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QUALITY CHECKS

TESTS FOR RAW MATERIALS

…
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CEMENT
(Reference – IS:4031 – Part – 1 to 14)
A. FIELD TESTS :
For every lot received at site, the following field tests should be performed:
1. Grade & Colour:
The cement should be of the grade which is indented and its colour should be Grey.

2. Freshness Test:
Chose any bag at random from check for the Manufacturing Date. It should not be more than 30
days old.

3. Smoothness Test:
Open the cement bag from one corner. Take a pinch of dry cement and rub between fingers. It
should feel silky.

4. Lump Test:
Take any cement bag at random and test for presence of Lumps. Fresh cement should be in
powder form only. Any cement bag with lumps should be rejected.

5. Floating Test:
Take a glass jar filled with clean water and add some dry cement slowly to the water. Good
cement floats for a while and sinks slowly to the bottom. Any light weight impurity may remain
floating even after cement sinks. A heavier impurity sinks immediately.

6. Paste Test:
Prepare 5cm x5cm x 5cm cement paste in plastic or tin boxes and place the cube in water
immediately. After 24 hours the edge, the cubes should remain sharp and it should gain some
strength.

7. Average Weight Test:

Take 5 bags at random from the lot and take average weight of the bags. The difference in
average weight should not be more than 5%.
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B. LABORATORY TESTS :

1. Fineness Test
(a) Fineness of cement by dry Sieving method
(b) By Blain air permeability method\

(a) By Sieve Analysis

Apparatus used:-
1. Weight balance digital with list count 0.01 gram
2. IS Test sieve 90 microns (confirming to IS-460 Part –I)
3. Trowel
4. Tray 30cm x 30cm
5. Bristle brush with 25cm handle

Procedure:-

1. Weight 100 gram of cement and place it on a standard IS Sieve 90 microns.

2. Continuously sieve the sample by holding the sieve in both hands and giving a gentle wrist
motion or mechanical sieve shaker may be used for this purpose. The sieving should be continues
for 15 minutes.
3. Weigh the residue left after 15 minutes sieving. This residue shall not exceed the specified limits.
 Fineness of cement should not greater than 10% according to IS 269-1989

Calculation of Fineness Test of Cement

Steps Taken ↓ SAMPLE

I II III
Weight of Cement( W) gm
I.S sieve size micron
Sieving time min
Weight retained on sieve(W1) gm
W1
Percentage weight retained on sieve =--------x100
W
Mean Percentage
 Page |5

(b) Blaine’s Air Permeability Method

Apparatus Used
1- Blaine’s Air Permeability Apparatus
2- Digital Balance
3- Stop Watch
4- Camel Hair Brush
5- Mercury
Procedure:-
1-Calculate the bulk volume of compacted bed of standard
(WA-WB)
V=- -----------------
D
WA= gms of mercury required to fill the Permeability cell
WB= gms of mercury required to fill the Portion of the cell not occupied by the bed of cement formed
by 2.8 gms of standard cement sample.
D= Density of mercury at temperature of test.
2-Determine the weight of the standard sample (W) required producing a bed having porosity of 0.50
+0.005(e) as follows:
W=3.15V(1-e)
V= Bulk volume of compacted cement powder
e = Desired porosity of bed of cement (0.50+ 0.005)
3- Determine the time taken by the manometer liquid to fall from second from the top to the third mark
of the manometer when air is allowed to permeate through the compacted bed of cement using the
quantity of standard cement calculated in procedure 2.
4-Calculate the constant of the apparatus (k) by using the following formula:
S s=K√ Ts
K= √ Ts/ Ss
Where Ss is the fineness of standard Portland cement in cm2 /gm.
5-Using the same quantity (w) of the cement sample find the time (T s) in the seconds
required for the manometer liquid to fall from second mark to third mark.
6-Calculate the specific surface of cement in cm2 / gm using the formula
S= K √ Ts
Observation and Calculations:-
(i)- Weight of empty crucible = gms
(ii)-Weight of crucible+ mercury filling permeability cell = gms
(iii)- Weight of mercury filling cell (ii) –(i)-W A = gms
(iv)- Weight of crucible+ mercury filling portion above cement bed = gms
(v)Weight of mercury filling cell above cement bed
of 2.80 gm of standard cement WB (iv)-(i) = gms
(vi) Temperature of the laboratory = 0C
(vii) Time taken by the manometer liquid to
fall from Second to third mark( Ts) =Secs

The fineness of given cement sample = cm2/gm

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2. Normal Consistency Test

Apparatus used:-

1. Vicat Needle Apparatus with plunger of 10mm dia. and 50mm length, 300gms
Vicat’s mould. (Confirming to IS-5513)
2. Balance & Weights of capacity-1 Kg. (list count – 0.1)
3. Trowel (IS-10086)
4. Enamel Trough.
5. Standard Spatula.
6. Stop watch.
7. A Non-Porous plate.
Procedure:-
1. The temperatures of molding room will be ensured i.e. dry material and water at 27±2 0C and the
related humidity of the molding room at 65±5%
2. Weigh about 400 gms. Of cement accurately and place in the enamel trough.
3. Add about 25% clean water by weight of cement and mix with the spatula. The time of gauging
should be between 3 to 5 minutes.
4. Fill this cement paste into the Vicat’s Mould resting on a non-porous plate. Make the surface of
cement paste in the level with the top edge of mould with a trowel and shake the mould slightly to
expel the air.
5. Place the mould with non-porous plate under the rod bearing plunger. Adjust the plunger
indicator at 0-0 reading when it touches the surface of test block.
6. Release the plunger, allowing sinking into the paste.
7. Prepare the trial paste with varying percentage of water and test as described above until the
needle penetrates 5mm to 7mm above the bottom of the mould.
8. Express this amount of water as a percentage by wt. of dry cement, which is called as
consistency.
 Normally Consistency of cement should be come 30% of wt. of dry cement.
Calculation of Standard Consistency
Date of test:-
Temperature of testing (i) Cement------0C
(ii) Water------0C
(iii) Room---- 0 C

SNo Quantity of % by Weight Time of Gauging Penetration

Water Added( minutes from bottom of
W) the mould
1
2
3
4
5
6
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3. Initial & Final Setting Time:

Apparatus used:-
1. Vicat Needle Apparatus with plunger of 10mm dia. and 50mm length, 300gms
Vicat’s mould. (IS-5513)
2. Balance & Weights box (list count – 0.1)
3. Trowel
4. Enamel Trough.
5. Standard Spatula.
6. Stop watch.
7. A Non-Porous plate.
8. Measuring Cylinder -500ml

Procedure:-

Initial Setting Time:

1. The temperatures of molding room will be ensured i.e. dry material and water at 27±2 0C and the
related humidity of the molding room at 65±5%
2. Weigh about 400 gms. Of cement accurately and place in the enamel trough.
3. Prepare a neat cement paste by adding 0.85 times the percentage of water required for standard
consistency.
3. Start the stop watch at the instant when water is added to the cement.
4. Fill this cement paste into the Vicat’s Mould resting on a non-porous plate Make the surface of
cement paste in the level with the top edge of mould with a trowel and shake the mould slightly to
expel the air.
5. Place the mould with non-porous plate under the rod bearing needle.
6. Lower the needle gentle till come in contact with surface block and quickly release, allowing
penetrating into the test block and noting penetration after every 2 minutes.
7. Repeat the procedure until the needle fails to penetrate the block for about 5 mm measured from
the bottom of the mould. Stop the stop watch and note the time. This time is the Initial Setting
Time.

Final Setting Time:

1. Replace the needle from the Vicat’s Appratus by the needle with annular attachment.
2. Go on releasing the needle as described earlier till the needle make an impression thereon, while
the attachment failed to do so.
3. The time elapses between the water is added to the cement and when the needle makes only an
impression is considered as the Final Setting Time of the Cement.

 The Initial Setting Time of Ordinary Portland Cement should not be less than 30
minutes and Final Setting Time should not be greater than 10 hours.
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Calculation of Initial and Final Setting Time Test

Sample prepared:-
Time :-
(i) Cement:-
Temperature at testing: - (ii)Water:-
(iii)Room:-
Quantity of Cement(C):-
Water for Standard consistency (P):-
Water to be added 0.85PXC :- Date
Sample I Sample II
Time at which water is first Time at which Time at which Time at which
SNo added(T1) penetration water is first penetration
reading are added( T1) reading are taken
taken
1 2 3 4 5

Sample I Sample II
Time When needle fails to penetrate 5mm
to 6mm from the bottom of the mould(T2)
Time at which water is first added ( T1)
Initial Setting Time (T2 - T1)

Record of Penetration
Sample I Sample II
Penetration Reading Penetration Reading

Sample I Sample II
Time when the needle makes an
impression but the attachment fails to
make one( T3)
Final Setting Time(T3- T1)
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4. Soundness Test :

(i) By Le Chattlier’s Apparatus:-

Apparatus used:-
1. Le Chattlier’s Apparatus.
2. Balance & Weights of capacity-1 Kg.
3. Trowel
4. Enamel Tray.
6. Stop watch.
7. 2 nos. glass sheets.
8. Blow Lamp or Stove or a water bath with electric heating arrangement.
Procedure:-

1. Weigh about 200 gms. Of cement accurately and place in the enamel tray.
2. Prepare a neat cement paste by adding 0.78 times the percentage of water required for standard
consistency.
3. Fill this cement paste into the Mould resting on a glass sheet. Make the surface of cement paste in
the level with the top edge of mould with a trowel and cover the mould with another piece of glass
sheet.
4. Place a small weight on this covering the glass sheet and immediately submerged the whole
assembly in water for 24 hours.
5. Measuring the distance separating indicators in mm.
6. Put this mould again in water and boil upto 3 hours. Remove the mould from the water and allow it to
cool.
7. Measure the distance between indicator points.
8. The difference between these two measurements gives expansion of the cement.
 For Ordinary Portland cement the difference should not be more than 10 mm.

Calculation of Soundness Test

SNo Steps Taken SAMPLE

↓
I II III
1 Weight of Cement sample (C )
2 Water Required for Standard Consistency
3 Water added to sample ( 0.78 PX C )
4 Time at which the sample is put in water
at270C to 320C
5 Time when the water is brought to the boiling
point
6 Distance between the pointer ends before
heating ( D1)
7 Time of heating
8 Distance between the pointer ends after
heating(D2)
9 Difference (D1-D2)
 P a g e | 10

(ii) By Autoclave Method

Apparatus used:-

1-Autoclave apparatus
2-Scale
3-Digital balance
4-Graduted glass cylinders
5-Length of Comparator
6-Moulds of size 25mmX25mmX250mm
7-Autoclave apparatus

Procedure:-

1. Mould shall be thinly covered with mineral oil. Then the reference point which is clean and
free from oil shall beset.
2. 500gm of cement shall be mixed with sufficient water to given paste of standard consistency.
3. After mixing, the mould shall be filled in one two layers by pressing the paste into corners by
thumb, the top level shall be smoothened by trowel.
4. After preparing the mould, they shall be stored in a moist room and after 24hours the
specimens shall be taken out of the mould.
5. After specimen taken out of the mould, measured length and placed into the autoclave at room
temperature in a rack so that the four sides of each specimen shall be exposed to saturated
steam. The autoclave shall contain enough water to maintain an atmosphere of saturated
steam vapour during the entire period of test.
6. To permit air to escape from autoclave during the early portion of the heating period, the vent
value shall be open until stem begins to escape. The valve shall then be closed and the
temperature of the autoclave shall be raised at such a rate as will bring the gauge pressure of
the steam to 2.1 N/mm2. shall be maintain.
7. After 3 hours the autoclave shall be switched off and it shall be cooled at the rate so as to
lower the pressure by 0.1N /mm2.
8. The specimen shall be immediately removed from the autoclave and placed in the water of
temperature above 900C.Then the water shall be cooled in 15 minutes.
9. Surface is dried and their lengths (L2) measured again.
10. Calculate the soundness of cement = L1-L2( expressed as percentage of effective gauge
length)

 When tested by Auto clave method should not less than 0.8%
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(c) Compressive Strength Test :

Apparatus used:-
1. Cube Moulds – 70.6 x 70.6 x 70.6 mm (IS-10080)
2. Cube Vibration Machine. (IS-10080)
3. Trowel.
4. Enamel Trough.
5. Measuring Cylinder.
6. Weighing Balance.
7. Non Porous Plate.

Procedure:-

1. Take 1200 gms. Cement and 3 kgs. Of standard sand and take (P/4 +3) % of combined weight of
cement and sand.
2. Prepare a mixture of cement and standard sand in the proportion of 1:3 on a non- porous plate.
3. Mix it dry with a trowel for one minute and then add water until mix is of uniform colour.
4. Oil the interior face of the mould.
5. Place assemble mould on the table of vibration machine and Fill the mortar in the mould until
vibration period (2 minutes) completed.
6. Keep the cube in normal temperature for 24 hours after completion of vibration.
7 After 24hrs. Remove cube from the mould and immediately subermeged in the water.
8. Test three cubes for compressive strength after 7days and rest 3 cubes after 28 days.

 For Ordinary Portland Cement the Compressive strength 0f 33/43/ 53 grade

Should not be less than 22/ 33/ 37 N/mm2 and 33/43/53 N/mm2 for 7 days
and 28 days respectively.
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Calculation of Compressive strength test of cement

Sample prepared on (i) Date:--

(ii) Time:----hrs---minutes
Temperature (i) Room----------0C
(ii) Water----------0C

Steps Taken SPECIMENS

↓
I II III IV V VI
Weight of cement gm.
Weight of standard sand gm.
Weight of Water (P/4+3) x wt. of dry
aggregate & cement
Area of Specimen (A) cm2
Load at Fracture( P) Kg
Age: 7 days
28 days
Compressive strength
Age: 7 days
28 days
Average Strength
 P a g e | 13

SAND
A. FIELD TESTS:
7
For every lot received at site, the following field tests should be performed:
1. Rub a little sand in the finger Stain left on the fingers will indicate the presence of undesirable
clayey impurities.
2. Taste of sand shall provide a suitable check for the presence of salt.
3. A sample of sand in a glass of water and allow it to rest amount of clay or silt present in it would
settle on the sand.
4. A sample of sand in a three percent solution of caustic soda and keep the bottle corked for 24
hours. If the colour of liquid turns brown then presence of organic matter is indicated.
The presence of inorganic impurities should not be more than 1% of the total sand.

B. LABORATORY TESTS:

1- Surface Moisture Content in Fine Aggregate( Sand)

Apparatus used:-

1. Balance Weighing Machine. Tray 60cmx30cm

2. Flask of Glass suitably graduated the volume of flask should be from 2 to 3times the loose
volume of the sample .The container should be so designed that it can be filled up to the mark or the
volume of its content read with in 0.5ml or less.
3. Heater Thermostatically Controlled

Procedure:

1. Take the weight of fine aggregate sample (Ms). It should weigh not less than 200 gm.
2. Water is added in the container up to the mark and than take the weight of sample (Mc)
3. Empty the container and than added some water sufficient to cover the sample.
4. Sample is now introduced into the container and any entrained air is removed.
5. Fill the container with water up to the original mark and the weight in grams is determined (M).
The amount water displaced by the sample is calculated as follows:
Vs= Mc+ Ms-M
Where
Vc is the weight in grams of water displaced by the sample.
Mc is the weight in grams of container filled up to the mark with water.
Ms is the weight of the sample in grams
M is the weight in grams of the sample and container filled to the mark with water.
 P a g e | 14

Calculation of Surface Moisture in Fine Aggregate

Steps Taken Sample I Sample II

↓
I II I II
Weight of Sample ( Ms) gm
Weight of Container filled upto the mark
with water (Mc) gm.
Weight of sample and container filled to the
mark with water (M ) gm
Weight of Water displaced Vs= Mc+Ms-M
Ms
Vd=----------------------------
Specific gravity of sample
%surface moisture in term of saturated and
surface dry aggregate wt. P1=(Vs-Vd)/ (Ms-
Vs) X100
%surface moisture in term of weight of wet
aggregate P2=(Vs-Vd)/ (Ms-Vd) X100
Average P1
Average P2

2-Bulking of Sand

Apparatus Used

1-Container
2-Steel rule
3-Steel rod 6mm diameter
4- 250cc measuring cylinder

Procedure
1. Take sufficiently quantity of sand in the container until it is about 2/3 rd full.
2. Level off the top of sand pushing a steel rule vertically down through sand at middle to bottom
Measure height say h1.
3. Empty the sand out of the container, take into another into another container.
4. Fill the container with water to ¼ th volume occupied by sand.
5. Put back about half the sand and rod it with a steel rod 5mm dia so that its volume reduces
minimum.
6. Add remainder of sand and rod it in the same way
7. Smooth the top level surface of the inundated sand and measure its depth at middle surface with
steel rule say h2.
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Calculation of Bulking of Fine Aggregate

Steps Taken Sample 1 Sample 2

↓
I II III I II III
Height of loose sand (h1)
mm
Height of Saturated sand (h2)
mm
h1 –h2
% of Bulking =------x100
h2
Average Value:-

3-Specific Gravity& Water Absorption of sand

Apparatus Used

1-Pycnometer
2-Digital Balance
3. Funnel
4. Tray

Procedure
1. Take about 500gm of sample is place in the tray.
2. Weigh the sample says W1
3. The aggregate is then placed in the pycnometer and then it should be filled with distilled water. and
air entrapped is eliminated by rotating the pycnometer on its side ,the hole of apex cone cover with
finger .
4. The pycnometer is then dried outside and weighed says W 2.The content of pycnometer is transferred
on the tray.
5. The pycnometer is then refilled with distilled water to same level as before dried on outside and
weighed asW3
6. The water from the sample is removed and then and then sample is dried in the oven cooled and
weighed as W4.
 P a g e | 16

Calculation of Specific gravity and Water Absorption

Steps Taken Sample I Sample II

↓
I II I II
Weight of sample taken

Weight of saturated and surface dry

aggregate ( (W3)gm
Weight of pycnometer + sample
+water(W1) gm.
Weight of pycnometer +water(W2) gm.
Weight of oven dry sample(W 4) gm.
W4
Specific Gravity = -----------------
W3- ( W1-W2)
(W3- W4)
Water Absorption= ------------ x100
W4

4-Silt in Fine Aggregate

Apparatus Used:-
1- 250ml Measuring cylinder

Procedure:-
1. 50ml of approximately1% solution of common salt in water is placed in the measuring jar.
2. Sand is added, till the level reaches 100ml mark.
3. More solution is then added until the total volume of mixture in the cylinder is150ml.
4. Cylinder is cover with palm of the hand, shaken vigorously, repeatedly turned upside down and
then allowed to stand for 3hours.
5. The silt will now settle in a above the sand.
6. Percentage of silt is calculated

Calculation of Silt content in Fine Aggregate

SNo Steps Taken Sample
↓
I II III
1 Volume of Sample ( V1) ml
2 Volume of Silt after three hours( V2)
ml
3 Percentage silt by volume (V2 / V1)*100
4 Average Value
 P a g e | 17

5-Particle size Distribution (Grading of Aggregate) of Fine

& Coarse Aggregate

Apparatus Used
1-Type Sieve - 40mm, 20mm, 16mm, 12.5mm, 10mm, 4.75mm, 2.36mm, 1.18mm,
600 μ, 300 μ, 150 μ, 75 μ.
2-Balance
3-Square hole perforated plate, 30cm diameter
4-Fine mesh
5-Wire Cloth
6-Brushes with fine camel hair

Procedure
1. The sample is air dry, before weighing and sieving.
2. Sample is weighed
3. Weighed sample is placed on the sieve, starting with the largest
4. Each sieve is taken separately over a clean tray for period of not less than 2 minutes.
5. At the end of the sieving 150 μ and 75 μ. sieve are cleaned from the bottom by light brushing
with fine camel hair brush.
6. 6- On completion of sieving, the material retained on each sieve together with any material
cleaned from is weighed
 P a g e | 18

Determination Of Particle Size Distribution of Fine & Coarse

Aggregate

IS Weight of aggregate
Sieve Retained , Size TOTAL WEIGHT:-
Size
I II III Sum Average Percent Cumulative %
Sum Retained Percent Passing
Retained

1 2 3 4 5 6 7 8 9
80mm
63mm
40mm
20mm
16mm
10mm
4.75mm
2.36mm
1.18mm
600 μ.
300 μ.
150 μ.
75 μ.
80mm
63mm
40mm
20mm
16mm
10mm
4.75mm
2.36mm
1.18mm
600 μ.
300 μ.
150 μ.
75 μ.

Nominal Size: mm
Shape :
 P a g e | 19

Coarse Sand
A. FIELD TESTS:
1. Coarse sand should be of good quality, it should not get muddy when mixed with water.
2. Size should be of irregular shape in the range of 5mm to 285mm.
3. No mixing should be observed in the coarse sand.
4. The particles of the coarse sand should be hard enough.
5. The coarse sand should not contain moisture.
Fineness Modulus
Apparatus Used
1-Different type of Sieve-10mm, 4.75mm, 2.36mm, 1.18mm, 600μ,300 μ,
150 μ, 75 μ.
2- Pan
Procedure
1. The sample is air dry, before weighing and sieving.
2. Sample is weighed
3. Weighed sample is placed on the sieve, starting with the largest
4. Each sieve is taken separately over a clean tray for period of not less than 2 minutes .5- At the end of
the sieving 150 μ and 75 μ. sieve are cleaned from the bottom by light brushing with fine camel hair
brush.
5. On completion of sieving, the material retained on each sieve together with any material cleaned
from is weighed
6. Fine Modulus is obtained by adding the percentage of weight of material retained on I.S. sieves
and dividing by 100.
Calculation of Fine Modulus of fine aggregate (Sand)
SNo IS sieve Weight Percentage Percentage Cumulative
Designation retained in Passing by Weight Percentage
sieve in gm weight retained retained
1 10mm
2 4.75mm
3 2.38mm
4 1.18mm
5 600 μ
6 300 μ
7 150 μ
8 75 μ
Total % Weight Retained
Fineness Modulus=---------------------------------
100
 Fine modulus of Fine aggregate (sand) should lie between 2 to 3.5.
 Fine modulus of Coarse sand for brickwork and plaster shall not be less than 1.2 and that for
plain concrete and reinforced cement concrete shall not be less than 2.00
 P a g e | 20

BRICKS
A. FIELD TESTS :
For every lot received at site, the following field tests should be performed:
1. Bricks are well burnt and reddish uniform colour
2. All the face of bricks should be uniform, smooth and edge should be sharp.
3 Scratch with finger nails leaves no mark.
4 Broken surface shows a uniform compact texture.
5 Two brick when struck with each other give a sharp metallic ringing sound.
6. The frog depth should not be less than 1cm and should not be more than 2cm..
 All the above tests shall confirm to IS 1077 giving classes of common burnt clay bricks.
7. Water Absorption Test
Take 3 No. of bricks of proper size and shape at random from lot and weight each
Sample and note it down as W1, W2, and W3. Take the average weight. Submerge the sample in
water for 24 hours weigh the wet sample again take average weight.
Calculate the % absorption by the formula.

Difference in Weight
%Absorption= -------------------------------
Original Weight
▪For good quality brick this value should not exceed 20%.

8-Test of Efflorescence
Apparatus Used
1-Glass/Procelain Dish of 150mm diameter and depth 30mm .
Procedure
1. Place on ends the bricks in 25mm depth of water in a dish.
2. The experiment is performed in a well ventilated room (20 to 30 0C) till all the water in the dish is
either absorbed by the specimen or is evaporated
3. After the specimen have dried and similar quantity of water to the dish and let it too be absorbed by
the specimen or evaporate as before.
4. Examine the specimen for efflorescence shall be classified as nil, slight, moderate, heavy or serious
as defined below.
(i) Nil: - When the deposit of efflorescence is imperceptible.
(ii) Slight: - When the deposit of efflorescence does not cover more than 10% of
the exposed area of the brick.
(iii)Moderate: - When the deposit of efflorescence is heaver than slight and does not
cover more than 50% of the exposed area of brick surface.
(iv) Heavy: - When the deposit of efflorescence salts is heavy and cover50% or
more of the exposed area of brick surface.
(v) Serious:- When the deposit of efflorescence salts is heavy and accompanied
powdering and flaking of the exposed surfaces

 Efflorescence in the bricks shall not be more than moderate.If efflorescence is present in the
brick , to remove efflorescence Trataric acid
 P a g e | 21

1. Strength Test.

Take a brick at random from the stacking. Hold it straight in one hand up to height of 60cm and drop
it on flat surface, a good brick should not break. If any breakage is noticed the lot should be immediately
rejected.

B. LABORATORY TESTS

1-Compressive Strength Test

Apparatus Used

1. Compressive testing M/C.

Procedure

1- Provide smooth, even, and parallel faces by grind the two bed faces.
2- Immerse the specimen in water for 24 hours.
3- Removing the specimen from water.
4- Fill up flush the frog and all voids with cement mortar (1part cement and 1part course sand).
5- After 24 hours immersed the specimen in clean water for 3 days.
6- After 3 days, remove the specimen from clean water and wipe out any traces of moisture.
7- Place specimen between two plywood each 3mm thick with flat faces horizontal and mortar filled
face upward.
8- Put the specimen on compressive testing machine and apply axial load at uniform rate of 140 Kg/cm2
per minute till failure
9- The maximum load at failure divided by the average area of the bed face gives the compressive
strength
 P a g e | 22

Calculation of Crushing Strength of Brick

SNo Steps Taken Sample
↓
1 2 3

1 Weight of cement
2 Weight of sand
3 Weight of dry aggregate & cement
4 Size of Sample L mm
B mm
5 Area of Specimen
6 Load at fracture ( P)
Age
3days
7 Compressive Strength
8 Average Strength

 According to IS code :-
 Crushing strength of first class brick should not less than 150Kg/cm2
 Crushing strength of Second class brick should not less than 100 Kg/cm2
 Crushing strength of Third class brick should not less than 75 Kg/cm 2

Dimensional Tolerance Test

To check the length, breadth & height of the brick

Procedure
1. 1-20 whole brick shall be selected at random.
2. 2-Their dimension shall be measured by spreading the bricks in contact with one another length
breadth and height wise on a level surface.
3. 3-These dimensions should be with in the limit specified below:-

Length: - 4600 mm ±80mm

Width: - 2200 mm ±40mm
Height: - 1400 mm ±40mm
 P a g e | 23

STONE AGGREGATE
A. FIELD TESTS:

1. The size of the Aggregate should be as per the Indented Details.

2. The shape of the aggregate should be Angular, Flaky.
3. No mixing should be observed in the aggregates.
4. The stone should be of uniform colour and hard.

Water Absorption Test (Reference IS-2386 – Part – III)

After unloading of Aggregate, collect small quantity of aggregate from different part of the heap. Mix these
quantities and take exactly 2 Kgs in a container. Submerge the sample aggregates in water for 24 ±1/2
hours, weigh the wet sample again. Calculate the % absorption by the following formula.

Difference in Weight
%Absorption = ------------------------------- X100
Original Weight
 P a g e | 24

B. LABORATORY TESTS:

1-Fineness Modulus

Apparatus Used

1-Different type of Sieve-80mm, 63mm, 40mm, 20mm, 16mm, 12.5mm, 10mm,

4.75mm, 2.38mm.
2- Pan

Procedure

1. The sample is air dry, before weighing and sieving.

2. Sample is weighed, (Sample should not less than 10 Kg.)
3. Weighed sample is placed on the sieve, starting with the largest
4. Each sieve is taken separately over a clean tray for period of not less than 2 minutes
5. On completion of sieving, the material retained on each sieve together with any material cleaned
from is weighed
6. Fine Modulus is obtained by adding the percentage of weight of material retained on I.S. sieves
and dividing by 100.

Calculation of Fineness Modulus of Coarse aggregate (Stone)

SNo IS sieve Weight Percentage Percentage Cumulative

Designation retained Passing by Weight Percentage
in sieve in weight retained retained
gm
1 80mm
2 63mm
3 40mm
4 20mm
5 16mm
6 12.5mm
7 10mm
8 4.75mm
9 2.36mm

Total % Weight Retained

Fineness Modulus=---------------------------------
100
 P a g e | 25

1-Sizes of sieves required for nominal size coarse aggregate

Balance and I.S. sieves – sizes as following:

No22minal size of aggregate Sieve size (mm)
40 mm 80 mm, 63 mm, 40 mm, 20 mm, 10 mm, 4.75
mm
20 mm 40 mm, 25 mm, 20 mm, 10 mm, 4.75 mm

12.5 mm 20 mm, 16 mm, 12.5 mm, 10 mm, 4.75 mm,

600 μ, 150 μ.
10 mm 12.5 mm, 10 mm, 4.75 mm, 2.36 mm, 600 μ,
150 μ.

2-SHAPE TEST- Flakiness Index

Apparatus Used
1-Balance Weight
2-Apparatus consist of standard thickness gauge. IS-sieve of sizes of 63mm,50mm,
40mm, 31.5mm, 25mm, 20mm, 16mm, 12.5mm, 10mm, 6.3mm .

Procedure:-
1- Take a quantity of aggregate to provide minimum number of 200 pieces of any fraction tested.
2- The sample is sieved through I.S. Sieves as specified in the table for example 20mm aggregate size
20mm, 16mm, 12.5mm, 10mm and 6.3 mm
3- Separate the aggregate retained on the sieves mentioned in the table above.
4- Try to pass each aggregate through the corresponding slot in the thickness gauge, example the
material passing 20mm and retained on IS 16mm should be made to pass only through 10.9 slots. If
the material passes through the slot, since consider as flaky
5- Weight the pieces which pass through the slot.
6- Calculate the flaky index as follow:

Weight of material passing through thickness gauge

Flakiness Index=----------------------------------------------------------------X100
Total Weight of Aggregate
 P a g e | 26

SNo Size of Aggregate2 Retained on Thickness of Length of

IS Sieve Gauge(3/5*mean Gauge(9/5*mean
size of size of
aggregate) mm aggregate) mm
1 63mm 50mm
2 50mm 40mm
3 40mm 31.5mm
4 31.5mm 25mm
5 25mm 20mm
6 20mm 16mm
7 16mm 12.5mm
8 12.5mm 10mm
9 10mm 6.3mm
 The value of thickness gauge and length gauge has been prescribed for aggregate passing through
_____mm sieve and retained on ________mm size

Bulk Density of Aggregate

Apparatus Used
1- Balance M/C.
2- Cylindrical metal measure15 litres & 30 litres
3- Tamping Rod dia 60cm long with one end rounded
4- Container, trough, Steel rule
5- Measuring cylinder

Procedure

1- Measure selected sample according to the size of the aggregate, filled about 1/3 rd full with
thoroughly mixed aggregate.
2- The aggregate is now tamped with 25 strokes of the rounded end of the tamping rod.
3- A further quantity of aggregate is added and further tamping of 25 strokes given.
4- The measure is now finally filled to over flowing, tamped 25 times and the surplus aggregate struck
off .using the tamping rod as straight edge.
5- The net weight of the aggregate in the measure is determined and bulk density is calculated in Kg /
litre

Note:-
 The following cylinder used for determine the bulk density of Coarse Aggregate
Coarse Aggregate Measure
4.75mm and under 8litre
4.75mm to40mm 30litre
 P a g e | 27

3-Specific Gravity& Water Absorption of sand

Apparatus Used
1-Pycnometer
2-Digital Balance
3. Funnel
4. Tray

Procedure
1. Take about 500gm of sample is place in the tray.
2. Weigh the sample says W1
3. The aggregate is then placed in the pycnometer and then it should be filled with distilled water. and
air entrapped is eliminated by rotating the pycnometer on its side ,the hole of apex cone cover with
finger .
4. The pycnometer is then dried outside and weighed says W2.The content of pycnometer is transferred
on the tray.
5. The pycnometer is then refilled with distilled water to same level as before dried on outside and
weighed asW3
6. The water from the sample is removed and then and then sample is dried in the oven cooled and
weighed asW4.

Calculation of Specific gravity and Water Absorption of Coarse Aggregate

Apparatus Used
1-Balance
2-Oven
3-Jar of about 1.5litres
4-Cloth
5-Tray of area not less than 325 cm2
6-Container
7-Wire basket of not more than 6.3mm mesh or perforated container of convenient size , perforated chromium plate and
polished with wire hangers not thicker than one mm for suspending it from the balance.

Procedure:-

1- Take two 2 kg of sample.

2- The sample screened on a10mm IS sieve, wash to remove the fine particles of dust drained, then
placed in the wire basket immersed in distilled water and allowed to remain at temperature for 24hrs.
3- The vessel is over filled by adding water and the plane glass disc slid over the mouth so as to ensure
that no air is trapped in the vessel and weighed.(W 1)
4- The vessel is emptied and the aggregate is allowed to drain out. Refill the vessel with distilled water.
The vessel shall be dried on the outside and weighed ( W 2)
5- The aggregate is placed on a dry cloth hand gently surface dried with the cloth transferring it to a
second dry cloth when the first will remove no further moisture.
6- The aggregate shall than be weighed says (W3).
7- Then aggregate is placed in the oven at a tempt. 1000C to 1100C for 24 hours. It is then be weighed
(W4)
8- Determine the specific gravity and water absorption.
 P a g e | 28

Steps Taken Sample I Sample II

↓
I II I II
Weight of vessel+sample+water (W1)

Weight of vessel+ water ( (W2)gm

Weight of Saturated and surface dry
sample(W3) gm.
Weight of oven dry sample (W4) gm.
Weight of oven dry sample(W 4) gm.
W4
Specific Gravity = -----------------
W3- ( W1-W2)
(W3- W4)
Water Absorption= ------------- x100
W4
Average Value:-
Specific Gravity=
Water absorption=
 P a g e | 29

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS

L
LOOSSSS A
ANNG
GEEL
LEESS A
ABBR
RAASSIIO
ONNT
TEESST
T

A
Appppaarraattuuss U
Usseedd

11--LLoossA Annggeelleess M Maacchhiinnee

22--DDiiffffeerreenntt SSiieevveess
33--BBaallaannccee
44--OOvveenn

PPrroocceedduurree

1- Clean the aggregate and dry in the oven at 1050C -1100C then weighing 5Kg. for grading A, B, C, D
and 10Kg. for grading E,F and G grade .
2- Place aggregate in cylinder of the machine. The cover is then fixed dust tight.
3- The machine is rotated at a speed of 30 to 33 revolutions per minutes.
4- The machine is rotated for 500 revolution for grading A, B, C& D and 1000 revolution for grading E,
F& G.
5- The M/C should be balanced and driven in such way as to M/C uniform perpherial speed.
6- After desire number of revolution the M/C is stopped and the material is discharged from the
machine taking care to take out entire stone dust.
7- The portion of material coarser than 1.7mm size is washed and dried in oven at 1050C to 1100C and
weighed.
8- Calculate the abrasion value of aggregate.
Original Weight of Aggregate = W1 gm.
Weight of aggregate retained on 1.7mmIS sieve after the test= W2 gm.
Loss in Weight due to wear = (W1 -W2) gm.
(W1 -W2)
Loss Angeles abrasion value %= Percentage Wear=---------------------X100
W1
 P a g e | 30

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS

IIM
MPPA
ACCT
TVVA
ALLU
UEE T
TEESST
T ooff A
AGGG
GRREEG
GAAT
TEE
1. Purpose:

The impact test machine is used to determine the aggregate impact value of coarse aggregate as per IS
2386 Part IV – 1963 – Methods of test for aggregates for concrete.
2.
Procedure:

1. Take about 1000 g of dry sample passing through 12.5 mm IS sieve and retained on 10 mm IS sieve.
2. Fill the cylindrical metal measure with the dried sample. The sample should be placed in three
increments, each increment being rodded 25 times with the tamping rod.
3. Strike off the excess sample using the tamping rod as a straight edge.
4. Take the weight of sample in the measure (W1).
5. Now drop the hammer in the testing machine 15 times on the sample test in the cup. Height of the
fall of the hammer should be 380 mm. The interval between each blow should be about one second.
6. Remove the sample from the cup and sieve it on 2.36 mm IS sieve until no more sample passes
through the sieve.
7. Find the weight of sample retained on 2.36 mm sieve (W2).
8. Repeat the test for another sample from the same lot and calculate the average of the two values.

Calculation:
Aggregate impact value, % = (W1 – W2)/ W1 x 100
Where
W1 = weight of dry sample passing through 12.5 mm IS sieve and
retained on 10 mm IS sieve, g
W2 = weight of dry sample retained on 2.36 mm IS sieve, g
Report the aggregate impact value in percentage and as the mean of two determinations
rounded off to the nearest whole number.
 P a g e | 31

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
C
CRRU
USSH
HIIN
NGGT
TEESST
TOOFF A
AGGG
GRREEG
GAAT
TEE

A
Appppaarraattuuss U
Usseedd

1-Open-ended 150cyclinderical cell with appropriate base plate and plunger

2-Weighing M/c
3-IS- Sieve 12.5mm, 10mm and 2.36mm.
4-Compression testing machine
2. Procedure:
1. Take about 2000 g of dry sample passing through 12.5 mm IS sieve and retained on 10 mm IS sieve.
2. Fill the cylindrical metal measure with the dried sample. The sample should be placed in three
increments, each increment being tamped 25 times with the tamping rod.
3. Strike off the excess sample using the tamping rod as a straight edge.
4. Take the weight of sample in the measure (W1).
5. The apparatus with the test sample and the plunger in position between platens of the test
machine and loaded at fairly uniform rate so that the total load of 400KN is reached in
600seconds.
6. The load shall be released and the whole of material removed from the cylinder and sieved on a
2.36mm IS–sieve. The fraction passing the sieve shall be weighed.
7. 7-Repeat the procedure from another set.

Observations and Calculations

Aggregate sample passing Sieve =mm

Aggregate retained on Sieve =mm
Appropriate sieve for getting the fines =mm
Weight of dry sample(A) = A Kg.
Weight of sample passing the appropriate sieves(B) =B1Kg.
=B2 Kg

Aggregate Crushing Value C.V1 = B1/A

C V222 =
C..V = BB222//A
A
C.V1+ C C..VV222
A
Avveerraaggee C Crruusshhiinngg VVaalluuee == ------------------
22
R
Reessuulltt::--A
Aggggrreeggaattee ccrruusshhiinngg vvaalluuee == --------------------------------

Reporting
Report the Crushing Value in percentage rounded off to the nearest whole number.
 P a g e | 32

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
E
ELLO
ONNG
GAAT
TIIO
ONNT
TEESST
T

1. Elongation Index
Elongation index of an aggregate is the percentage by weight of particles whose greatest
dimension (length) is greater than one and four-fifth times their mean dimension.
It is measured on particles passing through mesh size of 63 mm and retained on mesh size 6.3
mm.

2. Apparatus
Balance, Elongation gauge (Length gauge) and IS sieves of the following mesh sizes – 63 mm, 50
mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5 mm 10 mm and 6.3 mm

3. Procedure
1- Take enough quantity of dry blended sample so that atleast 200 pieces of any fraction is present.
This is not applicable for the biggest and smallest size.
2- Sieve the blended sample through all the sieves mentioned above starting from the largest sieve
i.e. 63 mm.
3- Separate all the individual fractions – 63 mm to 50 mm, 50 mm to 40 mm, 40 mm to 25 mm, 31.5
mm to 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mm
and 10 mm to 6.3 mm.
4- Take the entire fraction separately; gauge them one by one through the corresponding slot
provided in the gauge. Keep the particles retained by the length separately. The aim should
be to retain as much as possible to avoid testing bias.
5- Weigh the particles retained on length gauge.
6- Elongation index is the total weight of the material retained on the various length gauges,
expressed as a percentage of the total weight of the sample gauged.

Calculation
Elongation index of aggregate in % is calculated as follows:

Ei = (W1/W2) x 100%
Where
W1 = weight of particles retained in length gauge,g
W2 = weight of total sample taken for test, g
Reporting
Report the elongation index in percentage rounded off to the nearest whole number.
 P a g e | 33

STEEL
A. FIELD TESTS:
1. The diameter of the steel bars should be checked as per the Indented Details.
2. The coil of bars shall be suitably marked with ISI certification mark as per IS 1387- 1993. AlsoTor
and Brand Marking should be rolled on every meter length.
3. Pitch of twist of the bar should be 8 to 12 times the nominal dia. of bar.
4. Colour should be steel grey and the steel should not be rusted.
5. Length of Bars should be 11m to 12m.
6. Hardness Test:
Take 1m length from each dia. of bars of different lots. Bend the bar by applying pressure at both ends
with the hands. The bend should be smooth and if the cracks develop on the bend surface, such steel
should be rejected.
7. Weight Checking:

Take exactly 1m length of each dia. of Bar on random basis. Weigh each sample on a weighing scale.
Compare the weight with theoretical weight given. The difference in weight should not be more than 5
%.
B. LABORATORY TESTS:

1- TENSILE TEST
To Determine the Yield Strength, Ultimate tensile Strength, Percentage reduction in area,
Percentage elongation and Modulus of Elasticity M.S bar & binding wire.
Apparatus Used:-

1-Tensile testing Machine

2-Extensometer
3-Screw gauge
4-Vernier Calipers
5-Scale

Procedure

1- Cross- sectional area of test pieces shall be measured.

2- Original gauge length can be rounded off nearest 5mm marked by means of fone marks or scribed
line.
3- Test piece should be held in the testing machined. Every effort should be made to ensure that test
pieces are held in such way that the load is applied as axially.
4- Determine the young modulus (E), the elongation are recorded by means of extensometer upto the
yield point of the material.
5- When determining the yield stress, the test piece shall be so loaded that the strain rate during elastic
range is controlled and shall not exceed 0.15 / min.
 P a g e | 34

6- While determining the tensile strength the speed of testing should be uniform as possible and the
change of speed from one range to the other should made gradually and without shock.
7- Tensile strength is determined as maximum load divided by the original c/s area of test piece.
8- The percentage elongation after the fracture should be expressed to the nearest 1% and is
determined as permanent elongation of the gauge length after the fracture (Lu-Lo) expressed as a
percentage of the original gauge length Lo.
9- The percentage reduction in the area is determined as the ratio of the maximum change in the c/s
area, which has occurred during the test (Ao-Au) to the original c/s area expressed as percentage.
10- Knowing the extension on the extensometer gauge length for increment of loading, stress and strain
can be calculated. Plot the stress and strain curve upto yield sress, the slope of the line shall give the
value of E.

Calculation:-
Percentage elongation = (Lu- Lo) / Lo X100
Percentage reduction in area = (Ao- Au)/ AoX100
Yield Strength = Yield load in N ( Kg ) / Area of C/S ( Original) in mm 2
Ultimate tensile strength = Maximum load in N ( Kg ) / Area of C/S ( Original) in mm 2
Where
Lu= Final gauge length after fracture
Lo = Original gauge length = 5.65√Ao
Ao= Original C/s area of the gauge length
Au= Minimum C/S area after fracture
Table-1
Recording the Observation for Stress-Strain Curve

Load(N/Kg.) Extensometer reading (cm ) Stress= Load/ Area of Strain=Change in

cross section length/Original gauge
length
1
2
3
4
5
Table-2
Sample Identifica Length Weight Average Size(m Area(m Yield Yield Max Ultimat % %
No. tion (mm) N(Kg) Dia(mm) m) m2) LoadN( stress Load e Elongatio reduction
kg) N/mm2( N( Kg) tensile n in area
Kg/cm2) strengt
h
N/mm2
(
Kg/cm
2)
 P a g e | 35

BINDING WIRE
FIELD TESTS:
1. The Gauge of wire should be as per the Indented Details. Normal gauge should be 17
S.W.G.
2. The wire should be soft enough and does not crack while twisting.
3. When tied it should not loosen from its position.
4. It should not be corroded

WOODEN DOOR FRAME

FIELD TESTS:
1. The size of the wooden door frame should be as per the Indented Details.
2. The section of the wooden door frame should be as per the Indented Details.
3. The color of the wooden door frame should be as per the specific quality in the Indented Details.
4. The type of wood of the wooden door frame should be as per the Indented Details & should be
perfectly seasoned.
5. The diagonal of frame should be correct.
6. The edge of frame should be sharp.
7. The depth of shutter notch in wooden door frame should be as per the Indented Details.
8. The length of horn on either side of the wooden door frame should be as per the Indented Details. It
should be not less than 3”.
9. The wooden frame should free from all defects like presence of holes/ knots/termites Cracks and
bends.
10. Checking of joints should be as per drawing.
11. Frame should be at 90 degrees.

FLUSH DOOR SHUTTER

FIELD TESTS:

1. The Size/ thickness of the flush door Shutter should be as per the Indented Details.
2. The type of the flush door Shutter should be as per the Indented Details.
3. The bonding material of the flush door Shutter should be as per the Indented Details.
4. The edge should be sharp straight and no damages in top layer.
5. Test for Bending:-
(i) Choose a flush door at random. Check that there is no bend or twist.
(ii) Place the shutter on the flat surface, on raised block pillars with no other support for
24hours.Check for any bends.
(iii) A good quality shutter will not bend
 P a g e | 36

B.LABORATORY TESTS:-

1- End Immersion Test

Procedure:-
1- The door shutter shall be immersed to a minimum depth of 300mm in water at ambient temperature
for 24 hours and then allowed to dry for 24 hour at ambient temperature.
2- This cycle shall be repeated eight times.
3- The door shutter shall be examined for any delamination in the immersed portion of the shutter

2-Knife Test

Apparatus Used
1- Specified Knife
2-Chisel
3-Table

Procedure
1. This test carried out on stout table to which screwed a wooden batten which the edge of the test
specimen is placed.
2. The Knife is inserted with its cutting edge parallel to the grain of the outer veneer and worked into or
if possible along glue line and the veneer are praised upward.
3. It is essential that the knife be firmly guided along the glue line and affecting the separation in the
direction of the core strips.
4. The grading should be assessed on the basis of the appearance of the failure.

3-Glue Adhesion Test

Procedure

1- Two square sections 150mm x 150mm shall be cut from the corner of the door shutter.
2- The sample shall be submerged in a pan of water at ambient temperature, care being taken that the
pieces do not touch the bottom of the pan.
3- The water shall then be brought to boiling temperature and maintained at this temperature for 4-
hours and then dried in a chamber at 27+20C and realitive humidity of 65 + 5 percent for 24 hours.
4- At the end of the drying period the sample shall be examined for delamination. Glue lines in 6-All the
four exposed edges of the plywood on both faces of a specimen and the glue lines between the
plywood faces and stile and rail shall be examined for delamination
 P a g e | 37

4-Steel Ball Impact Test

Apparatus

1-Steel ball:- 50mm dia. and weighing 500+5 gm

Procedure
1. The door shutter be placed horizontally resting on a suitable frame equally on all four edges.
2. A steel ball of about50mm diameter and weighing 500+5gm shall be allowed to fall freely from a
height of 750+5 mm.
3. This procedure will repeated 10different points on both the surface of the door shutter leaving
distance of 75mm from edges.
4. The depth of indentation shall be measured to an accuracy of 0.1mm.

M.S. WINDOW
FIELD TESTS :
2. The Size/ thickness of M.S .Window should be as per the Indented Details.
3. Check for trade mark embossed on section at every metre.
4. The gauge and section of window and accessories provided should be as per the Indented Details.
5. Windows diagonal should be same and correct.
6. Opening of shutter of M.S .Window should be as per the Indented Details.
7. Looking system of M.S .Window should be as per the Indented Details.
8. Hinges should be smooth working.
9. Checked the weight of one window in every 20 Nos. of window as per the Indented Details.
10. The finishing quality of M.S. Window should be uniform.

GLASS FIXING
FIELD TESTS:
1. The Size, thickness & type of glass of Glass Fixing should be as per the Indented Details. The
tolerance limit for thickness of glass sheets should be between 4mm to 7mm.
2. Glass fixing should be free from waviness, cracks, and cavities.
3. Straightness and right angle of glass fixing should be prefect.
4 Scratches should not be present.

ALUMINIUM. WINDOW
 P a g e | 38

FIELD TESTS:
1. The Size/ thickness, Quality of Aluminum window should be as per the Indented Details.
2. Section /accessories used for mullion tracks shutters interlocking should be as per the Indented
Details
3. Sliding of glass panels should be smooth.
4. Windows diagonal should be same and correct.
5. Aluminum window should free from all defects such as scratches, bends, and cracks etc.

CERAMIC / GLAZED / VITRIFIED TILES

FIELD TESTS:
1. The size & colour of the tiles should be as per the Indented Details.
2. Both the Diagonal of tiles should be perfect.
3. Edges of tiles should be correct and perfect at right angles.
4. Tiles should be straight
5. Tiles should free from all defects such as scratches, bends, cracks, cavities and holes.
6. Corners should be straight and not broken.
7. Thickness of tile should not be less than 5mm.
8. Top layer finishing of tiles should be smooth, uniform and good.

Water Absorption Test

Apparatus Used
1-Digital Balance
Procedure

1-Choose three tile at random.

2-Take initial weight and submerge them in water for 24hours.
3-Weigh the wet mosaic tiles and note down the difference in weight.
Difference in Weight
% Absorption = ------------------------------x100
Original Weight

Test for Strength

Procedure
1-Choose a mosaic tile and check it for any cracks and bends.
2-Simply support the tile at four corners and apply the force in the middle and see the results
3-Good cured tile will not break easily.

Crazing Resistance-Glazed Tiles

Apparatus
 P a g e | 39

1-AutoClave

Procedure
1. Take specimen (five tiles) in the Autoclave in such a way that there is air space between them.
2. Raised the pressure of the autoclave gradually for a period of 1hour until it reaches 750+20kpa and
temperature 168+10C for tiles with water absorption greater than 6 %.and pressure 500+200kpa and
152+10C for water absorption lessthan equal to 6%
3. This pressure is maintained for 1hour.then turn off the steam source or the heat supply in the case of
directly heated autoclaves allow the pressure to fall as rapidly as possible to atmospheric and cool
the test specimen in the autoclave for 1hours.
4. Remove the specimen to atmosphere, place them singly on flat surface and allow cooling for further
period of 1/2h.
5. Brush 1% aqueous solution of methylene blue containing a small quantity of wetting agent on glazed
surface.After 1 minute wipe off the stain with a dampcloth.
6. Examine the test specimens for crazes taking care avoid confusing crazes with scratches and ignoring
cracks
Test Report
(a) A description of the tiles.
(b) The number of test specimens showing crazing
© A Description of the crazing (photograph)

Scratch Hardness of Surface according to MOHS

Apparatus

1-MOHS- Hardness
Procedure

1- Take three tiles for the test.

2- Place the tile under test on a firm support with the glazed or proper surface uppermost.
3- Draw over the surface to be tested by hand a sharp freshly –broken edge of the reference mineral
applying a uniform effort such that at the end of the test its edge or the tile surface is intact
4- Repeat the procedure four times with sharp freshly- broken edge of reference mineral.
5- Repeat the procedure for each tile with each mineral that is necessary to obtain a result.
6- Examine the tile for scratches by the naked eye with the aid of spectacles if usually worn.
7- For each tile note the mineral of highest Mohs hardness.
8- In the case of tiles having variable scratch hardness note the lowest Mohs hardness.

 Note:-Test Minerals

Mohs Hardness
Talc 1
Gypsum 2
Fluorspar 3
 P a g e | 40

Apatite 4
Felspar 5
Quartz 6
Topaz 7
Corundum 8
Diamond 9

CHEMICAL RESISTANCE TEST- GLAZED TILES

Apparatus Used
1-Cylinder of borosilicate glass
2-Cloth
3-Pencil
4-Electrical Lamp
5-Aqueous Test Solution─►
(i) Household Chemicals
(a) Methylene blue solution 10gm/l
(b) Potassium permanganate
(ii) Stains
(a)Ammonium Chloride solution 100gm/l
(b)Standard cleaning agent solution prepared from:
( i ) Anhydrous sodium 33% carbonate
(ii) Sodiam percarbonate 7%
(ii) Sodiam silicate 7%
(iii)Commercial sodium 30% oleate soap flakes
(iv) Distilled water or deionized water 23%
Procedure

1. Take five test specimens; allow 3 or 4 drops of each of the test solution on test specimen.
2. Place approximately 30mm dia convex watch glass on the applied drop in order to spread it an
approximately circular area
3. Allow to remain for 24hour and then rense the surface with running water and wipe with a damp
cloth.
4. If the stain remains thoroughly clean with a solution of standard cleaning agent.
5. A uniform layer of the sealing material, 3mm, to the rim of the cylinder.
 P a g e | 41

6. Turn the cylinder upside down on to a fresh part of the glazed surface , pour the test solution through
the height of 20+1 and maintain the test assembly at 27+20C\
7. For testing resistance to household chemicals, maintain the test solution in contact with the test
specimen for 6 hours. Remove the cylinder and clean the glazed surface with grease solvent.
8. Examine the surface, if there is no visible effect, perform the pencil test If there is visible effect
perform the reflection test

Pencil Test:-
 Draw the several lines with an HB pencil, both on the surface under test and on the untreated
surface.
 Attempt to remove the pencil lines by means of soft dry cloth .If removed the surface corresponds
to class AA If not removed, attempt to remove with a soft damp cloth and wringing out. If
removed the surface corresponds to class A, if not removed to class B.

Reflection Test:-
 Hold the tile in such a manner that the image of the lamp is reflected on the untreated
surface. The angle of incidence of the light upon the surface shall be approximately 450
and the distance between the tile and light source shall be 350+100mm.
 The criterion of the judgment shall be the sharpness of the reflection and not the brightness of the
surface. Position of the tile such that the image falls simultaneously on both treated and untreated
parts and determine whether it is any less clear on treated part
 If the reflection is clear perform the pencil test with damp wiping , if lines are removed, the surface
corresponds to class A if not removed to class B
 If the reflection is blurred but does not disappear completely, the classification is C and if the image
disappears completely, the classification is D.

CLASSIFICATION OF RESULTS

Table 1-Classification By Staining Test

SN0 Test Solution Observation Class

Methylene blue Stain removedby water 1

Stain removedby cleaning 2

agent

Stain not removed 3

Potassium Permanganate
 P a g e | 42

VISIBLE EXAMINATION
___ ___________ ________↓___________________
↓ ↓
No Visible Test Visible Test
↓ ↓
HB Pencil Test Reflection Test
Dry Wiping ↓
____________↓__________ _______________
↓ ↓ ↓ ↓
Removed Not Removed Clear Blurred

The image does not The image

Disappear Damp Wiping not Disappear Completely
Completely

Removed Not Removed

↓____________________↓
↓ ↓ ↓ ↓ ↓
Class AA Class A Class B Class C Class D

 Classes of Resistance

ClassAA No Visible effect

ClassA Slight change in appearance
Class B Definite change in appearance
ClassC Partial Loss of the Original Surface
ClassD Complete Loss of the Original Surface

CHEMICAL RESISTANCE TEST- UNGLAZED TILES

Apparatus
1-Vessel
2-Drying Oven
3-Chamois Leather
4-Balance
5-Chemical
(i) Household Chemical
(a) Ammonia Chloride solution 100gm/l
(b) Standard Cleaning agent solution prepared from :
I. Anhydrous sodium 33% carbonate
II. Sodiam percarbonate 7%
III. Sodiam silicate 7%
IV. Commercial sodium 30% oleate soap flakes
V. Distilled water or deionized water 23% © 100gm of this standard cleaning agent contain 70gm of dry
substance. Use in a conc. Of 10gm dry substance per litre.
 P a g e | 43

Swimming Pool Salts

(a)Sodium hypochlorite solution 20mg/l prepared from technical grade hypochlorite with about 13 %
active chlorine.
(b) Copper sulphate solution 20mg/l
Acids
(a) Sulphuric acid solution,
(b) Lactic acid
Alkali
Potassium hydroxide

Procedure

1. Take five test specimen of size 50mmx 50mm, thoroughly clean with proper surface
2. Dry the test specimens at 110+50C.
3. Immerse test specimen vertically to a depth of 25mm in test solution in the test vessel. Cover with the
lid and maintain the test assembly for 28 days at temperature 27+20C .
4. After 28 days, the test specimens to running water for 7 days and then boil them for 30minutes while
completely immersed in water.
5. Remove the test specimens from the water and dab with a wet but wrung –out chamois leather.
6. Examine the test specimens with the naked eye for changes on the proper surface and non cut edge.
Secondarily examine the parts of the cut edge that were immersed.

Resistance to Surface Abrasion-Unglazed

Apparatus

1-Abrasion Apparatus
2- Measuring Gauge

Procedure

1. Take five test specimen of size 100mm x 100 mm, thoroughly clean with proper surface .
2. Place test specimen in the apparatus so thar it is tangential against rotating disc. Ensure that the feed of
abrasive material into grinding zone ar uniform rate of at least 100gm per 100revolutions.
3. Rotate the steel disc for 150 revolutions. Remove the test specimen from the apparatus and measure
chord length of the groove by means of measurement to the nearest 0.5mm
4. Test each specimen in at least two places at right angle on its proper surface.
 P a g e | 44

Resistance to Surface Abrasion-glazed

Apparatus
1-Abrasion Apparatus
2- Measuring Gauge
3-Drying Oven

Procedure
1. Take five test specimen of size 100mm x 100 mm, thoroughly clean with proper surface .
2. Calibration of the apparatus is only necessary or When there is doubt regarding the validity of the result
One method given below.
3. Clamp the metal holder on the glazed surface of each test specimen on the PEI apparatus. Introduce
the abrasive load into the holder through a hole in its upper surface. The hole may then sealed to
prevent loss from abrasive load
4. The number of revolution of the preset counter required for each abrasion stage of the wet test is
150,300,450,600,750,900,1200 and 1500 .Test each specimen in at least two places at right angle on its
proper surface
5. After abrasion rinse the test specimen under running water and dry in the oven.
6. The result is checked by resting at this abrasion stage and the next higher and lower abrasion stage , the
lower of the two abrasion stages shall be used to decide the classification
7. After use the steel balls should be cleaned with water followed by methylated spirits and then
thoroughly dried to prevent the rusting.

CLASSIFICATION OF RESULT

Wet Abrasion Test

SNo Abrasion Stage( Failure Visible at Class
Revolution
1 150 I
2 300,450or600 II
3 750,900,1200or1500 III
4 >1500 IV

CALIBRATION OF PEI APPARATUS USING FLOAT GLASS

Reference Material
The reference material shall be float glass of a minimum thickness of 6 mm.

Identification of the Float bath surface of the glass

The float bath surface of the glass may be identified by one of the following methods.
 P a g e | 45

Chemical Method

Reagents Required

(a)Etching solution: 10vol concentrated HCl, 10vol distilled water, 8 vol hydrofluoric acid 40% all
thoroughly mixed.
(b) 0.18 cacotheline in distilled water.
Place 2 or 3 drops of the etching solution on to surface followed by 1 or 2 drops of the cacotheline solution
Float bath side: in 5 to 10s a purple coloration will be seen.
Top surface solution will remain yellow.

UV Method
Dry the test specimen at 110+50C and measure the mass of the each for 6000 revolution and again dry the
test specimens at 110+0C and determine the loss in mass. The average loss in mass shall be 0.032+0.002
mg/mm2.of the abraded area.
Calculate the percentage loss at the centre of the abraded area shall be 50+5%
If any difficulty is experienced in obtaining stable initial gloss values, the glass may first be cleaned by
immersion in water containing a trace of detergent for 1 hr at 75 0C and subsequently with warm water.

GRANITE / MARBLE / STONE SLABS

FIELD TESTS:

1. The size & quality of the slabs should be as per the Indented Details.
2. The colour should be uniform.
3. One face should be polished with four side’s machine cut. Polishing & cutting quality should be
perfect.
4. Edges of slabs should be correct and perfect at right angles, if procured in cut size.
5. 5. The top layer should be free from all defects such as scratches, bends, cracks, cavities and holes.
6. The slabs should be straight
7. Thickness of slab should not be uniform throughout and as per the Indented Details.
 P a g e | 46

PLUMBING G.I. PIPES AND FITTINGS

FIELD TESTS :
1. The class, diameter, and wall thickness should be marked with proper colour making
and thickness should be given in as per class .
2. It should free from cracks, bend, hole and cavities.
3. The weight of pipe should be as per standard.
4 The length and size should be as per the Indented Details.

SSm
mookkee T
Teesstt FFoorr SSooiill PPiippee::--

A
Appppaarraattuuss U
Usseedd
11--SSm
mookkee tteessttiinngg M
Maacchhiinnee

PPrroocceedduurree
1. All pipes when above the ground shall be approved gas tight by a smoke test conducted under
pressure of water and maintained for 15 minutes.
2. All the traps are filled with water before starting the smoke test.
3. A smoke testing machine consists of a length of flexible rubber tubbing and smoke is made by firing
oily waste ( brown paper or cotton waste soaked in creosote)
4. Smoke is pumped into drains and pipes through gully.
5. The top of the soil and ventilating pipes are left open until smoke is seen. When opening are plugged
securely with wet cloth or wet clay tied in a cloth and smoke is pumped in some considerable time
which is easily detectable by sight as well as by smell ,if leaking at any point of the drain..

W
Waatteerr TTeesstt FFoorr G
Gllaazzeedd SSttoonneew
waarree aanndd ccoonnccrreettee ppiippee::--
PPrroocceedduurree

1. Take test specimen which the joint have properly dried.

2. Apply water at least 1.50m head water at the highest point of the section under test. If the
earthenware pipes should not be subjected to head of more than 3m of water.
3. Closing the ends of the sections and maintaining this water level for one hour.
4. After air bubbles have escaped, the Water again added to completely fill the pipe.
5. The water placed in pipe should not be drain out until the trenches have been filled about 90 cm to
detect if any joints have given during the filling.
6. In case leakage the defective part of the work shall be cut out and made good.
 P a g e | 47

Concrete Test
T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
SSL
LUUM
MPP T
TEESST
T
1. SLUMP TEST
This method of test specifies the procedure to be adopted, either in the laboratory or in the field
during work, for determining the workability of concrete where the nominal maximum size of
aggregate does not exceed 38 mm.

2-APPARATUS

Metal slump cone of at least 1.6 mm thickness provided with suitable base plate and also handles
for lifting it from the moulded concrete test specimen vertically. Internal dimension of the cone
should have the following sizes :
Bottom diameter 20 cm
Top diameter 10 cm
Height 30 cm
Tamping rod of 16 mm diameter, 0.6 m long and rounded at one end.

3-PROCEDURE :

1. Firstly decide the frequency of slump value to be taken during concreting.

2. Oil the interior surface of the slump cone with mould releasing oil to prevent adhesion of the
concrete.
3. Place the slump cone on a leveled surface.
4. Collect the sample in a wheelbarrow after mixing the concrete properly in the transit mixer.
5. Remix the sample thoroughly in wheel barrow with sampling scoop.
6. After remixing immediately fill the slump cone in layers approximately one – quarter of the height of
the cone.
7. Each layer shall be compacted with the tamping rod by 25 strokes distributed in a uniform manner
over the cross-section of the cone and for the second and subsequent layers tamping rod shall
penetrate into the underlying layer.
8. After compacting the top layer, the concrete shall be struck off level with the top of the slump cone,
using a trowel. Any mortar, which may have leaked out between the mould and the base plate, shall
be cleaned away.
9. Unscrew the slump cone from the base plate and remove it immediately from the concrete by raising
it slowly and carefully in a vertical direction.
10. After the concrete subsides place the slump cone on the base plate in reverse position and place a
scale on it. Measure the height between the top of the mould and the highest point of the specimen
being tested.
 P a g e | 48

Calculation of Slump of Concrete:-

Particulers Ceme Total FA: F.A C.A Water W/C Slum Workabilit
nt Aggre CA Added Rati p y
gate o
1 2 3 4 5 6 7 8 9 10
Initial
proportions by
Volume/Bagof
Cement
Laboratory Trial
Batch Per 3 Kg
of Cement by
Volume
Proportions by
Weight
( Multiply by
Bulk density )
I Trial
II Trial
III Trial

 REPORTING OF SLUMP VALUE :

The slump measured shall be reported in terms of millimeters of subsidence of the specimen
during the test. Any slump specimen, which collapses or shears off laterally, shall be repeated
with another sample. If, in the repeat test also, the specimen shears, the slump shall be measured
and the fact that the specimen sheared, shall be reported. Take corrective action to make the mix
cohesive.
 P a g e | 49

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
C
COOM
MPPA
ACCT
TIIO
ONN FFA
ACCT
TOOR
RTTE
ESST
T
A
Appppaarraattuuss U
Usseedd::--

1-Compaction factor test apparatus

2-Two Trowels
3-Hand Scoop
4-Tamping rod
5-Platform Weighing Machine

Procedure

1. Place the sample in the upper hopper with a hand scoop. Fill up the concrete in the level with the
brim.
2. Open the trap door so that the concrete falls into the lower hopper.
3. If the concrete sticks to the sides of the hoppers put up gently with the help of rod from top.
4. Open the trap door of the lower hopper and allow concrete to fall into the cylinder.
5. Removing the excess concrete remaining above the level of top of the cylinder.
6. Clean the outside diameter of the cylinder and determine the weight of the cylinder says W 1.
7. Refill the cylinder from the same sample of concrete in layers, being heavily rammed or vibrated so
as obtain full compaction then clean the outside cylinder and weigh it again says W 2

Calculation of Compaction Factor of Concrete:-

SNo Steps Taken ↓ SPECIMENS

I II III
1 Weight of Cylinder (W1) Kg
2 Weight of Cylinder+ Concrete falling through
Standard height ( W2) Kg.
3 Weight of Concrete(W2-W1 ) =W3 Kg.
4 Weight of fully Compacted Concrete +Cylinder
(W4) Kg.
5 Weight of fully Compacted Concrete W5= W3- W1
6 Compaction Factor W4/W5
7 Proportion of Sample
8 W/C ratio chosen
 P a g e | 50

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
FFL
LOOW
WTTE
ESST
TOOFF C
COON
NCCR
REET
TEE``

Apparatus Used

1-Flow table apparatus

2-Mould
2-Trowel
3-Platform Weighing Machine

Procedure

1. Wet and clean the table top and inside of the mould of all the grilling material and remove all
excess water with a wet cloth.
2. Centre the mould on the table and hold it firmly in place.
3. Fill the mould in two layers, Each layer shall be rodded with 25 strokes of straight round metal rod
16 mm in diameter and 600 mm long, rounded at lower tamping end.
4. After the top layer has been rodded, the surface of the concrete shall be struck with trowel so that
the mould is exactly filled.
5. The mould shall be immediately removed from the concrete by a steady upward pull
6. The table shall be raised and dropped 12.5mm, giving 15 jolts in 15 seconds.
7. Measure the diameter of the spread concrete as the average of six symmetrically distributed
measurements read to the nearest 5 mm.
8. The flow of the concrete shall be recorded as the percentage increase in the diameter of the spread
concrete over the base diameter of the moulded concrete.
Spread the diameter in mm250
Flow ( % )=--------------------------------------X100
250
 P a g e | 51

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
C
CAASST
TIIN
NGGO
OFF C
COON
NCCR
REET
TEEC
CUUB
BEEM
MOOU
ULLD
DSS

MAKING AND CURING CONCRETE CUBES:

This method covers the procedure for making and curing of concrete cubes as per IS : 516 – 1959.

APPARATUS :

Wheel barrow, sampling scoop, trowel, cube moulds of 15 x 15 x 15 cm size and tamping bar 16
mm in diameter, 0.6 m long and bulleted point at the lower end.

PROCEDURE :

1. Firstly decide the number of samples to be taken during concreting.

2. Oil the interior surface of the mould with mould releasing oil to prevent adhesion of the
Concrete.
3. Collect the sample in a wheel barrow after mixing the concrete properly in the transit Mixer.
4. Remix the sample thoroughly in wheel barrow with sampling scoop.
5. After remixing immediately fill the mould in layers approximately 5 cm deep.
6. During filling the mould, the scoop shall be moved around the top edge of the mould as the
concrete slides from it, in order to ensure a symmetrical distribution of the concrete within the
mould.
7. Each layer shall be compacted with the tamping rod by minimum 25 strokes distributed in a
uniform manner over the cross-section of the mould.
8. After compacting the top layer, top surface of the concrete shall be finished level
with the top of the mould, using a trowel.
9. Store the cube moulds in a place which is free from vibration and cover the surface of the
concrete with a piece of damp sacking for initial 24 hours.
10. Remove the specimen from the mould and keep it submerged in clean water and keep there
until taken out just prior to test.
11. Test for Compressive strength by placing the specimen in the machine. Apply load slowly and
at the rate of 140Kg /cm2/min till the cube breaks.

Calculation of Compressive Strength of Concrete

 P a g e | 52

SNo Steps Taken SPECIMENS

↓
I II III IV V VI
1 Concrete mixM15/M20/M25
2 Prescribed Strength
3 Identification number
4 Produced on Date
Time
5 Tested on Date
Time
6 Age of Testing hrs
7 Measurements Length mm
Breadth mm
Height mm
8 Area Subjected to Compression A=axb
mm2
9 Volume V=Axc
mm3
10 Weight of Cube Wc
Kg.
11 Unit Weight of Cube Kg/l
12 Breaking Load Kg.
13 Compressive Strength P/A Kg./cm2
14 Average Compressive Strength Kg./cm2
 P a g e | 53

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
C
CHHE
EMMIIC
CAAL
LAAN
NAAL
LYYSSIISS O
OFF C
COON
NCCR
REET
TEE ((M
Miixx PPrrooppoorrttiioonn))

A
Appppaarraattuuss U
Usseedd

1-Oven
2-Beaker
3-Test tube
4-Chemical Used (HCl)
5-Balance
6-Ashless filter paper

Procedure:-
1. Take ½ Kg. sample is required for analysis.
2. Put this sample, in oven at 1100C for 15 minute.
3. After heating, cool the sample and then weigh.
4. Grind the sample so that cement particle gets separated from sand and aggregate.
5. Weigh the fractions so separated individually.
6. Take about 5-6 gm powder fraction and fine sand fraction, about 50-60gm from course Sand and
about 100-150gms of aggregate fraction for actual silica and calcium oxide determination
7. Take the entire four fractions as above in 250ml beakers and sufficient quantity of 3.3 N HCl to
dissolve the cement particle. then digest on water bath for 10-15 minutes and filter The filter is
obtained is used for silica determination.
8. Filterate evaporate the filtrate to dryness on hot plate, dry silica remain in the beaker along with
calcium and aluminum salts.
9. Add 3.3 N HCl and digest on the water bath for 5 minutes Filter the silica through ash less filter
paper, wash with water until chloride is free.
10. Dry silica in the oven and further in the furnace at 8000C-10000C for 2 hrs, from silica calculate the
weight of cement obtain in different fraction. Each fraction contains some cement portion and rest
being fine sand, sand and aggregate respectively.
11. Take sand and fine sand fractions together .Thu s calculate the total cement, total sand and total
aggregate present in the sample and hence calculate the ratio of cement: sand: aggregate
 P a g e | 54

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
FFL
LEEX
XUUR
REE SST
TRRE
ENNG
GTTH
HOOFF C
COON
NCCR
REET
TEE

A
Appppaarraattuuss U
Usseedd

11--SSttaannddaarrdd bbeeaam
mmmoouulldd 115500m
mmm xx115500m
mmm xx 770000m
mmm as per IS : 516 – 1959.
2-Tamping Bar
3-Hand scoop
4-20ton Universal testing machine
5-Trowels

Procedure:-

1. Firstly decide the number of samples to be taken during concreting.

2. Oil the interior surface of the mould with mould releasing oil to prevent adhesion of the concrete.
3. Collect the sample in a wheel barrow after mixing the concrete properly in the transit mixer.
4. Remix the sample thoroughly in wheel barrow with sampling scoop.
5. After remixing immediately fill the mould in layers approximately 5 cm deep.
6. During filling the mould, the scoop shall be moved around the top edge of the mould as the concrete
slides from it, in order to ensure a symmetrical distribution of the concrete within the mould.
7. Each layer shall be compacted with the tamping rod by minimum 25 strokes distributed in a uniform
manner over the cross-section of the mould.
8. After compacting the top layer, top surface of the concrete shall be finished level with
the top of the mould, using a trowel.
9. Store the moulds in a place which is free from vibration and cover the surface of the concrete with a
piece of damp sacking for initial 24 hours.
10. Remove the specimen from the mould and keep it submerged in clean water and keep there until
taken out just prior to test.
11. Place the specimen in the testing machine such that the load shall be applied to the upper most
surface as cast in mould, along two lines spaced 20 cm or 13.3 cm apart.
12. Apply load carefully without shock and rate of 400 Kg./min.
13. If a equals the distance between the line of fracture and the nearer support in cm , then modulus of
rupture
pxl
fb= --------------------
bbxxdd222
 P a g e | 55

When a is greater than 20cm but greater than 15cm specimen or 13.3cm to 10 cm specimen.
OR
3Pxa
Fb= ---------------
bxd2
When a less than 20cm but greater than 17.0cm for 15cm cm specimen or lessthan 13.3cm but greater
than 11.0cm for 10 cm specimen.

Where p is maximum load in Kg. applied in the specimen b and d are width and depth of beam and l is
the span of the beam.

(ii) If a is less than 17cm for 15cm specimen or less than 11cm for 10cm specimen, the result of test are
to be discarded.

SNo Steps Taken SPECIMEN

I II III IV V VI
Concrete mix
Prescribed modulus 3days
7days
Identification No
Mode of curing
Produced on date
Time
Tested on date
Time
Age of Testing
Measurement
Length (l)
Breadth(b)
Depth (d)
Volume(lxbxd)=V mm3
Weight of beam (Wb) Kg
Unit Weight of beam
Breaking Load( P ) Kg.
Modulus of rupturefb=PXL/
bXd2
Average value of Modulus (fb)
 P a g e | 56

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
N
Noonn D
Deessttrruuccttiivvee T
Teessttiinngg ooff C
Coonnccrreettee

A
Appppaarraattuuss

1-Universal Testing Machine

2-Balance
3-Scale
4-Ultrasonic pulse velocity equipment
5-Schmidt hammer

PPrroocceedduurree

((ii)) U
Ullttrraassoonniicc PPuullssee V
Veelloocciittyy

1. Make standard cylinders with capping at the top. Weight each cylinder and measure its
dimensions accurately
2. Grease shall be applied to the transducer surface of the ultrasonic probes and the sides of the
specimen so as to ensure complete contact as the interface without any air voids.
3. The equipment shall be kept on about 10 minutes before taking the actual measurement.
4. The equipment shall be held against grease surfaces, under gentle manual pressure. The
transducer shall applied near the centre of the surface and never the edge or corner of the
specimen.
5. Time taken by the pulse to travel through the specimen is measured in micro seconds in the
apparatus. The reading may generally be varying within very small range. The most probable or
most consistent reading shall assume to be actual reading.
6. At least one reading shall be taken on each face and for cylinders at least three reading shall be
taken between the same surfaces.

O
Obbsseerrvvaattiioonnss aanndd C
Caallccuullaattiioonnss

1-Concrete mix Used

2- Type of Cement and aggregate used
3- Curing Conditions
4-Age of Concrete
5-Wheather wet or dry

SNo Repetitions Average

Velocity
1 2 3
1
2
3
 P a g e | 57

((iiii)) R
Reebboouunndd H
Haam
mmmeerr T
Teesstt

PPrroocceedduurree

1. The specimen to be tested shall be kept and cured in such way that softening or hardening of the
surface due to leaching of calcium hydroxide, corrosion or carbonation is avoided.
2. Thes specimen surface shall be cleaned.
3. The specimen shallbe held or fixed in such way that is not yield under impact of hammer.
4. The plunger of the hammer shall always be kept perpendicular to the surface.
5. About 10 to 12 reading shall be taken and then their average value calculated to get a
representative index of hardness.

O
Obbsseerrvvaattiioonnss aanndd C
Caallccuullaattiioonnss
S.No 1 2 3 4 5 6 7 8 9 10
Rebound No

Compressive
Strength
 P a g e | 58

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
C
CHHE
EMMIIC
CAAL
LTTE
ESST
TOOFF M
MOOR
RTTA
ARR

Apparatus Used

1-Oven
2-Beaker
3-Test tube
4-Chemical Used (HCl)
5-Balance

Procedure

1. Take approx. 200 gm sample, heated in oven at 110 0C for 15 minute.

2. Cool the sample and then weigh.
3. Separate the cement portion from sand by slowly grinding the lump in iron mortar.
4. 4- Sieve the material and make three fractions. Powder, fine sand and coarse sand.
5. Weigh individually and record
6. Take about 5-10gm of each fraction in beaker and 5-10ml 3.3N HCl till all the material is wet with
HCl, if required add further 5-10ml HCl to dissolve the material.
7. The cement portion gets dissolved and sand portion gets separated from cement, digest on water
bath for 10minutes & filter the liquid through filter paper, wash with water till chloride free.
8. The filtrate is evaporated and silica determined in each fraction. Weight of sand obtained by
subtracting Wt. of cement by total weight of sand, hence the ratio of cement to sand is calculated.
9. Percentage of cement in the sample is calculated.
 P a g e | 59

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
C
COOH
HEESSIIV
VEEN
NEESSSS T
TEESST
T ((T
TEEN
NSSIIL
LEE SST
TRRE
ENNG
GTTH
H)) O
OFF M
MOOR
RTTA
ARR

Apparatus Used
1-Briquette Testing Machine
2-Briquette Mould
3-Digital Balance
4-Trowel

Procedure

1. 1- Take 1200 gms. Cement and 3 kgs. of sand and take (P/5 +2.5) % of combined weight of
cement and sand.
2. Prepare a mixture of cement and standard sand in the proportion of 1:3 on a non- porous plate.
3. Mix it dry with a trowel for one minute and then add water until mix is of uniform colour.
4. Oil the interior face of the Briquette mould.
5. Place assemble Briquette mould on the table of vibration machine and Fill the mortar in the
mould until vibration period (2 minutes) completed.
6. Keep the cube in normal temperature for 24 hours after completion of vibration.
7 After 24hrs. Remove cube from the mould and immediately subermeged in the water.
Test three Briquette for tensile strength after 3 days and rest 3 Briquette after 7days.

 For Ordinary Portland Cement the Tensile strength after 3 days and 7 days
should not be less than 20 Kg/cm2 and 25Kg/cm2 .
 P a g e | 60

T
TEESST
T PPR
ROOC
CEED
DUUR
REESS
B
BIIT
TUUM
MEEN
N

11--SSoofftteenniinngg PPooiinntt T
Teesstt

A
Appppaarraattuuss U
Usseedd ::--
1-Steel Balls-They are two numbers. Each has diameter of 9.5mm and weights 2.5+ 0.05gm.
2-Brass Ring –There two rings of the following dimensions,
I. Depth – 64mm
II. Inside diameter at the top- 17.5 mm
III. Inside diameter at bottom- 15.9 mm
IV. Outside diameter- 20.6 mm
3-Support:-Metallic Support is used for placing pair of ring
4-Bath and Stirrer

Procedure:-

1. Sample material is heated to temperature between 750C and 1000C above the approximate softening
point until is completely fluid and poured in heating ring placed on metal plate.
2. To avoid sticking of the bitumen to metal plate, coating is done to this with a solution of glycerin and
dextrin.
3. After cooling the rings in air for 50minutes the excess bitumen is trimmed and ring are placed in the
support, at this time temperature of distilled water is kept at 5 0C.
4. This temperature is maintain for 15 minutes after which the ball are placed in the position
5. The temperature is maintained is raised at uniform rate of 5 0C per minutes with controlled heating
until, unit of bitumen softens and touches the bottom plate by sinking of the balls , at least two
observation are made .

Note- For material whose softening point is above 80 0C glycerin is used and starting
temperature is 350C instead of 50C.

CALCULAION OF SOFTENING POINT TEST

1. Bitumen Grade=
2. Approximate Softening Point=
3. Liquid used in the bath=
4. Period of air cooling, minutes=
5. Period of cooling in water bath, minutes=
 P a g e | 61

Rate of Heating:-

S. No Time minutes Temperture 0C

1 1
2 2
3 3
4 4
5 5

Test Property Sample No-1 Sample No-2 Mean Value of

Softening Point
( i) (ii) ( i) (ii)
0
Temperture( C) at
which sample
touches bottom plate
Repeatability

Reproducility

2-Viscosity Test

Apparatus Used :-

1-Ten millimeter orifice viscometer is specified for testing road tar

2-Cup

Procedure :-
1. The tar cup is properly leveled and water in the bath is heated to the temperature specified (20 0C for
the test and is maintained throughout the test and material is allow to cool.
2. When material reaches slightly above test temperature, the same poured in the tar cup until the
leveling peg on the valve rod just immersed.
3. The receiver placed under the orifice, when the sample material reaches the specified testing
temperature within+0.10C and is maintain for 5 minutes the value is opened.
4. The stop watch is started, when cylinder records 25ml. The time is recorded for flow up to a mark of
75ml (50ml of the test sample to flow through the orifice).
5. If the sample does not flow freely the test may be repeated at the next higher temperature, till the
viscosity value falls in the specified range.
 P a g e | 62

Observation Sheet

1-Material:-
2-Grade:-
3-Specified Test Temperature:-
4-Size of the Orifice mm:-
5-Actual test temperature0C :-

SNo Test Property Test Run Mean Value

I II III
Viscosity in Seconds
Repeatability %
 P a g e | 63

PENETRATION TEST
Apparatus Used

1-Container
2-Needle
3-Water Bath
4-Penetrometer

Procedure

1. The bitumen is softened to a pouring consistency between 750C to 1000C above the approximate
temperature at which bitumen softens. The materials are stirred to make it homogenous and free from air
bubble and water. The sample are cooled in atmosphere temperature not lower than 13 0C for one hour then
placed in temperature controlled water bath at a temperature of 25 0C for a period of one hour .
2. Sample container is placed in the tray with water from the bath and placed under the needle of the
pentrometer.
3. Using the adjusting screw the needle assembly is clamped ,the contact of the tip of the needle is checked
using the mirror placed on the rear of the needle The initial reading of the pentrometer dial is either
adjusted to zero or initial reading is taken before releasing the needle .
4. The needle is released exactly for the period of 5.0sec. by pressing the knob and final reading is taken on
the dial.
5. At least three measurement are made on this sample by testing at distance of not less than 10mm apart.

Observation Sheet:-
1-Pouring temperature:-
2-Period of Cooling in atmosphere minutes:-
3-Room Temperature0C:-
4-Period of cooling in water bath minutes:-

5-Actual test Temperature 0C :-

Reading SAMPLE I SAMPLE II

Test1 Test2 Test3 Mean Test1 Test2 Test3 Mean
Value Value
PENETROMETER
DIAL READING
Initial
Final
Penetration Value
Repeatability %
 P a g e | 64

PHYSICAL SPECIFICATIONS
Portland Cement
Physical Method Of Grade (N/mm2)
S.No.
Requirements Testing 33 43 53
Blaine's air
1 Fineness (m2 / kg) 225 225 225
Permissibility
Le Chatelier
10mm 10mm 10mm
2 Soundness Apparatus
Autoclave 0.008 0.008 0.008
Specific gravity of
3 3.15
cement
4 Setting time
a Initial (Mint.) Vicat 30 30 30
Apparatus
b Final (Mint.) 600 600 600
Compressive Strength
5
(MPa) not less then
a 72 hr/ 3 Days 16 23 27
b 168 hr/ 7 Days 22 33 37
c 672 hr/ 28 Days 33 43 53
 P a g e | 65

CEMENT (33 /43 / 53)

Sr. Relative IS
Test Requirement
No. Code

1 Fineness

a) By sieving
Percentage retained shall not be more
through 90 micron 460 -1962
than 10
I.S. sieve
b) By Blaine's air
Specification surface shall not be less
permeability 269- 1976
than 2250 sqcm/ gm
method.
2 Soundness
Expansion shall not be more than 10 mm
a) By Le chatelter's
269 – 1976
(un areated) .

b) By autoclave
Percentage of expansion shall not be
method (un 269 – 1976
more than 0.8%
areated)
3 Setting time
a) Intial Setting 269- 1967 Not less than 30 minutes
Final Setting 269- 1967 Not more than 600 minutes
Compressive 33 garde
Strength (269 - 1976)
(MPa) (Minimum) 43 garde
(Average of 3 (8112- 1089)
4 Read as 33/ 43/ 53 garde
cubes) Using
standard sand 53 garde
confirming to IS (12269-
650- 1966 1987)
3 Days +/- 1 hour 160/ 230 /270 kg/cm2
7 Days +/- 2 hour 220/ 330 / 370 kg/cm2
28 Days +/- 4 hour 330/ 430 / 570 kg/cm2
 P a g e | 66

STEEL
(Fe 500 Grade)
Sr. Relative IS
Test Requirement
No. Code
Elongation
In %
IS 1786 -
(On gauge length
1 1976 Not less than 14.5%
of 5.65 A, where A
(II revision)
is cross sectional
area)
IS 1786 -
Minimum 15% More than the actual 0.2 %
2 Tensile Strength 1976(II
Stress
revision)
IS 1786 -
3 0.2 % Proof Stress 1976 Not less than 500 N/mm2
(II revision)
 P a g e | 67

SAND (FINE AGGREGATES)

Sr. Relative IS
Test Requirement
No. Code

F.M. may range between 2.6 0 to 3.60 for

1 Fineness Modulus 386 – 1963 concrete up to 1.60 for plastering and up
to 3 .00 for masonry.

Specific gravity of
2 387 – 1963 Its may be range between 2.55 to 2.65
sand

If silt content exceeds 4% by weight then

3 Silt Content 386 – 1963
it should be washed before use.

Surface moisture
4
carried by sand
(i) Very Wet Sand 7.5% by mass
Moderately wet
(ii) 5.0% by mass
sand
(iii) Moist sand 2.5% by mass
 P a g e | 68

COARSE AGGREGATES
Sr. Relative IS
Test Requirement
No. Code

(a) Shall not exceed 45% for aggregates

used for concrete other than for wearing
Aggregate 2386 – 1963
1 coat.
Crushing Value Part IV
(b) Shall not exceed 30% for concrete
wearing surfaces.

(a) Shall not exceed 45% by weight for

concrete other than for wearing surface.
Aggregate Impact 2386 – 1963
2
Value Part IV
(b) Shall not exceed 30% by weight for
concrete wearing surfaces.

(a) Shall not exceed 50% for aggregate to

Aggregate be used in concrete other than for
Abrasion Value 2386 – 1963 wearing surface.
3
(Using Los Part IV
Angeles) (b) Shall not exceed 30% for aggregate to
be used in concrete for wearing surfaces.

4 Fineness Modulus
(i) 20mm 6 to 6.9
(ii) 40mm 6.9 to 7.5
(iii) 75mm 7.5 to 8.0
5% by Wt of Aggregate
5 Water Absorption

6 Flakiness Index
Water bounded
(i) 15%
Macadam
Bitumen Surface
(ii) 25%
Dressing
Bitumen Bound
Macadam,
(iii) 15%
Bituminous
Concrete
 P a g e | 69

BRICKS
Sr. Relative IS
Test Requirement
No. Code
Compressive
1
strength

IS 1077 - Average compressive strength is not less

a Average
1976 than 35 kg/ cm2

IS 1077 - Not less than 20% of minimum average

b Individual
1976 required.
IS 1077 -
2 Water Absorption Shall not be more than 20%.
1976
IS 1077 -
3 efflorescence Shall not be more than moderate.
1976
MARBLE MOSAIC TILES
Sr. Relative IS
Test Requirement
No. Code
IS 1237 -
1 Water Absorption Average value shall not exceed 10%.
1980

Wet transverse IS 1237 - Average value Shall not be less than 3

2
Strength 1980 N/mm2.

IS 1237 - Wear on individual specimen shall not

3 Resistance to wear
1980 exceed 4 mm.
 P a g e | 70

CONCRETE
Sr. Relative IS
Test Requirement
No. Code
1 Workability Test
(i) Slump Test IS 456-2000
Mass concrete,
Lightly reinforced
sections in slab 25mm to 75mm
,beam Column
floor , Strip footing
Heavily reinforced
Section in slabs,
50mm to 100mm
beams, walls,
Columns
Slimform work
75mm to 100mm
Pumped Concrete
Trench fill In-situ
100mm to 150mm
piling
Compaction
(ii) IS 456-2000
Factor
Small Section
Subject to
IS 456-2000 0.70-0.75
intensive vibration-
Very Low
Normally
reinforced section
IS 456-2000 0.83-0.85
with vibe ration -
Low
Normally
reinforced section
IS 456-2000 0.90-0.92
with out vibration -
Medium
Heavily reinforced
Section without
vibe ration not IS 456-2000 0.95
normally suitable
for vibe ration

(iii) Flow Table IS 456-2000

 P a g e | 71

Specified
Compressive Grade
(iv) IS 456-2000 Compressive
Strength Designation
strengthN/mm2
Ordinary Concrete M10 10
M15 15
M20 20
Standard Concrete M25 25
M30 30
M35 35
M40 40
M45 45
M50 50
M55 55

BITUMEN

(i) Softening Test Repeatability Reproducibility

Below 32°C 2 4
30◦C to 80◦C 1 2
Above 80◦C 2 4
(ii) Viscosity Test
(iii) Penetration Test
Bitumen grade Pentration Value
A25 20 to30
A35 &S35 30 to40
A45 &S45 40 to50
A65 &S65 60 to70
A90 &S90 80 to100
A200 &S200 175 to220
 P a g e | 72

CONCRETE

SPECIFICATIONS:

Some important specifications for durability and concrete mix design: parameters are given below
to enable site engineers to have easy access to some important requirements in their day to day work.
Before commencing the concrete mix design it is necessary to study the specifications of concrete
and also to have enough information of environment around the structure, the size and cross section
of structure, reinforcement details, the methods proposed to be adopted for batching, mixing,
transporting, placing and compacting of concrete.

2.0 Concrete specifications generally cover the following:

Specified minimum or characteristic strength (fck)
Minimum cement content, maximum water to cement ratio and the type of cement. This will depend
on the environmental conditions prevailing around the proposed structure as shown in the tables
below.

Table No. 1

Minimum cement content, Maximum Water-cement ratio and Minimum Grade of

Concrete for different Exposures with Normal Weight Aggregates of 20mm
Nominal Maximum size (IS 456)
Plain Concrete Reinforced Concrete

Exposure
Minimum Maximum Minimum Minimum Max.free Minimum
Cement Free grade of Cement water Grade of
Content Water- concrete Content cement concrete
kg/m3 cement kg/m3 ratio
Ratio
Mild 220 0.60 -- 300 0.55 M20

Moderate 240 0.60 M15 300 0.50 M25

Severe 250 0.50 M20 320 0.45 M30

Very 260 0.45 M20 340 0.45 M35

Severe

Extreme 280 0.40 M25 360 0.40 M40

 P a g e | 73

NOTES:
Cement content prescribed in this table is irrespective of the grades of cement and
it is inclusive of Mineral Admixtures specified in IS 456-2000. The additions such
as fly ash or ground granulated blast furnace slag may be taken into account in the
concrete composition with respect to the cement content and water-cement ratio if
the suitability is established and as long as the maximum amounts taken into
account do not exceed the limit of pozzolona and slag specified in IS 1489 (part 1)
and IS 455 respectively
Minimum grade for plain concrete under mild exposure condition is not specified

Table No. 2
Adjustments to Minimum Cement Contents given in Table No.1 for Aggregates other than
20mm Nominal Maximum Size
Nominal Maximum Aggregate size (mm) Adjustments to Minimum Cement
Contents in (Kg/m3)
10 + 40

15 * + 20

20 0

30 * -15

40 -30

* Not in IS 456-2000, but included on account of this sizes being available in and around
Mumbai.

5.0 Table No.3

Details of Environmental Exposure Conditions given in Table No. 1 (IS 456):

Environment Exposure Conditions
Mild Concrete surfaces protected against weather or aggressive
conditions, except those situated in coastal area.
Moderate Concrete surfaces sheltered form severe rain or freezing
whilst wet.
Concrete exposed to condensation and rain
Concrete continuously under water.
Concrete in contact or buried under non-aggressive soil /
ground water
Concrete surfaces sheltered from saturated salt air in coastal
area.
 P a g e | 74

Severe Concrete surfaces exposed to severe rain, alternate wetting

and drying or occasional freezing whilst wet or severe
condensation.
Concrete completely immersed in sea water
Concrete exposed to coastal environment
Very Severe Concrete surfaces exposed to sea water supply, corrosive
fumes or severe freezing conditions whilst wet.
Concrete in contact with or buried under aggressive sub-
soil/ground water
Extreme Concrete surfaces in tidal zone.
Members in direct contact with liquid / solid aggressive
chemicals.

6.0 Table No.4

The FIP recommendations for concrete exposed to sea water are given below

Specification Exposure Zones

Submerged Splash Atmospheric

Max. water cement < 0.45 < 0.45 < 0.45

ratio

Min. cement content 360 400 360

(kg / m3)

Min. cover (mm)

- reinforcing steel 50 65 65
- prestressing 50 90 90
steel
 P a g e | 75

7.0 Table No. 5

Requirements for Concrete exposed to Sulphate Attack (IS 456):
Concentration of sulphates Dense, fully compacted
Expressed as
concrete made with
SO3 20mm
nominal max size
aggregate complying
Type of with
Class Cement IS:383 – 1970
In soil Free
total SO3 in 2:1 In ground Cement water
SO3 % water : soil water content not cement
extract g/l g/L less than ratio
Kg/m3
0.5
1 Less than Less than Less than Ordinary portland 280 5
0.2 1.0 o.3 cement or portland slag
cement or portland
pozzolana cement

0.5
2 0.2 to 0.5 1.0 to1.9 0.3 to 1.2 Ordinary portland 330 0
cement or portland slag
cement or portland
pozzolana cement

0.5
Supersulphated 310 0
cement or
sulphate
resisting
Portland
cement
0.5
3 0.5 to 1.0 1.9 to 3.1 1.2 to 2.5 Supersulphat 330 0
ed cement or
sulphate
resisting
Portland
cement
Portland
0.4
pozzolana 350 5
cement or
portland slag
cment
 P a g e | 76

Supersulphat
4 1.0 to 2.0 3.1 to 5.6 to 5.0 ed 370 0.45
sulphate
resisting
Portland
cement
Supersulphat
5 Over 2.0 Over 5.6 Over 5.0 ed 400 0.40
cement or
sulphate
resisting
Portland
cement

NOTES:
 Cement content given in above table is irrespective of grades of cement use of supersulphated
cement is generally restricted where the prevailing temperature is above 40 oC Supersulpated
cement gives as acceptable life provided that the concrete is dense and prepared with a
water/cement ratio of 0.4 or less, in mineral acids, down to ph 3.5
 The cement contents given in Col.6 are the minimum recommended. For SO3 contents near
the upper limit of any class, cement contents above these minimum are advised.
 For severe conditions, such as this sections under hydrostatic pressure on one side only and
sections partly immersed, considerations should be given to a further reduction of water /
cement ratio.
 Cement content given in above table is irrespective of grades of cement use of supersulphated
cement is generally restricted where the prevailing temperature is above 40 oC Supersulpated
cement gives as acceptable life provided that the concrete is dense and prepared with a
water/cement ratio of 0.4 or less, in mineral acids, down to ph 3.5
 The cement contents given in Col.6 are the minimum recommended. For SO3 contents near the
upper limit of any class, cement contents above these minimum are advised.
 For severe conditions, such as this sections under hydrostatic pressure on one side only and
sections partly immersed, considerations should be given to a further reduction of water
/cement ratio.
 Portland sand cement conforming to IS:455-1989 with slag content more than 50 percent exhibits
better sulphate resisting properties where chloride is also encountered along with sulphate in soil
or ground water, ordinary Portland cement with C3A content from 5 to 8 percent shall be
desirable to be used in concrete, instead of sulphate resisting cement. Alternatively, Portland slag
cement conforming to IS 455 having more than 50 percent slag or a blend of ordinary Portland
cement and slag may be used provided sufficient information is available on performance of such
blended cements in these conditions
 P a g e | 77

8.0 Determination of Target mean strength of concrete

The following situations lead to different methods of determining the target mean
strength fT = fck + t x s where fck = Characteristic strength
t = Marginal statistical constant
= Standard deviation

When the concrete mix design is being worked out at site for the first time having no old track
record of atleast 30 previous compressive strength test results of the same grade of concrete
using similar types of materials (NEW SITE)

When old track record is available with more than 30 previous compressive strength results of
the similar grade (OLD SITE)

NEW SITE:

The value of standard deviation given below may be assumed for design of the mix in the first
instance.

Table No. 6

Assumed standard Deviation (IS 456 – 2000)

Grade of Concrete Assumed Standard Deviation (N/MM2)
M10
M15 3.5
M20
M25 4.0
M30
M35
M40 5.0
M45
M50
NOTE:
The above values correspond to the site control having proper storage of cement; weigh
batching of all materials; controlled addition of water; regular checking of all materials,
aggregate grading and moisture content; and periodical checking of workability and
strength. (Where there is deviation from the above the values given in the above table
shall be increased by 1 N/mm2)
 P a g e | 78

he target mean strength (Fm) is then determined using the following formula:
Fm = Fck + t x s
Wherein ‘Fck’ the specified minimum or characteristic strength of concrete
‘s’ is the standard deviation determined from above table for the above value of Fck and degree of
quality control expected at site.
‘t’ is the constant depending on the probability of certain number of results likely to fall below Fck.
The value of t is obtained from below table

Table No.7
Value of ‘t’ (IS: 10262 – 1982)
Accepted proportion of low results t
1 in 5 0.84

1 in 10 1.28

1 in 15 1.50

1 in 20 1.65

1 in 40 1.96

1 in 100 2.33

Degree of Concrete Workability will depend on the following factors: Workability: The
ease with which concrete can be transported; placed and compacted.
Cross section of the structure to be concreted
Density of Reinforcement in the structure
Type of transportation and placing equipment available or proposed to be deployed.
Type of compaction equipment available or proposed to be deployed

Degree of Workability is determined from the above factors. The appropriate workability test values
are given below for different placing conditions and degrees of workability.
 P a g e | 79

Workability for different purposes and appropriate test values (IS 456-2000)

Placing conditions Degree of Slump (mm)

workability
Blinding concrete; Very low C.F *(0.75 to 0.80)
Shallow sections;
Pavements using pavers
Mass concrete; Low 25 – 75
Lightly reinforced
Sections in slabs,
Beams, walls, columns;
Floors;
Hand placed pavements;
Canal lining;
Strip footings
Heavily reinforced sections in slabs, Medium 50 – 100
beams, walls, columns;
Slipform work; 75 - 100
Pumped concrete
rench fill; High 100 – 150
In-situ piling
Tremie concrete Very high Flow in mm **
*C.F.: In the ‘Very low” category of workability, measurement of workability by
determination of compacting Factor (C.F.) will be more appropriate than slump (IS 1199)
**Flow in mm: In the ‘Very high” category of workability, measurement of workability
by determination of flow will be appropriate (IS 9103)
NOTE:
For most of the placing conditions, internal vibrators (needle vibrators) are suitable. The
diameter of the needle shall be determined based on the density and spacing of
reinforcement bars and thickness of sections. For tremie concrete, vibrators are not
required to be used.
 P a g e | 80

10.0 Steps for concrete productions:

It is extremely important to supervise and control each and every step of concrete production. The
dos and don’ts and check lists covering each step are given in the following points. The dos and
don’ts must be followed strictly and in conjunction with the points mentioned in the checklists. The
site supervisors have to ensure that they have understood these requirements and see to it that they are
implemented on site without missing out on any point pertaining to their work.

BATCHING SPECIFICATIONS:

Table No. 9
Accuracy required for measuring various materials of concrete are recommended as follows:
Materials Accuracy of measurement in % of batch quantity
Aggregates + 2 to 3
Cement + 1 to 3
Water + 1 to 3
Admixtures + 3 to 5

Table No. 10
Recommended sizes of boxes (farmas) at site as per mixer and given in the table below:
Reference Width(cm) Height(cm) Depth(cm) Volume(ltrs) Qty (Nos)
A 33.3 30 20 20 1
B 33.3 30 25 25 2
C 33.3 30 30 30 2
D 33.3 30 35 35 2
E 33.3 30 40 40 2
F 33.3 30 45 45 2
G 33.3 30 50 50 1

PROCEDURE:
o Weigh batcher should be calibrated as frequently as required
o Cement should be stored in dry and moisture free shed and stacked above ground level
and covered with plastic sheets
o If water meter is used to measure water, it should be calibrate as frequently as required
o Presence of surface moisture in all moist or wet materials should be taken into account
while calculating water required to be added to the mixer. Everyday surface moisture to
be calculated.
o Absorption of water by dry aggregates should be taken into account while calculating
water to be added to the mixer.Water to be added to mixer = {free water as per w/c –
S.M of(FA1 CAICAII) + Absorption of Aggregates}
o Adequacy of all materials at site specially aggregate stored in odd shaped heaps
o The farmas used should be of good quality preferably made of steel plates, of
2.5mm thickness or 12 guage and having rigid pipe handles of adequate length.
o Weigh batcher should be on levelled ground or platform
o Set the weigh batcher dial for different loading of materials as per mix design
o Bulkage correction should be done of moist natural sand if batched by volume.
o 12nos. of farmas should be available at site per mixer as indicated in Table No.10 (above)
o Must maintain one set of farmas per mixer and paint their capacity for clear
identification.
 P a g e | 81

11.3 PRECAUTIONS:

1. Do not permit under filling of materials in farmas

2. Do not mix up cement and mineral admixtures
3. Do not mix up different sizes of aggregate; it should be stacked separately in bins.

11.4 CHECKLIST:

 Requirements of materials and parameters of concrete mix design

 At the time of batching of material supervisor must be present

 Temperatures of all materials specially water and aggregates at the time of batching
 Accuracy of batching within allowable limits as given in Table No.9 above
 Cleanliness and smooth surfaces of hoppers of weigh batchers and weigh batchers should be
on leveelled ground
 Batching of cement must be by weight only.
 Size of container used for water and measuring cylinder used for chemical admixture
 Accuracy of volumetric batching i.e. quality and size of farmas, determination of dry loose
bulk density, bulkage of natural moist sand

MIXING: SPECIFICATIONS:

The mixing time for the type of mix materials and mix consistancy should be optimum. It is always
preferable to mix the materials for optimum time which may vary from anything between 30
seconds to 120 seconds depending on the type of equipment and mix consistency (workability /
Slump).

Types of mixing
Manual mixing
Machine mixing
 P a g e | 82

12.2 PROCEDURE:

12.2.1 Manual Mixing (Not recommended for controlled concrete):

 Watertight platform or trough at least of size 3m x 3m should be available

 The platform should be such that at least two men can work upon the same simultaneously
 The platform or trough should have a peripherial kerb of a suitable height to prevent cement
slurry from draining away or other materials to overflow
 The platform should be clean and free from mortar / concrete laitance and other materials
 Mix the sand and cement with shovels (powrahs). Turn the mixture over and over till it is of
even colour throughout and free from streaks of brown and grey, then spread the coarse
aggregates uniformly over the sand and cement layer.
 Make a hollow in the centre of the mixture and 75% of the total water requirement is poured
and simultaneously the material is turned towards the centre with the shovel.

12.2.2 Mechanical mixing:

 Mixer should be set up on firm and levelled base

 All moving parts should be clean
 All nipples should be greased
 Interior of mixer drum should be clean and watertight
 Blades and baffel plates should be clean
 Gap between the drum and blades should not be more than 25mm if gap is more, weld steel bar
or plate so that gap is reduced.
 Ratio of drum volume to wet concrete volume should be minimum 2.5:1
 Mixer operator should be experienced
 After concreting operation mixer should be cleaned and washed thoroughly to
remove all adhering materials from the blades and drum
 The rotating parts should be covered and protected when mixer not in operation.

12.3 PRECAUTIONS:

12.3.1 Manual Mixing

Do not mix all the materials at a time

12.3.2 Mechanical Mixing:

Do not over load the mixer drum

Do not pour the water without measuring container
Do not use ghemalas instead of using farmas while loading the mixer

1. be uniform, cohesive and of right workability

 P a g e | 83

TRANSPORTATION:

SPECIFICATIONS:

Mode of Transportation
There are several modes of transportation of concrete mixes available. They can be broadly classified
as :

 Fully Manual
 Semi-manual and semi-mechanised
 Fully mechanised

The fresh concrete mix should be transported in the fastest possible time and without causing
segregation of the mix constituents.

13.2 PROCEDURE:

 Distance of travel should be short

 Pathways, walkways, scaffolds, steps etc. used by working gang should be adequate and safe.
 Sheltered pathways and walkways over reinforcement cage should be provided in monsoon.
 Protection against rain water ingress in concrete during the monsoon
 Safety apparel and foot wear should be used by workers
 Guard railing should be provided all around to prevent accidental fall
 Concrete should be placed in position within 30 minutes after mixing
 Whenever concrete is dumped or dropped, the direction of fall should be vertical,
otherwise segregation will take place
 Conveying and placing equipment should be kept free from hardened concrete and
foreign material and should be cleaned at frequent intervals
 Containers used to concrete should be water tight.
 At the time of transporting concrete adequate number of workers should be deployed.

13.3 PRECAUTIONS:

 Do not pour additional water during transportation.

 Do not drop the concrete from more than 1m height
 Do not delay and / or interrupt transportation as this cause cold joints, honey combing,
porosity, discoloration.
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13.4 CHECKLIST:
 Check the workability during the journey if the duration is long or ambient temperatures are high
 If in doubt, check workability of concrete (slump) just before the placement
 Check availability of adequate number of workers for transporting concrete.
 Check supervisor’s availability through out the pour.

CONCRETE PLACING:
Placing should be done as fast as possible and without segregation of the concrete
mix. Concrete should be placed as close to its final position as possible.

PROCEDURE:

 Plan and design formwork and reinforcement layout to suit the speed of placement and
equipment proposed to be used
 Plan sequence of each layer and width of the layer avoiding cold joints (massive pour)
(step system to be followed)
 Concrete must be placed at or as near as possible to its final position without loss of
workability or causing segregation
 Concrete must be placed in layers without occurrence of cold joints, if due to some reason
cold joint can not be avoided pour slurry on concrete
 Concrete must be dumped vertically without hitting any obstruction (formwork, insert,
reinforcement etc.)
 Vertical dumping (free fall) should be maximum 1.0 m height
 Placing should be in layers of uniform thickness between 150 to 300 mm, however, not
more than 500 mm in any case
 Placing speed must match compaction speed
 Placing speed of concrete in walls, columns and deep members at a rate greater than 2 m per
hour (improve finish)
 Delays , interruptions and stoppages should be avoided
 Flow of concrete or concrete placing should commence from corners and ends
 Concrete in slab must be first placed against hardened concrete of the previously cast
concrete slab. Removal of laitance by chipping of old concrete must be done.
 First layer in deep beams, columns and wall should be rich in mortar or rich mortar 1:2
proportion, with identical water to cement ratio of the concrete mix must be placed prior to
placing concrete mix over it
 Level of top layer must be maintained uniformly during placement
 Concrete of top layer can be slightly drier in consistency
 Prevention of bleeding by attending to deficiencies like less fines or high slump
 Width of working platform to be adequate
 Workers with muddy boots or bare foot kept out of freshly placed concrete
 Engineers / supervisors / workers must be available, to continuously inspect forms,
bracings, props and other supports\
 Chutes or conveyor belts should be mobile enough for easy placement
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PRECAUTIONS:

 Do not heap concrete

 First layer should not more than 500 mm. if placed on hardened concrete of previous pour or
on rock surface
 Slopes of inclined chutes should not be less than 1 vertical to 2.5 horizontal

14.3 CHECKLIST:

 Drop chutes with rounded cross section should be available at site

 For large drops tremie pipe or funnel should be available
 Place of upper layer only after lower layer is well compacted
 Place of upper layer before the lower layer commences to harden
 Plastic sheets must be available to protect slab concrete from plastic shrinkage cracks as soon as
concrete is trowelled and finished.
 Availability of protective covers for freshly placed concrete in case of unforeseen stoppage or
monsoons.
 Clear visibility of deep areas for inspection during placing (provision of windows, lighting
etc.).
 Availability of temperature monitoring devices for concrete temperature measurement (if
necessary or specified). Use Bimetallic thermometer to check concrete temperature.
 In hot weather, all placing equipment used, must white or light coloured and covered with wet
hassian. Concrete temperature preferably to be kept below 32 degree C.
 Suitability of ambient temperatures during the placing
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CONCRETE PLACING IN MASSIVE CONCRETE STRUCTURE:

PROCEDURE:
 Temperatures of all materials must reduce to maximum possible by cooling or chilling so that
temperature of concrete at the time of placing is below the required minimum temperature
specified. If temperature is above 32 degree use ice flakes to chill the water to be added to
mixer.
 Placing to be continuous and non-stop without occurrence of cold joint
 Prevention of segregation in deep and/or densely reinforced sections
 Heaping of concrete while unloading large buckets to be avoided – concrete spread
uniformly in each layer.
15.2 CHECK LIST:
 Cement to have low heat of hydration
 Concrete temperatures at the time of placing within specified limits. (32 0C)
 Availability of adequate quantity of flaked ice. If temperature is above 32 0C, generally
in higher grade of concrete.
 Adequacy of placing large quantity of concrete in shortest possible time
 Non stop supply of concrete assured (adequate manpower, availability of all materials,
capacity of equipment, standby equipment)
 Adequatly sized gaps (openings) between reinforcement provided to facilitate lowering of
drop chutes, placer boom hose pipes and needle vibrators
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CONCRETE PLACING IN SLENDER / DEEP SECTIONS:

PROCEDURE:
 Reinforcement layout must be planned to facilitate concrete placement without segregation and
to achieve full compaction
 Compaction speed must match speed of placing and compaction should be stopped when air
bubbles stop surfacing.
 Concrete placed at uniform rate of 1 m to 2 m vertically per hour
 Placement to be gradual and uniformly distributed, restricting height of each layer to a
maximum of 300 mm
 Concrete placed without hitting reinforcement, inserts or formwork (to avoid segregation)
 Commence concrete placing with a richer mix (more cement and sand) in the lowest layer and
then revert to normal mix in subsequent layers
 Precautions must taken when concrete placed around void formers, inserts and for concrete
wall of rectangular, square or circular shape (caissons, large lift shafts, silos, chimneys etc),
concrete to be placed on either side of the starting point on both sides and continued so in each
layer
 Water stops correctly fixed and positioned and not displaced in case of U.G. tanks.
 Shear keys correctly located and properly fixed

CHECK LIST:

 Formwork designed to take hydrostatic pressures without displacement or bulging.

 Availability of long tremies and pipe chutes for very deep sections
 All locations where concrete is to be placed to be visible for inspection – proper lighting,
windows provided at least at every 2 m height
 Explain to the concrete placing gangs and/or equipment operators regarding the sequence of
pour (thickness of layers, width of layers and time required for each layer)
 Proper stop ends (bulk heads) provided at construction joint (strong and leakproof)
 Construction joint should be step joint as per sketch
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CONCRETE COMPACTION SPECIFICATIONS:

Table No.11
Range of characteristics, performance and application of Internal Vibrators are given below:
Frequence Type of Workabilit Remark
Diameter y Average structure y Radius Rate of s
Amplitud of compactio
of needle (VPM) e of concrete action n
head
(mm) (mm) (mm) (mm) (Cum/hr)
Less than 50 -75 Less than Not
50 0.75 suitable

20-30 9000 - 0.40 – This section

50-75 75- 0.75-1.5 Suitable
15000 0.80 confined
100
locations, cover

areas
Over 75 100 – Over 1.5 Suitable
150
In this walls,
coloumns, Less than 75- 1-2 Suitable
beams, precast
piles &
thin slabs(over
75mm 50 100
slump) in general
construction
beams,
columns,
lsbs (less than 75
30-50 800- 0.50-0.65 mm
12500 slump)

50-75 100- 2-4 Suitable

250

Over 75 250- 4-6 Suitable

300
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17.2 PROCEDURE:

17.2.1 Internal vibration :

 Properly plan the compaction to match the concrete placing speed and sequence of
concrete pouring
 Diameter of needle head, frequency and amplitude should depend on type of
structure, workability of concrete and density of reinforcement steel
 Bearings should be greased
 Before connecting the motor of vibrators moisture (water) should be cleared
 Before starting compaction the security of connections on compressed air lines should be
double checked.
 To avoid repeated shifting in massive concrete pours. Placement of motors of needle
vibrators should be planned to minimize their shifting.
 Needle insertion should be quick and penetration easy and fast due to its own weight right
upto the bottom of the concrete layer
 Needle withdrawal should be slow
 Concrete heap should be gradually leveled from the side of the heap and moving away from
the heap all round
 For full compaction, in small columns reduction of placing speed should be less than
300mm height every 20 seconds
 In column, first deposit 300mm layer of concrete then, lower the needle and vibrate.
 Concrete in columns compacted layer by layer by slow withdrawal and reinsertion after
placement of next layer
 Small holes to be drilled at regular intervals in the soffit of the void former to ensure air escape.
 All the chutes and its extensions should be ½ round so that concrete will flow smoothly and
will not stick to the chutes. Chute should be at 45 degree.
 When needle is not in concrete the motor should be switched off
 Adequacy of concrete surcharge (at least 15mm) in concrete slabs to allow for settlement of
concrete during compaction.
 Revibrate to reduce plastic cracking of concrete if required.
 After each pour the needles should be thoroughly cleaned.
 Provide the plastic sheets to cover the finished surface
 Compaction should be completed before the initial setting time. If concrete already set should
not be disturbed by successive vibrations.
 Curing compound should be sprayed on the finished surface
 Trowel the surface to give proper finish
 Surface should be smooth and without undulations.

53
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17.2.2 External Vibration of concrete:

 Formwork should be designed to take excessive vibration and transfer them to concrete.
 Vibrators should be securedly fixed
 Vibrators should be fixed 1000mm below the top finishing level of concrete
 Compaction time should be between 1 to 2 minutes
 Needle vibrators should also be used for thick sections and for concrete in top layers
 Adequacy of space should be provided for form vibrators.

PRECAUTIONS:

Internal vibration:
 Do not pull or drag drive motor using flexible shaft of the needle vibrator.
 Do not shift the motor of needle vibrator as far as possible.
 Needle vibrators should be not overworked but rested intermittently
 Do not allow the needle to touch formwork, inserts or reinforcement steel
 Do not place and compact simultaneously on both sides of the void former
 Do not over vibrate when entrapped air bubbles stop surfacing on concrete. Needle’s
pitch becomes constant when over vibrating and thin shining film appears on the
surface which is vulnerable to cracking.
 Do not under vibrate. Entrapped air/voids will result in loss of strength.

External vibration:
1. Do not fix the vibrators on top of vertical form work

17.4 CHECKLIST:

17.4.1 Internal Vibration:

 Type of vibrator and its source of power supply
 Adequacy of needles and motors depending on volume of concrete pour and workability
 Spare needle vibrators and spare motors should be in working condition
 Needle penetration should be full in concrete layer just placed
 Thickness of concrete layer should not be deeper than needle length
 Needle must penetrate about 100mm into the previous layer
 Check the handling of the needle by the operator (needle should be held atleast 600mm to
750mm above the connection between rigid and flexible shaft)

17.4.2 External Vibration:

Check the spacing of vibrators

Check the operating sequence at the time of compaction
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18.0 CONCRETE FINISHING:

18.1 PROCEDURE:
 Adequate number of trained / skilled masons (manual) and / or trained operators
(mechanical trowelling) should be available.
 Coarse aggregate should be available on top surface while rendering (if coarse aggregates
not present in the top layer use fork or panja and rake the concrete till coarse aggregates
surface up)
 Adequacy of texturing or raking of surface if required or specified
 Slurry surfacing due to compaction of concrete must be adequate for finishing.

18.2 PRECAUTIONS:

1. Cement water or cement mortar should not be added to facilitate surface finishing as it will cause
shrinkage cracks.

18.3 CHECKLIST:

 Adequate number of plastic sheets to cover the finished surface

 Availability of curing compound to be sprayed on the finished surface.
 Surface should be smooth and without undulations.
 Roof slab should be trowelled even and smooth with a wooden float

19.0 CONCRETE CURING:

19.1 PROCEDURE:

19.1.1 Vertical surfaces:

 All materials and equipment needed for curing and protection of the concrete should be on
hand and ready for use before actual placing is started
 The curing period should be such that concrete attains at least 70% of the specified compressive
or flexural strength. However, in warm or hot climate, concrete may achieve this strength
within 3 days
 Concrete or mortar made by using cement of slow strength gain characteristics will need
longer period or curing. Use of pozzolanic materials in concrete mix will also require longer
curing periods. It is recommended to cure heavily reinforced massive concrete structures for
at least a minimum of 7 days.
 uring should be continued for specified period (generally 7 days)
 Adequate water should be supplied for curing
 In hot weather conditions form work should be removed as soon as possible and wet curing
should be commenced.
 Concrete should be allowed to dry gradually at the end of curing period
 Minimum thickness of plastic sheet should be 0.10mm
 Transparent plastic sheet should be used to cover concrete immediately after finishing is
over in hot weather.
 P a g e | 92

 In cold weather thick insulating blanket covers should be placed on concrete

 Curing compound should be sprayed/applied uniformly.
 In very hot weather, curing compound should be applied after 24 hrs of wet curing.
 Curing compound sprayed uniformly on moist concrete in two layers at right angles to each other
 Exposed reinforcement from concrete and concrete construction joints should be covered
properly while spraying curing compound.
 Water used for curing purposes should be of the same quality as mixing water for concrete

19.1.2 Horizontal surfaces:

 Replenish ponded water throughout the curing period. Watta’s should be 2’ x 2’ size
and minimum 3” deep in flat surfaces.
 Clay or mortar bunds must be high enough to facilitate adequate quantity of ponded water over
the concrete surface
 Polythylene sheet on finished concrete surface should be placed immediately after finishing
 Polythylene sheet placement on lightweight frame may be used for specially textured surfaces
 Provided special walkway for spraying curing compound

19.2 PRECAUTIONS:

19.2.1 Vertical surfaces:

 Water does not fall on freshly placed concrete surfaces in the neighborhood.
 Chilled curing water is not to be used in hot weather.
 Use of sea water for curing is not allowed.
19.3 CHECKLIST:

19.3.1 Vertical surfaces:

 Surfaces completely covered preferably with plastic sheet or wet hessian or burlap?
 The sheet or other covering material should be fixed immediately on removal of formwork.
 Plastic sheets and other covering materials should be properly taped or fixed or clamped down.
 Curing compound should be applied soon after form work removal.
 Dates of casting the member should be written immediately so as to know curing period.

19.3.2 Horizontal Surfaces:

 Ensure that ponded water covers all corners and edges and even chajjas / projection / sunken
areas etc.
 Check the bund, if any damages are there immediately repaired it.
 Is the polyethylene sheet well fixed and weighed down against winds.

FIELD TESTING:

Slump test: The test procedure and tabulation for this test is given in Annexure I and II
respectively.

Compressive strength: The test procedure and tabulation for this test is given in Annexure III and
IVrespectively.
 P a g e | 93

READY MIX CONCRETE

Ready mixed concrete shall be supplied from a source approved by the QUALITY IN-CHARGE and
shall comply with the requirements of relevant IS code. The R.M.C supplier shall be responsible for
ensuring that the concrete compiles with this specification including quality control, regularity of
delivery and continuous supply of concrete. If any of the requirements of this specification is not
complied with the QUALITY IN-CHARGE may withdraw his approval and require changing the
supplier or stopping using ready – mixed concrete.

The contractor shall ensure that proper records are kept. The weights of cement and of coarse and fine
aggregates shall be continuously recorded at he batching plant by scaled recording heads cross
referenced to the delivery dockets. Periodic tests shall be made to determine the water content of the
aggregates and the amount of water added to each batch shall be adjusted accordingly.

The concrete shall be discharged from the truck within 2 hours of the time when the cement first
comes into contact with the mixing water and shall be placed compacted and left undisturbed in its
final position within 60 minutes of discharge. The record book shall be available for inspection by the
Engineer or his representative at all times.

Keep on site a record containing the following particulars:

 Time of arrival of truck
 Time of batching and adding water
 Registration number of truck and name of depot
 Time when the concrete has been placed and left undisturbed
 The grade or specified strength of the concrete and maximum size of aggregate
 Position where the concrete is placed
 Reference marks of any test cubes taken from this delivery
 The slump (or compacting factor)
 P a g e | 94

The site civil contractor shall provide on site a drum mixer of minimum 10/7 capacity and keep it in
working order in case of an interruption of the supply of ready mixed concrete during concreting. A
good fresh stock of materials shall always be kept by the Contractor on site for use with the stand by
mixer.

ADVANTAGES BY USING RMC

 There is a considerable wastage of material on site due to poor storage condition and repeated
shifting of mixer location. This is prevented if RMC is used.
 In most citied, the plot area is barely sufficient to store reinforcement steel, formwork, and
concrete and other construction material. Using RMC can cause less congestion and better
housekeeping on the site resulting in efficient working environment.
 Obtaining RMC at site can reduce supervision and labour costs which would otherwise be
required for batching and mixing of concrete.
 Many sites in cities house their work force on the site itself to reduce the time and cost of daily
travel. This creates unsafe and unhygienic conditions on the site as well as for the surrounding
areas. This will reduce to a certain extent if RMC is utilized.
 Fluctuations of raw material prices and their availability has always caused delays and problem
of inventory and storage for site producers of concrete. This is totally avoided when use RMC is
used.
 Availability of labour gangs intermittently has always posed problems to concrete producers on
site. This can now be avoided. Besides these labour gangs are difficult to supervise and control
as they are only interested in completing the concreting operations as fast as possible.
 Concrete mix design and its control due to variation of material properties is avoided as RMC
producer are responsible for the same and supply concrete as specified by the purchaser as per
the requirements of the construction site.
 P a g e | 95

 The modern RMC plants have an automatic arrangement to measure surface moisture on
aggregate
 RMC plants have proper facilities to store and accurately batch concrete admixtures to improve
properties of concrete both in plastic and in hardened stage this accuracy is useful.
 RMC plants have efficient batching and mixing facilities which improve both quality and speed
of concrete production.
 There is a code of practice available for RMC supplier and users the IS: 4926-2003 Published by
BIS this code adequately covered to meet the needs of both the supplier and consumer of RMC.

Specified Requirements for RMC

 Characteristic strength or grade (N/mm2) [ Refer clause 6.1 & 6.3 of IS:4926]
 Target workability or slump in mm required at site [ Refer clause6.2 of IS:4926]
 Exposure conditions for durability requirement [ Refer clause 7.2 of IS:4926]
 Frequency of concrete testing [ Refer clause 6.3.2 & 6.3.3 of IS:4926]
 Details of last calibration done on various weighing / dosing equipments [Refer clause 9.12 &
9.13Annexure E of IS:4926]
 Maximum aggregate size.
 Method of placing,
 Quantity of concrete required.
 Details of material and their required tests.
 Maximum water cement ratio.
 Minimum cement content.
 Type of cement.
 Mineral admixture and its proportion (Kg / M3)
 Permeability test required if any.
Checks Necessary before ordering RMC
 Reliability of the plant and transit mixers for consistent and continuous concrete
supply as per requirement.
 Calibration of all measuring devices and their accuracy.
 Mode of operation of plant should preferably be fully automatically and not manual.
 Quality of materials proposed to be used.
 Adequacy of quantity of material proposed to be used.
 Compliance of concrete specification based on the mix parameters specified.
 Adequacy of testing facilities.
 Time likely to be taken by transit mixers from plant to site and back.

Checks needed at site prior to receipt of RMC

 Reinforcement layout for proper concrete placement without segregation.

 Adequacy of form work to take the hydrostatic pressure and adequacy of loading
on propping system to match the speed of placing.
 Opening and chutes provided, at predetermined locations, between reinforcement
bars to lower the placing hose to avoid segregation of concrete.
 Adequacy of manpower and equipment for placing, compacting, finishing and curing
of concrete.
 Proper approach for transit mixers free from all encumbrances water logging,
material stacking etc.
 Proper platform to receive concrete.
 Proper precaution required to be taken to ensure that concrete from the transit mixer
is unloaded at the fastest possible speed does not take more than 30 minutes.
 If pumping is proposed, the location of the pump should be approachable.
 Dropping concrete from a height more than 1 mtr can cause segregation.
 Obstruction of inserts and incorrect placing caused segregation and poor quality of
concrete finish.
 Correct method of concrete placing without segregation.
 P a g e | 97

Checks at site during Concrete

 Proper co-ordination between the RMC supply and placing and compacting gangs.
Proper signaling or communication at site is necessary.
 Workability of concrete within accepted limits.
 Adequacy of cohesiveness of concrete for pumpability.
 Ensure that water addition or chemical admixtures are not added during transportation
by RMC unauthorized person and without the knowledge of the site in charge of the
consumer.
 Continuous and steady supply at site and speedy unloading of the transit mixers.
 Monitor speed and progress of placing to avoid formation of cold joints.
 Arrange for curing as soon as finishing is completed. This is specially required in case
of slabs, pathway and roads in HOT/WARM weather.
 Many a times fixed slump value is insisted upon by the consumer. This is practically
not possible. Variation are likely to occur and should be within the limits say ± 25
mm as stated in clause 6.2.1 of IS:4926 – 2003.
 Protect freshly placed concrete with a plastic sheet and eliminate plastic cracking of
concrete in slabs, pavements and roads.
 Plastic shrinkage cracks in concrete due to inadequate protection of concrete against
wind, hot ambient temperature and low humidity.

REFERENCE: IS 4926: 2003 Code of practice – Ready Mixed Concrete.