laboratory work procedure

8/2/2019 Laboratory Work Procedure

1/57

SIGNATURE:

DESIGNATION:

PREPARED BY: REVIEWED BY: APPROVED BY;

Laboratory Testing Procedures
http://rds.yahoo.com/_ylt=A0Je5qgQDHhE.n0AVdOJzbkF;_ylu=X3oDMTBjdmNoOTVjBHBvcwMyBHNlYwNzcg--/SIG=1g54b4jm1/EXP=1148804496/**http%3a/images.search.yahoo.com/search/images/view%3fback=http%253A%252F%252Fimages.search.yahoo.com%252Fsearch%252Fima


2/57

SIGNATURE:

DESIGNATION:


Ahluwalia Contracts (India) Ltd. DOCUMENT NOWI/01

WORK INSTRUCTIONS ISSUE NO : DATE

Inspection & Testing- SILT CONTENT

(Fine agg)

REV. NO : 01 DATE

PAGE : 1 OF 3

METHOD-1 (By Volume- As per CPWD Specification)

OBJECT:

This method of test deals with the procedure for determining the Silt Content of Sand by

Sedimentation Method.

APPARATUS:

The apparatus required for the test is as follows:

A 250 ml capacity-measuring cylinder.TEST SAMPLE:

Material sampled for the test should be thoroughly mixed before sampling and it should

contain sufficient moisture to prevent segregation.

PROCEDURE:

Fill the cylinder to 50 ml mark with salt water. (Salt to be 1 teaspoonful to half litre ofwater).

Pour in the sample of sand to be tested until the level of sand is 100 ml mark. Add more water until 150 ml mark is reached. Shake the cylinder well, talking a particular care to spill any of the contents. Keep the cylinder filled with sand for 3 hours. Note the Silt height (above sand layer) and sand height (below silt layer).

REPORTING OF RESULTS:

The Calculation & Reports shall be maintained in the Format F-01/WI/IT/01.


3/57

SIGNATURE:

DESIGNATION:





(Fine agg)

REV. NO : 01 DATE

PAGE : 2 OF 3

METHOD-2 (By Weight- As per IS 2386 part-1)

OBJECT:

This method of test deals with the procedure for determining the total quantity of material

finer than 75-micron IS sieve in aggregates by washing.

APPARATUS:


The balance or scale shall be of sufficient capacity and sensitivity and shall have anaccuracy of 0.1 percent of the weight of test sample. Sieves-A nest of two sieves, the lower being 75-micron IS Sieve and the upperapproximately 1.18 mm IS Sieve.

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

water.

Oven-An oven of sufficient size capable of maintaining a uniform temperature of110

oC 5

oC.

TEST SAMPLE:

The weight of sample available shall not be less than the weight

Maximum Nominal Size of Aggregates

(mm)

Approximate minimum weight of sample

(gm)

4.75 500

10.0 2000

20.0 2500

40 or over 5000

PROCEDURE:

The test sample shall be dried to constant weight at a temperature of 110oC5oC andweighed to the nearest 0.1 percent.

The dried and weighed sample shall be placed in the container and sufficient water isadded to cover it. Then the contents of the container are agitated vigorously.

The agitation shall be sufficiently vigorous such that the coarse particles are separatedand the fine particles are brought into the suspension.

The water (mixed with fine particles) shall be poured over the nested sieves arrangedwith the coarser sieve at the top.


4/57

SIGNATURE:

DESIGNATION:





(Fine agg)

REV. NO : 01 DATE

PAGE : 3 OF3

All materials retained on the both the sieves shall be container containing coarserparticles.

Steps 3, 4 & 5 are repeated till the wash water looks clear. Care should be taken suchthat no materials retained on the sieve get lost.

The retained materials should be dried to a constant weight at a temperature notexceeding 110

oC and weighed to the nearest 0.1 percent.

REPORTING OF RESULTS:The Calculation & Reports shall be maintained in the Format F-02/WI/IT/01.


5/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- PARTICLE SIZE

DISTRIBUTION (Coarse & Fine agg)

REV. NO : 01 DATE

PAGE : 2 OF 2

OBJECT:

This method of test covers the procedure for the determination of Particle size distribution of

Fine & Coarse aggregates by sieving or screening (As per IS: 2386 part-1)

APPARATUS:


Sieves- Sieves (Conforming to IS:460-1962) of size 40mm ,20mm ,12.5mm ,10mm,4.75mm ,2.36mm ,1.18mm ,600 micron ,300 micron & 150 micron.

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

Sieve shaker.TEST SAMPLE:

The weight of the sample available shall not be less than the weight given in the table below.

The sample for sieving shall be prepared from the larger sample either by quartering or by

means of sample divider.

Maximum Size present in Substantial

proportions (mm)

Minimum weight of sample required for

quartering (Kg)

20 2510 6

6.3 3

Minimum weight of sample required for Sieve analysis after Quartering shall be as follows.

Maximum Size present in Substantial

proportions (mm)

Minimum weight of sample required for

Sieve analysis (Kg)

20 2.0

10 0.5

4.75 0.2

PROCEDURE:

Bring the sample to an air-dry condition before weighing and sieving. Weigh the air-dry sample and sieve successfully on the appropriate sieves starting

with the largest.


6/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- PARTICLE SIZE

DISTRIBUTION (Coarse & Fine agg)

REV. NO : 01 DATE

PAGE : 2 OF 2

Each sieve shall be shaken separately over a clean tray until not more than a tracepasses, but in any case for a period of not less than 2 minutes.

Shake with a varied motion so that the material is kept moving over sieve surface infrequently changing directions.

Light brushing of the underside of sieve with a soft brush may be used to clear thesieve openings.

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


The Calculation & Reports shall be maintained in the Format F-01/WI/IT/02,

F-02/WI/IT/02, F-03/WI/IT/02 & F-04/WI/IT/02.


7/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- SP.GRAVITY &

WATER ABSORPTION (Coarse & fine agg)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedures for determining the Specific gravity & Water

Absorption of aggregates. (As per IS: 2386 part-III)

APPARATUS:


A balance of capacity 3 kg or more, readable & accurate to 0.5g.

An Oven to maintain a temperature of 100

o

C to 110

o

C. A Pycnometer of about one liter capacity A tray of area not less than 325 cm2. Filter papers & funnel.

TEST SAMPLE:

The sample taken for test shall be approximately 500 g for fine aggregates & 1000 g for coarse

aggregates.

PROCEDURE:

Making the sample at SSD condition: A sample of about 1000 g for coarseaggregates & 500 g for fine aggregates shall be placed in separate trays and water ispoured in the tray such that the sample gets completely immersed in water. The

temperature of water shall be maintained between 22oC to 32

oC.The immersed

aggregates shall be agitated with rod so the entrapped bubbles gets completely

removed from the aggregates. Then the sample is left immersed in water for 241/2

hours. The water shall then be carefully drained from the sample such that no

particles get lost. The sample is kept in exposed air or below fan so that the surface

moisture gets evaporated (i.e. the sample shall be stirred at frequent interval to ensure

uniform drying until no free surface moisture is seen and the material just attains a

free running condition. The weight (W1) of the sample is taken which is SSDweight.

The SSD aggregate shall then be placed in the Pycnometer, which shall then be filledwith distilled water. The hole at the top of brass cone of pycnometer shall be closed

with finger and the trapped air shall be removed by rotating the pycnometer on its

side. The Pycnometer shall be filled completely with water, wiped/dried from outside

and weighed. (W2)


8/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- SP.GRAVITY &

WATER ABSORPTION (Coarse & fine

agg)

REV. NO : 01 DATE

PAGE : 2 OF 2

The aggregates along with water are taken out carefully on a tray. The Pycnometershall be completely filled with water, wiped/dried from outside & weighed. (W3).

The water present in the tray along with aggregates shall be completely drained suchthat no aggregate particles get lost. The sample with tray shall then be kept in the

oven at a temperature 100oC to 110

oC for 241/2 hours. It shall be cooled and

weighed (W4).

W1 = Weight in g of SSD sample.W2 = Weight in g of pycnometer containing sample and filled with water

W3 = Weight in g of pycnometer filled with water only.

W4 = Weight in g of oven dried sample.


The Calculation & Reports shall be maintained in the Format F-01/WI/IT/03 &

F-02/WI/IT/03.


9/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-MOISTURE

CONTENT(Coarse & Fine agg)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedures for determining the Moisture Content of

aggregates. (As per IS: 2386 part-III)

APPARATUS:


A balance of capacity 3 kg or more, readable & accurate to 0.5g. An Oven to maintain a temperature of 100oC to 110oC. A Container.

TEST SAMPLE:

The sample taken for test shall be approximately 500 g for fine aggregates & 1000 g for

coarse aggregates.

PROCEDURE:

1. Take the sample in container and weigh it accurately.(W1)

2. Dry the sample in oven and weigh it. (W2)3. Now weigh the empty container. (W3)4. Weight of water can be calculated as follows:

Weight of water (W4) = W1W2

5. Weight of dry sample can be calculated as follows:Weight of dry sample (W5) = W2W3

6. Moisture content can be calculated as follows:Moisture Content % = W4 x 100

W5


10/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-MOISTURE

CONTENT(Coarse & Fine agg)

REV. NO : 01 DATE

PAGE : 2 OF 2

RESULTS:

The calculations and results can be reported as per Format F-01/WI/IT/04.


11/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- BULKING OF SAND REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedures for determining the necessary adjustment for

bulking of Fine aggregate. (As per IS: 2386 part-III)

APPARATUS:


A container of capacity 3 liter. A Steel Ruler.

A Steel Rod 6 mm in diameter. A 250 ml capacity measuring cylinder.

TEST SAMPLE:

The sample taken for test shall be approximately 5kg.

PROCEDURE:

METHOD 1

1. Put sufficient quantity of sand loosely into a container until it is about two-third full.Level off the top of the sand.

2. Push a steel rule vertically down through the sand at the middle to bottom. Measure theheight. Suppose this is h cm.

3. Empty the sand out of the container into another container where none of it is lost.4. Half fill the first container with water. Put back about half the sand and rod it with a

steel rod so that its volume is reduced to a minimum.

5. Then add the remainder, rod it and level the top surface of inundated sand.6. Measure its depth at the middle with steel rule. Suppose this is h1 cm.7. Percentage bulking of sand due to moisture content shall be calculated as:

Percentage Bulking = (h/h11) x 100


12/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- BULKING OF SAND REV. NO : 01 DATE

PAGE : 2 OF 2

METHOD 2

1. In a 250ml-measuring cylinder, pour the damp sand and consolidate it by staking until itreaches the 200 ml mark.

2. Fill the cylinder with water and stir the sand well (the water shall be sufficient to submergethe sand completely).

3. It will be seen that the sand surface is now below its original level.4. Suppose the surface is at the mark of h Level, therefore the % of bulking of sand due to

moisture shall be calculated as:

Percentage Bulking = (200/h-1) x 100.


The Calculation & Reports shall be maintained in the Format: F-01/WI/IT/05


13/57

SIGNATURE:

DESIGNATION:


OBJECT:

This method of test covers the procedure for determining the aggregate crushing value of

coarse aggregate. (As per IS: 2386)

APPARATUS:


A 15-cm diameter open-ended steel cylinder, with plunger and base-plate. Thesurfaces in contact with the aggregate shall be machined and case-hardened or

otherwise treated so as to have a diamond (VH) pyramid hardness number of not less

than 650VH. A straight metal tamping rod of circular cross-section 16mm in diameter and 45 to60cm long, rounded at one end.

A balance of capacity 3 kg, readable and accurate to one gram. IS Sieves of sizes 12.5mm, 10mm and 2.36mm. A compression testing machine capable of applying a load of 40 tonnes and which

can be operated to give a uniform rate of loading so that the maximum load is

reached in 10 minutes. The machine may be used with or without spherical seating.

For measuring the sample, cylindrical metal measure of sufficient rigidity its formunder rough usage and of the following internal dimensions:

Diameter 11.5cm

Height 18.0cm

TEST SAMPLE: -

1. The material for the standard test shall consist of aggregate passing a 12.5 mm IS Sieve

and retained on a 10 m IS Sieve, and shall be thoroughly separated on the sieves before

testing. For other sizes, the material shall be separated on the appropriate sieves given in

Table 1.

2. The aggregate shall be tested in a surface-dry condition. If dried by heating, the period of

drying shall not exceed four hours, the temperature shall be 100 C to 110 C and the

aggregate shall be cooled down to room temperature before testing.

3. The quantity of aggregate shall be such that the depth of material in the cylinder, after

tamping as described next shall be 10 cm.

4. The appropriate quantity may be found conventionally by filling the cylindrical measure in

three layers of approximately equal depth, each layer being tamped 25 times with the

rounded end of the tamping rod as a straightedge.



Inspection & Testing-AGGREGATE

CRUSHING VALUE

REV. NO : 01 DATE

PAGE : 1 OF 3


14/57

SIGNATURE:

DESIGNATION:


5. The weight of material comprising the test sample shall be determined (Weight A) and the

same weight of sample shall be taken for the repeat test.

TABLE I. DETAILS OF AGGREGATE CRUSHING TEST FOR NON-STANDARD

SIZES OF AGGREGATE

NOMINAL Sizes (IS SIEVE) DIAMETER OF SIZE OF IS SIEVECYLINDER TO BE USED FOR SEPRATING FINES

Passing through Retained on

(mm) (mm) (cm)

25 20 15.0 4.75mm

20 12.5 15.0 3.35mm

10 6.3 15.0 to 7.5 1.70 mm

6.3 4.75 15.0 to7.5 1.18 mm

4.75 3.35 15.0 to7.5 850 microns

3.35 2.36 15.0 to 7.5 600 microns

PROCEDURE:

1. The cylinder of the test apparatus shall be put in position on the base-plate and the testsample added in thirds, each third being subjected to 25 strokes from the tamping rod . The

surface of the aggregate shall be carefully levelled and the plunger inserted so that it rests

horizontally on the surface, care being taken to ensure that the plunger does not jam in the

cylinder.2. The apparatus, with the test sample and plunger in position, shall then be placedbetween the platens of the testing machine and loaded at a uniform rate as possible so that the

total load is reached in 10 minutes. The total load shall be 40 tonnes.

3. The load shall be released and the whole of the material removed from the cylinder andsieved on a 2.36-mm IS Sieve for the standard test, or the appropriate sieve given in Table I.

The fraction passing the sieve shall be weighed (Weight B).




CRUSHING VALUE

REV. NO : 01 DATE

PAGE : 2 OF 3


15/57

SIGNATURE:

DESIGNATION:


In all of these operations, care shall be taken to avoid loss of the fines, two tests shall be

made.

The ratio of weight of fines formed to the total sample weight in each test shall be expressed

as a percentage, the result being recorded to the first decimal place:

Aggregate Crushing Value = B /A * 100

RESULTS:The Calculation & Reports shall be maintained in the Format: F-01/WI/IT/06.




CRUSHING VALUE

REV. NO : 01 DATE

PAGE : 3 OF 3


16/57

SIGNATURE:

DESIGNATION:


OBJECT:

This method of test covers the procedure for determining the aggregate impact value of coarse

aggregate. (AS per IS: 2386)

APPARATUS:


An impact testing machine of the general form and in compliance as per I.S.2386 (partIV)-1963. I.S Sieves of sizes 12.5mm, 10mm & 2.36mm. A cylindrical metal measure, tarred to he nearest gram , of sufficient rigidity to retain its

form under rough usage, and of the following internal dimensions:

Diameter 75mm

Depth 50mm.

A straight metal tamping rod of circular cross-section 10mm in diameter and 230mm long,rounded at one end.

A balance of capacity not less than 500g, readable and accurate to 0.1gram. A well ventilated oven thermostatically controlled to maintain a temperature of 100-110 oC.

TEST SAMPLE: -

1. The material for the standard test shall consist of aggregate passing a 12.5 mm IS Sieve and

retained on a 10 m IS Sieve, and shall be dried in an oven for a period of 4 hours at a

temperature of 100oC to 110

oC and cooled.

2. The measure shall be filled about one-third full with the aggregate and tamped with 25

strokes of the rounded end of the tamping rod. A further similar quantity of aggregate shall be

added and a further tamping of 25 strokes given. The measure shall be finally being filled till

overflowing, tamped 25 times and the surplus aggregate struck off, using the tamping rod as astraight edge. The net weight of aggregate in the measure shall be determined to the nearest

gram (wt. A) & this wt. of aggregate shall be used for the duplicate test on the same material.

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/07


Inspection & Testing-

IMPACT VALUE

REV. NO : 01 DATE

PAGE : 1 OF 2


17/57

SIGNATURE:

DESIGNATION:


PROCEDURE:

1. The impact machine shall rest without wedging or packing upon the level plate, block orfloor, so that it is rigid and the hammer guide columns are vertical.

2. The cup shall be fixed firmly in position on the base of the machine and the whole of thetest sample placed in it and compacted by a single tamping of 25 strokes of the tamping

rod.

3. The hammer shall be raised until its lower face is 380mm above the upper surface of the

aggregate in the cup, and allowed to fall freely on to the aggregate. The test sample shallbe subjected to a total of 15 such blows each being delivered at an interval of not less than

one second.

4. The crushed aggregate shall then be removed from the cup, and the whole of it is sieved on

the 2.36mm I.S. Sieve until no further significant amount passes in one minute. The

fraction passing the sieve shall be weighed to an accuracy of 0.1g (wt. B). The fraction

retained on the sieve shall also be weighed (wt. C), and if the total weight (wt. B+C) is less

than the initial weight (wt. A) by more than on gram, the result shall be discarded and a

fresh test be made. Two tests shall be made.

The ratio of weight of fines formed to the total sample weight in each test shall be expressed

as a percentage, the result being recorded to the first decimal place:

Aggregate Impact Value = B /A * 100

RESULTS:

The Calculation & Reports shall be maintained in the Format F-01/WI/IT/07

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/07



IMPACT VALUE

REV. NO : 01 DATE

PAGE : 2 OF 2


18/57

SIGNATURE:

DESIGNATION:


OBJECT:

This method of test lays down the procedures for determining the Flakiness Index of coarse

Aggregate. (As per IS: 2386 part-I)

APPARATUS:


A balance of sufficient capacity, sensitivity & accuracy of 0.1 % of the weight of thetest sample.

A Metal gauge of the pattern specified in I.S.2386 (part I)-1963. I.S.Sieves of sizes 50mm, 40mm, 20mm, 16mm, 12.5mm, 10mm & 6.3mm.

TEST SAMPLE:

A quantity of aggregate shall be taken sufficient to provide the minimum number of 200

pieces of any fraction to be tested.

PROCEDURE:

Sieving-The sample shall be sieved in accordance with the method described as perIS: 2386 part-I with the sieves specified in table I.

Separation of Flaky Material- Each fraction shall be gauged in turn for thickness on ametal gauge of the pattern as specified in I.S.2386 (part I)-1963 or in bulk on sieves

having elongated slots. The width of the slot used in the gauge or sieve shall be of the

dimensions specified in col. 3 of table I for the appropriate size of material.

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

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/08



FLAKINESS INDEX

REV. NO : 01 DATE

PAGE : 1 OF 2


19/57

SIGNATURE:

DESIGNATION:


TABLE I DIMENSIONS OF THICKNESS AND LENGTH GAUGES

SIZE OF AGGREGATE THICKNESS GAUGE LENGTH GAUGE


IS Sieve IS Sieve

mm mm mm mm

50 40 27 81

40 25 19.5 58.520 16 10.8 32.4

16 12.5 8.55 25.6

12.5 10 6.75 20.2

10 6.3 4.89 14.7

REPORTING OF RESULTS: The calculations & reports shall be maintained in the format

F-01/WI/IT/08

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/08



FLAKINESS INDEX

REV. NO : 01 DATE

PAGE : 2 OF 2


20/57

SIGNATURE:

DESIGNATION:


OBJECT:

This method of test lays down the procedures for determining the Elongation Index of coarse

Aggregate (As per IS: 2386 part-I)

APPARATUS:


A balance of sufficient capacity, sensitivity & accuracy of 0.1 % of the weight of thetest sample.

A Metal gauge of the pattern specified in I.S.2386 (part I)-1963. I.S.Sieves of sizes 50mm, 40mm, 20mm, 16mm, 12.5mm, 10mm & 6.3mm.

TEST SAMPLE:

A quantity of aggregate shall be taken sufficient to provide the minimum number of 200

pieces of any fraction to be tested.

PROCEDURE:

Sieving-The sample shall be sieved in accordance with the method described as perIS: 2386 part-I with the sieves specified in table I.

Separation of Elongated Material- Each fraction shall be gauged in turn for thicknesson a metal gauge of the pattern as specified in I.S.2386 (part I)-1963. The gauge

length used shall be that specified in col. 4 of table I for the appropriate size of

material.

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

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/09



ELONGATION INDEX

REV. NO : 01 DATE

PAGE : 1 OF 2


21/57

SIGNATURE:

DESIGNATION:


TABLE I DIMENSIONS OF THICKNESS AND LENGTH GAUGES

SIZE OF AGGREGATE THICKNESS GAUGE LENGTH GAUGE


IS Sieve IS Sieve

mm mm mm mm

50 40 27 81

40 25 19.5 58.5

20 16 10.8 32.416 12.5 8.55 25.6

12.5 10 6.75 20.2

10 6.3 4.89 14.7

REPORTING OF RESULTS: The calculations & reports shall be maintained in the format

F-01/WI/IT/09

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/09



ELONGATION INDEX

REV. NO : 01 DATE

PAGE : 1 OF 2


22/57

SIGNATURE:

DESIGNATION:


OBJECT: To determine the workability of Concrete by taking the slump with the help of

the required apparatus. (As per IS: 1199)

APPARATUS:

Slump Cone. Tamping Rod. Scoop. Tray. Wheel Burrow.

PROCEDURE:

Mould shall consist of a metal frustum of cone having the following internal dimensions:

Bottom diameter:.20 cm

Top diameter...10 cm

Height..30 cm

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/10



CONCRETE SLUMP

REV. NO : 01 DATE

PAGE : 1 OF 2


23/57

SIGNATURE:

DESIGNATION:


1. The mould shall be of a metal other than brass and aluminium of at least 1.6 mmthickness. The top and bottom shall be open and at right angles to the axis of the cone.

2. The mould shall have a smooth internal surface and shall be provided with suitable footpieces and hand pieces to facilitate lifting it from the moulded concrete test specimen in

a vertical direction as required by the test.3. Tamping Rod shall be of steel or other suitable material 16 mm in diameter 60 cm long

and rounded at one end.

4. Clean the internal surface of the mould and place it on a smooth, horizontal, rigid andnon-absorbent surface.

5. Hold the mould firmly in place while it is being filled with test specimen of concrete.6. Fill the mould in 4 layers, each approximately one-quarter of height of mould.7. Tamp each layer with 25 strokes of the rounded end of the tamping rod.8. Clean any mortar leaked pout between the mould and base plate.9.

Remove the mould from the concrete immediately after filling by raising it slowly.

10.Allow the molded concrete to subside and immediately measure the slump bydetermining the difference between the height of the mould and that of the highest point

of specimen.

RESULT

Record the slump in terms of millimeters of subsidence of the specimen during the test. Any

slump specimen which collapses or shears off laterally gives incorrect results; hence, test

shall be repeated with another sample.


24/57

SIGNATURE:

DESIGNATION:


TABLE-1/WI/ IT/10

ACCEPTABILITY LIMITS:

Frequency: At the time of commencement of concreting on everyday of concreting

S.No Placing Conditions Degree of

Workability

Slump (mm) Remarks

Blinding concrete;

Shallow Sections;

Pavements using Pavers

Very Low Determination of

Compacting Factor

more appropriate

IS: 1199 Compacting

factor of 0.75

to 0.80suggested

1. Mass concrete;

Lightly reinforced sections in slabs,beams, walls, columns;

Floors;

Hand placed pavements;

Canal lining;

Strip Footing

Low 25-75

2. Heavily Reinforced sections in slabs,

beams, walls, columns

Medium 50-100

Slip form Work;

Pumped Concrete

Medium 75-100

3. Trench Fill;In-situ piling

High 100-150

4. Tremie Concrete Very High Determination of flow IS: 9103 for

determination

of flow

If water cement ratio changes, moisture in aggregate increases or decreases and at the time of

commencement of concrete, slump test shall be done.



Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/10



CONCRETE SLUMP

REV. NO : 01 DATE

PAGE : 2 OF 2


25/57

SIGNATURE:

DESIGNATION:


OBJECT: To determine the Compressive Strength of Concrete by testing the Cube Samples in

Compression Testing Machine. (As per IS: 516)

PROCEDURE:

1. One sample consisting of 6 cubes 15x15x15 cm shall be taken for every 20 cum or partthereof concrete work with aggregate size not more than 40mm.

2. For concrete with aggregate size more than 40 mm size of mould shall be specified bythe Engineer-in-charge.

3. Take samples of concrete for test specimen at the mixer or in the case of ready mixedconcrete from the transportation vehicle discharge.

4. Lightly oil the interior surfaces of the mould before placing concrete.5. Place fresh concrete in the mould in three layers, each approximately one-third of the

volume of the mould.

6. Rod each layer 35 times with 16 mm rod, 60 cm in length, bullet-pointed at the lowerend.

7. In case of vibration, care is to be taken that there is no mortar loss.8. After the top layer has been rodded, the surface of the concrete shall be struck of with a

trowel and covered with a glass plate.

9. If needed, the concrete can also be compacted by vibration.10.Cover the moulds with wet straw or gunny bags to ensure uniform temperature and

moisture conditions during the first 24 hours.

11.Place them in storage box such that the temperature is always between 22C to 33C.12.The tests shall be made generally at the end of 7 days and at the end of 28 days and

immediately after the removal of test specimen from the curing room.

13.Place the test specimen in the machine in such a manner that the load is applied to theside of the specimens as cast.

14.The load shall be applied axially without shock at the rate of approximately 140 kg. sqcm per minute.

15.Record the total load indicated by the testing machine at failure of test specimen.16.Calculate the unit compressive strength in kg per cm sq using the area computed from the

measured dimensions of the test specimen.

17.The type of failure and the appearance of the concrete shall be noted.

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/11



CONCRETE COMP.

STRENGTH (CUBE

TESTING)

REV. NO : 01 DATE

PAGE : 1 OF 5


26/57

SIGNATURE:

DESIGNATION:


TABLE-1/WI/IT/11

GRADES OF CONCRETE WITH COMP. STRENGTH

GROUP GRADE

DESIGNATION

SPECIFIED CHARACTERISTIC

COMP. STRENGTH AT 28 DAYS IN

N/mm2

Ordinary Concrete M 10 10M 15 15

M 20 20

Standard Concrete M 25 25

M 30 30

M 35 35

M 40 40

M 45 45

M 50 50

M 55 55

High Strength Concrete M 60 60

M 65 65

M 70 70

M 75 75

M 80 80

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/11



CONCRETE COMP.

STRENGTH (CUBE

TESTING)

REV. NO : 01 DATE

PAGE : 1 OF 5


27/57

SIGNATURE:

DESIGNATION:


ACCEPTANCE CRITERIA: (As per IS: 456)

The concrete shall be deemed to comply with the strength requirements when both the

following condition is met:

a) The mean strength determined from any group of four consecutive test results compiles with

the appropriate limits in col. 2 of Table 11.

b) Any individual test result complies with the appropriate limits in col. 3 of Table 11.

REPORTING OF RESULT:


Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/11



CONCRETE COMP.

STRENGTH (CUBE

TESTING)

REV. NO : 01 DATE

PAGE : 1 OF 5


28/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-SETTING TIME

TEST (CEMENT)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedures for determining the Initial & Final Setting Time of

cement (As per IS: 4031-1968)

APPARATUS:


1. The Vicat Apparatus conforming to IS: 5513-1969.

PROCEDURE:1. The temperature of water and that of the test room at the time of gauging shall be

within 27 2oC.

2. Take 500 gram of cement sample & gauge it with 0.85 times the water required toproduce cement paste of standard consistency (0.85P)

3. Fill the paste into the Vicat mould in specified manner within 3-5 minutes.4. Start the stopwatch the moment water is added to the cement.

Determination of Initial Setting Time-

1.

Place the test block confined in the mould & resting on the non-porous plate, under therod bearing the needle.

2. Lower the needle gently in contact with the surface of the test block & quickly release,allowing it to penetrate into the test block.

3. In the beginning, the needle will completely pierce the test block. Repeat this procedureuntil the needle, when brought in contact with the test block & released as described

above, fails to pierce the block for 5 0.5mm measured from the bottom of the mould.

4. The period elapsing between the time when water is added to the cement & the time atwhich the needle fails to pierce the test block by 0.5mm shall be the initial setting

time.


29/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-SETTING TIME

TEST (CEMENT)

REV. NO : 01 DATE

PAGE : 1 OF 2

Determination of Final Setting Time-

1. Replace the needle of the Vicat apparatus by a circular attachment.2. The cement shall be considered as finally set when, upon, lowering the attachment

gently cover the surface of the test block, the center needle makes an impression, while

the circular cutting edge of the attachment fails to do so.

3. The period elapsing between the time when water is added to the cement and the timeat which the needle makes an impression on the surface of test block while the

attachment fails to do so shall be the Final setting time

RESULTS:

The requirements of the setting time shall be as per Table I.

The reports and results for the test should be maintained in the Format F-01/WI/IT/12


30/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-COMPRESSIVE

STRENGTH TEST (CEMENT)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedures for determining the Strength of cement as

represented by compressive strength tests on mortar cubes compacted by means of a standard

vibration machine. (As per IS: 4031-1968)

APPARATUS:


1. Enamel tray.2. Trowel.

PROCEDURE:

1. The standard sand to be used in the test shall conform to I.S.650-1991.

2. Take 555 grams of standard sand, 185 grams of cement (i.e. ratio of cement to sand is1:3) in a non-porous enamel tray & mix them with a trowel for 1minute.

3. Add water of quantity (P/4) + 3 % of combined weight of cement & sand and mix thethree ingredients thoroughly until the mixture is of uniform colour. The time of mixing

should not be less than 3minutes nor more than 4minutes.

4.

Immediately after mixing, the mortar is filled into a cube mould of size 7.06cm.5. The area of the face of the cube will be equal to 50sq.cm.6. Compact the mortar either by hand compaction in a standard specified manner or on the

vibrating equipment (12000RPM) for 2minutes.

7. Keep the compacted cube in the mould at a temperature of 27 oC 2 oC & at least 90%relative humidity for 24hours.

8. Where the facility of standard temperature & humidity room is not available, the cubemay be kept under wet gunny bag to stimulate 90% relative humidity.

9. After 24hours, remove the cubes from the mould & immerse in clean fresh water untiltaken out for testing.

10.Three cubes are tested for compressive strength at the interval of 3, 7 & 28 days.The compressive strength shall be the average of the strengths of the 3 cubes for each period

respectively.

The strength required for the various types of cement is shown in Table I.


31/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-COMPRESSIVE

STRENGTH TEST (CEMENT)

REV. NO : 01 DATE

PAGE : 1 OF 2

RESULTS:

The requirements for the compressive strength of various types of cement should be as per

Table I.

The calculations and results should be maintained as per Format F-01/WI/IT/13


32/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-FINENESS TEST BY

DRY SIEVING (CEMENT)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedures for determining the Fineness of cement by dry

sieving as represented by the weight of the residue left on a standard 90-micron I.S. Sieve

conforming to IS: 460-1962.(As per IS: 4031-1968)

APPARATUS:


1. I.S. Sieve no.92.

Sieve Shaker

PROCEDURE:

1. Break down any air-set lumps in the cement sample if any with fingers.2. Place 100gram of the cement accurately weighed on a standard I.S. Sieve no. 9/ 90

microns. (Wt. A)

3. Continuously sieve the sample giving circular and vertical motion for a period of 15minutes. Mechanical sieving devices may also be used.

4. Weigh the residue left on the sieve (Wt. B).5. This weight shall not exceed 10% for ordinary cement.

Percentage of fineness of sample shall be calculated as follows & the average of 3 tests shall bereported.

% Of fineness (C) = B X 100

A

RESULTS:

The requirements of fineness should be as per Table I.

The reports and results for fineness test should be maintained in the Format F-01/WI/IT/14


33/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-FINENESS TEST BY

DRY SIEVING (CEMENT)

REV. NO : 01 DATE

PAGE : 1 OF 2

TABLE.I

PHYSICAL CHARACTERISTICS OF VARIOUS TYPES OF O.P.CEMENT

GRADE OF

CEMENT

SETTING TIME FINENESS COMPRESSIVE STRENGTH

Initial

(minutes)

Min.

Final

(minutes)

Max.

Max. 3 days

Mpa

7 days

MPa

28 days

MPa

33 OPC

(I.S.269-1989)

30 600 10% 16 22 33

43 OPC

(I.S.8112-1989)

30 600 10% 23 33 43

53 OPC

(I.S.12269-1987)

30 600 10% 27 37 53


34/57

SIGNATURE:

DESIGNATION:


PROCEDURE: (As per IS: 3025)

1. Water used for mixing and curing shall be free from injurious quantities of alkalis, acids,oils, sugar, organic materials, vegetable growth or other substances that may be

deleterious.

2. Ph Value of water shall generally not be less than 6.3. Limits of Acidity: To neutralize 100 ml sample of water, using phenolphthalein as an

indicator, it should not require more than 5 ml of 0.02 normal NaOH.

4. Limits of Alkalinity: To neutralize, 100 ml sample of water, using mixed indicator as anindicator, it should not require more than 25 ml of 0.02 normal H2SO4.

5. Percentage of Solids: Maximum permissible limits of solid:Tested as Per Permissible Limit, Max

Organic IS 3025 (Part 18) 200mg/litre

Inorganic IS 3025 (Part 18) 3000 mg/litre

Sulphates (as SO3) IS 3025 (Part 24) 400 mg/litre

Chlorides (as Cl) IS 3025 (Part 32) 500 mg/litre for RCC and

2000mg/litre

for other worksSuspended Matter IS 3025 (Part 17) 2000mg/litre

6. Water from each source shall be tested before the commencement of work and thereafteronce every three months.

RESULTS:

The reports and results for the test should be maintained in the Format

F-01/WI/IT/15

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/15



CHEMICAL & PHY.

PROP. OF WATER

REV. NO : 01 DATE

PAGE : 1 OF 1


35/57

SIGNATURE:

DESIGNATION:


OBJECT:

This method of test covers the procedures for determining the Relative Density & PH Value of

admixture. (As per IS: 9103-1999)

APPARATUS:

The apparatus required for the tests is as follows:

Relative Density:1. Constant temperature bath.2. Hydrometer.3. Measuring Cylinder.

PH Value:

1. PH meter.PROCEDURE:

RELATIVE DENSITY-

1. Take a 500 ml graduated cylinder and place 400 ml of admixture in it avoiding theformation of air bubbles in the liquid.2. Maintain the temperature of the liquid at 20 5 oC.3. Insert the hydrometer into the cylinder ensuring that it floats free and does not touch the

side of the cylinder.

4. Release the hydrometer when approximately it has attained equilibrium position.5. When in equilibrium read the scale at the bottom of the meniscus for transparent liquids

or where the meniscus merges with the stem of the hydrometer for opaque liquids to

report the Relative Density.

PH VALUE:The Hydrogen ion concentration of the liquid superplasticiser shall be determined with the help

of a suitable PH meter.

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/16



RELATIVE DENSITY &

PH VALUE of Concrete

Admixture

REV. NO : 01 DATE

PAGE : 1 OF 2


36/57

SIGNATURE:

DESIGNATION:


RESULTS:

The reports and results for relative density test should be maintained in the Format

F-01/WI/IT/16 & for PH test should be maintained in the Format F-01/WI/IT/16

Ahluwalia Contracts

(India) Ltd.

DOCUMENT NOWI/16



WATER RELATIVE

DENSITY & PH VALUE

(Admixture)

REV. NO : 01 DATE

PAGE : 1 OF 2


37/57

SIGNATURE:

DESIGNATION:




Inspection & Testing-TEST FOR

DIMENSIONAL TOLERANCE (Bricks)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedure for determining whether the bricks used for

construction are of specified dimensional tolerance. (As per IS: 1077)

APARATUS:


A measuring steel tape.

PROCEDURE:

1. Select 20 or more bricks at random from the stack.

2. Remove all the blisters, loose particles of clay and small projections from the surface of

bricks.

3. Arrange a specimen of 20 bricks upon a level surface successively in contact with each

other and in straight line as per 2A, 2B & 2C below for measurement of Length, width &

height respectively.

4. The overall length of the assembled bricks shall be measured with a steel tape sufficientlylong to measure the whole row at one stretch.


38/57

SIGNATURE:

DESIGNATION:





DIMENSIONAL TOLERANCE (Bricks)

REV. NO : 01 DATE

PAGE : 2 OF 2

ACCEPTABILITY:

The actual dimensions of bricks when tested should be within the following limits per 20

bricks:

Modular Bricks:

Length 3800 80 mm Width 1800 40 mm Height 1800 40 mm (For 90 mm high bricks) 800 40 mm (For 40 mm high bricks)

Nonmodular Bricks:

Length 4600 80 mm Width 2200 40 mm Height 1400 40 mm (For 70 mm high bricks) 600 40 mm (For 30 mm high bricks)

RESULTS:



39/57

SIGNATURE:

DESIGNATION:





COMPRESSIVE STRENGTH (Bricks)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test covers the procedures for determining the Compressive strength of bricks.

(As per IS: 1077-1992/3495)

APPARATUS:

The apparatus required for the test is as follows;

A trowel. 3 plywood sheets of thickness 3mm. A Compression Testing machine.

PROCEDURE:

1. Five whole bricks shall be taken from the samples as specimen. Length andwidth of each specimen shall be measured correct to 1 mm.

2. The specimen shall be immersed in water for 24 hours at 25 to 29 C. Anysurplus moisture shall be allowed to drain at room temperature.

3. Fill the frog of the bricks with mortar 1:3 and keep them under damp jute bagsfor 24 hours.

4.

Then immerse them in water for 3 days.5. After removal from water, place the specimen with flat faces horizontal and

mortar filled face upward between 3 plywood sheets each of thickness 3 mm.

6. Apply the load carefully axially at uniform rate of 14 N/mm2 per minute till thefailure of the specimen occurs.

7. The compressive strength of each specimen shall be calculated as:Compressive Strength = Maximum load at failure (in N)

Area of Specimen (in sq mm)

8. Compressive strength of all the individual bricks comprising the sample shall beaveraged and reported.


40/57

SIGNATURE:

DESIGNATION:





COMPRESSIVE STRENGTH (Bricks)

REV. NO : 01 DATE

PAGE : 2 OF 2

ACCEPTABILITY:

A lot shall be considered having satisfied the requirements of average compressive

strength if it is not below the minimum average compressive strength specified for the

corresponding class of bricks by more than 20%.

Average Compressive Strength is given in Table-1/WI/IT/18

Table-1/WI/IT/

Class

Designation

Average Compressive Strength

Not Less than Less than

N/mm2

Kgf/cm2

N/mm2

Kgf/cm2

10 (100) 10 100 12.5 1225

7.5 (75) 7.5 75 10 100

5.0 (50) 5.0 50 7.5 75

3.5 (35) 3.5 35 5.0 50




41/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- TEST FOR WATER

ABSORPTION (Bricks)

REV. NO : 01 DATE

PAGE : 1 OF 1

OBJECT:

This method of test covers the procedures for determining the Water Absorption of bricks.

(As per IS: 1077-1992)

APPARATUS:

The apparatus required for the test is as follows;

A Balance sensitive to weigh 0.1 % of the weight of the specimen.PROCEDURE:

1. Five whole bricks shall be taken from the sample as specimen.2. Allow the specimen to dry in a ventilated oven at 110 oC to115oC till it attains a

substantial constant weight.

3. It shall be then allowed to cool at room temperature and then weighed (wt.1)4. Specimen should be completely dried before immersion in water.5. Keep it in clean water at a temperature of 27oC +/- 2oC for 24 hours.6. Wipe out the specimen after taking out from water and then weigh it within 3 mins. of

removal from water.(wt.2)

7. The water absorption of each specimen shall be calculated as follows and the average of5 tests shall be reported.

Water Absorption = W2W1 x 100

W1

ACCEPTIBILITY:

A lot is considered to have satisfied the requirements of water absorption if the average water

absorption is not more than 20% by weight.

RESULTS:



42/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- COMPACTIONTEST OF SOIL (PROCTOR TEST)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This test deals with the procedure to determine the compaction characteristics of a soil

specimen by Proctor test. (As per IS: 2720)

APPARATUS:


1. Compaction mould, capacity 1000ml.2. Rammer, mass 2.6 kg.3. Detachable base plate.4. Collar, 60mm high.5. IS Sieve 4.75mm.6. Oven.7. Desiccator.8. Weighing balance, accuracy 1gram.9. Large mixing pan.10.Straight edge.11.Spatula.12.Graduated jar.13.Mixing tools, spoons, trowels, etc.

PROCEDURE:

1. Take about 20 kg of air-dried soil. Sieve it through 20 mm & 4.75mm I S Sieves.2. Calculate the percentage retained on 20mm sieve, and 4.75mm sieve, and the

percentage passing 4.75mm sieve. Do not use the soil retained on 20mm sieve.

Determine the ratio of fraction retained & that passing 4.75mm sieve.

3. If percentage retained on 4.75 mm sieve is greater than 20, use the larger mould of150mm diameter. If it is less than 20%, the steel mould of 100mm diameter can be

used.

4. Mix the soil retained on 4.75mm sieve & that passing 4.75 sieve in the proportionsdetermined in step (2) to obtain about 16-18 kg of soil specimen.

5. Clean & dry the mould & the base plate. Grease them lightly.6. Weigh the mould with the base plate to the nearest 1-gram.7. Take about 16-18 kg of soil specimen. Add water to it to bring the water content to

about 4 % if the soil is sandy and to about 8 % if the soil is clayey.

8. Keep the soil in air tight container for about 18-20hours for maturing .Mix the maturedsoil thoroughly. Divide the processed soil into 6-8 parts.

9. Attach the collar to the mould. Place the mould on a solid box.


43/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- COMPACTIONTEST OF SOIL (PROCTOR TEST)

REV. NO : 01 DATE

PAGE : 1 OF 2

10.Take about 2 1/2kg of the processed soil, and place it in the mould in 3 equal layers.Take about 1/3

rdthe quantity first, & compact it by giving 25 blows of the rammer. The

blows should be uniformly distributed over the surface of each layer. The top surface of

the 1st

layer should be scratched with a spatula before placing the second layer. The

second layer should also be compacted by 25 blows of rammer. The amount of the soil

used should be just sufficient to fill the mould & leaving about 5mm above the top of

the mould to be struck off when the collar is removed.

11.Remove the collar, and trim off the excess soil projecting above the mould using astraight edge.

12.Clean the base plate & the mould from outside. Weigh it to the nearest gram.13.Remove the soil from the mould.14.Take the soil sample for the water content determination from the top, middle & bottom

portions.

15.Add about 3% of the water to a fresh portion of the processed soil, & repeat thesteps(10-14)

RESULTS: Calculations & reports shall be maintained as per Format F-01/WI/IT/20


44/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- DRY DENSITY

TEST OF SOIL (Core Cutter

method)

REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This test deals with the field method of determination of dry density of soil. (As per IS: 2720)

APPARATUS:


1. A cylindrical cutter, 100mm internal dia & 130mm long.2.

Steel rammer, mass 9 kg overall length, with the foot and staff about 900mm.3. Steel dolley, 25mm high & 100mm internal dia.

4. Weighing balance, accuracy 1gram.5. Palette knife.6. Straight edge, steel rule.

PROCEDURE:

1. Determine the internal diameter & height of the core cutter to the nearest 0.25 mm.2. Determine the weight (W1) of the cutter to the nearest gram.3. Expose a small area of the soil mass to be tested. Level the surface, @300mm square in

area.

4. Place the dolley over the top of the core- cutter and press the core-cutter into the soilmass using the rammer. Stop the process of pressing when @ 15mm of the dolleyprotrudes above the soil surface.

5. Remove the soil surrounding the core-cutter and take out the core-cutter. Some soilwould project from the lower end of the cutter.

6. Remove the dolley. Trim the top and bottom surface of the core-cutter filled with thesoil to the nearest gram (W2)

7. Remove the core of the soil from the cutter. Take a representative sample for the watercontent determination.

RESULTS:

The Dry density is obtained as:

d = / (1 + w % ) = W3/V(1 + w %)

The calculations & reports can be maintained as per Format F-01/WI/IT/21


45/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- REINFORCEMENT REV. NO : 01 DATE

PAGE : 1 OF 2

OBJECT:

This method of test lays down the procedures for calculating Nominal Mass of steel for

reinforcement. (As per IS: 1786-1985)

PROCEDURE:

The nominal mass per meter of individual sample, batch and coils shall be determined as

given below:

1.

The tolerance on mass/weight for round and square bars shall be the percentage given inTable-01/WI/IT/22 of the mass/weight calculated on the basis that the masses of the

bar/wire of nominal diameter and of density 0.785 kg/cm3.

2. Physical properties of all sizes of steel bars shall be as mentioned in Table-02/WI/IT/223. Select all the test pieces wither by cutting the bars. The test pieces shall be of length not

less than 1 meter and of full sections of the bars as rolled and subsequently cold worked

and subjected to physical test without any further modifications.

4. The nominal mass of an individual sample be calculated by determining the mass of anyindividual sample at random as specified in Table-03/WI/IT/22 anddividing the same by

the actual length of the sample.5. The nominal mass of a batch shall be calculated by determining the mass of the test

specimens taken as specified in Table-03/WI/IT/22 anddividing the same by the actual

length of the specimens. Each specimen shall be of length not less than 0.5metre.

6. The nominal mass of a coil shall be calculated by determining the mass of two samplesof minimum1metre length taken from each end of coil and dividing the same by the

actual length of the samples

7. No test piece shall be enacted or subjected to heat treatment8. Store steel for reinforcement in such a way to prevent any distortion and corrosion.


46/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- REINFORCEMENTREV. NO : 01 DATE

PAGE : 1 OF 2

Table1/WI/IT/22

TOLERANCE ON NOMINAL MASS

S.No. Nominal Size in mm Tolerance on the Nominal Mass Percent

Batch Individual

Sample

Individual Sample

of Coil (-x-)

1 Up to and including 10 7 - 8 8

2 Over 10, up to and

including 16

5 - 6 + 6

3 Over 16 3 - 4 4

Table2/WI/IT/22

PHYSICAL PROPERTIES OF STEEL BARS

S.No. Property Grade

Fe 415 Fe 500 Fe 550

1. 0.2% proof stress/yield stress,

min. N/mm2

415 500 550

2. Elongation, percent min. on

gauge length 5.65A, where Ais the X-sectional Area

14.5 12 8

3. Tensile Strength 10% more than

actual proof stress

but not less than

465 N/mm2

8% more than

actual proof

stress but not

less than 545

N/mm2

6% more than

actual proof

stress but not

less than 585

N/mm2

Table3/WI/IT/22

FREQUENCY FOR NOMINAL MASS, TENSILE,BEND AND REBEND TESTSNOMINAL SIZE QUANTITY

For casts /heats below 100tonnes For casts /heats over 100tonnes

Under 10 mm 1 sample from each 25 tonnes or part

thereof

1 sample from each 40 tonnes or part

thereof

10 mm to 16 mm

inclusive


thereof


thereof

Over 16 mm 1 sample from each 45 tonnes or part

thereof


thereof


47/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- REINFORCEMENT REV. NO : 01 DATE

PAGE : 1 OF 2

RESULTS:



48/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- MARBLES REV. NO : 01 DATE

PAGE : 1 OF 2

PROCEDURE: (As per IS: 1122, IS: 1124)

1. The size of marble blocks, slabs and tiles shall be as mentioned in Table IT/23-01.2. Tolerance that shall be allowed in the dimensions of blocks, slabs and tiles is given in

Table IT/23-02.

3. The physical properties of marble for blocks, slabs and tiles and method of tests arementioned in Table IT/23-03.

4. In any consignment of blocks/slabs/tiles of the same group, size and finish shall begrouped together to constitute a lot.

5. Samples shall be selected and tested separately for each lot and for determining itsconformity or otherwise to the requirements of the specification. Sample size and

criteria shall be in accordance with Table IT/24-04.

Table-01/WI/IT/23

S.No. Length (mm) Width (mm) Thickness (mm)

1. Blocks 300 to 2500 300 to 1000 300 to 900

2. Slabs 700 to 2500 300 to 1000 20 to 150

3. Tiles 100 to 600 100 to 600 8 to 24

Table-02/WI/IT/23Tolerance

Blocks

(a) Length + 2 %

(b) Width + 2 %

(c) Thickness + 2 %

Slabs

(a) Length + 2 %

(b) Width + 2 %

(c) Thickness + 3 %

Tiles

(a) Linear dimension + 3 %

(c) Thickness

+ 1 %


49/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- MARBLES REV. NO : 01 DATE

Table IT/23-03

S.No. Characteristic Requirements Method of Test

1. Moisture absorption

after 24 hours

immersion in cold water

Max. 0.4% by weight IS: 1124

2. Hardness Minimum 3 Mhos Scale

3. Specific Gravity Minimum 2.5 IS: 1122

Table IT/23-04

Number of blocks/

slabs /tiles in the lot

Number of blocks/

slabs /tiles to be

selected in sample

Permissible

number of

defectives

Method of

Test

Up to 25 3 0 2

26 to 100 5 0 2

101 to 200 8 0 3201 to 500 13 0 4

501 to 1000 20 1 5

RESULTS:



50/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- TIMBER REV. NO : 01 DATE

PAGE : 1 OF 2

PROCEDURE: (As per IS:1141, IS: 401)

METHOD 1

1) Moisture content of timber shall be checked for every 1 cum or part thereof byelectrical moisture meters as per IS: 287.

2) Electrical moisture meters are of resistance type and shall be used when the moisturecontent is within the range of 8 to 25 %.

3) When checking moisture content with electrical moisture meter it shall be ensured that:a) Timber is hot or the surface wet and the moisture gradient is not large due to

wet cores.

b) Electrode probes are of adequate depth (not less than 1/5th the thickness of thetimber).

4) Sufficient number of readings at different positions is taken on each piece of timber toeliminate localized variations in surface moisture and species corrections are applied

for the make of electrical resistance, type moisture meter.

METHOD 21. For checking the moisture content by oven drying method, a complete test cross section,

12 to 19 mm long in the direction of timber grain, free from all defects shall be cut from

each piece of timber selected for test as follows:

a) If weighing can be done immediately, the test section can be cut from a point atleast 450 mm from one end of the piece or from its center.

b) In case cutting is not allowed then a boring shall be collected by augur upto halfof the thickness of the piece.

2. The test sections obtained shall be immediately weighed on a balance with sensitivity notless than 10 mg.

3. They shall be dried in a ventilated, and preferably thermostatically controlled, oven at atemperature of 100C to 105C until the weight is constant.

4. The weight of the test section will deemed to have become constant if successiveweighing at intervals of 2 to 4 hours do not differ from one another by more than 50 mg.

5. The percentage moisture content in the test section shall be calculated as:Moisture Content (%) = W1W0 x 100

W0


51/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- TIMBER REV. NO : 01 DATE

PAGE : 1 OF 2

Where: W1 = initial weight of test section

W0 = Oven dry weight of test section

TOLERANCE ON MOISTURE CONTENT

Average Moisture content of all the samples shall be within + 3% and moisture content of

individual samples within + 5% of maximum permissible moisture content.

RESULTS:The Calculation & Reports shall be maintained in the Format F-01/WI/IT/24


52/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- FLUSH SHUTTERS REV. NO : 01 DATE

PAGE : 1 OF 2

PROCEDURE: (As per IS: 2202)

Shutters of decorative or non-decorative type shall be grouped separately and each group

shall constitute a lot. Sampling shall be as per Table-1/WI/IT/25

Table-1/WI/IT/25

LOT SIZE SAMPLE SIZE

Up to 50 1

50-150 2

151-300 3

301-500 4

501 and above 5

I. END IMMERSION TEST

1. Door shutters shall be tested for resistance of their base to immersion in water as follows:

a) The door shutter shall be immersed vertically to a height of 300 mm in water atroom temperature for 24 hours and then allowed to dry for 24 hours at 27 2C

and relative humidity of 65 5%.

b) The cycle shall be repeated eight times.c) There shall be no delamination at the end of the test.

II. KNIFE TEST

1. The type of knife required to be used may be made from a 250 x 25 mm file. The cuttingedge shall be kept chisel sharp.

2. The knife is inserted with its cutting edge parallel to the grain of the outer veneer andworked into, or if possible along glue line and the veneers are prised upwards. In soft

timber the knife tends to follow an easy course through the wood and in this case it is

essential that the knife be firmly guided along the glue line.

3. The bond should just pass the requirement, which is judged, by the relative amount ofwood fibre left on the core veneer, and the area prised off. The grading is assessed

chiefly on the appearance of the break.


53/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- FLUSH SHUTTERS REV. NO : 01 DATE

PAGE : 1 OF 2

4. The bond is excellent when it is difficult to find the glue line and impossible to keep thetool within it for more than 6 mm without cutting adjacent wood.

5. The bond is poor when knife meets little opposition in the glue line and the prise resultsin the easy removal of almost all the veneers.

III. GLUE ADHESION TEST

1. Four square sections, 150 x 150 mm shall be cut from the corners of the door andimmersed in boiling water for four hours and then dried at 27 2C and relative

humidity of 65 5% for 24 hours.

2. At the end of the drying period, the samples shall be examined for delamination.3. A specimen shall be considered to have passed the test if no delamination has occurred

in the glue lines in the plywood and if no single delamination more than 50 mm in length

and 3 mm in depth has occurred in the assembly glue lines between the plywood faces

and the stile and rail.

4. Delamination at the corner shall be measured continuously around the corner. A doorshall be deemed to have passed this test if three of the four specimens pass the test.

RESULTS:



54/57

SIGNATURE:

DESIGNATION:




Inspection & Testing- PRECAST CEMENTCONCRETE/TERRAZZO TILES

REV. NO : 01 DATE

PAGE : 1 OF 2

PROCEDURE: (As per IS: 1443, IS: 1237)

Sampling of tiles for each mandatory tests shall be as follows:

a. For conformity to requirements on shape and dimensions, wearing layer, andgeneral quality12 tiles

b. For wet transverse strength test6 tilesc. For resistance to wear tests6 tilesd. For water absorption test6 tiles

I. WET TRANSVERSE STRENGTH TEST

1. Six full size tiles shall be test for the determination of wet transverse strength.2. When tested according the procedure laid down in IS:1237, the average wet transverse

strength shall not be less than 3 N/mm2

II. RESISTANCE TO WEAR TEST

1. The 12 test specimens shall be square in shape and of size 7.06 cm x 7.06 cm. Theabrasion test of specimens shall be carried out in a machine conforming to IS: 1237. A

suitable instrument capable of measurement to accuracy of 0.01 mm shall be used for

determining the change in the thickness of the specimen after abrasion.

2. The specimen shall be dried at 110C for 24 hours and then weighed to the nearest 0.1gm. The specimen after initial drying and weighing shall be placed in the thickness

measuring apparatus with its wearing surface uppermost and the reading of the

measuring instrument taken.

3. The grinding path of the disc abrasion machine shall be evenly strewn with 20 gm. ofabrasive powder. The specimen shall then be fixed in the holding device with the

surface to be ground facing the disc and loaded at the center with 30 kg.

4. The grinding disc shall then be put in motion at a speed of 30 rpm. After every 22revolutions, the disc shall be stopped, the powder removed and fresh abrasive powder

in quantities of 20m gm applied each time.

5. After 110 revolutions, the specimen shall be turned about the vertical axis through anangle of 90 and test continued until 220 revolutions have been completed.

6. After abrasion is over, the specimen shall be reweighed to the nearest 0.1 gm. It shallthen be placed in the thickness measuring apparatus once again in the identical manner

and the reading taken with the same position and setting of the dial gauge.

7. The wear shall be determined from the difference in readings obtained by themeasuring instrument before and after the abrasion of the specimen.


55/57

SIGNATURE:

DESIGNATION:





REV. NO : 01 DATE

PAGE : 1 OF 2

t = 10 x (W1W2) V1W1 x A

Where t = Average loss in thickness in mm

W1 = Initial weight, in gm. of the specimen

W2 = Final weight, in gm of the abraded specimenV1 = Initial volume, in CC, of the specimen, and

A = Surface area, in sq.cm. of the specimen

Acceptable Tolerance

When tested their average wear shall not exceed 3.5 mm and the wear on any individual

specimen shall not exceed 4 mm

III. WATER ABSORPTION

1. Full six size tiles shall be used for this test. They shall be immersed in water for 24hours, then taken out, wiped dry and tested for waster absorption.

2. Each tile shall be weighed immediately after saturation and wiping. The tile shall beoven dried at a temperature of 65 1C for a period of 24 hours, cooled to room

temperature and reweighed.

3. The water absorption per cent by weight for each tile shall be determined as follows:On oven dry basis water absorption per cent by weight = (W1W2) x 100

W2

Where W1 = weight in grams of the saturated specimen; and

W2 = Weight in gram of the oven dried specimen

RESULTS:



56/57

SIGNATURE:

DESIGNATION:





REV. NO : 01 DATE

PAGE : 1 OF 2

BIBLIOGRAPHY

1. CPWD Specifications 1996Revised 20002. Compilation of Quality Assurance Circulars of CPWD, 20013. IS 2386 (Part-1): 1963; Methods of Test for Aggregate for Concrete Part 1: Particle Size

and Shape

4. IS 2386 (Part-2): 1963; Methods of Test for Aggregate for Concrete Part 2: Estimation ofdeleterious materials and organic impurities

5. IS 2386 (Part-3): 1963; Methods of Test for Aggregate for Concrete Part 3: Specificgravity, density, voids, absorption and bulking

6. IS 516: 1959; Method of Test for Strength of Concrete7. IS 1599: 1985; Method for Bend Test8. IS 1608: 1972; Method for tensile testing of steel products9. IS 1786: 1985; High strength deformed steel bars and wires for concrete reinforcement10.IS 3495: 1992; Method of Test for Clay Building Bricks11.IS 456: 2000; Plain and Reinforced ConcreteCode of Practice


57/57

laboratory work procedure

Documents