Roads Department

Operating Procedures
for Central Materials
Laboratory

Operating Procedures for Central Materials Laboratory 1

 Roads Department

Ministry of Works and Transport

Roads Department
Private Bag 0026
Gaborone, Botswana
Phone + 267 - 3913511
Fax + 267 - 3914278

October 2003
ISBN 99912 - 0 - 451 - 2

Reproduction of extracts from this Guideline may be made subject to due acknowledgement of the source.
Although this Guideline is believed to be correct at the time of printing, Roads Department does not accept any con-
tractual, tortious or other form of liability for its contents or for any consequences arising from its use. Anyone using
the information contained in the Guideline should apply their own skill and judgement to the particular issue under
consideration.

2 Operating Procedures for Central Materials Laboratory

Roads Department

ROADS DEPARTMENT
Under the policy direction of the Ministry of Works and Transport, Roads Department is responsible for providing an
adequate, safe, cost-effective and efficient road infrastructure within the borders of Botswana as well as for facilitating
cross-border road communications with neighbouring countries. Implied in these far ranging responsibilities is the
obligation to:

1. Ensure that existing roads are adequately maintained in order to provide an appropriate level of service for road users;

2. Improve existing roads to required standards to enable them to carry prevailing levels of traffic with the required
degree of safety;

3. Provide new roads to the required geometric, pavement design and safety standards.

The Department has been vested with the strategic responsibility for overall management of the Public Highway Net-
work (PHN) of some 20 000 km of roads. This confers authority for setting of national specifications and standards and
shared responsibility with the District Councils and Department of Wildlife and National Parks for the co-ordinated
planning of the PHN.

Roads Department is also responsible for administering the relevant sections of the Public Roads Act, assisting local
road authorities on technical matters and providing assistance in the national effort to promote citizen contractors in the
road construction industry by giving technical advice wherever possible. This task is facilitated by the publication of a
series of Technical Guidelines dealing with standards, general procedures and best practice on a variety of aspects of the
planning, design, construction and maintenance of roads in Botswana that take full account of local conditions.

Guideline No. 1 The Design, Construction and Maintenance of Otta Seals (1999).
Addendum to Guideline No. 1 Seminar Proceedings (June, 2000).

Guideline No. 2 Pavement Testing, Analysis and Interpretation of Test Data (2000).
Addendum to Guideline No. 2 Seminar Proceedings (January, 2002).

Guideline No. 3 Methods and Procedures for Prospecting for Road Construction Materials (2000).
Addendum to Guideline No. 3 Seminar Proceedings (April, 2002).

Guideline No. 4 Axle Load Surveys (2000).

Addendum to Guideline No. 4 Seminar Proceedings (January, 2002).

Guideline No. 5 Planning and Environmental Impact Assessment of Road Infrastructure (2001).

Guideline No. 6 The Prevention and Repair of Salt Damage to Roads and Runways (2001).
Addendum to Guideline No. 6 Seminar Proceedings (April, 2002).

Guideline No. 7 Technical Auditing of Road Projects (2001).

Addendum to Guideline No. 7 Seminar Proceedings (February, 2004).

Guideline No. 8 The use of Silcrete and Other Marginal Materials for Road Surfacing (2002).
Addendum to Guideline No. 8 Seminar Proceedings (February, 2004).

Operating Procedures for Central Materials Laboratory 3

 Roads Department

FOREWORD
This document sets out quality management and operating procedures for the Government Central Materials Laboratory
(CML) of the Materials and Research Division of the Roads Department.

This Guideline on the operating procedures for Central Materials Laboratory (CML) is a very useful document in that it
captures the experiences gained, over a period of twenty years, both within CML and in commercial Laboratories in and
outside Botswana. CML is the principal materials testing laboratory in Botswana. The quality of services provided by
CML has important influence on the quality of Botswana’s road infrastructure. The laboratory could also be a standard
bearer for the nation’s commercial laboratories.

This manual is intended for daily use of CML staff at all levels for management and operational functions including
outline of test procedures. The primary aim is to maintain quality, consistency and appropriate standards in the testing of
road construction materials.

It is my sincere hope that this guideline will be useful to the Technicians and Engineers especially those deployed to
CML for the first time and will assist in ensuring that the testing procedures are standardised and the results are quality
assured. I trust that this is an important step towards establishing an internationally accepted code of practice on quality
assurance.

Gaborone, October 2003

Andrew Nkaro
Director of Roads
Roads Department
Ministry of Works and Transport

4 Operating Procedures for Central Materials Laboratory

Roads Department

ACKNOWLEDGEMENTS
This Guideline is one of a series that is being produced under the Institutional Co-operation Agreement that exists
between the Roads Department and the Norwegian Public Roads Administration (NPRA). This Agreement falls under a
NORAD Technical Assistance Programme to Roads Department that is co-funded by the Kingdom of Norway and the
Government of the Republic of Botswana.

The production of this Guideline has been a joint effort amongst Civil and Planning Partnership (CPP), Botswana,
CSIR-Transportek, RSA, and Dr. B Obika. The Guideline was written by:

Mr. K.J. Motswagole, CPP Botswana

Mr. D. Ventura, CSIR
Dr. P. Paige-Green, CSIR
Dr. B. Obika, Consultant
Mr.P. A. P. Oosthuizen (peer review) - MTS.

The Working Group that guided the project and reviewed the Guideline comprised the following people:

Mrs. N. Mpotokwane, Roads Department

Mr. C. Overby, NPRA
Mr. M.E. Segokgo, Roads Department
Mr. B. M. Sharma, Roads Department
Mrs. M. D. Sarma, Roads Department
Mr. P.D. Monametsi, Roads Department
Mr. K. Bale, Roads Department
Mr. M. Rahman, Roads Department
Mr. M. Molefe, Roads Department
Mr. P. Tsiako, Roads Department
Mr. R. Nduna, Roads Department
Ms. D. U. Ndwapi, Roads Department
Mrs. G. Solomon, Roads Department
Mr. S. M. Seloka, Roads Department
Mrs. P. Gilika, Roads Department
Ms. E. Botshomanyane, Roads Department
Mr. E. T. Phang, Roads Department

Mr. C. Overby co-ordinated production of the Guideline including final editing and formatting.

Photographs were provided by:

C. Overby, NPRA
K. J. Motswagole, CPP Botswana
D. Ventura, CSIR

Operating Procedures for Central Materials Laboratory 5

 Roads Department

LIST OF ABBREVIATIONS
10% FACT 10 Percent Fines Aggregate Crushing Value
AASHTO American Association of State Highway and Transportation Officials
ABCC Aggregates, Bitumen, Concrete & Chemistry
ACV Aggregate Crushing Value
AIV Aggregate Impact Value
ALD Average Least Dimension
ARRB Australian Road Research Board
ASTM American Society For Testing And Materials
BOTEC Botswana Technology Centre
BS British Standards
CBR California Bearing Ratio
CML Central Materials Laboratory
CO Computer Officer
CPP Civil and Planning Partnership
CSIR Council for Scientific and Industrial Research
CTO Chief Technical Officer
DCP Dynamic Cone Penetrometer
DMI Durability Mill Index
FET-UB Faculty of Engineering and Technology within the University of Botswana
FI Flakiness Index
FWD Falling Weight Deflectometer
GM Grading Modulus
HETC Highway Engineering Technicians Diploma Course
HOD Head of Division
HUM Heads of Units Meeting
ICL Initial Consumption of Lime
IRI International Roughness Index
ISRM International Society For Rock Mechanics
LA Laboratory Assistant
LL Liquid Limit
LM Laboratory Manager
LMS Laboratory Management System
LS Linear Shrinkage
MDD Maximum Dry Density
MRD Materials and Research Division
MTS Material Testing Services
NORAD Norwegian Agency for International Development
NPRA Norwegian Public Roads Administration
NRN National Road Network
OMC Optimum Moisture Content
OPM Operating Procedures Manager
OPQA Operating Procedures Quality Audit
PHN Public Highway Network
PI Plasticity Index
PO Project Officer
PRE Principal Roads Engineer
PSV Polished-Stone Value
PTA Principal Technical Assistant

6 Operating Procedures for Central Materials Laboratory

Roads Department

PTO Principal Technical Officer

QO Quality Officer
RE Roads Engineer
RTC Roads Training Centre
RTCC Roads Technician Certificate Course
RTFO Rolling Thin Film Oven Test
SABS South African Bureau of Standards
SATCC Southern African Transport and Communications Commission
SO Safety Officer
SRE Senior Roads Engineer
SRP Sample Receiving and Preparation
STA Senior Technical Assistant
TA Technical Assistant
TFO Thin Film Oven Test
TMH Technical Methods for Highways
TO Technical Officer
TOR Terms of Reference
TRH Technical Recommendations for Highways
TRL Transport Research Laboratory (Based in the UK)
UCS Unconfined Compressive Strength
UH Unit Head
UK United Kindom
WS Works Superintendent

Operating Procedures for Central Materials Laboratory 7

 Roads Department

ROADS DEPARTMENT .....................................................................................................................................................3

- Foreword ...........................................................................................................................................................4
- Acknowledgements ...........................................................................................................................................5
- Abbreviations ....................................................................................................................................................6

PART A
1 INTRODUCTION .....................................................................................................................................................15
1.1 Background .....................................................................................................................................................15
1.2 Scope and Layout of the Guideline .................................................................................................................15
1.3 Applicability and Status ..................................................................................................................................16
1.4 Compliance with CML Guideline ...................................................................................................................16
1.5 Build Up and Update of Guideline ..................................................................................................................16
1.6 Operating Procedures Manager .......................................................................................................................16
1.7 Quality Officers ...............................................................................................................................................17
1.8 Quality Review and Audits..............................................................................................................................17
1.9 Inter-Laboratory Quality Audit .......................................................................................................................17

2: ORGANISATION AND MANAGEMENT .............................................................................................................18

2.1 The Public Road Network ...............................................................................................................................18
2.2 Roads Department ...........................................................................................................................................18
2.3 Maintenance Division......................................................................................................................................18
2.4 Development Division.....................................................................................................................................21
2.5 Forward Planning Division .............................................................................................................................21
2.6 Roads Training Centre .....................................................................................................................................21
2.7 Materials and Research Division .....................................................................................................................22
2.7.1 Composition ........................................................................................................................................22
2.7.2 Responsibilities ...................................................................................................................................22
2.8 Central Materials Laboratory (CML). .............................................................................................................22
2.8.1 Roles and Functions ...........................................................................................................................24
2.8.2 Organisational Set up ..........................................................................................................................25
2.8.3 Support Services .................................................................................................................................26
2.8.4 Organisational Review ........................................................................................................................27
2.8.5 Laboratory Units .................................................................................................................................27
2.9 Correspondence ...............................................................................................................................................29
2.10 Heads of Units Meeting (HUM) ......................................................................................................................29
2.11 Annual Work Plan ...........................................................................................................................................29
2.12 Technical Standards and Information ..............................................................................................................30
2.13 Client Satisfaction and Complaints .................................................................................................................30

PART B
3 LABORATORY MANAGEMENT PROCEDURES..............................................................................................32
3.1 Introduction .....................................................................................................................................................32
3.2 Resources.........................................................................................................................................................32
3.2.1 General ................................................................................................................................................32
3.2.2 Manpower ...........................................................................................................................................32
3.2.3 Equipment ...........................................................................................................................................33
3.3 Sample Storage System ..................................................................................................................................33
3.4 Recording Incoming Work (Jobs) ...................................................................................................................35
3.5 Planning The Work Load (Scheduling Work) ................................................................................................36
3.5.1 General ................................................................................................................................................36
3.5.2 Use of equipment ...............................................................................................................................36
3.5.3 Programming work loads for testing staff...........................................................................................36

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Roads Department

3.6 Checking and Quality Control.........................................................................................................................36

3.6.1 General ................................................................................................................................................36
3.6.2 Quality Control ...................................................................................................................................37
3.6.3 Check samples ....................................................................................................................................37
3.7 Inter-laboratory study ......................................................................................................................................38
3.7.1 General ................................................................................................................................................38
3.7.2 Procedure ............................................................................................................................................38
3.8 Reporting Test Results .....................................................................................................................................39
3.8.1 General ................................................................................................................................................39
3.8.2 Types of reports ...................................................................................................................................39
3.8.3 Checking and verification ..................................................................................................................39
3.8.4 Numbering of reports and Archive .....................................................................................................40
3.8.5 Invoicing (if required) .........................................................................................................................40
3.9 Training Laboratory Assistants........................................................................................................................40
3.10 Calibration and Checking of Equipment .........................................................................................................41
3.10.1 General ................................................................................................................................................41
3.10.2 Balances ............................................................................................................................................41
3.10.3 Compacting equipment .....................................................................................................................42
3.10.4 Sieves ..................................................................................................................................................43
3.10.5 Atterberg Limit devices ......................................................................................................................43
3.10.6 Ovens ..................................................................................................................................................44
3.10.7 pH electrodes ......................................................................................................................................44
3.10.8 Thermometers .....................................................................................................................................44
3.10.9 Distilled Water ....................................................................................................................................44
3.10.10 Presses ................................................................................................................................................44
3.10.11 Equipment records ..............................................................................................................................46
3.11 Sample Storage and Disposal ..........................................................................................................................46
3.11.1 Soil Samples........................................................................................................................................46
3.11.2 Aggregate samples ..............................................................................................................................46
3.11.3 Water, Concrete, Bitumen, Brick and other samples ..........................................................................46
3.12 Computer Software..........................................................................................................................................46
3.13 Quality Audits..................................................................................................................................................47
3.13.1 Scope ...................................................................................................................................................47
3.13.2 Procedure ............................................................................................................................................47

PART C
4 LABORATORY TESTS ............................................................................................................................................50
4.1 Introduction .....................................................................................................................................................50
4.2 Project Definitions, Name Convention and Internal Project Officer ...............................................................50
4.3 Sample Receipt and Logging ..........................................................................................................................51
4.4 Sample Numbering ..........................................................................................................................................51
4.5 List of Tests .....................................................................................................................................................51
4.6 Quantities of Materials Required ...................................................................................................................51
4.7 Resources for Carrying out Tests and Expected Output ..................................................................................51
4.8 Soils Tests ........................................................................................................................................................58
4.8.1. CML Test No. S1. Sieve Analysis of Gravel, Sand and Soil Samples .............................................. 58
4.8.2. CML Test No. S2. The Determination of the Liquid Limit of Soils ................................................. 58
4.8.3. CML Test No. S3. The Determination of the Plastic Limit and Plasticity Index of Soils. ............... 59
4.8.4. CML Test No. S4. The Determination of the Bar Linear Shrinkage of Soils ................................... 59
4.8.5. CML Test No. S5. The Determination of the Maximum Dry Density (MDD) and the
Optimum Moisture Content (OMC) of Soils ...................................................... 60
4.8.6. CML Test No. S6. The Determination of the California Bearing Ratio (CBR) of Untreated Soils ... 60
4.8.7. CML Test No. S7. The Determination of the Unconfined Compressive Strength (UCS)
of Stabilized Soils, Gravels and Sand ................................................................. 60

Operating Procedures for Central Materials Laboratory 9

 Roads Department

4.8.8. CML Test No. S8. The Determination of One-Dimensional Consolidation

Properties of Soils ....................................................................................... 61
4.8.9. CML Test No. S9. The Identification of Dispersive Soils Using Crumb Test ........................... 61
4.8.10. CML Test No. S10. The Determination of Durability for Cement-Treated Materials ................ 61
4.8.11. CML Test No. S11. The Electrometric Determination of the pH Value of a Soil Suspension .... 62
4.8.12. CML Test No. S12. The Determination of the Electrical Conductivity of Saturated Soil
Paste and Water ........................................................................................... 62
4.8.13. CML Test No. S13. The Determination of the Initial Consumption of Lime (ICL).................... 63
4.8.14. CML Test No. S14. The Determination of the Sand Equivalent Value of Soils and Fine
Aggregates ................................................................................................... 63
4.8.15. CML Test No. S15. The Direct Shear Test of Soils .................................................................... .63
4.8.16. CML Test No. S16. The Determination of Shear Strength of Soils under
Unconsolidated Undrained, Consolidated Drained and Consolidated
Undrained conditions in Tri-Axial Compression .......................................... 64
4.8.17. CML Test No. S17. The Determination of the Dry Density/Moisture Content
Relationship of Granular Soil (Vibratory Hammer Method) ...................... 64
4.9 Aggregates Tests ............................................................................................................................................. 65
4.9.1. CML Test No. AG1. Sieve Analysis of Aggregates, Including the Determination of
Material Passing 0.425 mm Sieve and 0.075mm Sieve ............................... 65
4.9.2. CML Test No. AG2. The Determination of Aggregate Crushing Value (ACV)............................ 65
4.9.3. CML Test No. AG3. The Determination of 10 Per Cent Fines Aggregate Crushing
Value (10 % FACT) ..................................................................................... 66
4.9.4. CML Test No. AG4. The Determination of Aggregate Impact Value (AIV) ................................ 66
4.9.5. CML Test No. AG5. Assessment of Aggregate Durability Using Durability Mill Test ................ 66
4.9.6. CML Test No. AG6. The Determination of the Flakiness Index of Coarse Aggregates ............... 67
4.9.7. CML Test No. AG7. The Determination of Adhesion of Bituminous Binder to Stone
Aggregate by Means of Chemical Immersion Test (Riedel And Weber)..... 68
4.9.8. CML Test No. AG8. The Determination of Dry Bulk Density, Apparent Relative Density
and Water Absorption of Aggregates Retained on 4.75 mm
Sieve and Passing 4.75 mm Sieve ............................................................... 68
4.9.9. CML Test No. AG9. The Determination of Accelerated Laboratory Polished-Stone
Value (PSV) ................................................................................................. 69
4.9.10. CML Test No. AG10. The Determination of the Aggregate Fingers Value and the
Aggregate Pliers Value................................................................................. 69
4.10 Bitumen Tests ................................................................................................................................................. 70
4.10.1. CML Test No. B1. The Determination of the Penetration Value of Bituminous Binders .......... 70
4.10.2. CML Test No. B2. The Determination of the Ductility of Bitumen........................................... 70
4.10.3. CML Test No. B3. The Distillation of Cutback Bitumen ........................................................... 70
4.10.4. CML Test No. B4. The Determination of the Softening Point of Bituminous Binders
using Ring and Ball Method ........................................................................ 71
4.10.5. CML Test No. B5. The Determination of the Kinematic Viscosity of Cutback Bitumen .......... 71
4.10.6. CML Test No. B6. The Performance of Bitumen when Subjected to the Thin Film
Oven Test (TFO) .......................................................................................... 71
4.10.7. CML Test No. B7. The Performance of Bitumen when Subjected to the Rolling
Thin Film Oven Test (RTFO) ...................................................................... 72
4.10.8. CML Test No. B8. The Determination of the Percentage of Bitumen Soluble in
Trichloro- Ethylene ...................................................................................... 72
4.11 Concrete Tests ................................................................................................................................................ 72
4.11.1. CML Test No. C1. The Making, Curing and Compressive Strength Determination of
Concrete Test Cubes .................................................................................... 72
4.11.2. CML Test No. C2. The Determination of the Slump of Freshly Mixed Concrete ..................... 72
4.12 Asphalt Mixes................................................................................................................................................. 73

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Roads Department

4.12.1. CML Test No. AS1. The Determination of a Suitable Binder Content for use in an
Asphalt Mix ................................................................................................. 73
4.12.2. CML Test No. AS2. The Determination of the Binder Content of a Bituminous Mixture ........... 73
4.12.3. CML Test No. AS3. The Determination of the Bulk Relative Density of a Compacted
Bituminous Mixture and the Calculation of the Voids Content ................... 73
4.12.4. CML Test No. AS4. The Determination of the Resistance to Flow of a Cylindrical
Briquette of a Bituminous Mixture by Means of the Marshall Apparatus... 74
4.12.5. CML Test No. AS5. The Determination of the Maximum Theoretical Relative Density of
Asphalt Mixes (Rice’s Method) and the Quantity of Bituminous
Binder Absorbed by the Aggregates ............................................................ 74

5 FIELD TESTS............................................................................................................................................................... 75
5.1 CML Test No. F1. The Determination of the In-Situ Strength of Soils by the Dynamic
Cone Penetrometer ...................................................................................... 75
5.2 CML Test No. F2. The Determination of the Radius of Curvature of a Road Pavement
using Deflection Measurement .................................................................... 75
5.3 CML Test No. F3. The Determination of the In-Place Dry Density of Soils or Gravels
by the Sand Replacement Method ............................................................... 76
5.4 CML Test No. F4. The Determination of the In-Place Dry Density and Moisture
Content of Soils or Gravels by Nuclear Method.......................................... 76
5.5 CML Test No. F5. Measurement of the Texture Depth of a Road Surface ................................ 76
5.6 CML Test No. F6. Measurement of Road Roughness Using the Merlin Apparatus .................. 77
5.7 CML Test No. F7. Method for Determining the Point Load Strength Index ............................. 77
5.8 CML Test No. F8. Rapid Field Test For Determining The Carbonation Of Lime Or
Cement Treated Materials ............................................................................ 78
5.9 CML Test No. F9. Visual Assessment of Flexible Pavements ................................................... 78
5.10 CML Test No. F10. Visual Assessment of Unsealed Roads ........................................................ 78
5.11 CML Test No. F11. Non-Repetitive Static Plate Load Test for Soils and Flexible
Pavements .................................................................................................... 78
5.12 CML Test No. F12. The In-Situ Evaluation of Base Course Materials by Means of the
Clegg Hammer ............................................................................................. 79
5.13 CML Test No. F13. The Modified Tray Test for Chip Seals ........................................................ 79
5.14 CML Test No. F14. Determination of the Moisture in Soils By Means of a Calcium
Carbide Gas Pressure Moisture Tester ......................................................... 80

PART D
6 LABORATORY LAYOUT AND SAFETY ................................................................................................................ 82
6.1 Laboratory Layout .......................................................................................................................................... 82
6.1.1 General ............................................................................................................................................... 82
6.1.2 Sample reception area ........................................................................................................................ 82
6.1.3 Sample preparation area ..................................................................................................................... 82
6.1.4 Testing that creates a lot of dust ........................................................................................................ 82
6.1.5 Testing that creates a lot of noise ....................................................................................................... 83
6.1.6 Lighting in laboratories ...................................................................................................................... 83
6.1.7 Handling loads in work areas ............................................................................................................. 83
5.1.8 Other considerations .......................................................................................................................... 84
6.2 Safety In The Work Place ............................................................................................................................... 84
6.2.1 General ............................................................................................................................................... 84
6.2.2 Housekeeping ..................................................................................................................................... 85
6.2.3 Guards for machines .......................................................................................................................... 85
6.2.4 Personal protective equipment ........................................................................................................... 85
6.2.5 Fire Prevention Equipment ................................................................................................................ 86

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 Roads Department

6.2.6 Gas cylinders ...................................................................................................................................... 86

6.2.7 First Aid ............................................................................................................................................. 86
6.2.8 Smoking ............................................................................................................................................. 87
6.2.9 Intoxicating substances ...................................................................................................................... 87
6.2.10 HIV and AIDS. ................................................................................................................................... 87
6.2.11 Safety representative .......................................................................................................................... 87

PART E
REFERENCES ............................................................................................................................................................ 90

APPENDICES

Appendix A - Laboratory Forms ................................................................................................................................... 92

Appendix B - General and Managerial Forms ........................................................................................................... 129

LIST OF FIGURES

Figure 2.1 The recommended life-cycle of a project involving MRD and Maintenance Division ............................20
Figure 2.2 Materials and Research Division Organogram – based on the currently approved
personnel establishment ............................................................................................................................23
Figure 3.1 Flow Chart of Sample Movement and Associated Activities at CML ......................................................34
Figure 3.2 Various Types of Storage Systems ............................................................................................................35
Figure 3.3 Sensitive Balance on Thick Slate Base to Minimise Vibrations ...............................................................42
Figure 3.4 Worn compaction hammer with rounded face ..........................................................................................42
Figure 3.5 Straight edge that is no longer straight ......................................................................................................42
Figure 3.6 Indentation on Rubber Base of the Atterberg Liquid Limit Device Caused by the fall of the Cup ..........43
Figure 3.7 Thermometer Positioned Through Hole on Top of Oven to Check Oven Temperature Directly..............44

LIST OF TABLES
Table 2.1 CML Personnel Task Schedule .................................................................................................................26
Table 2.2 Types of Training for Various Categories of Staff at CML .......................................................................30
Table 3.1 Laboratory Equipment that needs frequent calibration and/or checking .................................................45
Table 4.1 Tests carried out by the CML and the standards / specifications followed ...............................................52
Table 4.2 Approximate quantities of materials required for the various tests ..........................................................54
Table 4.3 Approximate resources required to carry out tests and output per day or per week ................................56

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LAYOUT OF THE GUIDELINE

Introduction
Organisation and
Management

Laboratory Management
Procedures

Laboratory Testing
Procedures
Field Testing Procedures

Laboratory Layout
and Safety

References

Appendices

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 Roads Department

PART A

Introduction
Organisation and
Management

Laboratory Management
Procedures

Laboratory Testing
Procedures
Field Testing Procedures

Laboratory Layout
and Safetyy

References

Appendices

14 Organisation and Operating Procedures for Central Materials Laboratory

Management
Roads Department

1 INTRODUCTION
1.1 Background
This document sets out quality management and operating procedures for
the Government Central Materials Laboratory (CML) of the Materials and
Research Division of the Roads Department.
The Roads Department is responsible for the construction and maintenance
of the primary and the secondary road network in Botswana. It also provides
a demand led technical services to other Government Departments when
permitted by available resources.
The Materials and Research Division (MRD) is responsible for quality con-
trol of road projects and for materials related research. An important part of
MRD’s work is the testing of materials and this is undertaken by CML.
CML is the principal construction materials testing laboratory for Govern-
ment in Botswana. The quality of services provided by CML has an important
influence on the quality of Botswana’s road infrastructure. The laboratory
could also be a standard bearer for the nation’s commercial laboratories.
This Guideline is intended for daily use by CML staff at all levels for mana-
gerial and operational functions including outline of test procedures. The
primary aim is to maintain quality, consistency and standards.

1.2 Scope and Layout of the Guideline

This Guideline is divided into five parts as follows:

PART A: Organisation and Management

Part A consists of two chapters. This part of the guideline will primarily be
of use to laboratory management personnel whose responsibilities include
the setting up of and monitoring quality assurance procedures.

Chapter 1: Introduction
This chapter provides a background and format of the guideline.

Chapter 2: Organisational Set-up

This chapter sets out the role and function of the laboratory, it’s clients, man-
agement structure and quality standards.

PART B: Laboratory Management Procedures

The most important resource of the laboratory is its trained human resources.
Chapter 3 describes the roles and responsibilities of each functional position
in accordance with the schemes of service. The staff management and train-
ing procedures are outlined.
The necessary equipment and physical resources are also documented. The
care for and calibration of testing equipment is emphasised. Accepted quality
procedures, which are adopted by the laboratory for procurement, maintenance,
calibration and disposal of equipment, are described.

This part of the guideline will be most useful to personnel responsible for
equipment maintenance and staff development and management.

Operating Procedures for Central Materials Laboratory Organisation and 15

Management
 Roads Department

PART C: Testing Procedures

Part C forms the major part of the Guideline. The specific methodologies for
type of tests undertaken in the laboratory and in the field are described to ensure
consistency and common standards. Many tests are standards or variations of
internationally accepted methodology and as such are not repeated but merely
referred to.
Chapter 4 is concerned with laboratory testing and Chapter 5 with field tests
and are intended as reference sources for all laboratory and field staff and
those responsible for quality control.

Part D: Laboratory Layout and Safety

Part D of this Guideline deals with the layout of the laboratory and safety
issues affecting workers within the work place and is intended to impress
upon the management and the employees in general at CML the need for
safety in the work place and good house keeping procedures. The chapter
also highlights the need for adherence to good health practices such as no-
smoking within the work places.
Chapter 6 is intended for all users of this Guideline.

Part E: References and Appendices

This part contains references and appendices.

1.3 Applicability and Status

The CML Guideline is subservient to Government General Orders, Circulars,
Savingrams and Roads Department written policies as issued by Director of
Roads. Where there is a conflict Government General Orders take precedence
and is paramount.

1.4 Compliance with CML Guideline

All employees of Roads Department are required to comply with the CML
Guideline except where there is conflict as defined in Section 1.3. The Head
of Materials and Research Division (HOD) is the primary custodian of the
Guideline and is responsible for ensuring compliance. The Operating Pro-
cedures Guideline shall be regarded as a ‘controlled document’. The HOD
shall maintain a register of holders (Form M1.1 in appendix B).

1.5 Build Up and Update of Guideline

This Guideline is dynamic and needs to be built up and refined over time. The
Head of Materials and Research Division shall initiate a periodic review of
parts of the Guideline with a more general review to be carried out every two
years. Form M1.2 (appendix B) is used by staff to suggest/recommend an
update to specific clauses to the Operating Procedures Manager. Any member
of staff of CML may suggest changes to the Operating procedures Guideline.

1.6 Operating Procedures Manager

The Head of Materials and Research Division shall be the Operating Procedures
Manager (OPM) of the CML Operating Procedures. The HOD may, in turn,
delegate this function to an appropriate senior officer who shall not be lower
than a Senior Roads Engineer (SRE) or Chief Technical Officer (CTO) in rank.
The role and functions of the OPM is defined in Part B of this Guideline

16 Organisation and Operating Procedures for Central Materials Laboratory

Management
Roads Department

1.7 Quality Officers

The OPM shall nominate Operating Procedures Officers (OPO) for each unit
of the laboratory, who shall normally be the heads of the respective units.
The OPO shall be responsible for ensuring compliance with the Guideline in
their respective units.

1.8 Quality Review and Audits

The OPM shall initiate a periodic review and audit of compliance with the
Guideline. The Audit shall be carried out by an independent person follow-
ing the procedures set out in Section 3.6.
The auditor shall compile a report stating areas of compliance/non-compli-
ance and recommended actions required to rectify any non-compliance.
Forms M1.3 and M1.4 (appendix B) shall be used for audit schedule, check-
list and corrective action request respectively. Any changes to the guideline
resulting from the audit shall be recorded in Form M1.5 (appendix B). The
findings of the audit shall be summarised in an audit report in a format pre-
sented in Form M1.6 (appendix B).

1.9 Inter-Laboratory Quality Audit

The laboratory shall undertake an annual inter-laboratory testing to check
quality, reproducibility and repeatability of results amongst at least three
major commercial materials laboratories in Botswana. The procedure for
carrying out such audits is described under Section 3.7 of this Guideline.

Operating Procedures for Central Materials Laboratory Organisation and 17

Management
 Roads Department

2 ORGANISATION AND
MANAGEMENT
2.1 The Public Road Network
The administration of the Public Road Network (PRN) in Botswana is divided
into two major areas of responsibility. The responsibility for constructing and
maintaining the PRN is shared between Roads Department in the Ministry of
Works and Transport, and Local Councils in the Ministry of Local Government.
The total length of the Public Road Network is more than 20 000 km of roads
comprising paved, gravel, earth and sand wearing courses. The total length
of the National Road Network (NRN) i.e. those under the responsibility of
Roads Department, accounts for about 6350 kilometres of bituminous roads,
about 2 610 kilometres of gravel roads and about 1 440 kilometres of earth /
sand roads. The remaining roads fall under the management of Local Councils.

2.2 Roads Department

Roads Department is responsible for the forward planning, budgeting and
implementation of projects pertaining to upgrading of gravel and sandy roads
to bituminous and gravel roads respectively, construction of new roads, main-
tenance of existing roads and investigations of poor performance of newly
constructed roads or old roads due for rehabilitation.
In the majority of cases, the Materials and Research Division (MRD), is in-
volved right from the beginning in drafting of the Terms of References for
various aspects such as pavement investigation and rehabilitation design, fea-
sibility or detailed design and materials investigation for construction of new
roads, and in the case of maintenance of gravel roads, the gravel and materi-
als investigation required for spot improvement or gravelling/regravelling of
sand or gravel roads respectively. Furthermore, where projects are undertaken
by consultants, the MRD is responsible for supervising the former on issues
pertaining to materials investigation, geotechnical investigation and searches
for construction materials. The biggest task, however, is in proving sources of
construction materials for maintenance projects.
Materials and Research Division is one of the six divisions comprising
Roads Department. The other divisions are:
● Maintenance.
● Development.
● Forward Planning.
● Training.
● Administration.
Clear lines of communication between the Materials and Research Division
and sister divisions are paramount for the efficient planning and execution of
road projects. This is particularly so for the Maintenance and the Develop-
ment divisions.

2.3 Maintenance Division

Maintenance Division is one of the most important clients for the MRD.
Maintenance Division is charged with maintaining the National Road Net-
work (NRN) in a sound and cost effective manner. The main activities of

18 Organisation and Operating Procedures for Central Materials Laboratory

Management
Roads Department

Maintenance Division which require input from MRD are:

● Routine maintenance.
● Periodic maintenance.
● Evaluation of consultancy proposals and tenders.
● Control of overloading by heavy vehicles.
There are three sub-divisions within Maintenance Division namely Region
North-with headquarter in Francistown, Region South with headquarter in
Gaborone and Region West with headquarter in Maun. The Maintenance
regions are tasked with maintaining all roads falling under the NRN within
their region. This involves planning, budgeting and executing by force ac-
count or by private contractors, the maintenance of candidate roads.
All of these maintenance regions are required to send their construction
materials and or pavements related requirements to Maintenance Head-
quarters in Gaborone from where they are collated, prioritised and sent to
MRD for action.
It is quite common that the requests are brought in late leading to late de-
livery of the required services by MRD. In order to avoid these delays, the
following communication schedule and time limits must be adhered to.
It is important to note that all Government projects, whether done in house
or outsourced, need to have been budgeted for and the funds approved by 31
March of each year for the projects to commence during the financial year
starting in April of the same year. In the case of MRD where pavement fail-
ure investigations and/or gravel survey need to be completed by the time the
project is implemented the planning takes an even longer period.
For MRD to deliver services to Maintenance Division on time, requests for
investigation/services should be submitted to the PRE - MRD two fiscal
years before the intended start of the project. The request should be made
preferably in April but not later than July two years before the construction
stage of the project. This time is meant to give MRD time to include the
project in the budget to be approved in April the following year. When the
funds to carry out gravel survey or pavement evaluation have been approved
then field work and testing or even outsourcing can commence after April.
The investigation report should, therefore, be submitted to Maintenance divi-
sion before March of the construction year. Figure 2.1 shows the life-cycle
of a project involving MRD and Maintenance Division. A similar life-cycle
could be used for projects involving MRD and other divisions.
In order to facilitate quality control and prevent delays during construction, a
Technician from MRD should be seconded to maintenance contracts section
for the duration of the project. Wherever feasible, routine and simple tests
such as sieve analysis and Atterberg limits should be carried out on site.
The upkeep, transport and related field expenses of the officer should be the
responsibility of the client, i.e. Maintenance Division.

Operating Procedures for Central Materials Laboratory Organisation and 19

Management
 20
Management
Organisation and
Year 1 Year 2 Year 3
Activities
Division Apr Jun Oct Dec Mar Apr Jun Oct Dec Mar Apr Jun Oct Dec Mar
Responsible
Submit requests for gravel and/or pavement Maintenance
investigations Division
MRD submits budget to RD Headquaters MRD
Funds approved for MRD MRD
Gravel and Pavement Investigations and
MRD
reporting
Tendering for maintenance projects using Maintenance
MRD reports as Information to Tenderers Division
Maintenance
Award of maintenance contracts
Division

Figure 2.1: Recommended life-cycle of a project involving MRD and Maintenance Division.

Operating Procedures for Central Materials Laboratory

Roads Department
Roads Department

2.4 Development Division

The Development Division is another main user of the services provided by The project life-cycle suggested for Maintenance
the MRD. The Development Division is responsible for: Division (figure 2.1) could also be adopted for
other divisions depending on the nature of the
project.
● Rehabilitation and construction of roads and bridges.
● Road and bridge design.
● Contract administration of road design and construction, through
consultancy agreement and construction contracts.
● Traffic studies.
● Award of consultancies and construction contracts.
The MRD is critically required in most of the above functions specially super-
vision of consultants during the design stage, quality control on site during
construction stage and technical input into the TOR services of consultants.
The lines of communication and target months are similar to those for
maintenance. It is, however, much clearer in Development Division as to
which projects are due for construction in the next two years or so as forward
planning publishes these projects in advance. A list of projects that would
require inputs from the MRD should be known at least 12 months prior to
the start of the project. This would enable the MRD to budget in advance for
the division’s input in July of the year before commencement.

2.5 Forward Planning Division

The division is responsible for the overall planning of the department, which
includes: Project appraisal, evaluations, cost estimates and implementation
schedule; coordination of feasibility studies to determine projects viability
for upgrading to bitumen standard and review of cost estimates; liaison with
District Authorities in determining their road improvement requirements.
Forward Planning Division comprises Planning section, Information Tech-
nology section, Network Management section, and Traffic section.

2.6 Roads Training Centre

The Roads Training Centre (RTC) exists symbiotically with the MRD in that
RTC train technicians who are later deployed at MRD. MRD, on the other
hand, provides the necessary equipment and technical expertise required by
the students during their training especially with regard to site investigations,
construction quality control and testing of construction materials.
RTC exists in order to provide:
● Technical training in design, construction, supervision and maintenance
of roads.
● Training with regard to the use of labour intensive methods of road con-
struction.
The graduates of the RTC that are employed by MRD are those that have
completed:
● Highway Engineering Technician Diploma Course (HETC).
● Road Technician Certificate Course (RTCC).
In order to avoid disruption to the works at MRD, it would be prudent that
RTC submits their training requirements/schedule to HOD at MRD at the

Operating Procedures for Central Materials Laboratory Organisation and 21

Management
 Roads Department

beginning of each year. The schedule shall include the objective of the visit
or attachment, the number of students, if in groups the number of groups and
the number of students per group, the dates and times of the visit, and state
if the students are accompanied by their supervisors/lecturers or otherwise.
MRD shall promptly inform RTC about the resources required from them
during these visits.

2.7 Materials and Research Division

2.7.1 Composition
Materials and Research Division (MRD) is headed by a Principal Roads En-
gineer (PRE) who reports directly to the Chief Roads Engineer – Materials
and Maintenance and indirectly to the Director of Roads.
The Division comprises the following Sections:
● Administration and Supplies: – Facilitates the smooth running of the
entire division by providing manpower and other resources necessary for
MRD to discharge its responsibilities.
● Central Materials Laboratory (CML): – It is primarily responsible for
carrying out various tests on construction materials and is the main focus
Entrance to Materials and Research Division. of this guideline.
● Materials Investigations: – Primarily responsible for the location of
road building materials throughout the country.
● Research and Development including Pavement Monitoring: – It is
responsible for investigating properties of various pavement materials
and facilitating their use for appropriate pavements. The section is also
responsible for conducting research on road building materials, usually
in association with other research organisations such as FET-UB,
BOTEC, NPRA, TRL, CSIR, etc.
● Design and Specifications: – Undertakes in-house design and updates
national standards and specifications for roads and bridges.

These sections interact very closely and their duties and responsibilities over-
lap. The Materials and Research Division organogram is shown as Figure 2.2.
The organogram is based on the approved structures for the MRD.

22 Organisation and Operating Procedures for Central Materials Laboratory

Management
 PRE I - MRD
(HOD)

Receptionist Typists
Roads Department

PRE II WS - Site Investigation

Pavement Eng & Laboratorv

approved personnel establishment.

SRE SRE CTO
Site Iab & Inv CTO - admin. CTO - Lab
D&S I&R

R. E. I R. E. II PTO PTO ASO A.A.O PTO - Lab

D&S I&R I&R Site I ab

Operating Procedures for Central Materials Laboratory

SK II - store S.A.A.
STO - SL PTA - SL
STO - class STO - comp STO - abcc
R. E. II 3 x SK III Transport
ARE officer
D&S I&R TO - SL TO - PM
TO - class TO - comp TO - abcc
Drivers
PTA - SL TA - SL
3 x Sec Gatekeeper TA - class STA - comp TA - abcc

CMAs, SMAs, MAs, Labourers, and Cleaners as per work load

Figure 2.2: Materials and Research Division Organogram - based on the currently

Management
Organisation and
23
 Roads Department

2.7.2 Responsibilities
The main responsibilities of the Materials and Research Division include:
● Reviewing and advising on materials aspects of feasibility study, design,
construction and maintenance projects.
● Undertaking in-house pavement design.
● Prospecting, testing and approving sources of road construction materials.
● Assessing and evaluating consultancy proposals and contract documents
to ensure adequacy of materials in-put and pavement design.
● Designing and undertaking appropriate research to increase efficiency
and value for money within Roads Department, including bilateral co-
operation with relevant research organisations in other countries.
● Conducting quality control monitoring and testing for all Roads Departments
projects including in-house projects and projects undertaken by consultants
and contractors on behalf of the Department.
● Designing and undertaking special investigations to establish causes of
premature pavement failures/distress and assessing liability where relevant.
● Undertaking project level pavement investigation of projects identified by
pavement management system for maintenance and rehabilitation purposes.
● Providing advice and assisting the Director of Roads on implementation
of policy changes relating to pavement and materials technical standards,
training and quality control of Roads Department projects.
● Providing advice on pavements, research and materials testing services
to other Government departments and parastatals.
● Training of materials staff and assisting Roads Training Centre in materials
aspects of its training programme.
● Support services to other divisions of Roads Department including:
o teaching at Roads Training Centre
o assistance to Maintenance and Development Divisions with the
procurement of consultants by contributing to TOR preparation and
evaluation of technical and financial proposal
● Development/preparation of technical guidelines and their dissemination
to stakeholders.

2.8 Central Materials Laboratory (CML).

2.8.1 Roles and Functions
The main function of the Central Materials Laboratory (CML) is to test road
building materials and to ensure that appropriate testing methods are followed.
The section is also responsible for:
● Periodic checking and calibration of all testing equipment.
● Continuous training of laboratory staff to enhance competence in carrying
out most of the routine tests.
● Field and laboratory testing of various construction materials and prepar-
ation of factual reports.
● Provision of advice to other sections of the MRD, Roads Department and
other Government Departments on materials testing and quality control.
● Management and operation of on-site laboratory testing facilities for
nominated projects.

24 Organisation and Operating Procedures for Central Materials Laboratory

Management
Roads Department

The day-to-day management and operation of the CML shall be in accord-

ance with these operating procedures and the HOD shall ensure that CML
has the resources to carry out the tests listed in Table 4.1.

2.8.2 Organisational Set up

The CML shall be headed by a Chief Technical Officer (CTO) who shall report
directly to the Works Superintendent (WS) or Principal Roads Engineer (PRE).
The head of CML shall be referred to as the Laboratory Manager (LM) for
the purpose of this guideline. The LM shall get managerial and technical
support from Engineers and technicians at MRD.
The LM shall be assisted by heads of various units, who shall be Senior
Technical Officers (STO) or Principal Technical Officers (PTO) except for
the sample preparation and receiving unit who shall be a Technical Officer
(TO) or a Senior Technical Assistant (STA). There shall be four units within
CML. The heads of the various units within the CML shall be referred to as
Unit Head (UH) for purpose of this guideline. Each UH shall be assisted by
Technical Officer (TO) and/or Technical Assistants (TA).
The UH shall also perform the role of Safety Officer (SO) and Quality Officer
for their respective units. The UH shall be responsible for the overall quality,
timely delivery, safety and general welfare of staff, quality of equipment,
training of his/her staff, and accuracy of data produced and presented to the
LM.
The actual qualification required for the various positions shall be determined
by the Director of Roads Department from time to time as dictated by the
dynamics of the service and ruling schemes of service. Provided however
that the LM and UH are competent technicians who are qualified and well
trained in the field of material testing.
It is not the duty of the Unit Head or the Lab Manager to interpret the data in
terms of passing or failing any specification. Once the UH is satisfied that
the results are in order he shall pass them on to the LM who shall in turn
check and satisfy himself that the tests were performed in accordance with
acceptable procedures and standards before passing them on to the Project
Engineer for analysis and onward transmission to the client.
Depending on the availability of staff the HOD shall assign an Engineer of
the level of Roads Engineer or higher, to the laboratory to assist with inter-
pretation of results and assistance with specialized tests.
For major projects, such as road construction, road rehabilitation and road
gravelling, it would be prudent to assign a specific officer to the project. An
officer so appointed shall be referred to as the Project Officer (PO). The PO
shall be responsible for determining the type and number of tests to be carried
out on samples from the given project. It is, therefore, imperative that the
officers are adequately trained in laboratory testing and handling of problems
relating to construction materials for them to be able to handle the complexi-
ties of construction materials related problems. Such training is available at
numerous reputable institutions such as Technicons in South Africa, TRL
in UK, and universities. Table 2.1 summarises the primary and secondary
responsibilities (task schedule) of engineers and technicians at CML.

Operating Procedures for Central Materials Laboratory Organisation and 25

Management
 Roads Department

2.8.3 Support Services

Administrative, Information Technology, Secretarial and Supplies Support
services to the laboratory are provided by other sections of the Materials and
Research Division. The effective functioning of the laboratory is dependent on
the services provided by these support services. Primary support services are:
● Administrative support: Reception, typing and file management, clerical
and routine accounting.
● Supplies: Purchase administration, storage, inventory, disposal and
management of all supplies and equipment.
● Information Technology Services: Procurement, servicing, repair of hard-
Data is stored in electronic media.
ware, network management, back up support, training on IT, virus man-
agement, software management and licensing, website support, mainten-
ance of Laboratory Management System (LMS) and Database and others.

Table 2.1: CML Personnel Task Schedule.

Preparat’n Unit Head

Compa’n Unit Head

Classif’n Unit Head

ABCC Unit Head
CTO SL & Inv.

PTO SL & Inv.

HOD (PRE I)

LM (CTO)

IT Officer
PRE II

SRE’s

RE 1

AS0
WS

TASK DESCRIPTION
Preparation of Annual and monthly Work Programmes 2 1 1
Assessment and Approval of programmes 1
Staffing Planning & Annual Training programme 2 1 2
Preparation of testing schedule for samples 2 2 2 2 2 1 1 1 1 1 1
Sample and sample book management 2 2 2 2 1
Inter-laboratory testing 2 2 1 2 2 2
Review of testing methodology 2 2 2 1 2 2 2
Equipment Calibration - Compaction unit 2 1
Equipment Calibration - ABCC Unit 2 1
Equipment Calibration - Classification Unit 2 1
Disposal of Obsolete equipment 2 2 1 1 1 1 1 1
Laboratory Health & Safety 2 2 1 1 1 1 1
Review & Update of Quality Procedures Manual 2 1 1 1 1 2 2 2
OP Management & Approval of Procedures 1 2 2
Convening of laboratory Weekly and Monthly Meetings 2 1
Preparation of lab. Testing factual reports 1 2 2 2 1 1 1 1
Certification of laboratory factual reports 1 1
Checking & Certification of laboratory reports 1 2 1 2
Customer complaints Procedure 1 2 2 2
Project Officer functions 1 1 1 2 1
Annual Organisational Review 1 2 2 2 2
Laboratory Computing 2 2 2 2 1
Quality Audits 1 2 2 2 2 2
1 - Primary responsibility. 2 - Secondary/supporting responsibility

26 Organisation and Operating Procedures for Central Materials Laboratory

Management
Roads Department

2.8.4 Organisational Review

The Head of Division in consultation with Laboratory Senior Personnel shall
undertake a biannual review of laboratory staffing status and shall delegate
duties as appropriate to cover for any unfilled posts.
An annual organisational review shall be conducted by the Head of Division
assisted by senior personnel including the Laboratory Manager. From this
review the organisation plan for the year is developed including the requests
for staff recruitment and transfers as appropriate to fulfil specific functions
in the organogram. The annual review process shall be timed to complement
the Roads Department Head quarter annual staff deployment review.
Staff development and training is described in Chapter 3 of this Guideline.

2.8.5 Laboratory Units

Due to the various and differing range of tests carried out by CML, the lab-
oratory shall be subdivided into specialized units depending on the types of
tests. The units are:
● Sample Receiving and Preparation (SRP) Unit.
● Classification unit.
● Compaction unit.
● Aggregates, Bitumen, Concrete and Chemistry (ABCC) unit.

Sample Receiving and Preparation (SRP) Unit

The Sample Receiving and Preparation (SRP) Unit shall be responsible for:
● Receiving of samples from field teams, other divisions and other stake-
holders.
● Storage of samples in an orderly and neat manner until they are required
for testing. Samples shall be received and stored in accordance with the
sample receiving and storage procedure as detailed in Sections 3.3 and
4.3 of this Guideline.
● Preparation of the sample and making them ready for testing by the
respective CML unit.
● Managing the sample shed and upkeep of the preparation area. One of the tests carried out by the classification
● Temporary storage of waste samples and the management of the disposal unit is the PI.
of the same to the dumping site. A tidy storage such as “Skip hire” is
considered prudent.
The SRP unit shall be headed by a Technical Officer (TO) or Senior Tech-
nical Assistant (STA). The number of materials assistants assigned to the
unit shall be dependent on workload.

Classification Unit
The classification unit is tasked with testing soil samples in order to deter-
mine their classification in terms of the AASHTO soil classification system or
any other system as appropriate. The unit shall undertake the following tests:
● Sieve analysis of gravel, sand and soil samples.
● Liquid Limit of soils.
● Plastic Limit of soils.
● Linear Shrinkage of soils
● Hydrometer Analysis for samples finer than 0.075mm.
The PI test requires skill and diligence.

Operating Procedures for Central Materials Laboratory Organisation and 27

Management
 Roads Department

The classification unit is also responsible for storage of unused fines from
soil samples, which may be required for future use or repeat testing.
The Classification Unit shall be headed by a Senior Technical Officer (STO)
who shall report to the Laboratory Manager (LM). The UH of Classification
unit shall be assisted by Technical Officers and Technical Assistants. The
number of Materials Assistants of various grades attached to the unit shall
depend on the workload.

Compaction Unit
The compaction unit is responsible for testing soil samples in order to deter-
mine their density (compaction) characteristics. The compaction unit shall
primarily undertake the following tests:
● Determining the Density–Moisture relationships in order to find the
Optimum Moisture Content for achieving the desired Maximum Dry
Compaction is an essential component of the Density of materials.
CML.
● Determining the California Bearing Ratio (CBR).
● Determination of Unconfined Compressive Strength (UCS) of chemi-
cally stabilised materials.
The compaction unit shall be headed by a Senior Technical Officer (STO)
who reports to the LM. The UH of Compaction unit shall be assisted by a
TO and a Technical Assistant (TA). The number of Materials Assistants of
various grades attached to the unit shall depend on the workload.

Aggregates, Bitumen, Concrete & Chemistry (ABCC) Unit

The ABCC unit is responsible for carrying out Aggregates, Bitumen, Concrete
and Chemical tests. The following are some of the tests that shall be carried
out within the unit:
Aggregates
● Aggregate Impact Value (AIV) test.
● Aggregate Crushing Value (ACV) test.
● 10% FACT.
● Average Least Dimension (ALD).
AIV test is also carried out at CML.
● Water Absorption.
● Bulk Densities.
● Adhesion test (Riedel and Weber).
● Flakiness Index.
● Dust Content.
● Particle size Distribution.
● Durability Mill Index.

Bitumen Tests
● Bitumen Penetration.
● Softening point (Ring and Ball test).
Bitumen Adhesion Test at ABCC unit. ● Viscosity.
● Ductility.
● Asphalt Tests, mainly Marshall tests i.e. flow and stability.

Concrete Tests
Currently CML does not carry out tests related ● Cube Casting.
to chemical stabilizations of materials such as
Initial Consumption of Lime (ICL). It is recom- ● Slump test.
mended this test be conducted in CML because ● Cube Crushing.
chemical stabilization is being performed on a
number of projects. ● Brick Crushing.

28 Organisation and Operating Procedures for Central Materials Laboratory

Management
Roads Department

Chemical Tests
● Electrical Conductivity.
● pH.
The ABCC Unit shall be headed by a Senior Technical Officer who shall report
to the Laboratory Manager. The UH of ABCC shall be assisted by two TOs each
of whom shall head a sub-unit being Bitumen and Chemistry, and Aggregate and
Concrete. Each TO shall be assisted by a TA and a number of Materials
Assistants whose number shall vary depending on workload.

2.9 Correspondence
All correspondence into and out of the laboratory to external individuals
and organisations shall be addressed through the Head of Division (HOD).
The HOD shall distribute all incoming mail by assigning action officer for
specific query or request.
All requests for laboratory testing by external clients shall be addressed to
the HOD while those from within the CML shall be addressed to the LM
using a letter from the former or Form M2.1 (Appendix B) from the latter.
The content of telephone conversations with any client shall be recorded and
discussed with the relevant Project Officer (PO).
All reports emanating from the laboratory shall be channelled through the
LM to the PO or the HOD. The HOD will sign-off all reports from the LM
and or PO to the respective clients. Where a project was not assigned a PO,
the LM shall submit the factual reports directly to the HOD. Should the
HOD require further work on the project or the report, he/she shall assign a
PO to carry out the task.

2.10 Heads of Units Meeting (HUM)

The Laboratory manager shall convene a monthly meeting of Heads of Units
to assess and discuss among other things:
● Current workloads.
● Resources (human & equipment).
● Plans and programme for the coming month.
At the monthly HUM, minutes shall be taken and action items noted for
individual unit heads and their members.
Each UH may nominate a maximum of two additional officers from their
respective units to attend the HUM.

2.11 Annual Work Plan

The Laboratory Manager, Works Superintendent, CTO Administration, the
Principal and Senior Road Engineers, and the HOD shall carry out a review
of CML’s projects and activities, and produce an annual work plan prior to
the beginning of each financial year. This shall normally be undertaken prior
to budget preparation.
In order to facilitate this, it is critical to ensure that Maintenance Division
and other outside clients submit their materials prospecting and testing
requirements to MRD at least 8 months prior to the start of the financial year.
The annual work plan will normally include all divisional activities. For the
laboratory, these shall include:
● Testing workload/plan for the coming year.
● Resource requirements (human & equipment).

Operating Procedures for Central Materials Laboratory Organisation and 29

Management
 Roads Department

● Personnel development and training programme (see Table 2.2).

● Building and equipment maintenance.
● Developmental activities.
The LM shall maintain the annual work plan for the laboratory. The work plan
shall be monitored monthly and progress reported at the monthly management
meetings.

Table 2.2: Types of Training for Various Categories of Staff at CML.

Courses leading to engineering degrees

On-the-job Laboratory Testing Trainning

TYPES OF COURSES

Technical Conferences-International

Customer Services & Supervisory

Conferences - Local & Regional
Laboroary Testing -Advanced
Management/Organisational
Contracts & Quality Control
Materials & Pavement Eng

Materials Testing-Basics

Admin. And Computing

RTC Certificate
RTC Diploma
STAFF GRADE

Senior Engineers (REI and above) 1 1 1 2 1 1 2

Junior Engineers 2 1 1 2 1
Senior Technicians (STO and
above) 2 1 1 2 2
Junior Technicians 1 1 2 1 1
Materials Assistants 2 2 1 1 1
Administrative and support staff 1 1
1 - Primary relevance 2 - Secondary relevance

2.12 Technical Standards and Information

In order to ensure that most upto date technical standards are used for test-
ing, frequently used documents such as TMH 1, ASTM, BS 812, BS 1377,
etc. shall be registered as Controlled Documents.
The Laboratory Manager shall maintain a Register of Controlled Documents
in the laboratory. The Laboratory Manager shall ensure that all Controlled
Documents are updated with all revisions.
The controlled reference documents shall be held either in the library or issued
to named individuals. The Designated Member of Staff shall record the names
of individuals and their holdings of controlled publications in the Register.
Note that TMH 1 is available on the Internet and The Laboratory manager shall clearly mark each controlled reference docu-
includes periodic updates and improvements. ment as such.
Web-site: www.csir.co.za.

2.13 Client Satisfaction and Complaints

All complaints received from outside parties shall be recorded in Form M2.2
(Appendix B).
All complaints shall be brought to the attention of Head of Division who shall
ensure that appropriate authority is delegated to deal with the complaint.
The Head of Division and Laboratory Manager shall counter-sign Form M2.2
signifying that the complaint has been dealt with. A copy of the signed form
shall be filed both under the Divisional filing system and Laboratory filing
system.

30 Organisation and Operating Procedures for Central Materials Laboratory

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Roads Department

PART B

Introduction
Organisation
g and
Management

Laboratory Management
Procedures

Laboratory Testing
Procedures
Field Testing Procedures

Laboratory Layout
and Safetyy

References

Appendices

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3 LABORATORY MANAGE-
MENT PROCEDURES
3.1 Introduction
The word ‘management’ has several meanings, depending on the context
and purpose. There is no universally accepted standard definition of manage-
ment. However, management may be simply defined as the process by which
managers get things done through the efforts of others. To manage is primar-
ily to direct people and organizations in such a way that certain objectives
are accomplished.
With the adoption of stringent standards for materials testing, the importance
of laboratory operation and the generation of credible data have increased.
Competent management is essential to bring about reliable laboratory perfor-
mance, thereby increasing the laboratory use as a tool for maintaining proper
performance to ensure compliance with accepted standards.
In the various chapters of this report the following aspects of laboratory
management and administration are discussed:
● Resources.
● Handling samples.
● Sample storage.
● Incoming work.
● Planning workload.
● Quality control of testing.
● Reporting results.
● Keeping records.
● Staff training.
● Calibration of equipment.
● Laboratory lay-out.
● Laboratory safety aspects.
● Laboratory housekeeping.
It is suggested that the Central Materials Laboratory (CML) supplement their
existing operational procedures with those outlined in this Guideline.

3.2 Resources
3.2.1 General
The resources required both in terms of manpower and equipment is dependent
on the amount of testing that is done by the laboratory on a regular basis. This
has to be determined over a period of time, say one year, as the workload of lab-
oratories is typically erratic. Sufficient resources should be available to handle
the average workload. Too much equipment and staff will be expensive in terms
of salaries, maintenance, capital costs etc., whereas too little resources will ham-
per laboratory operations and negatively affect production. An optimum level
of resources is often difficult to achieve but should be strived for. Experience
gained with time is the best indicator for determining resource requirements.

3.2.2 Manpower
Regardless of the amount of work, each unit should have at least one experi-
enced (senior) Technician and one or two Technical Assistants as detailed in
Section 2.8 of this Guideline.

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A cleaner should also be available to clean and tidy up after testing and may
be shared by the various units within the laboratory, however, where units
handle large volumes of work more than one cleaner may be necessary.
At different times one unit, say the Classification unit, may have a greater
workload than, for example, the ABCC unit. In such cases personnel from
the ABCC unit should be temporarily used in the unit experiencing the high
workload. It is thus important to train technicians to do various types of test-
ing so that they are interchangeable amongst units.
Staffing the laboratory to deal with peak workloads is not recommended as
this leads to people being idle for long periods when the workload is low.
This normally results in personnel that are not used to working full days,
which creates poor work habits in terms of efficiency.
The existing schemes of services and establishment register are considered
to be adequate to meet the objectives of MRD. This is based on the past and
present workload at MRD. The number of vacancies in engineering posts
must however be filled to enhance the project monitoring and increase the
number of Engineers assisting with specialised testing and data interpretation
where required.

3.2.3 Equipment
CML has all the types of equipment, which are necessary to do the tests that
are routinely carried out. When specialised testing is requested for which the
laboratory does not have the equipment the work should be contracted out to
a laboratory that does such testing.
The number of apparatus required for any particular test is dependent on
the number of requests for that test in a given period. Where this is insuffi-
cient the productivity of the laboratory will be adversely affected. However,
excessive amounts of equipment will have certain negative cost implica-
tions, in terms of purchasing, depreciation, maintenance etc. Also, space that
could be used for other purposes will be occupied. It is the responsibility of
the LM, in consultation with the HOD, to plan for the purchasing of new
equipment and the boarding of disused equipment. The LM shall maintain an
equipment control list (Form M3.1, Appendix B).

3.3 Sample Storage System

An efficient sample storage facility must allow for ease of sample storage
and retrieval thus facilitating orderly storage of samples. There should be
sufficient space in which to handle samples. Samples may be large (50 kg) or
small (a few kg’s) or anywhere in between and the system must cater for the
various sample sizes.
Large samples should not be stored high above ground level (probably not
more than 1,2 m above ground - chest height) as they are cumbersome to han-
dle and incorrect handling may result in injury to the person storing/retrieving
the samples. The storage height above ground may naturally be increased if
some form of mechanical hoisting system is used to lift samples. In most lab-
oratories, however, samples are handled manually as a mechanical hoist has A well-organised storage facility such as this
the disadvantage of being expensive, slow, and cumbersome to move about. one, facilitates easy identification and retrieval
of samples as and when required.
Also, a mechanical hoist requires more space, in which to manoeuvre, which
means that less of the available floor space can be used for sample storage.
A storage facility must have provision for the temporary or short-term storage
of samples and also storage for longer periods.

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Samples that are to be tested soon after arrival, should preferably be stored at
a location close to the sample preparation area. Samples that have been tested
and are awaiting disposal should be stored in another location. Figure 3.1
shows the flow of samples between the various storage areas in the laboratory.
Figure 3.2 depicts various types of storage that can be used to accommodate
different types and sizes of samples.

Sample delivered to CML

(Must have a request for testing) Sample Registration

Scheduling

YES Testing Imminent NO

Sample Sample
preparation Store

Testing and Sufficient Sample

recording results YES Prepared NO

Checking results Check testing or

(Lab) further testing

Result OK NO
Client
Satisfied
YES NO
YES

Checking by Output to
Lab. Manager Client

Result OK

Discard/store
YES NO samples
(As per Guideline)

Figure 3.1: Flow Chart of Sample Movement and Associated Activities at CML.

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R R Q
F

X V
W
M

B
N
J
P

B Shelf Q Panelled end frame

F Sliding door frame R Panelled intermediate
J Bin fronts V Vertical division pieces
M Hinged doors U Open end frame
N Hanging strip for doors W Drawer units
P Plinths X Cross brace
Figure 3.2: Various types of storage systems.

3.4 Recording Incoming Work (Jobs)

Requests for testing have to be recorded in order to keep track of the work
details. This will normally be done in a job ledger. This may also be done
electronically using a computer. The information required for the records is,
however, the same whether it is done manually or electronically. It is desir-
able to have the following information concerning the work requested:
● Each work request is given a job number.
● The name of the person requesting the work.
● The date on which the job was received.
● Date on which job was started.
● The number and types of tests required.
● The numbers of the samples being tested.
● The estimated or required completion date.
● The estimated cost of doing the work.
● The person or persons that are going to be doing the testing.
● Date on which the job was completed.
● Amount invoiced for the job (if necessary).

A file should be opened on each job received. This file should contain all
the information pertaining to the specific job, i.e. the work request form, all
the working sheets, test results summary sheet and all the correspondence
concerning the particular job. The LM shall maintain a register of project
numbers using Form M3.2 (Appendix B).

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3.5 Planning The Work Load

(Scheduling Work)
3.5.1 General
For work to be done efficiently it has to be planned and scheduled. This is
especially important when several job requests are received simultaneously
or more work is received than the testing facility can comfortably cope with
within a specified time limit. In any event jobs normally have to be done
within a certain time and within specific cost constraints and this can only be
achieved if the workload is adequately scheduled.
Work may be scheduled in various ways such as on a first come first serve
basis or it may be prioritised according to the urgency of the situation. When
scheduling work, factors such as use of equipment, optimal use of laboratory
assistants, technical staff etc., shall be considered.

3.5.2 Use of equipment

It is often the case that various people request similar testing, which means
that the same equipment needs to be used at the same time, which is obvi-
ously not possible. In this case it is advisable to stagger the start of the jobs
so that optimal use of the equipment is made.

3.5.3 Programming work loads for testing staff

Work has to be set out in such a way that the technicians and technical
assistants are as fully occupied as possible. This is cost effective and also
prevents staff from developing bad work habits (staff used to being idle).
Naturally at times when there is little or no work this is not possible. When
this occurs staff should be employed to calibrate and service the equipment.
It is, therefore, important that an adequate number of technical staff are
trained in the service and calibration of most frequently used equipment. The
training on these aspects could be arranged with equipment suppliers and
testing institutions such as CSIR and equipment manufacturers etc.

3.6 Checking and Quality Control

3.6.1 General
CML shall maintain three levels of quality check and verification.
● First level checks shall be undertaken by the Unit Head supervising tests
conducted within his/her unit of the Laboratory. The Unit Head shall check
all the results submitted to him/her to ensure that tests were carried out in
accordance with standards and that calculations and graphs, where appli-
cable, were done correctly.
● Second level quality checks shall be carried out by the Laboratory Man-
ager. The Laboratory Manager is required to check at least 20 percent of
all results submitted to him/her. This would normally include visual
inspection of the sample tested, checking of calculations and an interpretive
assessment of whether the results make sense. The Laborator Manager
shall signify his/her quality checks by signing the sample results sum-
mary sheet.
● Third Level verification shall be conducted by the Project Officer or SRE
on receipt of the factual report from the Laboratory. Where an interpre-
tive report is not required, the PO or SRE is required to check at least 10

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percent of all results submitted to him/her. Where an interpretive report

is required, the PO or SRE is required to check all results submitted to
him/her. The PO or SRE shall sign the final certification prior to trans-
mission of reports to external clients through the HOD.

3.6.2 Quality Control

It has to be ensured that the testing being done is of high quality. Test results
have to be checked to ensure that they are correct and also that all the testing
requested has been done. This could be achieved by ensuring that:
● Only persons who have been trained to do a given test should be allowed
to carry out that particular test.
● An experienced technician should supervise testing so as to ensure that
the correct procedures are being followed. This would normally be a
senior technician such as the UH.
● Testing details and results should be recorded on a standard form and
signed off by the technician doing the testing.
● The UH or his appointed unit supervisor shall check all calculations for
Checking and verification of test results is an
accuracy and ascertain that the correct testing procedures were followed. essential component of quality control.
This may be done by means of a calculator or, if available, with a com-
puter. Presently a variety of computer programs are available to calculate
test results. Computers have the advantage that they are fast, accurate
and can immediately store the test data. Drawing a graph by hand (say of
a MDD/OMC curve) can be time consuming and is also not very accurate.
A computer, on the other hand, will do this quickly, accurately and con-
sistently.
● The UH shall also ensure that all the client’s requirements have been met
(all the testing and procedures requested) before submitting the test results
to the Laboratory Manager.
● Should there be, in the opinion of the UH, any discrepancies concerning
test results or procedures then re-testing may be required before submit-
ting the test results to the laboratory manager.
● Any anomalies concerning the tests or the sample/materials shall also be
reported to the LM.
● The LM shall ensure that the test results are within acceptable limits for
the materials being tested and that the client’s requirements have been
satisfied.
● The LM could only forward the final report to the PO or client (through
HOD) once he is satisfied of the correctness of the test results. Repeat
testing should be carried out in the case where he is uncertain of the results.
● Check samples shall be put through the testing production line on a
regular basis to verify that the testing is being done correctly as sug-
gested below in Section 3.6.3. The test results of these samples should be
within previously determined acceptable limits (Within the standard
deviation values previously obtained for the test results of the particular
method). Should this not be the case then the testing procedures and
equipment used for the test must be investigated to ascertain the reasons
for the discrepancy.
● Inter-laboratory studies should also be carried out on the more important
test methods on a yearly basis.

3.6.3 Check samples

Use of check samples is a useful method for determining whether testing
is being done correctly. Check samples are obtained by repeat testing of a

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sample by various technicians who are familiar with the test method being
done. An average test result is thus obtained for a particular sample for a
particular test or several results for several tests. The most likely test result
and the expected variability for that sample is thus known.
This check or control sample may occasionally be sent for testing together
with other samples that are being tested at the time. The check sample’s
result is then compared with the average result obtained earlier to determine
whether or not the testing is being carried out correctly. Should this result be
close to the average then the test is in all likelihood being carried out correctly.
If, however, this is not the case then the cause of the error has to be ascer-
tained. It is possible that the technician conducting the test is not following
the test method exactly as prescribed or that he/she may simply require more
training. There may also be an equipment problem.

3.7 Inter-laboratory study

3.7.1 General
Inter-laboratory study is a useful exercise for determining the quality and
accuracy of outputs emanating from participating laboratories. Inter-laboratory
study is also used to establish acceptable limits for test results.
Tests performed on presumably identical materials under so-called identical
conditions do not, generally, yield identical results. This is attributed to un-
avoidable random errors inherent in every test procedure, because factors that
may influence the outcome of the test cannot always be completely controlled.
In the practical interpretation of test data, and especially where these data
are used for quality control purposes, this inherent variability has to be taken
into account. If this is not done it could happen that the difference between
a test result and a value specified by the contract may be within the scope of
unavoidable random errors.
Some factors that may contribute to the variability of a test procedure are:
● The operator’s skill.
● The equipment used.
● The calibration of the equipment.
● The testing environment.

3.7.2 Procedure
Samples that are used in inter-laboratory investi- This inherent variability in testing procedures is normally expressed in terms
gations are normally prepared by one labora- of the repeatability and reproducibility of the testing procedure. Repeatability
tory and distributed to the other laboratories for
testing so that the test method is examined and (r) refers to tests performed at short intervals in one laboratory by one operator,
not the method of sample preparation, unless using the same equipment on one sample. Reproducibility (R) refers to tests
the sample preparation method is being investi-
gated. performed in different laboratories on supposedly identical samples, which implies
different equipment, different operators and a different testing environment.
Multi-laboratory precision (reproducibility) and inter-laboratory precision
(repeatability) testing are usually carried out using not less than 8 laboratories.
This is not always possible as there may not be that number of laboratories in
the region carrying out the test method under investigation. For purposes of
this Guideline, therefore, inter-laboratory testing shall involve not less than 3
laboratories.
Samples shall be prepared by CML and then distributed to participating lab-
oratories for testing. The test results received from all laboratories (including

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CML) shall then be statistically analysed in order to determine the repeat-

ability and reproducibility values for the test method.
These values shall be used to identify laboratories whose test results are not
within acceptable limits. After further investigation steps could be taken
to rectify errors within those laboratories, whether these be procedural or
equipment related. In addition, appropriate action must be taken to improve
quality, as necessary.

3.8 Reporting Test Results

3.8.1 General
Once the testing has been completed and the results checked the test results
have to be reported to the person that requested the testing.
Normally Clients are only interested in the final test results. Sometimes,
however, as in a research environment the researcher is interested in all the
details pertaining to the test. In such cases he/she will wish to see the work-
ing sheets as completed by the technician doing the work as well as a sum-
mary of the test results. Summaries of various test results should be made on
sheets such as those shown in Appendix A.
A computer may be used to process the test results and normally in such a
case the computer is programmed to provide a summary sheet of the test
results as well as store the test data. When using a computer program to store
test data it is advisable to always make backup copies of the results. This
data should be stored safely until required.
It is important to keep all working sheets safely as queries often arise con-
cerning possible mistakes etc. and these can be traced on the working sheets
in the job file. This file should be kept, whether or not a computer is used to
process and store test data, as it is not only the test data that is important but
also all the correspondence, working sheets etc., concerning the job. The file
should be kept in the laboratory filing system. The original documentation
must remain in the file and only copies given out, if required.

3.8.2 Types of reports

The CML generates the following types of reports:
● Test result sheets with calculations produced by Materials Assistants or
individuals carrying out the tests in each unit of the Laboratory. These
reports relate to specific samples and contain primary data or test information
and are presented on pre-determined forms (see Appendix A).
● Sample results summary sheets produced by Unit Heads. These summarise
all of the tests results.
● Factual reports produced for sets of samples or a project are compiled by
UH and LM.
● Interpretive report where required are produced by the PO or SREs. These
reports are usually required by clients from sister Divisions especially
Maintenance division and Development division, and other Government
Departments such as Civil Aviation and Botswana Defence Force.

3.8.3 Checking and verification

As indicated in the tests sheets, each test sheet shall be checked and counter-
signed by the Unit Head. The LM shall check at least 20 per cent of all test
sheets and initial those checked.

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The Results summary sheet report shall be checked and countersigned by the LM.
It is not the duty of the laboratory to produce interpretative reports. The lab-
oratory, however, shall produce factual reports summarising the results includ-
ing any remarks or problems arising from the testing. Such reports originating
from the Laboratory shall be checked and signed by the LM. The PO or SRE
shall be responsible for compiling the interpretative report as and when required.
A senior engineer shall check the report before it is submitted to the Client
through the PRE.

3.8.4 Numbering of reports and Archive

Each test sheet report shall contain the same number as the sample number
to which the results relate. The sheet will also contain a description of the
project.
Each results summary sheet shall be numbered in accordance with the
sample number to which it relates.
All reports produced within the MRD shall be numbered in accordance with
“The Materials and Research Division Report System – Report Number IC
001)”.
All reports shall be entered in a central report register maintained in the
divisional library and a copy of the report deposited in the same library. An
electronic copy of all factual reports is also to be retained in the divisional
central database.
Results summary sheets are to be retained in the electronic database only.
The MRD reporting system, is described in
Report no. IC 001. Test or work sheets are to be retained for only 24 months after the tests were
conducted or 12 months after the completion of construction which ever is
the longer. After this period, test sheets may be disposed off by the UH with
the consent of the LM, PO and HOD.
Summarised results shall be stored electronically in the CML database. Hard
copy summary sheets shall be kept in the MRD archive for at least 10 years.
The archived factual report shall be recorded in Form M3.3 (Appendix B).

3.8.5 Invoicing (if required)

Once the job has been completed to the customer’s satisfaction an invoice must
be sent to the customer. The invoice should specify what testing or other work
was carried out and the cost of such work. The amount of the invoice and the
date on which it was sent to the client must be recorded in the job register.
Internal clients may require cost estimates instead of invoices so as to deter-
mine full analysis of project costs.

3.9 Training Laboratory Assistants

The quality of the test data generated depends, to a large extent, on the skills
of the Laboratory Assistant (LA). It is imperative that the technician doing a
specific test is fully conversant with the test method and does the test to the
best of his/her ability. The laboratory shall have an on-going training program
to train technicians and ensure that skills levels are maintained.
The training program must allow the Laboratory Assistant to progress through
the various test methods. This allows the Technical Assistant to “grow” in his
job. The LA experiences a sense of growth, which is good for his self-esteem,
job satisfaction and is ultimately of benefit to the organization.

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The Technical Assistant should be trained on only one test method at a time
to avoid confusion. He/she must be trained to do the test strictly according
to the test method described in an approved testing standard (specification).
Laboratory test results should be repeatable (should the test be repeated by
the same person a similar result should be obtained) and reproducible (similar
results should be obtained by another person in another Laboratory doing the
same test on the same material). Repeatability and reproducibility can only be
achieved if the standard method is followed exactly. The use of shortcuts or
“tricks of the trade” not in the test specification must be discouraged.
It is advisable that the technician first tests check samples (Section 3.6.3) to
determine whether he is doing the test correctly before allowing him/her to
test samples for specific jobs.
Training records of Laboratory Assistants shall be properly kept. The records
shall show what testing the LAs are trained to do. The training history shall
be recorded in the Form M3.4 while training consultation shall be recorded
in Forms M3.5(a), M3.5(b) and M3.5(c) (Appendix B).

3.10 Calibration and Checking of Equipment

3.10.1 General
From time to time it is necessary to check and calibrate the equipment used
for testing. This is important to ensure that the test results obtained are accurate
and repeatable.
Equipment used for testing has to be used carefully and according to the in-
structions pertaining to the particular equipment. Nonetheless, use of equip-
ment, no matter how careful, results in some wear and thus periodic main-
tenance and calibration is essential.
It sometimes happens that there is insufficient work to keep all the staff fully
occupied. This is the ideal time to check and calibrate equipment. This per-
tains only to equipment where specialized knowledge is not required for the
purposes of calibration and checking, for example mould dimensions, check-
ing the condition of sieves, checking the condition of compaction hammers
etc. Equipment checking and calibration is, however, very important and must
be done whether free time is available or not.
Some of the equipment that will most likely require checking and calibration
on a regular basis is discussed below. The equipment calibration requirements
shall be recorded in Form M3.6 (appendix B).

3.10.2 Balances
Balances must be checked regularly to ensure that they are performing
according to specifications. The easiest way to do this is to use several weights
of different masses (for balances having different weighing capacities) to
determine the accuracy of the balances
The masses of these weights must be determined very accurately preferably
by an institution that specialises in the calibration of equipment such as the
South African Bureau of Standards (SABS), or the Division of Metrology at
the CSIR. The weights must only be used for the purpose of calibration of
scales and nothing else. To avoid their use for other purposes it is best that
the weights be safely locked away.
The older mechanical or electro-mechanical balances need to be serviced
regularly as they have many moving parts. These balances need to be ser-
viced, by an appropriately qualified technician, approximately once a year.

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Presently, most balances used at CML are of the electronic type. This type of
balance generally requires less maintnance than the older mechanical type.
There should be a specific bench for
very sensitive balances. The sides of
this bench are usually made of thick
wood, concrete or brick and the top
is usually a concrete slab or perhaps
thick slate. The idea is to minimize
vibrations that may affect readings
(see Fig. 3.3). This is especially
important in Chemical laboratories
where small quantities of chemicals
Figure 3.3: Sensitive balance on thick slate
base to minimize vibrations. are used.

3.10.3 Compacting equipment

Compacting equipment such as
compaction hammers, moulds etc. is
especially prone to wear due to the
nature of its use
Compaction hammers need to be
checked regularly to determine
whether they conform to specifica-
tions. The weight must be deter-
Compaction moulds like other equipments in the Figure 3.4: Worn compaction hammer with mined, the length of fall of the ham-
laboratory must be taken care of. Appropriate rounded face. mer must be measured and it must be
storage is imperative.
checked that the hammer falls freely.
It is also important to check that the hammer face is flat as this sometimes
becomes rounded with use (see Fig. 3.4). The hammer should be discarded
when this occurs. Where an automatic compaction machine is used the ham-
mer should also be checked regularly as is the case with hand held hammers
(weight, fall, free movement and hammer face). Most automatic compaction
machines have a mechanism that rotates the mould or the hammer or both
and the operation of these mechanisms should also be checked.
In most laboratories compaction moulds are weighed and the volume deter-
mined and this data recorded in a book. Each time the mould is used these
mould values are re-used. The moulds are, however, subject to rusting and
also chipping from blows of the compaction hammer. It is thus imperative
that the weight and volume of the moulds be determined from time to time
depending on use but not less than twice a year.
The steel straight edge that is used to
cut off the excess material protruding
from the mould after compaction must
also be checked for wear. The straight
edge tends to become rounded with
use (see Fig. 3.5) and this results in the
mould containing more material ie the
mould volume effectively increases.
When this happens the straight edge
Figure 3.5: Straight edge that is no longer should be machined to a true straight
straight.
edge.
Special care must be taken of moisture content
tins to avoid rust. The tins used for moisture content determinations are weighed and these

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values reused when the tins are used successively. The tins are especi-ally
susceptible to rust and also accumulation of dirt and soil. Special care must
be taken when cleaning the tins. They should also be weighed on a regular
basis, depending on use, but not less than twice a year.

3.10.4 Sieves
Sieves have a limited life because of the wear that they are subjected to. The
finer sieves (≤ 0.425mm) are especially vulnerable to the abrasive materials
that pass through them. Sieves should be inspected regularly, at least once a
month (depending on usage) to determine whether or not they need replacing.
The 0.075 mm sieve is especially subjected to tearing and stretching of the
sieve mesh and should be examined more regularly than other sieves. Once
the sieve mesh has stretched (manifested as sagging in its frame) the sieve no
longer conforms to specifications and must be replaced.

3.10.5 Atterberg Limit devices

The most important aspect is to calibrate the instrument so that the fall of the
cup is exactly according to the specified 10 mm fall. This should be done
before any sample is tested and is normally obtained by using the back of the
grooving tool, which is usually designed for this purpose.
With use a groove usually develops inside the Cassagrande cup (bowl of
apparatus), which is caused by cutting the sample in the cup with the grooving
tool. When this groove is too large it may affect test results. When this occurs
the cup should be machined to remove the groove or preferably replaced.
The cam that is part of the mechanism that lifts the cup also wears with time
and this should be machined so that it has a sharp edge at the end of the cam.
The fall of the cup on the hard rubber base plate causes an indentation at the
point of contact (see Fig. 3.6). When the indentation is too big it is no longer
possible to set the cup height accurately and this, therefore, affects the result
obtained. At this time the cup base should be machined or replaced. With
some devices it is also possible to turn the base around so that the bottom
faces upwards. It is also sometimes possible to move the cam/hinge mecha-
nism forward or backward on the base so that the point of contact between
the cup and base changes to a point where the base is flat.

The tool used to cut the groove in the It must be ensured that the correct Casagrande
material in the Cassagrande cup is also apparatus is used for the test. The hardness of the
base materials differs, for example, the apparatus
subject to wear with regular use. The specified by ASTM uses a harder base than does
cutting edge of the tool should be 2 mm the BS apparatus.
wide. This tends to widen with use
and at this point the tool is no longer
suitable and should be discarded.
The linear shrinkage troughs used for
linear shrinkage determinations are
sometimes inadvertently damaged.
Figure 3.6: Indentation on the rubber base of the These should be checked for dents,
Atterberg Liquid Limit device caused by the fall shape etc before being used.
of the cup and a worn out spatula. Such deformed
equipment should be removed from the labora-
tory. It must be ensured that the correct
Casagrande apparatus is used for the
test. The hardness of the base materials differ, for example, the apparatus
specified by ASTM uses a harder base than does the BS apparatus.

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3.10.6 Ovens
The ovens’ thermostat should be checked periodically to ascertain whether or
not it is working properly. This is best done by putting a thermometer in the
oven and checking that the thermometer reading is similar to the thermostat
reading. It is in any event good practice to keep a thermometer in the oven
so that there is a constant check on the oven temperature. Most ovens have a
hole in which a thermometer can be permanently kept (see Fig. 3.7). A fan is
present in most ovens (especially larger ones) to provide air circulation and
thus equalise the temperature throughout the oven. It should be checked that
this is working properly. The door seal of the oven must also be inspected
periodically to ensure that it is not broken or defective in any way.

3.10.7 pH electrodes
The electrodes used in pH determina-
tions have a limited life span, this be-
ing dependent on the solutions tested.
Very high and very low pH solutions
considerably shorten the life span of
the electrodes. The electrodes have
thus to be checked regularly using
buffer solutions to ascertain whether
or not they are still functioning
properly. The calibration values of the
Figure 3.7: Thermometer positioned through electrodes change with usage and it is
hole on top of oven to check oven temperature
directly. thus best to re-calibrate the electrode
each day. Electrodes not in use must
be placed in a solution suggested by the manufacturer and must never be
allowed to dry out.
The manufacturer’s instructions, which are usually supplied with the elec-
trodes, should be followed to ensure that correct results are obtained and that
the electrode has a relative long life. Replacement of electrodes is costly.

3.10.8 Thermometers
Thermometers have to be highly accurate for certain types of testing such as
the bitumen tests discussed in Part C. It is best to have these thermometers
calibrated by the institutions mentioned earlier (see section 3.10.2). New
thermometers may then be checked against the calibrated thermometers to
determine whether or not they are performing satisfactorily.

3.10.9 Distilled Water

Distilled water is often used in the laboratory. The quality of the distilled
water being produced by the water still must be checked periodically. It may
happen that some form of contamination has occurred. Also, vessels that are
used to store distilled water must be thoroughly cleaned from time to time
and should be used for no purpose other than keeping distilled water.

3.10.10 Presses
Presses such as those used for CBR and UCS testing must be calibrated regu-
larly, preferably once a year. This should be done by reputable institutions such
as the SABS, CSIR and others. Where this is not possible the presses should be
checked with a proving ring that has been calibrated by one of the institutions
mentioned. A calibrated load cell may also be used for this purpose.

44 Laboratory Management Operating Procedures for Central Materials Laboratory

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Proving rings that are used regularly also need to be calibrated. This is a
specialised job and can only be done by institutions such as those mentioned
previously.
Many more equipment and tools than the items mentioned in this section
need to be calibrated and checked. It is however, impractical to discuss them
all. The important point to remember is that good test results are very dependent
on equipment that is calibrated and in good working order. Calibration and
checking of equipment is something that technicians and managers should
always bear in mind.
Some of the equipment that should be calibrated and/or checked and the
frequency with which this should be done are listed in Table 3.1.

Complete records of all calibrations must be kept.

Table 3.1: Laboratory Equipment that needs frequent calibration and/or checking.
EQUIPMENT ACTION FREQUENCY
Balances, Scales and weights Calibrate 12 months
Test thermometers Calibrate 6 months
Analytical balances and weights Calibrate 24 months
Viscometers Calibrate 36 months
Kneading compactor Calibrate 36 months
Timers Check accuracy 24 months
Ovens Verify temperature settings 3 months
Penetrometer: Dial, needles, timer Check condition 24 months
Ductility apparatus Check speed of travel 24 months
TFO & RTFO oven shelf/carriage Check rotation speed 24 months
Verify load indications 12 months
Check squareness of setting platens 12 months
Compression or loading device
Check that correct load ratings are Daily
applied for different sizes of specimen.
Mechanical compactor Calibrate 6 months
Moulds Check critical dimensions 12 months
Manual hammer Check weight & critical dimensions 3 months
Sieves Check condition 6 months for sieves
larger than 0.425mm
Monthly for ≤ 0.425mm
sieves
Loss Angels Abrassion. machine Check R.P.M, dimensions and weight 24 months
of Steel balls
Vacuum system Check pressure 24 months
Atterberg Limit device Check fall and indentation Daily

Conductivity Meter Calibrate 6 months

Leak Test 6 months

Check for conformity with sand Monthly

replacement density test
Nuclear Gauges
Calibrate When the above checks
give erroneous results
or 24 months whichever
is less.

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3.10.11 Equipment records

It is advisable to keep a register of all the laboratory equipment. This register
should contain information such as; date of purchase of equipment, name
and other details of the supplier, details of repairs, and maintenance and cali-
bration of such equipment etc. It is also important to keep a file containing
all the instruction manuals of the laboratory equipment.

3.11 Sample Storage and Disposal

Samples shall be stored in accordance with Section 3.3.

3.11.1 Soil Samples

The sample shed shall be maintained in a dry and clean state, free of water
leakage. The floor of the shed shall be paved with concrete paving blocks.
Soil samples received by the laboratory shall be stored in the sample shed
in clearly defined tidy rows. Each row shall be clearly identified by a board.
The board shall contain the name of the project from which samples in that
row originate and the name of the PO responsible for the project. The sample
bag nomenclature currently used by the laboratory shall be used.
The Sample Receiving and Preparation Unit shall maintain the sample stor-
age and preparation areas in a clean state at all times.
The remainder of tested soil samples shall be returned to and kept in their
original sample bags. These samples shall be disposed off after 6 months
of their testing unless instructed otherwise by the LM or the PO. The UH
for the Sample Receiving and Preparation Unit shall be responsible for the
disposal of tested soil samples.
Due to the limited storage space and the untidy nature of the waste soil samples
it is prudent that a tidy disposal system such as “Skip hire” is engaged. Such
a system has the advantage of regular collection and would therefore make
more space available for sample preparation.

3.11.2 Aggregate samples

Stone and aggregate samples shall be stored and disposed off as per Section
3.11.1 of this guideline.

3.11.3 Water, Concrete, Bitumen, Brick and other samples

The Laboratory Manager shall, in liaison with the Project Officer, determine
the sample storage and disposal requirements for sample other than soil and
aggregate samples.
The Waste Disposal Act (1998) shall be fully adhered to especially with regard
to the disposal of chemicals. No chemicals shall be disposed off without
written authority of the LM. Where in doubt, the Department of Sanitation
and Waste Management shall be consulted.

3.12 Computer Software

All requests for new software, whether produced in-house, “off the shelf” or
written specifically for the CML, shall be referred to the Head of Division
for approval.

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New software shall be passed to the Computer Officer (CO) who is respon-
sible for control of all software in the Laboratory.
● The CO shall be responsible for loading all new software onto the com-
puters within the laboratory.
● The CO shall maintain a master list of all approved software held within
the laboratory, which shall indicate the release or version reference of the
software package.
● The master list shall indicate which software is loaded on which com-
puter and shall be completed and signed by the CO each time a new soft-
ware package is loaded onto or unloaded from any computer.
● Prior to approval by the CO for use, all technical software shall be validated
by reference to hand calculated worked examples.
● Validation of technical software shall be the responsibility of the Head
of Division who may delegate this authority to the Laboratory Manager
or a Senior Engineer
● Problems encountered with a particular software package shall be referred
to the CO who shall be responsible for ensuring that corrective action is
taken either in-house or, where applicable, under a software maintenance
contract.
The CO shall be responsible for maintaining the master disks for all approved
software in storage and ensure that back ups of computer data are performed
on regular basis. The computer backups shall be logged using Form M3.7
(Appendix B).
The Laboratory Manager shall be responsible for removing obsolete con-
trolled reference documents from the library.
Where an obsolete document is required for reference purposes, the Labora-
tory Manager shall mark it as superseded and file it separately.
The Laboratory Manager, in consultation with Senior Engineers (SRE’s
and/or PRE’s) and Head of Division, shall be responsible for maintaining
subscriptions for technical standards for laboratory testing and ensuring that
the Laboratory is updated with new, widely approved test methods.

3.13 Quality Audits

3.13.1 Scope
To ensure that the operating procedures guideline remains efficient and effective
economic and complies with the requirements of the Laboratory and International
Standards.

3.13.2 Procedure
Operating Procedures Quality Audit (OPQA) shall be scheduled by the Oper-
ating Procedures Manager (OPM) at maximum intervals of two years and shall
be conducted by an Engineer of Principal Roads Engineer grade or higher.
Prior to the OPQA, a meeting comprising the LM, UHs and the OPM shall
be held to enable the OPM to appreciate the concerns of implementers of the
guideline.
The OPQA meeting shall address the effectiveness of the operating proce-
dures guideline in meeting the requirements of CML particularly in terms of
client complaints and satisfaction.

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The register of client complaints shall be reviewed at each OPQA meeting

and the close out of each complaint recorded on the register. The action taken
since the last OPQA to address each complaint shall be recorded. (See Forms
M1.4, M1.5, M1.6, M1.7 and M2.2 in Appendix B).
The OPQA meeting shall also address future quality strategy, which may be
influenced by:
● New products or equipment.
● New Client requirements.
● Changes in the work place.
● Changes in testing standards and specifications.
Any actions adopted by the OPQA meeting resulting in changes to the oper-
ating procedures guideline shall be delegated to a senior member of staff and
monitored until completion by the OPM.
The UH or LM shall prepare minutes of each OPQA meeting showing items
discussed, corrective actions to be carried out and responsibilities for follow-
ing up and closing out corrective actions.

48 Laboratory Management Operating Procedures for Central Materials Laboratory

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PART C

Introduction

Organisation
g and
Management

Laboratory Management
Procedures

Laboratory Testing
Procedures
Field Testing Procedures

Laboratory Layout
and Safety

References

Appendices

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4 LABORATORY TESTS
4.1 Introduction
This part of the guideline summarizes various laboratory tests, which are
routinely carried out at CML. It is not the intention of this chapter to repro-
duce testing procedures/methods but rather to highlight pertinent points on
the affected tests.
Sampling from large quantities of material shall be done by riffling or
quartering according to Testing Methods for Highways 5 (TMH 5), to obtain
manageable amounts of material required for testing. This shall be done on
a clean hard dry surface, preferably a concrete slab, or on a large tarpaulin
made of a thick durable material.
The specific quantities of material required for various tests shall be obtained by
using a riffler having the correct size openings as specified by the test method.
Sample preparation should be done according to TMH 1 with the following
exceptions:
● Where the person requesting the testing asks for a different method of
preparation.
● Only the wet preparation method (TMH1: Method A1(a)) shall be
followed except where otherwise requested.

4.2 Project Definitions, Name Convention

and Internal Project Officer
Each sampling or testing work undertaken by CML shall be linked to a ‘Project’
and each project shall have a Project Officer, (PO) with MRD (Section 2.8.2).
The primary reference number for all samples processed through the laboratory
shall be the Project Reference and the primary responsibility for all action
relating to the testing including determination of testing and reporting require-
ments shall rest with the PO. The PO is also the internal client to whom the
Lab. Manager reports/discusses any issues pertaining to the sample.
A ‘project’ may be a major road project such as Artesia-Dibete rehabilitation
involving the testing of many samples or it may be a small project comprising
a single or a few sample(s).
The Project Name shall be the first three letters of the start and end of the
project to which the material samples relate.
The sample number shall include project name as a prefix and the sample
number as a suffix. Up to 10 Characters are allowed for any sample number
in a given project. The letters shall comprise the first 3 characters of the project
start, followed by a hyphen and the first 3 characters of the project end. The
number shall start at 001 and increase sequentially to the last sample of the
given project.
Example: The 173rd sample from Artesia – Dibete Road Rehabilitation project
would be named; Art-Dib 173.

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4.3 Sample Receipt and Logging

All samples delivered to the laboratory by external clients shall be accom-
panied by a covering letter or sample submission form for internal clients
(Form M2.1 in Appendix B) addressed to PRE – Materials and Research
Division with a minimum of the following information:
● Name, address and contact details of the sender.
● Description and number of samples sent and the project to which they relate.
● Purpose of sampling and required tests (if known).
● Date by which results are required and whether interpretation is required.
No sample shall be received without a letter or submission form. Where the
sample is submitted without a submission form, the Sample Receiving Officer
(SRO), shall store the sample in the shed and inform the LM immediately.
The LM shall cause the error or omission to be corrected as appropriate. Where
the error could not be corrected, the sample shall be kept for 4 calendar weeks
and then disposed off.
All samples delivered to the Laboratory shall be received and logged by the
sample-receiving officer (There may be more than one nominated sample
receiving officer). The information required for logging (in accordance with More details regarding sample description can
Guideline Number 3-”Methods and Procedures for Prospecting for Road be found in Guideline number 3 “Methods and
Construction Materials”) shall be detailed in the Sample book. Procedures for Prospecting for Road Construc-
tion Materials”.

4.4 Sample Numbering

The sample numbering convention, as detailed in section 4.2 above, shall be
followed for all samples received into the laboratory.

4.5 List of Tests

Tests carried out by CML are listed in Table 4.1. The table also gives the
standard specification that should be referred to for more details on the test.
These tests are discussed further in some detail in Section 4.8 through section
4.12 and in Section 5, Field Tests.

4.6 Quantities of Materials Required

The approximate quantities of materials required to perform the various tests
are given in Table 4.2.

4.7 Resources for Carrying out Tests and

Expected Output
The time taken to do a specific test is very dependent on the material type
and also the skill of the operator as well as the equipment available (number
of pans, sieves, ovens etc.). Proper planning will also improve efficiency and
therefore reduce testing time.
The resources indicated in Table 4.3 should be considered at best a rough
guide of the number of tests that can be carried out in a given time period.
Some activities such as sample preparation or tests such as Atterberg Limit
determinations span over several days because of drying time in the oven.

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Table 4.1: Tests carried out by the CML and the standard specifications followed.
CML
TEST
TEST TEST DESCRIPTION STANDARD
NUMBER
NUMBER
Soils Tests (S)
Sieve Analysis of Gravel, Sand and Soil Samples
Wet Preparation TMH1 A1 (a)
S1 Dry Preparation TMH1 A1 (b)
Material Passing the 0.075 mm Sieve TMH1 A5
Hydrometer Analysis TMH1 A6
S2 The Determination of the Liquid Limit of Soils TMH1 A2
S3 The Determination of the Plastic Limit And Plasticity Index of Soils TMH1 A3
S4 The Determination of the Bar Linear Shrinkage of Soils TMH1 A4
S5 The Determination of the Maximum Dry Density (MDD) and Optimum Moisture Content (OMC) of Soils TMH1 A7
S6 The Determination of the California Bearing Ratio (CBR) of Untreated Soils TMH1 A8
S7 The Determination of the Unconfined Compressive Strength (UCS) of Stabilized Soils, Gravels and Sands TMH1 A14
S8 The Determination of One-Dimensional Consolidation Properties of Soils ASTM D2435
S9 The Identification of Dispersive Soils Using Crumb Test BS 1377 1990
S10 The Determination of Durability for Cement-Treated Materials TMH 1 A19
S11 The Electrometric Determination of the pH Value of a Soil Suspension TMH 1 A20
S12 The Determination of the Electrical Conductivity of Saturated Soil Paste and Water TMH 1 A21T
S13 The Determination of the Initial Consumption of Lime (ICL) BS 1924 Part 2
S14 The Determination of the Sand Equivalent Value of Soils and Fine Aggregates AASHTO T176-00
S15 The Direct Shear Test of Soils ASTM D 3080-72
S16 The Determination of Shear Strength of Soils under Unconsolidated Undrained, Consolidated Drained and
AASHTO T 296-95
Consolidated Undrained conditions in Tri-Axial Compression
S17 The Determination of the Dry Density/Moisture Content Relationship of Granular Soil (Vibratory Hammer
BS 1377
Method)
Aggregates Tests (AG)
Sieve Analysis of Aggregates, including the Determination of Material Passing the 0.425 mm sieve and
AG1 TMH1 B4
0.075 mm Sieve
AG2 The Determination of the Aggregate Crushing Value (ACV) TMH1 B1
AG3 The Determination of 10 Per Cent Fines Aggregate Crushing Test (10% FACT) BS 812 Part 3
AG4 The Determination of Aggregate Impact Value (AIV) BS 812 Part 3
AG5 Assessment of Aggregate Durability Using the Durability Mill Test SATCC (1988)
TMH1(1986) B3
AG6 The Determination of the Flakiness Index of Coarse Aggregates
or BS 812 Part 1
The Determination of the Adhesion of Bituminous Binder to Stone Aggregate by Means of the Chemical
AG7 TMH1 B11
Immersion Test (Riedel And Weber)
The Determination of Dry Bulk Density, Apparent Relative Density and Water Absorption of Aggregates
AG8 TMH1 B14 and B 15
Retained on the 4.75 mm Sieve and Passing the 4.75 mm Sieve
AG9 The Determination of the Accelerated Laboratory Polished Stone Value (PSV) BS 812 Part 3
AG10 The Determination of the Aggregate Fingers Value and the Aggregate Pliers Value CSIR CB 22

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Table 4.1: continued.

CML
TEST
TEST TEST DESCRIPTION STANDARD
NUMBER
NUMBER
Bitumen Tests (B)
B1 The Determination of the Penetration Value of Bituminous Binders ASTM D5
B2 The Determination of the Ductility of Bitumen ASTM D113
B3 The Distillation of Cutback Bitumen ASTM D402
B4 The Determination of the Softening Point of Bituminous Binders by the Ring and Ball Method ASTM D36
B5 The Determination of the Kinematic Viscosity of Cutback Bitumen ASTM D2170
B6 The Performance of Bitumen When Subjected to the Thin Film Oven Test (TFO) ASTM D1754
B7 The Performance of Bitumen When Subjected to the Rolling Thin Film Oven Test (RTFO) ASTM D2872
B8 The Determination of the Percentage of Bitumen Soluble in Trichloro-Ethylene ASTM D2042
Concrete Tests (C)
C1 The Making Curing and Compressive Strength Determination of Concrete Test Cubes TMH1 D1
C2 The Determination of the Slump of Freshly Mixed Concrete TMH1 D3
Asphalt Tests (AS)
AS1 The Determination of a Suitable Binder Content for use in an Asphalt Mix TMH1 C1
TMH1 C7
AS2 The Determination of the Binder Content of a Bituminous Mixture
ASTM D1856
The Determination of the Bulk Relative Density of a Compacted Bituminous Mixture and the Calculation of
AS3 TMH1 C3
the Voids Content
The Determination of the Resistance to Flow of a Cylindrical Briquette of a bituminous mixture by Means of TMH1 C2
AS4
the Marshall Apparatus ASTM D1559
The Determination of the Maximum Theoretical Relative Density of Asphalt Mixes (Rice’s Method) and the TMH1 C4
AS5
Quantity of Bituminous Binder Absorbed by the Aggregates ASTM D2041
Field Tests (F)
F1 The Determination of In Situ Strength of Soils using the Dynamic Cone Penetrometer (DCP) TMH6 ST6
F2 The Determination of the Radius of Curvature of a Road Pavement using Deflection Measurements TMH6 ST9
F3 The Determination of In Situ Dry Density of Soils or Gravels using Sand Replacement Methods TMH1 A10 (a)
F4 The Determination of the In-Situ Dry Density and Moisture Content of Soils or Gravels by Nuclear Methods TMH1 A10 (b)
F5 Measurement of the Texture Depth of a Road Surface TMH1 ST 1
F6 Measurement of Road Roughness Using The Merlin Apparatus TRRL
F7 Method for Determining the Point Load Strength Index ISRM
F8 Rapid Field Test For Determining The Carbonation of Lime or Cement Treated Materials CSIR RS/2/84
F9 Visual Assessment of Flexible Pavements TMH 9
F10 Visual Assessment of Unsealed Roads TMH 12
F11 Non-Repetitive Static Plate Load Test for Soils and Flexible Pavements AASHTO T222-81
F12 The In-Situ Evaluation of Base Course Materials by Means of the Clegg Hammer ARRB (1996) Vol. 8
F13 The Modified Tray Test for Chip Seals TRH 3 Appendix L
F14 Determination of the Moisture in Soils By Means of a Calcium Carbide Gas Pressure Moisture Tester TMH1 C1

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Table 4.2 Approximate quantities of materials required for the various tests.
CML Approximate
TEST TEST DESCRIPTION Quantity
NUMBER (kg or g)
Soil tests
Sieve analysis of Gravel, Sand and Soil Samples
Wet preparation
S1 Dry preparation 5kg
Material passing the 0.075 mm sieve
Hydrometer analysis
S2 The Determination of the Liquid Limit of Soils
250g
S3 The Determination of the Plastic Limit and Plasticity index of Soils
(-0.425 mm)
S4 The Determination of the Bar Linear Shrinkage of Soils
S5 The Determination of the Maximum Dry Density (MDD) and Optimum Moisture Content (OMC) of Soils 35kg
S6 The Determination of the California Bearing Ratio (CBR) of Untreated Soils 22kg
S7 The Determination of the Unconfined Compressive Strength (UCS) of Stabilized Soils, Gravels and Sands 22kg
S8 The Determination of One-Dimensional Consolidation Properties of Soils Undisturbed sample
S9 The Identification of Dispersive Soils Using Crumb Test A few lumps
S10 The Determination of Durability for Cement-Treated Materials 50kg
S11 The Electrometric Determination of the pH Value of a Soil Suspension 50g (-0,425mm)
S12 The Determination of the Electrical Conductivity of Saturated Soil Paste and Water 250g (-6,7mm)
S13 The Determination of the Initial Consumption of Lime (ICL) 2kg
S14 The Determination of the Sand Equivalent Value of Soils and Fine Aggregates 1kg (-4,75mm)
S15 The Direct Shear Test of Soils 2kg
S16 The Determination of Shear Strength of Soils under Unconsolidated Undrained, Consolidated Drained and
5kg
Consolidated Undrained conditions in Tri-Axial Compression
S17 The Determination of the Dry Density/Moisture Content Relationship of Granular Soil (Vibratory Hammer
40kg
Method)
Aggregates Tests (AG)
Sieve Analysis of Aggregates, including The Determination of Material Passing the 0.425 mm sieve and the Depends on nominal size of
AG1
0.075 mm Sieve aggregates
AG2 The Determination of the Aggregate Crushing Value (ACV) Enough to fill the test
AG3 The Determination of 10 Per Cent Fines Aggregate Crushing Value (10% FACT) cylinder
AG4 The Determination of Aggregate Impact Value (AIV) 1kg (-13.2,+9.5mm)
AG5 Assessment of Aggregate Durability Using the Durability Mill Test 20kg
AG6 The Determination of the Flakiness Index of Coarse Aggregates 5kg
The Determination of the Adhesion of Bituminous Binder to Stone Aggregate by Means of the Chemical
AG7 100g (-6.7,+4.75 mm)
Immersion Test (Riedel And Weber)
The Determination of Dry Bulk Density, Apparent Relative Density and Water Absorption of Aggregates Retained
AG8 5kg
on the 4.75 mm Sieve and Passing the 4.75 mm Sieve
AG9 The Determination of the Accelerated Laboratory Polished Stone Value (PSV) 1.5kg(-10+8mm)
300 stones
AG10 The Determination of the Aggregate Fingers Value and the Aggregate Pliers Value
(-19 +13,2mm)

54 Laboratory Testing Operating Procedures for Central Materials Laboratory

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Table 4.2: continued.

CML Approximate
TEST TEST DESCRIPTION Quantity
NUMBER (kg or g)
Bitumen Tests (B)
B1 The Determination of the Penetration Value of Bituminous Binders 100g
B2 The Determination of the Ductility of Bitumen 100g
B3 The Distillation of Cutback Bitumen 200g
B4 The Determination of the Softening Point of Bituminous Binders using Ring and Ball Method 20g
B5 The Determination of the Kinematic Viscosity of Cutback Bitumen 10g
B6 The Performance of Bitumen When Subjected To The Thin Film Oven Test (TFO) 250g
B7 The Performance of Bitumen When Subjected to The Rolling Thin Film Oven Test (RTFO) 300g
B8 The Determination of the Percentage of Bitumen Soluble in Trichloro-Ethylene 10g
Concrete Tests
C1 The Making Curing and Compressive Strength Determination of Concrete Test Cubes 30kg
C2 The determination of the slump of freshly mixed concrete 10kg
Asphalt Tests
AS1 The Determination of a suitable Binder Content for use in an Asphalt Mix 25kg
AS2 The Determination of the Binder Content of a Bituminous Mixture 1.5 kg (briquette)
The Determination of the Bulk Relative Density of a Compacted Bituminous Mixture and the Calculation of the
AS3 Briquette
Voids Content
The Determination of the Resistance to Flow of a Cylindrical Briquette of a bituminous mixture by Means of the
AS4 5kg (3 briquettes)
Marshall Apparatus
The Determination of the Maximum Theoretical Relative Density of Asphalt Mixes (Rice’s Method) and the 1.5 kg
AS5
Quantity of Bituminous Binder Absorbed by the Aggregates (briquette)
Field Tests (F)
F13 The Modified Tray Test for Chip Seals 2 kg

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Table 4.3: Approximate resources required to carry out tests and output per day or
per week.
CML Number Number of tests per time
TEST TEST DESCRIPTION of period
NUMBER persons
Soil Tests
Riffling 50 kg bags 2 10 per day
Sieve Analysis of Gravel, Sand and Soil Samples (prepared material) 1 12 per day
Wet preparation 1 25 per week
S1 Dry preparation 1 35 per week
Material passing the 0.075 mm Sieve 1 20 per day
Hydrometer analysis 1 12 per day
S2 The Determination of the Liquid Limit of Soils
S3 The Determination of the plastic Limit and Plasticity index of Soils 1 10 per day
S4 The Determination of the Bar Linear Shrinkage of Soils
The Determination of the Maximum Dry Density (MDD) and Optimum Moisture Content (OMC) of
S5 2 5 per day
Soils
7 per day (compaction)
S6 The Determination of the California Bearing Ratio (CBR) of Untreated Soils 2
7 per day (testing)
The Determination of the Unconfined Compressive Strength (UCS) of Stabilized Soils, Gravels and 8 per day (compaction)
S7 2
Sands 8 per day (testing)
S8 The Determination of One-Dimensional Consolidation Properties of Soils 1 1 Per apparatus per week
S9 The Identification of Dispersive Soils Using Crumb Test 1 50 per day
2 Spec prep – 6 per day
S10 The Determination of Durability for Cement-Treated Materials
1 Testing – 10 per day
S11 The Electrometric Determination of the pH Value of a Soil Suspension 1 30 per day
S12 The Determination of the Electrical Conductivity of Saturated Soil Paste and Water 1 20 per day
S13 The Determination of the Initial Consumption of Lime (ICL) 1 12 per day
S14 The Determination of the Sand Equivalent Value of Soils and Fine Aggregates 1 6 per day
S15 The Direct Shear Test of Soils Under Consolidated Drained Conditions 1 1 Per apparatus per day
S16 The Determination of Shear Strength of Soils under Unconsolidated Undrained, Consolidated
1 1 Per apparatus per week
Drained and Consolidated Undrained conditions in Tri-Axial Compression
S17 The Determination of the Dry Density/Moisture Content Relationship of Granular Soil (Vibratory
2 5 per day
Hammer Method)
Aggregates Tests (AG)
Sieve Analysis of Aggregates, including The Determination of Material Passing the 0.425 mm Sieve
AG1 1 12 per day
and the 0.075 mm Sieve
AG2 The Determination of the Aggregate Crushing Value (ACV) 2 12 per day
AG3 The Determination of 10 Per Cent Fines Aggregate Crushing Test (10% FACT) 2 4 per day
AG4 The Determination of Aggregate Impact Value (AIV) 1 8 per day
AG5 Assessment of Aggregate Durability Using the Durability Mill Test 1 6 per day
AG6 The Determination of the Flakiness Index of Coarse Aggregates 1 6 per day
The Determination of the Adhesion of Bituminous Binder to Stone Aggregate by Means of the
AG7 1 4 per day
Chemical Immersion Test (Riedel And Weber)
The Determination of Dry Bulk Density, Apparent Relative Density and Water Absorption of
AG8 1 24 per week
Aggregates Retained on the 4.75 mm Sieve and Passing the 4.75 mm Sieve
AG9 The Determination of the Accelerated Laboratory Polished Stone Value (PSV) 1 30 per day
AG10 The Determination of the Aggregate Fingers Value and the Aggregate Pliers Value 1 3 per week

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Table 4.3: continued.

CML Number Number of tests per time

TEST TEST DESCRIPTION of period
NUMBER persons
Bitumen Tests
B1 The Determination of the Penetration Value of Bituminous Binders 1 25 per day
B2 The Determination of the Ductility of Bitumen 1 15 per day
B3 The Distillation of Cutback Bitumen 1 3 per day
B4 The Determination of Softening Point of Bituminous Binders using Ring and Ball method 1 20 per day
B5 The Determination of the Kinematic Viscosity of Cutback Bitumen 1 6 per day
B6 The Performance of Bitumen when subjected to the Thin Film Oven Test (TFO) 1 2 per day
B7 The Performance of Bitumen when subjected to the Rolling Thin Film Oven Test (RTFO) 1 4 per day
B8 The Determination of the Percentage of Bitumen Soluble in Trichloro-Ethylene 1 5 per day
Concrete Tests
The Making, Curing and Compressive Strength Determination of Concrete Test Cubes (3 2 per day (compaction)
C1 2
replicates), (Prepared materials) 8 per day (testing)
C2 The Determination of the Slump of Freshly Mixed Concrete 1 10 per hour
Asphalt Tests (AS)
AS1 The Determination of a Suitable Binder Content for use in an Asphalt Mix 2 3 days
AS2 The Determination of the Binder Content of a Bituminous Mixture 1 5 per day
The Determination of the Bulk Relative Density of a Compacted Bituminous Mixture and the
AS3 1 5 per day
Calculation of the Voids Content
The Determination of the Resistance to Flow of a Cylindrical Briquette of a bituminous mixture by
AS4 1 30 per day
means of the Marshall apparatus
The Determination of Maximum Theoretical Relative Density of Asphalt Mixes (Rice’s method) and
AS5 1 6 per day
Quantity of Bituminous Binder Absorbed by the Aggregates
Field Tests (F)
F1 The Determination of In-Situ Strength of Soils using the Dynamic Cone Penetrometer (DCP) 3 ½ hour per test
F2 The Determination of the Radius of Curvature of a Road Pavement using Deflection Measurements 3 ½ hour per point
F3 The Determination of In-Situ Dry Density of Soils or Gravels using Sand Replacement Methods 1 1 hour per test
F4 The Determination of In-Situ Dry Density of Soils or Gravels using Nuclear Methods 1 ½ hour per point
F5 Measurement of the Texture Depth of a Road Surface 2 1 hour per point
F6 Measurement of Road Roughness Using The Merlin Apparatus 1 2 km per hour
F7 Method for Determining the Point Load Strength Index 1 10 per day
F8 Rapid Field Test For Determining The Carbonation of Lime Or Cement Treated Materials 2 1 hour per test
F9 Visual Assessment of Flexible Pavements 1 1 km per hour (1 lane)
F10 Visual Assessment of Unsealed Roads 1 1 km per hour
F11 Non-Repetitive Static Plate Load Test for Soils and Flexible Pavements 2 3 hours per test
F12 The In-Situ Evaluation of Base Course Materials by Means of the Clegg Hammer 1 5 min’s per point
F13 The Modified Tray Test for Chip Seals 1 8 tests per day
F14 Determination of the Moisture in Soils By Means of a Calcium Carbide Gas Pressure Moisture
1 4 tests per hour
Tester

NB: The resources and time for processing the results is not included. Preparation of material for
testing also not included in tests (e.g. Fines for Atterberg Limits - see sample preparation). Time
taken to do many of the tests is dependent on material properties.

For the field tests, people required for traffiic safety reasons are NOT included.

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4.8 Soils Tests

4.8.1 CML TEST NO. S1:
Sieve analysis of Gravel, Sand and Soil Samples
Scope:
The test involves the quantitative determination of particle size distribution
in an essentially cohesionless soil down to fine sand size.
In the wet preparation procedure the sample is wet sieved to remove silt and
clay sized particles followed by dry sieving of the remaining coarse material.
The Hydrometer test is necessary where it is Definition:
important to know the distribution of particles Sieve analysis is an important classification test for soils, especially coarse
smaller than 0.075 mm sieve, for instance where
it is necessary to determine the heave potential of soils, as it presents the relative portion of different sizes of particles. From
soil using Van der Merwe’s curves. This test shall this it is possible to determine whether the soil consists of predominantly
be carried out by a trained and skilled operator.
gravel, sand, silt or clay sizes.
Procedure:
The following procedures shall be used as appropriate.
Wet preparation: method A1 (a): TMH 1:1986
Dry preparation: method A1 (b): TMH 1:1986
Material passing 0.075 mm sieve: method A5 TMH 1:1986
Hydrometer analysis: method A6 TMH 1:1986.

Notes:
● The decision of whether to use dry preparation or wet preparation shall
be taken by the Laboratory Manager after consulting the Project Officer.
● The test sieves must be inspected for defects before use. A more detailed
examination shall be made at regular intervals for signs of wear and tear,
splits, holes, blockages etc.

4.8.2 CML TEST NO. S2:

The Determination of the Liquid Limit of Soils
Scope:
The liquid limit (LL) of a soil is determined from the liquid limit device by
plotting a curve of the number of taps necessary to obtain a specific con-
sistency of the soil fines against the moisture contents in three trials. The
method also provides for the calculation of the liquid limit from a one-point
determination if so required.
Definitions:
The liquid limit of a soil is the moisture content, expressed as a percentage
of the mass of the oven-dried soil, at the boundary between the liquid and
the plastic states. The moisture content at this boundary is arbitrarily defined
as the liquid limit and is the moisture content at a consistency determined by
means of the standard liquid limit apparatus.
Procedure:
Shall be carried out in accordance with method A2: TMH1: 1986.
Notes:
● It is very important to note that under the TMH1 procedure, liquid limit
is carried out using the Casagrande device. The base of the device must
be made of hard rubber with a Shore D value of 85 to 95 at 23±2ºC.
● The Unit Head shall ensure that only equipment that conforms to the
specification is used.

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● The Unit Head shall carry out general inspection of the apparatus at least
once a month.
● The bowl and the hard rubber base of the liquid limit device shall be
inspected by the Unit Head regularly, as they tend to wear readily.
● If the bowl is badly worn, it shall be replaced.
● If the base is badly worn, it shall be reversed or machined off level or
replaced.
● Use of a BS Liquid Limit device will result in a Liquid Limit up to 4
percentage points higher than the TMH1 method.
● Pedocretes, particularly calcrete, often give lower Liquid Limits after
oven drying than when air-dried. This aspect should be considered when
testing these materials.
● When testing Kalahari sands the liquid Limit of the 0,075 mm fraction
should also be determined.

4.8.3 CML TEST NO. S3:

The Determination of the Plastic Limit and Plasticity Index of
Soils .
Definitions:
The Plastic Limit (PL) of a soil is the moisture content, expressed as a
percentage of the mass of the oven-dried soil, at the boundary between the
plastic and the semi-solid states.
The Plasticity Index (PI) of a soil is the numerical difference between the
liquid limit and the plastic limit of the soil and indicates the moisture content
range in which soil is in a plastic state.
Procedure:
Shall be carried out in accordance with method A3: TMH1: 1986.
Notes:
● The hands of the operator should be clean and dry when performing the test.
● When testing Kalahari sand it may be desirable to also perform the plastic
limit test using fines passing the 0.075 mm sieve.

4.8.4 CML TEST NO. S4:

The Determination of the Bar Linear Shrinkage of Soils
Definition:
The Linear Shrinkage (LS) of a bar of a soil is the linear change in length The linear shrinkage test also serves as an ap-
of the fraction of a soil sample passing 0.425 mm sieve as it dries from the proximate check on the plasticity Index results.
Most types of soils exhibit a rough relationship
liquid limit moisture content. between PI and LS which is commonly reported
as PI = 2 x LS. For calcrete PI = 1.5 x LS. It
Procedure: is therefore recommended that the test be con-
This test shall be carried out in accordance with method A4: TMH1: 1979. ducted, but that no decisions other than to check
the Atterberg results should be based on this
Notes: relationship.

● Do not allow the filled troughs to air dry before placing in the oven. Air-
drying reduces the tendency for higher plastic materials to “bow” but
reduces the measured linear shrinkage.
● Where the LL is carried out on non-standard fines i.e. P 0.075 mm sieve,
the LS should also be carried out on the same.

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4.8.5 CML TEST NO. S5:

The Determination of the Maximum Dry Density (MDD) and
the Optimum Moisture Content (OMC) of Soils
Scope:
Material retained on the 19.0 mm sieve can be The maximum dry density and optimum moisture content are determined by
handled in a number of ways. The suggested method
is for all the material > 19 mm to be discarded and establishing the moisture-density relationship of the material when compact-
the OMC/MDD to be corrected according to ASTM ed at the Modified AASHTO compaction effort at different moisture contents.
D4718. Should 5 per cent or less be greater than
19 mm then there is no need for correction. Caution Definition:
should be exercised when more than 30 per cent of
the sample is retained on the 19 mm sieve.
The Maximum Dry Density (MDD) of a material for a particular compac-
tion effort is the highest density obtainable when the compaction is carried
In spite of the above it is recommended that out on the moist mass of the material and the moisture content is varied.
method A7: TMH1 should be followed to avoid
variations in the results from one Laboratory to
the other.
The Optimum Moisture Content (OMC) for a definite compaction effort is
the moisture content at which the maximum density is obtained.
Procedure:
Shall be carried out in accordance with method A7: TMH1: 1986.
Notes:
● The test is only carried out on material passing the 19 mm sieve. The results
are therefore not truly representative of the field conditions. This must be
borne in mind when determining the in-situ compaction based on the lab-
oratory MDD.
● The OMC determined is that of a specific compaction effort and may not
represent that of light or very heavy field compaction equipment.

4.8.6 CML TEST NO. S6:

The Determination of the California Bearing Ratio (CBR) of
Untreated Soils
Scope:
The California Bearing Ratio (CBR) of a material is determined by measuring
the load required to allow a standard piston to penetrate the surface of a material
compacted according to TMH 1, method A7. The determination of the CBR-
density relationship is also part of the method.
Definition:
The California Bearing Ratio of a material is the load in kN, which is expressed
as a percentage of California standard values at maximum dry density of a
material for a particular compaction effort.
Procedure:
Shall be carried out in accordance with method A8: TMH1: 1986.
Notes:
● The same problems concerning the percentage of material greater than 19
mm discussed for MDD/OMC compaction, also occur with the CBR test.

4.8.7 CML TEST NO. S7:

The Determination of the Unconfined Compressive Strength
(UCS) of Stabilized Soils, Gravels and Sands
Scope:
In this method, the unconfined compressive strength of stabilized materials
is determined by subjecting prepared specimens to an increasing load until
failure under unconfined conditions.

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Definition:
The Unconfined Compressive Strength (UCS) of a stabilized material is the load
in kilopascals (kPa) required to crush a cylindrical specimen 127.0 mm high and
152.4 mm in diameter to total failure at a loading rate of 140 kPa per second.
Procedure:
The test should be carried out according to method A14: TMH 1, 1986.
Notes:
● See notes given in test method A14: TMH1, 1986.

4.8.8 CML TEST NO. S8:

The Determination of One-Dimensional Consolidation
Properties of Soils
Scope:
The test method covers a procedure for determining the rate and magnitude
of consolidation of soil when it is restrained laterally and loaded and drained
vertically.
Procedure:
The test should be carried out according to test method D2435: ASTM, 1998

4.8.9 CML TEST NO. S9:

The Identification of Dispersive Soils Using Crumb Test
Scope:
The test method covers a procedure for the identification of dispersive soils. Dispersive soils are these containing high
exchangable sodium percentage that cause the
The dispersive clays soils are identified by observing the behaviour of few fine clay particle to go into suspension in fresh
crumbs of soil placed in distilled water. The dispersion is classified depend- water.
ing on the degree of muddiness of the water.
General:
The Crump test is a simple test that is recommended for the initial field iden-
tification of dispersive soils.
Procedure:
The test should be carried out according to test method Part 5: BS 1377,
1990.
Notes:
● For flocculated soils, a dilute solution of sodium hydroxide is required
instead of distilled water. The Sodium hydroxide is prepared by dissolving
0.04g of anhydrous sodium hydroxide in distilled water to make 1 litre of
the solution.
● The test report shall state the details of the reagent used.

4.8.10 CML TEST NO. S10:

The Determination of Durability for Cement-Treated Materials
Scope:
The test method covers the procedure for determining the soil-cement losses The wet/dry brushing test was originally devel-
obtained by repeated wetting, drying and brushing of hardened soil-cement oped for cement treated materials but it can be
used with equal success on material treated
specimen. with other chemical stabilisers such as lime and
blast-furnace slag. It must, however, be noted
Procedure: that with these stabilising agents, it may take
The test shall be carried out according to test method A19: TMH 1, 1986. more than seven days to produce strengths
equivalent to that of cement.

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Notes:
● Ensure that the brushing is performed vertically and that the applied force is
approximately 1.36kg.
● Mass determinations of specimen shall be made at the end of each cycle.

4.8.11 CML TEST NO. S11:

The Electrometric Determination of the pH Value of a Soil
Suspension
Scope:
The test method covers the determination of the pH value of a soil suspension
by measuring the hydrogen ion concentration in the suspension with a pH meter.
Definition:
The pH expresses the degree of effective acidity or alkalinity of a solution and
is defined as the negative logarithm of the hydrogen ion concentration of a
solution i.e. pH = -log[H+]. The pH range for aqueous solutions extends from
0 to 14 with 0 to 7 indicating the acidic range and 7 to 14 the alkalinic range.
Procedure:
The test should be carried out according to test method A20: TMH 1, 1986.
Notes:
● The pH meter should be calibrated prior to the beginning of the testing and
at frequent intervals between testing in accordance with the manufacturer’s
instructions.
● The tip of the combination electrode should be kept immersed in distilled
water for at least one hour prior to starting the test to wet the salt bridge
in the reference electrode, and should be kept immersed in distilled water
between tests.
● pH probes are very sensitive to damage and should be treated carefully.
● pH is a function of dilution (quantity of water) and it should be ensured
that the water content is consistent.
● The probes tend to have a short life span when used for testing high
alkaline solutions (such as ICL determinations). When this type of testing
is carried out it should be ensured that the probe is still fully functional.

4.8.12 CML TEST NO. S12:

The Determination of the Electrical Conductivity of Saturated
Soil Paste and Water
Scope:
The test method covers the determination of the electrical conductivity of a
saturated soil paste and of water using standard cup cell. The method also
describes the procedure for estimating the soluble salt content of a soil or
water from the conductivity.
Definitions:
The resistance of an electrolytic solution, as represented by the saturated soil
paste or water, is that property of the solution that opposes the flow of an elec-
tric current through it.
Resistivity is the resistance in Ohms of 1m3 of an electrolytic solution at a
specified temperature.
Conductance is the reciprocal of the resistance and is recorded in Siemens.
Procedure:
The test shall be carried out according to test method A21T: TMH 1, 1986.

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Notes:
● If the material is dried at a temperature above 800 oC some salts may
decompose resulting in a higher conductivity reading.
● Conductivity measurements may be used to estimate the soluble salt content
of a sample.

4.8.13 CML TEST NO. S13:

The ICL does not dispense of the need to estab-
The Determination of the Initial Consumption of Lime (ICL) lish the lime content required to achieve design
strength or the required reduction in plasticity. It
Scope: only gives a thresh-hold value to achieve a per-
The test method covers the procedure for the determination of Initial manent stabilisation effect.
Consumption of Lime (ICL).
Definition:
The ICL is the amount of lime consumed in the initial ion exchange reaction
in a material-lime mixture, and is the minimum lime content required to
achieve a permanent gain in strength of the material.
Procedure:
The test shall be carried out according to test method Part 2: BS 1924, 1990.
Notes:
● The lime used in the test shall have a pH value ranging from 12.35 to
12.45 at 25 oC.
● The buffer solutions used in the test shall not be kept for more than 7 days.
● Electrodes used in the test must be suitable for highly alkaline solutions.

4.8.14 CML TEST NO. S14:

The Determination of the Sand Equivalent Value of Soils and
Fine Aggregates
Scope:
This method is intended to serve as a rapid field test to show the relative fine
dust or clay like material in soils or fine aggregates.
Procedure:
The test shall be carried out according to method ASTM D2419 or
AAHSTO T176-00.

4.8.15 CML TEST NO. S15:

The Direct Shear Test of Soils
Scope:
This method describes the procedure for determining the consolidated
drained shear strength of a soil material in direct shear mode. The test may
be conducted in either a single shear or a double shear.
General:
The direct shear test is well suited to a consolidated drained test because the
drainage paths through the specimens are short, thereby allowing excess pore
pressure to dissipate fairly rapidly. The test can be made on all soil material,
and on undisturbed or remoulded samples.
Procedure:
The test shall be carried out according to method ASTM D 3080-72.

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4.8.16 CML TEST NO. S16:

The Determination of Shear Strength of Soils under Unconsoli-
dated Undrained, Consolidated Drained and Consolidated Un-
drained conditions in Tri-Axial Compression.
Scope: A
This test method describes the determination of unconsolidated strength and
stress-strain relationships for a cylindrical specimen of either an undisturbed
or remoulded cohesive soil sheared un-drained in compression at a constant
rate of axial deformation (strain controlled).
General:
The test method provides for the calculation of total stresses on, axial com-
pression of the test specimen by measurement of the axial load and axial
deformation.
The test provides data which is useful in determining strength and deformation
properties of cohesive soils such as Mohr strength envelopes and Young’s
modulus.
Procedure:
The test should be carried out according to method AASHTO T 296-95.
Scope: B
This test method describes the determination of strength and stress-strain
relationships for a cylindrical specimen of either an undisturbed or re-
moulded saturated cohesive soil when it is isotropically consolidated and
sheared un-drained in compression at a constant rate of axial deformation
(strain controlled).
General:
The test method provides for the calculation of total and effective stresses on,
axial compression of the test specimen by measurement of the axial load and
axial deformation and pore water pressure.
The test provides data which is useful in determining strength and deformation
properties of cohesive soils such as Mohr strength envelopes and Young’s
modulus. Generally, three specimens are tested at different effective consolida-
tion stresses to define a strength envelope.
Procedure:
The test shall be carried out according to method ASTM D 4767-88 or
AASHTO T 297-94.
Note:
Similar test is done in Tri-Axial Compression in Drained condition also
where pore pressure gets dissipated and becomes equal to zero. The Mohr´s
Strength Envelope in this case is expressed in terms of Effective stress where
Total stress becomes equal to Effective Stress.

4.8.17 CML TEST NO. S17:

The Determination of the Dry Density/Moisture Content
Relationship of Granular Soil (Vibratory Hammer Method)
Scope:
This test method covers the determination of the mass of dry soil per cubic metre
when the soil is compacted in a specified manner over a range of moisture
contents, including that giving the maximum mass of dry soil per cubic metre.
The optimum moisture content and maximum dry density for a compacted
material are thus determined.

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General:
In this test which is suitable for fine-grained soils and for the fraction of
medium and coarse grained granular soils passing the 37,5 mm sieve, the
soil is compacted into a California Bearing Ratio mould of 152 mm diameter
and 127 mm depth, using an electrically operated vibrating hammer.
Procedure:
The test shall be carried out according to method BS 1377: 1975.
Notes:
See notes given in the stated test method.

4.9 Aggregates Tests

4.9.1 CML TEST NO. AG1:
Sieve Analysis of Aggregates, Including the Determination of
Material Passing 0.425 mm Sieve and 0.075 mm Sieve
Scope:
This method describes the sieve analysis of a dried aggregate sample, after it
has been washed through a 0.075 mm sieve, and the subsequent determination
of the percentages of material by mass passing the 0.425 mm and 0.075 mm
sieves, also called the fines and dust content of aggregates respectively.
These determinations are done on aggregate for asphalt, surface treatments
and concrete.
Procedure:
The test shall be carried out according to test method B4: TMH 1:1986.
Notes:
● The decision on whether to use dry preparation or wet preparation shall
be taken by the Laboratory Manager after consulting the Project Officer/
SRE-Lab.
● The test sieves must be inspected for defects before their use. A more
detailed examination shall be made at regular intervals for signs of wear, More detail regarding ACV/10% FACT and
testing of weaker aggregates can be found in
working, tear, splits, holes, blockages etc. Guideline No. 8.

4.9.2 CML TEST NO. AG2:

The Determination of Aggregate Crushing Value (ACV)
Scope:
The Aggregate Crushing Value of an aggregate is determined by crushing
a prepared confined aggregate sample under a specified, gradually applied
compressive load and determining the percentage of the crushed material
finer than a specified size.
Definition:
The Aggregate Crushing Value (ACV) of an aggregate is the mass of material,
expressed as a percentage of the test sample, which is crushed finer than 2.36
mm when a sample of aggregate passing the 13.2 mm and retained on the
9.5 mm sieve is subjected to crushing under a gradually applied compressive
load of 400 kN.
Procedure:
The test shall be carried out according to test method B1: TMH 1:1986.

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Notes:
● For softer aggregates (say ACV higher than 30) it is recommended that
the 10% FACT be done instead of the ACV in order to reduce the effect
of compaction of the crushed material.
● Testing of material after water soaking and/or ethylene glycol soaking
can provide useful additional information on the nature and durability of
the material being tested.

4.9.3 CML TEST NO. AG3:

The Determination of 10 Per Cent Fines Aggregate Crushing
Value (10 % FACT)
Scope:
The 10 per cent Fines Aggregate Crushing Value (10 % FACT) of an aggregate
is determined by measuring the load required to crush a prepared aggregate
sample to produce 10 per cent material passing a specified sieve after crush-
ing.
Definition:
Ethylene glycol soaking of aggregates can be The 10 per cent Fines Aggregate Crushing Value is the force in kN required
carried out for 24 hours, 4 days or even 28 days
before ACV, 10% FACT or AIV testing, particular- to crush an aggregate sample passing 13.2 mm sieve and retained on the 9.5 mm
ly for basic crystalline rocks where the presence so that 10 per cent of the total test sample will pass a 2.36 mm sieve.
of smectite clays is suspected.
Procedure:
The test shall be carried out according to BS 812: Part 3: 1983.
Notes:
● Testing of material after water soaking and/or ethylene glycol soaking
can provide useful additional information on the nature and durability of
the material being tested.

4.9.4 CML TEST NO. AG4:

The Determination of Aggregate Impact Value (AIV)
Scope:
The aggregate impact value (AIV) of aggregates is a measure of the resistance
of aggregate to impact. The aggregate is subjected to blows of a falling hammer
and the resulting disintegration is measured in terms of the quantity of material
passing the 2.36 mm sieve, which is then expressed as a percentage of the test
sample. This is called the Aggregate Impact Value.
Procedure:
The test methods shall be carried out according to BS 812: Part 3: 1983.
Notes:
● The test is normally done on aggregates in their dry state but may also be
carried out on aggregates that have been soaked in water or ethylene
glycol for 24 hours.
● Water soaking is done to determine whether the aggregates are exces-
sively susceptible to breakdown in wet conditions.

4.9.5 CML TEST NO. AG5:

Assessment of Aggregate Durability Using Durability Mill Test
Scope:
The test method provides a measure of the ability of an aggregate to withstand
degradation both during construction and under various service conditions. It
also furnishes additional data pertaining to the quality of the material and the

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possible change in index properties likely to occur in the road and be detri-
mental to its performance. The test has the advantage of testing a full grad-
ing that is used in practice, unlike comparable tests such as the Los Angeles
Abrasion test (LAA).
Definition:
The Durability Mill values are taken as the mass of dry material passing the
0.425 mm sieve after treatment, expressed as a percentage of the original dry
mass of the sample. The Durability Mill Index (DMI) is the product of the
highest percentage passing 0.425 mm for any of the treatments and the high-
est Plasticity Index (PI) for any treatment.
Procedure:
The test should be carried out according to test method (d) in Standard
Specifications for Road and Bridge Works (1998) issued by SATCC.
Notes:
● Materials that contain high smectite contents within aggregate particles
are clearly identified by the DM test as these are released during the
treatments and manifested as high PI’s in the wet test.
● Although no direct comparisons have been done in Southern Africa, it is
thought that the dry treatment with balls in the DMI compares closely
with the Los Angeles Abrasion (LAA) test, after consideration of the
initial fines content.

4.9.6 CML TEST NO. AG6:

The Determination of the Flakiness Index of Coarse Aggregates
Scope:
The Flakiness Index of a coarse aggregate is determined by gauging screened-
out fractions with the appropriate slot(s) given in a table in the test method.
Aggregate retained on the 75 mm and passing the 4.75 mm sieve is not included
in the test.
Definition:
The Flakiness Index (FI) of a coarse aggregate is the mass of particles in
that aggregate, expressed as a percentage of the total mass of that aggregate,
which will pass the slot or slots of specified width for the appropriate size
fraction. The width of the slots is half that of the sieve openings through
which each of the fractions passes.
Procedure:
The test should be carried out according to method B3: TMH 1: 1986 or BS
812: Part 1.
Notes:
● Do not force the pieces of aggregate through the slots in the gauge. The
aggregates that do not pass easily through the slots should be considered
too large for the particular opening and recorded as such.
● The slots in the gauge tend to wear with time and should, therefore, be
measured periodically to determine whether they comply with the speci-
fications. Gauges with worn slots should be replaced.
● Flaky materials will often be manifested as a lower strength in the ACV
or 10 % FACT tests, compared with cubical aggregate particles.

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4.9.7 CML TEST NO. AG7:

The Determination of Adhesion of Bituminous Binder to
Stone Aggregate by Means of Chemical Immersion Test
(Riedel And Weber)
Scope:
This method covers the determination of the adhesion of bitumen to stone
aggregate by boiling bitumen coated aggregate successively in distilled
water and in increasing concentrations of sodium carbonate. These concen-
trations are numbered 0 to 9. The number of the concentration at which the
bitumen strips to such an extent that it is no longer a film but only specks or
droplets, is called the stripping value.
Definition:
The Riedel and Weber value is an expression of ability of an aggregate to
bond to a standard bitumen (150/200 pen).
Procedure:
The test should be carried out according to method B11: TMH 1: 1986.
Notes:
● It is advisable to keep a stock of a reference stone of a known stripping
value for reference purposes and to check new consignments of bitumen.
The characteristics of bitumen may differ between consignments even
though the penetration values are similar.

4.9.8 CML TEST NO. AG8:

The Determination of Dry Bulk Density, Apparent Relative
Density and Water Absorption of Aggregates Retained on
4.75 mm Sieve and Passing 4.75 mm Sieve
Scope:
The dry bulk density and apparent relative density of both the plus and minus
4.75 mm fraction of the material, as defined below, are calculated from the
loss in mass of saturated surface dry aggregate when it is submerged in water.
The water absorption is determined by calculating the mass of water absorbed
after 24-hour immersion in water of the oven-dried material.
Definition:
Relative density is the ratio of the mass in air of a given volume of material at
a stated temperature to the mass in air of an equal volume of distilled water
at the same temperature.
Bulk Relative density is the ratio of the mass in air of a given volume of
material (including the permeable and impermeable voids normal to the
material) at a stated temperature to the mass in air of an equal volume of
distilled water at the same temperature.
Apparent relative density is the ratio of the mass in air of a given volume
of material (excluding permeable voids but including the impermeable voids
normal to the material) at a stated temperature to the mass in air of an equal
volume of distilled water at the same temperature.
Procedure:
The test shall be carried out according to the following procedures:
Material retained on the 4,75 mm sieve tested according to method
B14: TMH1: 1986.
Material passing the 4,75 mm sieve tested according to method B15: TMH1:
1986.

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Notes:
● The test results are very dependent on obtaining the correct value for the
surface dry state of the aggregates and it is sometimes difficult to achieve
this, particularly where the fine fraction is concerned. Every effort must
be made to ensure that this condition is achieved.
● The loss of fine aggregates when drying must be guarded against.

4.9.9 CML TEST NO. AG9:

The Determination of Accelerated Laboratory Polished-Stone
Value (PSV)
Scope:
The object of the test is to give a relative measure of the extent to which dif-
ferent types of road-stone in the wearing surface will polish under traffic.
General:
Where the surface of a road consists mainly of road-stone the state of polish
of a sample will be one of the major factors affecting the resistance of the
surface to skidding. The actual relationship between polished stone value
and skidding resistance will however, vary with traffic conditions, type of
surfacing and other factors.
Procedure:
The test methods shall be carried out according to Part 3: BS 812, 1990.
Notes:
● The use of a resin instead of cement is recommended for making the
briquettes containing the surfacing aggregate as test results may be ob-
tained much sooner. Briquettes made of cement have to be cured for a
minimum period of 7 days.

4.9.10 CML TEST NO. AG10:

The Determination of the Aggregate Fingers Value and the
Aggregate Pliers Value
Scope:
The test was developed for rapid field or laboratory strength-assessments of
aggregates with particular reference to calcrete.
Definition:
The Aggregate fingers value is the percentage of aggregate pieces of a
sample of a material that cannot be broken by finger pressure, whereas the
aggregate pliers value is a measure of the number of aggregate pieces of
the same sample that cannot be broken by a person using a standard pliers
described in the test method.
Procedure:
The test methods shall be carried out according to method C.B. 22: Manual
of Testing Procedures for Highway Materials, CSIR. Transportek.
Notes:
● Use only the type of pliers described in the method.
● Do not use these pliers for any other purpose other than testing.
● People doing the test should be of medium build (don’t use the biggest,
strongest person in the lab because he or she can crush the most aggre-
gate pieces).

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4.10 Bitumen Tests

4.10.1 CML TEST NO. B1:
The Determination of the Penetration Value of Bituminous
Binders
Scope:
Penetration is defined as the consistency of semi-solid and solid bituminous
binders expressed as the distance that a standard needle vertically penetrates a
sample of the material under known conditions of loading, time and temperature.
The units of penetration indicate tenths of a millimeter.
Definition:
Consistency is an engineering term defined as an empirical measure of resis-
tance offered by a fluid to continuous deformation when it is subjected to a
shearing stress.
Procedure:
The test shall be carried out according to method D5: ASTM, 1998.
Notes:
● Pre-soak penetration needles in a 1% solution of Oleic acid to remove
any oils or dirt that may be present from handling, etc.
● Ensure that the needle being used complies with the test specifications.
● The performance of new needles should be compared with that of a certi-
fied needle, which is kept solely for this purpose and is not used for general
testing.
● The penetration should always be done at the centre of the mould to
avoid edge effects.
● Use only calibrated thermometers in Bitumen testing.

4.10.2 CML TEST NO. B2:

The Determination of the Ductility of Bitumen
Scope:
The ductility of bitumen is expressed as the distance in centimetres by which a
standard briquette can be elongated before it breaks under specified conditions.
Procedure:
The test shall be carried out according to method D113: ASTM, 1998.
Notes:
● After filling the mould the excess bitumen must be carefully cut to the
exact level of the mould. Too little or too much bitumen in the mould
will obviously influence the test results.
● It should be ensured that there are no air bubbles in the specimens after
moulding otherwise the test results may be erroneous.

4.10.3 CML TEST NO. B3:

The Distillation of Cutback Bitumen
Scope:
This method describes a procedure intended to give approximate information
concerning volatile constituents in cutback bitumen and to provide a means for
separating the bitumen from the more volatile constituents. The residue from
the distillation is tested as required. Tests can also be carried out on the distillate.
Procedure:
The test shall be carried out according to method D402: ASTM, 1998.

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Notes:
● Ensure that the correct mould is used to do the test, as other moulds with
different dimensions are available for specifications other than ASTM.

4.10.4 CML TEST NO. B4:

The Determination of the Softening Point of Bituminous Binders
using Ring and Ball Method
Scope:
This method provides a measure of the temperature susceptibility of a
bituminous material. Bituminous materials do not change from a solid state
to a liquid state at any definite temperature, but gradually become softer and
less viscous as the temperature rises.
Definition:
The softening point is defined as the point at which the bitumen attains a
particular degree of softness under specified conditions of test.
Procedure:
The test shall be carried out according to method D36: ASTM, 1998.
Notes:
● Use only freshly boiled distilled water.
● Use the correct mould size as specified by the method. Other sizes are
available on the market.
● The container in which the specimens are heated must have the correct
dimensions, as specified by the method.

4.10.5 CML TEST NO. B5:

The Determination of the Kinematic Viscosity of Cutback
Bitumen
Scope:
The method covers the determination of the kinematic viscosity of opaque
liquid petroleum products by measuring the time of flow of a fixed volume
of liquid at a given temperature through calibrated glass capillary instru-
ments using gravity flow. A procedure is given for the calculation of dynamic
viscosities from measured kinematic viscosities.
Definition:
For the purposes of this method, kinematic viscosity is a measure of the
time for a fixed volume of liquid to flow by gravity through a capillary tube.
Dynamic viscosity can also be calculated from the kinematic viscosity.
Procedure:
The test shall be carried out according to method D2170: ASTM, 1998.
Notes:
● The capillary tubes must be spotlessly clean otherwise erroneous results
may be obtained.

4.10.6 CML TEST NO. B6:

The Performance of Bitumen when Subjected to the Thin Film
Oven Test (TFO)
Scope:
This method covers the determination of the effect of heat and air on bitumen
by evaluating the degree of hardening that occurs after heating in an oven
for a specified time at a specific temperature. The amount of hardening is
evaluated from the reduction in penetration expressed as a percentage of the
original value.

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Procedure:
The test shall be carried out according to method D1754: ASTM, 1998.
Notes:
● The correct oven temperature is extremely important.

4.10.7 CML TEST NO. B7:

The Performance of Bitumen when Subjected to the Rolling Thin
Film Oven Test (RTFO)
Scope:
This method is intended to measure the effect of heat and air on a moving film
of semi-solid asphaltic material. The effects of this treatment are determined
from measurements of the properties of the asphalt before and after the test.
Procedure:
The test shall be carried out according to method D2872: ASTM, 1998.
Notes:
● The correct oven temperature is imperative.

4.10.8 CML TEST NO. B8:

The Determination of the Percentage of Bitumen Soluble in
Trichloro- Ethylene
Scope:
This method is applicable to bitumen and materials containing more than 95
per cent bitumen. This is intended for bitumen in which volatile constituents
will not normally be present. If water is present, the amount will normally be
small and can be removed and neglected in the calculation.
The bituminous binder is dissolved in the solvent and the bitumen content
calculated as the percentage of material that is soluble in carbon disulphide.
Procedure:
The test shall be carried out according to method D2042: ASTM, 1998.

4.11 Concrete Tests

4.11.1 CML TEST NO. C1:
The Making, Curing and Compressive Strength Determination of
Concrete Test Cubes
Scope:
This method describes the making, curing and testing of concrete test cubes
for compressive strength.
Procedure:
The test shall be carried out according to method D1: TMH1: 1986.

4.11.2 CML TEST NO. C2:

The Determination of the Slump of Freshly Mixed Concrete
Scope:
The slump test is used to determine the workability of concrete mixes and
is carried out by filling a specified mould with freshly mixed concrete and
measuring the slump after removal of the mould.

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Procedure:
The test shall be carried out according to method D3: TMH1: 1986 or
method C143-74: ASTM.

4.12 Asphalt Mixes

4.12.1 CML TEST NO. AS1:
The Determination of a Suitable Binder Content for use in an
Asphalt Mix
Scope:
The method covers the procedure for determining the binder content(s) to
be used for a particular aggregate to make a bituminous mixture, which will
satisfy certain criteria.
Procedure:
The test shall be carried out according to method C1: TMH1: 1986 or method
C143-74: ASTM, 1998.
Notes:
● It must be ensured that the masses of the aggregates used for the various
briquettes are identical.
● The Marshall hammer must be calibrated regularly (every 3-6 months
depending on use).
● Segregation of the aggregate fractions must be prevented, by regular mixing,
when placing the asphalt in the moulds for compaction. It is imperative
that the temperatures of the aggregates, bitumen and compaction equipment
must be at the required levels.

4.12.2 CML TEST NO. AS2:

The Determination of the Binder Content of a Bituminous
Mixture
Scope:
The method deals with the quantitative determination of the binder content
of a bituminous mixture by extracting the binder from the mixture using an
organic solvent, and determining the binder in the solution by evaporation
This method is not suitable for tar mixes. The binder so extracted may be
tested, if required, according to standard binder tests.
Procedure:
The test shall be carried out according to method C7 (a): TMH1: 1986 or
method D1856 ASTM, 1998.

4.12.3 CML TEST NO. AS3:

The Determination of the Bulk Relative Density of a Compacted
Bituminous Mixture and the Calculation of the Voids Content
Scope:
The bulk density of a compacted bituminous mixture is calculated from the
mass and bulk volume of a briquette in a saturated surface dry condition. The
voids content is calculated as the difference between the bulk volume of the
compacted mix and the theoretical volume of its combined constituents and
expressed as a percentage of the latter. The voids in the aggregate and voids
filled with binder are also calculated.
Procedure:
The test shall be carried out according to method C3: TMH1: 1986 or
methods D1188 and D2726: ASTM, 1998.

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Notes:
● The water bath temperature must be measured accurately.

4.12.4 CML TEST NO. AS4:

The Determination of the Resistance to Flow of a Cylindrical
Briquette of a Bituminous Mixture by Means of the Marshall
Apparatus
Scope:
This method deals with the determination of the stability and flow (resistance
to flow) of a cylindrical briquette loaded on the lateral surfaces by means of
the Marshall apparatus.
Procedure:
The test shall be carried out according to method C2: TMH1: 1986 or
method D1559: ASTM, 1998.
Notes:
● The calibration of the Marshall apparatus should be checked on a regular
basis (every 12 months is suggested).
● The water bath temperature must be measured accurately.

4.12.5 CML TEST NO. AS5:

The Determination of the Maximum Theoretical Relative
Density of Asphalt Mixes (Rice’s Method) and the Quantity of
Bituminous Binder Absorbed by the Aggregates
Scope:
The maximum theoretical relative density of asphalt mixes is determined
after filling all permeable voids in the material with water under reduced
pressure.
Definitions:
The maximum theoretical relative density of asphalt is the relative density of
the void-less mixture.
The absorption of bituminous binder of an aggregate is determined in terms
of the mass of binder, expressed as a percentage of the mass of dry aggregate,
which is absorbed by the aggregate without altering the bulk volume of the
aggregate, and which does not contribute to inter-particle adhesion.
Procedure:
The test shall be carried out according to method C4: TMH1: 1986 or
method D2041: ASTM, 1998.
Notes:
● The calibration of the flasks should be done accurately and they should
be inspected for defects such as cracks and chips at each use.
● The temperature of the water is very important. For consistent results
keep the temperature at 25OC.

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5 FIELD TESTS
5.1 CML TEST NO. F1
The Determination of the In-Situ Strength of Soils by the Dynamic
Cone Penetrometer
Scope:
This method describes the determination of the rate of penetration of the The DCP is used to assess the shear strength of a
Dynamic Cone Penetrometer (DCP) into a natural or compacted material by fairly uniform material by relating to penetration rate
on the same material. In this way under compacted
virtue of the action of the built-in sliding hammer. or “soft spots” can be identified, even though the
DCP does not measure density directly.
Definitions:
The DCP refers to the specific arrangement of an 8 kg hammer sliding along DCP data is usually evaluated in terms of CBRs
of the in situ layers derived from well-established
a 575mm long rod to push a cone with 60oC into the ground. The penetration DCP/CBR correlations.
rate is inversely proportional to the resistance of the ground to the penetration
of the DCP and may be related, inter alia, to the in situ CBR or soil density.
Procedure:
The test shall be carried out according to method ST6: TMH6: 1984.
Notes:
● The cone must be replaced when its diameter has been reduced by 5 per
cent or it has been visibly damaged.
● Spare parts for the DCP apparatus should be available in the field, as the
apparatus tends to break owing to the stress it is subjected to during testing
(fall of the hammer).
● Disposable cones could be used. This ensure that the cones used are
always sharp and reduces the damage to the DCP during removal of the
equipment from the test hole after testing.
● DCP analysis computer programmes are available and their use is recom-
mended.

5.2 CML TEST NO. F2:

The Determination of the Deflection and Radius of Curvature of a
More details on DCP and other field tests
Road Pavement using Deflection Measurements can be found in Guideline no. 2.
Scope:
This method covers the measurement of the deflection and radius of the Experience in Botswana has shown that the de-
longitudinal curvature of a road pavement under dual wheels of a loaded flection in the dry season can be as low as 65%
of that taken in the wet season. Deflection mea-
truck with a standardized axle load, tyre size, tyre spacing and tyre pressure. surement should therefore preferably be carried
The deflection is measured by means of a deflection beam and the radius of out in the wet season.
curvature by either the deflection beam or the curvature meter.
The strength of a road pavement is inversely re-
Definitions: lated to its maximum vertical deflection under a
Deflection - The amount of down ward vertical movement of a surface known dynamic load. Deflection measured under
a load can, therefore be a good indicator of the
due to the application of a load, which is usually a loaded truck, to the strength of a pavement.
surface of the pavement.
It should be noted that there are other techniques
Transient deflection - The difference between original and final elevations of measuring deflections using automated equip-
of a surface resulting from the application and removal of one or more ment such as Deflectograph and Falling Weight
Deflectometer (FWD).
load to and from the surface of the pavement.
Rebound deflection - The amount of vertical rebound of a surface that
occurs when a load is removed from the surface of the pavement.
Procedure:
The test shall be carried out according to method ST9: TMH6: 1984.

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Notes:
● It is important to ensure that the correct tyre pressures are applied on the
truck used to load the pavement.
● It is imperative that the dial gauge on the beam moves freely. If this is
not the case the gauge must be cleaned or replaced where cleaning does
not resolve the problem.
● Also read notes given in test method ST9: TMH6: 1984.

5.3 CML TEST NO. F3:

The Determination of the In-Place Dry Density of Soils or Gravels
by the Sand Replacement Method
Scope:
The method describes the determination of the in-place dry density of com-
pacted soil or gravel. The dry density is determined by making a hole in a
compacted layer and dividing the dry mass of the material removed from the
hole by the volume of the hole. The volume is determined by filling the hole
with a fine sand of known density.
Definitions:
The in-place dry density of a material is the dry mass per unit volume of the
material and is expressed in kilograms per cubic metre.
Procedure:
The test shall be carried out according to method A10 (a): TMH1: 1986.
Notes:
See notes given in the Test Method.

5.4 CML TEST NO. F4:

The Determination of the In-Place Dry Density and Moisture
Content of Soils or Gravels by Nuclear Method
Scope:
The method describes the in-place determination of the density and moisture
content of a compacted soil or gravel layer by nuclear methods.
Definitions:
The in-place dry density of a material is the dry mass per unit volume of the
material and is expressed in kilograms per cubic metre.
The in-place moisture content is the mass of water per unit volume of the
in-place material expressed in kilograms per cubic metre. (In this method
moisture content will refer to this definition). This moisture can be converted
and expressed as a percentage of dry material.
Procedure:
The test shall be carried out according to method A10 (b): TMH1: 1986.
Notes:
● Always ensure that the batteries of the apparatus are fully charged before
field use. Where disposable batteries are used a spare set should be taken
to the field.
● It is advisable to check that the apparatus is fully operational before field use.

5.5 CML TEST NO. F5:

Measurement of the Texture Depth of a Road Surface
Scope:
This method describes the procedures for measuring the texture depth of a

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road surface by spreading a known volume of sand on the surface and mea-
suring the area covered. This is known as the sand patch method.
Definitions:
The texture depth is calculated in millimetres, which is determined by filling
the surface voids of a given area of a road surface with a known quantity of
graded sand and measuring the area covered by the sand.
Procedure:
The test shall be carried out according to method ST1: TMH1: 1986.
Notes:
● The sand used should be washed quartzitic sand, passing a 0.300 mm
sieve and retained on a 0.075 mm sieve.
● Ensure that the sand used is completely dry.
● See notes given in the test method.

5.6 CML TEST NO. F6:

Measurement of Road Roughness Using the Merlin Apparatus
Scope:
The Merlin apparatus is an uncomplicated device for measuring road roughness.
Definitions:
The longitudinal unevenness of a road surface, commonly referred to as the
road roughness, is measured in units of vertical movement of a wheel per unit
length of the road, and expressed as meters (vertical) per kilometer (longitu-
dinal). A fairly accurate estimation of International Roughness Index (IRI)
can be obtained using the Merlin apparatus.
Procedure:The test shall be carried out according to Transportation Research
Record 1291, National Research Council, Washington D.C., pp 106-112.
Notes:
● The Merlin apparatus should preferably be used for routine evaluations
of short pavement sections, probably less than 10 km. The time and effort
required for longer sections probably make vehicle mounted measure-
ment devices more cost-effective and practical.
● The apparatus should routinely be checked for wear, as excessive play
will have an effect on the accuracy of the readings.
● See notes given in Appendix C of Guideline number 2 (Pavement Testing,
Analysis and Interpretation of Test Data) of Roads Department, Botswana.

5.7 CML TEST NO. F7:

Method for Determining the Point Load Strength Index
Scope:
This test is intended as a method for measuring the strength of rock speci-
mens in the field for which portable equipment is used.
General:
Specimens used are in the form of either rock cores or irregular lumps
broken by application of a concentrated load using a pair of conical platens.
A point-load strength index is obtained and may be used for rock strength
classification.
Procedure:
The test shall be carried out according to method given by the International
Society for Rock Mechanics (ISRM) - Committee on Laboratory Tests
Document No. 1 (1973).

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Notes:
● The test is intended as a simple procedure for field classification of rock
materials, and when necessary the recommended procedures can be modified
to overcome practical limitations. Such modifications to procedure
should however be clearly stated in the report.
● Point-load strength is closely correlated with the results of uniaxial com-
pression and other strength tests.

5.8 CML TEST NO. F8:

Rapid Field Test For Determining The Carbonation Of Lime Or
Cement Treated Materials
Scope:
This is a rapid indicator test for determining the carbonation of a layer, which
has been treated with lime, lime-slag, lime-PFA, cement, cement-PFA and
cement-slag.
Definitions:
Carbonation may be defined as the absorption of carbon dioxide (CO2),
which is present in the atmosphere by the calcium hydroxide (Ca(OH)2) in
lime or cement treated layers in order to form calcium carbonate (CaCO3).
Procedure:
The test shall be carried out according to Technical Report RS/2/84,
Transportek, CSIR,1984.
Notes:
● See notes given in the testing procedure .

5.9 CML TEST NO. F9:

Visual Assessment of Flexible Pavements
Scope:
The visual assessment or evaluation of a flexible pavement is done to de-
termine the condition of the pavement surfacing and pavement structure.
Aspects of distress such as cracking, ravelling, potholing, patching, pump-
ing, deformation, bleeding, surfacing conditions, drainage and edge-break
are evaluated visually.
Procedure:
The visual assessment shall be carried out according to TMH 9.

5.10 CML TEST NO. F10:

Visual Assessment of Unsealed Roads
Scope:
Guideline no. 2 gives more details regarding The visual assessment or evaluation of unsealed road is done to determine the
Pavement Testing, Visual Condition Rating and condition of the gravel wearing course and factors, which may affect it. Aspects
Analysis.
of distress such as, ravelling, rutting, corrugations, potholing, drainage, dust,
gravel quality , gravel thickness, loose gravel etc. are evaluated visually.
Procedure:
The visual assessment shall be carried out according to TMH 12.

5.11 CML TEST NO. F11:

Non-Repetitive Static Plate Load Test for Soils and Flexible
Pavements
Scope:
This method covers the carrying out of non-repetitive static plate load tests on

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sub-grade soils and flexible pavement components, either in the compacted

condition or in the natural state. It is intended to provide data for use in the
evaluation and design of rigid and flexible type pavements.
Definitions:
Deflection - The amount of down ward vertical movement of a surface due A minimum of four different plate sizes is recom-
to the application of a load to the surface. mended for pavement design of evaluation
purposes.
Residual Deflection - The difference between original and final elevations
A single plate of any selected size may however
of a surface resulting from the application and removal of one or more loads be used to give an indicative bearing index.
to and from the surface.
Rebound Deflection - The amount of vertical rebound of a surface that occurs
when a load is removed from the surface.Procedure:
The test shall be carried out according to AASHTO: T222-81.
Notes:
● Keep a record of all conditions, which may affect the results such as
weather conditions, list of testing personnel, any unusual conditions
observed at the test site etc.
● Also see notes given in the testing procedure

5.12 CML TEST NO. F12:

The in-situ Evaluation of Base Course Materials by Means of the
Clegg Hammer
Scope:
This method describes the impact testing of compacted base course layers using 300
the Clegg hammer apparatus, and is intended to provide data for acceptable
compaction. The values obtained from the Clegg hammer may be compared 250
to California Bearing Ratio (CBR) values.
General: 200
FROM THEORY
The device consists mainly of a laboratory compaction hammer to which an
CBR %

-1 mm penetration
accelerometer has been attached. The peak output from the accelerometer, 150

as generated by impact with the surface, is indicated on a specially designed

hand-held meter. The procedure is to apply a series of impacts at one position 100

on the surface until a constant value is recorded. Using a hammer weighing

500 grams, it is possible to extend the procedure for application to density 50 FROM LAB. TESTS
- as compacted
control of fine sand. - no soaking
- no surcharge
0
Procedure: 0 10 20 30 40 50
Impact Value 10g´s
There is no specified test method. A description of the apparatus and details Relationship Clegg Impact Value and CBR.
for its use are given in ARRB proceedings, Volume 8, 1976. Instructions
for the use of the instrument are supplied with it.
Notes:
● Checking and calibration of the instrument is required before its use
every time.
● It is advisable to carry a spare set of batteries when testing in remote areas.
● A sample of the material being tested should be taken for moisture content
determination.

5.13 CML TEST NO. F13:

The Modified Tray Test for Chip Seals
Scope:
This method is used to determine the effective layer thickness of stone chip-
pings, the void content in the stone layer, the void content in bulk aggregate
and the practical and theoretical spread rates of aggregate.

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Definitions:
Effective layer thickness: This is the average height of the layer of stone.
Void content: The air voids in the stone layer expressed as a percentage of
the volume of the stones (voids between the stones).
Void content in bulk aggregate
The volume of the voids expressed as a percentage of the total volume of the
un-compacted bulk density of the aggregate.
Aggregate spread rates: The volume of aggregate that covers a given sur-
face area (m3/m2).
Procedure:
The test shall be carried out according to TRH 3 1998, appendix L.

5.14 CML TEST NO. F14:

Determination of the Moisture in Soils By Means of a Calcium
Carbide Gas Pressure Moisture Tester
Scope:
This method describes the determination of the moisture content of soils by
means of a calcium carbide gas pressure moisture tester. The manufacturer’s
instructions shall be followed for the proper use of the equipment.
Definitions:
The moisture content of a soil is defined as the amount of free water present
in the soil expressed as a percentage of the dry mass of the material.
Procedure:
The test shall be carried out according to AASHTO: T217-96.
Notes:
● This method shall not be used for on granular materials having particles
large enough to affect the accuracy of the test, in general any appreciable
amount retained on the 4.75 mm.
● The super 200 D tester is intended to test aggregate.
● The shelf life of the calcium carbide reagent is limited, so it should be
used according to the manufacturer’s instructions.

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PART D

Introduction
Organisation and
Management

Laboratory Management
Procedures

Laboratory Testing
Procedures
Field Testing Procedures

Laboratory Layout
and Safety

References

Appendices

Operating Procedures for Central Materials Laboratory Laboratory Layout 81

and Safety
 Roads Department

6 LABORATORY LAYOUT
AND SAFETY
6.1 Laboratory Layout
6.1.1 General
The layout of the laboratory is very important for aspects such as productiv-
ity, safety, work flow, ergonomics etc.

The individual work areas or sections of a laboratory must all form a rational
whole. The CML consist of the following areas:
● Sample reception area.
● Sample storage facility.
Equipment and stationary shall be placed in
an organised and orderly manner and must be ● Sample preparation area.
clearly labelled for easy retrieval. ● Laboratory where “dirty” tests are carried out (dusty area).
● A section where “noisy” tests are done (such as compaction).
● An area where “cleaner” tests are carried out such as Atterberg Limits.
● A section for bitumen testing.
● A section for asphalt tests and a section for chemical tests.

6.1.2 Sample reception area

This area must be fairly large so that large samples may be easily handled
and easily accessible to vehicles delivering samples. It should be close to
where the samples are to be stored prior to testing and also close to the
sample preparation area so that it is not necessary to manually transport
samples long distances as this can be physically demanding especially where
large samples are concerned. It is also a good idea to have some form of
mechanical hoist so that large samples or samples in crates may be unloaded
from delivery vehicles. This area should also not be situated close to offices
Samples shall be stored in a dry and clean envir- as it is often noisy and dusty and the noise generated may be disturbing to
onment in an orderly manner. office staff.

6.1.3 Sample preparation area

This area should be close to the sample reception area to facilitate sample
movement. It should not be situated close to offices or areas that must be
kept clean such as the laboratories where delicate testing is done as dust
and noise tend to be generated when samples are being processed for test-
ing. This area should also be well ventilated, as the dust created will be a
nuisance to the people working there. It may be necessary for the workers to
wear dust masks when handling very dusty material.

6.1.4 Testing that creates a lot of dust

There has to be a laboratory where tests such as grading, compaction etc. are
carried out as such testing tends to be messy and create dust. It is best to use
an area close to the soil preparation area for this purpose, which is also an
area that requires seclusion from the rest of the laboratory. It must be easy to
clean this area as it becomes very soiled due to the nature of the testing done
there. The floor should preferably be of a hard concrete, which is also true of
the sample preparation area. Also, only the minimum furniture and equip-
ment should be kept in such a laboratory, as excess furniture and equipment
will only gather dust and make cleaning up difficult.

82 Laboratory Layout Operating Procedures for Central Materials Laboratory

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6.1.5 Testing that creates a lot of noise

Some of the work or testing carried out in a laboratory generates a lot of
noise (eg compactions, sieve shakers, ball mills etc.) Strong or repeated
stimulation from noise can lead to loss of hearing to those working close to
the noise source. This is only temporary at first, but after being “deafened”
repeatedly some permanent damage may occur. This is called noise deafness,
and is brought about by slow but progressive degeneration of a person’s
hearing ability. The louder the noise, and the more often it is repeated, the
greater the damage to hearing. It is also well known that noise consisting of
predominantly high frequencies is more harmful than low frequency noise.
Intermittent noise, such as hammering, is more harmful than continuous
noise, and a single very loud noise such as a detonation or explosion can
A typical example of poor stacking.
damage the ears immediately. Noise intensity (measured in dB) above 85 dB
can be considered harmful to hearing.

Noise must be isolated either by placing the apparatus in a sound proof room
or enclosing in sound proof container or the testing or work must be carried
out in an area that is remote from other working areas. Some procedures are
so noisy (eg. sawing asphalt slabs to obtain a sample suitable for testing) that
the only practical way to curb the sound is to do the work in a sound proof
room. Workers in noisy environments must wear personal ear protection (ear
muffs or ear plugs) to protect them from the noise. Earplugs give sufficient
protection where noise levels are not too high. In very noisy areas (noise
levels above 100 dB) earmuffs should be worn.

Moving machinery, and motors in operation not only make noise, but also
set the structure of the building in vibration. Such vibrations and resonance,
and the secondary noises that they set up, can be disturbing throughout the
building. For this reason these machines (eg compactor) should be mounted
onto thick concrete slabs.

6.1.6 Lighting in laboratories

Laboratories should have good lighting; this is especially the case in lab-
oratories where precision work is done. Where it is required to read meters,
dials etc. good lighting is imperative. Laboratories should have sufficient
natural light coming in through windows and also have electric lighting for
occasions when natural light is insufficient (eg overcast conditions). Fluores-
cent lighting is recommended as shadows are reduced.

6.1.7 Handling loads in work areas

Lifting, handling and dragging loads, is often done in laboratories. It is part
of the nature of the work in laboratories. These types of actions involve
a good deal of physical effort. The main problem with this type of work,
however, is not the heavy loads on the muscles, but much more the wear and
tear on the vertebral discs of the back, with increased risk of back trouble.
Back troubles are painful and reduce one’s mobility and vitality. They lead
to long absences from work, and in modern times are among the main causes
of early disability. They are comparatively common in the age group 20 - 40,
with certain occupations being particularly vulnerable to back problems
(occupations that are physically demanding). Bad house keeping such as this may leads to
accidents and fires.
It is thus imperative that handling of loads be considered when designing
work areas. The following are a few practical hints:

Operating Procedures for Central Materials Laboratory Laboratory Layout 83

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● Workers should not have to rotate or twist when lifting a load.

● Workers should be able to lift loads close to their bodies as this position
causes less strain on the back.
● It should not be necessary to lift a load with a bent back. Lifting with a
bent back causes a lot strain on the spinal column.
● A person’s hold on a load should not be lower than knee height.
● Whenever possible trolleys should be used to transport heavy loads
(samples, equipment etc.).
● Under optimum conditions 40 kg should be the maximum load that is
lifted (not continuously or repeatedly). This is, however, dependent on
the person’s size, strength, state of health etc.
● The use of trolleys is recommended to reduce physical strain.

6.1.8 Other considerations

Unpleasant or toxic fumes: Some tests cause unpleasant or toxic fumes
(some bitumen tests, tests using mercury etc.). There should be fume cup-
boards with extractor fans available in these areas to extract the toxic fumes.
Chemical tests such as pH determination, titration, conductivity measure-
ments etc. should be done in a laboratory that is not situated close to or is
sealed off from dusty areas. Dust and soil may contaminate the workplace
and produce erroneous test results.
All the laboratories should have running water, as this is necessary for most
testing. Basins should all have soil traps to prevent soil from getting into the
drainage system and causing blockages.
Waste bins must be emptied on a regular basis.

6.2 Safety In The Work Place

6.2.1 General
An aspect of laboratory management that is often neglected or overlooked is
a safe working environment. Unsafe working conditions can lead to numer-
ous accidents. Accidents result in loss of productivity and are costly to the
organization. There is no doubt that safety in the work place is an important
aspect of laboratory management.
The basic causes of accidents are:
● Personal factors; Lack of knowledge, Physical or mental defect, improper
attitude or motivation.
● Job factors; Un-safe conditions or physical environment, inadequate
work standards.
Stack material away from aisles and exits. It is the responsibility of the management to provide a safe working envir-
onment for its employees. Some of the aspects that have to be considered
The latest report of the Workmen’s Compensation
by the employer to create such an environment are: good housekeeping
Commissioner in South Africa reveals that more practices; safe machinery; supply of protective equipment to staff; First Aid
than 300 000 cases resulting in injury or disease supplies and equipment; fire fighting and fire prevention equipment.
are reported annually. There are some 30 000 per-
manent disablements and about 2 000 fatalities Form M5.1 (Appendix B) provides a safety checklist, which shall be referred
every year. The actual potential loss in man-days is
more than 28 million which is equivalent to 100 000 to when performing safety inspections. Further more the safety rules and reg-
workers lying idle each year. Apart from this each ulations written in both English and Setswana shall be displayed at strategic
year millions of Pula are paid out in compensation
to injured or disabled workers. places around the laboratory.
For purposes of enforcing safety rules and regulations, each UH shall be
the safety officer in-charge for his unit. The LM shall be responsible for
the overall safety within the laboratory. The LM shall cause the statistics

84 Laboratory Layout Operating Procedures for Central Materials Laboratory

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of accidents and injuries sustained in the work place and their extent, to be
compiled every month. Such statistics shall be displayed on a board to be
mounted in front of the laboratory.

6.2.2 Housekeeping
Basically good housekeeping means having a place for everything and keep-
ing everything in its proper place. Typical examples of poor housekeeping are:
● Floors cluttered with objects that are in the way and over which people
can trip.
● Too few and overflowing waste bins.
● Materials and objects poorly stacked on shelves.
● Aisles and exits cluttered or blocked with objects.
● Liquids spilt on floors not cleaned up.
Accidents in the workplace that are typical of poor housekeeping include: peo-
ple tripping over loose objects on floors; articles falling on people; people slip- Clean up spilt oils and water to avoid accidents.
ping on greasy, wet or dirty floors; workers bumping against projecting, poorly
stacked or badly placed materials. Fires can also result from poor housekeeping.
Some of the reasons why good housekeeping is important and desirable are:
● It cuts down the time spent looking for articles, tools etc.
● Space is saved when everything is stacked away tidily.
● Injuries are avoided when gangways and working areas are kept clear of
superfluous material.
● Fire hazards are reduced if combustible materials are kept in proper
receptacles.
It is also true that good housekeeping improves the working environment.
This means more pleasant working conditions, which arouses a desire in
workers for greater efficiency. The end product is increased production.
Compression machine shall not be operated
while the safety cage is open.
6.2.3 Guards for machines
Machines that have moving parts (gears, pulleys, driving belts etc.) must
have guards covering these to protect personnel from accidental injury.
Injuries caused by machines are usually severe and permanent but the danger
they pose is usually reduced or removed altogether by mechanical safeguards.
Well-designed guards will not affect the efficient operation of the machine.

6.2.4 Personal protective equipment

Many types of personal protective equipment are available. The worker The location of fire extinguishers must be clearly
indicated by the use of red ‘fire’ arrows of by red
should be provided with protective equipment if the situation warrants it. painted strips. Reserve ’no parking’ area imme-
The most commonly used types of protective equipment that are used are: diately in front of the extinguisher.

● Hard hats to protect the head from falling objects.

● Goggles for the protection of eyes. These should be used when the worker is
doing any work that may pose a threat to his eyes (e.g. - sawing rock)
● Overalls (overcoats) to protect the workers clothing from damage.
● Different types of gloves to protect the hands (e.g. from hot bitumen or
acids).
● Safety boots and shoes to protect feet from heavy objects falling on them.
● Dust masks for working in dusty environments.
● Earmuffs or earplugs to protect workers in noisy environments.

Operating Procedures for Central Materials Laboratory Laboratory Layout 85

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6.2.5 Fire Prevention Equipment

Fires in the work place are dangerous to lives and property. Fires, can to a
large extent, be prevented by good housekeeping practices. Materials that are
flammable (wood, paper, oily rags etc.) should not be left lying around. Most
fires start in a small way and if they can be extinguished at this stage property
and human lives can be saved. It is obviously much easier to extinguish a
small fire than to allow it to spread and later have to extinguish a major blaze.
Laboratories should be equipped with some form of fire fighting equipment
to deal with incipient fires immediately before they spread and become
major fires. The most common fire fighting appliances are different types of
Fire extinguishers shall be placed in clearly vis- fire extinguishers. Extinguishers should be placed close to likely fire hazards
ible places with unrestricted access. but not so close that they can be damaged or cut off from use by fires. They
should be located outside entrances to danger areas, never inside where they
might become inaccessible. At least one person per unit must be trained in
the use of fire extinguishers. The Fire Brigades should be invited to give fire
prevention workshops at least once a year. Extinguishers should be placed at
conspicuous places.

6.2.6 Gas cylinders

Special precautions must be taken when handling or storing gas cylinders.
Because of their shape large gas cylinders are awkward to carry. They may
be rolled but never dragged. It is best to have a purpose built trolley to move
the cylinders. Cylinders should also be prevented from falling or bumping
against each other.
Cylinders should be stored in a well-ventilated area away from heat or direct
sunlight and on a level fireproof surface. Racks and/or chains should be pro-
vided for securing cylinders individually in an upright position.

Poor temporary disposal of waste soils. Waste

soil samples must be managed in an organised
and tidy manner to prevent wastage of space
and contaminating the CML premises.

Interesting statistics were published a few years

ago by the US National Institute for Occupational
Safety and Health. Over-exertion was claimed to
be the cause of lower back pain by over 60 % of
the people suffering from it.
Handling and storage of gas cylinders.
Another UK report presents the following data:
61 % of the over exertion injuries involve the
back and 74 % of these back injuries were due
6.2.7 First Aid
to lifting loads.
Owing to the nature of the work done in laboratories it is more likely that
In Western Germany it was also found that back accidents will occur than say in an office environment. It is thus desirable
problems cause 20 % of absenteeism and 50 % that each unit in the laboratory has at least one person who has been trained
of premature retirements.
in First Aid techniques. A well-stocked First Aid box should also be kept in
the laboratory.

86 Laboratory Layout Operating Procedures for Central Materials Laboratory

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6.2.8 Smoking
Smoking is a health hazard and it is against the law to smoke in offices and
enclosed work places. No smoking signs must be placed at strategic places
around the laboratory. In addition the worker shall be educated about the
dangers of smoking. The Ministry of Health should be requested to conduct
health workshops at MRD once a year.

6.2.9 Intoxicating substances

It is against the industrial rules and regulations for workers to work while
under the influence of intoxicating substances. It is very hazardous for any
worker to enter the laboratory while intoxicated. No worker shall be allowed
to operate any equipment or machinery if they are suspected to be under the
influence of intoxicating substances. Where a worker is suspected of being
intoxicated, the UH shall inform the LM who shall immediately cause the
person to be removed from the laboratory. Disciplinary measures as set out
in the Regulations for Industrial Employees (RIE) and the General Orders
shall then be applied as appropriate.

6.2.10 HIV and AIDS.

The HIV and AIDS epidemic continues to ravage the country through loss of
the workforce. It is, therefore, in the interest of every organisation to join the
fight against this disease. Currently the MRD has an AIDS committee, which
operates on an ad-hoc basis. It is prudent that the operations of the AIDS
committee are formalised. The LM shall chair the committee and committee
members shall come from both the management and the laboratory assistants.
The committee must be entrusted with planning and executing awareness
campaigns, distribution of literature, sourcing and presentation of videos,
distribution of condoms and any other strategies that may assist in the fight
against the spread of HIV and AIDS.
Aids awareness messages shall be placed at
Regular awareness campaigns shall be held. The Ministry of Health and Non strategic places around the CML premises.
Governmental Organisations such as Tebelopele Testing Centre and the Coping
Centre for People Leaving with AIDS should be invited to make presentations
at these workshops. It is imperative that during these workshops work is
stopped and all workers are encouraged to attend.
The MRD shall develop an AIDS policy, which shall be written in both Eng-
lish and Setswana. The policy shall be displayed at strategic places around
the laboratory.

6.2.11 Safety Representative

There are many more safety issues that need to be considered than those dis-
cussed above. It is advisable that the LM appoints one of the lab staff to deal
with safety matters. Apart from his normal duties in the laboratory it will
also be this person’s responsibility to ensure that safety standards are being
adhered to. Apart from attending training courses this should not take more
than a few hours of his/her time per month.

Operating Procedures for Central Materials Laboratory Laboratory Layout 87

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88 Laboratory Layout Operating Procedures for Central Materials Laboratory

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Roads Department

PART E

Introduction
Organisation
g and
Management

Laboratory Management
Procedures

Laboratory Testing
Procedures
Field Testing Procedures

Laboratory Layout
and Safetyy

References

Appendices

Operating Procedures for Central Materials Laboratory References and 89

Appendices
PART E - References and Appendices Roads Department

REFERENCES

A COMPENDIUM OF ROAD PAVEMENT IN BOTSWANA. 2000. Roads Department.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO). 1982.
Materials: Part 2: Tests. 13th Edition, AASHTO, Washington, DC.
AMERICAN SOCIETY FOR TESTING AND MATERIALS. 1978. ASTM manual for conducting an inter-laboratory
study of a test method. ASTM Special Technical Publication, No. 335. ASTM, Philadelphia.
AMERICAN SOCIETY FOR TESTING AND MATERIALS. 1998. Annual book of ASTM standards, Part 19: Soil and
Rock; Building Stones. ASTM, Philadelphia.
BOTSWANA GOVERNMENT. 1996. General Orders Governing the Conditions of Service of the Public Service of the
Republic of Botswana. Government Printers, Gaborone, Botswana.
BOTSWANA GOVERNMENT. 1996. Regulations for Industrial Class Employees. Government Printers, Gaborone,
Botswana.
BOTSWANA ROAD DESIGN MANUAL. 1982. Botswana Roads Department.
BOTSWANA ROADS DEPARTMENT. 1992. ROADS IN BOTSWANA.
BOTSWANA ROADS DEPARTMENT. 2000. Methods and Procedures for Prospecting for Road Construction Materials.
Guideline No. 3. Gaborone, Botswana.
BOTSWANA ROADS DEPARTMENT. 2000. Pavement Testing, Analysis and Interpretation of Test Data
Guideline No. 2. Gaborone, Botswana.
BOTSWANA ROADS DEPARTMENT. 2002. The use of Silcrete and Other Marginal Materials for Road Surfacing.
Guideline No. 8. Gaborone, Botswana.
BRITISH STANDARDS INSTITUTION. 1975. Methods for sampling and testing of mineral aggregates, sands and
fillers. BS 812, Part 3. British Standards Institution, London.
BRITISH STANDARDS INSTITUTION. 1975. Methods of Testing for Soils for Engineering Purposes. BS 1377.
British Standards Institution, London.
BRITISH STANDARDS INSTITUTION. 1990. Methods for sampling and testing of mineral aggregates, sands and
fillers. BS 812. British Standards Institution, London.
BURROW BINNIE BOTSWANA. 1988. Institutional Study of the Botswana Roads Agencies, Final Report. Roads
Department, Ministry of Works Transport and Communications. Gaborone, Botswana.
COMMITTEE OF STATE ROAD AUTHORITIES. 1979. Standard methods of testing road construction materials.
Pretoria: Department of Transport. (Technical Methods for Highways, No.1).
COMMITTEE OF STATE ROAD AUTHORITIES. 1981 Sampling Methods for Road Construction. Pretoria:
Department of Transport. (Technical Methods for Highways No. 5).
COMMITTEE OF STATE ROAD AUTHORITIES. 1986. Standard methods of testing road construction materials.
CSRA Technical Methods for Highways, No 1, Pretoria.
CSIR, Transportek. 1984. Technical Report RS/2/84 Pretoria
CSIR, Transportek. 1984. Technical Report RS/2/84, Pretoria.
CSIR. 1968.. Manual of testing procedures for highway materials. NIRR, Pretoria.
CSIR. Transportek: Manual of Testing Procedures for Highway Materials,. C.B. 22. Pretoria.
DIRECTORATE OF PUBLIC SERVICE. 1994. Job Descriptions for Engineer and Technicians at Materials and
Research Division. Form MSU 10B. Gaborone, Botswana. (These are numerous forms for each of the Positions at
MRD).
DIRECTORATE OF PUBLIC SERVICE. 2001. Generic Schemes of service for Artisan and Technical Models in
Government. Savingram, Ref. DP II.i.i.20(5). Gaborone, Botswana.
DIRECTORATE OF PUBLIC SERVICE. 2002. Establishment Register for the fiscal Year 2002 – 2003. Government
Printers, Gaborone, Botswana.

90 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

EDWARDS, J A. 1960. Laboratory management and techniques. Butterworth & Co. limited, London.
GRANDJEAN, E. 1988. Fitting the task to the man. Taylor and Francis, London.
International Society for Rock Mechanics (ISRM).1973. Committee on Laboratory Tests Document No.1
INTERNATIONAL STANDARDS ORGANIZATION. 1981. Precision of test methods- Determination of repeatability and
reproducibility by inter-laboratory tests. ISO 5725-1981 (E).
MATERIALS AND RESEARCH DIVISION. 1998. The Materials and Research Division Report System – Report Number
IC 001. Roads Department.
NATIONAL OCCUPATIONAL SAFETY ASSOCIATION. 1991. Questions and answers (on safety). National
Occupational Safety Association, Pretoria.
SATCC. 1998. Standard Specifications for Road and Bridge Works. Southern African Transport and Communications
Commission. CSIR, Pretoria, RSA.
STANDARD SPECIFICATIONS FOR ROAD AND BRIDGES. 1983. Botswana Roads Department.
TRANSPORTATION RESEARCH RECORD 1291, National Research Council, Washington D.C., pp 106-112.
WASTE DISPOSAL ACT. 1998. Department of Sanitation and Waste Management. Government Printers. Gaborone
Botswana.
WATER POLLUTION CONTROL FEDERATION. 1981. Laboratory management. Manual of Practice No. SM-1. Board
of control Water Pollution Control Federation, Washington.
LABORATORY TESTING MANUAL 2000. Central Materials Laboratory (CML) Tanroads, Tanzania.
BRITISH STANDARDS INSTITUTIONS B S 1377 Part 7: 1990.

Operating Procedures for Central Materials Laboratory 91

PART E - References and Appendices Roads Department

APPENDIX A – LABORATORY AND FIELD TESTING FORMS

● FORM S1(a) Mechanical Sieve Analysis for Soils and Gravels

● FORM S1(b) Moisture Content Determination
● FORM S1(c) Hydrometer Analysis
● FORM S1- S4 Soil Classification Test Results
● FORM S1- S6 Compaction, CBR and Classification Summary
● FORM S1- S6(b) Compaction, CBR and Classification
● FORM S2- S4(a) Atterberg Limits
● FORM S2- S4(b) Atterberg Limits
● FORM S5 (a) Maximum Dry Density Optimum Moisture Content
● FORM S5 (b) Maximum Dry Density Optimum Moisture Content Graph
● FORM S6 California Bearing Ratio
● FORM S7 Unconfined Compressive Strength – stabilised soils and Gravels
● FORM S8 (a) Consolidation Test Work Sheet
● FORM S8 (b) Consolidation Test
● FORM S9 Crump Test
● FORM S12 Conductivity and pH of Saturated Soil and Water
● FORM S13 Initial Consumption of Lime (ICL)
● FORM S15 (a) Direct Shear Tests
● FORM S15 (b) Direct Shear Tests
● FORM S16 (a) Unconsolidated Undrained Shear Strength of Cohesive Soils
● FORM S16 (b) Unconsolidated Undrained Shear Strength of Cohesive Soils Tests
● FORM S16 (c) Unconsolidated Undrained Shear Strength of Cohesive Soils Tests
● FORM AG1 Mechanical Sieve Analysis of Aggregates
● FORM AG2 Aggregate Crushing Value (ACV)
● FORM AG3(a) Dry 10% FACT Value
● FORM AG3(b) Soaked 10% FACT Value
● FORM AG4 Modified Aggregate Impact Value (AIV)
● FORM AG5 Durability Mill Index (DMI)
● FORM AG9 Accelerated Polished Stone Value
● FORM AG10 Aggregate Fingers and Pliers Value
● FORM B1 Penetration Test
● FORM B2 Ductility Test
● FORM B4 Softening Point
● FORM AS3 Bulk Relative Density of a Compacted Bituminous Mix
● FORM AS5 Maximum Theoretical Relative Density of Asphalt Mix
● FORM F1 Dynamic Cone Penetrometer (DCP)

92 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM S1 (a)
Soil Tests:
Work Sheet
Mechanical Sieve
Ministry of Works and Transport
Roads Department Analysis for Soils/Gravels Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Mass of Sample Taken: Mass of Sample Taken:

Sieve Size (mm) Sample Number: Sample Number:
Mass % Cumulative Cumulative Mass % Cumulative Cumulative
Retained Retained % Retained % passing Retained Retained % Retained % passing
75.0
53.0
37.5
26.5
19.0
13.2
9.50
6.70
4.75
2.36
2.00
1.18
0.600
0.425
0.300
0.150
0.075
<0.075
Total

Operating Procedures for Central Materials Laboratory 93

PART E - References and Appendices Roads Department

FORM S1 (b)
Soil Tests:
Work Sheet
Moisture Content
Ministry of Works and Transport
Roads Department Determination Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Sample No.
Pan number.
Wt. pan + wet soil (g)
Wt. pan + dry soil (g)
Wt. pan only (g)
Wt. moisture (g)
Wt. dry soil (g)
Moisture content (%)

Sample No.
Pan number.
Wt. pan + wet soil (g)
Wt. pan + dry soil (g)
Wt. pan only (g)
Wt. moisture (g)
Wt. dry soil (g)
Moisture content (%)

Sample No.
Pan number.
Wt. pan + wet soil (g)
Wt. pan + dry soil (g)
Wt. pan only (g)
Wt. moisture (g)
Wt. dry soil (g)
Moisture content (%)

94 Operating Procedures for Central Materials Laboratory

 FORM S1 (c)
Soil Tests: Work Sheet
Roads Department

Ministry of Works and Transport Hydrometer Analysis

Roads Department Materials and Research Division

Project: …………….……………………. Sample Location: ……………………………...

Client: ……….…………………… Date:………… Tested by: ……………………….…. Checked by: ….……………….…….…..……………....

Hydrometer Ref. No.: …………………….. R = Hydrometer Reading %passing N = % finer 0.425 x P/100 = ……….…..% RC = Corrected Hydrometer Reading

Percentage soil in suspension P = R/W X 100% C1 = Temperature Correction C2 = Dispersing Agent Correction C3 = Meniscus Correction f1 = 1,130 f2 = 1,205

Operating Procedures for Central Materials Laboratory

Sample Mass of Date Time Elapsed R Temp Total RC P Estimated N. fN
Number Dispersed Correction. Diameter
soil (mg) (mm)
18 s 0.075
40s 0.050
60 min 0.005
7h 0.002
18 s 0.075
40s 0.050
60 min 0.005
7h 0.002
18 s 0.075
40s 0.050
60 min 0.005
7h 0.002

95
PART E - References and Appendices
96
FORM S1 - S6 (a)
Soil Tests: Summary Sheet

Ministry of Works and Transport Compaction, CBR and Classification

Roads Department Materials and Research Division

SUMMARY OF COMPACTION, CBR AND CLASSIFICATION TEST RESULTS

Project:……………………...…… Sample Location…………………. Sample number:………………… Tested:….………………………..
PART E - References and Appendices

Client:…………………………………………………...……. Date:………...………………...… Checked:………………………….

Compaction Test Results (vibration / ……..kg x …….layers x …….blows) Interpolated CBR Results
Dry Density (kg/m3)
CBR@ 100% Mod. AASHTO = ………………
Moisture Content (%)
CBR@ 98% Mod. AASHTO = ………………

Maximum Dry Density = ……..….kg/m3 Optimum Moisture Content = .…..% CBR@ 95% Mod. AASHTO = ………………

California Bearing Ratio Test Results (Soaked or Unsoaked) CBR@ 93% Mod. AASHTO = ………………

Campactive Effort CBR CBR CBR Moulding Dry Density Relative MC after Swell CBR@ 90% Mod. AASHTO = ………………
2.54mm 5.08mm 7.62mm MC(%) kg/m3 Density (%) soaking (%) %

Mod. AASHTO

Intermediate Index Tests

Standard Proctor
Liquid Limit: ……………….....……%
Particle Size Distribution Plasticity Index:...………...…......…...%
Percentage passing Seive Size (mm)
75.0 53.0 37.5 26.5 19.0 13.2 9.5 6.7 4.7 5 2.36 1.18 0.425 0.250 0.150 0.075 Linear Shrinkage: …………....…......…

Grading Modulus = ………………. Linear Shrinkage Product (LS x P0.425) = ……………. Conductivity: ……………..........mS/cm

Sample Classification Remarks pH: .........................................................

AASHTO: ……………………………. …………………………………………………………………….. Relative Density:………………...kg/m3

TRH: ………………………..………… ……………………………………………………………………..

Operating Procedures for Central Materials Laboratory

Roads Department
Roads Department PART E - References and Appendices

FORM S1- S6 (b)

Soil Tests:
Work Sheet
Compaction, CBR and
Ministry of Works and Transport
Roads Department Classification Materials and Research Division

Project: …………….…………................ .. Sample Location: …………………..... .... Sample Number.................................

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

MAX STONE SIZE 3)%6%!.!,93)3

+75.0 

75.0 
SIEVE ANALYSIS (% PASSING)

53.0 

37.5 

26.5 

19.0 0!33).' 
13.2 
4.75 
2.0 
0.425

0.075




















GRADING MODULAS
LIQUID LIMIT
STANTS

3)%6%3):%MM
CON-

PLASTICITY INDEX
#"20,/4
LINEAR SHRINKAGE % 
PLOT CODE
USPRA CLASSIFICATION
TRH 14 CLASSIFICATION
MAX DRY DENSITY
O.M.C. %
MOD AASHTO

HYGRO % 
3
DRY DENSITY (Kg/m )
CBR / UCS CALCS

% MOD AASHTO
#"2

MOD AASHTO VALUE

SWELL %
DRY DENSITY (Kg/m3)
INTER

% MOD AASHTO

INTERMEDIATE VALUE
PROCTOR

DRY DENSITY (Kg/m3)

% MOD AASHTO
PROCTOR VALUE
98% AASHTO
95% AASHTO
93% AASHTO 














90% AASHTO -/$!!3(4/

Operating Procedures for Central Materials Laboratory 97

PART E - References and Appendices Roads Department

FORM S2 - S4 (a)
Soil Tests:
Work Sheet
Ministry of Works and Transport Atterberg Limits
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Test LL LL LL LL Av. PL PL Av. Field MC

No. of blows
Tin No.
Wt. Tin + wet soil (g).
Wt. Tin + dry soil (g).
Wt. Tin (g).
Wt. Water (g).
Wt. Dry soil (g).
Moisture Content (%)
Fully shrunk length of linear shrinkage specimen 10 cm trough (No………)

10000

1000

Number 100
of blows

10

Moisture content (%)

Liquid Limit %
Plastic Limit %
Plasticity Index %
Shrinkage %
Linear shrinkage %
LS = Sx (100/150) x 0´8/(1 - 0´00 8N)

98 Operating Procedures for Central Materials Laboratory

 FORM S1 - S4
Soil Tests: Summary Sheet
Roads Department

Ministry of Works and Transport SOIL CLASSIFICATION TEST RESULTS

Roads Department Materials and Research Division

Project: …………….……………………. Sample Location: …………….............

Client: ……….……………………........... Date:…………............... Tested by: ………………............ Checked by: ….……………….…….....

Location SN Depth Sample Particle Size Distribution – Percentage passing GM LL Ls PI PM AASHTO

(m) Descrip- Millimetres Microns (%} (%) (%) Classification
tion
75 53 37.5 26.5 19.0 13.2 9.5 4.75 2.0 1.18 425 250 150 075 a b a b a b

Operating Procedures for Central Materials Laboratory

SN: Sample Number a: 0.425mm sieve b: 0.075mm sieve
GM: Grading Modulus LL: Liquid Limit. PI: Plasticity Index. LS: Linear Shrinkage. PM: Plasticity Modulus
(P0.425xPI)

99
PART E - References and Appendices
PART E - References and Appendices Roads Department

FORM S2 - S4 (b)
Soil Tests:
Work Sheet
Ministry of Works and Transport Atterberg Limits
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Sample Number…………….. MOISTURE CONTENT PLASTIC LIMIT RESULTS

Trough No. LL
Wt. tin. + wet soil (g) PL
Wt. tin. + dry soil (g) PI
Wt. tin (g) LS
Wt. of moisture (g)
Wt. of dry soil (g)
Percentage Moisture (g)
Number of taps (N)

N= number of taps at Liquid Limit (TMH 1: 1986)

Trough Number ………….. Shrinkage (S) (mm): …………… Linear Shrinkage: …….%

LS = S x (100/150) x 0.8/(1-0.008N)

Sample Number…………….. MOISTURE CONTENT PLASTIC LIMIT RESULTS

Trough No. LL
Wt. tin. + wet soil (g) PL
Wt. tin. + dry soil (g) PI
Wt. tin (g) LS
Wt. of moisture (g)
Wt. of dry soil (g)
Percentage Moisture (g)
Number of taps (N)

N= number of taps at Liquid Limit (TMH 1: 1986)

Trough Number ………….. Shrinkage (S) (mm): …………… Linear Shrinkage: ….….%
LS = S x (100/150) x 0.8/(1-0.008N)

100 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM S5 (a)
Soil Tests:
Work Sheet
Maximum Dry Density &
Ministry of Works and Transport
Roads Department Optimum Moisture Content Materials and Research Division

Project: …………….…………................ .. Sample Location: …………………..... .... Sample Number.................................

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Container Number
Mass of container + wet material (g)
Mass of container + dry material (g)
Mass of container (g)
Mass of moisture (g)
Dry Mass of Material (g)
Moisture Content (%)
Water required....................................... Mould Factor.........................

% Moisture added
Mass of Mould (g)
Mass of Mould + wet material (g)
Wet Mass of Material (g)
Wet Density (kg/cm3)

MOISTURE CONTENT DETERMINATION AFTER COMPACTION

Conrainer Number
Mass of container + wet material (g)
Mass of container + dry material (g)
Mass of container (g)
Mass of moisture (g)
Moisture Content (%)
Dry Density (kg/cm3)

Maximum Dry Density.........................kg/cm3 Optimum Moisture Content...........................%

Operating Procedures for Central Materials Laboratory 101

PART E - References and Appendices Roads Department

FORM S5 (b)
Soil Tests:
Work Sheet
Maximum Dry Density &
Ministry of Works and Transport
Roads Department
Optimum Moisture Content Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Dry Density of soil (kg/cm3)

Moisture Content (%)

102 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM S6
Soil Tests:
Work Sheet
California Bearing Ratio
Ministry of Works and Transport
Roads Department (CBR) Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Maximum Dry Density..…………....kg/m3 at OMC …...….... Stabilization …….……% Days Cured…..…….... Days Soaked………..…..

MOISTURE CONTENT DATA

Hygro Moisture Content Molding Moisture After Soaking
Moisture
Pan Number Mould Number (kg)
Wt. of wet sample (g) Water Mould +wet weight (kg)
Wt. of dry sample (g) Required Mould weight (kg)
Weight of pan (g) ……..% Wet weight (kg)
Weight of moisture (g) Dry weight (g)
Weight of dry Soil (g) Moisture (g)
………ml
% Moisture (g) % Moisture
Average Average
COMPACTION DATA
Effort Modified Intermediate Proctor
Mould Number.
Factor
Weight of mould (Kg)
Weight of mould+ wet sample (kg)
Weight of wet Sample (kg)
Weight of dry Sample (kg)
Wet Density (kg) m3
Dry Density (kg) m2
% Compaction
% Swell
PENETRATION DATA
DEPTH Reading Correct CBR Reading Correct CBR Reading Correct CBR
(mm) Reading Reading Reading
0
0.5
1.0
1.5
2.0
(0.1II)* 2.5
3.0
3.5
4.0
4.5
(0.2II)* 5.0
5.5
6.0
6.5
7.0
(0.3II)* 7.5

Operating Procedures for Central Materials Laboratory 103

PART E - References and Appendices Roads Department

FORM S7
Soil Tests:
Work Sheet
Unconfined Compressive
Ministry of Works and Transport
Roads Department Strength - stabilised soils Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Type of Stabilizer Stabilizer Modified AASHTO data Specimen Data

Content Max Dry Optimum Dry Density. Moisture 7 day compressive strength
(%) Density Moisture (Kg/m3) (%) Individual applied load Average
(Kg/m3) Content Applied UCS UCS
(%) Load (kPa) (kPa)

Compressive Strength

104 Operating Procedures for Central Materials Laboratory

 FORM S8 (a)
Soil Tests: Work Sheet
Roads Department

Ministry of Works and Transport

Consolidation Test Results
Roads Department Materials and Research Division

Specimen Measurements: Consolidation ring weight = .................gm

Interior Diameater of ring =......................... cm ring+wet soil weight = ..........................m
Specimen Area = ..................................cm2 = A Ring+dry soil weight = .........................m
Initial thickness of soil sample = .................cm Dry soil weight = ........................gm = WS
Specific Gravity of soil = ............................G1 Moisture content = ................................%
WS

Operating Procedures for Central Materials Laboratory

Equivalent height of solids, 2Ho =m
G1 γW X A

Applied Final dial Change in Thickness of Equivqlent Void ratio Change in Coefficient of 1+e0 Coefficient Fitting time Coefficient Compression Coefficient of
Pressure reading dial reading soil sample hight of 2H –1 void ratio com- of volume in minutes of con- index perme-
e=
in (kg/cm2) df (mm) 2H voids 2Ho ∆e pressibilty change t90 solidation Ce ablity
(mm) (mm) 2H-2Ho ∆e av 0,848 d2 K = Cv mv γw
av = ∆p mv= Cv = t
(mm) 1+e2 90
(cm2/Kg) (cm2/Kg) (cm2/sec) (cm/sec)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
0.00

0,10

0,20

0,50

1.00

2.00

4.00

8.00

16.00

8.00

4.00

105
PART E - References and Appendices
PART E - References and Appendices Roads Department

FORM S8(b)
Soil Tests:
Work Sheet
Consolidation Test
Ministry of Works and Transport
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Load given = ………kg/cm2

√t90 = ………….

Dial Reading
in mm

√t in minutes
Void Ratio ℮

Consolidation Pressure log p in kg/cm2

106 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM S9
Soil Tests:
Work Sheet
Crumb Test
Ministry of Works and Transport
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Sample Number Soil Description Reagent Used Classification Classification

(Grade 1 – 4) (Non-Dispersive/Dispersive)

• Grade 1 and 2 represent a non-dispersive reaction

• Grade 3 and 4 represent a dispersive reaction

Operating Procedures for Central Materials Laboratory 107

PART E - References and Appendices Roads Department

FORM S12
Soil Tests:
Work Sheet
Conductivity and pH
Ministry of Works and Transport
Roads Department of Soil and Water Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Sample
Number
Container
Number
Size
Fraction

EC Reading

Temperature
(0C)
Temp. Conversion
Factor
Cell
Number
Cell
Constant
Conductivity
(S/m)
Percentage Soluble
Salts

PH

Percentage Sat.
Moisture Content

NB: Electrical Conductivity (EC) is measured in Siemens per meter (S/m) at 25 0C

108 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM S13
Soil Tests:
Work Sheet
Initial Consumption of
Ministry of Works and Transport
Roads Department Lime (ICL) Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Calcium hydroxide Lime used in the test

pH of Saturated Solution
Temperature (oC)
pH corrected to 25 oC

Lime Content (%)

pH value of suspension
Temperature (oC)
pH corrected to 25 oC
pH value

1 2 3 4 5 6 7
LIME CONTENT (%)

Proportion of material < 0.425 mm %

Initial Consumption of Lime (ICL) %

Operating Procedures for Central Materials Laboratory 109

PART E - References and Appendices Roads Department

FORM S15 (a)

Soil Tests:
Work Sheet
Direct Shear Tests
Ministry of Works and Transport
Roads Department Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Maximum Dry Density..…………....kg/m3 at OMC

Length of Sample L0 =…………………………...... mm, Width of Sample B0 = …………………………..mm

Area of Sample A0 = L0 x B0 = …………………………..cm2 , Sample Thickness = ……………………...mm

Elapsed Time Shear Dial in Shear strain in Normal Dial Normal Proving Ring Corrected Shear Stress
in min. in mm Displacement Dial in KN Contact Area A
mm L0 % = L
in mm (P) =
L0
(
= A0 1–
L0
L
) A

110 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM S15 (b)

Soil Tests:
Work Sheet
Direct Shear Tests
Ministry of Works and Transport
Roads Department Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Maximum Dry Density..…………....kg/m3 at OMC

Maximum Shear Stress

f = ……………………….........................
KN/cm2

Normal Stress = ….....................KN/cm2

Shear Stress

Strain / Displacement L
Cohesion (c) = .............................KN/cm2
Angle of Shearing Resistance
(φ) in degrees =……….............…….............o

Shear
Stress at
failure
f

Normal Stress n

Operating Procedures for Central Materials Laboratory 111

PART E - References and Appendices Roads Department

FORM S16 (a)

Soil Tests:
Work Sheet
Triaxial Tests
Consolidated Drained
Ministry of Works and Transport Consolidated Undrained
Roads Department Unconsolidated Undrained Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Confining stress (σ3) = …………………………..kPa, Sample Diameter (D0) = ..................................... mm

Sample Height (H0) = ......................................... mm
Consolidation Pressure = ………………………….kPa Sample Area (A0) = ............................................ mm2

Dial Compres- Strain Proving Axial Corrected Burette Deviator Volume

_
Change sion of φ= L Ring Load Area in cc Stress σ1 σ1 Change
Reading sample Reading A = A0 σ1 - σ3
L0 kPa _ ,
L (1 - φ) = 1000 P/A
in % (N) σ3 in (cc)
(mm2) kPa
(mm)

112 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM S16 (b)

Soil Tests:
Work Sheet
Triaxial Tests
Consolidated Drained Test
Ministry of Works and Transport Consolidated Undrained Test
Roads Department Unconsolidated Undrained Test Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

_
σ1
_
σ3
Increase

20
V
volume
change
in cc
0
Decrease

20
Axial strain L in %
L0

Operating Procedures for Central Materials Laboratory 113

PART E - References and Appendices Roads Department

FORM S16 (c)

Soil Tests:
Work Sheet
Triaxial Tests
Consolidated Drained Test
Ministry of Works and Transport Consolidated Undrained Test
Roads Department Unconsolidated Undrained Test Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Cohesion (c)
=
Angle of Sharing
Resistance (φ ) in
Degrees = ………….............

Plotting of Mohr´s Circle

114 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM AG1
Aggregates Tests:
Work Sheet
Mechanical Sieve
Ministry of Works and Transport
Roads Department Analysis Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

Mass of Sample Taken: Mass of Sample Taken:

Sieve Size (mm) Sample Number: Sample Number:
Mass % % Cumulative Mass % % Cumulative
Retained Retained passing % passing Retained Retained passing % passing
75.0
53.0
37.5
26.5
19.0
13.2
9.50
6.70
4.75
2.36
1.18
0.600
0.300
0.150
0.075
<0.075
Total

Operating Procedures for Central Materials Laboratory 115

PART E - References and Appendices Roads Department

FORM AG2
Aggregates Tests:
Work Sheet
Aggregate Crushing
Ministry of Works and Transport
Roads Department Value (ACV) Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….….................... Checked by: ……………...................

.
Weight of dried aggregate (A) g.
Weight of fines after crushing (B) g.
Dry ACV. = (B/A x 100%)
Mean ACV

Weight of dried aggregate (A) g.

Weight of fines after crushing (B) g.
Wet ACV. = (B/A x 100%)
Mean ACV

Remarks: Specify the aggregate size if non-standard aggregate sizes are used.

116 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM AG3 (a)

Aggregates Tests:
Work Sheet
Ministry of Works and Transport
Dry 10% FACT Value
Roads Department Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………....................

TRIAL TESTS FOR LOAD (X)

Weight of dried aggregate (A) in grams.
Load applied (W) Tons
Weight of fines (B) in grams.
Percent fines (P) = 100B/A
Load required for 7.5 – 12.5 % Fines (X) =
14W/(P+4) (kN)

TEST AT LOAD (X) TONS

Weight dried aggregate (C) in grams.
Load applied (X) in Tons
Weight fines (D) in grams.
Per cent Fines (E) = 100D/C
Mean percent fines (Y)
10% FACT = 14X/(Y+4) (kN)

Remarks: Specify the aggregate size if non-standard aggregates sizes are used.

Operating Procedures for Central Materials Laboratory 117

PART E - References and Appendices Roads Department

FORM AG3 (b)

Aggregates Tests:
Work Sheet
10% FACT Value
Ministry of Works and Transport
Roads Department
□ Dry □
Soaked Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Number: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

TRIAL TESTS FOR LOAD (X)

Weight of dried aggregate (A) in grams.
Load applied (W) in kN
Weight of fines (B) in grams
Percent fines (P) = 100B/A
Load required for 7.5 – 12.5 % Fines (x) = 14W/(P+4)
(kN)

TEST AT LOAD (X ) kN
Weight dried aggregate (C) in grams.
Weight soaked aggregate (F) in grams
Load applied (X) kN
Weight fines (D) in grams.
Per cent Fines (E) = 100D/C
Water Absorption = 100[ (F-C)/C]%
Mean percent Fines (Y)
10% FACT = 14X/(Y+4) (kN)
Mean Water Absorption %

Remarks:
• Specify the aggregate size if non-standard aggregate sizes are used.
• This method is similar to the Dry 10% FACT except that aggregates are soaked in water for 24 hours, allowed to drain
briefly until surface dry and weighted. After crushing all material is oven-dried before screening.

The ratio of soaked 10% FACT / Dry 10% FACT gives an indications of potential durabiliy of the aggregates in service.
Currently a minimum ratio of 0.75 is considered necessary for the aggregatesto be durable- Low ratios have however been
advocated for N-values > 5, low volume roads and graded (Otta) seal (Guideline no. 8 - The use of silcrete and other
marginal materials for road surfacing.

SUMMARY OF 10% FACT

DRY 10% FACT
SOAKED 10% FACT
RATIO OF SOAKED 10% FACT / DRY 10% FACT

118 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM AG4
Aggregates Tests:
Work Sheet
Aggregate Impact Value
Ministry of Works and Transport
Roads Department (AIV) Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Dry AIV Sub-sample No:……………….. Aggregate Fraction used…………….

No of blows (normally 15), n

Mass of dry aggregates, M1 (g)

Mass of fines (passing 2.36 mm sieve for standard test),
M2 (g)
Dry A.I.V. = (M2/M1 x (15/n) x 100%

Mean Dry A.I.V

Median Dry A.I.V

Soaked AIV Sub-sample No:……………….. Aggregate Fraction used………….

No of blows (normally 15), n

Mass of surface dry soaked aggregates, M1 (g)

Mass of fines (passing 2.36 mm sieve for standard test),
M2 (g)
Soaked A.I.V = (M2/M1) x (15/n) x 100%

Mean Dry A.I.V

Median Soaked A.I.V

Ratio of dry AIV to Soaked AIV (Dry AIV / Soaked AIV)

Operating Procedures for Central Materials Laboratory 119

PART E - References and Appendices Roads Department

FORM AG5
Aggregates Tests:
Work Sheet
Ministry of Works and Transport
Durability Mill Index (DMI)
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Sample No.
Sub-sample no. A B C D A B C D
Sample Mass
Sieve Size (mm) Percentage Passing Percentage Passing
37.5
26.5
19.0
13.2
9.50
6.70
4.75
2.00
0.850
0.425
0.250
0.150
0.075
<0.075

ATTERBERG LIMITS
Liquid Limit
Plastic Limit
Plasticity Index
DMI

Durability Mill Index (DMI) = PI(max) X P0.425(max)

120 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM AG9
Aggregates Tests:
Work Sheet
Aggregate Polished
Ministry of Works and Transport
Roads Department Stone Value Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Control Mould
Stone Polishing Coefficient Mean
Specimen Number

PSV:………………………………………………………….
PSV = S + 52.5 – C Where S = mean of control stone
C = mean of tested specimen

Operating Procedures for Central Materials Laboratory 121

PART E - References and Appendices Roads Department

FORM AG10
Aggregates Tests:
Work Sheet
Aggregate Fingers &
Ministry of Works and Transport
Roads Department Pliers Value Materials and Research Division

Project: …………….…………................ .. Sample Location and Depth …………….............................…….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Container
Sample Number Details of Aggregate Test
Number
Size (mm) Sieved Visually Crushed or Soaked Unsoaked
Selected Natural

Test Sample Number Container Number Number of pieces not Total number of Percentage
broken pieces (AFV or APV)
( = B or C)
Not broken by
Fingers

(AFV Test)

Not broken by
Pliers

(APV Test)

122 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM B1
Bitumen Tests:
Work Sheet
Ministry of Works and Transport
Penetration Test
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Sample Number. TIME Penetration Value Mean

Poured Placed in Water at Tested (0.1mm)
250C

Operating Procedures for Central Materials Laboratory 123

PART E - References and Appendices Roads Department

FORM B2
Bitumen Tests:
Work Sheet
Ministry of Works and Transport
Ductiliy Test
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Sample No.
Mould No.
Time poured
Time placed in water bath
Distance elongated in mm.

Sample No.
Mould No.
Time poured
Time placed in water bath
Distance elongated in mm.

Sample No.
Mould No.
Time poured
Time placed in water bath
Distance elongated in mm.

Sample No.
Mould No.
Time poured
Time placed in water bath
Distance elongated in mm.

124 Operating Procedures for Central Materials Laboratory

Roads Department PART E - References and Appendices

FORM B4
Bitumen Tests:
Work Sheet
Ministry of Works and Transport
Softening Point
Roads Department Materials and Research Division

Project: …………….…………................ .................................................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Time Poured: ……………………………………………………………………..........................................................……

…………….……………………....................................................................................................................
o
Water at 5 C
Sample Number Sample Number
Time(minutes) Temperature ( oC) Time(minutes) Temperature ( oC)

0 13
1 14
2 15
3 16
4 17
5 18
6 19
7 20
8 21
9 22
10 23
11 24
12

Ring 1 Ring 2 Average

0
Softening Point ( C)

Operating Procedures for Central Materials Laboratory 125

PART E - References and Appendices Roads Department

FORM AS 3
Asphalt Mixes Tests:
Work Sheet
Bulk Relative Density of
Ministry of Works and Transport
Roads Department Compacted Bituminous Mix Materials and Research Division

Project: …………….…………................ .. Sample Location .................................... Depth …………….............................

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Specimen Number

Mass of briquettes in air, A. (g)

Mass of briquettes in water, C. (g)

Mass of saturated Surface-dry briquette in

air, B. (g)

Bulk Relative Density, A/(B – C)

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FORM AS 3
Asphalt Mixes Tests:
Work Sheet
Bulk Relative Density of
Ministry of Works and Transport
Roads Department Compacted Bituminous Mix Materials and Research Division

Project: …………….…………................ .. Sample Location .................................... Depth …………….............................

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Predetermined input data:

Bulk relative density of aggregate (Ga)
Apparent relative density of binder (Gb)
Percentage of binder in mix (P) %

Test Data

Mass of flask (a) grams

Mass of flask + sample (b) grams
Mass of flask + sample filled water after removal of air (c) grams
Mass of flask filled with water (d) grams

Calculations

Maximum theoretical density of mixture

G/cm3
(RDm) = (b-a) / [(d-a) – (c-b)]
Percentage of binder in mix (P) %

Mass of binder in sample (B) = P(b – a) / 100 grams

Mass of aggregates in sample (A) = [(100 – P)(b – a)] / 100 grams

Volume of aggregates in sample (Vb) = B/Gb cm3

Volume of binder in sample (Vb) = A/Ga cm3

Volume of voidless mix (Vm) = (d – a) – (c – b) cm3

Percentage of binder absorbed by the aggregate
%
(Pb) = {[(Vb + Va – Vm)Gb] / A} x 100

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FORM F1
Field Tests:
Work Sheet
Dynamic Cone Penetrometer
Ministry of Works and Transport
Roads Department (DCP) Materials and Research Division

Project: …………….…………................ .. Sample Location.. .................................. Sample Location: ………………….....

Client: ………………….. Date:…………....Tested by: ……………….…....................Checked by: ……………...................

Km _____________ Offset _____________ Km ______________ Offset ___________

Remarks ____________________________ Remarks ___________________________

No. of Reading Depth D.N. CBR No. of Reading Depth DN CBR
Blows mm mm mm/blow % Blows mm mm mm/blow %

DCP/CBR Relationship: Log10 CBR = -1.30 (Log10 D.N. ) + 2.65

128 Operating Procedures for Central Materials Laboratory

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APPENDIX B – GENERAL AND MANAGERIAL FORMS

● FORM M1.1 Controlled Distribution List

● FORM M1.2 Guideline Changes Request Sheet
● FORM M1.3 Guideline Audit Check List
● FORM M1.4 Guideline Corrective Action Request
● FORM M1.5 Summary of Operating Procedures Guideline Changes
● FORM M1.6 Guideline Audit Report
● FORM M2.1 Internal Test Schedule/Requisition
● FORM M2.2 Client Complaint Record
● FORM M3.1 Equipment Control and Calibration
● FORM M3.2 Register of Project Numbers
● FORM M3.3 Factual Report Archive
● FORM M3.4 Record of Education and Training
● FORM M3.5(a) Training Consultation
● FORM M3.5(b) Training Consultation
● FORM M3.5(c) Training Consultation
● FORM M3.6 Equipment Calibration Requirements
● FORM 3.7 Computer Data Backup Log
● FORM 5.1 Safety Checklist

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FORM M1.1

GENERAL
Controlled Distribution
Ministry of Works and Transport
Roads Department List Materials and Research Division

Name of Holder Office Date Issued Date Returned

Approved: Date

Quality Manager

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FORM M1.2

GENERAL
Guideline Changes
Ministry of Works and Transport
Roads Department Request Sheet Materials and Research Division

To: Operating Procedure Manager

From: Office:

Signed: Date:

Unit Head or Higher

The following changes are suggested to the procedure, form or document:

Procedure/Form/Document
Section No(s).
Proposed Changes

Reasons for Changes

Changes agreed / not agreed at Operating Procedures Review Meeting: CR No.

Signed: Date:

Operating Procedures Manager/PRE-Mat.

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FORM M1.3

GENERAL
Guideline Audit Check
Ministry of Works and Transport
Roads Department
List Materials and Research Division

Audit Reference Page No. Auditor Date

Project No.

COMPLIANCE
PROCEDURE / YES NO Unclear COMMENTS
SECTION

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FORM M1.4

GENERAL
Guideline Corrective
Ministry of Works and Transport
Roads Department
Action Request Materials and Research Division

Audit Reference Auditor Date

Form No. Contact Unit

Guideline Document Project No.

Non-compliance

Agreed Preventive and

Corrective Action

Date for Completion

Signed (Auditor)
Acceptance Signature

Action Complete Action Verified No Further Action Required

(LM) (HOD) (HOD)
Signature
Date

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FORM M1.5

GENERAL
Summary of Operating
Ministry of Works and Transport
Roads Department
Procedures Guideline Changes Materials and Research Division

Summary of changes/revisions made to the Operating Procedures Guideline

Document Page No. Section No. Revision
Reference

Signed: Date:

Operating Procedures Manager

134 Operating Procedures for Central Materials Laboratory

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FORM M1.6

GENERAL

Ministry of Works and Transport

Guideline Audit Report
Roads Department Materials and Research Division

Audit Reference Auditor Audit Date

Office

Procedures Audited
Persons Contacted

Summary:

Signed: Date:

Auditor

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FORM M2.1

MANAGERIAL
Internal Test
Ministry of Works and Transport
Roads Department
Schedule/Requisition Materials and Research Division

To: Laboratory Manager

For the attention of:

From: Date:

Sample Numbers:

Brief Description of Samples, Origin and Purpose of Testing:

Tests Required:

Review, Checking and Approvals Required (by PO or SRE-Laboratory):

Programme:
Start Date: Completion Date:
Comments:

Signed:
Internal Client Officer/Requestor
Acceptance (Sign below and return copy to originator):
Signed:

Laboratory Manager Date:

136 Operating Procedures for Central Materials Laboratory

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FORM M2.2

MANAGERIAL

Ministry of Works and Transport

Client Complaint Record
Roads Department Materials and Research Division

Complaint ID Project Number Date of Complaint Date Complaint Registered

Project Name

Client

Nature of Complaint

Result of Complaint Investigation

Action Taken

Preventive Action Recommended

Head of Division Laboratory Manager Preventive Action Implemented

Signature
Date

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PART E - References and Appendices Roads Department

FORM M3.1

MANAGERIAL
Equipment Control and
Ministry of Works and Transport
Roads Department
Calibration Materials and Research Division

Laboratory Unit (where equipment is located) Sheet No.

of

Item Manufacturer Serial No. Date Date when the next calibration or in-house check
or Purchased is due.
ID Mark (Following calibration/check, initial along with
date and add next date to adjacent column.)

138 Operating Procedures for Central Materials Laboratory

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FORM M3.2

MANAGERIAL
Register of Project
Ministry of Works and Transport
Roads Department
Numbers Materials and Research Division

Project Number Project Name Date of Date

report Archived

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PART E - References and Appendices Roads Department

FORM M3.3

MANAGERIAL

Ministry of Works and Transport

Factual Report Archive
Roads Department Materials and Research Division

Project Project Title and Report Contents Report Date Earliest Date of Location
Number Number Archived Destruction

Signed: Date:

Hand entries since this date shall be individually initialed.

140 Operating Procedures for Central Materials Laboratory

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FORM M3.4

MANAGERIAL
Record of Education and
Ministry of Works and Transport
Roads Department
Training Materials and Research Division

Name Position Date of Joining Roads Dept.

Education

Date Name of School/College/University/RTC Qualification Obtained

From To

Previous Employment (Including other Roads Dept. Divisions and other organisations)

Date Employer Position

From To

Record of In-House and External Training Attended

Date Name of Institution e.g RTC/CML Qualification Obtained /

From To Training Received

Professional Qualifications/Membership
Date Organisation Qualification/Membership
(e.g. BSc./ MBIE)

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FORM M3.5 (a)

MANAGERIAL

Ministry of Works and Transport

Training Consultation
Roads Department Materials and Research Division

Personal Details
Name Position Date of Appointment

Laboratory Unit Supervisor

Section A
Aim: To help the staff member develop his or her capabilities and performance at work
for the benefit of both the staff member and Roads Department.
Objectives agreed at appraisal interview for the coming year:

Comments by interviewer based on sections B and C attached:

Signed: Date

Unit Head/ Laboratory Manager

Signed: Date

Staff Member, having seen Sections B and C

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FORM M3.5 (b)

MANAGERIAL

Ministry of Works and Transport

Training Consultation
Roads Department Materials and Research Division

Section B Self Assessment

Name:
Training undertaken and qualifications obtained since the last consultation (attach
copies of certificates) eg courses at RTC and others.

Please indicate how effective the above training/courses were in improving your
performance.

What training do you consider would improve your performance on tasks similar
to those undertaken in the last year?

What training do you consider would enable you to undertake additional tasks
that would benefit the Laboratory?

Signed: Date

Staff Member

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FORM M3.5 (c)

MANAGERIAL

Ministry of Works and Transport

Training Consultation
Roads Department Materials and Research Division

Section C Training
Name Position

Training since last interview: (Attach copies of certificates where applicable)

Date Description comprising

From To Institution, Type of training received and qualification attained

Future training requirements

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FORM M3.6

MANAGERIAL
Equipment Calibration
Ministry of Works and Transport
Roads Department
Requirements Materials and Research Division

Name of Laboratory Unit Sheet No.

of

Item Year of Manufacturer Serial No. or Details of calibration, Next

Manufacture ID Mark service and/or in-house Calibration
checks

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FORM M3.7

MANAGERIAL
Computer Data Backup
Ministry of Works and Transport
Roads Department
Log Materials and Research Division

DATE TYPE OF BACK-UP MEDIA TYPE BACKED UP BY SIGNED

146 Operating Procedures for Central Materials Laboratory

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FORM 5.1

MANAGERIAL

Ministry of Works and Transport

Safety Checklist
Roads Department Materials and Research Division

No Potential Hazard
1 Outside structures safe? e.g sample shed
2 Eye goggles and other protective clothing during testing
3 Hazardous materials left outside the laboratory (e.g biological hazards, used condoms etc).
4 Electrical and other mains crossing the laboratory.
5 Hazard information signs used.
6 Essential fire precautions.
7 Emergency alarms and escape routes.
8 Toxic Chemicals in the ABCC unit properly stored.
9 Processes producing dust such as in the compaction unit, dust extractor
10 Structural instability in any of the buildings.
11 Traffic/pedestrian conflict at Entrance to Laboratory.
12 Water (work over, flooding etc.). Is shower area kept clean
13 Personnel (security).
14 Pollutants / confined spaces etc. e.g. fume cupboard in ABCC unit working?
15 Sample storage area run-off affecting neighbouring properties
16 Noise / vibration in the laboratory.
17 Slippery floors during cleaning
18 Adverse conditions e.g. hot weather/cold weather affect on staff.
19 Lifting of heavy equipment, samples and apparatus by staff.

Maintenance/Repairs
20 Ladders (Hooped/Fenced)
21 Roofs (Fragile and Edges)
22 Windows opening/closing obstructing
23 Doors opening/closing obstructing/operating:
Do they obstruct passageways or lead into hazardous situations.
24 Safety Controls for test machine operation:
Stop/start/emergency stop. Dibble visual warning of operation.
25 Pressure systems such as water boiler-checked regularly.
26 Fire Alarms, Escape Routes etc. Is Extinguisher checked and filled?
27 Resistant bench surfaces - Electrical/Chemical.
28 Safety warning/information in the equipment.
29 Operating and maintenance manuals available at or before hand over.
30 Maintenance:
Are there adequate maintenance arrangements for:-
• Internal/external building fabric.
• Window cleaning, Lighting, Movement of useable.
• Ventilation/extraction, Gutter cleaning, Drains, sewers.

Operating Procedures for Central Materials Laboratory 147