test prcedure for concrete

8/4/2019 Test Prcedure for Concrete

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TEST PROCEDURES

SLUMP CONE

1. Purpose :

The slump cone is used for determining the workability of concrete where the nominal maximum size of aggregate doesnot exceed 38 mm.

2. Procedure as per IS 1199 – Methods of sampling and analysis

of concrete

a. Firstly decide the frequency of slump value to be takenduring concreting.

b. Oil the interior surface of the slump cone with mouldreleasing oil to prevent adhesion of the concrete.

c. Place the slump cone on a leveled surface.d. Collect the sample in a wheelbarrow after mixing the

concrete properly in the transit mixture.

e. Remix the sample thoroughly in wheelbarrow withsampling scoop.f. After remixing immediately fill the slump cone in layers

approximately one – quarter of the height of the cone.g. Each layer shall be compacted with the tamping rod by

25 strokes distributed in a uniform manner over thecross-section of the cone and for the second andsubsequent layers tamping rod shall penetrate into theunderlying layer.

h. After compacting the top layer the concrete shall be

struck off level with the top of the slump cone, using a _______. Any mould which may have leaked outbetween the mould and the base plate shall becleaned away.



i. Unscrew the slump cone from the base plate andremove it immediately from the concrete by raising itslowly and carefully in a vertical direction.

j. After the concrete subsides place the slump cone onthe base plate in reverse position and place a scale onit. Measure the height between the top of the mouldand the highest point of the concrete specimen beingtested.

3. Reporting of slump value

The slump measured shall be reported in terms of millimeters.



VIBRATING TABLE

1. Purpose

Vibrating table is used for proper compaction of concrete (asper IS 516-Methods of tests for strength of concrete) whilecasting specimens for compressive strength determination.

2. Procedure

i. After preparing the concrete mix, put moulds on thevibration table platform.

ii. Fill concrete in the mould in layers of 50 mm deep.iii. In placing each scoopful of concrete, move the scoop

around the top edge of the mould as the concreteslides from it, in order to ensure a symmetricaldistribution of the concrete within the mould.

iv. Let each layer compact by vibration.v. After compacting concrete in 3 layers, finish the

surface of the concrete level with the top of the mould.vi. Stop the table and remove the mould from it.



TEST PROCEDURES

BULK DENSITY MEASURE(For Density of Concrete)

1. Purpose

The bulk density measure is used for determining the weightper cubic meter of freshly mixed concrete (density) fromwhich the yield of concrete per cubic meter can becalculated.

2. Procedure as per IS 1199 – methods of sampling andanalysis of concrete

i. Take freshly mixed concrete from transit mixer byusing wheel borrow.

ii. Fill the cylindrical measure with concrete as soon aspracticable after mixing.

iii. Fill the cylindrical measure with concrete in layersapproximately 5 cm deep and each layer shall becompacted.

iv. While compacting the concrete the standard tampingbar shall be distributed in uniform manner over thecross section of the measure.

v. The number of strokes per layer is 60 for 10 litrescylinder and 120 for 20 litres cylinder.

vi. The exterior surface of the cylinder shall be tapped 10to 15 times or until no large bubbles of air appear onthe surface of the compacted layer.

vii. Strike-off the top surface and finish it smoothly with aflat cover plate.

viii. Clean all excess concrete from the exterior and weighthe filled measured.

ix. Density of concrete (W1): The weight per cubicmeter of concrete shall be calculated by dividing the



weight of fully compacted concrete in the cylindricalmeasure by the capacity of measure in kg/cu.m (W1).

x. Yield of concrete (V2) : The volume of concreteproduced per cum. shall be calculated as follows.

xi. V2 = Wc + Wf + Wca + Ww

W1

Wc = Weight of cement, kgWf = Weight of fine aggregate, kgWca = Weight of coarse aggregate, kgWw = Weight of water, kg



TEST PROCEDURES

150 x 150MM Cube Moulds

1. Purpose

The moulds are used for making of concrete cubes as per IS : 516 – 1959 – Methods of tests for strength of concrete.

2. Apparatus

Wheel barrow, sampling scoop, trowel cube moulds of 15 x15 x 15 cm size and tamping bar 16 mm in diameter, 0.6 mlong and bulleted point at the lower end.

3. Procedure as per IS 516

a. Firstly decide the number of samples to be taken duringconcreting.

b. Oil the interior surface of the mould with mould releasing

oil to prevent adhesion of the concrete.c. Collect the sample in a wheelbarrow after mixing theconcrete properly in the transit mixer.

d. Remix the sample thoroughly in wheelbarrow withsampling scoop.

e. After remixing immediately fill the mould in layersapproximately 5 cm deep.

f. During filling the mould, the scoop shall be moved aroundthe top edge of the mould as the concrete slides from it, inorder to ensure a symmetrical distribution of the concrete

within the mould.g. Each layer shall be compacted with the tamping rod (of

16 mm dia 60 cm long and rounded at one end) by



minimum 35 strokes distributed in a uniform manner over the cross-section of the mould.

h. After compacting the tip layer, top surface of the concreteshall be finished level with the top of the mould, using atrowel.

i. Store the cube moulds in a place which is free fromvibration and cover the surface of the concrete with apiece of damp sacking for initial 16 to 24 hours.

j. After this period, mark the specimen and remove it fromthe mould by dismantling and submerge it clean water ata temperature of 27 +2oC and keep it till the time of testing for compressive strength.



TEST PROCEDURES

PENETRATION RESISTANCE APPARATUS

1. Purpose

Penetration resistance apparatus : (Penetrometer) is used tofind out initial and final setting time of concrete as per IS 8142-Method of test for determining setting time of concrete bypenetration resistance.

2. Procedure

a. Select a representative sample of concrete of knownproportion.

b. Oil the interior surface of the cube mould with mouldreleasing oil to prevent adhesion of the concrete.

c. Remove all of the mortar from the sample by sieving itthrough a 4.75 mm IS sieve into a mortar pan.

d. Remix the sample thoroughly and fill it in a 15 cm cubemould in two layers, leaving a space of 13 mm (1/2 inch)

at top.e. Compact each layer with tamping rod by tamping eachlayer 25 times. For each test, a set of three cube mouldsshould be filled.

f. Keep the moulds covered with a water impermeablecover and under shed for the duration of test.

g. Prior to making each penetration resistance test, removebleeding water by using a pipette. For easy removal of water, tilt the mould by placing a 3 cm block under one of the edges and allow water to collect at the shallow portion

for 2 minutes.h. Select 65 mm2 and 16 mm2 removable needles for initial

and final setting time respectively.

i. After removing the bleed water, insert the penetrometer vertically into the mortar. Push the apparatus gradually



until the needle (65 mm2) penetrates the mortar uptoscribe mark, in about 10 seconds. The force required isindicated by the white ring.

j. Record the force required and the elapsed time after adding water to the mix.

k. Make penetration test at hourly intervals, initial test beingmade after 3 hours.

l. Leave a space of 20 mm from previous impression insubsequent penetration test.

m. Initial setting time is read off against a penetrationresistance corresponding to 35 kg f/cm2.

n. Change the needle dia i.e. 16mm2 and final setting time isread off against a penetration resistance corresponding to275 kgf/cm2



ACCELERATED CURING METHOD

1. Purpose :

To find out 28 days compressive strength of concrete in 28hours by accelerated curing method. (As per IS 9013-1978-Method of making, curing and determining compressivestrength of accelerated cured concrete test specimens)

Procedure :

1. After the test specimens (whose 28 days strength to bedetermined) have been made, store it in moist air of atleast 90 percent humidity for 23 hours + 15 min.

2. Cover the specimens with flat steel cover plate to avoiddistortion during the use.

3. Carefully and gently lower the specimens into the curingtank and shall remain totally immersed for a period of 3½Hours + 15 min.

4.The temperature of water in the curing tank shall be atboiling (100 oC) when the specimens are placed.

5. After curing for 3 ½ hours in boil water, the specimenshall be carefully removed from the boiling water andcooled by immersing in cooling tank at 27 +2oC for 2 hrs.

6. After cooling remove the specimens from the mould andtested for its accelerated compressive strength (Ra) inN/mm2.

7. The 28 days can be found out using following formula.8. Predicted 28 days compressive strength = R28 = 8.09 +

1.64 Ra, where Ra is accelerated compressive strengthand R28 is predicted compressive strength at 28 days.



TEST PROCEDURES

DIGITAL COMPRESSION TESTING MACHINE

1. Purpose :

The digital compression – testing machine is used to determinethe compressive strength of hardened concrete specimens.

Procedure as per IS 516 – Methods of tests for strength of concrete

1. Keep the specimen to be tested centrally on theclean lower platen so that small clearance is left between the

upper platen and the top the specimen under test.2. Close the pressure release valve.3. Make the digital display to read “Zero” by adjusting

the zero knob.4. Put the display unit on “Peak Hold” mode to hold the

maximum load reading.5. Start applying the load at the specified pace rate,

which could be maintained by adjusting the slow fast knob.6. If the pace rate is on higher side the indicator

displays red colour and the pace rate is on lower side theindicator will display yellow colour.7. If the pace rate is exactly equal to set rate then the

indicator will display green colour.8. As soon as sample fails, release the pressure

slowly by opening valve.9. The digital display will be holding the maximum load

reading at which sample has failed. Note down the pattern of failure and calculate the compressive strength in N/mm2 or kg/cm2.

10. Pace rate for 15 cm cube is 5.15 kN/s.11. Before starting another test, clean the lower platen

and bring the digital display to “Zero” position by depressing the“Reset” switch.



TEST PROCEDURES

VICAT APPARATUS(Standard Consistency)

1. Purpose :

It is used to determine the standard consistency, initial and finalsetting of cement (As per IS 4031 – Methods of physical tests for hydraulic cement)

Procedure for determination of standard consistency :

a. Take the Vicat apparatus and fit the standard consistencyplunger (Cylindrical one). Lower the stem and check if thereading is zero when the plunger touches the non-porousresting plate (glass plate). If not adjust it to zero.

b. The temperature of cement and water and that of testing roomshall be preferably within the range of 27 +2oC.

c. Coat the non-porous resting plate (glass plate) with petroleum jelly. Place the mould after coating it lightly with petroleum jelly on the non-porous resting plate (glass plate).

d. Take 300 g of cement.e. Prepare a past with weighed quantity of water (30% of weightof cement = 90ml).

f. The time from adding water to the dry cement till starting to fillthe Vicat mould should be within 3 to 5 minutes.

g. Fill the Vicat mould completely with the cement past madeand smooth off the surface of the paste, make it level to thetop of the mould.

h. Place the mould under the plunger together with non-porousresting plate.

i. Lower the plunger gently to touch the surface of the block andrelease quickly. Make sure that the dash pot works properly.

j. Measure and note down the penetration.k. Clean the mould and plate.l. If the value obtained is below 5 mm then try with lesser

quantity of water (say 29%, 28%, etc.) repeat steps c to kabove with the lesser water.



m. If the value obtained is above 7 mm then try with morequantity of water (say 31%, 32% etc.) repeat steps c to kabove with more water.

n. Keep doing above tests with varying percentages of water until the amount of water for the required penetration of 5 to7mm value is found.

o. Standard consistency : Express the amount of water as apercentage by weight of the dry cement.



TEST PROCEDURES

VICAT APPARATUS

(Initial setting time of cement)

1. Procedure as per IS 4031 – Methods of physical tests for hydraulic cement

a. Take the Vicat apparatus and fit the standardconsistency plunger (Needle type). Lower the stem andcheck if the reading is zero when the plunger touchesthe non-porous resting plate (glass plate). If not adjust itto zero.

b. The temperature of cement and water and that of testingroom shall be preferably within the range of 27 + 2oC.

c. Coat the non-porous resting plate (glass plate) withpetroleum jelly. Place the mould after coating it lightlywith petroleum jelly, on the non-porous resting plate(glass plate).

d. Take 300 g of cement.e. Prepare a neat cement paste mixed with water which is

0.85 times that of standard consistency (i.e. If standard

consistency = 30%; water for initial setting time = 0.30 x300 x 0.85 = 25.5 ml).f. The time from adding water to the dry cement until

starting to fill the Vicat mould should be within 3 to 5minutes.

g. Start the stop watch as soon as you start adding water and mixing the cement past. The mixing should be doneusing a stainless steel trowel called gauging trowelwhich is available with lab equipment dealers.

h. Fill the Vicat mould completely with the cement paste

made and smooth off the surface of the paste, make itlevel to the top of the mould.



i. Place the mould under the needle (1 mm square)together with non-porous resting plate and cementpaste.

j. Lower the needle gently to touch the surface of the blockand release quickly. Make sure that the dash pot worksproperly.

k. Initially the needle will pierce completely into the testblock. Repeat this procedure until the needle fails topenetrate into the test block by 5 + 0.5 mm from thebottom of the mould.

l. Initial setting time : The time started from mixing of water to the cement to the time when the needle fails topenetrate the test block by 5 + 0.5 mm is described asthe initial setting time.



TEST PROCEDURES

VICAT APPARATUS(Final setting time of cement)

1. Procedure as per IS 4031 – Method of physical tests for hydraulic cement

a. After determining the initial setting time replace theneedle of Vicat apparatus by the needle with annular attachment.

b. Lower the attachment gently to touch the surface of theblock and release. Use the dash pot.

c. Repeat this procedure at regular intervals until the time tofind the needle makes an impression on the surface of theblock and the circular impression is not seen.

d. Final Setting time : The time elapsed from mixing of water to the cement and the time till step c is the finalsetting time of cement.



TEST PROCEDURES

VIBRATING MACHINE

(Compressive strength of cement)

1. Procedure as per IS 4031 – Methods of physical test for hydraulic cement

a. Take 200 g of cement and 600 gms of standard sandconforming to IS : 650 – 1966. The 600g of standardsand will be made up o 200g each of grade I, Ii & III Sandpurchased from TAMIN, Manali, Chennai.

b. Mix it dry with a trowel for one minute on a non-porousmixing plate.

c. Take water @ (P/4 + 3)% of combined weight of cementand sand (800g) where P is the standard consistency of cement paste.

d. Mix the dry mixture with the quantity of water specifiedabove for 3 to 4 minutes.

e. Place the 50 cm2 ( 7.07 x 7.07 x 7.07 cm) mould on thevibration table and clamp it to hold it firmly in position.

Attach a hopper of suitable size on the top of the mould tofacilitate filling.f. Immediately after mixing the mortar place it in the cube

mould and tamp it with the poking rod for 20 times inabout 8 seconds.

g. Place the remaining quanitity of mortar place it in thecube mould and tamp it again as specified for the firstlayer.

h. Compact the mortar further by means of vibration for twominutes.

i. At the end of vibration remove the mould from themachine and finish the top surface of the cube with theblade of a trowel.



j. Keep the filled moulds preferably at a temperature of 27 + 2oC and atleast 90 percent relative humidity for 24hours after completion of vibration.

k. After 24 hours remove the cubes from the moulds andimmediately submerge in clean water for curing.

l. Temperature of the curing water should be preferably27 + 2oC.

m. Cast twelve such cubes so that we can find thecompressive strength for 3 cubes each at 1 day, 3 days, 7days and 28 days.Report average of compressive strength of three cuberesults to the nearest 5 kg/cm2.



TEST PROCEDURES

SCHMIDT CONCRETE TEST HAMMER

1. PURPOSE

It is used for estimation of compressive strength of concreteby rebound hammer method. (As per IS 13311 part – 2-Non destructive testing of concrete – methods of test)

2. PROCEDURE

a. For testing, smooth, clean and dry surface preferably

bottom of the slab is to be selected.b. If loosely adhering scale is present, this should be rubbed

of with grinding stone.c. Release the impact bolt by applying pressure to it.d. Place test hammer perpendicular to the test surface.e. Press housing against the test surface at moderate speed

until impact is triggered.f. The rebound value is arrested and read by means of the

push-button.

g. Each test point should be tested with at least 8 to 10impacts.h. Minimum distance between impact points 20 mm.i. Rebound values, which are abnormally high or low, must

be eliminated. j. After using the hammer the impact bolt is to be arrested

by means of the push-button after the initiation of animpact.

k. Plot the average rebound value in the conversion curve todetermine the compressive strength of concrete.

l. The strength determined from the curve is to be correctedby using correction factors (as per manual of manufacture).



m.The test can be conducted horizontally on verticalsurfaces like column or vertically upward or downward onhorizontal surfaces like slabs and beams.

n. The correlation between compressive strength of concrete cubes and its rebound number is to beestablished for most satisfactory results.



TEST PROCEDURES

SIEVE ANALYSIS FOR FINE AGGREGATE

1.

Purpose :

The sieves are used for the determination of particle sizedistribution of fine aggregate by sieving. (As per IS 2386 part 1 –Methods of test for aggregates for concrete)

2. Sizes of sieves :

Sieves of the sizes 10mm, 4.75 mm, 2.36 mm, 1.8mm, 6000 mic.,300 mic., and 150 mic.

3. Procedure :

a. Take known weight of dry sample.b. Sieve the sample progressively starting from the largest

sieve i.e. 10 mmc. On completion of sieving weigh the material retained on

each sieve.d. Calculate the percentage of sand retained in each sieve

and cumulative percentage retained on each sieve.e. Calculate cumulative percentage passing through eachsieve.

f. Calculate the fineness modulus of sand by summing upthe cumulative percentage of sand retained on 10 mm,4.75 mm, 1.18 mm, 600 mic., 300 mic., and 150 mic.,sieves and dividing the sum by 100.

g. Find out which grading zone the sand conforms to bychecking with the table – 1 given below.



Table 1 : Grading zones (I.S. 383) 1978

I. S. SieveCumulative percentage passing IS sieves for grading zone

(natural sand)Crushed

Sand

I II III IV

10mm 100 100 100 100 100

4.75mm 90-100 90-100 90-100 90-100 90-100

2.36mm 60-95 75-100 85-100 95-100 75-100

1.18mm 30-70 55-90 75-100 90-100 55-100

600 micron 15-34 35-59 60-79 80-100 35-79

300 micron 5-20 8-30 12-40 15-50 8-40

150 micron 0-10 0-10 0-10 0-15 0-20

75 micron 0-3 0-3 0-3 0-3 0-15



TEST PROCEDURES

SIEVE ANALYSIS FOR COARSE AGGREGATE

1. Purpose :

The sieves are used for the determination of particle sizedistribution of coarse aggregate by sieving (As per IS 2386part I – Methods of test for aggregates for concrete)

2. Sizes of sieves required for nominal size coarse aggregate

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

Nominal 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 mic., 150 mic.

10 mm 12.5 mm, 10 mm, 4.75 mm, 2.36

mm, 600 mic., 150 mic.

3. Procedure :

a. Take a known weight 9 2kg) of dry aggregate.b. Sieve the aggregate progressively starting from the

largest sieve.c. Note down the weight of the material retained in each

sieve.

d. Calculate the percentage of aggregate retained in eachsieve.

e. Calculate the cumulative percentage of aggregateretained in each sieve.

f. Calculate the cumulative percentage of aggregatepassing through each sieve.



g. Check the values of percentage passing with the limitsspecified in IS 383 and record it.

Grading requirement of coarse aggregate (IS : 383)

25 mm20 mm12.5 mm10 mm4.75 mm



TEST PROCEDURES

SILT CONTENT OF FINE AGGREGATE(BY VOLUME METHOD)

1. Purpose :

The 250 ml capacity glass-measuring cylinder is used for determination of silt and clay content in sand on volumebasis.

2. Procedure :

a. Fill the glass-measuring cylinder with sample of sandupto 100 ml mark.

b. Add clean water upto 150 ml and shake the contentswell.

c. Allow contents to settle for 15 to 20 min.d. Clay and silt will be seen as a separate layer over

sand.e. Measure the total height of material (A).f. Measure the height of sand layer (B).

g. Find out height of silt and clay layer (A-B).h. Calculate the percentage of silt and clay in the totalsand layer.

i. Calculation : Silt & Clay %, (A-B) /B* 100



SIEVE SHAKER

1. Purpose :

Sieve shaker is used for the process of sieving easier andquicker as per IS 2386 part I – Methods of test for aggregates for concrete.

2. Procedure :

a. Unbolt the nuts of the sliding retaining plate, raise itto a suitable height and tighten the nuts.

b. Select the required group of sieves for the sieve

analysis.c. On the base of the sieve holder mount the sieves in

order of decreasing opening size from top tobottom, together with a receiver fitted below thebottom sieve.

d. Keep the material on the top sieve.e. Place the lid on the sieve.f. Unbolt the nuts of the clamping plate, slide it down

to pass the whole sieve assembly and tighten the

nuts.g. Start the sieve shaker by switching on the motor,and continue the sieving operation for specified timesay 10 minutes.

h. At the end of sieving operation, dismantle the sieveassembly and collect separately the materialretained on each sieve and on the receiver for weighin

TEST PROCEDURES

AIR OVEN



1. Purpose

Air oven is used to dry the material for finding outmoisture content present in aggregate. Moisture contentof aggregate is the percentage of weight of water in theaggregate sample to the total dry weight of the aggregatesample. The procedure is the same for both coarse andfine aggregate.

2. Procedure

a. Take the moist or wet sample weigh (W1)

b. Dry it in a hot air oven for 10-15 min. at thetemperature of 100oC.

c. Take the sample out of air oven and cool it.d. Take the weight of dry sample (W2).

3. CalculationMoisture content of aggregate is calculated as follows :M=(W1-W2) / W2 x 100

Where

M = Moisture content of aggregate, %W1=weight of moist sample, gmW2= weight of dry sample, gm



TEST PROCEDURES

SPECIFIC GRAVITY TEST FOR AGGREGATE

1. Purpose :

The pycnometer is used to determine the specific gravity of aggregate as per IS 2386 part III – Methods of test for aggregatesfor concrete.

2. Procedure

a. Weight an empty pycnometer (W1)b. Fill up half of the pycnometer with dry aggregate sample

and weigh.c. Add water to the sample, fill the pycnometer with water,

roll it on a flat surface and then fill it completely with water and weigh (W3).

d. Empty the contents of the pycnometer, refill it with water only and weigh. (W4).

e. Calculate the specific gravity using this formula.Specific Gravity = (W2 – W1) / [(W4-W1)-(W3-W2)]

Where W1 = weight of empty pycnometer, g.W2 = weight of pycnometer and dry aggregate, g.W3 = weight of pycnometer with aggregate and water, gW4 = weight of pycnometer filled with only water, g



TEST PROCEDURES

CYLINDRICAL METAL MEASURE(For Density of Aggregate)

1. Purpose :

The cylindrical metal measures are used for determining unitweight or bulk density of aggregate.

2. Procedure as per IS 2386 part III- Methods of test for aggregates for concreteA. Rodded or Compacted Density

a. Fill the measure about 1/3rd height with thoroughlymixed aggregate.

b. Tamp it with 25 strokes of the rounded end of tamping rod.

c. Again fill the measure with approx. same quantity& tamp it with 25 strokes.

d. Overflow the measure with aggregate, tamp it 25times & struck off surplus aggregate with tampingrod.

e. Determine the net weight of aggregate by knowingempty weight of measure and calculate Bulkdensity in Kg/cu.m.

B. Loose Density

a. Fill the measure to overflow with aggregate bydischarging from height not more than 5 cm abovethe top of measure.

b. Level the sample with a straight edge.

c. Determine the net weight of aggregate by knowingempty weight of measure and calculate Bulkdensity in Kg/cu.m.



TEST PROCEDURES

LENGTH GAUGE

1. Purpose

The length gauge is used to determine the Elongation indexof coarse aggregate (As per IS 2386 part – 1 – Method of test for aggregates for concrete)

2. Procedure

a. Take enough quantity of dry blended sample so that

atleast 200 pieces of any fraction is present. b. Sieve the blended sample through all the sieves

mentioned above starting from the largest sieve i.e. 63mm.

c. 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 10 mm to 6.3 mm.

d. Take all the fraction separately, gauge them one by one

through the corresponding shot provided in the gauge.Keep the particles retained by the length separately.e. Weigh the particles retained on length gauge.f. Elongation index is the total weight of the material

retained on the various length gauges, expressed as apercentage of the total weight of the sample gauged.

3. Calculation

Elongation index of aggregate in % is calculated as

follows:

Ei = (W1/W2) x 100%

WhereW1 = Weight of particles retained in length gauge, gW2 = Weight of total sample taken for test, g



TEST PROCEDURES

THICKNESS GAUGE

1. Purpose :

Thickness gauge is used to find out flakiness index of coarseaggregate. (As per IS 2386 part 1 – Methods of test for aggregates for concrete).

2. Procedure :

i. Take enough quantity of dry blended sample so that

atleast 200 pieces of any fraction is present. This isnot applicable for the biggest and smallest size.

ii. Sieve the blended sample through all the sievesmentioned above starting from the largest sieve i.e.63 mm.

iii. Separate all the individual fractions – 63 mm to 50mm, 50 mm to 40 mm, 40 mm to 31.5mm, 31.5 mmto 25 mm, 25 mm to 20 mm, 20 mm to 16 mm, 16mm to 12.5 mm, 12.5 mm to 10 mm and 10 mm to

6.3 mm.iv. Take all the fraction separately, gauge them one byone through the corresponding slot provided in thegauge. Keep the particles passing through the slotof the gauge and retained in gauge separately.

v. Note the number of particles passing and notpassing through the corresponding slot in the gaugefor each fraction.

vi. Calculate for each fraction the following :a. Percentage of number of particles passing the

slot to the total number of particles in fraction.This is noted as X.

b. Percentage of weight of particles in fraction takenfor testing to the total weight of particles infraction taken for the test (total qty.). This isnoted as Y.



3. Calculation :

Flakiness Index = Fi = X (Xi – Yi)/100%i=1 to n

WhereXi = Percentage of number of particles passing the slotto the total number of particles in that fraction, %Yi = Percentage of weight of particles in fraction to thetotal weight of particles in all fraction, %



IMPACT VALUE TEST FOR 10 mm AGGREGATE

1. Purpose :

The impact test machine is used to determine the aggregateimpact 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 12.5mm 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, eachincrement being rodded 25 times with the tamping rod.

3. Strike off the excess sample using the tamping rod as astraight 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 thehammer should be 380 mm. The interval between eachblow should be about one second.

6. Remove the sample from the cup and sieve it on 2.36 mmIS 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.9. Calculation :

Aggregate impact value, % = (W1 – W2) W1 x 100Where

W1 = weight of dry sample passing through 12.5 mm ISsieve and retained on 10 mm IS sieve, gW2 = weight of dry sample retained on 2.36 mm ISsieve, g

10. Report the aggregate impact value in percentage and asthe mean of two determinations rounded off to the nearestwhole number.



TEST PROCEDURES

SIEVES FOR COARSE AGGREGATE

Sieve analysis of Coarse Aggregate

Coarse aggregate consists of material above 4.75mm size. It may becrushed aggregate of natural gravel of different sizes.

Apparatus

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

Nominal size of aggregate Sieve size (mm)40 mm 80 mm, 63 mm, 40 mm, 20 mm,

10 mm, 4.75 mm20 mm 40 mm, 25 mm, 20 mm, 10 mm,

4.75 mm12.5 mm 20 mm, 16 mm, 12.5 mm, 10 mm,

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

mm, 600 mic., 150 mic.

Procedure :

a. Take a known weight (2 kg) of dry aggregate reduced byquartering.

b. Sieve the aggregate progressively starting from thelargest sieve.

c. Note down the weight of material retained in each sieve.d. Calculate the percentage of aggregate retained in each

sieve.e. Calculate the cumulative percentage of aggregate

retained in each sieve.f. Calculate the cumulative percentage of aggregate

passing through each sieve.



g. Check the values of percentage passing with the limitsspecified in IS 383 and enter the values.

h. If the grading deviates from limit specified, it can becorrected by blending it to coarser of finer size fractionsavailable to make it according to the limit specified in IS383 (Grades Coarse Aggregate).



TEST PROCEDURES

ELONGATION TEST

1. Elongation Index

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

2. Apparatus

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

3. Procedure

a. Take enough quantity of dry blended sample so thatatleast 200 pieces of any fraction is present. This isnot applicable for the biggest and smallest size.

b. Sieve the blended sample through all the sievesmentioned above starting from the largest sieve i.e.63 mm.

c. Separate all the individual fractions – 63 mm to 50 mm,50 mm to 40 mm, 40 mm to 25 mm, 31.5 mm to 25mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to12.5 mm, 12.5 mm to 10 mm and 10 mm to 6.3 mm.

d. Take all the fraction separately, gauge them one byone through the corresponding slot provided in thegauge. Keep the particles retained by the length

separately. The aim should be to retain as much aspossible to avoid testing bias.

e. Weigh the particles retained on length gauge.f. Elongation index is the total weight of the material




Calculation

Elongation index of aggregate in % is calculated as follows:

Ei = (W1/W2) x 100%WhereW1 = weight of particles retained in length gauge,gW2 = weight of total sample taken for test, g

Reporting

Report the elongation index in percentage rounded off to thenearest whole number.



TEST PROCEDURES

FLAKINESS TEST

1. Flakiness Index :

Flakiness index of an aggregate is the percentage by weight of particles in it whose least dimension (thickness) is less then three-fifth of their mean dimension. It is measured on particles passingthrough mesh size of 63 mm and retained on mesh size 6.3 mm.

2. Apparatus :

Balance, Flakiness gauge (thickness gauge) and GI sieves of thefollowing mesh sizes – 63 mm, 50 mm, 40 mm, 31.5 mm, 25 mm,20 mm, 16 mm, 12.5 mm, 10 mm and 6.3 mm.

3. Procedure :

a. Take enough quantity of dry blended sample so thatatleast 200 pieces of any fraction is present. This isnot applicable for the biggest and smallest size.


c. Separate all the individual fractions – 63 mm to 50 mm,50 mm to 40 mm, 40 mm to 31.5 mm, 31.5 mm to 25mm, 25 mm to 20 mm, 20 mm to 16 mm, 16 mm to12.5 mm, 12.5 mm to 10 mm and 10 mm to 6.3 mm.

d. Take all the fraction separately, gauge them one byone through the corresponding slot provided in thegauge. Keep the particles passing through the slot of

the gauge and retained in gauge separately. The aimshould be to pass as many as possible through the slotto avoid testing bias.

e. Calculate for each fraction the following :a. Percentage of number of particles passing the slot

to the total number of particles in fraction. This isnoted as X.



b. Percentage of weight of particles in fraction takenfor testing to the total weight of particles in allfractions taken for the test (total qty.). This isnoted as Y.

Calculation

Flakiness Index = Fi = ∑ (Xi – Yi)/100%

WhereXi = Percentage of number of particles passing the slot tothe total number of particles in the fraction, %.Yi = Percentage of weight of particles in fraction to thetotal weight of particles in all fraction, %

Reporting

Report the flakiness index in percentage rounded off to thenearest whole number.



TEST PROCEDURES

PENETROMETER

1. Initial setting time of concrete by penetration resistance

Initial setting time of concrete is the time interval required for themortar sieved from the concrete mixture to reach a penetrationresistance of 3.43 N/mm2 (35 kgf/cm2) after the initial contact of cement and water.

2. Apparatus

Concrete cube moulds of 15 cm x 15 cm size, penetrometer

graduated from 0 kgf to 60 kgf in increments of 2 kgf, pipette, tampingrod of 16 mm in diameter and 600 mm length rounded at one end.

Procedure

a. Select a representative sample of concrete of knownproportion.

b. Oil the interior surface of the cube mould with mouldreleasing oil to prevent adhesion of the concrete.

c. Remove all of the mortar from the sample by sieving itthrough a 4.75 mm IS sieve into a mortar pan.d. Remix the sample thoroughly and fill it in a 15 cm cube

mould in two layers, leaving a space of 13 mm (1/2 inch) attop.

e. Compact each layer with tamping rod by tamping each layer 25 times. For each test, a set of three cube moulds shouldbe filled.

f. Keep the moulds covered with a water – impermeable cover and under shed for the duration of test.

g. Prior to making each penetration resistance test, removebleeding water by using a pipette. For easy removal of water, tilt the mould by placing a 3 cm block under one of theedges and allow water to collect at the shallow portion for 2minutes.

h. After removing the bleed water, insert the pocketpenetrometer vertically into the mortar. Push the apparatus



gradually until the needle penetrates the mortar upto thescribe mark, in about 10 seconds. The force required isindicated by the white ring.

i. Record the force required and the elapsed time after addingwater to the mix.

j. Make penetration tests at hourly intervals, initial test beingmade after 3 hours.

k. Leave a space of 20 mm from previous impressions insubsequent penetration tests.

l. Plot the penetration resistance against time. Initial settingtime is read off against a penetration resistancecorresponding to 35 kgf/Cm2.

Reporting :

Average value of elapsed time of three tests shall be reported asinitial setting time. Report the type and proportion of cement, fineaggregate, coarse aggregate and the water-cement ration withambient temperature during test period with the result.



TEST PROCEDURES

CASTING OF CONCRETE CUBE MOULDS

1. MAKING AND CURING CONCRETE CUBES:

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

2. APPARATUS :

Wheel barrow, sampling scoop, trowel, cube moulds of 15 x15 x 15 cm size and tamping bar 16 mm in diameter, 0.6 mlong and bulleted point at the lower end.

3. PROCEDURE :

a. Firstly decide the number of samples to be taken duringconcreting.

b. Oil the interior surface of the mould with mould releasingoil to prevent adhesion of the concrete.

c. Collect the sample in a wheelbarrow after mixing theconcrete properly in the transit mixer.

d. Remix the sample thoroughly in wheelbarrow withsampling scoop.e. After remixing immediately fill the mould in layers

approximately 5 cm deep.f. During filling the mould, the scoop shall be moved around

the top edge of the mould as the concrete slides from it, inorder to ensure a symmetrical distribution of the concretewithin the mould.

g. Each layer shall be compacted with the tamping rod byminimum 35 strokes distributed in a uniform manner over

the cross-section of the mould.



h. After compacting the top layer, top surface of the concreteshall be finished level with the top of the mould, using atrowel.

i. Store the cube moulds in a place which Is free fromvibration and cover the surface of the concrete with apiece of damp sacking for initial 16 to 24 hours.



TEST PROCEDURES

SLUMP TEST

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 nominalmaximum 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 themoulded concrete test specimen vertically. Internaldimension of the cone should have the following sizes :Bottom diameter 20 cmTop diameter 10 cmHeight 30 cmTamping rod of 16 mm diameter, 0.6 m long and rounded atone end.

3. PROCEDURE :a. Firstly decide the frequency of slump value to be taken

during concreting.b. Oil the interior surface of the slump cone with mould

releasing oil to prevent adhesion of the concrete.c. Place the slump cone on a leveled surface.d. Collect the sample in a wheelbarrow after mixing the

concrete properly in the transit mixer.e. Remix the sample thoroughly in wheel barrow with

sampling scoop.

f. After remixing immediately fill the slump cone in layersapproximately one – quarter of the height of the cone.

g. Each layer shall be compacted with the tamping rod by 25strokes distributed in a uniform manner over the cross-section of the cone and for the second and subsequentlayers tamping rod shall penetrate into the underlyinglayer.



h. After compacting the top layer, the concrete shall bestruck off level with the top of the slump cone, using atrowel. Any mortar, which may have leaked out betweenthe mould and the base plate, shall be cleaned away.

i. Unscrew the slump cone from the base plate and removeit immediately from the concrete by raising it slowly andcarefully in a vertical direction.

j. After the concrete subsides place the slump cone on thebase 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.

4. REPORTING OF SLUMP VALUE :

The slump measured shall be reported in terms of millimeters of subsidence of the specimen during the test. Any slumpspecimen, which collapses or shears off laterally, shall berepeated with another sample. If, in the repeat test also, thespecimen shears, the slump shall be measured and the fact

that the specimen sheared, shall be reported. Take correctiveaction to make the mix cohesive.



TEST PROCEDURES

DENSITY CYLINDER FOR AGGREGARE (Coarse and Fine)

1. Bulk density of aggregate

This method of test covers the procedure for determining unitweight or bulk density of aggregate

2. Apparatus

Balance cylindrical metal measure with handle and tamping rodof 16 mm dia. And 60 cm long, rounded at one end.Sizes of metal measures for different sizes of aggregate are

given in table – 1. A straight tamping rod of cylindrical c/s 16mm in diameter, 60 cm long and rounded at one end.

Table 1 : Size of container for Bulk density test

Size of largestparticles

NominalCapacity

Litre

Insidediameter

cm

Inside Heightcm

Thickness of Metal

Min mm

4.75 mm andunder

3 15 17 3.15

Over 4.75 mmto 40 mm

15 25 30 4.00

Over 40 mm 30 35 31 5.00

3. Procedure

Rodded or Compacted weight –

a. Fill the measure about 1/3rd height with thoroughly mixedaggregate.

b. Tamp it with 25 strokes of the rounded end of tampingrod.

c. Again fill the measure with approx. same quantity & tampit with 25 strokes.



d. Overflow the measure, tamp it 25 times and struck off surplus aggregate with tamping rod.

e. Determine the net weight of aggregate and calculate Bulkdensity in Kg/lit.

Loose Density –

a. Fill the measure to overflow with aggregate bydischarging from height not more than 5 cm above the topof measure.

b. Level the sample with a straight edge.c. Determine the net weight of aggregate and calculate Bulk

density in Kg/lit.



TEST PROCEDURES

PYCNOMETER

1. Specific gravity of aggregates

This method cover the procedure for finding the specific gravity of aggregate using glass pycnometer.

2. Apparatus

Pycnometer (glass bottle with conical cap) and balance.

3. Procedure

a. Weigh an empty pycnometer.b. Fill up half of the pycnometer with dry aggregate sample and

weigh.c. Add water to the sample, fill the pycnometer with water, roll it

on a flat surface and then fill it completely with water andweigh.

d. Empty the contents of the pycnometer, refill it with water onlyand weigh.

e. Calculate the specific gravity using this formula,

Sp. Gravity = (W2-W1) [(W4-W1)-(W3-W2)]WhereW1

Where W1 = weight of empty pycnometer, g.W2 = weight of pycnometer and dry aggregate, g.W3 = weight of pycnometer with aggregate and water, gW4 = weight of pycnometer filled with only water, g



TEST PROCEDURES

AIR OVEN

1. Moisture Content of Aggregate

Moisture content of aggregate is the percentage of weight of water in the aggregate sample to the total dry weight of theaggregate sample. The procedure is the same for both coarseand fine aggregate.

2. Apparatus

One hot plate or over, tray and balance

3. Procedure

a. Take the weight of moist or wet sampleb. Dry it in a hot plate or ovenc. Take the weight of dry sample

4. Calculation

Moisture content of aggregate is calculated as follows :M=(W1 – W2)/W2 x 100WhereM = Moisture content of aggregate, %W1 = Weight of moist sample, gW2 = Weight of dry sample, g



TESTING METHOD OF IMPACT TEST MACHINE

(As per IS 2386 Part IV) – 1963

Purpose :

This method is used to determine the aggregate impact value of coarse aggregate

Procedure :

a. Take about 1000 g of dry sample passing through 12.5 mm ISsieve and retained on 10 mm sieve.

b. Fill the cylindrical metal measure with the dried sample. The

sample should be placed in three increments, each incrementbeing rodded 25 times with the tamping rod.

c. Strike off the excess sample using the tamping rod as a straightedge.

d. Take the weight of sample in the measure (W1)e. Now drop the hammer in the testing machine 15 times on the

sample kept in the cup. Height of the fall of the hammer shouldbe 380 mm. The interval between each blow should be aboutone second.

f. Remove the sample from the cup and sieve it one 2.36 mm ISsieve until no more sample passes through the sieve.g. Find the weight of the sample retained on 2.36 mm sieve (W2).h. Repeat the test for another sample from the same lot and

calculate the average of the two values.i. Calculation :

Aggregate impact value, % = (W1-W2)/W1 x 100WhereW1 = weight of dry sample passing through 12.5mm IS sieve

and retained on 10 mm IS sieve, gW2 = weight of dry sample retained on 2.36 mm IS sieve, g

j. Report the aggregate impact value in percentage and as themean of two determinations rounded off to the nearest wholenumber.



TEST PROCEDURES

Air Oven for Aggregate (Coarse and Fine)

1. Moisture content of Aggregate

Moisture content of aggregate is the percentage of weight or water in the aggregate sample to the total dry weight of the aggregatesample. The procedure is the same for both coarse and fineaggregate.

2. Apparatus

One hot plate or oven tray and balance

3. Procedure

a. Take the weight of moist or wet sampleb. Dry it in a hot plate or ovenc. Take the weight of dry sample

4. Calculation

Moisture content of aggregate is calculated as follows :M=(W1-W2) / W2 x 100WhereM = Moisture content of aggregate, %W1 = Weight of moist sample, gW2 = Weight of dy sample, g



TEST PROCEDURES

ELONGATION GAUGE COARSE AGGREGATE

1. Elongation Index :

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

2. Apparatus :

Balance, Elongation gauge (Length gauge) and IS sieves of thefollowing mesh sizes – 63 mm, 50 mm, 40 mm, 31.5 mm, 25mm, 20 mm, 16 mm, 12.5 mm, 10 mm and 6.3 mm.

3. Procedure :

a. Take enough quantity of dry blended sample so thatatleast 200 pieces of any fraction is present. This is notapplicable for the biggest and smallest size.


c. Separate all the individual fractions – 63 mm to 50 mm,50 mm to 40 mm, 40 mm to 25 mm, 25 mm to 20 mm, 20mm to 16 mm, 16 mm to 12.5 mm, 12.5 mm to 10 mmand 10 mm to 6.3 mm.

d. Take all the fraction separately, gauge them one by onethrough 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 avoidtesting bias.

e. Weigh the particles retained on length gauge.f. Elongation index is the total weight of the material




4. Calculation :

Elongation index of aggregate in % is calculated as follows :

Ei = (W1 / W2) x 100, %WhereW1 = weight of particles retained in length gauge, gW2= weight of total sample taken for test, g

5. Reporting :

Report the elongation index in percentage rounded off to thenearest whole number.



TEST PROCEDURES

FLAKINESS GAUGE FOR COARSE AGGREGATE

1. Flakiness IndexFlakiness index of an aggregate is the percentage by weight of particles in it whose least dimension (thickness) is less thenthree-fifth of their mean dimension. It is measure on particlespassing through mesh size of 63 mm and retained on meshsize 6.3 mm.

2. ApparatusBalance, Flakiness gauge (thickness gauge) and GI sieves of

the following mesh sizes – 63 mm, 50 mm, 40 mm, 31.5 mm,25 mm, 20 mm, 16 mm, 12.5 mm, 10 mm and 6.3 mm.

3. Procedurea. Take enough quantity of dry blended sample so that

atleast 200 pieces of any fraction is present. This is notapplicable for the biggest and smallest size.

b. Sieve the blended sample through all the sievesmentioned above starting from the largest sieve i.e. 63

mm.c. Separate all the individual fractions – 63 mm to 50 mm,50 mm to 40 mm, 40 mm to 31.5 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.

d. Take all the fraction separately, gauge them one by onethrough the corresponding slot provided in the gauge.Keep the particles passing through the slot of the gaugeand retained in gauge separately. The aim should be topass as many as possible through the slot to avoid testing

bias.e. Note the number of particles passing and not passing

through the corresponding slot in the gauge for eachfraction.



f. Calculate for each fraction the following :1. Percentage of number of particle passing the slot to

the total number of particles in fraction. This is notedas X.

2. Percentage of weight of particles in fraction taken for testing to the total weight of particles in all fractionstaken for the test (total qty.). This is noted as Y.

Calculation :

Flakiness Index = Fi = X (Xi – Yi)/100%

i=1 to nWhereXi = Percentage of number of particles passing the slotto the total number of particles in that fraction, %Yi = Percentage of weight of particles in fraction to thetotal weight of particles in all fraction, %

Reporting :

Report the flakiness index in percentage rounded off to thenearest whole number.



TEST PROCEDURES

SIEVES FOR FINE AGGREGATE

1. Purpose :The sieves are used for the determination of particle sizedistribution of fine aggregate by sieving.

2. Sieve analysis of Fine Aggregate :Fine aggregate consists of material mostly between 4.75 mmand 150 micron. It may be natural sand or crushed stone dust.Sand based on sieve analysis is classified into four zonesconforming to zone-I, zone-II, zone-III and zone-IV as per IS-

383.

3. Sizes of sieves :Sieves of the sizes 10 mm, 4.75 mm, 2.36 mm, 1.18 mm, 600mic., 300 mic., and 150 mic. And weighing balance.

4. Procedure :a. Take known weight of dry sample (about 1 kg min.)b. Sieve the sample progressively starting from the largest

sieve i.e. 10 mm.c. On completion of sieving weigh the material retained oneach sieve.

d. Calculate cumulative percentage of sand retained in eachsieve and cumulative percentage retained on each sieve.

e. Calculate cumulative percentage passing through eachsize.

f. Calculate the fineness modulus of sand by summing upthe cumulative percentage of sand retained on 10 mm,4.75 mm, 1.18mm, 600 mic., 300 mic., and 150 mic.

Sives and dividing the sum by 100.g. Find out which grading zone the sand conforms to by

checking with the table – 1 given below :



Table 1 : Grading zones (I.S. 383) 1978

I. S. SieveCumulative percentage passing IS sieves for grading zone

(natural sand)Crushed

Sand

I II III IV

10mm 100 100 100 100 1004.75mm 90-100 90-100 90-100 90-100 90-100

2.36mm 60-95 75-100 85-100 95-100 75-100

1.18mm 30-70 55-90 75-100 90-100 55-100

600 micron 15-34 35-59 60-79 80-100 35-79

300 micron 5-20 8-30 12-40 15-50 8-40

150 micron 0-10 0-10 0-10 0-15 0-20

75 micron 0-3 0-3 0-3 0-3 0-15

test prcedure for concrete

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