material testing

1 | P a g e T i r t h P a t e l U C 1 6 0 9 S c h o o l o f B u i l d i n g S c i e n c e a n d T e c h n o l o g y

About GERI

Ever since the dawn of civilization, construction activities have

thrived. The early constructional works comprehensively used

naturally available stone being strong as well as durable.

Subsequently use of more compact and easy to handle materials like

bricks came into being. The research activities in the field brought

forth cement and steel and a combination of the two as reinforced

cement concrete. The Gujarat Engineering Research Institute (GERI)

made a humble beginning as a sub-division in 1950, and developed

into a research division by 1957. Keeping pace with the development

activities and on formation of Gujarat State in 1960, it attained a

status of a state research institute. It progressively increased its

activities and has now 17 divisions.

GERI is one of the leading state research institutes in the country. It

had the distinction of being adjudged as one of the best research

stations in the country, by Central Board of Irrigation and Power

(CBIP) in the year 1989. The institute aims at providing research and

development inputs to the activities of Gujarat State in the fields of

Water Resources and Roads and Buildings. The activities of the

institute are centred on investigation and testing, research and

development, constancy and training in various areas listed earlier.

The institute extends its activities to both Government and

Public/Private sector bodies.

GERI is working under the Narmada Water Resources & Water

Supply Department of Government of Gujarat. The institute is

headed by 'Chief Engineer & Director' an officer of the rank of the

State Chief Engineer. Two joint Directors of the rank of state

Superintending Engineer and one Superintending Engineer assist the

Chief Engineer & Director. The research work in various


divisions/units is organized by Research Officers of the rank of

Executive Engineers with the supporting engineering & scientific

staff.

Being a Government premier research and testing institute, it was

the demand of the situation to streamline the processes to achieve

quality assured testing, better Customer Relationship Management

(CRM) and to enhance market share by competing with

mushrooming private laboratories. GERI's management was

determined to acquire ISO certification to combat this challenge.

GERI's intention was not only to get recognized as an ISO certified

organization but to have a quality consciousness arising from ground

level upwards and quality commitment from the bottom to top and

enter in to a state of self-sufficiency two marches towards true

Autonomous Institute

SWOT Analysis carried out for identifying strength, weakness,

opportunities and threats.

All the testing Laboratories of GERI up to District level have ISO

9001:2008 accreditation for Testing Engineering Construction

Materials with validity up to 15-5-2011


Materials:

Burnt Clay Building Bricks

Hydraulic Cement

Concrete

Steel


Materials: BURNT CLAY BUILDING BRICKS

IS Code: IS 3495 (Part 1 to 4): 1992

Part 1: Determination of compressive strength

Part 2: Determination of water absorption

Part 3: Determination of Efflorescence

Part 4: Determination of Warpage


Test 1:

Determination Dimension and Tolerance

IS:

IS 1077 - 1992

Apparatus:

25 random bricks from 20,000

Steel Tape

Procedure:

Align all the bricks in a row as per its dimensions.

Measure the total length, breadth and width

And then divide by total bricks of the sample.

Acceptance:

For 19 x 9 x 9 cm

Length: 4520 4680 mm

Breadth: 2160 to 2240 mm

Height: 1360 to 1440 mm

Purpose:

Uniform bricks need minimum thickness of joints and hence less mortar bonds

improve.


Test 2:

Determination of compressive strength

IS:

3495 (Part 1): 1992

Apparatus:

Compression Testing Machine

Water tank

Preparation of Test Sample:

Remove unevenness observed in the bed faces to provide two smooth and parallel

faces by grinding.

Immerse in water at room temperature for 21 hours. Remove the specimen and

drain out any surplus moisture at room temperature. Fill the frog ( where provided )

and all voids in the bed face flush with cement mortar ( 1 cement, clean coarse sand

of grade 3 mm and down ).

Store under the damp jute bags for 24 hours followed by immersion in clean water

for 3 days.

Remove, and wipe out any traces of moisture.

Procedure:

Place the specimen with flat faces horizontal, and mortar filled face facing upwards

between two 3-ply plywood sheets each of 3 mm thickness and carefully centred

between plates of the testing machine.

Apply load axially at a uniform rate of 14 N/mm2 (140 kgf/cm2) per minute till failure

occurs and note the maximum load at failure.

The load at failure shall be the maximum load at which the specimen fails to produce

any further increase in the indicator reading on the testing machine.

NOTE - In place of plywood sheets plaster of Paris may be used to ensure a uniform

surface for application of load.


Calculations:

The report shall be as given below:

Compressive strength in N/mm2

(Kgf/cm2) = Maximum load at failure in N (kgf)

Average area of the bed faces in mm2 (cm2)

Acceptance:

The Compressive strength shall not be less than 3.5 N/mm2.

Purpose:

Strong and durable masonry is ensured.

More loads can be laid on the wall.

High strength bricks are ideal for hollow brick masonry.


Test 3:

Determination Water Absorption

IS:

3495 (Part 2): 1992

Apparatus:

Balance 1000 1 g.

Water Tank

Oven

Preparation of Test Sample:

Dry the specimen in a ventilated oven at a temperature of 105 to 115C till it attains

substantially constant mass.

Cool the specimen to room temperature and obtain its weight (M1). Specimen warm

to touch shall not be used for the purpose.

Procedure:

Immerse completely dried specimen in clean water at a temperature of 27 2C for

24 hours.

Remove the specimen and wipe out any traces of water with a damp cloth and weigh

the specimen.

Complete the weighing 3 minutes after the specimen has been removed from water

(M2).

Calculation:

Water absorption, percent by mass, after 24-hour immersion in cold water is given

by the following formula:

(M2 M1) x 100

M1

Acceptance:

Not more than 20 % or as relevant specifications

Purpose:

More absorption means inadequate burning and less durability

Excess leads to dampness, leaching of salts.


Test 4:

Determination of Efflorescence

IS:

3495 (Part 3): 1992

Apparatus:

A shallow flat bottom dish containing sufficient distilled water to completely saturate

the specimens. The dish shall be made of glass, porcelain or glazed stoneware and of

size180 mm x 180 mm x 40 mm depth for square shaped and 200 mm diameter x 40

mm depth for cylindrical shaped.

Procedure:

Place the end of the bricks in the dish, the depth of immersion in water being 25

mm. Place the whole arrangement in a warm ( for example, 20 to 30C ) well

ventilated room until all the water in the dish is absorbed by the specimens. And the

surplus water evaporates.

Cover the dish containing the brick with suitable glass cylinder so that excessive

evaporation from the dish may not occur.

When the water has been absorbed and bricks appear to be dry, place a similar

quantity of water in the dish and allow it to evaporate as before.

Examine the bricks for efflorescence after the second evaporation and report the

results.

Reports:

The liability to efflorescence shall be reported as nil, slight, moderate, heavy or

serious in accordance with the following definitions:

Nil - When there is no perceptible deposit of efflorescence.

Slight - When not more than 10 percent of the exposed area of the brick is

covered with a thin deposit of salts.

Moderate - When there is a heavier deposit than under slight and covering up

to 50 percent of the exposed area of the brick surface but unaccompanied by

powdering or flaking of the surface.

Heavy - When there is a heavy deposit of salts covering 50 percent or more of

the exposed area of the brick surface but unaccompanied by powdering or

flaking of the surface.

Serious - When there is a heavy deposit of salts accompanied by powdering

and/or flaking of the exposed surfaces.


Purpose:

Excess efflorescence causes disintegration and defacement.


Materials: HYDRAULLIC CEMENT

IS Code: IS 4031 (Part 1 to 8): 1996

Part 1: Determination of fineness by sieve analysis

Part 2: Determination of fineness by blain air

permeability method

Part 3: Determination of soundness

Part 4: Determination of consistency of standard

Cement paste

Part 5: Determination of initial and final setting time

Part 6: Determination of compressive strength of

hydraulic cement other than masonry cement

Part 7: Determination of compressive strength of

masonry cement

Part 8: Determination of transverse and compressive

strength of plastic mortar using prism


Test 1:

Determination of consistency of standard cement paste

IS:

4031 (Part 4) 1988

Apparatus:

Vicat Apparatus (IS: 5513 1996)

Balance 1000 1 g.

Standard weights

Gauging Trovel 100 to 150 mm long weighing 210 10 g.

Temperature and Humidity:

27 2 C @ 65 5 % Humidity

Definition:

The standard consistency is defines as that consistency which will permit the Vicat

plunger G to penetrate to a point 5 to 7 mm from the bottom of the Vicat mould

when the cement paste is tested

Procedure:

Prepare a paste of weighed quantity of cement with a weighed quanity of potable

distilled water. Time of gauging shall not be less than 3 minutes nor more than 5

minutes. Gauging shall be completed before any sign of cement paste is tested.

Fill the Vicat mould E with this paste, the mould resting upon a non-porous plate.

Smoothen the surface of the plate; make it level with the top of the mould. Expel the

air by slightly shaking the mould.

Place the test block in the mould, together with the non-porous resting plate, under

the rod bearing the plunger: lower the plunger gently to touch the surface of the test

block, and quickly release, allowing it to sink into the paste. This operation shall be

carried immediately after filling the mould.

Prepare the trial paste with varying % of water and test as describes above until the

amount of water necessary for making up the standard consistency as defined

above.

Calculation:

Express the amount of water as a % by mass of dry cement to the first place of

decimal


Test 2:

Determination of initial and final setting time

IS:

4031 (Part 5) 1988

Apparatus:

Vicat Apparatus (IS: 5513 1996)

Balance 1000 1 g.

Standard weights

Gauging Trovel 100 to 150 mm long weighing 210 10 g.


27 2 C @ 65 5 % Humidity

Procedure:

Prepare a neat cement paste by gauging the cement with 0.85 times the water

required to give a paste of standard consistency. Potable or distilled water shall be

used in preparing the paste.

Immediately after moulding, place the test block in the moist closet or moist room

and allow it to remain there except when determinations of time of setting being

made.

Determination of initial setting time:

1. Use the rod bearing the needle C: Lower the needle gently until it comes in

contact with surface of the test block and quickly release, allowing it to

penetrate into the test block. In the beginning the needle will completely

pierce the test block. Repeat this procedure until the needle, when brought

in contact with the test block till fails to pierce the block beyond 5 5 mm

measured from the bottom of the mould.

2. The period elapsing between the time when water is added to the cement

and the time at which the needle fails to pierce shall be the initial setting

time.

Determination of final setting time:

1. Replace the needle ( C ) of the vicat apparatus by the needle with an annular

attachment ( F ). The cement shall be considered as finally set when, upon

applying the needle gently to the surface of the test block, the needle makes

an impression there on, while the attachment fails to do so.


2. The period elapsing between the time when water is added to the cement

and the time at which the needle makes an impression on the surface if the

test block while the attachment fails to do so shall be the final setting time

Calculation:

The results of initial and final setting time shall be reported to the reported to

nearest five minutes.


Test 3:

Determination of soundness by Le Chatelier Method

IS:

4031 (Part 3) 1988

Apparatus:

Le - Chatelier Apparatus (IS: 5514 1969)

Balance 1000 1 g.

Water bath : Temp 27 2 C to boiling Temperature in 27 + 3 minutes

Procedure:

Prepare cement paste forming by gauging cement with 0.78 times water required to

give paste of standard consistency.

Place the lightly oiled mould on a lightly oiled glass sheet and fill it with above

prepared cement paste. Cover the mould with another piece of glass-sheet and

immediately submerge the whole assembly in water in water at temperature of 27

2 C and keep for 24 hours.

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

Submerge again in water. Bring the temperature of water to boiling in 25 to 30

minutes and keep it boiling for 3 hours.

Remove from the water, allow cooling and measuring the distance the distance

between two of indicator points.

The difference between two measurements indicated the expansion of cement.

Calculation:

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

of cement.


Test 4:

Determination of soundness by compressive strength of hydraulic cement other than

masonry cement

IS:

4031 (Part 6) 1988

Material:

Standard Sand IS : 650 1966

Apparatus:

Vibration machine

Balance 1000 1 g.

Poking Rod

Cube Mould ( IS 10080 1982) of size 70.6 mm

Gauging Trovel

Graduated Glass Cylinders


27 2 C @ 65 5 % Humidity

Procedure Mixing:

Cement 200 gms, - Standard and 600 gms water (P/4 + 3.0) % of combined weight of

cement and sand. Where P is the consistency as per IS: 4031 (Part 4) 1988.

Mixing Time:

Not less than 3 min, and not more than 4 minutes.

Vibration:

Shall be 2 minutes at rate of 12000 40 vibrations per minutes.

Curing:

Keep the filled mould in Humidity Chamber for 24 hours after completion of

vibration. After this remove from moulds and immediately submerge in clean fresh

water till date at a temperature of 27 2C.


Testing:

The cubes shall be tested on the sides without any packing between the cube and the steel

plates of the testing machine.

Rate of loading 35 N/mm2, / min.


Test 4:

Determination of fineness by specific surface by blain air permeability method

IS:

4031 (Part 2) 1988

Apparatus:

Variable flow type air permeability apparatus (Blaine Type) (IS : 5516 1969)

Timer

Balance with last count 0.001 gm.


27 2 C @ 65 5 % Humidity

Calibration of Apparatus:

Standard reference material SRM 1000

Bulk Volume of compacted Bed of Power

Preparation of Sample

Mass of Sample

Mass of Sample

Preparation of Bed of Cement

Permeability

Procedure:

Size of Test Sample

Preparation of the bed of Test Sample

Permeability Test

Calculation:

S = Sn T

Ts

T = measured time interval in seconds of manometer drop for test sample

Ts = measured time interval in seconds for manometer drop for standard sample used in

calibration of the apparatus


S = specific surface in m2/kg of test sample

Sn = specific surface in m2/kg of the standard sample used in calibration of apparatus.


Materials: Steel

IS Code: IS: 1786 - 1985


Materials: Concrete

IS Code: IS: 456 - 1985


Reference:

IS Codes:

IS: 3495 (Part 1 to 4): 1992

IS: 4031 (Part 1 to 8): 1996

IS: 1786 1985

IS: 456 - 1985

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