Indian Standard Method for Tar and Bitumen, Determination of Ductility of Bitumen, IS:
1208, Indian Standards Institution.
104
6.2.3. SOFTENING POINT OF BITUMEN
Theory and Scope:

Bitumen does not suddenly change from solid to liquid state, but as the temperature
increase, it gradually becomes soften until it flows readily. The softening point is the
temperature at which the substance attains particular degree of softening under specified
condition of test. For bitumen it is usually determined by Ring and Ball apparatus. The test is
conducted as per IS: 1205.
Aim: To determine the softening point of given paving bitumen as per IS: 1205.
Apparatus: Ring and Ball apparatus, Water bath with stirrer, Thermometer, Glycerin, etc.
Steel balls each of 9.5mm and weight of 2.5±0.08gm.
Procedure:
 Sample material is heated to a temperature between 75º and 100ºC above the
approximate softening point until it is completely fluid and is poured in heated rings
placed on the metal plate.
 To avoid sticking of the bitumen to metal plate, coating is done to this with a solution
of glycerin and dextrin.
 After cooling the rings in air for 30 minutes, the excess bitumen is trimmed and rings
are placed in the support.
105
 At this time the temperature of distilled water is kept at 5ºC. This temperature is
maintained for 15 minutes after which the balls are placed in position.
 Then the temperature of water is raised at uniform rate of 5ºC per minute with a
controlled heating unit, until the bitumen softens and touches the bottom plate by
sinking of balls. At least two observations are made. For material whose softening
point is above 80ºC, glycerin is used for heating medium and the starting temperature
is 35ºC instead of 5ºC.
 The temperature at the instant when each of the ball and sample touches the bottom
plate of support is recorded as softening point value.
Softening Test Concept
106
Softening Point Apparatus and Ring and Ball

Guides
Trails
Test Property Mean Value
1 2 3
Temperature (0C) at which I

ball touches the bottom plate
Temperature (0C) at which II

ball touches the bottom plate
Final Softening Point Temperature
Result: The softening point value of given bitumen sample is ___________________ºC and
grade of bitumen is _________________.
Viva Voce:
1. What are the factors which affect the ring and ball test results?
2. What is softening point?
If material A has softening point of 56 and B has 42 which binder is good and why?
References:
1. Indian Standard Method for Tar and Bitumen, Determination of Softening Point of
Bitumen, IS: 1205, Indian Standards Institution.
107
6.2.4. FLASH AND FIRE POINT TEST
Theory and Scope:

Flash and Fire point test is a safety test conducted on a bituminous material so that it
gives an indication of the critical temperature at and above where precautions should be taken
to eliminate fire hazards during its applications. Bituminous materials leave out volatiles at
high temperature depending upon their grade. These volatile vapors catch fire causing a
flash. This condition is very hazardous and it is therefore essential to qualify this
temperature for each bitumen grade, so that the paving engineers may restrict the mixing or
application temperature well within the limits. Flash and Fire point test is conducted as per IS:
1209.
As per IS: 1209 the definitions of flash and fire point are:
Flash Point: "The flash point of a material is the lowest temperature at which the vapour of
substance momentarily takes fire in the form of a flash under specified conditions of
test".
Fire Point: "The fire point is the lowest temperature at which the material gets ignited and
burns under specified condition of test".
Aim: To determine the flash and fire point of a given bituminous

material.
Apparatus: Pensky-Martens closed cup tester, thermometer, heating
source, flame exposure.
Procedure:
 All parts of the cup are cleaned and dried thoroughly before the test is started.
 The material is filled in the cup upto a mark. The lid is placed to close the cup in a
closed system. All accessories including thermometer of the specified range are suitably
108
fixed.
 The bitumen sample is then heated. The test flame is lit and adjusted in such a way
that the size of a bed is of 4mm diameter. The heating of sample is done at a rate of 5º
to 6ºC per minute. During heating the sample the stirring is done at a rate of
approximately 60 revolutions per minute.
 The test flame is applied at intervals depending upon the expected flash and fire
points
 and corresponding temperatures at which the material shows the sign of flash and fire
are noted.
Flash and Fire Point Test Concept
Flash and Fire Point Test in Progress
109
Trails
Test Mean Value
1 2 3
Flash Point
Fire Point
Table
Result: The temperature at which the flame application that causes a bright flash
____________ºC and temperature at which the sample catches fire ______________ºC.
Viva Voce:
1. Define flash and fire points.
2. What is the significance of flash and fire point test?
3. What are the parameter that affects the result of flash and fire point
tests?
References:
1. Indian Standard Method for Tar and Bitumen, Determination of Flash and Fire Point of
110
111
Observations and Calculations:
Result: The optimum binder content of the given mix is ______________________

Viva Voce:
1. What is the significance of flow value in Marshall Test?
2. What is filler?
3. What are the essential properties of bituminous mixes?
Reference:
2. Ministry of Road Highway Transport, fourth revisions, by Indian Road Congress.
112
TEST FOR FRESH SCC CONCRETE
6.3.8. NON-DESTRUCTIVE TESTING ON CONCRETE
REBOUND HAMMER
AIM
To assess the likely compresive strength of concrete by using rebound hammer as per IS:
13311 (Part 2) - 1992.
PRINCIPLE
The rebound of an elastic mass depends on the hardness of the surface against which its mass
strikes. When the plunger of the rebound hammer is pressed against the surface of the
concrete, the spring-controlled mass rebounds and the extent of such a rebound depends upon
the surface hardness of the concrete. The surface hardness and therefore the rebound is taken
to be related to the compressive strength of the concrete. The rebound value is read from a
graduated scale and is designated as the rebound number or rebound index. The compressive
strength can be read directly from the graph provided on the body of the hammer.
APPARATUS
113
FIG. REBOUND HAMMER
i) Rebound hammer
PROCEDURE
i) Before commencement of a test, the rebound hammer should be tested against the test
anvil, to get reliable results, for which the manufacturer of the rebound hammer indicates the
range of readings on the anvil suitable for different types of rebound hammer.
ii) Apply light pressure on the plunger - it will release it from the locked position and allow it
to extend to the ready position for the test.
iii) Press the plunger against the surface of the concrete, keeping the instrument perpendicular
to the test surface. Apply a gradual increase in pressure until the hammer impacts. (Do not
touch the button while depressing the plunger. Press the button after impact, in case it is not
convenient to note the rebound reading in that position.)
iv) Take the average of about 15 readings.
INTERPRETATION OF RESULTS
The rebound reading on the indicator scale has been calibrated by the manufacturer of the
rebound hammer for horizontal impact, that is, on a vertical surface, to indicate the
compressive strength. When used in any other position, appropriate correction as given by the
manufacturer is to be taken into account.
114
ULTRASONIC PULSE VELOCITY
AIM
To assess the quality of concrete by ultrasonic pulse velocity method as per IS: 13311 (Part 1)
- 1992.
PRINCIPLE
The method consists of measuring the time of travel of an ultrasonic pulse passing through
the concrete being tested. Comparatively higher velocity is obtained when concrete quality is
good in terms of density, uniformity, homogeneity etc.
APPARATUS
FIG. ULTRASONIC PULSE VELOCITY METER
115
i) Ultrasonic pulse velocity meter
PROCEDURE
i) Preparing for use: Before switching on the 'V' meter, the transducers should be connected
to the sockets marked "TRAN" and " REC".
The 'V' meter may be operated with either:

a) the internal battery,
b) an external battery or
c) the A.C line.
ii) Set reference: A reference bar is provided to check the instrument zero. The pulse time for
the bar is engraved on it. Apply a smear of grease to the transducer faces before placing it on
the opposite ends of the bar. Adjust the 'SET REF' control until the reference bar transit time
is obtained on the instrument read-out.
iii) Range selection: For maximum accuracy, it is recommended that the 0.1 microsecond
range be selected for path length upto 400mm.
iv) Pulse velocity: Having determined the most suitable test points on the material to be
tested, make careful measurement of the path length ‘L’. Apply couplant to the surfaces of
the transducers and press it hard onto the surface of the material. Do not move the transducers
while a reading is being taken, as this can generate noise signals and errors in measurements.
Continue holding the transducers onto the surface of the material until a consistent reading
appears on the display, which is the time in microsecond for the ultrasonic pulse to travel the
distance 'L'. The mean value of the display readings should be taken when the units digit
hunts between two values. Pulse velocity = Path length Travel time
v) Separation of transducer leads: It is advisable to prevent the two transducer leads from
coming into close contact with each other when the transit time measurements are being
116
taken. If this is not done, the receiver lead might pick-up unwanted signals from the
transmitter lead and this would result in an incorrect display of the transit time.
INTERPRETATION OF RESULTS
The quality of concrete in terms of uniformity, incidence or absence of internal flaws, cracks
and segregation, etc., indicative of the level of workmanship employed, can thus be assessed
using the guidelines given below, which have been evolved for characterising the quality of
concrete in structures in terms of the ultrasonic pulse velocity.
Pulse Velocity Concrete Quality

(km/second) (Grading)
Above 4.5 Excellent
3.5 to 4.5 Good
3.0 to 3.5 Medium
Below 3.0 Doubtful
117
Content beyond syllabus
1. VISCOSITY TEST
Theory and Scope:
Viscosity is defined as the increase of fluidity. The degree of fluidity at the
application temperature greatly influences the ability of bituminous material to spread,
penetrate in to void and also coat the aggregates and hence affects the strength characteristics
of the resulting paving mixes. There is an optimum value of fluidity or viscosity for mixing
and compacting for each aggregate gradation of the mix and bitumen grade. At high fluidity
or low viscosity, the bitumen binder simply "lubricates" the aggregate particles instead of
providing a uniform film thickness for binding action. Similarly, low fluidity or high
viscosity does not enable the bitumen to coat the entire surface of aggregates. It will increase
the compactive force or effort. The test is conducted as per IS: 1206.
References:
1. Indian Standard Method for Tar and Bitumen, Determination of Viscosity of Bitumen, IS:
1206, Indian Standards Institution.
2.SPECIFIC GRAVITY TEST FOR BITUMEN
Theory and Scope:

The density of a bitumen binder is a fundamental property frequently used as an aid
in classifying the binders for use in paving jobs. In most applications, the bitumen is
weighed, but finally in use with aggregate system, the bitumen content is converted on
volume basis. Thus an accurate density value is required for conversion of weight to volume.
The specific gravity is greatly influenced by the chemical composition of binder. Increased
amount of aromatic type compounds cause an increase in the specific gravity.
118
The specific gravity is defined by ISI as the ratio of the mass of a given volume of the
bituminous material to the mass of an equal volume of water, the temperature of both being
specified at 27ºC±0.1ºC.
References:
1. Indian Standard Method for Tar and Bitumen, Determination of Specific Gravity of
Chand Bros. Roorkee
3. BLAINE'S AIR PERMEABILITY TEST

Theory and Scope:
The degree of fineness of cement is a measure of the mean size of the grains in the
cement. The rate of hydration and hydrolysis and consequent development of strength
depends upon the fineness of cement. To have the same rate of hardening in different brands
of cement, the fineness has been standardized. The finer cement has quicker action with
water and gains early strength though it's ultimate strength remains unaffected. However the
shrinkage and cracking of cement will increase with fineness of cement.
References:
1. Neville. A. M, Properties of concrete, 3rd edition, Pitman publishing company, 1981. 2.
Gambhir. M. L, Concrete manual, 4th edition, Dhanpat Rai and Sons, Delhi.
4. CALIFORNIA BEARING RATIO TEST
Theory and Scope:

The California Bearing Ratio (C.B.R.) test was developed by California Division of
119
Highway as a method of classifying and evaluating soil subgrade and base course materials
for flexible pavements. The test is empirical and the results can not be related accurately with
any fundamental property of the material.
The CBR is a measure of resistance of a material to penetration of standard plunger
under controlled density and moisture conditions. The CBR test may be conducted in re-
moulded or undisturbed specimen in the laboratory. The test is simple and has been
extensively investigated for field correlations of flexible pavement thickness requirement.
The test is conducted by causing a cylindrical plunger of some diameter to penetrate a
pavement component material at 1.25mm/minute. The loads, for 2.5mm and 5mm are
recorded. This load is expressed as a percentage of standard load value at a respective
deformation level to obtain C.B.R. value. The values are given in the table
Unit Standard Load,

Penetration, mm Standard Load, kg
kg/cm2
2.5 1370 70
5.0 2055 105
7.5 2630 134
10.0 3180 162
12.5 3600 183
As per IRC recommendation the minimum value of C.B.R. required for a subgrade should be
8%. The procedure is standardized by Indian Standards Institution in two different
categories. The first being Test of Soils in laboratory, determination of CBR, IS: 2720 part
XVI. The second being Methods of Test for soils, field determination of CBR, IS: 2720
XXXI.
Aim: To determine California Baring Ratio (C.B.R.) value of a given soil
120
sample.
Apparatus: Loading machine which can be operated at a constant rate of 1.25mm per
minute,
cylindrical moulds of 150mm diameter i.e., 175mm height provided with a collar
of about 50mm length and detachable perforated base are used for this purpose,
Compaction Rammer.
Procedure:
 Each batch of soil is (of atleast 5.5kg for granular soils and 4.5 to 5kg weight for fine
grained soils) mixed with water upto the optimum moisture content or the field
moisture content if specified so.
 The spacer disc is placed at the bottom of the mould over the base plate and a coarse
filter paper is placed over the spacer disc.
 The moist soil sample is to be compacted over this in the mould by adopting either the
I.S. light compaction or the I.S. heavy compaction.
 After compacting the last layer, the collar is removed and the excess soil above the top
of the mould is evenly trimmed off by means of straight edges.
 The clamps are removed and the mould with the compacted soil is lifted leaving
below the base plate and the spacer disc is removed.
 A filter paper is placed on the base plate, the mould with compacted soil is inverted
and placed in position over the base plate and clamps of the base plate are tightened.
 Weights of 2.5 to 5kg are placed over the soil sample in the mould. Then the whole
mould is placed in water tank for soaking.
 A swelling measuring device consisting of tripod and the dial gauge are placed on top
edge of the mould and the spindle of the dial gauge is placed touching the top of the
sample. The initial dial gauge reading is recorded and the test set up is kept
undisturbed in the water tank to allow soaking of the soil specimen for four full days or
96 hours.
 After 96 hours of soaking, the mould with specimen is clamped over the base plate
and the same surcharge weights are placed on the specimen centrally such that the
121
penetration test can be conducted. The mould with base plate is placed under
penetration plunger of the loading machine.
 The penetration plunger is seated at the centre of the specimen and is brought in
contact with the top surface of the soil sample by applying a seating load of 4.0kg.
 The dial gauge for the measuring the penetration values of the plunger is fitted in
position. The dial gauge of the proving ring and the penetration dial gauge are set to
zero. The load is applied through the penetration plunger at a uniform rate of
1.25mm/minute. The load readings are recorded at penetration readings of 0.0, 0.5,
1.0, 1.5, 2.0, 2.5, 3.0, 4.0, 5.0, 7.5, 10.0, 12.5 mm penetration. The maximum load
value and the corresponding penetration value are recorded.
 After the final reading, the load is released and the mould is removed from the loading
machine. The proving ring calibration factor is noted so that the load dial values can
be converted into load in kg.
 The load values noted for each penetration level are divided by the area of the loading
plunger (19.635cm2) to obtain the pressure.
 A graph is plotted by penetration in mm on x-axis and the pressure in kg/cm2 on y-
axis. Then the unit pressure values corresponding to 2.5 and 5.0mm penetration
values are
 found from the graph. Then the CBR value is calculated from the formula:
CBR in % =
⎡ Unit pressure carried by soil sample at defined penetrationlevel ⎤

⎢Unit pressure carried by s tan dard crushed stones at above penetrationlevel ⎥
x100
⎣ ⎦
 The CBR values at 2.5mm and 5.0mm penetrations are calculated for each specimen
from the corresponding graphs. Generally the CBR value at 2.5mm penetration if
higher and the value are adopted. However if higher CBR value is obtained at
5.0mm penetration, the test is to be repeated to verify the results. If the value at
5.0mm penetration is again higher, this is adopted as the CBR value of the soil sample.
122
C.B.R Testing Apparatus
123
124
Typical Graph Plotted in C.B.R Test
Result: The CBR value of the given soil sample is _________________%.
Viva Voce:
1. What is the significance of surcharge load while s0aking and testing the soil in CBR
test?
2. CBR value of soil A is 15 and of soil B is 4. Which one is a better soil?
Why? 3. Discuss the limitations of CBR test.
Reference:
1. Indian Standard Method of determining CBR as per IS: 2720-Part-XVI
Chand Bros. Roorkee
Laboratory evaluation of straight-run bitumen:

1. Viscosity as per IS:1206-1978
2. Penetration as per IS:1203-1978
125
3. Softening Point as per IS:1205-1978

4. Ductility as per IS:1208-1978
5. Specific Gravity as per IS:1202-1978
6. Flash and Fire point as per IS: 1209-1978.
The requirements of straight-run bitumen used for paving purposes are given in table as per
IS: 73-1992 "Paving Bitumen-Specification".
Before that there are two Straight-Run Bitumen types:
1) The grades for paving bitumen "TYPE-1" are:
Grade Penetration Test Values

S35 30/40
S45 40/50
S55 50/60
S65 60/70
S90 80/100
S20 175/225
2) Similarly, the grades for paving bitumen “TYPE-2” are:
Grade Penetration Test Values

S35 30/40
S55 50/60
S65 60/70
S90 80/100
The straight-run bitumen Type2 is not recommended for paving purposes, because of
excessive way content and low ductility values which would adversely affect the performance
of coating of aggregates by bitumen.
126
The requirement for paving Bitumen “Type-I” as per IS : 73-1992
S. METHODS OF
CHRACTERISTICS REQUIREMENTS FOR GRADES
No TEST REF to
Specific gravity at 270
1. 0.99 0.99 0.99 0.99 0.99 0.99 IS:1202-1978
C min
Penetration at 250 C 175-
2. 30-40 40-50 50-60 60-70 80-100 IS:1203-1978
100g, 5sec,1/10mm 225
3. Softening point 0C 55-65 50-60 50-60 45-55 40-55 30-45 IS:1205-1978
Ductility at 270C, cm
4. 50 75 75 75 75 - IS:1208-1978
min
Flash point
5. Cleveland open cup 175 175 175 175 175 175 IS:1209-1978
0C, min
5000 4000 3000 2000 1000 250 IS:1206(part-2)-
Viscosity at:
+ + + + + + 1978
6. 1)600C poises
1000 800 600 400 200 50 IS:1206(part-3)-
1) 2) 135 0C, min
500 400 350 300 250 125 1978
127
5. Bituminous Mix Design by Marshall Method

Theory and Scope:
Bituminous mixes are used in the surface course of road and airfield pavements. The
desirable bituminous mix properties include stability, density, durability, flexibility, resistance
to skidding and workability during construction. Stability is defined as resistance of the
paving mix to deformation under load and is thus a stress level which causes strain
depending upon anticipated field conditions. Stability is function of friction and cohesion.
Durability is defined as the resistance of the mix against weathering which causes hardening
and this depends upon loss of volatiles and oxidation.
In this method the resistance to plastic deformation of cylindrical specimen of
bituminous mixture is measured when the same is loaded at the periphery at 5 cm per
minute. This test procedure is used in designing and evaluating bituminous paving mixes.
ASTM vide designation D 1559-62 T has standardized the test procedure.
Aim: To determine optimum binder content of given bituminous mix by Marshall method of
Mix Design.
Apparatus: Mould Assembly, Sample Extractor, Compaction Pedestal and Hammer,

Breaking
Head, Loading Machine, flow meter, thermometers, water bath and
oven.
Procedure:
 The coarse aggregates, fine aggregates and mineral filler material should be
proportioned and mixed in such a way that final mix after blending has the gradation
within the specified range.
 Approximately 1200 grms of aggregates and filler are taken and heated to a temperature
128
of 1750 to 1900 C.
 The compaction mould assembly and rammer are cleaned and kept pre-heated to a
temperature of 1000C to 1450C. The bitumen is heated to temperature of 1210 to 1380
C and the required quantity of first trail percentage of bitumen is added to the heated
aggregate and thoroughly mixed using a mechanical mixer or by hand mixing with
trowel.
 Then the mix is heated and a temperature of 1500 to 1600C is maintained and then the
mix is transferred into the pre-heated mould and compacted by giving seventy five
blows on each side.
 The specific gravity values of different aggregates, filler and bitumen used are
determined first. The theoretical specific gravity of the mix is determined.
 Soon after the compacted bituminous mix specimens have cooled to room temperature,
the weight, average thickness and diameter of the specimen are noted. The specimens
are weighed in air and then in water.
 The bulk density value of the specimen if calculated from weight and volume.
 Then the specimen to be tested are kept immersed under water in a thermostatically
controlled water bath maintained at 600 + 10 C for 30 to 40 minutes.
 The specimens are taken out one by one, placed in the Marshall test head and the
Marshall stability value and flow value are noted.
 The corrected Marshall Stability value of each specimen is determined by applying the
appropriate correction factor, if the average height of the specimen is not exactly 63.5
mm.
 Five graphs are plotted with values of bitumen content against the values of density,
Marshall Stability, Voids in total mix, Flow value, Voids filled by Bitumen.
 Let the bitumen contents corresponding to maximum density be B1, corresponding to
maximum stability be B2 and that corresponding to the specified voids content (at
4.0%) be B3. Then the optimum bitumen content for mix design is given by: Bo=
(B1+ B2+ B3) / 3
129
1. Materials Selection 2. Design Aggregate Structure
3. Preparation of Specimen 4. Design Binder Content
130
Steps Showing the Procedure of Marshall Mix Design
131
132
Pictorial Representation of Marshall Mix Design

133
6. Split Tensile Strength of Concrete
Theory and Scope:

The tensile strength is one of the basic and important properties of the concrete. The
concrete is not usually expected to resist the direct tension because of its low tensile strength
and brittle nature. However, the determination of tensile strength of concrete is necessary to
determine the load at which the concrete members may crack. The cracking is a form of
tension failure. The test is conducted as per IS: 5816.
Aim: To determine the split tensile strength of concrete of a given

concrete.
Apparatus: A compression Testing Machine of adequate capacity and with an arrangement

for applying the load at the specified rate. Cylinder moulds of 150 mm diameter and 300 mm
height, weighting machine, mixer and tamping rod.
Procedure:
 Take the mix proportions as per requirement and mix them thoroughly until uniform
colour of concrete is obtained.
 In mixing by hand the cement and fine aggregate shall be first mixed dry to uniform
colour and then coarse aggregate is added and mixed until coarse aggregate is
uniformly distributed throughout the batch.
 Pour concrete in moulds oiled with medium viscosity oil. Fill the cylinder mould in
four layers each of approximately 75 mm and ram each layer more than 35 times with
134
evenly distributed strokes.

 Remove the surplus concrete from the top of the moulds with the help of a trowel.
 Cover the moulds with wet mats and put the identifications marks after about 3 to 4
hours.
 Remove the specimens from the moulds after 24 hrs and immerse them in water for
final curing.
 Tests at least three specimens for each age of test are tested.
 Apply the load without shock and increase it continuously at a rate to produce a split
tensile stress of approximately 1.4 to 2.1 N/MM 2/ Min, until no greater load can be
sustained. Record the maximum load applied to the specimen.
 Note the appearance of concrete and any unusual feature in the type of failure.
 Compute the split tensile strength of the specimen to nearest 0.05 N/ MM2.
Result: The tensile strength of the given concrete is ____________________

N/MM2.
Viva Voce:
1. Why do you perform the split cylinder test?
2. What is the basic difference between the direct and indirect methods used in the tensile
strength determinations?
3. Which one is superior and why?
Reference:
1. Indian Standard, for Methods of Test for Splitting Tensile Strength IS: 5816.
2. Neville. A. M, Properties of concrete, 3rd edition, Pitman publishing company, 1981. 3.

Gambhir. M. L, Concrete manual, 4th edition, Dhanpat Rai and Sons, Delhi.
135
7. AUTOCLAVE TEST (Soundness test)

Theory and Scope:
Excess of free lime and magnesia present in cement slake vary slowly and cause
appreciable change in volume after setting.
In consequent cracks, distortion and disintegration results, thereby giving passage to
water and other foreign matters which may have injurious effect on concrete and
reinforcement. This defect is known as Soundness. The expansion can be prevented by
limiting the quantity of free lime and magnesia in cement. The test is designed to accelerate
the process of slaking by application of heat and to measure to extent of expansion and to see
if this expansion is less than the specified limit.
Aim: To determine soundness of given cement and lime samples by Autoclave test.
Apparatus: Weighing balance, weights, graduated glass cylinder, trowel, length compactor,
moulds of size 25x25x250 mm.
Procedure:
 Oil the mould lightly with a layer of mineral oil, set the reference points which are
clean and free from oil.
 Take 500 gm of cement and gauge it with a weighed quantity of water just sufficient
to give a paste of standard consistency (approx 30%).
 Fill the mould in one or two layers by pressing the paste into corners by thumb.
Smooth the top surface with the flat side of trowel.
 Immediately upon completion of moulding, place the mould in a moist room
(Humidity chamber). After 24 hours remove the specimen from the moulds.
 At 24+1/2 hours after moulding remove the specimen from the moist atmosphere and
136
measure the length l1
 Place the specimen in an autoclave at room temperature in a rack so that the four sides
of
 each specimen shall be exposed to the air. Turn on the heat and allow the air to escape
from the autoclave during early heating period. The air vent valve shall be kept open
until steam begins to escape. Close the valve and rise the temperature of autoclave at
such a rate as will being the gauge pressure of the steam to 2.1 N/sq mm in 1 to 1½
hours from the time heat is turned on. Maintain a pressure of 2.0+0.1 N/sq mm.
 Switch off the autoclave after 3 hours and cool it at such a rate so as to lower the
pressure to 0.1 N/sq mm in an hour and open the air vent well to bring it to atmospheric
pressure.
 Remove the specimen immediately from the autoclave and place it in the water of
temperature above 90o C. Then cool the water to 27+2 o C in 15 min.
 Calculate the unsoundness as the percentage of the effective gauge length.
Observations and Calculations:
Table
Type of cement tested
Gauge length in mm
Initial length of the specimen 11 in mm
Final length of the specimen 12 in mm
Expansion of the specimen (12 – 11) in mm
Unsoundness in percent %
137
Result: The unsoundness of given cement sample is ___________________%
Viva voce:
1. What do you understand by the term unsoundness? What is likely the cause of unsound
cement?
2. What precautions should be taken while performing the test?
3. Why it is necessary to keep the cement paste moist in the test while it is setting?
References:
1. Indian Standard Specifications for ordinary and low heat Portland cement IS: 269, Indian
2. Indian Standard, Methods of Physical tests for cement IS: 4031, Indian Standards
Institution.
4. Gambhir. M. L, Concrete manual, 4th edition, Dhanpat Rai and Sons, Delhi.
138
8. SAMPLE VIVA VOCE QUESTIONS
1. What do you understand by the term "Ten percent Fines value"?
2. Define aggregate crushing value and how crushing strength test is carried out on
cylindrical stone specimen explain.
3. What is the use or application of the aggregate crushing test?
4. The abrasion value found from Los Angeles test for two aggregates A and B are 50% and
38% respectively. Which aggregate is harder? Why? For what types of constructions
are these suitable?
5. Why Los Angeles abrasion test is considered superior to the other form of tests which are
used to determine the hardness of aggregates?
6. Two materials have abrasion values 3 and 10 respectively. Which one is harder and why?
7. How is aggregate Impact expressed?
8. What do you understand by dry and wet Impact value?
9. Aggregate Impact value of material A is 15 and that of B is 35. Which one is better for
surface course?
10 Explain what is meant by flaky and elongated particles?
11. Explain Angularity Number. How is it found?
12. What do you understand by the term Combined Index?
13 what is normal or standard consistency of a cement paste?
14. What are the factors affecting the result of the test?
15. What do you understand by the term flash setting?
16. What do you understand by the term unsoundness? What is likely the cause of unsound
cement?
17. What precautions should be taken while performing the test?
139
18 Why it is necessary to keep the cement paste moist in the test while it is setting?
19. What you understand by term ultimate strength of cement?
20. What precautions do you take during determination of compressive strength?
21. What is the significance of this test?
22. What are the applications of penetration test?
23. What do you understand by the term 30/40 bitumen?
24. What are the precautions to be taken while conducting a penetration test?
25. List the factors that affect the result of a ductility test.
26. What do you understand by the term repeatability and reproducibility? 3.

27.Explain the significance of ductility test.
28. What are the factors which affect the ring and ball test results?
29. What is softening point?
30.If material A has softening point of 56 and B has 42 which binder is good and why?
31. Define flash and fire points.
32. What is the significance of flash and fire point test?
33. What are the parameter that affects the result of flash and fire point tests?
34. Describe the factors affecting the choice of the method of test.
35. What are the advantages and disadvantages of Vee-Bee method of test over the other
methods?
36. How does strength correlate with other properties of hardened concrete?
37. What are the requirements for curing the specimens?
38. What is the rate of loading in flexure test?
140
39. Why do you perform the split cylinder test?
40. What is the basic difference between the direct and indirect methods used in the tensile
strength determinations?
41. Which one is superior and why?
42. What is the significance of flow value in Marshall Test?
43. What is filler?
44. What are the essential properties of bituminous mixes?
45. What is the significance of surcharge load while s0aking and testing the soil in CBR test?
46. CBR value of soil A is 15 and of soil B is 4. Which one is a better soil? Why?
3. 47.Discuss the limitations of CBR test.
141
9. SAMPLE EXTERNAL LAB QUESTION PAPER
I ROAD AGGREGATES
1. For the given sample of aggregates find the aggregate crushing value.
2. For the aggregate sample given find out the impact value and mention the test
procedure.
3. How can you find out the specific gravity by Water absorption for nominal size
aggregates and what is the standard specific gravity & what is the amount of water
absorption for the given sample of aggregate.
4. What is the attrition value of given sample of aggregate as mention the test procedure.
5. Find out the abrasion of the given aggregate sample mention the value as amount of
abrasion test procedure in detail.
6. Find the flukiness index of elongation index by angular number of a given sample of
aggregate
II.
1. For the given bitumen sample find the amount of penetration and test procedure in
detail.
2. Flow can you find the ductility of the given sample of the bitumen material
3. What is the test procedure to find the flash & fire point of bitumen and find it with
the given sample.
4. Find the softening point of given bitumen sample by ring & ball apparatus
III.
1. What is the normal consistency? Find the normal consistency of given sample of
cement paste.
2. Find the initial setting time & final setting time of a given sample of cement paste &
write test results.
3. What is specific gravity of the sample of cement and also find out the soundness of
cement.
4. Find the compression test of cement by preparing the standard Mould of the given
sample.
142
5. 13. GRAPHS, IF ANY.
143
144
145
146

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CONCRETE AND HIGH WAY ENGINEERING LABORATORY

1. OBJECTIVE & RELEVANCE

The objective of highway materials laboratory is to determine some of the properties of

5 A protective screen or curved shield of perforated metal should be used to surround

Be cautious about ﬂying fragments.

8. Most of these safety admonitions have been prompted by recollections of actual

5. LIST OF THE EXPERIMENT AS PER JNTUH

S.No List of the Experiment

1 Introduction to C&HM lab

3 Aggregate Impact Test.

4 Specific Gravity and Water Absorption.

10 Softening Point Test.

11 Flash and fire point tests.

12 Normal Consistency of fineness of cement.

13 Initial setting time and final setting time of cement.

14 Specific gravity and soundness of cement.

15 Compressive strength of cement.

16 Workability test on concrete by compaction factor, slump and Vee-bee.

17 compressive strength of concrete.

19 Non-Destructive testing on concrete

20 Blaine's Air Permeability Test

SNO Name of the Experiment Unit Text /Reference

1 Introduction to C&HM lab 1-8 --

2 Normal Consistency of fineness of cement. 1 T1:48,T3-1.29,1.30

3 Initial setting time and final setting time of 1 T1:52,53,T3-(1.31-

4 Specific gravity and soundness of cement. 1 T1:54, T3-1.35

5 Compressive strength of cement. 1 T1:421,T3-1.33

6 Bulking of sand. 2 T1:80,T3-2.21

7 Aggregate Crushing value 2 T1:113,75,T3-2.27,

8 Aggregate Impact Test. 2 T1:114-115,T3-2.29,

9 Specific Gravity and Water Absorption. 2 T1:78,T3-2.25,T4-

10 Attrition Test 2 T1:76,T4-7.8

11 Abrasion Test. 2 T1:77,T3-2.32,T4-

12 Shape tests 2 T1:70,T4-7.5

13 Workability test on concrete by compaction factor, 4 T1:227,222,232,

14 Penetration Test. 5 T2:182-183,T4-7.18

15 Ductility Test. 5 T2:190-192,T4-7.19

16 Softening Point Test. 5 T2:184-185,T4-7.19

17 Flash and fire point tests. 5 T2:192,T4-7.18

18 compressive strength of concrete. 5 T1:421,T4-5.1

19 Non-Destructive testing on concrete (for 6 T1:437-44,T4-5.7

20 Blaine's Air Permeability Test 6 T3-1.29,T5-1

21 Bituminous Mix Design By Marshall Method 7 T4-7.24,T6-7.22

22 Split Tensile Strength Of 8 T3-5.4,T7-181

4.Relevant IS Codes and IRC Codes.

1 1-8 Introduction to C&HM lab Prerequisite

5 1 Specific gravity and soundness of cement. JNTUH

6 1 Compressive strength of cement.

8 2 Aggregate Impact Test.

9 2 Specific Gravity and Water Absorption.

13 4 Workability test on concrete by compaction

15 5 . Ductility Test. JNTUH

17 5 Flash and fire point tests.

18 5 compressive strength of concrete.

19 6 Non-Destructive testing on concrete

20 6 Blaine's Air Permeability Test

21 7 Bituminous Mix Design By Marshall Method

22 8 Split Tensile Strength Of

9.1. Introduction to concrete and highway materials lab

Equipments used in the lab:

1.PENETRO METER As Per IS 1203

2. Ring & Ball (Softening Point) Test Apparatus