HAND BOOK

ON
ROAD WORKS
PREPARED BY : Mr. V.S.Kulkarni.
QAQC- Dept.
MORTH Requirements for
Flexible Pavement
 TYPICAL CROSS SECTION OF FLEXIBLE PAVEMENT WITH PROPERTIES
Tack Coat.( Gen. 0.5Kg/M2)
BC-Bituminous Course.
Min. Bitumen Content 5%
1)LAA-30%(Max) 2) AIV-24%(Max) 3)Camber(Transverse)- 2.5% Remaining SAME AS DBM 30 to 65 mm

DBM-Dense Bitumen 1)Los Angeles Abrasion(LAA)- 35%(Max) 2)Aggregate Impact Value(AIV)- 27% (Max) 3)Stability -9KN(Min)
Macadam 4)Water Absorption -2%(Max) 5)(Flakiness+Elongation)Indices -30% Max 6) Field Density - 98% (min) 50 to 150mm
Minimam Bitumen content 7) Cleanliness Test - 5% (Max) 8) Air voids-3-6% 9)Water Sensitivity Test -80%( Min)
4% 10)Polished stone Value - 55% ( Min) 11) Stripping Value -95%(Min) 12) Flow- 2 to 4mm

1) Los Angeles Abrasion( LAA)- 40% ( Max) 2)Aggregate Impact Value(AIV)- 30% ( Max)
WMM- Wet mix
3)Flakiness & Elongation Indices - 30% ( Max) 4)Water Absorption -2% ( Max)
Macadam. 150 to 250mm
5) Plasticity Index - 6% ( Max)

GSB - Granular Sub 1) 10% fines value- 50KN (Min.) 2)Liquid Limit-25% ( Max) 3)Plasticity Index- 6% ( Max) 150 to 250mm
Base 4)Water Absorption -2% ( Max) 5)Field Density- 98%( Min.) 6) CBR- As per Grade

1)MDD- 1.75 gm/cc ( Min) 2)Free Swell Index - 50% ( Max) 3)Liquid Limit - 70% ( Max)
SUBGRADE
4) Plasticity Index -45% (Max) 5)Field Density -97% (Min). 6) Total Sulphate Content - 0.5% ( Max) 500mm

Note: Camber in transverse direction shall be maintained as per design & from bottom to top.
Embankment Side Slope Value 1V : 2H unless Specified.
 Embankment & Sub grade - MORTH Cl. 305

Requirements as per Specifications:

Reference Requirements / Limits

Standard For AASHTO Embankment
Sl. No Description Embankment up Subgrade and Remarks
Method of Standard exceed 3m
Testing. to 3m height. Shoulders
height.
1 Gradation Test IS : 2720 Part - 4 T88
Max Dry Density & Optimam MDD-1.52 gm/cc MDD - 1.6 gm/cc MDD - 1.75 gm/cc
2 Moisture Content IS : 2720 Part - 8 T180 (min) (min) (min)
3 Liquid Limit IS : 2720 Part - 5 T89 70 % (max) 70 % (max) 70 % (max)
4 Plasticity Index IS : 2720 Part - 5 T90 45 % (max) 45 % (max) 45 % (max)
5 Free Swell Index IS : 2720 Part - 40 ASTM-D-720 50 % (max) 50 % (max) 50 % (max)
6 Field Density of Compacted Layer IS : 2720 Part - 28 T205 95 % (min) 95 % (min) 97 % (min)
7 CBR Value IS : 2720 Part - 16 T193 As per design.
8 Total Sulphate Content BS: 1377 Test 10 T190 0.5% ( Max) 0.5% ( Max) 0.5% ( Max)

Frequency tests as per MORTH Cl.900

Reference
AASHTO
Sl. No Description Standard For Frequency Remarks
Standard
Method of
1 Sieve Analysis IS : 2720 Part - 4 T88 2 tests / 3000m3
2 Plasticity Index IS : 2720 Part - 5 T90 2 tests / 3000m3 for each type
3 Laboratory dry density IS : 2720 Part - 8 T180 2 tests / 3000m3 for each type
4 Deleterious Content IS : 2720 Part - 27 As and when required
5 Field Density of Compacted Layer IS : 2720 Part - 28 T205 One measurement / 500-1000 sqm
6 CBR Value IS : 2720 Part - 16 T193 1 test / 3000 m3 (for Sub grade)
7 Moisture Content IS : 2720 Part - 2 T217 1 test / 250 m3 Prior to Compaction
 Granular Sub Base ( GSB ) - MORTH Cl.401

Requirements as per Specifications:

Reference Standard
AASHTO
Sl. No Description For Method of Requirements / Limits Remarks
Standard
Testing.
1 10 % fine Value (for CA) BS: 812 (part 111) 50 KN (min) In soaked condition
2 Water Absorption IS : 2720 Part - 3 T84 2 % (max) for Coarse aggregate
3 CBR Value IS : 2720 Part - 16 T193 30 %or 25%or 20% (min) Table:400.1
4 Liquid Limit IS : 2720 Part - 5 T89 25 % (max)
5 Plasiticity Index IS : 2720 Part - 5 T90 6 % (max)
Max. Dry Density & Optimum
6 Moisture Content. IS : 2720 Part - 8 T180
7 Gradation IS : 2720 Part - 4 T27 IS Sieve in mm % Passing % Passing % Passing
Gr-1 Gr-2 Gr-3
75 100
53 80-100 100
26.5 55-90 70-100 100
9.5 35-65 50-80 65-95
4.75 25-55 40-65 50-80
2.36 20-40 30-50 40-65
0.425 10-25 15-25 20-35
75mic 3-10 3-10 3-10
8 CBR 30% 25% 20%

Frequency tests as per MORTH Cl.900

Reference Standard AASHTO

Sl. No Description Frequency Remarks
for Method of Testing. Standard
1 Gradation IS : 2720 Part - 4 T27 1 tests / 200m3
2 Plasticity Index IS : 2720 Part - 5 T90 1 tests / 200m3
3 CBR Value IS : 2720 Part - 16 T193 As required
4 Deleterious Material Content IS : 2720 Part - 27 T21 As required
5 Field Density of Compacted Layer IS : 2720 Part - 28 T205 One measurement / 500 sqm
6 Moisture Content IS : 2720 Part - 2 1 test / 250 m3 During Compaction
 Wet Mix Macadam (WMM) - MORTH Cl.406

Requirements as per Specifications:

Reference Standard
AS PER
Sl. No Description For Method of Requirements / Limits Remarks
AASHTO
Testing.
1 Los Angeles Abrasion IS : 2386 Part - 4 T96 40 % (max) Aggregate may satisfy either of
2 Aggregate Impact Value IS : 2386 Part - 4 BS-812-P112 30 % (max) two tests.
3 Flakiness & Elongation Indices IS : 2386 Part - 1 ASTM-D-4791 30 % (max)
4 Plasticity Index IS : 2720 Part - 5 T90 Not more than 6 For material finer than 425mic
5 Water Absorption IS : 2386 Part - 2 T84 2 % (max)
6 Max. Dry Density (MDD) IS : 2720 Part- 8 T180
7 Optimum Moisture Content(OMC) IS : 2720 Part- 8 T180
8 Field Density & Moisture Content. IS : 2720 Part - 28 T191
9 Gradation IS : 2386 Part - 1 T27 IS Sieve in mm % Passing
53 100
45 95 - 100
22.4 60 - 80
11.2 40 - 60
4.75 25 - 40
2.36 15 - 30
600MIC 8 - 22
75mic 0-8

Frequency tests as per MORTH Cl.900

Reference Standard
Sl. No Description For Method of AS PER AASHTO Frequency Remarks
Testing.
1 Gradation IS : 2386 Part - 1 T27 1 tests / 100m3
2 Aggregate Impact Value IS : 2386 Part - 4 BS-812-P112 1 tests / 200m3
3 Flakiness & Elongation Indices IS : 2386 Part - 1 ASTM-D-4791 1 tests / 200m3
4 Plasticity Index IS : 2720 Part - 5 T90 1 tests / 100m3
5 Field Density of compacted layer IS : 2720 Part - 28 T191 1/500 sqm.
5 Moisture Content IS : 2720 Part - 28 T205 One measurement / 500 sqm
 PAVING BITUMEN TYPE AS PER IS-73.
Requirements as per IS-73

Reference
Standard For As Per
Sl. No Description Requirements / Limits Remarks
Method of AASHTO
Testing.
GRADES VG-10 VG-20 VG-30 VG-40

Absolute viscocity 600 c, poise ,

1 IS : 1206 Part 2 T202 800 1600 2400 3200
min

2 Kinematic V1350 c cst (min) IS : 1206 Part 3 T201 250 300 350 400

3 Flash Point ( 0c) Min IS : 1209 T48 220 220 220 220

4 Softening Point ( 0c) IS : 1205 T53 40 45 47 50

5 Penetration at 250c( mm) IS : 1203 T49 30-40 40-50 50-60 60-70

Solubility in Trychloroethylene, %
6 IS : 1216 T44 99 99 99 99
min

Test on residue from thin film over test :

7 Ductility at 270 c ( Min) in cm IS : 1208 T51 50 75 75 75

8 Viscosity ratio at 600c, Max 4 4 4 4

 POLYMER MODIFIED BITUMEN( PMB) - AS PER MORTH.
Requirements for Elastomeric Thermoplastic & Rubber Latex:

Reference
Standard For As per
Sl. No Description Requirements / Limits Remarks
Method of AASHTO
Testing.
GRADE PMB 120 PMB 70 PMB 40
0
1 Sp Gravity at 27 c ( Min) IS :1202 T228 0.99 0.99 0.99

2 Water % by mass ( Max) IS :1211 0.2 0.2 0.2

0
3 Flash Point ( c) Min IS : 1209 T48 220 220 220
0
4 Softening Point ( c) Min IS : 1205 T53 38 48 59
0
5 Penetration at 25 c( mm) IS : 1203 T49 90-150 50-89 30-49
0
6 Ductility at 27 c ( Min) in cm IS : 1208 T51 75 50 50
0
7 Frass Breaking Point C ( Max) IS : 9381 T314 -24 -16 -12

8 % Elastic Recovery at 15 c (Min) ASTM: D 5976 ASTM: D-5976 70 60 50

9 Viscosity at -
a) 1500 c, poise IS : 1206 1-3 2-6 4-8

Test on thin film over test residue :

Reference
Standard For As Per
Sl. No Description Requirements / Limits Remarks
Method of AASHTO
Testing.
GRADE PMB 120 PMB 70 PMB 40
0
1 Reduction in penetration at 25 ( c) Max. IS : 1203 T49 35 35 35
0
2 Increase in Softening Point ( c) Max. IS : 1205 T53 7 6 5
0
3 Penetration at 4 c( mm).200gm,60sec. IS : 1203 T49 18 15 12

4 Loss in weight %, ( Max) IS : 9382 1 1 1

 0
5 % Elastic Recovery at 15 c (Min) ASTM: D 5976 ASTM: D 5976 60 40 35
 POLYMER MODIFIED BITUMEN( PMB) - AS PER MORTH.
Requirements for Plastomeric Thermoplastic :

Reference
Standard For As Per
Sl. No Description Requirements / Limits Remarks
Method of AASHTO
Testing.
GRADE PMB 120 PMB 70 PMB 40
0
1 Sp Gravity at 27 c ( Min) IS :1202 T228 0.99 0.99 0.99

2 Water % by mass ( Max) IS :1211 0.2 0.2 0.2

0
3 Flash Point ( c) Min IS : 1209 T48 220 220 220
0
4 Softening Point ( c) Min IS : 1205 T53 38 48 59
0
5 Penetration at 25 c( mm) IS : 1203 T49 90-150 50-89 30-49
0
6 Ductility at 27 c ( Min) in cm IS : 1208 T51 50 40 30
0
7 Frass Breaking Point C ( Max) IS : 9381 T314 -20 -15 -10

8 % Elastic Recovery at 15 c (Min) ASTM: D 5976 ASTM: D 5976 60 50 40

9 Viscosity at -
a) 1500 c, poise IS : 1206 1-2 2-4 4-8

Test on thin film over test residue :

Reference
Standard For As Per
Sl. No Description Requirements / Limits Remarks
Method of AASHTO
Testing.
GRADE PMB 120 PMB 70 PMB 40
0
1 Reduction in penetration at 25 ( c) Max. IS : 1203 T49 35 35 35
0
2 Increase in Softening Point ( c) Max. IS : 1205 T53 7 6 5
0
3 Penetration at 4 c( mm).200gm,60sec. IS : 1203 T49 18 15 12

4 Loss of weight %, ( Max) IS : 9382 1 1 1

5 % Elastic Recovery at 15 c (Min) ASTM: D 5976 ASTM: D 5976 45 35 30
 CRUMB RUBBER MODIFIED BITUMEN( CRMB) - AS PER MORTH.
Requirements for CRMB:

Reference
Standard For As Per
Sl. No Description Requirements / Limits Remarks
Method of AASHTO
Testing.
GRADE CRMB 60 CRMB 55 CRMB 50
0
1 Sp Gravity at 27 c ( Min) IS :1202 T228 0.99 0.99 0.99

2 Water % by mass ( Max) IS :1211 0.2 0.2 0.2

0
3 Flash Point ( c) Min IS : 1209 T48 220 220 220
0
4 Softening Point ( c) Min IS : 1205 T53 50 55 60
0
5 Penetration at 25 c( mm) IS : 1203 T49 50-70 50-60 40-60

6 % Elastic Recovery at 15 c (Min) ASTM: D 5976 ASTM: D 5976 40 35 30

Test on thin film over test residue :

Reference
Standard For As Per
Sl. No Description Requirements / Limits Remarks
Method of AASHTO
Testing.
GRADE CRMB 60 CRMB 55 CRMB 50

0
1 Reduction in penetration at 25 c Max. IS : 1203 T49 60 60 60

0
2 Increase in Softening Point ( c) Max. IS : 1205 T53 5 5 5

3 % Elastic Recovery at 15 c (Min) ASTM: D 5976 ASTM: D 5976 25 20 15

 Bituminous Macadam - MORTH Cl.504
Requirements of as per Specifications:

Reference Standard As Per

Sl. No Description For Method of Requirements / Limits Frequency of test Remarks
AASHTO
Testing.
1 Los Angeles Abrasion IS : 2386 Part - 4 T96 40 % (max) -
2 Cleanlines Test( Dust) IS : 2386 Part - 1 T11 5% ( Max)- 0.075mm Pass
3 Aggregate Impact Value IS : 2386 Part - 4 BS: 812- P 112 30 % (max) 1 test / 50m3
4 Stripping Value AASHTO - T182 T812 Minimum 95 % retained coating As required For Coarse
5a Soundness with Na2So4 IS : 2386 Part - 5 T104 12 % (max) As required Aggregates
5b Soundness with MgSo4 IS : 2386 Part - 5 T104 18 % (max) As required
6 Comb.Flakiness & Elongation Indices IS : 2386 Part - 1 ASTM: D- 4791 30 % (max) 1 test / 50m3
7 Water Absorption IS : 2386 Part - 2 T84 2 % (max) As required
8 Water Sensitivity Test AASHTO - T283 T283 80% ( Min) As required
9 Density of Compacted layer - 98 % (min) 1 test / 250m2
10 Gradation ( Grade - I ) T27 IS Sieve in mm % Passing % Passing 2 test / day (min)
Gr-1 Gr-2
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.3 2-10 2-10
0.075 0-8 0-8
11 % Bituman MORTH NA 3.1-3.4 3.3-3.5
12 Quality of Bitumen IS : 73 - Two samples / lot
13 Bitumen extraction & gradation Contract Spec. T164 as above 2 test / day (min) For Bituminous Mix
14 Rate of Spreading Contract Spec. NA Thickness check At regular interval
 MANUFACTURING & ROLLING TEMPERATURE AS PER MORTH TABLE 500.5.

REQUIREMENT AS PER SPECIFICATION

sr. Bitumen Bitumen Mixing Mixed Materials Laying Rolling

Aggregate Mixing ( 0c)
no. Penetration ( 0c) ( 0c) ( 0c) ( 0c )
35 160-170 160-175 170 Max 130 Min 100 Min

65 150-165 150-170 165 Max 125 Min 90 Min

90 140-160 140-165 155 Max 115 Min. 80 Min

PRIME COAT & TACK COAT AS PER MORTH TABLE 500.1 & 500.2.

PRIME COAT & TACK COAT: Material Shall comply with requirement of IS 8887 or IS 217.
PRIME COAT :Viscosity & Quantity requirement of Liquid Bituminous Primer.
sr.
Type of Surface Kinematic Viscosity of Primer at 600c Quantity of Liquid Bituminous Material per 10Sq.m.
no.
low Porosity 30-60 6 to 9
Medium Porosity 70-140 9 to 12

High Porosity 250-500 12 to 15

TACK COAT : Rate application of tack coat.

sr.no. Type of surface Quantity of liquid Bituminous material in kg/m2

1 Normal Bituminous surface 0.20 to 0.25

2 Dry & hungry bituminous surface 0.25 to 0.30

3 Granular surface treated with primer 0.25 to 0.30

4 Non Bituminous surface
a) Granular base (not primed) 0.35 to 0.40
b)Cement concrete pavement 0.30 to 0.35
 TOLERANCES OF SURFACE LEVELS & SURFACE IRREGULARITIES - MORTH

TOLERANCES OF SURFACE LEVELS as perTable 900.1

The level of subgrade & different pavement course as constructed, shall not vary from those calculated
with reference to the longitudinal & cross profile or road shown on drawing or as directed by the Engineer
beyond the tolerances mentioned in below ta

PERMISSIBLE TOLERANCE
SR.NO LAYER
(MM)
1 SUBGRADE
+ 10
- 10
2 SUB BASE
+ 10
a) Flexible Pavement
- 20
+6
b)Concrete Pavement ( DLC or rolled Concrete.)
- 10
3 BASE COURSE FOR FLEXIBLE PAVEMENT
+6
a) Bituminous Concrete
-6
+ 10
i) Mechanical Laid
b) Other Than Bituminous - 10
Concrete + 15
ii)Manually Laid
- 15
4) WEARING COURSE FOR FLEXIBLE PAVEMENT
+6
a) Mechanically Laid
-6
+ 10
b) Manually Laid
- 10
5) CEMENT CONCRETE PAVEMENT
+ 5
- 6

MAXIMUM PERMITTED NUMBER OF SURFACE IRREGULARITIES as per Table 900.2.

The longitudinal Profile shall be checked with a 3-meter long straight edge / Moving straight edge as desired by the Engineer
at the middle of each traffic lane along a line parallel to the center line at the road.
The maximum permitted number of surface irregularities shall be as per MORT&H Table is below.
Surfaces of laybye,service areas and all
Surface Carriageways & paved shoulders
bituminous base course.

Irregularity 4mm 7mm 4mm 7mm

Length(m) 300 75 300 75 300 75 300 75

National
20 9 2 1 40 18 4 2
Highway/Expressways
Roads of Lower
40 18 4 2 60 27 6 3
Category
MINIMUM PERCENT (VMA), PERMISSIBLE VARIATION IN JMF & COMPACTION as per MORTH

MINIMUM PERCENT AIR VOIDS IN MINERAL AGGREGATE (VMA) as per Table 500.12.

Nominal Maximum Minimum VMA,Percent Related to Design air Voids,Percent.

Particle Size (mm)
3 4 5

9.5 14 15 16

12.5 13 14 15

19 12 13 14

25 11 12 13

37.5 10 11 12

PERMISSIBLE VARIATION FORM THE JOB MIX FORMULA as per Table 500.13.

Permissible Variation
DESCRIPTION
Base/Binder course Wearing course
Aggregate Passing 19mm or large +/- 8% +/- 7%
Aggregate passing 13.2mm, 9.5mm +/- 7% +/- 6%
Aggregate passing 4.75mm +/- 6% +/- 5%
Aggregate passing 2.36mm,1.18mm,0.6mm +/- 5% +/- 4%
Aggregate passing 0.3mm,0.15mm +/- 4% +/- 3%
Aggregate passing 0.075mm +/- 2% +/- 1.5%
Binder Content +/- 0.3% +/- 0.3%
Mixing Temperature +/- 100c +/- 100c

COMPACTION (DBM & BC)

Compaction: - Compaction at bituminous materials shall commence as soon as possible after laying. Compaction shall be
substantially completed before the temperature fall below the minimum rolling temperature stated in the relevant part at these
specificati
Sequence of Rolling operations :
1) Initial (Break down) Rolling: - The first pass of the roller on the freshly placed material and rolling shall be done with 8 – 10
tones dead weight smooth wheeled rollers/ Vibratory roller (Without vibrators)

2) Intermediate Rolling: - All subsequent passes by the roller(s) to obtain required density before the mix cools to 100 o C,
Rolling shall be done with 8 – 10 tones Vibratory roller or with a pneumatic tyred roller of 12 to 15 tones weight having nine
whee

3) Finish Rolling: Rolling done with tandem roller (without vibrations) solely for the improvement of the surface while the mix is
still warm enough to permit removal of any roller marks.Rollers should move at a speed of not more than 5 km per hour. The
roller shall not be permitted to stand on pavement which has not been fully compacted and necessary precaution shall be taken
prevent dropping of oil, Grease petrol or other foreign matter on the pavement either the rollers are operating or standing. The
wheels of rollers shall be kept moist with water and the spray system provide with the machine shall be in good working order.
The rolling shall be continued till the density achieved is at least 98% of that at laboratory Marshall specimen Compacted as
detailed.
 Dense Bituminous Macadam - MORTH Cl.507
Requirements of as per Specifications:

Reference
as Per
Sl. No Description Standard For Requirements / Limits Frequency of test Remarks
AASHTO
Method of Testing.
1 Los Angeles Abrasion IS : 2386 Part - 4 T96 35 % (max) -
2 Cleanliness Test( Dust) IS : 2386 Part - 1 T11 5% ( Max)- 0.075mm Pass
3 Aggregate Impact Value IS : 2386 Part - 4 BS: 812 P-112 27 % (max) 1 test / 50m3
4 Stripping Value AASHTO - T182 T182 Minimum 95 % retained coating As required
5 Polished Stone Value BS-812 Part 114 T279 55% ( Min) As required For Coarse Aggregates
6a Soundness with Na2So4 IS : 2386 Part - 5 T104 12 % (max) As required
6b Soundness with MgSo4 IS : 2386 Part - 5 T104 18 % (max) As required
7 Flakiness & Elongation Indices IS : 2386 Part - 1 ASTM:D-4791 30 % (max) 1 test / 50m3
8 Water Absorption IS : 2386 Part - 2 T84 2 % (max) Every New Source
9 Water Sensitivity Test AASHTO - T283 T283 80% ( Min) As required
10 Density of Compacted layer - 98 % (min) 1 test / 250m2
11 Gradation (JMF Limits) T27 IS Sieve in mm % Passing % Passing 2 test / day (min)
Agg.Size 40mm 25mm
45 100
37.5 98-100 100 Mix Requirements
26.5 63-93 90-100 Stability - 900 Kgs (min)
19 - 71-95 Air voids - 3 to 6 %
13.2 55-75 56-80 Flow - 2-4mm.
4.75 38-54 38-54 VMA - 12 to 14 % (min)
2.36 28-42 28-42 VFB - 65 to 75 %
0.3 7-21 7-21
0.075 2-8 2-8

% Bitumen MORTH Min.4 Min.4.5

12 Quality of Bitumen IS : 73 As per Specification. Two samples / lot For Bituminous Mix
13 Bitumen extraction & gradation - T164 2 test / day (min)
14 Marshall stability test ASTM D 1559 ASTM D 1559 As per approved JMF 2 test / day (min)
15 Temperature Control - During laying & Compaction At regular interval
16 Rate of Spread - Thickness check during laying At regular interval
 Bituminous Concrete - MORTH Cl.509

Requirements of as per Specifications:

Reference As Per
Sl. No Description Requirements / Limits Frequency of test Remarks
Standard AASHTO
1 Los Angeles Abrasion IS : 2386 Part - 4 T96 30 % (max) -
2 Cleanlines Test( Dust) IS : 2386 Part - 1 T11 5% ( Max)- 0.075mm Pass
3 Aggregate Impact Value IS : 2386 Part - 4 BS:812 P-112 24 % (max) 1 test / 50m3
4 Stripping Value AASHTO - T182 T182 Minimum 95 % retained coating As required
5 Polished Stone Value BS-812 Part 114 T279 55% ( Min) As required For Coarse Aggregates
6a Soundness with Na2So4 IS : 2386 Part - 5 T104 12 % (max) As required
6b Soundness with MgSo4 IS : 2386 Part - 5 T104 18 % (max) As required
7 Flakiness & Elongation Indices IS : 2386 Part - 1 ASTM:D-4791 30 % (max) 1 test / 50m3
8 Water Absorption IS : 2386 Part - 2 T84 2 % (max) As required
9 Water Sensitivity Test AASHTO T283 T283 80% ( Min) As required
11 Density of Compacted layer - 98 % (min) 1 test / 250m2
12 Gradation ( JMF Limits ) T27 IS Sieve in mm % Passing % Passing 2 test / day (min)
26.5 100
19.0 79-100 100
13.2 59-79 79-100 Mix Requirements
9.5 52-72 70-88
4.75 35-55 53-71 Stability - 900 Kgs (min)
2.36 28-44 42-58 Air voids - 3 to 6 %
1.18 20-34 34-48 Flow - 2 to 4 mm
0.6 15-27 26-38 VMA - 14 to 16 % (min)
0.3 10-20 18-28 VFB - 65 to 75 %
0.15 5-13 12-20
75mic 2-8 4-10
13 Min % Bitumen Tab.500.18 5-6 5-7
14 Quality of Bitumen IS : 73 As Per Specification. Two samples / lot For Bituminous Mix
15 Bitumen extraction & gradation Approved JMF T164 As above 2 test / day (min)
16 Marshall stability test ASTM D 1559 As per approved JMF 2 test / day (min)
17 Temperature Control - During laying & Compaction At regular interval
MORTH Requirements for
Rigid Pavement
 TYPICAL CROSS SECTION OF RIGID PAVEMENT WITH PROPERTIES

1)Los Angeles Aabrasion(LAA) - 30%(Max)
3) Aggregate Crushing Value-30%(Max)
PQC- Pavement quality 5) Flakiness Index -35% Max
Concrete. 7) Total sulphate Content- 0.25% ( Max.)
9)Min. Flexural strength - 4.5Mpa.
11)Temp. During concreting. >5 & <30 c.
2)Aggregate Impact Value( AIV)- 30% (Max)
4)Water Absorption -2%(Max)
6) Total Chloride Content-0.06%( Max.)
8) Min Cement Content -350Kg/m3 250 to 340mm
10)Min Tensile Strength- Dowel bar 240 & Tie bar 415Mpa.
12) Camber in transverse Direction -1.5 to 2%

1) LAA- 50% ( Max) 2)AIV- 45% ( Max) 3)Flakiness Index - 35% ( Max)
DLC- Dry Lean Concrete 4)Water Absorption -2% ( Max) 5) 7 Day Strength- 10 Mpa (Min) 6)Min Cement - 150Kg/m3
100 to 200mm
7) Field Compaction - Min.97% & 95%at Edge 0.5m .

1) 10% fines value- 50KN (Min.) 2)Liquid Limit-25% ( Max) 3)Plasticity Index- 6% ( Max) 150 to 250mm
DL- Drainage Layer.
4)Water Absorption -2% ( Max) 5)Field Density- 98%( Min.) 6) CBR- As per Grade

1)MDD- 1.75 gm/cc ( Min) 2)Free Swell Index - 50% ( Max) 3)Liquid Limit - 70% ( Max)
SUBGRADE
4) Plasticity Index -45% (Max) 5)Field Density -97% (Min). 6) Toal Sulphate Content- 0.5% ( Max) 500mm

Note: Camber in transverse direction shall be maintained as per design & from bottom to top.
Embankment Side Slope Value 1V : 2H unless Specified.
 Embankment & Sub grade - MORTH Cl. 305

Requirements as per Specifications:

Reference Requirements / Limits

Standard For AASHTO Embankment
Sl. No Description Embankment up Subgrade and Remarks
Method of Standard exceed 3m
Testing. to 3m height. Shoulders
height.
1 Gradation Test IS : 2720 Part - 4 T88
Max Dry Density & Optimam MDD-1.52 gm/cc MDD - 1.6 gm/cc MDD - 1.75 gm/cc
2 Moisture Content IS : 2720 Part - 8 T180 (min) (min) (min)
3 Liquid Limit IS : 2720 Part - 5 T89 70 % (max) 70 % (max) 70 % (max)
4 Plasticity Index IS : 2720 Part - 5 T90 45 % (max) 45 % (max) 45 % (max)
5 Free Swell Index IS : 2720 Part - 40 ASTM-D-720 50 % (max) 50 % (max) 50 % (max)
6 Field Density of Compacted Layer IS : 2720 Part - 28 T205 95 % (min) 95 % (min) 97 % (min)
7 CBR Value IS : 2720 Part - 16 T193 As per Design.
8 Total Sulphate Content BS: 1377 Test 10 T190 0.5% ( Max) 0.5% ( Max) 0.5% ( Max)

Frequency tests as per MORTH Cl.900

Reference
Standard For AASHTO
Sl. No Description Frequency Remarks
Method of Standard
Testing.
1 Sieve Analysis IS : 2720 Part - 4 T88 2 tests / 3000m3
2 Plasticity Index IS : 2720 Part - 5 T90 2 tests / 3000m3 for each type
3 Laboratory dry density IS : 2720 Part - 8 T180 2 tests / 3000m3 for each type
4 Deleterious Content IS : 2720 Part - 27 As and when required
5 Field Density of Compacted Layer IS : 2720 Part - 28 T205 One measurement / 1000 sqm
6 CBR Value IS : 2720 Part - 16 T193 1 test / 3000 m3 (for Sub grade)
7 Moisture Content IS : 2720 Part - 2 T217 1 test / 250 m3 Prior to Compaction
 DRAINAGE LAYER (DL) - MORTH Cl.401

Requirements as per Specifications:

Reference Standard
AASHTO
Sl. No Description For Method of Requirements / Limits Remarks
Standard
Testing.
1 10 % fine Value (for CA) BS: 812 (part 111) 50 KN (min) In soaked condition
2 Water Absorption IS : 2720 Part - 3 T84 2 % (max) for Coarse aggregate
3 CBR Value IS : 2720 Part - 16 T193 30 %or 25%or 20% (min) Table:400.1
4 Liquid Limit IS : 2720 Part - 5 T89 25 % (max)
5 Plasiticity Index IS : 2720 Part - 5 T90 6 % (max)
Max. Dry Density & Optimum
6 Moisture Content. IS : 2720 Part - 8 T180
7 Gradation IS : 2720 Part - 4 T27 IS Sieve in mm % Passing % Passing % Passing
Gr-1 Gr-2 Gr-3
75 100
53 80-100 100
26.5 55-90 70-100 100
9.5 35-65 50-80 65-95
4.75 25-55 40-65 50-80
2.36 20-40 30-50 40-65
0.425 10-25 15-25 20-35
75mic 3-10 3-10 3-10
8 CBR 30% 25% 20%

Frequency tests as per MORTH Cl.900

Reference Standard AASHTO

Sl. No Description Frequency Remarks
for Method of Testing. Standard
1 Gradation IS : 2720 Part - 4 T27 1 tests / 200m3
2 Plasticity Index IS : 2720 Part - 5 T90 1 tests / 200m3
3 CBR Value IS : 2720 Part - 16 T193 As required
4 Deleterious Material Content IS : 2720 Part - 27 T21 As required
5 Field Density of Compacted Layer IS : 2720 Part - 28 T205 One measurement / 500 sqm
6 Moisture Content IS : 2720 Part - 2 1 test / 250 m3 During Compaction
 AGGREGATE FOR DLC & PQC CONCRETE
Requirements as per Specifications:
S.No Description of Test Reference AASHTO Limits Remarks
A Coarse Aggregate for Concrete & All in Aggregate for Dry Lean Concrete.
1 Grain Size analysis IS Sieve 40mm Agg 20mm Agg 10mm Agg
80mm 100 - -
IS 383 40mm 95-100 100 -
T27 20mm 30-70 95-100 100
12.5mm - - 95-100
10mm 10--35 25-55 40-85
4.75mm 0-5 0-10 0-10
2 All in All Aggregate Grading IS Sieve 40mm Agg 20mm Agg

80mm 100 -
40mm 95-100 100
IS 383 T27 20mm 45-75 95-100
4.75mm 25-45 30-50
0.600mm 8--30 10--35
0.150mm 0-6 0-6
3 IS Sieve % Passing

26.5mm 100
19mm 80-100
All in Aggregate Grading for
MORTH T27 9.5mm 55-75
Dry Lean Concrete( DLC )
4.75mm 35-60
0.6mm 10-35
0.075mm 0-8
Max- 45%- DLC &
4 Aggregate Impact Value IS 2386 Part - II BS-812- P 112 30% -PQC. IS-383

5 Flakiness IS 2386 Part - IV max 35 % MORTH

6 Water absorption IS 2386 Part - III T84 max 2 % MORTH

Max- 50%- DLC &
8 Los Angeles Abrasion value IS 2386 Part - IV T96 30% -PQC. IS-383
Max- 45%- DLC &
9 Aggregate Crushing Value IS 2386 T96 30% -PQC. IS-383
9 Soundness IS 2386 Part - V T104 Na2So4 - Max 12% MORTH

T104 MgSo4 - Max 18% MORTH

10 Total Chloride Content MORTH T260 0.06% ( Max) MORTH

11 Total Sulphate Content MORTH 0.25% ( Max) MORTH

 FINE AGGREGATE FOR CONCRETE AS PER MORTH.
Requirements as per Specifications:
S.No Description of Test Reference AASHTO Limits Remarks

B Fine Aggregate for Concrete

1 Grain Size analysis IS Sieve Zone - I Zone - II Zone - III

10mm 100 100 100

4.75mm 90-100 90-100 90-100
2.36mm 60-95 75-100 85-100
IS 383 T27
1.18mm 30-70 55-90 75-100
0.600mm 15-34 35-59 60-79
0.300mm 5--20 8--30 12--40
0.150mm 0-10 0-10 0-15
2 Water absorption MORTH T84 2% Max
3 Clay Lumps MORTH T112 max 4.0 %
4 Materials finer than 75 micron. MORTH T11 Uncrushed - max 4% & Crushed - Max -15%
5 Coal & Lignite MORTH T113 max 1.0 %
6 Soundness Tast IS 383 T104 Na2So4 -10%& MgSo4-15% -Max
7 Alkality IS 383 max 0.60% as Na2O
 PHYSICAL & CHEMICAL PROPERTIES OF CEMENT & CONCRETE.
Requirements as per Specifications:
Description of Test Reference AASHTO Limits Remarks
I Physical Properties Cement
1 Finenss of cement IS 4031 Part - I T192 Max 10 %
2 Blaines air permeability IS 4031 Part - II T153 Not less than 225m2/kg
3 Normal Consistency IS 4031 Part - IV T129 Depending upon grade

4 Initial setting of cement IS 4031 Part - V T131 min 30 minutes

5 Final setting of cement IS 4031 Part - IV T131 max 600 minutes
6 Soundness of cement IS 4031 Part - III T107 max 10 mm Le chatelier
T107 max 0.8 % Autoclave
7 Compressive strength of mortar cube IS 4031 Part - III T105 Grade / Hr 72 +/- 1 168 +/- 2 672 +/- 4
33 16 22 33
43 23 33 43
53 27 37 53
8 Specific Gravity Cement IS 4031 Part - III 3.15
Chemical Properties Cement.
1 % of magnesia IS 8112 T105 max 6.0 %
2 % of insoluble residue IS 8112 T105 max 2.0 %
3 Sulphur calculated as SO3 IS 8112 T105 max 2.5 % if C3A is 5.0 or less

IS 8112 T105 max 3.0 % if C3A is more than 5.0

4 % Loss of ignition IS 8112 T105 max 5.0 %

5 Lime saturation factor IS 8112 T105 between 0.8 to 1.02
6 Proportion of Alumin to Iron Oxide IS 8112 T105 Not less than 0.66%
7 % of Chloride IS 8112 T105 max 1.0 %

Physical Properties Concrete.

1 Workability of Concrete mix IS 1199 T119 25mm,50mm,75,100mm Depending upon structure

2 Compressive Strength of cubes IS 456 Grade 7 days str. 28 days strength

IS 516 T22 M10 6.7 10 N / mm2
M15 10.05 15 N / mm2
M20 13.4 20 N / mm2
M25 16.75 25 N / mm2
M30 20.1 30 N / mm2
M35 23.45 35 N / mm2
M40 26.8 40 N / mm2
3 Permeability of concrete MORTH T259 max 25 mm
Chemical Properties Concrete.
1 Chloride content Concrete MORTH T260 Prestressed - max 0.1% OTHER - max 0.3%
2 SO3 ( Sulphuric anhydrxide )-Concrete. MORTH max 4.0 %
Testing Procedures
 Determination of Plastic Limit of soil.

Check the apparatus and balance.

Take the sample from air dry pulverised representatives sample by passing through 425mic
I.S sieve.

Prepare a paste by adding moisture and & keep on trying till 3mm thick thread break.

If thread not formed then no need to go through more process. Confirm sample as non
plastic.

If thread forms then take sample and take it minimum two trials and keep threads in oven for
determination of water content.This water content gives the plastic limit of soils .
Determination of Liquid Limit of soil by Casagrande liquid limit Apparatus.

Check the apparatus and balance.

Prepare sample by sieving through 425 mic I.S sieve from air dried, pulverized representative sample .

Take 120 gms of sample and add some water with soil and make a paste after that place it on the bowl of
apparatus with a height of 10 mm .

Make a groove with a specified grooving tools .

Note the No.of blows for which the grooved paste meet with each other by 10 mm on the bowl and take
sample for moisture content.

Repeat the above procedure for minimum 4 times with different water content , such as number of blows
falls 10 to 40.

Calculate moisture content and draw a graph in a semi log sheet and note down the moisture content at 25
blows from graph. this moisture content gives the liquid limit of the soil sample.

Plasticity Index (PI)=Liquid limit - Plastic Limit.

 Determination of Free Swelling Index (FSI) of soil sample.

Take 2 cylinder of 100ml capacity & 10 gm oven dried soil sample passing 425micron in cylinder.

One cylinder shall be filled with kerosene & other with distilled water both up to 100 ml.

Gently shake cylinder to remove entrapped air.

soil in both cylinder shall be allowed to settle (min 24Hrs.)

The final volume of soil in each of cylinder shall be read, Vd & Vk water &kerosene
respectively.

Free Swell Index(%) = (Vd-Vk)/(Vk) x100

 Grain Size Analysis of soil (Wet Sieving Method)

Devide soil by cone and quartering method select sufficient

quantity of test sample for further analysis.

Take the test sample in a tray and place it in a oven for drying,
preferably for overnight if required.

After drying allow the test sample to cool and weigh accurately it's total mass.

Wash the test sample through 2mm sieve placed on the 63 micron sieve.

The test sample retained on both sieves are allowed to transferd into separate tray and placed in
oven for drying.

The sieves are selected for sieving coarse & fine particles as per requirement of the contract
specification for gradation.

Remove the test sample from oven and allow to cool, after that mix &
weigh accurately it's total mass.

Weigh the test sample retained on each size fraction.

Calculate the percentage retained and cumulative percentage passing each size by considering the
total initial dry weight of test sample taken before washing.

Plot grading curve to a linear scale.

Report results.
 Sieve Analysis of Fine & Coarse Aggregate.

Sub division, using the cone and quartering method select sufficient
quantity of test sample for testing.

Place the test sample on a tray and in an oven for drying,

Take out sample oven dried & allow the test sample to cool and weigh accurately.

The sieves are selected as per requirement of the contract

specification for gradation limits.

The test sample are passed through the top most sieve size
descanting to the smallest sieve size used.

Weigh the test sample retained on each size fraction

Calculate the percentage retained and cumulative percentage

passing each size.

Report results.
 Determination of MDD & OMC using Heavy Compaction

Prepare compaction mould, extension collar and base plate and check rammer weight which should 4.89 kg.

Obtain sufficient quantity of test sample from original sample by sub-division, using the cone and quartering
method and then air-dry the test sample.

The air-dried test sample shall be weigh to the desired weight and then pass through the 19mm sieve, large
particles retained on 19mm sieve are weigh and removed.

Select a representative sample of about 5 kg. generally sandy gravelly sample a moisture content of 3 to 5% or
if cohesive sample a moisture content ranges from 12 to 16% shall be added and mixd thoroughly.

Compact the test samples into mould in five layers being given 25 blows and dropped from a height of 450mm
above the test samples.

Remove extension collar, trim off excess test sample level off to the top of the mould.

Weigh the compacted test sample attached with the base plate.

Remove the compacted test sample from mould.Break-up the test sample on tray.

Take two representative test sample in a moisture container for moisture content measurement.This must be
done immediately.

Break up the compacted sample by means of using the rubber mallet and thoroughly mix with the remainder of
the prepared sample.

Add an increment of water, generally if sandy or gravelly material 1 to 2% of water to 5 kg. Of test sample and
for cohesive material a 2 to 4% of water to 5 kg.of test sample.

Repeat stage 5 to stage 10 for each increment of water added so that at lest five compactions are achieved to
obtain the optimum moisture content at different range of water content added.

Stage 1: Calculate the bulk density of each compacted test sample with the calculated volume of mould.
Stage 2 : Calculate the average moisture content of the each compacted test sample.
Stage 3 : Calculate the corresponding dry density of the each compacted test sample.

Plot each dry density of compacted test sample against the corresponding moisture content. Draw a smooth
parabolic curve on a standard graph.

Read off the maximum dry density value corresponding to the optimum moisture content achieved at the
maximam degree of compaction.which corrousponds 100% MDD.

Report results.
 Determination of Laboratory CBR.

Check C.B.R test machine in working condition and insure properly calibrated proving ring is used
with certified dial gauge.

Remove compacted specimen in C.B.R mould from water tank and allow to drain for about 15
minutes.

Place the C.B.R mould with base plate, centrally on the plate of the testing machine.

Set the plunger as almost in contact with the top of the C.B.R specimen and ensure that the plunger is
aligned vertically.

Check that the connection between plunger,load ring and cross head are tight when initial setting are
carried out.

Mount the penetration dial gauge and the stem of the gauge almost at the edge on top of the C.B.R .
Mould.

Set the load dial gauge to zero and after adjusting set the penetration dial gauge to zero.

Switch on the machine and as the penetration proceeds record the load ling dial reading at every 0.25
mm interval of the penetration dial gauge after penetration reaches 75 mm stop the machine.

Remove the C.B.R specimen tested on top face from machine.

Repeat step 3 to stage 8, if C.B.R test to be carried out on bottom face also.

After final penetration test completed remove specimen from C.B.R and break-up into small particles
by means of using rubber mallet.

Take two representative sufficient amount of sample for measurement of moisture content.

Calculate the load ring dial gauge reading by multiplying with the proving ring factor and convert to
force units.

Value of the force units are plotted in 'Y' axis against the corresponding plunger penetration reading in
'X' axis.

Draw a smooth curve when convex upwards requires no correction, if initial few points have a
concave curve upwards then a smooth curve is profound a correction is required to reflect a smooth
convex curve.

Calculate C.B.R value from loads corresponding to plunger penetration of 2.5 mm and 5 mm from the
graph drawn.

Calculate the bulk density from the dimensions of the C.B.R mould and the weighed mass & find Dry
density of CBR Specimen from bulk Density & corresponding moisture content.

Report results.
 Determination of Stripping Value of Road Aggregate

Check binder to be used for testing and preparation apparatus.

Select sufficient quantity of test sample for the testing and oven dry if required.

Take 200grms of test sample passing 20mm test sieve and retaining on 12.5mm test
sieve.

0
Preheat the binder to used and maintain at 160 C, the test sample are also heated to a
temperature and maintain at 1500C.

5% of binder shall be used in the mixing, the temperature of the binder and test sample
must be maintained prior to the mixing .

After complete coating, the mixture is transfer to a 500ml beaker and allowed to cool for
a about 2Hrs.

Distilled water is then added to immerse the coated mixture and covered.

The mixture in the beaker filled with distilled water is kept in a water bath and
maintained at a temperature of 400C taking care the level of water in the water both is
maintained to at least half the height of beaker.

After 24Hrs the mixture in the beaker is removed from the water bath and cooled .

Visually examine that the % of stone surface that remains coated after specified period,
that % gives % stripping value of Aggregate.
Determination of Specific Gravity & Water absorption of Aggregate.

About 2kg of aggregate sample is washed thoroughly to remove fines, drained & then placed in
the wire basket & immersed in distilled water at temp. between 20 to 320 c & cover of at least
5cm of water above top of basket. Immediately after immersion entrapped air is removed from
sample.The basket & aggregate should remains immersed in water for 24 +/- 0.5 Hrs.

The basket & sample are then weighed while suspended in water at a temp 22 to 320c.=W1.

The basket & sample then removed from water & allow to drain for few min.& then aggregate
transferred to dry absorbent cloth.

Then empty basket returned to tank of water = W2.

Aggregate transferred to second dry cloth & allow to dry until the aggregate completely surface
dry.

Surface dried aggregate is then weighed=W3.

aggregate placed in oven with temp maintained 110 c for 24 hrs.

Aggregate removed from oven & weight = W4

Repeat same minimum 2 times.

Sp. Gravity = W4/W3-(W1-W2).

%Water Absorption =((W3-W4)/W4 )x100.

 Determination of Aggregate Impact Value.

Check balance and Aggregate Impact Value apparatus.

Sufficient test sample passing 12.5mm sieve and retain on 10.0mm sieve shall be selected for
testing.

The selected test sample shall be oven dried in an oven for a period of at least 4Hrs.

The test sample shall be removed from the oven and then cooled and weigh.

The test sample shall be filled in three layers and tamped with 25 strokes per layer in the measuring
container.

The surplus test sample shall be removed and the net weight of the test sample to fill the measuring
container shall be weigh.

The Cup shall be fixed firmly and the total test sample is placed in it and compacted by a tamping
rod giving 25 Strokes.

The test sample shall be subjected to a total of 15 blows each at an interval of not less than one
second of the aggregate impact machine.

The crushed test sample shall then be removed from the cup and the total sample is sieved through
2.36mm test sieve.

The test sample retained and passing on 2.36mm test sieve shall then be weighed.

Calculate the weight of test sample passing 2.36mm sieve with the weight of total test sample filled
in the cup.

Calculate % passing 2.36 mm sieve gives Aggregate impact value.

 Soundness Test of Aggregate.

Take solution of Sodium or Magnesium sulphate a per required concentration. Aggregate sample,
sieves, balance as per IS 2386 Part 5.

The sample of coarse aggregate should be washed & dried to a constant weight at 105 to 110 c &
separated different size range as given in code,

Proper weight of sample for each fraction is weighed & placed in separate containers for the test.

Sample are immersed in solution of Magnesium or Sodium sulphate for 16 to 18 hrs such manner that
solution cover them to a depth at least 15mm .

Containers are covered to reduce evaporation during immersion & temperature of solution is
maintained at 27 +/- 1 c.

After the immersion period the aggregate are removed from solution drained for 15 min & placed in
drying oven maintained at temp of 105 to 110 c. the sample are dried for constant weight at this temp
by checking the weight after 4 hrs up to 18 hrs.when successive weights differ by less than 1g it may
considered that constant weight has been attained & then may allowed to cool to room temperature.

Then the aggregate are again immersed in the prepared solution for the next cycle.

After the completion of five cycle sample is cooled washed free from the sulphate.

Each fraction of sample is then dried to constant temp of 105 to 110 c & weighed.

Coarse aggregate fraction are sieved by sieves given in Code.

Calculate % loss for each fraction based on grading of sample.

Result.
 Determination of 10% fine value of Aggregate.

Check balance, Sieves, Cube Testing Machine,Cylinders etc.

Sufficient test sample passing 14mm sieve and retain on 10.0mm sieve shall be selected for testing.

The selected test sample shall be oven dried in an oven at temp 100 to 110c for a period of at least
4Hrs.

The test sample shall be removed from the oven and then cooled and weigh.

The test sample shall be filled into cylinder in three layers and tamped with 25 strokes per layer . The
total depth of material in the cylinder after tamping shall be 10cm.About 6.5kg aggregate required for 2
test sample.

The test sample in the cylinder with the plunger in placed in comp. testing machine.

The load is applied at uniform rate so as to cause total penetration of plunger about 20mm for normal
crushed aggregate in ten minutes & take reading load at 20mm penetration =X KN.

After max specified penetration load released & aggregate from the cylinder is sieved on a2.36mm IS
sieve & determine %= Y .

10 percent fine value = ( 14X ) / (Y+4).

 Cleanness test of Aggregate.

Test sample shall be dried to constant weight at temp. of 110 +/- 50 c & weigh the nearest 0.1
percent.= W1.

Test sample after being dried & weighed shall be placed in the container & sufficient water is added
to cover it.

The contents of the container shall be agitated vigorously.

The agitation shall be sufficiently results in partical separation & finer than 75 micron bring into
suspension.

The operation shall repeated until the wash water is clear.

The washed aggregate shall be dried at temp not exceed 1100 c & weight. = W2

% finer than 75 micron = (W1-W2)/W2 X100

Result.
 Determination of Los Angeles Abrasion of Aggregate.

Clean aggregate & dried in oven at 105 to 110 c.

Confirming any one of grading A to G as per table II in cl no 5.3.3.( IS 2386 Part 4).

Aggregate weighing 5Kg for grading Ato D & 10kg for grading E,F or G.taken as test specimen & placed in
cylinder.

Abrasion charge to be chosen in accordance with cl no 5.3.3. depending on grading of aggregate & is places
in the cylinder of machine.

Cover fixed & start rotating 20 to 33 RPM, machine is rotated 500 revolution for grading A to D & 1000
revolution for Grading E to G.

After desired revolution machine stopped & takeout entire stone dust.

By taking 1.7mm sieve material coarser than 1.7mm washed & dried in oven at 105 to 110 c to constant
weight & weighed correct to 1 gms.

The difference between the original & final weight of sample is expressed as percentage of the original
weight of the sample is reported as the percentage wear.

Result.
Determination of Combined Flakiness & Elongation Indices of Aggregate.

Check balance and metal gauges of Flakiness & Elongation Indices.

Sub division using the cone and quartering method select sufficient quantity of test sample for
testing.

Place the test sample on a tray and in an oven for drying 'or' air dried.

The sieves are selected as per requirement of the IS code 2386 Part 1 (1963) Table-5.

The test sample are pass through the top most sieve size descanting to the smallest sieve
size selected.

Test sample shall consist of at least 200 pieces of each fraction retained on the sieve size
selected and weighed.

Every pieces of test samples from each fraction retained shall be gauged through the
flakiness standard gauge.

The test sample from each fraction retained on the flakiness standard gauge shall be weigh
and recorded and the test sample pass through the flakiness standard gauge shall be used to
determine the elongation.

The remander test sample from the passing through the flakiness index shall be gauged
individually for length on a elongation standard metal length gauge.

The test sample retained by the length gauge from each fraction shall be weighed and
recorded.

Calculate the Flakiness index by the total weight retained on each fraction with the total weigh
of test sample before test carried out.

For Elongation index use material retained thickness gauge.

Elongation Index= sample retained on length gauge /Sample retained on Thickness gauge.

Combine both the flakiness index percentage & elongation index percentage.
 Determination of Specific Gravity of Bitumen

Take density bottle.

Clean dry and Weigh empty density bottle with stopper.

Fill the density bottle with distilled water or freshly boiled water and fix the stopper.

Place the density bottle filled with distilled water in the beaker.

Fill the beaker with the distilled water up to the neck of the density bottle and maintain at the
temperature of 27+/- 0.10C or any other temp for 1/2 an hour .

Remove the density bottle filled with distilled water from the beaker and then wipe clean dry and
weigh.

Pour out the distilled water from the density bottle and then dry in the oven so as no moisture
presence in the density bottle.

The bitumen shall be gently preheated to a fluid condition and pour into the clean dried prewarmed
density bottle. The bitumen shall be half filled of the density bottle .

Allow the half filled density bottle to cool at a specified temp and weigh with the stopper.

Balance half density bottle half filled with bitumen to be filled with distilled water to the top rim and
insert the stopper gently and ensure no air bubbles entrapped in the density bottle.

Allow the density bottle filled with the bitumen and distilled water to remain in the water bath for a
period not less than 30 minutes.

Remove the density bottle from the water bath and wipe clean with dry cloth and weigh with the
stopper .

Calculate the specific gravity of test sample.

Report results.
 Determination of Penetration of Bitumen

Check apparatus and the needle .

Preheat the bitumen to a pouring consistency at the temperature not more than 900C until
it is thoroughly free from air bubble and water.

Pour the bitumen into the container to a depth at least 10mm in excess of the expected
penetration.

Protect the bitumen from dust and allow to cool at a temperature between 15 to 300C for
one and a half to two hours .

Then place the container with the transfer dish in the water bath and maintain the
temperature at 250C +/- 0.10C for one and a half to two hours .

Next remove the container with the transfer dish from the water bath but ensure the
transfer dish is fill with the water from the water bath to a depth sufficient to cover the
container .

Next place the container with the transfer dish upon the stand of the penetration apparatus,
adjust the needle so as it make contact with the surface of the sample but make sure the
temperature is maintain at 250C +/- 0.10C at all time.

Next using the source of light ( torch light ) place the needle point in direct contact with its
image reflected on the surface of the bitumen .

Before test bring the pointer to zero and release the needle until it stops penetrating,
measure the distance penetrated.

Make at least 3 determination at points on the surface not less than 10mm apart and not
less than 10mm from the side of the dish.

Express the depth of penetration of the needle in tenths of millimeter and shall be the
means of not less than three determination.

Report.
 Determination of Softening Point of Bitumen

Check the apparatus - ring and ball.

Select the material to be tested.

Heat the material to a temperature between 750C to 1000C until it is completely fluid and free
from air bubble and water.

Place the heated ring having approximate temp as the material temp place on a metal plate
coated with glycerin.

Next fill the ring with the preheated material and give an excess above the level of the ring
and let it to cool.

After cooling for about 30 minutes in air, level the material in the ring by removing excess with
a warmed sharp knife.

Transfer the ring filled with the material from the metal plate, the ring shall be supported in a
horizontal position with the upper surface of the ring 50mm below the the surface of the liquid.

Next place the apparatus with the ring, thermometer and ball guides in position in a beaker
and fill with freshly distilled water at a temp of 50C and maintain it for 15 minutes.

After that place the ball using by means of forceps in each ball guide and apply heat by
placing the beaker filled with distilled water on a hot plate.

Next place the mechanical stirrer which operates smoothly giving uniform heat distribution at
all times throughout the beaker so that the temp rises at a uniform rate of 5.0 0C +/- 0.50C per
minute.

The rate of temp shall be measured when the material soften and allows the ball to pass
through the ring, The rate of temp shall not fall within the specified limits after which the three
minutes shall be rejected.

Record for each ring and ball the temp shown by the thermometer at the instants the material
surrounding the ball touches the bottom plate of the support which having a distance of 25mm
between the bottom of the ring and the surface of the bottom plate.

Report to the nearest 0.50C the means of temperature recorded as the softening point.

Report results.
 Determination of Ductility of Bitumen

Check the mould and the testing machine.

Completely melt the bitumen to be tested to a temp of 750C to 1000C until it become thoroughly fluid.

Assemble the mould on a brass plate which is thoroughly coated with glycerin, the interior surface of
the mould shall also be coated with glycerin.

Next pour the preheated material in a thin stream back and forth from one end to another end of the
mould until it is more than level.

Leave it to cool at the room temp for about 30 to 40 minutes and then place in a water bath and
maintain at a specific temp for 30minutes.

Remove the mould filled with the bitumen from the water bath and cut off the excess bitumen by
means of a hot, straight edge putty knife, so that the level is corrected.

Next place the brass plate and mould filled with the bitumen in the water bath and kept at the
specified temp for about 80 to 90 minutes, make sure the water in the tank of the testing machine
covers the specimen both above and below it at least 25mm.

After that remove the mould filled with the bitumen from the brass plate and detach the sides piece
and test the bitumen immediately.

Attach the ring at each end of the clips to the pins in the testing machine and pull the two clips apart
horizontally at a uniform speed until the bitumen ruptures.

Measure the distances in centimeters through which the clips have been pulled to produce rupture.

Report results.
 Determination Flash & Fire Point of Bitumen

All part of cup should be cleaned and dry thoroughly before the test is started.

Material filled in cup up to filling mark.

Accessories including thermometer of specified range are suitably fix up.

Bitumen sample is then heated at the rate of 5 to 6 c per minute.

The stirring is done at a rate of approximately 60rpm.

the Flash point is taken as the temperature read on the thermometer at the time of the
flame application that cause bright flash in the interior of cup in closed system.

The heating is continued until the volatile ignites and the material continues to burn for 5
second, the temperature of the sample material when this occur is recorded as the fire
point.

Report.
 Determination of % Solubility in Trichloroethylene of Bitumen.

Weigh about 2gm( W1) of dry material correct to the nearest 0.001g into 200ml conical flask.

Add 100 ml trichloroethylene , Steer the content of flask & allow it to stand for period of 1 hrs.

Filter the content of flask through the grooch crucible & weighed to the nearest 0.001g.

Moist the asbestos pad with trichloroethylene before commencing filtration & filter at the rate of not
more than two drop per second at first.The filter shall be clear.

Transfer the insoluble remaining in flask to the crucible by washing out the flask with the stream of
trichloroethylene from a wash bottle.

Wash the material in the crucible with successive small amount of trichloroethylene until a filtrate is
obtained which is not discolored.

Allow the crucible to dry in air for 30 min. after which place it in an oven at 100 to 110 c for one hrs.

Allow the crucible to cool in a desiccator & then weigh.= W2

Matter Soluble in trichloroethylene(%)=(W1-W2)/W1 x100

Result.
 Determination of Elastic Recovery of Bitumen

Check the mould and the testing machine.

Completely melt the bitumen to be tested to a temp of 750C to 1000C until it become thoroughly fluid.

Assemble the mould on a brass plate which is thoroughly coated with glycerin, the interior surface of the
mould shall also be coated with glycerin.

Next pour the preheated material in a thin stream back and forth from one end to another end of the
mould until it is more than level.

Leave it to cool at the room temp for about 30 to 40 minutes and then place in a water bath and maintain
at a specific temp for 30minutes.

Remove the mould filled with the bitumen from the water bath and cut off the excess bitumen by means of
a hot, straight edge putty knife, so that the level is corrected.

Next place the brass plate and mould filled with the bitumen in the water bath and kept at the specified
temp for about 80 to 90 minutes, make sure the water in the tank of the testing machine covers the
specimen both above and below it at least 25mm.

After that remove the mould filled with the bitumen from the brass plate and detach the sides piece and
test the bitumen immediately.

Attach the ring at each end of the clips to the pins in the testing machine and elongate the specimen at
the specified rate to a deformation 10cm at rate of 5+/-0.25cm/min at specified temp.

Immediately cut the test specimen into two halves at the midpoint using the scissors.

Keep the test specimen in the water bath in an undisturbed condition for 1 hrs at specified temp.

After 1hrs time peroid,move the elongated half of the test specimen back into position near the fixed half
of the test specimen so that the two pieces of modified bitumen specimen just touch.

Record the length of the recombined specimen as X.

% Elastic Recovery = (10-X/10)100.

 Determination of Absolute Viscosity of Bitumen.

Calibrate viscometer by using liquid of known viscosity to find calibration factor K.

Heat sample mare than 90 c for bitumen until it has become sufficient fluid for pore.

Transfer it about 20ml into suitable container & maintain temp. of 135+/- 5.5 c String occasionally to
escape entrapped air.

Pore the hot bitumen in the canning manning vaccume viscometer so that bitumen is within +/-
2mm of fill line E.

Place the charged viscometer in oven or bath maintained at 135 +/-5.5 for the period 10+/- 2 min to
allow large air bubble to escape.

Maintain bath temp. 60 +/- 0.1 c place the viscometer so that uppermost timing mark at least 2cm below
the surface of bath liquid.

Establish & vaccume of 30+/-0.05cm of mercury in the vaccum system & connect to viscometer with
valve closed.

After viscometer has been in bath for 30+/- 5 min open the valve & allow the bitumen flow in the
viscometer & measure time required ( t-in sec with accuracy 0.5 sec) for the leading edge of meniscus
to pass between successive pair of timing marks.

Viscosity =K t

Report results.
 Determination of Field Density by Sand Replacement Method

The location where the field density test to be determined is cleaned & leveled using scrapper foe an
area of about 450 sq.mm & place metal tray with central hole on prepared surface.

Using central hole & trowel soil/material excavated up to 150mm depth & the material removed shall be
collected carefully in metal container and weighed= W

Sand pouring cylinder refilled with sand & weight=W1, Weight of sand in cone to be determined =W2

Metal tray with central hole removed & cylinder with sand placed over hole then open shutter till sand fill
the excavated hole. The shutter closed & cylinder weight again.=W3

Find sand filling excavated hole alone=Wb= (W1-W3-W2).

Find Volume of hole with known density of sand & weight of sand in hole =V.

Wet Density excavated material =W/V.

Moisture Content of excavated material is determined by taking a sample from excavated soil from hole.

From Wet Density & Moisture content find out dry density & % compaction.

Results.
 Consistency Test of Cement

Check apparatus, balance and cement to be used.

Take 300 gms of representative sample and add water with sample in different percentage in different
trial and make paste by proper mixing.

Fill mould in three layers in such a way that air bubles will not remain in the mould.

Place the mould at bottom of 10mm needle in the apparatus and note down the penetration of needle in
to the paste.

See, for which percent of water, needle will penetrate between 5mm to 7mm from bottom of the mould .
this percent of water is the Normal consistency of cement.
 Fineness of Cement

Check Balance and Sieve.

Take 100 gms of representative Cement sample (A).

Sieve the sample through 90 mic I.S sieve for 10 min.

Weight the retained materials on 90 mic I.S sieve (B).

Fineness of Cement :B/A*100.

Specific gravity of Aggregates (Pynometer Method).

Prepare Pynometer.

Weigh empty Pynometer with brass conical cap, screw ring and rubber
sealing ring.

prepare a selected quantity of test samples from original sample.

Oven dry the selected quantity sample.

Passing 10.0mm and retain on 4.75mm sieve shall be selected for testing.

Place in Pynometer and weigh.

Add water to half of the Pynometer and stir with spatula.

Shake the Pynometer until total air have been removed and top up with
water to the rim of pynometer bottle.

Wipe dry the outside Pynometer and weigh the full bottle filled with
water and test sample.

Remove water with test sample, wash & clean dry the Pynometer bottle .

weigh the Pynometer bottle full with water.

Calculate the specific gravity of test sample.

Report results.
 Compressive Strength of Cement

Check the Mortar Vibrator Machine and cube mould are in order.

The Standard sand shall be used conforming to IS 650 - 1966, and the proposed cement to be used.

Mix the cement and the Standard sand in a proportion of 1:3 by weight for at least one minute.

The mix material shall then add with water to a uinform colour percentage of water to be add shall be
calculate base on equation given is IS 4031 - 1968.

The mix material is then transfer immediately in the cube mould and shall be rodded twenty times in
about of eight seconds.

The mix material shall then be vibrate for two minutes.

After complete vibration remove the mould from the machine and smooth the top surface with the
trowel with excces mix material.

Keep the filled mould for at least 24Hrs and then remove it, immediately submerged in the water, prior
for testing.

Test the mortar cube on 7 & 28 days, 28 days strength gives Grade of cement.
 Initial & Final Setting Time of Cement.

Check Vicat apparatus and cement to be used.

Mix the cement with a selected weighted quantity of water to obtain a uniform mix and record
the time of intial mixing.

Fill the mixture immediatley to the vicat mould and the time of gauging is not less than three
minutes and not more than five minutes to penetrate to a point of 5mm to 7mm.

Predetermine the amount of water to give a standard consistency for the initial & final setting.

Next mix the given weighted cement with 0.85 times the water of the standard consistency
obtained and transfer to the vicat mould record the time & it shouldnot exceed 5 min & not
less than 3min.

Immediately carry out the initial setting needle in contact with the surface of the vicat mould
and release rod bearing .

Repeat this procedure until the initial setting needle fail to pierce the surface of the vicat
mould for 5 + 0.5 mm and record the initial setting time.

Replace the needle with the an annular ring to determine the final setting time.

The final setting time shall be recorded when the annular ring makes on impression on the
surface , on the surface of the vicat mould while the attachment fails to do so.

Report the results of the Normal Consistency,Intial and final setting time.
 Soundness of cement by Le Chatlier Method

Place the lightly oiled mould on a lightly oiled glass sheet & fill it with cement paste formed by
gauging cement with 0.78 times water required to give standard consistency.

Cover the mould with another piece of lightly oiled glass sheet,place a small weight on this
covering glass sheet.

Immediately submerge the whole assembly in water at a temp. of 27+/- 2c & keep there for 24
hrs.

Measure the distance separating the indicator point to the nearest 0.5mm.

Submerge the mould again in water at the temp. prescribed above , bring water to boiling with
mould kept submerged , in 25 to 30 minutes, & keep it boiling for three hrs.

Remove the mould from water allow it to cool & measure the distance between the indicator
points.

Difference between these two measurements indicates the expansion of the cement.

Calculate the mean of two values to the nearest 0.5mm to represent the expansion of the
cement.

Result.