Sumadhura Infra Pvt Ltd

QA/QC Department
Lab Manual
Page
Sl no Description
No
1 Coarse aggregate for Concrete  
1.1 Sieve analysis  
1.2 Flakiness Index  
1.3 Elongation index  
1.4 Materials finer than 75micron  
1.5 Specific gravity & water absorption  
1.6 Density & voids  
1.7 Aggregate crushing value  
1.8 Impact value  
1.9 10% fines value  
     
2 Fine Aggregate for Concrete  
2.1 Sieve analysis  
2.2 Materials finer than 75micron  
2.3 Silt Content  
2.4 Specific gravity & water absorption  
2.5 Density & voids  
2.6 Fineness modulus  
     
3 Fine Aggregate for Masonry mortar  
3.1 Sieve analysis  
3.2 Silt Content  
3.3 Fineness modulus  
     
4 Fine Aggregate for Plaster  
4.1 Sieve analysis  
4.2 Silt Content  
4.3 Fineness modulus  
     
5 Reinforcement Bars & Cuplers  
5.1 Rolling Margin  
5.2 Visual Inspection for Cuplers  
     
6 Cement  
6.1 Normal Consistancy  
6.2 Setting time test  
6.3 Compressive Strength  
6.4 Fineness of cement (dry sieving)  
7 GGBS  
7.1 Physical properties (mixed with 30% OPC 43/PPC)  
7.2 Normal Consistancy  
7.3 Setting time test  
7.4 Compressive Strength  
     
Water Reducing Admixture
Delivery & Inspection
Relative Density

8 Plywood for Concrete Shuttering  

8.1 Dimension  
8.2 Edge Sraightness  
8.3 Squareness  
8.4 Moisture Content  
8.5 Density  
8.6 Nailing test  
     
9 Laminated veneer Lumber (LVL) Runner  
9.1 Dimension  
9.2 Moisture Content  
9.3 Thickness swelling in 2 hour water soaking  
     
10 Silverwood runner  
10.1 Dimension  
10.2 Moisture Content  
10.3 Straigthness/Flatness  
     
11 Solid concrete blocks (grade C5)  
11.1 Dimension  
11.2 Density  
11.3 Compressive Strength  
11.4 Water absorption  
     
12 Autoclaved Areated Concrete blocks (AAC)  
12.1 Dimension  
12.2 Density  
12.3 Compressive Strength  
     
13 Sized Stones  
13.1 Crushing Strength  
13.2 Water absorption  
13.3 Density  
     
14 Integral Water proofing Compound  
14.1 Compressive Strength  
     
 15 Ceramic and Vitrified tiles  
15.1 Length & width  
15.2 Thickness  
15.3 Straightness of sides (facial side)  
15.4 Rectangularity  
15.5 Surface flatness  
15.6 Surface quality  
15.7 Water absorption % by mass  
     
16 Tile Adhesive  
1 Sieve analysis  
2 Adhesion check  
     
17 Door frames  
17.1 Dimension & Tolerance  
17.2 Width  
17.3 Thickness  
17.4 Moisture Content  
17.5 Visual Inspection  
     
18 Door Shutters  
18.1 Height  
18.2 Width  
18.3 Thickness  
18.4 Squareness  
18.5 General flatness  
18.6 Local Planeness  
18.7 Impact indentation test  
18.8 Flexture test  
18.9 Edge loding test  
18.10 Shock resistance test  
18.11 Buckling test  
18.12 Slamming test  
18.13 Misuse test  
18.14 Varying humidity test  
18.15 End immersion test  
18.16 Glue adhesion test  
18.17 Screw withdrawal resistance test  
     
19 Door Hardware  
19.1 Body & Body cover plate  
19.2 Case plate  
19.3 Face plate & Striking plate  
19.4 Materials for vearious components of Mortis lock  
19.5 Check for non interchangebility  
   
  
20 Paver Blocks  
20.1 Check for pigment  
20.2 Grade and thickness of paver  
20.3 Visual Inspection  
20.4 Dimension Tolerance  
20.5 Water absorption  
20.6 Compressive Strength  
     
21 Kerb Stone  
21.1 Test for transverse strength  
21.2 Dimension tolerance  
21.3 Water Absorption  
     
22 Marble  
1 Dimension tolerance  
2 Moisture absorption after 24 h  
     
23 Granite  
23.1 Visual Inspection  
23.2 Deviation of Straightness of facial/Polished sides  
23.3 Dimension Tolerance  
     
24 Non Shrink Grouts  
24.1 Compressive strength  
     
25 Curing Compound  
25.1 Compressive strength  
     
26 Fresh & Hardened Concrete  
26.1 Slump / Flow  
26.2 L box test  
26.3 V funnel test  
26.4 U box test  
26.5 Cube casting  
26.6 Compression test  
     
27 Trail Mix  

28 Soil
28.1 Soil Compaction test
28.2 Standard Procter test
1. COARSE AGGREGATE FOR CONCRETE

1.1 SIEVE ANALYSIS (FOR FINE & COARSE AGGREGATE)

Ref - IS 2386 part 1 – 1963

Objective

This method covers the procedure for the determination of particle size distribution of
fine, course aggregates by sieving.

Apparatus

IS Sieves - Sieves of the sizes given in Table, conforming to IS 460-1962 Specification for
Test Sieves shall be used

Is Sieves for Sieve Analysis of Aggregates for Concrete Type

Square hole, perforated plate 80-mm, 63-mm, 40-mm, 20-mm, 12.5-mm, 10-
mm, 4.75-mm
Fine mesh, wire cloth 2.36-mm, 1.18mm, 600 micron,
300 micron, 150 micron

Balance - The balance or scale shall be such that it is readable and accurate to 0.1 percent of
the weight of the test sample.

Sample

Sampling shall be 3 kg for Coarse aggregate and 1 kg for fine aggregate.

Test Procedure for Coarse and Fine Aggregate

The sample shall be brought to an air-dry condition before weighing and sieving. This
may be achieved either by drying at room temperature or by heating at a temperature of 100”
to 110°C. The air-dry sample shall be weighed and sieved successively on the appropriate
sieves starting with the largest. Care shall be taken to ensure that the sieves are clean before
use.

Each sieve shall be shaken separately over a clean tray until not more than a trace
passes, but in any case for a period of not less than two minutes. The shaking shall be done
with a varied motion, backwards and forwards, left to right, circular clockwise and anti-
clockwise, and with frequent jarring, so that the material is kept moving over the sieve
surface in frequently changing directions. Material shall not be forced through the sieve by
hand pressure, but on sieves coarser than 20 mm, placing of particles is permitted. Lumps of
fine material, if present, may be broken by gentle pressure with fingers against the side of the
sieve. Light brushing with a soft brush on the underside of the sieve may be used to clear the
sieve openings.
Light brushing with a fine camel hairbrush may be used on the 150-micron IS Sieves
to prevent aggregation of powder and blinding of apertures. Stiff or worn out brushes shall
not be used for this purpose and pressure shall not be applied to the surface of the sieve to
force particles through the mesh.

On completion of sieving, the material retained on each sieve, together with any
material cleaned from the mesh, shall be weighed.

Reporting of Results

The results shall be calculated and reported as, the cumulative percentage by weight
of the total sample passing each of the sieves, to the nearest whole number

The attached report format, which contains acceptance criteria, shall be used for
reporting the results.

1.2 DETERMINATION OF MATERIALS FINER THAN 75-MICRON

Ref - IS 2386 part 1 – 1963

Objective

This method of test deals with the procedure for determining the total quantity of
material finer than 75micron IS Sieve in aggregates by washing.
NOTE - Clay particles that are dispersed by wash water as well as water soluble materials
will be removed from the aggregate during the test.

Apparatus

Balance -The balance or scale shall be of sufficient capacity and sensitivity and shall have an
accuracy of 0.1 percent of the weight of the test sample.

Sieve - A nest of two sieves, the lower being 75-micron IS Sieve and the upper
approximately 1.18 mm IS Sieve [see IS: 460-1962 Specification for Test Sieves (Revised)I.

Container - A pan or vessel of a size sufficient to contain the sample covered with water and
to permit of vigorous agitation without inadvertent loss of any part of the sample or water.

Oven - An oven of sufficient size capable of maintaining a uniform temperature of 110 +/- 5
°C

Sample
 The test sample shall be selected from material which has been thoroughly mixed and
which contains sufficient moisture to prevent segregation. A representative sample, sufficient
to yield not less than the appropriate weight of dried material, as shown below, shall be
selected:

Maximum Nominal size of Approximate

Aggregate (mm) minimum weight of
sample (g)
4.75 500
10.0 2000
20 2500
40 or over 5000

Procedure for Fine & Coarse Aggregate

The test sample shall be dried to constant weight at a temperature of 110 +/- 5 °C and
weighed to the nearest 0.1 percent.
The test sample after being dried and weighed shall be placed in the container and
sufficient water added to cover it. The contents of the container shall be agitated vigorously.
The agitation shall be sufficiently vigorous to result in the complete separation from
the coarse particles of all particles finer than 75-micron and bring the fine material into
suspension. Care shall be taken to avoid, as much as possible, the decantation of the coarse
particles of the sample. The operation shall be repeated until the wash water is clear.
The wash water containing the suspended and dissolved solids shall be immediately
poured over the nested sieves arranged with the coarser sieve on the top.

All material retained on the nested sieves shall be returned to the washed sample. The
washed aggregate shall be dried to constant weight at a temperature not exceeding 110°C and
weighed to the nearest 0.1 percent.

Calculation & Results:

The amount of material passing the 75-micron IS Sieve shall be calculated as follows:
B−C
A= X 100
B
where
A = percentage of material finer than 75-micron,
B = original dry weight, and
C = dry weight after washing.
1.3 DETERMINATION OF FLAKINESS INDEX

Ref - IS 2386 part 1 – 1963

Objective
This method of test lays down the procedure for determining the flakiness index of
coarse aggregate.
NOTE -- The flakiness index of an aggregate is the percentage by weight of particles in it
whose least dimension (thickness) is less than three-fifth8 of their mean dimension. The test
is not applicable to sizes smaller than 6.3 mm.

Apparatus

Balance - The balance shall be of sufficient capacity and sensitivity (see 4.4.3) and shall have
an accuracy of 0.1 percent of the weight of the test sample.

Metal Gauge - The metal flakiness gauge.

Sieves - IS Sieves of sizes shown in Table 1.

Sample

A quantity of aggregate shall be taken sufficient to provide the minimum number of

200 pieces of any fraction to be tested.

Procedure

Sieving - The sample shall be sieved in accordance with the method described in “Sieve
Analysis” with the sieves specified in Table 1.

Separation of Flaky material - Each fraction shall be gauged in turn for thickness on a metal
gauge. The width of the slot used in the gauge or sieve shall be of the dimensions specified in
co1 3 of Table 1 for the appropriate size of material.
Table 1
DIMENSIONS OF THICKNESS AND LENGTH GAUGES
SIZE OF AGGREGATE
Passing through Retained on Thickness Gauge Length Gauge
IS sieves IS sieves
63-mm 50-mm 33.9 -
50-mm 40-mm 27 81
40-mm 25-mm 19.5 58.5
31.5 mm 25-mm 16.95 -
25-mm 20-mm 13.5 40.5
20-mm 16-mm 10.8 32.4
 16-mm 12.5-mm 8.55 25.6
12.5-mm 10-mm 6.75 20.2
10-mm 6.3-mm 4.89 14.7

Weighing of Flaky Material - The total amount passing the gauge shall be weighed to an
accuracy of at least 0.1 percent of the weight of the test sample.

Reporting of Results

The flakiness index is the total weight of the material passing the various thickness
gauges or sieves, expressed as a percentage of the total weight of the sample gauged. The
attached format shall be used for reporting.

1.4 DETERMINATION OF ELONGATION INDEX

Ref - IS 2386 part 1 – 1963

Object

This method of test lays down the procedure for determining the elongation index of
coarse aggregate.
NOTE - The elongation index of an aggregate is the percentage by weight of particles whose
greatest dimension (length) is greater than one and four-fifths times their mean dimension.
Normally, the properties of interest to the engineer are sufficiently covered by the flakiness or
angularity tests. The elongation test is not applicable to sizes smaller than 6.3 mm.

Apparatus

Balance - The balance shall be of sufficient capacity and sensitivity and shall have an
accuracy of 0.1 percent of the weight of the test sample.
Metal Gauge - The metal Elongation gauge
Sieves – IS Sieves of the sizes shown in Table 1.
Sample - A quantity of aggregate shall be taken, sufficient to provide a minimum number of
200 pieces of any fraction to be tested.

Procedure

Sieving - The sample shall be sieved in accordance with the method described in 1.1 with the
sieves specified in Table 1.
Separation of Elongated Material- Each fraction shall be gauged individually for length on a
metal length gauge of the pattern shown in Fig. 3. The gauge length used shall be that
specified in co1 4 of Table 1 for the appropriate size of material.
Weighing of Elongated Material - The total amount retained by the length gauge shall be
weighed to an accuracy of at least 0.1 percent of the weight of the test sample.
Report of Results - 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. In
addition, it shall be reported in the attached format.

1.5 SPECIFIC GRAVITY & WATER ABSORPTION FOR COARSE AGGREGATE

Ref - IS 2386 part 3 – 1963

Object
This test covers the procedures for determining the specific gravity, apparent specific
gravity and water absorption of aggregates.

Apparatus

Balance - A balance or scale of capacity not less than 3 kg, readable and accurate to 0.5 g and
of such a type and shape as to permit the basket containing the sample to be suspended from
the beam and weighed in water.
Oven - A well-ventilated oven, thermostatically controlled, to maintain a temperature of 100
to 110 °C.
A wire basket of not more than 6.3 mm mesh or a perforated container of convenient size,
preferably chromium plated and polished, with wire hangers not thicker than one millimeter
for suspending it from the balance.
A stout watertight container in which the basket may be freely suspended.
Two dry soft absorbent cloths each not less than 75 x 45 cm.
A shallow tray of area not less than 650 CM2.
An airtight container of capacity similar to that of the basket.

Sample

A sample of not less than 2000 g of the aggregate shall be tested. Aggregates, which
have been artificially heated, shall not normally be used. If such material is used the fact shall
be stated in the report. Two tests shall be made, and it is recommended that the two samples
should not be tested concurrently.

Test Procedure

The sample shall be thoroughly washed to remove finer particles and dust, drained
and then placed in the wire basket and immersed in distilled water at a temperature between
22°C and 32°C with a cover of at least 5 cm of water above the top of the basket.

Immediately. after immersion the entrapped air shall be removed from the sample by
lifting the basket containing it 25 mm above the base of the tank and allowing it to drop 25
times at the rate of about one drop per second. The basket and aggregate shall remain
completely immersed during the operation and for a period of 24 +/- l/2 hours afterwards.

The basket and the sample shall then be jolted and weighed in water at a temperature
of 22 to 32 °C If it is necessary for them to be transferred to a different tank for weighing,
they shall be jolted 25 times as described above in the new tank before weighing (weight
A1).

The basket and the aggregate shall then be removed from the water and allowed to
drain for a few minutes, after which the, aggregate shall be gently emptied from the basket on
to one of the dry clothes, and the empty basket shall be returned to the water, jolted 25 times
and weighed in water ( weight A2 ).

The aggregate placed on the dry cloth shall be gently surface dried with the cloth,
transferring it to the second dry cloth when the first will remove no further moisture. It shall
then be spread out not more than one stone deep on the second cloth, and lest exposed to the
Atmosphere away from direct sunlight or any other source of heat for not less than 10
minutes, or until it appears to be completely surface dry (which with some aggregates may
take an hour or more). The aggregate shall be turned over at least once during this period and
a gentle current of unheated air may be used after the first ten minutes to accelerate the
drying of difficult aggregates. The aggregate shall then be weighed (weight B).
NOTE : If the apparent specific gravity only is required the operation described above may
be omitted.
The aggregate shall then be placed in the oven in the shallow tray, at a temperature of
100 to 110°C and maintained at this temperature for 24 +/- l/2 hours. It shall then be removed
from the oven, cooled in the airtight container and weighed (weight C).

Calculations & Result

Specific gravity, apparent specific gravity and water absorption shall be calculated as
follows:

C
Specific Gravity =
B− A

C
Apparent specific gravity =
C−A

100(B−C)
Water Absorption =
C

Where
A = Weight in g of the saturated aggregate in water (A1-A2)
B = the weight in g of the saturated surface dry aggregate in
air, and
C = the weight in g of oven dried aggregate in air.

Reporting of Results

In the attached format, the individual and mean results shall be reported. The size of
the aggregate tested shall be stated, and whether it has been artificially heated.

1.6 DETERMINATION OF BULK DENSITY AND VOIDS (COARSE AND FINE

AGGREGATE)

Object

This method of test covers the procedure for determining unit weight or bulk density
and void of aggregates.
NOTE 1 - The bulk density is the weight of material in a given volume, and for the purpose
of this standard it is measured in kilograms per litre. The bulk density of an aggregate is
affected by several factors, including the amount of moisture present and the amount of effort
introduced in filling the measures.
NOTE 2 -It is emphasized that this is a laboratory test intended for comparing properties of
different aggregates. It is not generally suitable for use as a basis for quoting mix design
conversion factors.

Apparatus

Balance - A balance sensitive to 0.5 percent of the weight of the sample to be weighed.

Cylindrical Metal Measure - The measure shall preferably be machined to accurate internal
dimensions and shall be provided with handles. It shall also be watertight, and of sufficient
rigidity to retain its form under rough usage, and should be protected against corrosion.
The measure shall be of 3, 15 or 30 liters capacity, according to the maximum nominal size
of the coarsest particles of aggregate and shall comply with the requirements given in Table I.

Tamping Rod - A straight metal tamping rod of cylindrical cross section 16 mm in diameter
and 60 cm long, rounded at one end.

Calibration - The measure shall be calibrated by determining the weight of water at 27°C
required to fill it such that no meniscus is present above the rim of the container. The capacity
in litres shall be obtained by dividing the weight of water in kilograms required to fill the
container at 27°C by the weight of water in one liter at 27°C, which may be taken as one
kilogram.
Procedure

Condition of Specimen-The test shall normally be carried. Out on dry material when
determining the voids, but when bulking tests are required material with a given percentage
of moisture may be used.

Rodded or Compacted Weight - The measure shall be filled about one-third full with
thoroughly mixed aggregate and tamped with 25 strokes of the rounded end of the tamping
rod. A further similar quantity of aggregate shall be added and a further tamping of 25 strokes
given. The measure shall finally be filled to over-flowing, tamped 25 times and the surplus
aggregate struck off, using the tamping rod as a straightedge. The net weight of the aggregate
in the measure shall be determined and the bulk density calculated in kilograms per liter.

Loose Weight - The measure shill be filled to overflowing by means of a shovel or

scoop, the aggregate being discharged from a height not exceeding 5 cm above the top of the
measure. Care shall be taken to prevent, as far as possible, segregation of the particle sizes of
which the sample is composed. The surface of the aggregate shall then be levelled with a
straightedge. The net weight of the aggregate in the measure shall then be determined and the
bulk density calculated in kilogram per liter.

Calculation of Voids

The percentage of voids shall be calculated as follows:

Gs− y
Percentage of Voids =
Gs

Where
Gs = specific gravity of the aggregate, and
Y = bulk density in kg/litre.

Reporting of Result

The bulk density shall be reported in kg/liter to the nearest 0.01 kg. The voids shall be
reported as a percentage to the nearest whole number.

1.7 DETERMINATION OF AGGREGATE CRUSHING VALUE

Object
 This method of test covers the procedure for determining the aggregate crushing value
of coarse aggregate.
NOTE 1 -The ‘aggregate crushing value’ gives a relative measure of the resistance of an
aggregate to crushing under a gradually applied compressive load. With aggregate of
‘aggregate crushing value’ 30 or higher, the result may be anomalous, and in such cases the
‘ten percent fines value’ should be determined instead.
NOTE 2 - The standard aggregate crushing test shall be made on aggregate passing a 12.5-
mm IS Sieve and retained on a 10-mm IS Sieve. If required, or if the standard size is not
available, other sizes up to 25 mm may be tested but owing to the non-homogeneity of
aggregates the results will not be comparable with those obtained in the standard (see Note 1
under Reporting of results). Smaller sizes may also be tested (see Note 2 under Reporting of
results).

Apparatus

a) A 15-cm diameter open-ended steel cylinder, with plunger and base-plate, of the general
form and dimensions shown in Fig. The surfaces in contact with the aggregate shall be
machined and casehardened or otherwise treated so as to have a diamond (VH) pyramid
hardness number of not less than 650 VH
b) A straight metal tamping rod of circular cross-section 16 mm in diameter and 45 to 60 cm
long, rounded at one end.
c) A balance of capacity 3 kg, readable and accurate to one gram.
d) IS Sieves of sizes 12.5, 10 and 2.36 mm.
e) A compression testing machine capable of applying a load of 40 tones and which can be
operated to give a uniform rate of loading so that the maximum load is reached in 10 minutes.
The machine may be used with or without a spherical seating.
f) For measuring the sample, cylindrical metal measure of sufficient rigidity to retain its form
under rough usage and of the following
Internal dimensions:
Diameter 11.5 cm
Height 18 cm

Preparation of Test Sample

The material for the standard test shall consist of aggregate passing a 12.5-mm IS
Sieve and retained on a 10mm IS Sieve, and shall be thoroughly separated on these sieves
before testing. For other sizes, the material shall be separated on the appropriate sieves given
in following Table

DETAILS OF AGGREGATE CRUSHING TEST FOR NON-STANDARD SIZES OF AGGREGATE

NOMINAL SIZES (IS Sieves) Diameter of
Size of IS sieves to
Cylinder to be used
separate fines
Passing Through mm Retained on mm Cm

20 20 15 4.75 mm
 25 12.5 15 3.35 mm
10 6.3 15 or 7.5 1.7 mm
6.3 4.75 15 or 7.5 1.18 mm
4.75 3.35 15 or 7.5 850 mic
3.35 2.36 15 or 7.5 600 mic

The aggregate shall be tested in a surface-dry condition. If dried by heating, the period
of drying shall not exceed four hours, the temperature shall be 100 to 110°C and the
aggregate shall be cooled to room temperature before testing.

The appropriate quantity may be found conveniently by filling the cylindrical measure
in three layers of approximately equal depth, each layer being tamped 25 times with the
rounded end of the tamping rod and finally levelled off, using the tamping rod as a straight-
edge.
 The weight of material comprising the test sample shall be determined (Weight A)
and the same weight of sample shall be taken for the repeat test.

Test Procedure

The cylinder of the test apparatus shall be put in position on the base-plate and the test
sample added in thirds, each third being subjected to 25 strokes from the tamping rod. The
surface of the aggregate shall be carefully levelled and the plunger inserted so that it rests
horizontally on this surface, care being taken to ensure that the plunger does not jam in the
cylinder.

The apparatus, with the test sample and plunger in position, shall then be placed
between the platens of the testing machine and loaded at as uniform a rate as possible so that
the total load is reached in 10 minutes. The total load shall be 40 tones.

The load shall be released and the whole of the material removed from the cylinder
and sieved on a 2.36-mm IS Sieve for the standard test, or the appropriate sieve given in
Table. The fraction passing the sieve shall be weighed (Weight B). In all of these operations,
care shall be taken to avoid loss of the fines. Two tests shall be made.

Calculation

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

B
Aggregate crushing value = X 100
A
Where
B = weight of fraction passing the appropriate sieve, and
A = weight of surface-dry sample.

Reporting of Results

The mean of the two results shall be reported to the nearest whole number as the
‘aggregate crushing value’ of the size of material tested, which shall be stated.

NOTE 1 - Aggregate larger than 12.5 mm - In general, the larger sizes of aggregate will give
a higher aggregate crushing value, but the relationship between the values obtained with
different sizes will vary from one aggregate to another. Particular care shall be taken with
larger sizes of aggregate to ensure that the plunger does not jam in the cylinder. However, for
such aggregate, a 7.5-cm diameter cylinder may be used, and this has been found to give
slightly higher results than the standard cylinder, so that the errors are compensating.
NOTE 2 -Aggregate smaller than 10 mm - In general, the smaller sizes of aggregate will give
a lower aggregate crushing value, but the relationship between the values obtained with
different sizes will vary from one aggregate to another.

1.8 DETERMINATION OF TEN PERCENT FINES VALUE

Object

This method of test covers the procedure for determining the ‘ten percent fines’ value
of coarse aggregates.
NOTE - The ‘ten percent fines’ value gives a measure of the resistance of an aggregate to
crushing, that is, applicable to all aggregates.

Apparatus

a) A 15-cm diameter open-ended steel cylinder, with plunger and base-plate, of the general
form and dimensions shown in Fig.(in Crushing value test) The surfaces in contact with the
aggregate shall be machined and case-hardened or otherwise treated so as to have a diamond
(VH) pyramid hardness number of not less than 650 WI.
b) A straight metal tamping rod of circular cross-section 16 mm in diameter and 45 to 60 cm
long, rounded at one end.
c) A balance of capacity 3 kg, readable and accurate to one gram.
d) The IS Sieve-s of sizes 12.5, 10 and 2.36 mm.
e) A compression-testing machine capable of applying a load of 50 tones and which can be
operated to give a uniform rate of loading so that the maximum load in any test is reached in
10 minutes. This load may vary from 0.5 to 50 tones.
f) For measuring the sample, a cylindrical metal measure of sufficient rigidity to retain its
form under rough usage and of the following
Internal dimensions:
Diameter 11.5 cm
Height 18.0 cm
g) Means of measuring the reduction in the distance between the platens of the testing
machine to the nearest one millimeter during the test (for example, a dial gauge).

Preparation of Test Sample

The material for the test shall consist of aggregate passing a 12.5-mm IS Sieve and
retained on a 10-mm IS Sieve and shall be thoroughly separated on these sieves before
testing.
The aggregate shall be tested in a surface-dry condition. If dried by heating, the period
of drying shall not exceed four hours, the temperature shall be 100 to 110°C and the
aggregate shall, be cooled to room temperature before testing.
The appropriate quantity may be found conveniently by filling the cylindrical measure
in three layers of approximately equal depth, each layer being tamped 25 times with the
tamping rod and finally levelled off, using the tamping rod as a straight-edge, care being
taken in the case of weaker materials not to break the particles.
The weight of material comprising the test sample shall be determined (Weight A)
and the same weight of sample shall be taken for the repeat test.
NOTE - About 6.5 kg of natural aggregate is required to provide the two test samples.
Less of lightweight aggregate is required.

Test Procedure

The cylinder of the test apparatus shall be put in position on the base-plate and the test
sample added in thirds, each third being subjected to 25 strokes from the tamping rod, care
being taken in the case of weak materials not to break the particles. The surface of the
Aggregate shall be carefully levelled and the plunger inserted so that rests horizontally on this
surface, care being taken to ensure that the plunger does not jam in the cylinder.
The apparatus, with the test sample and plunger in position, shall then be placed in the
compression-testing machine. The load shall be applied at a uniform rate to cause a total
penetration of the plunger in 10 minutes of about:
15.0 mm for rounded or partially rounded aggregates (for example, uncrushed
gravels),
20.0 mm for normal crushed aggregates, and
24.0 mm for honeycombed aggregates (for example, expanded shales and slags).
These figures may be varied according to the extent of the rounding or Honeycombing.

After reaching the required maximum penetration, the load shall be released and the
whole of the material removed from the cylinder and sieved on a 2.36-mm IS Sieve. The
fines passing the sieve shall be weighed, and this weight expressed as a percentage of the
weight of the test sample. Normally, this percentage will fall within the range 7.5 to 12.5, but
if it does not, a further test shall be made at a load adjusted as seems appropriate to bring the
percentage fines within the range of 7.5 to 12.5.

A repeat test shall be made at the load that gives a percentage fines within the range 7.3 to
12.5.

Calculations

The mean percentage fines from the two tests at this load shall be used in the following
formula to calculate the load required to give 10 percent fines:

14 Xx
Load required for 10 percent fines =
y+4
where
x = load in tones, and
y = mean percentage fines from two tests at x tones load.
Reporting of Results

The load required to produce 10 percent fines shall be reported to the nearest whole number
for loads of 10 tons or more, the nearest 0.5 tone for loads of less than 10 tones.

1.9 DETERMINATION OF AGGREGATE IMPACT VALUE

Object

This method of test covers the procedure for determining the aggregate impact value of
coarse aggregate.
NOTE -The ‘aggregate impact value’ gives a relative measure of the resistance of an
aggregate to sudden shock or impact, which in some aggregates differs from its resistance to
a slow compressive load.

Apparatus

a) An impact-testing machine of the general form and complying with the following:

1) Total weight not more than 60 kg nor less than 45 kg.

2) The machine shall have a metal base weighing between 22 and 30 kg with a plane lower
surface of not less than 30 cm diameter, and shall be supported on a level and plane concrete
or stone block or floor at least 45 cm thick. The machine shall be prevented from rocking
either by fixing it to the block or floor or by supporting it on a level and plane metal plate cast
Into the surface of the block or floor.
3) A cylindrical steel cup of internal dimensions:
Diameter 102 mm
Depth 50 mm
and not less than 6.3 mm thick with its inner surface casehardened, that can be rigidly
fastened at the center of the base and easily removed for emptying.
4) A metal tup or hammer weighing 13.5 to 14.0 kg, the lower end of which shall be
cylindrical in shape, 100 mm in diameter and 5 cm long, with a 2-mm chamfer at the lower
edge, and case-hardened. The hammer shall slide freely between vertical guides so arranged
that the lower (cylindrical) part of the hammer is above and concentric with the cup.
5) Means for raising the hammer and allowing it to fall freely between the vertical guides
from a height of 380 +/- 5 mm on to the test sample in the cup, and means for adjusting the
height of fall within 5 mm.
6) Means for supporting the hammer whilst fastening or removing the cup.
NOTE - Some means for automatically recording the number of blows is desirable.
b) Sieves-The IS Sieves of sizes 12.5, 10 and 2.36 mm.
c) Measure - A cylindrical metal measure, tared to the nearest gram, of sufficient rigidity to
retain its form under rough usage, and of the following internal dimensions:
Diameter 75 mm
Depth 50 mm
d) Tamping Rod - A straight metal tamping rod of circular cross-section 10 mm in diameter
and 230 mm long, rounded at one end.
e) Balance - A balance of capacity not less than 500 g, readable and accurate to 0.1 g.
f) Oven - A well-ventilated oven, thermostatically controlled to maintain a temperature of
100 to 110°C.
Preparation of the Test Sample

The test sample shall consist of aggregate the whole of which passes a 12.5-mm IS
Sieve and is retained on a 10-mm IS Sieve. The aggregate comprising the test sample shall be
dried in an oven for a period of four hours at a temperature of 100 to 110°C and cooled.
The measure shall be filled about one-third full with the aggregate and tamped with
25 strokes of the rounded end of the tamping rod. Further similar quantity of aggregate shall
be added and a further tamping of 25 strokes given. The measure shall finally be fined to
overflowing, tamped 25 times and the surplus aggregate struck off, using the tamping rod as a
straightedge. The net weight of aggregate in the measure shall be determined to the nearest
gram (Weight A) and this weight of aggregate shall be used for the duplicate test on the same
material.

Test Procedure

The impact machine shall rest without wedging or packing upon the level plate, block
or floor, so that it is rigid and the hammer guide columns are vertical.
The cup shall be fixed firmly in position on the base of the machine and the whole of
the test sample placed in it and compacted by a single tamping of 25 strokes of the tamping
rod.
The hammer shall be raised until its lower face is 380 mm above the upper surface of
the aggregate in the cup, and allowed to fall freely on to the aggregate. The test sample shall
be subjected to 15 such blows each being delivered at an interval of not less than one second.
The crushed aggregate shall then be removed from the cup and the whole of it sieved
on the 2.36-mm IS Sieve until no further significant amount passes in one minute. The
fraction passing the sieve shall be weighed to an accuracy of 0.1 g (Weight. B). The fraction
retained on the sieve shall also be weighed (Weight C) and, if the total weight (B+C) is less
than the initial weight (Weight A) by more than one gram, the result shall be discarded and a
fresh test made. Two tests shall be made.

Calculations

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

B
Aggregate impact value = X 100
A

Where
B = Weight of fraction passing 2.36-mm IS Sieve, and
A = weight of oven-dried sample.

Reporting of Results

The mean of the two results shall be reported to the nearest whole number as the aggregate
impact value of the tested material.

1.10 DETERMINATION OF SURFACE MOISTURE

Ref: CPWD Spec 4.1.1.5

Procedure

Take a sample of wet aggregate and weigh it (A). Then place it in a frying pan and gently
apply heat, meanwhile stirring with a glass rod until the surface moisture disappears. This is
apparent when the aggregate loses its shining wet appearance and becomes dull, or when it
just attains a free funning condition. The saturated surface dry material is then weighed (B).
Continue the heating thereafter until the moisture is evaporated and weigh the dry sample
(C).

The surface moisture is then calculated as follows:

A−B
Surface moisture = = X 100
C

It is expressed as a percentage of dry aggregate.

2. FINE AGGREGATE FOR CONCRETE

2.1 SIEVE ANALYSIS – Ref 1.1

2.2 MATERIALS FINER THAN 75 MICRON – Ref 1.2

2.3 DENSITY & VOIDS – Ref 1.6

2.4 DETERMINATION OF SURFACE MOISTURE CONTENT – Ref 1.10

2.4 SPECIFIC GRAVITY & WATER ABSORPTION FOR FINE AGGREGATE

Object

This test covers the procedures for determining the specific gravity, apparent specific
gravity and water absorption of fine aggregates.

Apparats

Balance - A balance or scale of capacity not less than 3 kg, readable and accurate to 0.5 g,
and of such a type as to permit the weighing of the vessel containing the aggregate and water.
Oven - A well-ventilated oven, thermostatically controlled, to maintain a temperature of 100
to 110°C.
Vessel - Any form of vessel capable of holding 0.5 to 1 kg of material up to 10 mm in size
and capable of being filled with water to a constant volume with an accuracy of +/- 0.5 ml.
either of the two following vessels is suitable:
1) A glass vessel, referred to later as a pycnometer, of about one litre capacity having
a metal conical screw top with a 6-mm diameter hole at its apex. The screw top shall be
watertight when it is screwed on to the jar, and, if necessary, a rubber or fibre washer shall be
inserted in the joint. If such a washer is used, a mark shall be made on the jar to correspond
with a mark on the screw top so that the screw is tightened to the same position every time
and the volume contained by the jar is constant throughout the test. A suitable vessel can be
made from a 1 kg fruit preserving jar in which the glass lid normally used is replaced by a
sheet metal cone or
2) A wide-mouthed glass vessel, such as a gas jar, of about 1.25 litres capacity, with a
flat ground lip and a plane ground disc of plate glass to cover it, giving a virtually watertight
fit.
d) A means of supplying a current of warm air, such as a hair drier.
e) A tray of area not less than 325 cm2.
f) An airtight container large enough to take the sample.
g) Filter papers and funnel.

Test Procedure

Using the pycnometer - A sample of about 1 kg for 10 mm to 4.75 mm or 500 g if

finer than 4.75 mm, shall be placed in the tray and covered with distilled water at a
temperature of 22 to 32°C. Soon after immersion, air entrapped in or bubbles on the surface
of the aggregate shall be removed by gentle agitation with a rod. The sample shall remain
immersed for 24 +/- 1/2 hours.
The water shall then be carefully drained from the sample, by decantation through a
filter paper, any material retained being return& to the sample. The aggregate including any
solid matter retained on the filter paper shall be exposed to a gentle current of warm air to
evaporate surface moisture and shall be stirred at frequent intervals to ensure uniform drying
until no free surface moisture can be seen and the material just attains a ‘free-running’
condition. Care shall be taken to ensure that this stage is not passed. The saturated and
surface-dry sample shall be weighed (weight A).
Note- If the apparent specific gravity only is required, the operations described in this
paragraph may he omitted, although for material finer & 475 mm some surface drying may
be desirable to facilitate handling.
The aggregate shall then be placed in the pycnometer, which shall be filled with
distilled water. Any trapped air shall be eliminated by rotating the pycnometer on its side, the
hole in the apex of the cone being covered with a finger. The pycnometer shall be topped up
with distilled water to remove any froth from the surface and so that the surface of the water
in the hole is flat. The pycnometer shall be dried on the outside and weighed (weight B).
The contents of the pycnometer shall be emptied into the tray, care being taken to
ensure that all the aggregate is transferred. The pycnometer shall be refilled with distilled
water to the same level as before, dried on the outside and weighed (weight C). The
difference in the temperature of the water in the pycnometer during the first and second
weighings shall not exceed 2°C.
The water shall then be carefully drained from the sample by decantation through a
filter paper and any material retained returned to the sample. The sample shall be placed in
the oven in the tray at a temperature of 100 to 110°C for 24 +/- l/2 hours, during which period
it shall be stirred occasionally to facilitate drying. It shall be cooled in the air-tight container
and weighed (weight D).
Two tests shall be made.
Using the second (gas jar) apparatus described in section C of Apparatus, the
procedure shall be the same except that in filling the jar with water it shall be tilled just to
overflowing and the glass plate slid over it to exclude any air bubbles.

Calculations

Specific gravity, apparent specific gravity and water &sorption shall be calculated as
follows:
D
Specific gravity =
A−(B−C)

D
Apparent specific gravity =
D−( B−C )

100 X ( A− D)
Water Absorption (percent of dry Weight) =
D
where
A = weight in g of saturated surface-dry sample,
B = weight in g of pycnometer or gas jar containing sample and filled with distilled water,
C = weight in g of pycnometer or gas jar filled with distilled water only, and
D = weight in g of oven-dried sample.

Reporting of Results
The individual and mean results shall be reported and the grading of the aggregate shall be
stated.

2.5 DETERMINATION OF SILT CONTENT

Ref: CPWD spec 3.1.3.2

Test Procedure

A sample of sand to be tested shall be placed without drying in a 200 ml measuring

cylinder. The volume of the sample shall be such that it fills the cylinder upto 100 ml mark
Clean water shall be added upto 150 ml mark. Dissolve a little salt in the water in the
proportion one tea spoon to half a litre. The mixture shall be shaken vigorously, the last few
shakes being sidewise direction to level off the sand and the contents allowed to settle for
three hours.
The height of the silt visible as settled layer above the sand shall be expressed as a
percentage of the height of sand below. The sand containing more than the above allowable
percentage of silt, shall be washed to bring the silt contents within allowable limits.
The sand shall not contain more than 8% of silt as determined by field test with
measuring cylinder

3. FINE AGGREGATE FOR MASONRY MORTAR

3.1 SIEVE ANALYSIS – Ref 1.1

3.2 DETERMINATION OF SILT CONTENT - Ref 2.5

4. FINE AGGREGATE FOR PLASTER

4.1 SIEVE ANALYSIS – Ref 1.1

4.2 DETERMINATION OF SILT CONTENT - Ref 2.5

5 REINFORCEMENT BARS & COUPLERS

5.1 REINFORCEMENT BARS

5.1.1 Delivery & Inspection

Manufacturer’s Certificate

In the case of bar/wires which have not been inspected at the manufacturer’s works,
the manufacturer or supplier, as the case maybe, shall supply the purchaser or his authorized
representative with the certificate stating the process of manufacture and also the test sheet
signed by the manufacturer giving the result of each mechanical test applicable to the
material purchased, and the chemical composition, if required. Each test certificate shall
indicate the number of the cast to which it applies, corresponding to the number or
identification mark to be found on the material. The test certificate shall contain the following
information:

a) Place of manufacture of the reinforcing steel,

b) Nominal diameter of the steel,
c) Grade of the steel,
d) Rolled-in marking on the steel,
e) Cast/heat number,
f) Date of testing,
g) Mass of the tested lot, and
h) Individual test results for all the properties,

Identification and Marking

The manufacturer or supplier shall have ingots, billets and bars or bundles of
barskvires marked in such a way that all finished barshvires can be traced to the cast from
which they were made. Every facility shall be given to the purchaser or his authorized
representative for tracing the barslwires to the cast from which they were made.
For each bundlelcoil of barslwires a tag shall be attached indicating castilot number,
grade and size.
All bars/wires should be identifiable by marks/ brands introduced during rolling
which indicate the name of the manufacturer or their brand name.
Identification marks like brand name, tiade-mark, etc, that are introduced during
rolling shall be designed and located in such a manner that the performance in use of the bar
is not affected.

BIS Certification Marking

Each bundle containing the barsfwires may also be suitablymarkedwith the

StandardMark in whichcase the concerned test certificate shall also bear the standard Mark.
The use of the Standard Mark is governed by the provisions of the Bureau ofindian
Standards Act, 1986 and the Rules and Regulations made thereunder. The details of
conditions under which a license for the use of Standard Mark may be granted to
manufacturers or producers may be obtained from the Bureau of Indian Standard

5.1.2 Mass per Running Meter

To test Mass per running meter, the random samples of 1 m length of 3 no’s shall be
cut from the delivered material and the weight hall be as per the below table.
 Tolerance on Nominal Mass
Tolerance on nominal mass in
Sl percent
Nominal Size in mm
no Individual
Batch
sample
1 Up to and including 10 +/- 7 -8

2 Over 10 up to and including 16 +/- 5 -6

3 Over 16 +/- 3 -4
       

5.2 REINFORCEMENT COUPLERS

5.2.1 Delivery & Inspection

Identification and Marking

Each reinforcement coupler shall be indelibly and clearly marked indicating the class
designation and nominal size and grade of reinforcing bar for which it is intended. The
manufacturer or supplier shall mark the reinforcement coupler in such a way that all finished
reinforcement couplers can be traced to the original cast from which they were made along
with the date of manufacture. Every facility shall be given to the purchaser or his authorized
representative for tracing the reinforcement couplers to the cast from which they were made.
Each coupler should be identifiable by marks/ brands which indicate the name of the
manufacturer or their brand name.

BIS Certification Marking

The reinforcement coupler may also be marked with the Standard Mark. The use of
the Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 1986
and the Rules and Regulations made thereunder. The details of conditions under which a
license for the use of the Standard Mark may be granted to manufacturers or producers may
be obtained from the Bureau of Indian Standards.

5.2.2 Visual Inspection

No Formation of rust. Uniformity and number of pitch required. All samples must be
plugged with PVC caps.
6. CEMEMT

6.1 DETERMINATION OF FINENESS BY DRY SIEVING

Object

This section covers the procedure for determining the fineness of cement by dry
sieving as represented by the mass of residue left on a standard 90 micron IS Sieve.

Principle

The fineness of cement is measured by sieving it on standard sieve. The proportion of

cement of which the grain sizes are larger than the specified mesh size is thus determined.
A reference sample having a known proportion of material coarser than the specified
mesh size is used for checking the specified sieve.

Apparatus

Test Sieve - It comprises a firm, durable, non-corrodible, cylindrical frame of 150 mm to 200
mm nominal diameter and 40 mm to 100 mm depth, fitted with 90-micron mesh sieve cloth
of woven stainless steel, or other abrasion-resisting and non-corrodible metal wire.

The sieve cloth shall comply with the requirements of IS 460 (Part 1): 1985 and IS
460 (Part 3): 1985 and shall be free of visible irregularities in mesh size when inspected
optically by the methods of IS 460 ( Part 3 ) : 1985. A tray fitting beneath the sieve frame and
a lid fitting above it shall be provided to avoid loss of material during sieving.

Balance - Capable of weighing up to 10 g to the nearest 10 mg.

Brush - A nylon or pure bristle brush, preferably with 25 to 40 mm bristle, for cleaning the
sieve.

Material for Checking the Sieve - A Standard reference material of known sieve residue shall
be used for checking the sieve.
The material shall be stored in sealed, airtight containers to avoid changes in its
characteristics due to absorption or deposition from the atmosphere. The containers shall be
marked with the sieve residue of the reference material.

Procedure

Determination of the Cement Residue

Agitate the sample of cement to be tested by shaking for 2 min in a stoppered jar to
disperse agglomerates. Wait 2 min. Stir the resulting powder gently using a clean dry rod in
order to distribute the fines throughout the cement. Fit the tray under the sieve, weigh
approximately 10 g of cement to the nearest 0.01 g and place it on the sieve, being careful to
avoid loss. Disperse any agglomerates. Fit the lid over the sieve. Agitate the sieve by
swirling, planetary and linear movement until no more fine material passes through it.
Remove and weigh the residue. Express its mass as a percentage, R1, of the quantity first
placed in the sieve to the nearest 0.1 percent. Gently brush all the fine material off the base of
the sieve into the tray. Repeat the whole procedure using a fresh 10 g sample to obtain R2.
Then calculate the residue of the cement R as the mean of R1 and R2 as a percentage,
expressed to the nearest 0.1 percent. When the results differ by more than 1 percent absolute,
carry out a third sieving and calculate the mean of the three values. The sieving process is
carried out manually by a skilled and experienced operator.

NOTE - Alternatively, a sieving machine may be used if it can be shown to give the same
results as the manual operation.

Checking the Sieve

Agitate the sample of cement to be tested by shaking for 2 min in a stoppered jar to
disperse agglomerates. Wait 2 min. Stir the resulting powder gently using a clean dry rod in
order to distribute the fines throughout the cement.
Fit the tray under the sieve. Weigh approximately 10 g of the reference material to the
nearest 0.01 g and place it in the sieve, being careful to avoid loss. Carry out the sieving
procedure as above including the repeat determination of residue to yield two values P1 and
P2 expressed to the nearest 0.1 percent.
The two values of P1 and P2 for a satisfactory sieve should differ by not more than
0.3 percent. Their mean P characterizes the state of the sieve. Given the known residue on the
90 micron mesh of the reference material, Ro, calculate Ro/P as the sieve factor, F, expressed
to the nearest 0.01. The residue, R, determined as above shall be corrected by multiplying by
F, which may have a value of 1.00 +/- 0.20

Check the sieve after every 100 sieving.

NOTE - Any other checking procedure, such as the optical methods described in IS 460 (Part
3): 1985 may be used. All sieves will wear slowly and consequently their sieve factor, F, will
slowly change.

Expression of Results

Report the value of R, to the nearest 0. 1 percent, as the residue on the 90 micron
sieve for the cement tested. The standard deviation of the repeatability is about 0.2 percent
and of the reproducibility is about 0.3 percent.
6.2 NORMAL CONSISTENCY

Object
This test covers the procedure for determining the quantity of water required to
produce a cement paste of standard consistency.

Temperature and Humidity

The temperature of moulding room, dry materials and water shall be maintained at 27
+/- 2°C. The relative humidity of the laboratory shall be 65 +/- 5 percent.

Apparatus

Vicat Apparatus -Vicat apparatus conforming to IS 5513-1976.

Balance - The balance shall conform to the following requirements.

On balance in use, the permissible variation at a load of 1000 g shall be plus or minus
1.0 g. The permissible variation on new balance shall be one-half of this value. The
sensibility reciprocal shall not be greater than twice the permissible variation.

NOTE 1 -The sensibility reciprocal is generally defined as the change in load required to
change the position of rest of the indicating element or elements of a non-automatic
indicating scale a definite amount at any load
NOTE 2 - Self-indicating balance with equivalent accuracy may also be used.

Gauging Trowel - Gauging trowel conforming to IS 10086: 1982

Procedure

The standard consistency of a cement paste is defined as that consistency which will
permit the Vicat plunger G shown in IS : 5513-l 976 to penetrate to a point 5 to 7 mm from
the bottom of the Vicat mould when the cement paste is tested as described in following.

Prepare a paste of weighed quantity (Usually 300 g) of Cement with a weighed

quantity of potable or distilled water (start with 28% of water in weight of cement), taking
care that the time of gauging is not less than 3 minutes, nor more than 5 min, and the gauging
shall be completed before any sign of setting occurs. The gauging time shall be counted from
the time of adding water to the dry cement until commencing to fill the mould. Fill the Vicat
mould with this paste, the mould resting upon a non-porous plate. After completely filling
the mould, smoothen the surface of the paste, making it level with the top of the mould. The
mould may be slightly shaken to expel the a.ir.

Clean appliances shall be used for in filling the mould, the operator’s hands and the
blade of the gauging trowel shall alone be used.
 Place the test block in the mould, together with the non-porous resting plate, under the
rod bearing the plunger; lower the plunger gently to touch the surface of the test block, and
quickly release, allowing it to sink into the paste. This operation shall be carried out
immediately after filling the mould.

Prepare trial pastes with varying percentages of water and test as described above
until the amount of water necessary for making up the standard consistency as defined is
found.

Calculation

Express the amount of water as a percentage by mass of the dry cement to the first
place of decimal.

6.3 DETERMINATION OF INITIAL & FINAL SETTING TIME

Object

This section covers the procedure for determining the initial and final setting times of
cement.

Temperature and Humidity

The temperature of moulding room, dry materials and water shall be maintained at 27
± 2°C. The relative humidity of the laboratory shall be 65 ± 5 percent.

The moist closet or moist room shall be maintained at 27 ± 2°C and at a relative
humidity of not less than 90 percent.

Apparatus

Vicat Apparatus — Vicat apparatus conforming to IS: 5513-1976.

Balance — the balance shall conform to the following requirements:
On balance in use, the permissible variation at a load of 1000 g shall be ± 1.0 g. The
Permissible variation on new balance shall be one-half of this value. The sensibility
reciprocal shall be not greater than twice the permissible variation.

NOTE 1 — The sensibility reciprocal is generally defined as the change in load required to
change the position of rest of the indicating element or elements of a non-automatic
indicating scale a definite amount at any load.
NOTE 2 — Self-indicating balance with equivalent accuracy may also be used
Gauging Trowel — gauging trowel conforming to IS: 10086-1982.
Procedure

Preparation of Test Block

Prepare a neat cement paste by gauging the cement with 0.85 times the water required
to give a paste of standard consistency. Potable or distilled water shall be used in preparing
the paste. The paste shall be gauged in the manner and under the conditions prescribed in
Normal Consistency test Procedure. Start a stopwatch at the instant when water is added to
the cement. Fill the Vicat mould with a cement paste gauged as above, the mould resting on a
nonporous plate. Fill the mould completely and smooth off the surface of the paste making it
level with the top of the mould. The cement block thus prepared in the mould is the test
block.

Immediately after moulding, place the test block in the moist closet or moist room and
allow it to remain there except when determinations of time of setting are being made.
NOTE 1 — Clean appliances shall be used for gauging.
NOTE 2 — All the apparatus shall be free from vibration during the test.
NOTE 3 — Care shall be taken to keep the needle straight.

Determination of Initial Setting Time

Place the test block confined in the mould and resting on the non-porous plate, under
the rod bearing the needle ( C ); lower the needle gently until it comes in contact with the
surface of the test block and quickly release, allowing it to penetrate into the test block. In.
the beginning, the needle will completely pierce the test block. Repeat this procedure until the
needle, when brought in contact with the test block and released as described above, fails to
pierce the block beyond 5.0 ± 0.5 mm measured from the bottom of the mould. The period
elapsing between the time when water is added to the cement and the time at which the
needle fails to pierce the test block to a point 5.0 ± 0.5 mm measured from the bottom of the
mould shall be the initial setting time

Determination of Final Setting Time

Replace the needle ( C ) of the Vicat apparatus by the needle with an annular
attachment ( F ). The cement shall be considered as finally set when, upon applying the
needle gently to the surface of the test block, the needle makes an impression thereon, while
the attachment fails to do so. The period elapsing between the time when water is added to
the cement and the time at which the needle makes an impression on the surface of test block
while the attachment fails to do so shall be the final setting time. In the event of a scum
forming on the surface of the test block, use the underside of the block for the determination.

Reporting Of Results
The results of initial and final setting time shall be reported to the nearest five minutes.

6.4 COMPRESSION STRENGTH TEST

Object

This section covers the procedure for determining the strength of cement as
represented by compressive strength tests on mortar cubes compacted by means of standard
vibration machine.

Temperature and Humidity

The temperature of moulding room, dry materials and water shall be maintained at 27
± 2°C. The relative humidity of the laboratory shall be 65 ± 5 percent.
The moist closet or moist room shall be maintained at 27± 2°C and at a relative
humidity of not less than 90 percent.

General
Standard Sand. - The standard sand, to be used in the test shall conform to IS 650·1966·.

Apparatus

Vibration Machine - Vibration machine conforming to IS 10080-1982.

Poking Rod - Poking rod conforming to IS 10080-1982.
Cube Mould- The mould shall be of 70.6, mm size conforming to IS 10080-1982.
Gauging Trowel - Gauging trowel shall have a steel blade 100 to 150 mm in length with
straight edges weighing 210 ± 10 g.
Balance - The balance shall conform to the following requirements:

On balance in use, the permissible variation at a load of 1000 g shall be ± 1.0 g. The
permissible variation on new balance shall be one-half of this value. The sensibility
reciprocal shall be not greater than twice the permissible variation.

Non: 1 - The sensibility reciprocal is generally defined as the change in load required to
change the position of rest of the indicating element or elements at a non-automatic indicating
scale a definite amount of any load.
NOTE 2 - Self-indicating balance with equivalent accuracy may also be used.

Graduated Glass Cylinders

Graduated glass cylinders of 150 to 200 ml capacity. The permissible variation on

these cylinders shall be ± I ml. The main graduation lines of the cylinders shall be in circles
and shall be numbered. The least graduations shall extend at least one seventh of the way
around, and, intermediate graduations shall extend at least one-fifth of the way around the
cylinder. The graduation lines may be omitted for the lowest 5 ml.

Preparation of Test Specimens

Mix Proportions and Mixing

Clean appliances shall be used for mixing and the temperature of water and that of the
test room at the time when the above operations are being performed shall be 27 ± 2°C.
Potable distilled water shall be used in preparing the cubes.
The material for each cube shall be mixed separately/and the quantity of cement,
standard sand and water shall be as follows:
Cement 200g
Standard sand 600 g
P
Water +3.0 percent of combined mass of cement and sand, whether P is the
4
percentage of water required to produce a paste of standard consistency determined as
described in 6.2

Place on a nonporous plate, a mixture of cement and standard sand, Mix it dry with a
trowel for one minute and then with water until the mixture is of uniform color. The quantity
of water to be used shall be as specified above. The time of mixing shall in any event be not
less than 3 min and should the time taken to obtain a uniform color exceed 4 min, the mixture
shall be rejected and the operation repeated with a fresh quantity of cement, sand and water.

Moulding Specimens

In assembling the moulds ready for use, cover the joints between the halves of the
mould with a thin film of petroleum jelly and apply a similar coating of petroleum jelly
between the contact surfaces of the bottom of the mould and its base plate in order to ensure
that no water escapes during vibration. Treat the interior faces of the mould with a thin
coating of mould oil.

Place the assembled mould on the table of the vibration machine and hold it firmly in
position by means of a suitable clamp. Attach a hopper of suitable size and shape securely at
the top of the mould to facilitate filling and this hopper shall not be removed until the
completion of the vibration period.

Immediately after mixing the mortar in accordance with above , place the mortar in
the cube mould and prod with the rod specified in Apparatus The mortar shall be prodded 20
times in about 8 s to ensure elimination of entrained air and honeycombing. Place the
remaining quantity of mortar in the hopper of the cube mould and prod again as specified for
the first layer and then compact the mortar by vibration.
 The period of vibration shall be two minutes at the specified speed of 12 000 ± 400
vibration per minute.

At the end of vibration, remove the mould together with the base plate from the
machine and finish the top surface of the cube in the mould by smoothing the surface with the
blade of a trowel.

Curing Specimen

Keep the filled moulds in moist closet or moist room for 24 hours after completion of
vibration. At the end of that period, remove them from the moulds and immediately submerge
in clean fresh water and keep there until taken out just prior to breaking. The water in which
the cubes are submerged shall be renewed every 7 days and shall be maintained at a
temperature of 27 ± 2°C. After they have been taken out and until they are broken, the cubes
shall not be allowed to become dry.

Testing

Test three cubes for compressive strength for each period of curing mentioned under
the relevant specifications for different hydraulic cements, usually 3, 7, 28 days. The periods
being reckoned from the completion of vibration.

The cubes shall be tested on their sides without any packing between the cube and the
steel plattens of the testing machine. One of the plattens shall be carried on a base and shall
be self-adjusting, and the load shall be steadily and uniformly applied, starting from zero at a
rate of 35 N/mm2/min.

Calculation

The measured compressive strength of the cubes shall be calculated by dividing the
maximum load applied to the cubes during the test by the cross-sectional area, calculated
from the mean dimensions of the section and shall be expressed to the nearest 0.5 N/mm, In
determining the compressive strength, do not consider specimens that are manifestly faulty,
or that give strengths differing by more than 10 percent from the average value of all the test
specimens. After discarding specimens or strength values, if less than two strength values are
left for determining the compressive strength at any given period, a retest shall be made.

7. GGBS

7.1 Normal Consistency – Ref 6.2

7.2 Initial & Final Setting time – Ref 6.3

7.3 Compressive strength

For compressive strength the method described in 6.4 shall be followed. For
preparation of sample, the following method shall be adopted for GGBS.

Preparation of Sample

Mix Proportions and Mixing

Clean appliances shall be used for mixing and the temperature of water and that of the
test room at the time when the above operations are being performed shall be 27 ± 2°C.
Potable distilled water shall be used in preparing the cubes.
The material for each cube shall be mixed separately/and the quantity of GGBS,
Cement, standard sand and water shall be as follows:
Cement + GGBS 200g (70% OPC 43 & 30% GGBS)
Standard sand 600 g
P
Water +3.0 percent of combined mass of cement and sand, whether P is the
4
percentage of water required to produce a paste of standard consistency determined as
described in 6.2
Moulding the samples, Curing, Testing & Calculation shall be followed same as 6.4

7.4 Fineness by Wet Sieving (45 Micron)

Scope

This section covers the procedure for determining the fineness of cement by wet
sieving as represented by the mass of the residue left on a standard 45micron IS Sieve.

Temperature

The temperature of the room and the materials shall preferably be maintained at 27 +/-
2”C.

Apparatus

Sieve- The sieve frame shall be of non-corrodible material and shall be circular 50 +/- 5 mm
in diameter. The depth of the sieve from the top of the frame to the cloth shall be 75 +/- 5
mm. The frame shall have either sidewalls 90 +/- 5 mm in total height or legs of sufficient
length, 12.0 mm minimum, to allow air circulation beneath the sieve cloth. The sieve frame
shall be fitted with 45 micron stainless steel woven wire cloth sieve conforming to IS 460
(Part 1): 1985. The cloth shall be mounted in the frame without distortion, looseness or
wrinkling. For a sieve fabricated by soldering the cloth to the frame, the joint shall be made
smooth to prevent the cement from catching in the joints between the sieve cloth and frame.
Two-piece sieves shall clamp tightly on the cloth to prevent the cement from catching in the
joints between the sieve cloth and the frame.

Spray Nozzle - The spray nozzle shall be constructed with non-corrodible material and shall
be of 17.5 mm inside diameter with a central hole drilled in line with the longitudinal axis,
and intermediate row of eight holes drilled 6 mm center to center at an angle of 5 degree from
the longitudinal axis, and an outer row of eight holes drilled 11 mm centre to centre at an
angle of 10 degree from the longitudinal axis. All holes shall be of 0.5 mm diameter.

Pressure Gauge - The pressure gauge shall be of 75 mm minimum diameter and shall be
graduated in 0.01 N/mm3 increments and shall have a maximum capacity of 0.2 N/mm’ with
a marking at 0.07 N/mm. The accuracy at 0.07 N/mm2 shall be 0.005 N/mm2.

Balance - Analytical balance capable of reproducing results within 0.0002 g with an accuracy
of +/- 0.000 2 g.
NOTE -- Self indicating balance with equivalent accuracy may also be used.

Standard Weights
Oven

Calibration of 45 Micron Is Sieve

The calibration of the 45-micron sieve shall be made using standard reference material
(SRM) from National Council of Cement and Building Materials. Place 1.000 g of the SRM
on the clean dry 45 micron sieve and proceed as in “procedure” The sieve correction factor is
the difference between the test residue obtained and the assigned residue value indicated by
the electro-formed sheet sieve fineness specified for the standard sample, expressed as a
percentage of the test residue. The sieve shall be re-calibrated after every 100 determinations.

Example:
Residue on 45 micron IS Sieve of 14.0 percent SRM sample
Residue for a 1 g sample 0.140 g
Residue on Sieve being calibrated 0.105 g
Difference +0.035 g
Correction factor 0.35*100/0.105 = +33.3 %

Procedure

Place 1’000 g of sample of the cement on a clean, dry 45 micron IS Sieve. Wet the
sample thoroughly with a gentle stream of water. Remove the sieve from under the nozzle
and adjust the pressure on the spray nozzle to 0.07 +/- 0.005 N /mm2. Return the sieve to its
position under the nozzle and wash for one minute, moving the sieve with a circular motion
in a horizontal plane at the rate of one motion per second in the spray. The bottom of the
spray nozzle shall extend below the top of the sieve frame by about 12 mm. Immediately
upon removing the sieve from the spray, rinse once with 50 ml of distilled water, taking care
not to lose any of the residue, and then blot the lower surface gently upon a damp cloth. Dry
the sieve and residue in an oven or over a hot plate (see Note), supporting the sieve in such a
manner that air may pass freely beneath it. Cool the sieve, brush the residue from the sieve
and weigh.

NOTE - Care should be taken not to heat the sieve hot enough to soften the solder.

Calculation

Calculate the mass of the residue of the cement left on the standard 45 micron IS Sieve to the
nearest 0.1 percent as follows:

Rc= Rs x (100+C)
where
Rc = corrected residue in percent,
Rs = residue of the sample retained on the 45 micron IS Sieve in g, and
C = sieve correction factor which may be
Either plus or minus.

Example :

Sieve correction factor, C = + 33’3 percent

Residue from sample being tested, Rs = 0’092 g
Corrected residue = 0.092 x (100 + 33’3 ) = 12.3 percent

8. Water Reducing Admixture

8.1 Delivery & Inspection

Each container of admixture shall be legibly marked with the following information:
a) Identification of the source of manufacture,
b) Year and date of manufacture,
c) Type of admixture, that is, whether accelerating, retarding, water reducing, air
entraining, Normal super plasticizing or retarding super plasticizing,
d) Batch Number, and
e) Chloride ion content
Additional Information

The manufacturer in a printed form shall provide the following information

a) Physical State (that is, liquid or solid) and color;
b) Composition;
 1) Generic type of main active constituent(s), for example, lignosulphonate, organic
hydroxycarboxylic acid or carbohydrate;
ii) Dry material content;
iii) Ash content;
iv) Relative density of liquid admixture;
v) Chloride iron content, expressed as a percentage by mass of total admixture;
c) The chloride ion content relative to the cement mass contributed by the recommended
dosage or dosages expressed as percentage by mass of chloride ion
d) Recommended storage conditions, maximum storage time before use and necessary safety
precautions, for example, toxic or corrosive
e) Any known incompatibility with other admixture or with certain types of cement etc.
r) The recommended dosage or dosages;
g) The effect of under dosage and over dosages; and
h) Expiry date.

8.2 Relative Density

Apparatus

Following apparatus shall be used:

a) Constant temperature bath,
b) Hydrometer, and
c) Measuring cylinder.

Procedure

Place about 400 ml of admixture in a 500 ml graduated cylinder avoiding the

formation of air bubbles in the liquid. Allow the temperature of the liquid to be 20 +/-5°C.
Hold the temperature of the stem and insert it into the liquid in the cylinder. Insert the
hydrometer into the cylinder in such a way that it floats-free and does not touch the side of
the cylinder. Release the hydrometer when approximately in the equilibrium position. When
it has reached the equilibrium read the scale at the bottom of the meniscus for transparent
liquids or where the meniscus merges with the stem of the hydrometer for opaque liquids to
report the relative density.

9. Ply wood for Concrete Shuttering

9.1 Delivery & Inspection

 The following inspection shall be performed during delivery. The Manufacturer Shall
provide the MTC along with each delivery. The certificate shall cover all the test results as
per IS 4990.

1. Dimension
2. Edge straightness
3. Square ness
4. Nailing Test
Strike nails at minimum 3 locations in 3 samples, pull out with piler. Plywood shall
offer resistance while pulled.no delamination or extra chipping off at point of withdrawal.

9.2 DENSITY & MOISTURE CONTENT

Scope

This section covers the method of test for the determination of density and moisture
content of plywood by oven dry method.

Object

The object of this test is to determine the density of plywood, which is an indicator of
the properties of timber species. The determination of moisture content is necessary since it
has a bearing on several important mechanical properties of plywood.

Test Specimen

Each test specimen shall be of the full thickness of the material and 75 mm wide and
150 mm long. Smaller specimens may be used when deemed necessary. The dimensions of
the test specimens shall be measured to an accuracy of not less than ± 0.3 percent.

APPARATUS

Oven — An oven that can be maintained at a temperature of 103 ± 2°C through the drying
chamber for the time required to dry the specimen to constant mass. It may require forced air
circulation to maintain uniform temperature. Oven shall be vented to allow the evaporated
moisture to escape.
Balance — A balance to weigh a specimen within ± 0.2 percent. The accuracy and sensitivity
of the weighing balance shall be checked frequently.

Procedure
 The test specimen shall be weighed. The specimen shall then be dried in an oven at a
temperature of 103 ± 2°C until approximately constant mass is obtained. The specimen shall
be weighed to an accuracy of not less than ± 0.2 percent.

Calculation

The density shall be calculated as follows:

Mo
Density, in g/cm3 =
Lwt
where
Mo = oven dry mass of specimen in g,
L = length of the specimen in cm,
w = width of the specimen in cm, and
t = thickness of the specimen in cm.

Moisture Content — the moisture content shall be calculated as follows:

M 1−Mo
Moisture content, percent =
Mo
M1 = initial mass of specimen, and
Mo = oven-dry mass of specimen.

Precautions
Care shall be taken to prevent any change in moisture content between the cutting of
the sample and first weighing and between the removal from the oven and subsequent
weighing. The specimen may be wrapped in an aluminium foil or polyethylene film to
prevent moisture changes after cutting between consecutive weighing.

NOTE 1 — The moisture content and density, as determined by this method, are the average
values for the entire specimen. In plywood made up of thin veneers, that is, less than 0.8 mm
in thickness, the glue may constitute a significant part of the total mass and as a result the
calculated density and moisture content may vary substantially from the true values for the
veneers. In some instances, it may be desirable to consider this.
NOTE 2 — The density so obtained is based on the volume at test and mass when oven-dry.
If desired, the density may be obtained on an oven-dry mass and volume basis. In each
instance, the basis of the density value with respect to volume and moisture conditions shall
be stated.