Laboratory Instruction Manual - Phase -1

CE 242A: Civil Engineering Materials

Jan 2016

Course Instructors

Dr. Sudhir Misra

Dr. Syam Nair

Department of Civil Engineering

Indian Institute of Technology Kanpur

(This manual has been prepared with the help of

Staff of the Structural Engineering Laboratory and
is meant for Internal Circulation Only)

January 6, 2016
January 13, 2016
January 20, 2016
January 27, 2016
February 3, 2016
February 10, 2016
February 24, 2016

January 4, 2016

January 11, 2016

January 18, 2016

January 25, 2016

February 1, 2016

February 8, 2016

February 22, 2016

2
3
4
5
6
1

2
3
4
5
6

II & VIII

Expt. # 1

Group #
I & VII

2 n d Semester , 2015-16

No lab

III & IX

IV& X

V & XI

VI & XII

(2:00 PM to 4:00 PM)

Groups for phase 1 will have 4 or 5 students in each group.

All experiments will be conducted in the Structural Engineering Laboratory except experiment # 6 which will be
conducted in Transportation Engineering Laboratory.

Wednesday Batch

Monday Batch

Phase 1

C E 2 4 2 A : Laboratory Schedule ,

Structural Engine ering Laboratory, Department of Ci vil Engineering, IIT Kanpur

To the students
This document has been prepared to facilitate carrying out the laboratory experiments
in this course on Civil Engineering Materials. It should be pointed out at the very outset
that this document has NOT been prepared to replace the codes and specifications that
lay down procedures for carrying out experiments or for evaluating the results
obtained. You MUST go through those documents carefully and come appropriately
prepared to carry out the experiments in the laboratory.
Now, though certain specific procedures to be followed are laid down in the methods
of test, you are encouraged to apply your mind and try to understand the spirit behind
such procedures. You should remember that the procedures laid down serve not only
an instructional purpose, but are also used by practicing engineers and technicians at
site, or even by lawyers to resolve contractual disputes. To that extent, procedures need
to be as unambiguous as possible, and should be such that the tests may be carried out
at different places, by different people and at different times, but the results can be
compared. However, as students you should bear in mind that the procedures can and
should be changed with the passage of time, to incorporate changes in technology,
needs, and the like.
Thus, rather than thinking of codal procedures as binding you should study them
carefully and try to grasp the spirit of a certain requirement. For example, if the code
requires that the gauging of cement should be completed within two minutes from the time the
water comes in contact with the cement, the important thing is to appreciate that mixing
cannot be continued indefinitely. Though the limit of two minutes should also indeed
be adhered to, but should be understood in the light that it may be different if the tests
are being carried out for special cements, or a special mixing method (than gauging by
hand) is being used.
In this document, Explanatory Notes have been given for most of the experiments to
provide the backdrop for the experiment, and facilitate your understanding of the
procedure, which is also laid down. An effort has also been made to provide Food For
Thought, at the end of each experiment. The questions included therein will perhaps
help you check your understanding of the experiment, though the answers to some of
the questions also require knowledge of the underlying theoretical principles. Some
tasks have also been included to give direction to further reading in a certain area.
Though the procedures described here are primarily based on relevant Indian codes,
you are encouraged to study other codes (e.g. British, American or Japanese) and see
how the provisions (methods of test or the specifications), compare with the
corresponding Indian documents.

Lab Manual /2016

TABLE OF CONTENTS

Phase 1
Experiment Description

Page no.

1.

Standard consistency and initial and final setting time of

cement

2.

Specific gravity, fineness, soundness & compressive strength

of cement

3.

Mechanical properties of coarse aggregates

(aggregate crushing value, impact value and abrasion value)

17

4.

Physical properties of fine aggregate and coarse aggregates

(particle size distribution, fineness modulus, water
absorption, bulk density, specific gravity)

22

5.

Dimensions, water absorption, compressive strength and

efflorescence of bricks

32

6.

Flash point, penetration value, softening point & ductility

value of bitumen

36

Lab Manual /2016

Lab Report Format

Experiment No. #
Students Name:
Group No.:
Date of experiment
Room Temperature:
Relative Humidity:

The lab report is to be neatly prepared covering the following aspects.

Objective:
Equipments & Materials:
Relevant Indian Codes:
Observation Tables:
Results & Conclusions:

Lab Manual /2016

EXPERIMENT # 1
STANDARD CONSISTENCY AND INITIAL AND FINAL SETTING TIME OF
CEMENT
Objective
To determine the following properties of Ordinary Portland Cement (OPC):
(a) Standard consistency (b) Initial setting time (c) Final setting time.
Explanatory notes
A mixture of cement and water is called cement paste, and it could vary in consistency
depending upon:
(a) Amount of water added to the paste (as a percentage of cement), and,
(b) Properties of the cement, e.g. fineness, chemical composition etc.
Constituents of cement react chemically with water and the formation of hydration products
leads to changes in the consistency of the cement paste. It should be borne in mind that this
reaction starts as soon as cement comes in contact with water and stiffening, setting, hardening
and strength gain are some of the other terms used extensively in studies related to hydration of
cement. Now, in the absence of methods to measure consistency, an indirect method based on
penetration resistance is used. Generally the Vicat apparatus is used.
Standard consistency and initial and final setting times are routinely used as a measure of quality
control and better understanding of the properties of the cement being used for a concrete
construction project. They can be briefly described as follows:
(a) Standard consistency: A paste is said to have standard consistency if the Vicat plunger
penetrates to a point 5-7 mm from the bottom of the Vicat mould. Usually the amount of
water required to prepare such a paste is referred to as standard consistency of the cement
sample. It generally varies between 26 ~ 30% for OPC.
(b) Initial and final setting time: Setting refers to the process of solidification of cement as
more hydration products are formed. The test for initial and final setting is, in principle,
based on penetration resistance (as more solidification occur the penetration resistance
increases).
Initial setting time (IST) is said to have reached when the paste (prepared in a specified
manner) does not allow the (standard) IST needle to penetrate beyond 5+0.5 mm measured
from the bottom of the mould.
Final setting time (FST) is said to have reached when the (standard) FST needle makes an
impression upon applying gently to the surface of the test block while the annular attachment
fails to do so.
Equipment and Materials
x
x
x

Appropriate weighing machine with corresponding accuracy. (the code lays down
minimum standards for machines of different capacities)
Vicat apparatus
Consistency plunger and setting times needles

Lab Manual /2016

x
x
x

Gauging trowel
At least 3 kg of Portland cement
Potable water

Relevant Indian codes

IS 3535: 1986
IS 269 : 1989
IS 8112 : 1989
IS 12269 : 1987
IS 4031 (part 4) : 1988
IS 4031(Part 5) : 1988
IS 4845 : 1968

Methods of sampling hydraulic cements

Specification ordinary Portland cement, 33 grade.
Specification for 43 grade ordinary Portland cement.
Specification for 53 grade ordinary Portland cement.
Methods of physical tests for hydraulic cement : Part 4
- Determination of consistency of standard cement paste
Methods of physical tests for hydraulic cement : Part 5
- Determination of initial and final setting times.
Definitions and terminology relating to hydraulic cement.

Test Procedure
Step
Description
Standard consistency
1.
Weigh 400g of cement from the provided sample.
Prepare a paste using this (400 g of cement) with an
accurately weighed quantity of potable water, say, 28%
(112 g). The paste should be prepared by gauging
using a gauging trowel to a mix of uniform colour. The
gauging process should be completed within 3-5
minutes.

2.

3.

4.

Immediately fill the Vicat mould with the paste

completely, with the mould resting on a non-porous
surface. Smooth the surface of the paste making it level
with the top of the mould. Shake it slightly to expel the
air. The cement block thus prepared in the mould is
referred to as a test block.
Place the test block (immediately after preparing it)
under the rod bearing the Vicat plunger and lower the
plunger gently to touch the surface of the test block.
Quickly release the rod allowing it to sink into the paste
and measure the penetration of the plunger.
Depending upon the penetration of the Vicat plunger
alter the amount of water added to the paste, and repeat
steps 1 to 3. The exercise ends when the bottom end of
the plunger stops 5-7 mm above the bottom of the
mould. Note down the percentage of water added, and
we call this percentage as standard consistency (P).

Lab Manual /2016

Comments
An initial value 28% is
suggested only as a guideline.
Upper bound is given on the
time to ensure that the setting
process does not interfere with
the
readings
taken.
For
subsequent pastes the proportion
of water should be adjusted
depending upon the consistency
obtained in the initial paste.

If the penetration of plunger is

too little, increase the percentage
of water and if it is too much,
decrease the percentage.

Setting times
5.

6.

7.
8.

Notes:

Prepare the test block by gauging, a known quantity

cement with 0.85P percent water (by mass of the dry
cement). For example, if 400 g of OPC is used, and the
standard consistency of the cement is known to be 30%,
102g (i.e. 0.85 x 30 x 400/100) of water needs to be
added to make the paste for the test block.

Since the initial and final setting

times of the cement may be
several hours, and it may not be
possible for the observations to
be completed within the
stipulated time in the laboratory,
a pre-prepared test block may
be provided. Check the time
when the paste was prepared to
enable determination of the
initial and final setting times.
Place the test block under the rod bearing Initial Setting In the beginning, the needle will
Time (IST) needle and lower the needle so that it comes completely pierce the test block.
in contact with the surface of the test block. Quickly
release and allow it to penetrate into the test block.
Repeat this step until the needle fails to pierce beyond
5+0.5 mm measured from the bottom of the mould. Let
this time instant be t1 from the instant of adding water.
Using the same test block as used for determination of As t2 is usually in several hours,
initial setting time, replace the IST needle by Final the test block should be kept in
Setting Time (FST) needle. Note the time t2 (from the 90% relative humidity when the
instant of adding water), at which the needle makes an tests for setting time are not
impression upon applying gently to the surface of the being done. (Please also see note
test block while the annular attachment fails to do so. t1 regarding pre-prepared test
and t2 are respectively the initial and final setting times, blocks.)
and these should be reported to the nearest five minutes.

Maintain the temperature of room, cement and water at 27+2oC and relative humidity of
the room at 65+5%.
Record the time when the standard IST needle is changed to the standard FST needle.

Specifications
For 33 grade OPC and 43 grade OPC, t1 > 30 min and t2 < 10 hours.
[As per IS 269: 1989 and IS 8112 : 1989]
FOOD FOR THOUGHT
1. Study the standard needles for the consistency, IST and FST tests carefully and note the
similarities and differences.
2. How is the fineness of the cement likely to affect the standard consistency or the initial
and final setting times? Give reasons.
3. What are the major constituents of cement?
4. How the chemical composition is usually expressed?
5. Why do codes usually place a limit on the minimum initial setting time and a maximum
final setting time?

Lab Manual /2016

Observation Tables
(a) Standard Consistency
Sample

Water
content %

Cement
used (g)

Water
added (g)

Penetration of
needle (mm)

Remarks

1.
2.
3.
4.
5.
6.
Standard consistency: P =
(b) Initial and final setting time
Wt. of cement taken: g.
Time (min.)

Penetration of needle (mm)

IST:. (minutes)

Lab Manual /2016

Wt. of water used: g.

Time (min.)

Penetration of needle (mm)

FST: (minutes)

EXPERIMENT # 2
SPECIFIC GRAVITY, FINENESS, SOUNDNESS AND
COMPRESSIVE STRENGTH OF CEMENT
Objective
To determine the following properties of Ordinary Portland Cement (OPC):
(a) Specific gravity (b) Fineness (c) Soundness (d) Compressive strength.
Explanatory notes
It is important that the properties of cement are properly determined and understood before the
material is actually used in construction.
In this context, it may be pointed out that fineness of the cement plays an important role in
determining the rate of hydration and strength development (in concrete). Unsoundness
(deleterious expansion) is caused by the presence of harmful levels of magnesium oxides (these
are usually present in small quantities) in the raw materials used in the manufacture of cement.
Further, since cement is, in principle, the only binding material used in concrete, their
classification is often based on the compressive strength developed using standard mortar
specimens. Also, the specific gravity of cement could affect the proportioning of concrete mixes,
and could be also indicative of presence of other mineral admixtures. It should be borne in mind
that admixtures such as fly ash and blast furnace slag are indeed marginally lighter than OPC.
The clinker obtained from the fusion and cooling of the ingredients is ground in ball mills during
the manufacture, and depending upon the efficiency of the grinding process, cement could be
ground to varying degrees of fineness. Cement particles are thus irregular in shape and could
vary between about 10Pm and about 75Pm in size. It has been agreed that cement particles
larger than about 45Pm may be difficult to hydrate and those larger than 75Pm may never really
completely hydrate. Given the fine nature of cement particles, the fineness is often expressed in
terms of surface area (finer particles have a higher surface area). This measurement could be
based on adsorption (directly related to the surface area of the sample), or, could be carried out
through an estimation of the permeability characteristics of a bed made with the material.
Fineness of cement is often measured by the Blaines apparatus, which is based on the latter
principle.
As far as testing the cement for soundness is concerned, since it may take a very long time for
the symptoms of unsoundness (cracking, etc.) to appear, the tests in the laboratory are usually
carried out using accelerated methods. The hydration process is accelerated by curing the sample
prepared at high temperature, and observing any potential expansion.
The strength (rate of development and also the final strength) is closely related to factors such as
the properties of ingredients (including sand) and proportion (of ingredients) of the mortar used,
the conditions of curing (temperature and pressure), age of testing and conditions of the test (e.g.
specimen size and rate of loading). Thus, when the determination of strength of a cement is
carried out as part of a quality control exercise (or to compare different cements), it is important
that care is taken NOT to disturb the other factors. Attention is thus drawn to the following:

Lab Manual /2016

1. Due to the fact that paste is hardly ever used as a construction material, and displays
excessive drying shrinkage, mortar is used to prepare samples for the purpose of
characterization of the cement.
2. Given the fact that the ability to compact the sample could be affected by the consistency of
the mortar, an effort is made to relate the amount of water used to prepare the mortar to the
standard consistency of the cement. Also, since the properties of the sand used in the
preparation of the mortar also affect the consistency of the mortar, and may contribute to
absorption of the water mixed in the mortar, the sand used for the purpose is also
standardized.
3. In an effort to standardize the proportion of the ingredients, the cement - sand ratio of the
mortar is fixed at 1:3 in Indian standards. As far as the amount of water to be added is
concerned, it is prescribed as [0.25P + 3] % of the total weight of cement and sand.
4. Thus, it is clear that the water-cement ratio, has not been fixed in the experiments [See (2)
above also]. For example, for 200g of cement, 600g of sand needs to be taken, and if the
standard consistency is 28%, the water to be added is 80g [0.25 x 28 + 3 = 10% (of 800, i.e.
80)] which gives a water-cement ratio of 40% [80/200], which changes to 42% if the
standard consistency for the cement is 30%. This factor should always be kept in mind when
comparing the strength characteristics of different cements.
5. The size of the specimen, curing conditions, age at the time of testing, and parameters such
as the rate of loading, etc. are also laid down in standards, so as to enable a fair estimation of
the strength development characteristics of the cement being used.
Equipment and Materials
1. Specific gravity
x Standard Le Chatelier flask
x Heavy rubber pad about 30 cm x 30 cm
x Lead-ring weight to fit around stem of the flask
x Funnel
x Balance
x Thermometer
x Kerosene
2. Fineness
x Blaine air permeability apparatus
x 90 micron IS Sieve
x Balance
x Timer accurate to 0.5 sec.
x Standard Reference Material No. SRM-1001 (Standard cement sample with
known fineness) of NCCBM
3. Soundness
x Standard mould (small split cylinder of 0.5 mm thickness, 30 mm internal
diameter and 30 mm height)
x Tray, heater, balance
x Two glass sheets 5 cm x 5 cm
x Autoclave
x Moulds 25 x 25 x 250 mm size
x Scale to measure length (Should we not be using Vernier Calipers)

Lab Manual /2016

4. Compressive Strength
x Vibration machine
x Balance
x Poking rod
x Cube moulds (for cubes of 5000mm2 area on each face)
x Gauging trowel as per the BIS specifications
x Indian Standard Sand conforming to IS 650 : 1991
Relevant Indian codes
IS 269: 1989
Specifications for 33 grade ordinary Portland cement.
IS 8112: 1989
Specifications for 43 grade ordinary Portland cement.
IS 12269: 1987
Specifications for 53 grade ordinary Portland cement.
IS 4031
Methods of physical tests for hydraulic cement:
Part 1: 1996
Determination of fineness by dry sieving
Part 2: 1999
Determination of fineness by specific surface by Blaine Air permeability
method
Part 3: 1988
Determination of soundness
Part 6: 1988
Determination of compressive strength of hydraulic cement other than
masonry cement
Part 11: 1988
Determination of density
IS 4845 : 1968
Definitions and terminology relating to hydraulic cement.

Test Procedure
Step
Description
Specific gravity of cement
Fill the flask with kerosene so that the meniscus
1.
stands between the 0 and 1 ml mark on the stem.
Dry the inside of the flask if there are any drops
above the liquid level.
Place the flask in a constant temperature bath and
2.
record the initial height of the kerosene in the flask.
Also record the temperature of the stem of the flask
when commencing the experiment (A) and
temperature of the stem of the flask upon completion
of the experiment (B). The constant temperature bath
should be maintained at a temperature such that the
difference between the two temperatures should not
be more than 0.2oC.
Weigh about 64 gm of cement (between 62 gm and
3.
66 gm) using a paper boat and record its actual
weight accurately.
Introduce the cement into the flask.
Remove the flask from the bath and place it on the
4.
rubber mat. Take off the lead weight and roll the
flask in inclined position on the mat so as to remove
all air bubbles from the flask.
5.

Comments
To measure the change in volume
accurately, special care needs to be
taken to rid the drops above the
liquid level.
The temperature and volume is
recorded to ensure that the change
in volume of the kerosene
measured cannot be attributed to
changes in temperature.

Make sure that OPC does not

adhere to the sides of the stem. If
required, the cement may be
introduced slowly with the help of a
paper funnel. The actual mass of
cement added should also be
checked by weighing the flask
before and after addition of the
OPC.

Return the flask to the bath and check the

temperature within the flask. If it is within 0.2oC of
the original temperature inside the flask, proceed to
take the final reading (of the volume).

Lab Manual /2016

10

6.

Compute the density of the OPC using the following

relationship:
Density, U = mass of cement (g)/displaced volume
(cc)

Conduct the density determination on two samples of

cement. If the results do not differ by more than 0.03
g/cm3, the average of the two results may be taken.
Otherwise, additional determinations should be
carried out until a pair of values is obtained within
0.03 g/cm3. The density (g/cc) should be expressed as
specific gravity without any units.
Fineness of cement
Calibration of the apparatus is made by determining
1.
the bulk volume of the compacted bed of the
Standard Reference Material No. 1001 of NCCBM.
Press down two filter paper disks in the permeability
cell on the perforated metal disk with a slightly
smaller diameter rod and fill the cell with mercury.
Use tongs when handling the cell and remove any air
bubbles adhering to the sides of the cell. Level the
mercury to the top of the cell with a glass plate and
remove the mercury from the cell and weigh it, WA.
Remove the top filter paper from the permeability
cell and compress a trial quantity of 2.80 grams of
the Portland cement into the space above the filter
paper to the gauge line (height of 15 r 1.0 mm) in the
cell. It should be ensured that the cement bed is firm.
If it cannot be compressed to the desired volume,
adjust the quantity of cement and place the other
filter paper above the cement bed. Fill the remaining
space in the cell above the filter paper with mercury,
remove entrapped air in the mercury column, again
use tongs when holding the cell and remove any air
bubbles adhering to the sides of the cell. Level the
mercury to the top of the cell with a glass plate and
remove the mercury from the cell and weigh it, WB.
Compute the volume occupied by the cement bed in
the cell from the following equation: V = (WA
WB)/D.
If the results do not differ by more than 0.005 cm3,
the average of the two results may be taken.
Otherwise, additional determinations should be
carried out until a pair of values is obtained within
that limit.
D is the density of mercury which
can be assumed as 13.54 g/cm3 at
room temperatures between 18 to
28oC.
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11

The mass (in g) of the NCCBM Standard Reference

Material No. 1001 required to produce a bed of
cement having a porosity of 0.005 + 0.005 is
computed as: M= 1.58 V
Prepare a cement bed of the NCCBM Standard
3.
Reference Material No. 1001 of mass M, to the
nearest 0.001 grams; tap the sides of the cell to level
the cement, using filter papers at the top and bottom
as described in the previous step. Compress the
cement with the plunger until the plunger collar is in
contact with the top of the cell. Compress the cement
with the plunger a short distance, rotate 90, repress
the cement bed, and then slowly withdraw. Attach
the permeability cell to the manometer tube with an
airtight connection and slowly evacuate the air in the
manometer U-tube until the liquid reaches the top
mark, then tightly close the valve. Start the timer
when the bottom of the meniscus reaches the second
( next to the top) mark and stop the timer when the
bottom of the meniscus reaches the third ( next to the
bottom) mark. Note and record the time interval and
repeat this procedure three times. The same cement
bed may be used by refluffing the cement between
each determination. The average of these
determinations is designated as TS. All the tests in
this procedure should be conducted at approximately
the same room temperature. All of the cements tested
should be at room temperature.
Repeat step 3, only this time use the Portland cement
4.
whose fineness is to be found, using the same mass
M, with the following exceptions: only a one timeof-flow determination needs to be made and M for a
Type III, or other very fine ground Portland cement,
use a M = 1.48 V. The resulting time is designated as
T.
Soundness of cement
In the Le Chatelier method of determination of
1.
soundness, cement paste formed by gauging cement
with 0.78P water, is used.
The mould (consisting of a small split cylinder of 0.5
2.
mm thickness, 30 mm internal diameter and 30 mm
height) is lightly oiled, is kept on a lightly oiled glass
sheet, and is filled up with this cement paste. The
mould is then covered by another lightly oiled glass
sheet and a small weight is placed on it. The whole
assembly is immediately immersed in water at a
temperature of 27+2oC and is kept there for 24 hours.
The distance between the indicator points is now
measured to the nearest 0.5 mm.
2.

Lab Manual /2016

P is the standard consistency of the

cement, and needs to be determined
before this test is carried out. Thus,
if P=30%, 23.4g of water needs to
be added for every 100g of cement
used in preparing the paste.

12

After this, the mould is again submerged in water and

the water is brought to boiling in 25 to 30 minutes,
with the mould kept submerged. The water is kept
boiling for 3 hours. The mould is now removed from
the water, is allowed to cool, and the distance
between the indicator points is measured. The
difference between the two measurements is reported
as the Le Chatelier expansion of the given cement
sample.
In the Autoclave Method, specimens of 25x25x282
4.
mm size are prepared from cement paste of standard
consistency (made from 500g cement), and their
lengths are measured after keeping for 24 hours in a
room of 90% humidity.
These specimens are then kept in the autoclave where
5.
steam pressure is brought up to 2.1 MPa in about
1.25 hours. This pressure is maintained along with a
temperature of about 215.71.7oC for 3 hours, and
then specimens are cooled for one hour. These are
then placed in water with temperature greater than
90oC, which is then cooled down to 27+2oC in 15
minutes. After keeping for 15 more minutes in the
same water, their surfaces are dried and lengths are
measured again.
Compressive strength of cement
1.
For preparing one mortar cube, a mixture of 200g
cement, 600g standard sand(#), and (0.25P + 3.0)%
water is prepared on a non-porous plate. The cement
and sand are first mixed dry for about one minute and
then, with water for 3-4 minutes until the mixture
gets a uniform colour.
3.

2.

3.

Since casting a cube could take

some time it may be advisable to
mix the mortar for each cube
separately.
The amount of water should be
calculated on the basis of the total
quantity of cement and sand. Thus,
if P = 28% and 200 gm and 600 gm
of cement and sand respectively is
being used, 80 gm of water should
be added .

The mould is treated with a thin coating of mould oil

on its interior faces while petroleum jelly is used to
stop the escape of water through the joints of the
mould halves during vibrations. The assembled
mould is placed on the table of the vibration machine
and is firmly held in position by means of a suitable
clamp. To facilitate filling, a hopper is kept attached
at the top of the mould until the end of vibrations.
The mortar is placed in the cube mould immediately Tamping and compaction using the
after mixing and is prodded 20 times in about 8 vibratory table is carried out to
seconds with the help of tamping rod.
eliminate any entrapped air. The

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13

4.

The remaining quantity of mortar is placed in the

hopper and prodding is done once again. The mortar
is then compacted by vibrations @ 12000+400
vibrations/minute for 2 minutes. The mould is
removed together with the base plate from the
machine and the top surface is finished with the
blade of a trowel.
The filled moulds are kept at 27+2oC in an
atmosphere of having more than 90% humidity for
24 hours. The cubes are then removed from the
moulds and are submerged in clean water of 27+2oC
temperature. Water is renewed every 7 days.

5.

6.

At the time of testing, the cubes are taken out and

tested for compressive strength at each relevant
period (i.e. 3 days, 7 days, and 28 days) as measured
from the completion of vibration (rate of loading
being 35 MPa/minute). 3 cubes should be tested and
average obtained (to the nearest of 0.5 MPa) is
reported as the compressive strength.

cubes may be appropriately

numbered before putting in the tank
for future identification.

Cubes should be kept covered with

wet gunny bags in a room of
required temperature and humidity,
to prevent drying of specimens
during the initial period when they
cannot be immersed in water.
Before test the cubes should be
wiped clean of excess water etc.
and tested on their sides. The top
and bottom surfaces of the cube (at
the time of casting) should not be
used to apply the load as they
(specially the top) could be uneven.

(#) Standard sand is re-graded sand which passes 100% through 2 mm IS sieve and is retained
100% on the 90 micron IS sieve (IS: 650-1966, Indian Standard Specification for Standard
Sand for Testing of Cement). This sand has one-third particles (by weight) greater than 1
mm, one-third particles smaller than 1 mm and greater than 500 microns, and the remaining
one-third below 500 microns. The particles are of quartz, light grey, or of whitish variety,
with most of the particles approximating to the spherical form
Note :
x
x

x
x

Maintain the temperature of room, cement and water at 27+2oC and relative humidity of
the room at 65+5%.
If the strength of any cube differs by more than 10% from the average strength, the
average is recomputed after ignoring the strength of this cube. If there
are two
specimens with greater than 10 % deviation, the results of the test should be rejected and
the test carried out again.
All cubes should be measured in size to nearest 0.1 mm. and the actual area of load
application computed.
The cubes should be weighed to the nearest of 0.1 gm. and the weight reported.

Specifications
Soundness: BIS standards require that the Le Chatelier expansion shall not exceed 10 mm (for
43 grade cement). In the event that this is not satisfied, there is also a provision to test an aerated
cement sample (obtained after spreading cement in layers of 75 mm thickness and is stored for 7
days at 27+2oC and 50-80% humidity). The Le Chatelier expansion for aerated cement sample
shall not be more than 5mm. Further, the mean value of the difference is calculated to the
nearest 0.01% of the 250 mm gauge length and is reported as the autoclave expansion of the
cement. For 43 grade OPC, this expansion should not exceed 0.8% and if the expansion exceeds
this limit, the test may be carried out using an aerated sample, and then the mean expansion
should not exceed 0.6%.
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14

Strength: as given in the following table.

Grade

3 days
(72+1 hours)

7 days
(168+2 hours)

28 days
(672+4 hours)

OPC 33

16 MPa

22 MPa

33 MPa

OPC 43

23 MPa

33 MPa

43 MPa

OPC 53

27 MPa

37 MPa

53 MPa

FOOD FOR THOUGHT

1. Describe any method(s) for surface area determination based on adsorption.
2. Can any other liquid (other than kerosene used here, say water) be used in the
determination of specific gravity of cement?
3. Apart from the properties discussed here, what are some of the other properties that are
of interest for concrete and construction engineers?
4. On what properties of cement, does its strength development depend?
Observation Tables
(a) Specific gravity of cement
Description

Initial bath temperature, C

Initial reading, ml
Final reading, ml
Displaced volume, cm3
Final bath temperature, oC
Density of cement = 64 grams/displaced volume,
cm3
Average specific gravity of accepted specimen results =
(b) Fineness of cement
Weight in grams: WA =
Determination of V in cm3: V =

, WB =
,

Accepted value for V after at least two determinations =

Measured time interval for standard sample, Ts in sec.:
Accepted value. Ts, after at least three determinations =
Measured time interval for test sample, T in sec. =
Specific surface of cement specimen: S=Ss(T)1/2/(Ts)1/2
Ss is obtained from the data on the vial containing the standard cement sample (NCCBM
Standard Reference Material No. SRM 1001).

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15

(c) Soundness of cement

Le Chatelier Method:

Sample 1

Sample 2

Sample 1

Sample 2

Initial distance between the indicator points (mm)

Final distance between the indicator points (mm)
Difference between final and initial measurements (mm)
Average expansion in mm
Autoclave Method:
Initial length of specimen in mm (l1)
Final length of specimen in mm (l2)
Autoclave expansion = (l2-l1)/250 * 100

(d) Compressive Strength

Date of casting:
Specimen
No.

Time of Loading
(s)

Date of testing:
Ultimate Load
(kg)

Age:
Area of specimen
(mm2)

Compressive
Strength (MPa)

1.
2.
3.
4.
Average compressive strength

Lab Manual /2016

16

EXPERIMENT # 3
MECHANICAL PROPERTIES OF COARSE AGGREGATES
Objective
To determine the following mechanical properties of coarse aggregates:
(a) Crushing value (b) Impact value (c) Abrasion Value
Explanatory notes
The mechanical properties of the coarse aggregates are very important in determining the
properties of hardened concrete. This is especially true in the recent years, when effort is made
to develop and use high strength concrete, where the strength of the mortar paste could be
comparable to that of the aggregate. This has implications in terms of the failure mechanism of
the concrete (traditional low to medium strength concretes, say up to M30 grade), the failure
almost always occurs because of the weakness in the transition zone (between the aggregates
and the mortar) and the mortar itself. However, in high strength concrete, the fracture could
occur because of the failure of the rock itself, and hence it is imperative that greater attention is
paid to the properties of the aggregates used.
In addition to high strength concrete, as discussed above, certain specific applications, such as
roadways and airport runways, where concrete could be subjected to abrasion, require use of
good quality (in terms of mechanical properties) aggregate in concrete.
Equipment and Materials
1. Aggregate crushing value
x Aggregate Crushing value apparatus comprising 150 mm nominal diameter steel
cylinder, plunger and base plate
x IS Sieves 12.5, 10, 2.36 mm
x Balance of capacity 6 kg and accurate to 1 gm
x Metal measure, 115 mm diameter and 180 mm depth
x Steel tamping rod of 16 mm diameter and 450 600 mm length
2. Aggregate impact value
x Aggregate impact value apparatus
x Cylindrical measure 75 mm diameter and 50 mm depth
x Steel tamping rod of 10 mm diameter and 230 mm length
x Balance of capacity 3 kg and accurate to 1 gm
3. Aggregate abrasion value
x Los Angeles Abrasion Machine, comprising a heavy steel cylinder, rotated about
its horizontal axis at 20 to 33 rpm and a removable internal shelf
x Set of abrasive charges, cast iron or steel spheres of about 48 mm diameter and
weight 390-445 g each
x Balance of capacity 6 kg and accurate to 1 gm

Lab Manual /2016

17

Relevant Indian Codes

IS 383: 1970
IS 2386 (Part IV): 1963

Specification for coarse and fine aggregates from natural sources

for concrete.
Methods of test for aggregates for concrete Mechanical Properties

Test Procedure
Step
Description
Aggregate crushing value
1.
Use the available aggregate sample and obtain aggregate
finer than 12.5 mm that does not pass through the 10 mm IS
sieve. Sample is surface dried before testing (lay ovendrying at 100-110 degree centigrade for not more than four
hours) and is filled in a 15 cm diameter cylinder with
plunger and base plate to 100 mm depth.
2.
Take the aggregate sample and the cylinder is filled in three
layers of approximately equal depth and each layer is
tamped 25 times with the rounded end of the tamping rod.
Take the weight (A) of the sample.
3.
The aggregate is subjected to increasing compressive load of
40 T in about 10 minutes with the help of plunger inserted
into the cylinder. The crushed material is then removed
from the cylinder and is sieved through a 2.36 mm IS sieve.
The fraction passing through the sieve is weighed (say, B).
4.
The aggregate crushing value is obtained as 100 B/A % to
the first decimal place. The test is repeated from step 1 and
the mean of two results is reported to the nearest whole
number along with the size of the aggregate.

Comments

Aggregate impact value

5.
In this test, weight, A, is determined in the same way as in
the test for determining the crushing value of the aggregate.
However, the cylindrical measure here has 75 mm diameter
and 50 mm height.
6.
The measured aggregates are placed in a cylindrical steel
cup (102 mm diameter and 50 mm height) and compacted by
a single tamping of 25 strokes of the tamping rod.
7.
This test sample is then subjected to 15 blows of a 13.5-14
kg hammer freely falling by 380 mm. Each blow is delivered
at an interval of not less than one second.
8.
The crushed aggregate is sieved on the 2.36 mm IS sieve and
the fraction passing the sieve (say, B) is weighed to an
accuracy of 0.1 g. The fraction retained on the sieve is also
weighed (say, C), and if B + C < A 1 (where, A, B, and C
are in g), a fresh test is made. Aggregate Impact Value = 100
B / A %.
Aggregate abrasion value
9
In Los Angeles (abrasion testing) machine, we use cast iron
or steel spheres of about 48 mm diameter and 390-445 g
weight each (called as abrasive charge). Depending on the
Lab Manual /2016

18

10.

11.

12.

grading of the test sample from A to G, the number of these

spheres (total abrasive charge) and total weight of sample is
fixed.
The test sample is oven dried at 105 to 110 degree
centigrade and placed in the steel cylinder of the Los
Angeles machine along with the charge. The cylinder is then
rotated at the speed of 20-33 revolutions per minute with
uniform peripheral speed.
The total number of revolutions is 500 and 1000 respectively
for grading zones A to C and D to F. At the end of this, the
fraction of test sample retained on 1.7 mm IS sieve is
washed; oven dried at 105 to 110 degree centigrade, and is
weighed to the nearest gram.
Difference between the original weight and the final weight
of the sample, expressed as a percentage of the original
weight of the test sample, is reported as Abrasion Value.

Specifications
x
x
x
x

The aggregate crushing value shall not exceed 45 percent for aggregate used for concrete
other than for wearing surfaces, and 30 percent for wearing surfaces, such as runways,
roads and pavements.
The aggregate impact value shall not exceed 45 percent for aggregate used for concrete
other than for wearing surfaces, and 30 percent for wearing surfaces, such as runways,
roads and pavements.
In aggregate impact value determination, if B + C < A 1 (where, A, B, and C are in g),
a fresh test is made.
The abrasion value of aggregates when tested using Los Angeles machine, shall not
exceed the following values:
a.
For aggregates to be used in concrete for wearing surfaces 30 percent
b.
For aggregates to be used in other concrete
50 percent

FOOD FOR THOUGHT

1. What is the compressive strength of some of the rocks commonly used to obtain
crushed aggregates?
2. Why is the strength of rock not of major concern in most of the concrete construction?
3. Which of the three parameters defined here are closest to the compressive strength of
the rock?
4. Can crushed concrete be used as coarse aggregate in new concrete construction?

Lab Manual /2016

19

Observation Tables
(a) Aggregate crushing value

Description

Sample - 1

Sample - 2

Empty weight of cylindrical measure: X

Weight of cylindrical measure after filling with aggregate: Y
Weight of the material to be filled in the cylinder: A = Y - X
Weight of material passing 2.36 mm IS sieve: B
Aggregate crushing value = 100B/A
Average Aggregate crushing value =

Note: For reference, relevant pages of IS 2386 (Part IV): 1963 are added at the end of the manual.

Lab Manual /2016

20

(b) Aggregate impact value

Description

Sample - 1

Sample - 2

Empty weight of cylindrical measure: X

Weight of cylindrical measure after filling with aggregate: Y
Weight of the material to be filled in the cylinder: A = Y - X
Weight of material passing 2.36 mm IS sieve(after impact test) :
B
Weight of material retained on 2.36 mm IS sieve: C
Aggregate impact value = 100B/A
Average Aggregate impact value =
(c) Aggregate abrasion value

Description

Sample - 1

Sample - 2

Initial weight of sample placed in the steel drum of Los

Angeles Abrasion machine: A
Weight of test sample retained on 1.7 mm IS sieve after
washing and oven drying: B
Aggregate abrasion resistance value = 100(A B)/A %
Average Aggregate abrasion value =

Lab Manual /2016

21

EXPERIMENT # 4A
PHYSICAL PROPERTIES OF COARSE AGGREGATES
Objective
To determine the following properties of coarse aggregates:
(a) Particle size distribution
(b) Fineness modulus
(c) Water absorption
(d) Bulk density
(e) Specific gravity
Explanatory notes
Though it is widely believed that coarse aggregate are inert by nature, and only act as fillers in
the concrete, it should be borne in mind that they constitute a very large percentage of the total
volume of concrete and, as such have a very important bearing on the properties of fresh and
hardened concrete.
Besides the mechanical properties of the coarse aggregate, the physical properties such as the
shape, size, water absorption etc. are also very important and should be carefully studied.
Now, coarse aggregates should, in principle, be so graded that the voids between the particles
are minimized and at the same time, all the aggregates are adequately coated with a layer of
mortar. Thus, most specifications require that the grading (fraction of particles of a certain size)
falls between prescribed limits. Fineness modulus (FM) is one of the single measures that can be
used to convey the idea of the overall particle sizes. For example, the FM of normally used 20
mm down aggregate could be between 6.5 and 7.0, whereas that for fine aggregate used in
concrete could be about 2.7. (The FM of sand used for plaster could be about 1.2.) As far as the
shape of particles is concerned, use of elongated and/or flat particles is also considered
undesirable.
The aggregates used are normally derived from rocks and have a finite (though, indeed, very
small) porosity. Now, when the aggregates are mixed with the other ingredients, they could
either take away the water from the mix, or contribute additional water to the mix, depending
upon whether they are dry or wet at that time. Both the possibilities are not desirable, and it is
emphasized that aggregates used should be saturated surface dry. In any case, it is important
that the water absorption of the aggregates is determined, so that that can be accounted for in
case it becomes necessary to use aggregates that are not saturated surface dry. Obviously, the
absorption is related to the density (specific gravity) of the aggregates, which is related to the
type of the parent rock. The aggregate density is also related to the mineralogical composition of
the rocks. Aggregates such as limonite, magnetite, etc are heavier, whereas those such as
pumice, or expanded slate are lightweight in nature.
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22

Now, though it is desirable and recommended that the ingredients of concrete are proportioned
by weight, it often becomes necessary to use batching by volume. This requires an
understanding of the bulk density of the aggregates, as there is invariably a large amount of void
space that is usually (and inevitably) present when aggregates are taken in a heap.

Equipment and Materials

1. Particle size distribution and Fineness Modulus
x A set of IS Sieves of aperture size 40, 25, 20, 16, 12.5, 10, 4,75 and 2.36 mm
x Balance with a capacity of at least 6 kg, accurate to 1g
x A wire brush
2. Water absorption and specific gravity
x Balance of at least 6 kg capacity accurate to 0.1 g
x Pycnometer
x Electric Oven
x A tray
x An air tight container
3. Bulk density
x Cylindrical metal container of capacity 3, 15 or 30 liters depending upon the
largest size of the aggregates
x Balance sensitive to 0.5% of the weight of sample
x Tamping bar of 16 mm dia and 600 mm long
Relevant Indian Codes
IS 383: 1970
IS 2386 (Parts I): 1963
IS 2386 (Parts III): 1963

Lab Manual /2016

Specification for coarse and fine aggregates from natural

sources for concrete
Methods of test for aggregates for concrete Particle size and shape
Methods of test for aggregates for concrete Specific gravity, density, voids, absorption and bulking

23

Test Procedure
Step

Description

Comments

Particle size distribution and fineness modulus

1.

Take 5 kg of oven dry sample of aggregate and sieve

successively on the appropriate sieves, starting with the
sieve of largest aperture size. The sieves should be
shaken with a varied motion, backwards and forwards,
left to right, circular clockwise and anti clockwise and
with frequent jarring so that the material is kept moving
over the surface of the sieve.
2.
Weigh the quantity of aggregate retained on each of the
sieves used.
3.
Compute cumulative weight retained, percentage
cumulative retained on each of the sieves and thereby
percentage passing from each of the sieves.
4.
Compute Fineness Modulus (FM) as given below,
FM = [sum of % cumulative weights of aggregates
retained on all the sieves]/ [100]
Bulk density
1.
Take a cylindrical metal container of about 3, 15 or 30
liters capacity depending upon the nominal size of
aggregate. Let the actual volume be V.
2.
3.

4.
5.

For coarse aggregates of

nominal size 20 mm, a set of
sieves of aperture size 40, 20, 10
and 4.75mm.
For aggregates of nominal size
12.5 mm a set of sieves of size
16, 12.5, 10, 4.75 and 2.36 mm,
should be used.
For computing FM, a set of IS
sieves of aperture size 150, 80,
40, 20, 10, 4.75, 2.36, 1.18, 0.6,
0.3 and 0.15 mm, should be
considered.

In cases when the actual volume

of the container is not known, it
should be evaluated by weighing
the empty container, and
Weigh and record the weight (W1) of empty cylinder weighing it again after filling
with water.
(kg).
Fill the container with the given sample of aggregate in
three equal layers, tamping each layer with 25 strokes
of tamping bar. Fill the container completely and strike
off the surplus material using the tamping bar.
Weigh the container completely filled with aggregate.
Record this weight (W2) [kg].
Compute bulk density (kg/liter) as (W2 - W1) / V

Specific gravity and water absorption

1.

2.

3.

Place a sample of about 1 kg in a tray and cover with

distilled water at a temperature of 22 to 32C. The
sample should be remaining immersed for 24
hours.
Drain the water completely from the sample by
decantation and then air dry it by exposing to a gentle
current of warm air to evaporate only the surface
moisture, to make the sample Saturated Surface Dry
(SSD). Weigh this SSD sample and record its weight, A
in kg.
Place the aggregate sample in the pycnometer which
should be completely filled with distilled water. The
pycnometer should be dried on the outside and weighed
(B kg).

Lab Manual /2016

SSD sample is directly provided

to you after carrying out the
process mentioned in steps 1 and
2.

24

4.

Empty the contents of the pycnometer into the tray. The

pycnometer should then be completely filled with
distilled water only, dried on outside and weighed in kg
( C ).
Place the sample in the tray in an electric oven after the
water is drained out from the sample by decantation, at
a temperature of 100 1100C for 24 hours. The sample
should be cooled in an air-tight container and weighed
in kg (D).

5.

Specifications
% passing for
graded aggregate of nominal size

IS
sieve % passing for
size mm
single sized aggregates of nominal size

40 mm

20 mm

12.5 mm

10 mm

40 mm

20 mm

12.5 mm

40

85-100

100

95-100

100

20

0-20

85-100

30-70

95-100

100

16

100

90-100

12.5

85-100

100

95-100

10

0-5

0-20

0-45

85-100

10-35

25-55

40-85

4.75

0-5

0-10

0-20

0-5

0-10

0-10

2.36

0-5

FOOD FOR THOUGHT

1. Codes sometimes define and specify indices such as flakiness index or elongation index.
How are these indices determined?
2. What is the approximate porosity of some of the commonly available rocks?
3. What factors could affect the determination of bulk density of coarse aggregate, if the
procedure described above is followed?
4. It is not considered desirable to use very dry or wet aggregates in concrete construction.
Why?
5. Define saturated surface dry aggregates.
6. Assuming aggregates to be spherical particles and in contact with one another, what are
the possible ways of close packing them and what would be the resulting void ratios?
7. It is not desirable to use elongated or flaky particles in concrete construction. Why?
8. Can crushed concrete be used as a coarse aggregate in fresh concrete construction?
9. Comment on the extent of difference observed between the bulk density and the specific
gravity.
10. Draw particle size distribution curve in a semi-log graph paper.

Lab Manual /2016

25

Observation Tables
1. Particle size distribution and Fineness modulus
20 mm aggregates
IS Sieve
size (mm)

Weight
retained (g)

Cumulative weight
retained (g)

Cumulative weight
retained (%)

% Passing

Cumulative weight
retained (%)

% Passing

40
20
10
4.75

Fineness Modulus =
10 mm/ 12.5 mm aggregates
IS Sieve
size (mm)

Weight
retained (g)

Cumulative weight
retained (g)

16
12.5
10
4.75
2.36

Fineness Modulus =

Note: For computing FM, a set of IS sieves of aperture size 150, 80, 40, 20, 10, 4.75, 2.36,
1.18, 0.6, 0.3 and 0.15 mm, should be considered.

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26

2. Specific gravity & Water absorption

Description

Sample -1

Sample - 2

Sample -1

Sample - 2

Nominal size of the aggregate sample

Weight of SSD sample in g

(A)

Weight of pycnometer with SSD sample filled with

water (B)
Weight of pycnometer filled with water only ( C )
Weight of oven dried sample in g (D)
Specific gravity = D / [ A ( B C ) ]
Apparent Specific gravity = D / [ D ( B C ) ]
Water absorption = 100 ( A D ) / D
Average specific gravity =
Average apparent specific gravity =
Average water absorption =
3. Bulk Density
Description
Weight of empty cylindrical measure in kg (W1)
Weight of cylindrical measure completely filled with
aggregate, in kg (W2)
Bulk Density in kg/litre =(W1 W2) / V, where V is
the volume of the cylindrical measure in litres

Lab Manual /2016

27

EXPERIMENT # 4B
PHYSICAL PROPERTIES OF FINE AGGREGATE
Objective
To determine the following properties of fine aggregate
a) Particle size distribution and Fineness modulus
b) Specific gravity
c) Water absorption
d) Bulk density
Explanatory notes
In principle, there is no difference between the coarse and fine aggregate, and reference should
be made to the relevant Explanatory notes for the coarse aggregate. It may be borne in mind,
however, that special attention needs to be paid to (a) the fineness modulus of a given sand (fine
aggregate) sample, and, (b) the zone the given sand belongs. Appropriate adjustments need to be
made in the proportioning of the concrete mixes. Further, the proportioning should also take into
account the bulking that may be encountered in fine aggregate.
Bulking is the apparent increase in the volume of sand when it is wet. The presence of water
causes the sand particles to be artificially separated on account of the surface tension. Though
the presence of water (beyond the amount required render a sand saturate surface dry) is
accounted for when batching the sand by weight, in the case that the sand is batched
volumetrically, the presence of the excess water can be accounted for only by accounting for the
bulking.
Equipment and Materials
1. Particle size distribution and fineness modulus
x Set of IS sieves of sizes 4.75 mm, 2.36 mm, 1.18 mm, 0.6 mm, 0.3 mm, 0.15 mm
and pan
x Mechanical sieve shaker
x Balance with a capacity of at least 2 kg with an accuracy of 0.1 grams
2. Bulk density
x Balance a balance sensitive to 0.5 percent of the weight of the sample to be
weighed
x Cylindrical metal measure 15 cm diameter (inside)
x Tamping rod 16 mm dia , 600 mm long
3. Specific gravity and water absorption
x Balance with a capacity of at least 3 kg with an accuracy of 0.5 grams
x Pycnometer
x Tray
x An air-tight container
x 3 kg of fine aggregates, all particles passing the 4.75 mm IS sieve
x Oven well ventilated, maintain a temperature between 100C and 110C

Lab Manual /2016

28

Relevant Indian codes

IS 383: 1970
IS 2386 (Parts I): 1963
IS 2386 (Parts III): 1963

Specification for coarse and fine aggregates from natural

sources for concrete
Methods of test for aggregates for concrete Particle size and shape
Methods of test for aggregates for concrete Specific gravity, density, voids, absorption and bulking

Test Procedure
Step

Description

Comments

Particle size distribution and fineness modulus

1.
Weigh 500 grams of oven dry sample of sand and transfer it
to top sieve of the standard set comprising of IS sieves 4.75
mm, 2.36 mm, 1.18 mm, 0.6 mm, 0.3 mm, 0.15 mm and pan
and place the lid on the top sieve, ie., 4.75mm sieve
2.
Put the set in the mechanical sieve shaker and let it run for 15
minutes.
3.
Weigh the fractions of sand cumulatively starting with the
material retained on the top sieve.
4.
Fineness modulus is obtained by adding the percent
cumulative weight of material retained on each of the sieves
and dividing the resulting sum by 100.
Bulk density
5.

Take a standard cylindrical metal measure of 15 cm diameter

and fill it with thoroughly mixed aggregate.
6.
The measure is filled with the given fine aggregate in three
equal layers, each layer tamped with 25 strokes of the
rounded end of the tamping rod. The measure then
completely filled and surplus aggregate is struck off by using
the tamping rod as a straight edge.
7.
The net weight of the aggregate in the measure is determined
and the bulk density is calculated in kg/litre to the nearest
0.01 kg.
8.
To determine the exact capacity of the measure, calibration The volume of the
should be done with the help of water at 27oC and by measure given to you is
2.80 liters
assuming the density of water as 1 kg/litre.
Specific gravity and water absorption
9.
10.

11.

A sample of about 1 kg of fine aggregate is placed in a tray

and covered with distilled water at a temperature of 22 to
320C. The sample shall remain immersed for 24 hours.
The water shall be completely drained from the sample by
decantation and the sample air-dried by exposing to a gentle
current of warm air to evaporate only the surface moisture, to
make the sample Saturated Surface Dry (SSD). Take 500 g
of this SSD sample and record this weight (A).
Place this weighed aggregate sample in the pycnometer, fill it
completely with distilled water. Clean and dry outside of the
pycnometer and weigh it. (B)

Lab Manual /2016

SSD sample is directly

provided to you after
carrying out the process
mentioned in steps 1
and 2.

29

12.

13.

14.

Empty the contents of the pycnometer into the tray. Clean the
pycnometer for any left out particles of the sample and pour it
in the tray. Now fill the pycnometer completely with distilled
water, clean and dry outside, and record its weight (C).
Place the tray in an electric oven after the water is drained out
completely from the sample by decantation, at a temperature
of 100 1100C for 24 hours. Cool the sample in an air
tight container and record its weight (D).
Compute specific gravity, apparent specific gravity and water
absorption.

Specifications
Grading zones for fine aggregate: As per IS 383 1970, fine aggregate is divided into 4
grading zones as defined below. It is further recommended that fine aggregate confirming to
Grading Zone IV should not be used in reinforced concrete.
IS sieve
size (mm)

Percentage passing for

Zone I

Zone II

Zone III

Zone IV

10

100

100

100

100

4.75

90 100

90 100

90 100

95 100

2.36

60 95

75 100

85 100

95 100

1.18

30 70

55 90

75 100

90 100

0.6

15 34

35 59

60 79

80 100

0.3

5 20

8 30

12 40

15 50

0.15

0 10

0 10

0 10

0 - 15

FOOD FOR THOUGHT

1. What is the fineness modulus of the sand on the banks of the river Ganga likely to be.
2. Why is bulking of sand only of marginal significance when concrete is to be batched by
weight.
3. Can crushed concrete be used as a (partial) replacement for fine aggregate in new
concrete construction.
4. Compare the particle size distributions of the fine aggregate used with that of standard
sand, used in the testing of cement for its compressive strength.
5. Draw particle size distribution curve in a semi-log graph paper.

Lab Manual /2016

30

6. Observation Tables
(a) Particle size distribution and Fineness modulus
Cumulative Weight
% Cumulative
IS Sieve size
Retained (g)
Weight Retained

% Passing

4.75 mm
2.36 mm
1.18 mm
0.6 mm
0.3 mm
0.15 mm
Pan

Fineness Modulus =
Note: For computing FM, a set of IS sieves of aperture size 150, 80, 40, 20, 10, 4.75, 2.36, 1.18, 0.6,
0.3 and 0.15 mm, should be considered.

(b) Specific gravity and water absorption

Description

Sample -1

Sample - 2

Weight of SSD sample of fine aggregate in g (A)

Weight of pycnometer with SSD sample and filled with
water, in g ( B )
Weight of pycnometer filled completely with water
only, in g ( C )
Weight of oven dried sample in g ( D )
Specific gravity = D / [ A ( B C ) ]
Apparent specific gravity = D / [ D ( B C ) ]
Water absorption = 100 ( A D ) / D
Average specific gravity =
Average apparent specific gravity =
Average water absorption =
(c) Bulk density
Description

Sample -1

Sample - 2

Weight of empty cylindrical measure: ( W1 kg )

Weight of cylindrical measure after filling with aggregate: ( W2 kg)
Net weight of aggregate in the measure: (W2 W1) kg
Volume of measure ( V litres )
Bulk density:

( W2 W1 ) / V

kg / litre

Average bulk density =

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31

EXPERIMENT # 5
DIMENSIONS, WATER ABSORPTION, COMPRESSIVE STRENGTH
AND EFFLORESCENCE OF BRICKS
Objective
To determine the dimensions, water absorption, extent of efflorescence, and compressive
strength of bricks.
Equipment and Materials
1. Dimensions or tolerances
x Suitable measuring tape
x A set of 20 bricks
2. Water absorption
x Balance with an accuracy of 0.1 % of the mass of the specimen.
x Ventilated oven
x A set of 5 bricks
3. Compressive strength
x Suitable, graduated metal scale 30 cm in length accurate to 1 mm, to measure
brick dimensions
x Two 3-ply plywood sheets each of 3 mm thickness
x Compression testing machine
x A set of 5 bricks
4. Efflorescence
x A shallow flat bottom tray / dish
x Distilled water
x A set of 5 bricks
Relevant Indian codes
IS 1077: 1992
IS 3495 (Parts I to IV): 1992
IS 5454: 1978
IS 2180: 1988
IS 2222: 1991
IS 2691: 1988
IS 3583: 1988
IS 4885: 1988
IS 5779: 1986

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Common burnt clay building bricks - Specifications

Method of tests of burnt clay building bricks
Methods for sampling of clay building bricks
Specifications for heavy duty burnt clay building bricks
Specifications for burnt clay perforated building bricks
Specifications for burnt clay facing bricks
Specifications for burnt clay paving bricks
Specifications for sewer bricks
Specifications for burnt clay soling bricks

32

Test Procedure
Step

Description

Comments

Dimensions and tolerances

Select twenty (or more according to the size of stack) whole 20 common burnt clay
bricks at random from the sample.
building bricks shall be
provided to you.
2.
Remove all blisters, loose particles of clay and small projections
from the surfaces of all the bricks. Arrange upon a level surface
in a straight line to measure their overall length, width and
height.
3.
Interchange the positions of some bricks and again take the
overall dimensions.
4.
Take 5 readings to get an average of the dimensions of the brick
and compute variations in dimensions.
Water absorption
1.

5.
6.
7.
8.
9.

Dry five whole bricks in an electric oven for 24 hours at 105 to

1150C.
Cool the samples to room temperature and obtain its weight
(W1). Before weighing, remove all loose particles/dust etc. with
the help of a brush.
Immerse the specimens in clear water for 24 hours at a
temperature of 272C.
Remove these from water, and weigh (W2) the specimens after
wiping out traces of water with damp cloth.
Water absorption = 100 ( W2 W1 ) / W1 %

Efflorescence
10.

Place the end of 5 bricks in a shallow flat bottom tray, the depth
of immersion in the distilled water being 25 mm.
11. Let the tray remain in a warm (20 to 300C) well-ventilated room
until the specimens absorb all the water and the surplus water
evaporates. Cover the tray containing the brick with suitable
glass cylinder so that excessive evaporation from the dish may
not occur.
12. When the water has been absorbed and the bricks appear to be
dry, place a similar quantity of water again in the tray and allow
it to evaporate as before.
13. Examine the bricks for efflorescence after the second
evaporation and report the rating of efflorescence according to
the area of white patches and general appearance of the bricks.
Compressive strength of bricks
14.
15.

Take a sample of at least 5 bricks, remove unevenness if

observed in the bed faces by grinding, if necessary, to get two
smooth and parallel faces.
After immersion in water for 24 hours and draining out any
surplus moisture, fill the frog and all voids in the bed face flush
with cement mortar (1 cement, 1 clean coarse sand of grade
3mm and down).

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16.
17.
18.

19.

20.

Store under damp jute bags for 24 hours followed by immersion

in clean water for 72 hours.
Remove the bricks; wipe out any traces of water and note down
the dimensions (length and width) of each brick to get the
surface area (cm2).
Then place the specimen with flat faces horizontal, and mortar
filled face facing upwards between two 3-ply plywood sheets
each of 3 mm thickness, between the platens of the compressive
testing machine.
Apply the load axially at a uniform rate of 140 kg/cm2/minute
till failure occurs and note the maximum load at failure.
Compressive strength = Maximum load taken (kg) / Average
area of the bed faces (cm2)

The load at failure shall

be the maximum load at
which the specimen
fails to produce any
further increase in the
indicator reading in the
testing machine.
Express the compressive strength of all 5 bricks in MPa and The classification of
classify the bricks as to which class the whole lot of bricks bricks based on their
conform, depending upon the least compressive strength of the strength: classes 5, 7.5,
five bricks.
10, 12.5, 15, 20, 25 etc.
Class 15 means that the
least
compressive
strength of any brick in
the sample of 5 bricks is
not less than 15 MPa
and not more than 20
MPa, and so on.

Specifications
Dimensions: Depending upon the type of the brick, different specifications are applicable as
indicated in the following table.
Sl.
No.

Physical property

Heavy duty Perforated

IS 2180
IS 2222

Facing
IS 2691

Paving
IS 3583

Sewer
IS 4885

Soling
IS 5779

Tolerances in dimensions (mm)

1.

2.

3.

a) Length

+6

+7

+3

+ 80 (for 20 bricks)

b) Width

+3

+4

+2

+ 40 (for 20 bricks)

c) Height

+3

+4

+2

+ 40 (for 20 bricks)

Average
compressive
strength (kg/cm2)
not less than

400

70

100

160

175

10

20

15

10

Average water
absorption (%) not
more than

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100

20

34

Efflorescence: The rating of efflorescence shall be reported as nil, slight, moderate,

heavy or serious in accordance with the following definitions:
x Nil when there is no perceptible deposit of efflorescence.
x Slight when not more than 10 percent of the exposed area of the brick is covered with a
thin deposit of salts.
x 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.
x 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.
x Serious when there is a heavy deposit of salts accompanied by powdering and/or
flaking of the exposed surface.
The efflorescence rating shall be not more than moderate for bricks up to class 12.5 and
slight for higher classes.
Observation Tables
(a) Size of bricks
Dimensions of
20 bricks
Length (mm)

Reading -1

Reading -2

Reading -3

Reading -4

Reading -5

Width (mm)
Height (mm)
Average Length of one brick =
Average width of one brick =
Average height of one brick =
(b) Water absorption
Sample No.

Weight of oven dry bricks: W1 (kg)

Weight after immersing in water: (W2 (kg)

W2  W1
u 100
W1
Average water absorption (%) =
(c) Compressive strength of bricks
Sl. No.
Length
Width
Area
(cm)
(cm)
(cm2)
1.
% Water absorption =

Weight
(kg)

Ultimate
load (kg)

Compressive
Strength (MPa)

2.
3.
4.
5.
Average compressive strength in MPa =
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35

EXPERIMENT # 6A
DETERMINATION OF FLASH POINT OF BITUMEN
Objective
To determine the flash point of bitumen.
Definition
The flash point of a bituminous material is the lowest temperature at which the application of
the test flame causes the vapour from the material to catch fire momentarily in the form of a
flash under specified conditions of test.
Equipments & Materials
x Heater (attached with temperature control device)
x Bitumen cup
x Thermometer (Range 90C to 370C, graduation 2C
x Bitumen
Relevant Indian codes
IS: 1209-1978
Test Procedure
1. Clean the cup and dry it thoroughly before the test.
2. Fill bitumen in the cup up to a depth of approximately 1 cm from top.
3. Insert the thermometer into the material so that the tip penetrates at least 1cm. Ensure the tip
not to touch the bottom of the cup.
4. Heat the bitumen sample. Stir the bitumen in the cup at approximately 60 revolutions per
minute.
5. Apply the flame at 100C and at every 5C rise initially up to 150C and at 1C rise
subsequently till the first bright flash occurs. Discontinue the stirring during the application
of test flame.
6. Report the temperature at which flash occurred as flash point of the bitumen.
Observation Table
Bitumen grade :
Closed or open cup :
Test name

No. of tests

Flash point value, C

Reading

Mean

Flash point

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EXPERIMENT # 6B
DETERMINATION OF PENETRATION VALUE OF BITUMEN
Objective
To determine the consistency of bitumen for classifying bitumen sample into different
grades.
Definition
The penetration of a bituminous material is the distance in tenths of a millimeter that a
standard needle will penetrate vertically into a sample of the material under standard
conditions of temperature, load and time.
Equipments & Materials
x Universal Penetrometer
x Penetration needle
x Container
x Water bath (Thermostat maintained at 25.0C r 0.1C)
x Time device (graduated 0.1 s or less and accuracy within r 0.1 s for a 60s interval)
x
x

Thermometer (Range 0C to 44C)

Bitumen, Benzene, & Water

Relevant Indian codes

IS:1203-1978
Test Procedure
1. Connect the penetrometer to the timer and the timer to the external power source. Set the
timer to 5 Sec.
2. Place the bitumen sample cup on the stand of the penetration apparatus.
3. Clean the needle with benzene and fix it to the penetrometer. Adjust the needle assembly so
that the tip of the needle just touches the top surface of the bitumen.
4. Take the initial reading on graduated disk say, A.
5. Trigger the timer to release the needle for 5 sec.
6. Take the final reading, say B. Report (B-A) as penetration value.
7. Make at least three determinations, at points on the surface of the sample not less than 10
mm apart and not less than 10 mm from side of the dish. After each test clean the needle
with benzene.
Observation Table
Test name

No. of tests

Initial reading
(A)

Final reading
(B)

Penetration
(B-A)

Mean value

Penetration

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EXPERIMENT # 6C
DETERMINATION OF DUCTILITY VALUE OF BITUMEN
Objective
To determine the ductility of given bitumen sample.
Definition
The ductility of a bituminous material is measured by the distance in centimeters to which it
will elongate before breaking when the specimen of a specified form is pulled apart at a
specified speed and at a specified temperature.
Equipments & Materials
x Two ductility moulds
x Thermostat maintained water bath
x Pulling machine attached with scale
x Thermometer (Range 0C to 44C)
x Bitumen
x Water
x Methyl alcohol or sodium chloride (To adjust the specific gravity of water if required)
Relevant Indian codes
IS: 1209 1978
Test Procedure
1. Set the rate of pull of ductility machine to 50 mm/min.
2. Take out the moulds containing specimens (two) from water bath. Remove the side of the
moulds and hook the samples on the machine without causing any strain.
3. Check whether the sample is immersed in water at depth of at least 10mm. The water
temperature is to be maintained at 27C.
4. Start the machine to pull the samples.
5. Report the mean value of the lengths in cm at which the bitumen thread of each specimen
breaks as the ductility value at test temperature.
Observation Table
Grade of bitumen:
Specific gravity of bitumen:
Test name

No. of tests

Value, cm.
Reading

Mean

Ductility

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EXPERIMENT # 6D
DETERMINATION OF SOFTENING POINT OF BITUMEN
Objective
To determine the softening point of bitumen defined as the temperature at which bitumen
attains a particular degree of softening.
Equipments & Materials
x "Ring and ball apparatus" consisting of: Two steel balls, Two brass rings, Ball guide
Support, Thermometer (Range - 2C to 80C for low temperature and 30C to 200C for
high temperature), Heat proof glass vessel, Stirrer
x Bitumen
x Water or Glycerin
Relevant Indian codes
IS: 1205-1978
Test Procedure
1. Assemble the ring and ball apparatus with the rings and ball guides in position, and place the
balls on the bitumen sample put inside the rings.
2. Insert the thermometer such that its tip is approximately in level with the specimen rings.
3. Fill the beaker with water/glycerin to a height of approximately 5 cm above the upper surface
of the rings. Glycerin is recommended when the expected softening point is more than 80oC.
4. Heat the ring and ball apparatus such that the temperature of water rises by 5oC per minute.
Bitumen softens and allows the ball to pass through the rings. The temperature at which the
sample surrounding the ball touches the lower plate of the ring and ball guide is the
softening point.
5. The mean of two temperatures recorded for two samples is reported as softening point. If the
values differ by 2C, it requires repetition of test.
Observation Table
Bitumen grade:
Weight of the ball:
Approximate softening point: bellow/above 80C
Liquid used: Water / Glycerine

Test name

No. of tests

Value, qC
Reading

Mean

Softening Point

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