Laboratory Manual PDF

Quality Assurance & Quality Control - Laboratory Testing
A-2.2/09-10-1 - Laboratory Manual
LABORATORY MANUAL
Quality Control For

Laboratory Tests
Shapoorji Pallonji And Co. Ltd.

Engineering & Construction
Technology Quality Service
Shapoorji Pallonji E&C Page 1 of 82

LABORATORY MANUAL
PREFACE
The purpose of this Laboratory Manual is to standardize & provide test methods as
per the requirement of Clients / Consultant. The manual is brief and user friendly. It
also includes formats which have to be incorporated to record the results & thus in
toto is a ready reckoner.
This laboratory manual was initiated by Corporate QA / QC Department( Head Office),

Mr.Hemant Joshi, Head Q.A / Q.C Ahmedabad Region provided his technical
guidance to develop this manual. The standard practices & methods of testing &
measurement would be updated by QA/ QC Department (H.O) from time to time
based on the feedback received from the Regional QA/ QC Heads across the
country.
The update of this manual shall remain a continuous effort to bring Continual
Improvement into the Quality Management Systems of SPCL.
Corporate QA/ QC Department.
Second Edition Nov 2012.
Note :
1) This document is property of Shapoorji Pallonji & Co.Ltd and must be surrendered to the Document Controller / M.R. on
transfer or cessation of employment.
2) While every effort has been made to ensure the accuracy of the information presented in this Lab Manual, neither SPCL nor
its employees can accept responsibility for any loss or damage incurred in connection with the use of the contents.

LABORATORY MANUAL
INDEX
Page No.
I - General :
1. Scope of the Manual 6

2. Table-1.- List of tests to be conducted at Site 7
3. Table-2.- List of tests to be conducted at External Lab. 8 to 9
4. Table-3.- List of lab equipment‟s 10 to 11
5. Table-4.- List of reference IS codes 12
6. Table-5.- Acceptance Criteria for material 13 to 15
7. Acceptance Criteria Graph „Zone wise‟ for SanD 16 to 17
II - Procedures :
1. Area of Laboratory Required 19 to 20

2. Precautionary measures for testing equipment‟s 21 to 22
3. Procedure for Sampling of Material 23 to 26
4. Slump test 27
5. RMC Inspection/testing for Concrete 28 to 30
6. Cube filling from fresh concrete 31 to 32
7. Compressive strength of concrete 33 to 35
8. Procedure for Standard deviation 36 to 37
9. Field Test for Silt Content in Sand 38
10. Sieve Analysis of Fine aggregate 39 to 41
11. Sieve analysis of coarse aggregate 42 to 44
12. Specific Gravity and water Absorption of Aggregates 45 to 48
13. Flakiness Index 49 to 50
14. Elongation Index 51 to 52
15. Aggregate Crushing Value 53 to 55
16. Determination of Aggregate Impact Value 56 to 58
17. Tests for Common Burnt Clay Bricks
(Strength, Water Absorption) 59 to 62
18. Soil – Water Content 63 to 65
19. Soil – Field density by Core- cutter. 65 to 68
III - Calibration of Test Equipment’s :
1. General 70
2. Calibration Plan 71
3. Procedure for Verification of Equipment‟s 72 to 76
4. Calibration of Batching Plant 77 to 78
5. List of Abbreviations 79
6. Definitions 80 to 81
7. Amendment 82

LABORATORY MANUAL
CHAPTER – 1
GENERAL

LABORATORY MANUAL
SCOPE OF THE MANUAL :
This is a user manual for material testing and sampling at site. The scope of this manual is
pertaining to SPCL procedure Document and which includes data, procedures, formats as
following:
1. Setting up of infra-structure required for testing various regular materials as per the list
given in Table-1. Infra will comprise of :
a. Enclosed area for conducting the tests at desired conditions.
b. Equipment‟s for the various tests as listed in table-2 .
c. Filing rack / cabinet for keeping the records and table /chair.
d. Curing tank for concrete cubes.
e. Trained QC engineer & /or Trained Lab technician shall be deputed for the site.
2. Any other tests on same material or the material other than listed will have to be done in
external laboratory. The records of such tests will be maintained at the laboratory. ( List Of
Tests as per Table-1a )
3. Any approved samples, test pieces will be maintained at the laboratory.
4. Procedure for calibration of test equipments & validation of measuring
aids

LABORATORY MANUAL
TABLE – 1
List of Tests to be Conducted at Site Laboratory :
Sr.No Material to be tested Related IS Codes Tests to be Conducted
1. Soil 2720 part-1-2-29 In-situ core test.

(1975) Moisture Content
2. Concrete 1199(1959) Compressive strength
456(2000) Slump Test
10262(1982)
8112 (1989)
a. Coarse Aggregate 2430(1986) Sieve Analysis
2386 part-1-3-4 (1963) Aggregate Crushing
383 (1970) Value/Impact Value
Specific Gravity
Water absorption
b. Fine aggregate 1542 (1992) Sieve Analysis
2116 (1980) Silt Content
383 (1972) Specific Gravity
3. Bricks 3495 part-1-2 (1992) Compressive Strength
1077 (1992) Water Absorption Test
5454 (1978) Dimension
Efflorescence

LABORATORY MANUAL
TABLE – 2
List of the Material & Tests to be Conducted at External Laboratory :
*Note : External Laboratory shall be as per requirement of the project or as

approved by Client.
Sr. Material to Tests to be conducted Requirements

No. be Tested
1. Construction Potability, Sulphates, As per Requirements of IS :
Water Chlorides 456 which shall be done at the
start of project or change of
source.
2. Cement As per respective IS codes for
OPC, PPC, PSC and for
Grades 43 /53
a. Physical Strength, Fineness, Initial / For every batch if MTC is not
Final setting Time, Standard available. If MTC is available at
Consistency, Soundness by Random frequency.
Le-chatelier method
b. Chemical Loss on ignition, Insoluble In case cement is old or for
residue new brand along with above
tests
3. Reinf Steel For respective IS codes for Fe:
415/500/550
a. Physical Yield stress/UTS, Elongation, At given Frequency ( Project
bend- rebend, Weight per Specific)
meter
b. Chemical % of Carbon , Sulphur, For new manufacturer or
Phosphorus problem in physical tests
4. Structural
Steel
a. Physical Yield stress/UTS, Elongation, At given Frequency ( Project
bend- rebend, Weight per Specific)
meter
b. Chemical % of Carbon , Sulphur, For new manufacturer or
Phosphorus problem in physical tests
c. Weld tests Butt full strength joints- As per provision in tender or
Radiography requirements.
5. Concrete Compatibility with cement- New admixture or admixture is
Admixtures Marsh cone testing giving performance problems.
6. C.C. Block/ Compressive strength, water At given Frequency ( Project
Paver blocks absorption, Density Specific)
7. Aggregate
a. Physical Routine tests If specified by Client
Abrasion value Critically for road works

LABORATORY MANUAL
8. Concrete Mix Design At start of project and /or

change of cement .
Non Destructive Tests like When cube strengths are below
Ultra sonic or Rebound acceptance criteria or as
hammer required by client.
Core Test As specified by IS : 456 or as
per Client requirement
9. Soil Max dry density and water At the start of the activities and
content relationship ( proctor change of source.
test )
Gradation, Plastic Limit, As required.
Liquid Limit
Soluble sulphate contents As required
10. RCC Pipes- Three edge test, Water As required ( Normally test
NP ( Non- absorption setup available with
Pressure ) manufacturer )
class.
11. Galvanized Zinc coating thickness As required.
Steel

LABORATORY MANUAL
TABLE – 3
List of Laboratory Equipments :
Sr. Equipments Capacity/ Size Make

No
1. Compression Testing 100 /200 tonne Lawrence & Mayo /
machine Universal
2. Cube Moulds 150x150x150 mm ISI Mark (Contass)
3. Slump Cone Top Diameter – 100 mm,
Bottom Diameter – 200
mm,Height – 300 mm,
SheetThickness – 1.6 mm min.
4. G.I.Coarse Aggregate 40,20,16,12.5,10,6.32,4.75,2.36 ISI Mark (Contass)
Sieves- 300 mm dia mm
5. Brass Fine Aggregate 10mm & 4.75, 2.36, 1.18mm, ISI Mark (Contass)
sieves- 200 mm dia 600mcn, 300mcn,150mcn
6. Weigh Balance 10kg ( Accuracy 1g ISI Mark (Contass)
Pan )
a C.I. Weights 5,2,1,500g, 200g, 100g, 50g Duly calibrated and
stamped by Weight
and Measure Dept.
b S.S. Weights in box 100g, 50g, 20g, 10g, 5g, 2g, 1g Duly calibrated by
Weight and Measure
Dept.
7. Flakiness Index Gauge --
8. Elongation Gauge --
9. Measuring Cylinders 250 ml Borosil
a) Glass Height 335mm
b) Plastic (non-
transparent)
10. Pycnometer Bottle Capacity 1 litre approx.
11. Aggregate Crushing test --
apparatus
12. Oven with Thermostat 45x45cm size (2 tray) Expo
aluminium chamber
13 G.I. Trays Large / med
14. Thermometer 200 deg range (Indian Glass) ISI Mark
15. Vernier Caliper -- ISI Mark
16. Wire gauge -- ISI Mark
17. Core cutter ( For fine 3 cutters
grained soils) Cutter – Int. Dia – 100mm
Height – 130 mm
Dolly – Height – 25 mm
Rammer –Dia – 140 mm
Thickness – 75mm

LABORATORY MANUAL
18. Weigh Balance (10kg) Battery backup Eureka

Electronic Platform 345x 225mm
19. Circular Spring Balance 50kg , 100 kg ISI Mark
20. Misc.- Brush, duster,
Trowel, scoop,
Spanners, Sample metal
containers, gunny bags

LABORATORY MANUAL
TABLE – 4
LIST OF REFERENCE IS CODES:
IS: 383 - Specifications for Coarse and Fine aggregate

IS: 516 - Method of tests for strength of Concrete
IS: 808 - Dimensional Properties of Structural Steel Sections (For Ref)
IS: 1077 - Common Burnt Clay Bricks – Specifications
IS: 1199 - Method of Sampling & analysis of Concrete
IS: 1542 - Sand for Plaster
IS: 1786 - Specifications for High Deformed Bars (For Ref)
IS: 2062 - Steel for General Structural Purpose (For Ref)
IS: 2116 - Sand for Masonry Mortars
IS: 2386-I - Method of test for aggregates – Particle size , shape
IS: 2386-III - Method of test for aggregates – Sp. Gr, Density
IS: 2386-IV - Method of test for aggregates- Mechanical properties
IS: 2430 - Method of Sampling Aggregates
IS: 3495 - Test for Burnt Clay Bricks
IS: 8112 - Specifications for 43 Grade Ordinary Portland Cement.(For Ref)
IS: 10262 - Guidelines for Concrete Mix Design. (For Ref)
IS: 456 - Specification for Plain and Reinf. Cement Concrete. (For Ref)

LABORATORY MANUAL
TABLE – 5
ACCEPTANCE CRITERIA FOR VARIOUS MATERIAL
Material Reference Clause Details of Acceptance Frequency

/Pg
River Inspection of in-coming material
Sand Sand shall be free from clay lumps.
Sand shall be free from organic
matters
IS:383 Table - Physical Testing -
4/pg-11 As per Grading zone-I- III. 4.75 mm
passing 90-100%. 150 mcn passing 0-
10%. Grading Zone-I-III is generally
suitable for RCC.
600 mcn passing for Zone-I – 15-34%,
Zone-II- 35-59%, Zone-III- 60-79, Zone-IV-
80-100
Table- Limit of Deleterious material( % by weight)
1/pg-8 Coal & Lignite – 1%, Clay lumps – 1%,
75mcn passing – 3%, Shale-1%
Total % of deleterious material – 5%
Table- Limit of Deleterious material ( % by weight)
1/pg-8 Coal & Lignite- 1%, Clay lumps- 1%, 75
micron passing – 15%, shale-1%
Total % of deleterious material except 75
micron passing – 2%
Silt Content:8% by Volume for River sand
Coarse Inspection of in-coming material-

aggregat Shall be of angular shape and not
e flaky.
Shall be free from deleterious material
Shall be free from mud and soil.

LABORATORY MANUAL
IS:383 Table-2 % passing for Single size aggregate of

/pg-9 nominal size
IS sieves Nominal sizes
40mm 20 mm 16 mm 12.5 mm
10 mm
40mm 85-100 100
20 0-20 85-100 100
16 85-100
12.5 85-100
100
10 0-5 0-20 0-30 0-45
85-100
4.75 0-5 0-5 0-10
0-20
2.36
0-5
3.3/pg-6 Aggregate Crushing Value –
45% for concrete other than wearing
surface.
30% for concrete for wearing surface.
3.4 /pg-6 Aggregate Impact Value-Alt to 3.3
45% for concrete other than wearing
surface.
30% for concrete for wearing surface.
Table- Limit of Deleterious material ( % by weight)
1/pg-8 Coal & Lignite- 1%, Clay lumps- 1%, 75
micron passing – 3%, Total % of
deleterious material – 5%
Flakiness Index: 30% for concrete.
Common Inspection of in-coming material –
Clay Shall be of specified size and shape
Bricks Edges and corners shall be sharp and
straight
It should be rectangular and smooth.
It shall be free from undulations ,
cracks and properly burnt.
Shall not give efflorescence when
dipped in water.
It shall give clear ringing sound when
struck with each other.
Shall not break when dropped from 1
meter height.
5454 cl. 5.2.1.1 Compressive Strength of any individual

brick in the sample shall not fall below the
min average compressive strength
specified for corresponding class by more
than 20%.

LABORATORY MANUAL
1077 Table-1 Classification on basis of average

/pg-1 compressive strength:
Class Designation Min Avg.
Comp Strength, kg/sqcm
4.5 35
5 50
7.5 75 etc
Compressive strength shall not fall below
above limits.
cl.6.2 Tolerances Non-modular:
/pg-1 For 20 bricks
Length – 4600 +/- 80 mm
Width – 2200 +/- 40 mm
Height – 1400 +/- 40 mm
cl.7.2 Water Absorption :
/pg-3 Should not be more than 20% by weight
upto class 12.5 and 15% by weight for
higher classes.
cl.7.3/pg- Efflorescence: „Moderate‟ upto class 12.5
3 and „Slight‟ for higher classes.
Concrete 456 cl. 15.4 The test results shall be average of 3
/pg-29 specimens. Individual variation should not
be more than +/- 15%
Compressive Strength :The mean strength
from any group of 4 consecutive test
results shall be as below :
For M:15 - it shall be > / = Fck + 0.825 x
S.D.
Or
Fck + 3 N /
mm2 whichever is
Greater
Provided individual test results
shall be > /= Fck –
3 N/mm2
For M: 20 or Above – it shall be >/= Fck +
0.825 x S.D.
Or
Fck + 3 N /mm2
whichever is greater
Provided individual test
results shall be >/= Fck- 3N/mm2.
Note : In case S.D. is not established then
assumed S.D. as per Table-8 shall be
considered.

LABORATORY MANUAL
Acceptance Criteria Graph ' Zone Wise ' for Sand
600 mcn % passing

Lower Limit Upper limit ZONE DESIGNATION FOR FINE AGGREGATES
Zone-I 15 34
Zone-II 35 59 100
Zone-III 60 79 90
% PASSING 600 MCN SIEVE

Zone-IV 80 100 80
70
60
50
40
30
20
10
600 mcn %
0
passing
Zone-I
Zone-III
Zone-II
Zone-IV
Upper limit
600 mcn %
ZONES passing
Lower Limit
ZONE - I GRADING
ZONE-I GRADING CURVE
Sieves % Passing
10 mm 100 100 120

4.75 mm 90 100 100
% PASSING
2.36 mm 60 95 80
1.18 mm 30 70 60
40
600 mcn 15 34 20
300 mcn 5 20 0
10 mm
150 mcn
300 mcn
600 mcn
1.18 mm
2.36 mm
4.75 mm
150 mcn 0 10 % Passing

Lower
SIEVES SIZES % Passing
Upper
ZONE - II GRADING
Sieves % Passing ZONE -II GRADING CURVE
Lower Limit Upper limit
10 mm 100 100 120
4.75 mm 90 100 100
% PASSING
2.36 mm 75 100 80
1.18 mm 55 90 60
600 mcn 35 59 40
300 mcn 8 30 20
150 mcn 0 10 0
10 mm
150 mcn
300 mcn
600 mcn
1.18 mm
2.36 mm
4.75 mm
% Passing
Lower
% Passing
SIEVE SIZES
Upper

LABORATORY MANUAL
ZONE - III GRADING

Sieves % Passing ZONE -III GRADING CURVE
Lower Limit Upper limit
10 mm 100 100 120
4.75 mm 90 100
100
2.36 mm 85 100
1.18 mm 75 100
% PASSING
80
600 mcn 60 79
60
300 mcn 12 40
150 mcn 0 10 40
20
0 % Passing
10 mm
150 mcn
300 mcn
600 mcn
1.18 mm
2.36 mm
4.75 mm
Lower
% Passing
Upper
SIEVE SIZES
ZONE - IV GRADING
Sieves % Passing
Lower Limit Upper limit ZONE -IV GRADING CURVE
10 mm 100 100
4.75 mm 95 100 120
2.36 mm 95 100 100
1.18 mm 90 100
% PASSING
80
600 mcn 80 100
60
300 mcn 15 50
40
150 mcn 0 15
20
% Passing
0
Lower
10 mm
150 mcn
300 mcn
600 mcn
1.18 mm
2.36 mm
4.75 mm
% Passing
Upper
SIEVE SIZES
GRADING OF AGGREGATES :
Seives used for Coarse Aggregate : 80mm, 40mm, 20mm, 10mm, 4.75mm.
Seives used for Fine Aggregate : 10mm, 4.75mm, 2.36mm, 1.18mm, 600micron, 150micron.

LABORATORY MANUAL
CHAPTER – 2
PROCEDURES

LABORATORY MANUAL
CHAPTER – 1
Area of laboratory Required :

To have convenient working and storage of records and equipment area is required more than
12 sq. m. Working platform of approx 3 m long and 700 mm wide will be required. 2-15Amp /
2-5 Amp electric points other than regular lighting /fan points are required.
Curing tank :
Size of Tank is depend upon number of cube sets taken at decided frequency. Cubes to be
arrange in stack of three and day wise. Tank should have separate compartments for 7 days
and 28 days cubes. Thus for daily average 3 sets
( 18 cubes ) of cubes, tank will have plan dimensions 1250x900 for 7 day compartment and
3000x1250 for 28 days compartment. Clear Depth of tank shall be fixed one at 750 mm which
includes free board. For any increase and decrease of sampling size can be altered
considering cube stacking arrangements. Water tank should be kept clean and free from dust
particles & microorganism‟s growth. Water should be changed every 7th day. Curing tank
should be covered with a lid.

LABORATORY MANUAL
Sample of Laboratory :-
5.0 M
PLATFORM FOR SAMPLES

TILES, BRICKS ETC,. DISPLAY BOARD 1.5X1.5M CURING TANK
(3.0X1.2M) COMP. TESTING
MACHINE
DOWN BELOW
DOCUMENTATION CHAIR
SHELVES
W TABLE
4.0 M CHAIR CHAIR WASH BASIN W
X PLATFORM FOR TESTING PLATFORM FOR SOIL CONC. X'

AGG / SAND EQUIP. TESTING EQUIP.
W 1.0 M W
LAB PLAN
5.0 M
ROOF
FILING RACK FILING RACK
1.2 M RACKS FOR APPRATUS RACKS FOR APPRATUS
LAB SECTION XX'

LABORATORY MANUAL
CHAPTER – 2
PRECAUTIONERY MEASURES FOR TESTING EQUIPMENTS / TESTING
Certain work Culture and precautions are required to upkeep equipments and samples :
1. Cube Moulds :
Shall be always used in whole set. ( 1 set of 6 nos of moulds along with spanner )
Components of mould sets shall not be interchanged.
All bolts shall be checked for threading and shall be oiled from time to time after
cleaning.
Only fixed spanners shall be used for bolts.
Moulds shall be checked for dimensional correctness & daigonal check everytime
before use.
Moulds shall be thoroughly cleaned after the use and lightly oiled.
2. Slump Cone :
Shall be always ready in complete set including tamping rod and trowel.
Shall be cleaned and lightly oiled from inside after the use. Before use oil shall be
wiped out.
Cone shall be well fitted with base so as no leakage of slurry takes place.
3. Compression Testing machine :
Have authentic calibration report handy.
Always use designated oil in machine
Keep platens in clean condition.
CTM shall be properly fixed in position and shall be in level.
Keep adequate clear working area in front of CTM.
Check dial gauge pointer is on zero before testing.
Max. Loading on CTM shall be 85-90% of Rated Capacity.
4. Curing Tank :
Water in tank shall be clean and change at frequent intervals. The water shall not be
allowed to use for any other purpose.
Water shall always cover top of cube by at least 50-75 mm.
Water temperature must be controlled during winter.
5. Concrete Cubes :
Casting of cubes shall be done at well designated place and level / hard platform.

LABORATORY MANUAL
Freshly cast cubes shall be away from any vibrations and shocks. They will be covered
by wet gunny bags immediately after casting.
Cubes shall be correctly mkd for number / location , mix, date etc.
Cubes shall be placed in tank in correct sequential manner so as to locate them easily.
While handling cubes, utmost care to be taken not to damage edges / corners.
Always cast extra cubes to deal with serious situation.
6. Sieves :
Sieves shall be always kept in set in proper sequence and vertically arranged.
Fine sieves can get damaged due to incorrect use. Always clean sieves by brush and
remove stuck particle by forceps or needle. Do not bang on the mesh.
Sieves shall be kept clean and dry.
7. Core Cutters :
Use Cutters in set of three.
Do not use cutter in coarse grain /gravelly soil.
8. Weighing Balance :
Keep balance in clean condition. De-dust it frequently.
Always cover electronic balance when not in use.
Balance shall be loaded to max 90% of rated capacity.
Balance shall be kept on level platform. Remove the pan when not in use.
Do not weigh with Fan on. Breeze affects the accurate weighing.
9. Samples :
All samples shall be kept at laboratory in designated area in proper pack , container.
All samples shall be tagged for name, sources, collection points and dated.

LABORATORY MANUAL
CHAPTER – 3
PROCEDURE FOR SAMPLING
FOR AGGREGATES ( IS : 2430 ) :

Sample from Stock Pile of the Coarse / Fine aggregate:
Samples from stock piles should be made up of at least 10 increments; taken equally
from top third , mid point and bottom third.
Outer layer of sampling point shall be removed and the sample is taken from the
material beneath.
Gross Sample – the sample thus collected will be the gross sample. Qty of gross
sample is depends on the aggregate size :
Aggregate Size , mm 2.36 / 4.75 12.5 20 40
Min wt. Of
Gross sample, kg 10 15 25 80
Reduction of Gross Sample : Will be done as per method of Quartering to required
sample size for testing.
Quartering Method :
Take the gross sample on plain platform. For Fine aggregate use Tray so that residual
fines can be collected by brushing.
The aggregate shall be mixed and then scooped into a cone shape pile.
After the cone is formed, it shall be flattened by pressing the top.
Then it is divided in four quadrants diagonally.
The bulk of the sample is reduced by rejecting any two diagonally opposite quarters.
This method is repeated till sample size is approximately achieved for given testing.
FOR FRESH CONCRETE IN THE FIELD ( IS : 1199 )
Sample from Mixer :
At least three approximate equal samples totaling 0.02 m3 ( equivalent to fill 6 cube
moulds ) shall be taken from a batch.
For collection a scoop shall be used. No tool with flat edges ( like pawra) shall be
used.
3 samples are taken at about the time interval when ¼, ½ and ¾ of concrete is
discharged.
Sample from Place and Time of Deposition :
Sample shall be taken immediately after or during discharge at site.

LABORATORY MANUAL
Samples shall be collected from not less than 5 well distributed points avoiding the
edges of the mass where segregation may have occurred.
Mixing of Sample :
Sample thus received shall be immediately remixed on non-absorbent platform and
made ready for testing.
Frequency of Sampling :
The minimum frequency of sampling of concrete of each grade shall be as below:
Qty of Concrete in the No of Samples *
Work , m3
1-5 1
6-15 2
16-30 3
31-50 4
51 & Above 4+1 additional sample for each
addl 50 m3 or part thereof.
Note – At least one sample taken from each shift.
Where concrete is produced at continous production unit such as RMC plant,
frequency of sampling may be agreed upon mutually.
Note – Three specimens shall be made for each sample for testing at 28 days.
Additional samples may be required for determining strength at 7 days or at the time of
striking formwork.
Remarks – Sample* means qty of concrete required to fill one set of cubes ( 3nos
/ 6 nos ) for testing. Hence number of sample is equivalent to number of cube sets ( 3 /
6 nos. ). 3 cubes are drawn when only cube testing is done at 28 days . 6 cubes are
drawn for tests at 7 / 28 days required.
CONCRETING IN HIGH TEMPERATURE REGIONS (IS : 7861-1)

Ice is added
Water Cement Ratio should not change with addition of Ice
Adjust Quantity of water accordingl to the volume of melting ice
CONCRETING IN LOW TEMPERATURE REGIONS (IS : 7861-2)

LABORATORY MANUAL
Precautions must be taken to keep the temperature in control during mixing and
placing
Concrete.
The commonly adopted method is by using hot water upto 60 C .
In extreme frost conditions the concrete surface is covered with dry blankets of
straw,cement bags,tarpaulins etc.
FOR EARTH / SOIL ( IS : 2720 -I ) :

If the earth received for testing is wet for handling then same is air dried on platform in
outdoor.
The Gross sample shall be as below:
Max size of particles Min. Gross Sample
In Substantial qty in kg
75 mm 100
40 mm 80
19 mm 35
10 mm 25
4.75 mm 20
Sample size for required test shall be made as per quartering method described
above.
Care to be taken that no fines are lost in the operation as soil properties mostly
depend on them for testing.
BRICKS ( As per IS : 5454 ) :

Sampling a lot which shall contain maximum 50000 bricks. In case a consignment has
bricks more than 50000 bricks of same classification, size and manufactured under
relatively similar conditions, it shall be divided into lots of 50000 bricks or part thereof.
Sampling from the stack – When it is necessary to take sample from the stack, the
stack shall be divided into number of real or imaginary sections and required number
of bricks shall be drawn from each section. For the purpose bricks in the upper layers
of the stack shall be removed to enable units to be sampled from places within the
stack.

LABORATORY MANUAL
Sample size – For Visual / Dimensional Characteristics –
Lot Size of bricks Sample size for Individual brick Sample size For group of
Check 20 bricks Check
2001 – 10000 20 40
10001 – 35000 32 60
35001- 50000 50 80
Sample size – For Physical Characteristics –
Samples shall be drawn for these tests from above sample lot.
Lot size of bricks Sample size for Comp. Strength Warpage

Bulk density, water absorption
Efflorescence etc.
2001-10000 5 10
10001 – 35000 10 20
35001-50000 15 30

LABORATORY MANUAL
CHAPTER – 4
PROCEDURE FOR SLUMP TEST FOR FRESH CONCRETE ( IS : 1199)
Aim : To check Workability of Freshly mixed Concrete by Standard Slump Cone Method.
This method is suitable for max size of aggregate upto 38 mm only.
Apparatus :
Slump cone with base plate and cone having bottom dia 20 cms , top dia 10 cms and height
30 cms.
Smooth Tamping rod 16 mm dia and 600 mm long with one rounded edge.
Scoop , Trowel, Collection pan, measuring scale ( Tamping rod also have marking ).
Smooth / Leveled platform for working.
Procedure :
Sample is collected as per the sampling procedure given earlier.
Internal surface of the cone shall be cleaned and freed from extra moisture and any
layer of set cement slurry.
Conical mould shall be fixed tight on the base with screw arrangement ensuring that
no cement slurry will leak from the joint.
Assembly shall be placed on smooth and truly horizontal surface rigidly.
Mould shall be filled up in 4 layers. Each layer shall be tamped with tamping rod for 25
times evenly. Tamping shall penetrate in layer below.
The top level shall be struck off by trowel or rod flush to the top of cone.
The Cone shall loosened at the base and shall be lifted carefully vertically without
disturbing concrete mass.
The subsidence shall be measured immediately.
Above operations shall be carried out at place free from vibrations and shock.
The whole exercise is to be done within two minutes from sampling.
In any test in which specimen collapses or shears the test will be repeated.
Record :
Slump shall be recorded in mm.
If in repeat test the slump shears, it is to be recorded.
Format Used : It shall be recorded in Cube Register.

LABORATORY MANUAL
CHAPTER – 5
PROCEDURE FOR SAMPLING / INSPECTION / TESTING RMC CONCRETE
Aim:
To Check, Inspect Conformity of RMC Concrete which is manufactured outside and supplied
at site.
Pre-requisites :
RMC supplier shall be given prior information by the site regarding following:
1. Grade of Concrete.
2. Minimum Cement or cementetious material contents. ( Client Approval required )
3. Slump required and tolerances in slump. (Guidelines IS : 4926. Client Approval required)
4. W/C ratio.
5. Method of Concreting ( Manual, Bucket or Pumping )
6. Control of temperature if required shall be specified in case of Mass concreting.
7. Quantity of Concrete required – Total, Phasewise, daywise.
8. Supplier shall know site condition , distance and shortest route to the site from his plant
9. Decision shall be made between Supplier and Site regarding tests and method to be
adopted. ( Client Approval required )
10. Frequency and Acceptance criteria of each testing shall be decided before start. ( Client
Approval required )
RMC Supplier shall give following Information to Site :

1. Mix design details including admixures/ additives and cement used. ( To be approved by
Customer )
2. Material testing results for Cement, Admixures / Additives, water , Coarse and Fine
aggregate.
3. Transit mixer Capacity & time to travel from RMC plant to site.
4. Minimum and maximum quantity that can be supplied in a single pour.
5. Supplier‟s In-house testing facilities.
6. Method of concreting which Supplier can undertake for the pours.
7. Communication system which Supplier adopts.
8. Name of Important Plant Personnel.

LABORATORY MANUAL
Site Planning for RMC Concrete Laying :

1. Concrete Volume shall be planned for various grades. Concreting shall be released
possibly in multiple of Transit mixer capacities with concrete pumps at site.
2. Readiness for receiving concrete shall be assured for given pours. Pour shall be
completed at the earliest after receiving transit mixer on the site. ( As per IS : 4926 entire
operation of pouring in place shall be completed within 1 ½ hours water is mixed in mix
when retarder is not mixed.)
3. If multiple suppliers are planned to supply concrete in a given pour or concreting plan, it
shall be at well-defined locations for each supplier and not mixed up.
Procedure :
a) Slump Test : Shall be carried out for each Transit mixer as per procedure –1 and
sampling procedure.
b) Filling Cubes from Freshly mixed concrete : Shall be carried out as per Procedure –2 in
presence of Supplier‟s representative or by Supplier as decided. Sample shall be taken at
the earliest when transit mixer is received on the site.
c) Inspection of Coarse Aggregate in Mix ( Site Trial Method ) :
This shall be done on random basis to check coarse aggregate proportion and quality in
mix.
Take sample from transit mixer as per sampling procedure weighing around 15 kgs.
Put the sample in tray, remix thoroughly and select 8 kgs of sample by quartering
method so as correct representative sample is collected.
Place the test sample on sieves 20 mm /10 mm/ 4.75 mm and wash same in running
water and simultaneously sieving through the sieves.
Air dry the portion separately and weigh the same. Check the total weight of the
fractions vis –a –vis arrived from mix design calculations. These shall be more or less
conforming without major deviations.
Check the quality of aggregate vis –a –vis the samples collected from the Plant.
d) Cube testing shall be done at Site laboratory or as decided.
Reports :
Maintain all reports like slump tests , cube tests and random inspection of coarse
aggregate etc challanwise and date / time wise.
Mention location , layer of pour on challan. Mention challan no in cube register
alongwith location. Mention name of Supplier in all records.

LABORATORY MANUAL
FORMAT FOR RMC CUBE REGISTER

NAME OF PROJECT :
Name of Client :
Name of Consultant :
S Name Vide Time Time Grad Locat ID of Slum Temp of Random Date of
r of Delivery Mixer discharg e of ion of Cube p in fresh testing Testin
N Suppli Challan/ Left e Conc Use s mm Concret of g for 7
o er Date Mixin complet rete e recd. Aggrega days
. g ed te
Plant OK?
Yes / No
Date of Weight Area of Stren 7 days Strength 28 days Sign of Sign of Remarks
Testing of Cube gth at Avg at 28 Avg Contract Client /
for 28 Cubes Surface 7days Strength days in strength or Consulta
days in Kg cm2 in in kg/cm2 in nt
kg Kg/cm2 kg/cm2
/cm2
Remarks :
This format shall be used as Register. Preferably 7 days and 28days readings
shall be entered in different rows.

LABORATORY MANUAL
CHAPTER – 6
PROCEDURE FOR FILLING CUBES FROM FRESHLY MIXED CONCRETE
Aim : To prepare specimens for the test of Compressive Strength of concrete.
Apparatus :
Cube moulds fitted tightly on base plate (size in mm 150x150x150) in required set ( One set
comprises of 6 moulds.)
Smooth Tamping rod of size 16 mm dia and length of 600 mm with one rounded edge.
Trowels small and large.
Collection pan, scoop, measuring scale etc.
Flat working platform of adequate size.
Procedure of Cube Casting:

Cube moulds shall be verified for dimensions and tight fitting assembly. They shall be
lightly oiled and have clean surfaces.
Cube moulds shall be arranged in sets on working platform.
Sample is collected as per the procedure given earlier.
Concrete is filled in cubes one by one in three layers. Each layer is tamped 35 times
with tamping rod evenly. Tamping shall penetrate the layer below. Care to be taken
particularly at corners. Small trowel can be used at the sides to ensure proper surface
of sides and allow entrapped air to escape.
Cubes shall be filled slightly above top surface of mould.
The top extra layer shall be struck off by large trowel, flush to the top.
Cubes shall not be disturbed till at least 6 hours after the casting.
Cube concrete surface shall be marked with Cube I.D. , Mix, location of use, date,
source of concrete ( additional) when adequately set.
Cubes thus cast, shall be covered with wet gunny bags till they are replaced in curing
tank.
After about 24 (+/-1/2) hours cubes can be opened and place them in curing tank.
Cubes shall be checked for surface correctness, sharp edges and incorrect filling.

LABORATORY MANUAL
Such defective cubes may be rejected there it self. In such case Corrective /Preventive
actions shall be taken.
25
Procedure for Tank Curing :
Cubes shall be arranged in the curing tank sequentially as per ID mark, datewise.
Cubes shall be sorted out for 7 days , 28 days tests. Cubes shall be placed in the tank
in layer of three cubes with marked top upside.
Cubes once placed in tank shall not be handled, disturbed frequently so that edges are
not broken.
Water in tank shall cover cubes by at least 50-75 mm all the time.
Water temperature must be maintained in winter.
Procedure for In-Situ Curing :

This method is deployed to decide stripping time of shuttering when shuttering stripping is
planned earlier than given as per IS: 456. This method shall not be deployed for the cubes to
be tested for compressive strength of concrete at 28 days.
Record :
Details of Cubes thus sampled shall be entered serially in Cube Register maintained for
testing compressive strength.
The number of cube samples cast shall also be entered in pour card with proper traceability to
cube register.
Format to be Used : It shall be recorded in Cube register

LABORATORY MANUAL
CHAPTER – 7
PROCEDURE FOR COMPRESSIVE STRENGTH TESTING FOR CONCRETE
Aim : To establish Compressive strength of concrete sample for acceptance
Apparatus :
Compressive Testing machine having adequate capacity.
Weighing Balance.
Measuring Scale.
Procedure :
Remove the cubes required for testing from curing tank wipe clean of water and air dry
them to surface dryness.
Stack cubes in sequence as per mix, dates, locations etc.
Record the actual surface area ( Sq cm)of the cube which will be in contact with platen
of CTM ( A in cm2 or mm2 ).
Weigh the cubes and record the weights in the register in g.
Place the cube on platen centrally keeping trowelled side in front.
Position the top platen on cube surface. See that there is no gap left between cube top
and platen.
Load the CTM at 140kg./sq.cm.per minute speed without any shocks.( Pointer and
needle shall move together)
When crushing takes place in the specimen, needle will start falling back but pointer
will remain at maximum reading.
Record the reading shown by pointer viewing perpendicular to the face of dial. ( Load
applied in kN or tonne- W)
Relieve the load from CTM. Remove the cube. Clean the platens.
Check the features of cube failure. Good failure is that cube mass retained shall have
concavity on sides. If failures are occurring consistently by crack developing only on
one side it means cubes are eccentrically loaded. If cracks are always developed
centrally means point load is getting applied due to convexity of platens. Remedial
measures are required to be taken for this.

LABORATORY MANUAL
Calculations:
Compressive Stress ( c ) in N / mm2 or Kg / cm2 as below :
c = Wx1000 /A in N/mm2 or Kg /cm2

Average of the set of Three or more cubes to be recorded (c‟ ).
When three or more cubes from single batch/lot is tested, max variation is allowed +/-
15%. If any cube is showing more variation, result of that cube is discarded and
average of two or more is to be taken.
Recording :
Record is generated as per the sample format given in chronological order.
Format to be Used : To be recorded in Cube Register.

LABORATORY MANUAL
FORMAT FOR CONCRETE CUBE REGISTER
NAME OF PROJECT :
Name of Client :
Sr ID Mark Location Grade Slump Date of Date of Date of Weight

No of Cube of in mm casting Testing Testing of
Concre cubes for 7 for 28 Cubes
te days days in Kg
Area of Strength 7 days Strength 28 days Sign of Sign of Remarks

Cube at 7days Avg at 28 Avg Contract Client /
Surface in Strength days in strength or Consulta
Cm2 kg /cm2 in kg/cm2 in nt
Kg/cm2 kg/cm2
Remarks :
This format shall be used as Register. Preferably 7 days and 28days readings
shall be entered in different rows.

LABORATORY MANUAL
CHAPTER – 8
STANDARD DEVIATION FOR CONCRETE CUBE RESULTS AT 28 DAYS
( As per SP-23 )
A. Initial Set of 30 Readings :

1 List down 28days cube result of one concrete grade taking Averages of 3 cube samples ( Xi )
2 Std Dev shall first calculated for minimum 30 nos of results, n = No of results considered
3 Calculate Average of Xi = X bar
4 Calculate value of ( Xi - Xbar ) for each result and Calculate square of ( Xi -Xbar )
5 Add all values of ( Xi -Xbar ) ^2 = Xn
6 Calculate Std Deviation by Formula

S.D. = ( Xn / n-1 ) ^ 1/2
7 After first 30 results, SD to be updated on decided frequency ( say Monthly )
Site : Name of Client :
Concrete Grade : Period :

Individual Avg Result of Xi- Xbar ( Xi- Xbar ) ^2
Sr. No Cube strength 3 Cubes
in N/mm2 Xi
1
2
3
30
Total Xi = Total Xn = (I)
Xbar n = 30
S.D. = (I)

LABORATORY MANUAL
UPDATING THE SD FOR SUBSEQUENT SETS

OF RESULTS
Site : Name of Client :
Concrete Grade : Period :

Individual Avg Result ofXi- Xbar ( Xi- Xbar ) ^2
Sr. No Cube strength
3 Cubes
in N/mm2 Xi
31
32
33
55
Total Xi = Total Xn = ( II )
Xbar n = 25
S.D. = ( II )
To Calculate SD upto date Result 55
Total Xn = Xn( I ) + Xn ( II )
Total n = 29 + 24
Therefore S.D. = ( Total Xn / Total n ) ^ 1/2
Note : Do not calculate Average of SD ( I ) & SD ( II ).

LABORATORY MANUAL
CHAPTER – 9
PROCEDURE FOR FIELD TEST FOR SILT CONTENT IN SAND
( Ref : A. M. Neville )
Aim : To determine Silt content in Sand by volumetric method field test.
Apparatus :
Measuring cylinder 250 ml
Common Salt.
Procedure :
Prepare 1% solution by mixing 10gms of common salt in 1litre of water.
Put this solution in measuring cylinder upto the mark of 50 ml.
Add Sand as received in the cylinder till its level reaches 100 ml.
Add Solution again so that the mixture reaches the level of 150 ml.
Cylinder top is now covered with the palm of hand and shake vigorously by turning
upside down.
Then allow it to stand undisturbed for 3 hours.
Take reading for top layer of Silt ( A ) and layer of Sand ( B ).
Calculations :
Silt content % Volumetric = (A / B ) x100
Reporting :
% Silt contain (Volumetric ) shall be reported in whole number.
Note : This method is approximate and conversion to weight basis ( which is acceptance
criteria ) is dependent on fineness of material. However 8% volumetric content is treated as
reliable. It was suggested that weight ratio is obtained by multiplying volumetric ratio by ¼ for
natural sand and ½ for Crushed sand.
Accurate test when 8% limit of silt contain is exceeded can be done as per IS method of
Sedimentation if required.
Format to be Used :
It shall be recorded in Sieve Analysis for Fine aggregate. Alternatively separate register
for silt contents.

LABORATORY MANUAL
CHAPTER – 10
PROCEDURE FOR SIEVE ANALYSIS OF FINE AGGREGATES
( I.S. : 2386-I )
Aim : To determine the properties of Fine aggregate for size and distribution by calculating
Fineness modulus and deciding Grading Zone.
Apparatus :
Drying Oven
IS Sieves 10 mm, 4.75mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron, 150 mm, pan.
Weigh scale to the accuracy of 1g.
Brush , Metal trays etc.
Procedure:
Sample of sand shall be collected as given earlier.
Sieves shall be cleaned and arrange in sequence in descending order. Pan shall at the
lower most end and Lid on top.
Take around 1 kg of sample and dry it in oven at temp of 100-110 deg C.
Dried sample shall be then weighed ( 1 kg preferably) and sieved successively on
sieves starting with 10mm and then through 150 micron.
Each sieve shall be shaken at least for two minutes on clean tray until no more trace
passes.
Motion shall be varied like back and forth, left to right, circular clockwise and anti-
clockwise and with frequent jarring.
Material shall not be forced through the mesh. Lumps in fines shall be broken against
the wall of sieve.
Sieves shall be brushed from underneath of mesh and pass on to the next.
On completion of sieving, material retained on each sieve is to be weigh separately.
Calculations :
Fineness Modulus : Add values of Cumulative % Retained on each sieves and
divide by 100. (Normally accepted limit of FM is value between 2.2 to 3.2.

LABORATORY MANUAL
Higher value of FM indicates Coarser sand whereas lesser value indicates

Finer one. )
Grading Zone of Fine Aggregate – Value is shown between I to IV. Where zone- I is
associates with Coarser Fine aggregate and Zone IV is Finer. Zones are decided
from values of 600 micron passing % in sieve analysis. ( Refer Table-4 of IS : 383
)
Zone –I – 15-34%, Zone-II – 35-59 %, Zone-III- 60-79%, Zone-IV- 80-100%
Reporting:
The cumulative % by weight of the total sample passing each sieves, to the nearest
whole number.
Or
The % by weight of the total sample passing one sieve and retained on the next
smaller sieve to the nearest 1 decimal.
Calculate F.M. of the material and decide Grading Zone of material.
Format to be Used :
Format of Sieve Analysis of Fine Aggregate shall be used.

LABORATORY MANUAL
FORMAT FOR SIEVE ANALYSIS FOR FINE AGGREGATE

NAME OF PROJECT : DATE OF TESTING:
Name of Client :
Name Of Consultant :
Type of Aggregate : River Sand / Crushed Sand Date of sample

Collected :
Source :
Name of Supplier : Sample size : grams
IS Sieve Wt Wt Cumulative Cumulative Remarks

Size retained retained wt retained Passing %
on each % %
sieve, g
10 mm
4.75 mm
2.36 mm
1.18 mm
600
micron
300
micron
150
micron
Pan
Dry Loose Bulk Density : kg /cm3 Fineness Modulus :
Silt Content by Volume % : % Grading Zone :
Specific gravity : gms/cc Oversize % :
SAMPLE ACCEPTED / REJECTED
Tested by : Checked by :
Date Date

LABORATORY MANUAL
CHAPTER – 11
PROCEDURE FOR SIEVE ANALYSIS OF COARSE AGGREGATES
( I.S. : 2386-I )
Aim : To determine the properties of Coarse aggregate for size and grading distribution (
Nominal 20mm/12.5or10 mm metal).
Apparatus :
Drying Oven
IS Sieves 40 mm, 20 mm,16 mm, 12.5 mm, 10mm, pan. – for Analysis of 20 mm metal
IS Sieves 20 mm, 16 mm,12.5 mm, 10 mm, 4.75 mm ,2.36mm pan - for Analysis of 10/12.5
metal.
Weigh scale to the accuracy of 1g.
Brush , Metal trays etc.
Procedure:
Sample of aggregate shall be collected as given earlier.
Sieves shall be cleaned and arrange in sequence in descending order. Pan shall at the
lower most end and Lid on top.
Take around 5 kg of sample and dry it in oven at temp of 100-110 deg C.
Dried sample shall be then weighed ( 5 kg preferably) and sieved successively on
sieves starting with 40mm and then through 4.75mm( For 20 mm down aggregate size
) and through 2.36 mm (For 12.5/10 mm down aggregate size) .
Each sieve shall be shaken at least for two minutes on clean tray until no more trace
passes.
Motion shall be varied like back and forth, left to right, circular clockwise and anti-
clockwise and with frequent jarring.
Material shall not be forced through the mesh. But for coarser than 20mm particles,
placing is permitted (passing particles through sieve opening manually).
Sieves shall be brushed from underneath of mesh and pass on to the next.
On completion of sieving, material retained on each sieve is to be weigh separately.

LABORATORY MANUAL
Reporting:
The cumulative % by weight of the total sample passing each sieves, to the nearest
whole number.
Or
The % by weight of the total sample passing one sieve and retained on the next smaller sieve
to the nearest 1 decimal.
Check for permissible limits for passing.
Format to be Used :
Format of Sieve Analysis for Coarse Aggregate shall be used.

LABORATORY MANUAL
FORMAT FOR SIEVE ANALYSIS FOR COARSE

AGGREGATE
Name of Client :
Size of CA : mm Date of sample

Collected :
Source :
IS Sieve Wt Wt Cumulative Cumulative Remarks

Size retained retained wt retained Passing %
on each % %
sieve, g
40 mm
20 mm
16mm
12.5 mm
10 mm
4.75 mm
2.36 mm
Pan
Total
Dry Loose Bulk Density : kg / m3 % Fines passing 4.75% :
Water Absorption % : %
Specific Gravity : gms/cc
Tested By : Checked By:
Date Date

LABORATORY MANUAL
CHAPTER – 12
DETERMINATION OF SPECIFIC GRAVITY AND WATER ABSORPTION OF
AGGREGATES
( IS : 2386 – part-III)
Aim :
To determine the Specific Gravity of Coarse Aggregate ( Smaller than 10 mm ) and Fine
Aggregate by using Pychnometer Bottle.
Apparatus :
Balance of Capacity not less than 3 Kgs and accuracy of 0.5 g.
Thermostatically controlled Oven
Pychnometer Bottle
G.I. Tray, Air Tight Containers around 1kg capacity, Filter Paper and Funnel.
Sample :
1 kg sample of 10mm sieve passing and retained on 4.75 mm sieve for Coarse Aggregate
500 g sample of 4.75 mm sieve passing for River or Crushed Sand.
A. PROCEDURE FOR COARSE AGGREGATE –

A sample passing 10mm sieve and retained on 4.75 mm sieve is to be collected and
placed in the tray and covered with distilled water; gently rodded to remove entrapped
air.
The sample shall be kept for 24 hrs +/- ½ hrs
The water shall be then carefully drained from the sample by decantation through filter
paper and any material retained being returned to the sample.
The sample is then air-dried with help of air drier or fan gently until no free surface
moisture is seen.
The saturated and surface-dry sample shall be weighed. ( Weight „A‟ g )
The aggregate shall then be placed in pychnometer bottle which shall be filled with
distilled water. Any trapped air shall be removed by rotating bottle on its sides and
covering hole in the cone portion with finger.
The pychnometer bottle shall be topped with water full to the surface of hole in metallic
cone.
The pychnometer bottle shall be dried from outside and weighed (Weight „B‟ g )

LABORATORY MANUAL
The contents of Pychnometer bottle shall be then emptied in the tray ensuring all
aggregate is transferred properly.
Pychnometer bottle shall be then rinsed and filled up with distilled water fully, dried
from outside as above and then weighed ( Weight „C‟ g )
The sample of aggregate as collected above shall be drained and decanted through
filter paper and retained material on filter paper shall be returned to the sample.
The sample then shall be placed in oven at 100 to110 deg C for 24 +/- ½ hrs. During
this period it shall be stirred occasionally to facilitate drying.
It shall be cooled in air-tight container and weighed ( Weight „D‟ g )
Such two tests shall be made
Calculations :
Specific Gravity = D/ A–(B–C)
Water Absorption = 100 ( A – D ) / D
( % of Dry weight)
Reporting :
Individual and mean results shall be reported and grading of the aggregate shall be stated.
B. PROCEDURE FOR FINE AGGREGATE :

Procedure is similar to the above but only sample size shall be 500g.
Format to be Used :
Format of Determination of Specific Gravity shall be used.( For Sp. Gravity )
Format of Determination of Water Absorption of Coarse and Fine Aggregates shall be
used. ( Water Absorption)

LABORATORY MANUAL
FORMAT FOR DETERMINATION OF WATER ABSORPTION

OF COARSE & FINE AGGREGATE
( IS : 2386-III )
Name of Client :
Type of Aggregate : Date of sample

Collected :
Source :
Sr.No Description Sample-1 Sample-2

.
1. Weight of material after fan drying for
4-5 hrs to Surface Saturated Dry
condition ( A, g )
2. Weight of Oven dry material for 24 hrs
( D, g )
3. % Water absorption in SSD condition

100 x ( A – D ) / D
4. Average of % Water Absorption
Tested by : Checked by :
Date Date

LABORATORY MANUAL
FORMAT FOR DETERMINATION OF SPECIFIC GRAVITY

( IS 2386- III )
Name of Client :

Collected :
Source :
Sr Description Sample
I II
1. Weight of Saturated
Surface-dry sample, A in
g
2. Weight of Pychn. Bottle
+ Sample + Water , B in
g
3. Weight of Pychn. Bottle
+ Water, C in g
4. Weight of Oven Dried
Sample, D in g
5. Sp. Gravity = D / A – ( B
–C)
6. Average Sp. Gravity
Tested By : Checked By :
Date Date

LABORATORY MANUAL
CHAPTER – 13
PROCEDURE FOR DETERMINATION OF FLAKINESS INDEX OF AGGREGATE
( IS : 2386 – I )
Aim:
To determine the Flakiness of particles of Coarse Aggregate greater than 6.3 mm size.
Apparatus :
Balance with accuracy of 0.1% of weight of sample
Flakiness Index Gauge
All other as per Sieve analysis.
Sample :
It shall be taken from retained material from Sieve analysis preferably and should have at
least 200 pieces of any fraction.
Procedure :
Each sample of 20 mm and 10mm shall be taken from retained fraction.
Each fraction shall be gauged in turn for thickness on metal gauge.
The total amount passing the gauge shall be weighed.
Report :
The flakiness Index is the total weight of the material passing the various thickness
gauges; expressed as a % of the weight of total sample gauged.
Format to be Used :
Format for Flakiness Index shall be used.

LABORATORY MANUAL
FORMAT FOR FLAKINESS INDEX OF COARSE

AGGREGATE
Name of Client :

Collected :
Source :
Size of Aggregate Individual wt of Weight of

aggregates Aggregate
retained between passing through
sieves , g respective slot of
the gauge , g
63 – 50 mm W1 = w1 =
50- 40 mm W2 = w2 =
40 – 31.5 mm W3 = w3 =
31.5 – 25 mm W4 = w4 =
25 – 20 mm W5 = w5 =
20 – 16 mm W6 = w6 =
16 – 12.5 mm W7 = w7 =
12.5- 10 mm W8 = w8 =
10- 6.3 mm W9 = w9 =
Actual Flakiness Index = 100 x ( w1 +w2 + w3 + ----- / W1 + W2 + W3 --- )
Actual Flakiness Index =
Acceptable Flakiness Index =
Tested by : Checked By :
Date Date
LABORATORY MANUAL
CHAPTER – 14
PROCEDURE FOR DETERMINATION OF ELONGATION INDEX OF
AGGREGATE
( IS : 2386 – I )
Aim:
To determine the Elongated shape of particles of Coarse Aggregate greater than 6.3 mm size.
Apparatus :
Balance with accuracy of 0.1% of weight of the sample
Elongation Index Gauge
All other as per Sieve analysis.
Sample :
It shall be taken from retained material from Sieve analysis preferably and should have at
least 200 pieces of any fraction.
Procedure :
Each sample of 20mm and 10mm metal shall be taken from retained fraction.
Each fraction shall be gauged in turn for thickness on metal gauge.
The total amount passing the gauge shall be weighed.
Report :
The Elongation Index is the total weight of the material passing the various thickness
gauges; expressed as a % of the weight of total sample gauged.
Format to be Used :
Format for Elongation Index shall be used.

LABORATORY MANUAL
FORMAT FOR ELONGATION INDEX OF COARSE

AGGREGATE
Name of Client :

Collected :
Source :
Size of Aggregate Individual wt of Weight of

aggregates Aggregate
retained between passing through
sieves , g respective slot of
the gauge , g
63 – 50 mm W1 = w1 =
50- 40 mm W2 = w2 =
40 – 31.5 mm W3 = w3 =
31.5 – 25 mm W4 = w4 =
25 – 20 mm W5 = w5 =
20 – 16 mm W6 = w6 =
16 – 12.5 mm W7 = w7 =
12.5- 10 mm W8 = w8 =
10- 6.3 mm W9 = w9 =
Elongation Index = 100 x ( w1 +w2 + w3 + ----- / W1 + W2 + W3 --- )
Actual Elongation Index =
Acceptable Elongation Index =
Tested by : Checked By :
Date Date
LABORATORY MANUAL
CHAPTER – 15
PROCEDURE FOR DETERMINATION OF AGGREGATE CRUSHING VALUE
( I.S : 2386-IV )
Aim:
To calculate aggregate Crushing value by testing aggregate passing 12.5 mm sieve and
retained on a 10 mm sieve. ( This is Alternative method to Aggregate Impact Value.)
Apparatus:
15 cm dia steel cylinder with plunger and base plate
tamping rod 16 mm dia and 600 mm long with one end rounded.
Weighing balance of accuracy 1 g
I.S sieves 12.5 mm , 10 mm & 2.36 mm.
Drying Oven, CTM
Procedure :
Take sample of aggregates by sieving through 12.5mm and retained on 10mm.
The aggregate shall be tested in surface dry condition. If dried by heating, the period of
drying shall not exceed 4 hours and temp shall be 100-110 deg C.
Sample shall be cooled down to room temperature before testing. Take approximately
6 kgs of sample.
The quantity of the sample shall be such that the depth of material in the cylinder after
tamping shall be 10cms.
Cylinder shall be filled up in 3 layers and each layer shall be tamped 25 times with
tamping rod and finally leveled off.
The weight of material comprising the test sample shall be determined. ( A ), g
The plunger shall be placed in position and the apparatus shall be then placed
between the platens of CTM.
Load shall be applied at uniform rate so that load of 40t is reached in 10 minutes.
The load shall be removed from the cylinder and sieved through 2.36 mm sieve. The
fraction passing sieve 2.36 mm shall be weighed to nearest 1g
(B,g )
Such two tests shall be taken.

LABORATORY MANUAL
Reporting :
Aggregate Crushing Value, % = ( B / A ) x100
The mean of the two results shall be reported to the nearest whole number.
Format to be Used :
Format for Aggregate Crushing value to be used.

LABORATORY MANUAL
FORMAT FOR AGGREGATE CRUSHING VALUE
Name of Client :

Collected :
Source :
Description Sample
I II
Weight of Oven Dried
Sample „A‟ , g
Weight of Sample
passing 2.36 mm
sieve after Loading ,
„B‟ , g
Aggregate Crushing
Value
= 100x B/A
Average
Acceptable Limit
Date Date

LABORATORY MANUAL
CHAPTER – 16
PROCEDURE FOR DETERMINATION OF AGGREGATE IMPACT VALUE
( IS : 2386(PARTIV)-1963
Aim : To determine relative measure of resistance of an aggregate to sudden shock or
impact.
Apparatus :
A)An impact testing machine complying with following,
 Total weight not more than 60kg. nor less than 45 kg.
 A metal base weighing between 22 and 30 kg with a plane lower base of not less than
30 cm. dia
 Cylindrical steel cup of dia.102mm. and depth 50mm
 A metal hammer weighing 13.5 to 14.0kg. the lower end of which is is cylindrical shape
of 100mm dia. and 5cm. long.the hammer shall slide freely between vertical guides.
 Means for raising the hammer and allowing it to fall freely from a height of 380+/-5mm.
B) IS sieves of sizes 12.5,10 and 2.36mm
C) A cylindrical metal measure of dia.75mm and depth 50mm
D) A metal tamping rod of 10 mm dia. and 230 mm long.
E) Weighing balance of capacity not less than 500g. accurate to 0.1g
F) A oven to maintain the temperature of 100 to 110deg.c
Procedure :
 The aggregate sample which passes a 12.5mm sieve and retained on 10 mm sieve
shall be dried in oven for 4 hrs. at a tempr. Of 100 to 100 deg. C and cooled.
 The cylindrical measure shall be filled in three layers each tamped with 25 strokes of
tamping rod.
 The net weight of aggregate in measure shall be determined (Weight A)
 The impact machine shall be firmly fixed in position.
 The cup shall be firmly fixed in position on the base and whole test sample is placed
and tamped with 25 strokes of tamping rod.
 The hammer shall be raised 380mm above the upper face of aggregate cup and
allowed to fall freely on the aggregate.The sample shall be subjected to 15 such blows.

LABORATORY MANUAL
 The crushed aggregate shall then be removed from cup and sieved on 2.36 mm IS
sieve. The fraction passing the sieve shall be weighed (weight B)
 The fraction retained on the sieve also be weighed. (Weight C)
CALCULATION
Aggregate Impact Value = (B/A)*100
Where,
B= weight of fraction passing 2.36 mm IS Sieve
A= weight of oven dried sample

LABORATORY MANUAL
FORMAT FOR AGGREGATE IMPACT VALUE TEST

Name of Project;
Source of material: Name of Supplier:
Location of sampling:
Date of Sampling: Date Of Testing:
DESCRIPTION TRIAL1 TRIAL2 TRIAL3

Total weight of Oven dried sample
filled in the measure (A) in gms.
Weight of sample passing through 2.36
mm IS Sieve (B) in gms.
Aggregate Impact Value (B/A)x100
Average AIV
Result : Accepted / Not Accepted
Notes:
AIV shall be 30% max for wearing surfaces and 45 % max for non-wearing surfaces.
(As per IS 383)
Date Date

LABORATORY MANUAL
CHAPTER – 17
PROCEDURE FOR TESTS ON COMMON BURNT CLAY BRICKS
( I.S : 3495-I&II )
A. DETERMINATION OF COMPRESSIVE STRENGTH OF BRICKS:
Aim: To determine Compressive Strength of Common Burnt Clay bricks
Apparatus :
M.S. Packing Plates 10 / 12 mm thk of adequate size ( 250mm x 150 mm)- 2 nos, minimum
Plywood sheets 3mm thk /3 ply – 2 nos
CTM
Measuring Scale
Clean sand screened through 3 mm sieve ( Remark-Sieving through 4.75 mm normally will
do)
O.P. Cement, jute cloth
Pre- Conditioning :
Record the measurements of the samples to nearest 1mm.
Remove the unevenness observed in the bed faces to provide two smooth and parallel
faces by grinding ( rubbing )
Immerse the specimens in the water at room temperature for 24 hours.
Remove specimen and drain out surplus moisture. Fill the frog and voids in the bed
faces with CM 1:3 flushed to the surface.
Store under damp jute cloth for 24 hrs and then immerse in water for 3 days.
Remove specimen from water and wipe traces of moisture.
Procedure :
Place the specimen with flat faces horizontal and mortar filled face upward between
two ply sheets and required packing plates. Center it carefully.
Apply load at rate of 140 kg /cm2 per minute ( 30 tonne per minute ) , till failure
occurs.
Note the maximum load at the failure.

LABORATORY MANUAL
Calculations :
Compressive Strength, kg /cm2 = Max Load in Kg / Avg area of the bed faces of the
specimen, cm2
Report: Average of the results shall be reported.
Format to be Used :
Format for Testing of Common Burnt Clay Brick shall be used.
B. DETERMINATION OF WATER ABSORPTION :
Aim :
To determine water absorption of specimen by 24 hours immersion in cold water.
Apparatus :
Balance with accuracy of 1g
Oven
Measuring scale.
Pre- conditioning :
Dimensions shall be measured to accuracy of 1 mm of test specimen
Dry specimen in oven at temperature 105-115 deg C till it attains substantially constant
mass.
Cool the specimen to room temperature and obtain weight – M1, g ( Specimen warm
to touch shall not be weighed. )
Procedure:
Immerse completely dried specimen in clean water at temperature
27+/- 2 deg C.
Remove specimen after 24 hours and wipe out any traces of water with damp cloth.
Weigh the specimen within 3 minutes after removing from water. ( M2, g )

LABORATORY MANUAL
Calculations :
% Water Absorption = ( M2-M1 /M1) x100
Report :
Average of the results to be reported.
Format to be Used :
Format for Testing of Common Burnt Clay Bricks shall be used.

LABORATORY MANUAL
FORMAT FOR TESTING OF COMMON BURNT CLAY

BRICKS
( IS : 3495-I )
Name of Client :
A. Compressive Strength :
Sr. Date of Receipt Frog Mark I.D. Date of Testing Wt of Brick in gms
of Sample (Sketch)
Area of Load as Calibrated Strength Average Sign of Sign of

Brick per dial load in kN in N /mm2 Strength SPCL Client
sample gauge in engr. Consultan
kN t
B. Water Absorption :
Sr Date of Frog I.D. Date of Wt of oven Wt of brick Water Sign.
receipt mark testing dried brick immersed Absorpti
of Sketch in g for 24 hrs on %
sample in water in
g
Tested By : Checked By
Date Date

LABORATORY MANUAL
CHAPTER – 18
PROECEDURE FOR DETERMINATION OF
WATER CONTENT IN SOIL SAMPLE
( IS : 2720-II )
A. By Oven Drying Method :
Aim :
To determine Water Content in Soil Sample at Laboratory by Oven Method
Apparatus :
Container – Any suitable non-corrodable air tight container. ( Remarks- These can be
300ml aluminum or stainless steel boxes with lid )
Balance – Having accuracy of 0.04% of the weight of soil taken for test. Remarks-
Balance of capacity 500 g and accuracy of 0.1g can be used when accurate working is
required. If normal weighing balance with 1g accuracy is used then accuracy of water
content will be around 0.2 to 0.5% only; depending on sample size 500 to 200 g
respectively.
Drying Oven – Thermostatically controlled.
Soil Specimen :
It shall be true representative of soil mass. The size of specimen are recommended for
general laboratory use as below. However, the dryer the soil, greater shall be size.
Remarks : Preferably take 500g sample when weighing accuracy is 1g.
Size of particles, mm 37.5 19 9.5 4.75 2

More than 90% passing
Min qty of soil specimen

For test in g 1000 500 300 200 50
Procedure:
Clean the container with lid, dry and weigh ( W1,g )
Take the required quantity of the soil specimen in container, crumble clods and place
loosely and weigh with the lid ( W2, g )

LABORATORY MANUAL
Keep filled container in an oven with the lid removed and maintain the temperature at
110+/- 5 deg C. for maximum 24 hours.
Cool the container and record Final mass of container with lid and dried sample ( W3,
g ).
Calculations :
% of Water Content = 100 x ( W2-W3 ) / ( W3- W1)
Report :
The water content % shall be expressed to two significant figures ( e.g.- 23, 2.3, 0.23 )
Note : Oven drying at 110 +/- 5 deg C does not result in reliable values for soil containing
Gypsum and any other mineral having water of hydration or significant amount of organic
matter. Reliable values can be obtained in an oven by drying at temperature around 60-
80 deg C.
Remarks: Traces of Gypsum / lime / Alum can be seen as white particles. That of
Organic matter will show black colour fibrous traces. Particles of Green / Bluish Green can
be minerals having water of hydration.
B. By Sand Bath Method ( Suitable as Field Test )

This method is not suitable for soil containing a large portion of Gypsum , Calcareous
Matter or Organic matter.
Aim :
To determine water content in soil specimen in the field.
Apparatus:
Container – Any suitable Air tight container as given in Oven drying method.
Sand Bath : Suitable size and containing clean sand to a depth of 3 cms.
Stove, Spatula
Soil Specimen :
As given in Oven drying method.

LABORATORY MANUAL
Procedure :
Clean the container with lid, dry and weigh ( W1 , g )
Take the required quantity of the soil specimen in container, crumble the clods and
place loosely and weigh ( W2, g )
Add few pieces ( 3-4 small) of white paper if necessary. This the indicator for over-
heating. While heating the soil paper pieces shall not turn brown.
Place the container with lid removed on sand bath and heat sand bath on the stove.
During heating sample shall be turned frequently and thoroughly to assist evaporation.
It shall be done carefully so as no soil mass is spilled over.
When drying is complete, remove the container and cool it down. Remove pieces of
papers.
Weigh the container with lid on. ( W3, g )
Calculations :
w % = 100x ( W2 - W3 ) / ( W3 –W1 )
Report :
Same as Oven drying method to two significant figures ( e.g. – 23, 2.3, 0.23 )
Format to be Used :
Format of Field Dry Density by Core cutter Method to be used.

LABORATORY MANUAL
CHAPTER – 19
DETERMINATION OF DRY DENSITY OF SOIL IN-PLACE
BY CORE-CUTTER METHOD
( I.S : 2720-XXIX )
Aim : To determine the Field density of Fine grained soil by using Core-cutter. ( It is less
accurate than sand Replacement Method and recommended for well compacted soils.
Apparatus :
Core cutter / Dolly / Rammer.
Balance of 1 g accuracy.
Pallet knife, Straight edge, Steel rule, Pick axe etc.
Soil sample :
Soil sample is termed as fine-grained if 90% by weight is passes through IS sieve 4.75
mm.
Procedure :
Internal Volume ( Vc, cm3 ) of core cutter shall be calculated by taking dimensions to
nearest to 0.25 mm ( By vernier).
Cutter shall be weighed to nearest g. ( Wc, g )
A small area, approximately 30 cms square of the soil layer to be tested shall be
exposed and leveled.
Cutter shall be placed vertically on soil with dolly on top.
Cutter shall be rammed down vertically into the soil layer until only about 15 mm of
dolly protrudes above surface.
Care to be taken that cutter shall not rock sideways while hammering.
The cutter shall be dug out of surrounding soil by pick axe. Please take care so as to
have some protruding soil mass from the lower edge.
Soil from both the ends shall be trimmed flat to the ends of cutter.
The cutter containing soil mass shall be weighed to nearest g ( Ws, g )
The soil mass shall be removed from cutter and representative sample shall be tested
for water contents.
At least 3 tests are required to make average result.
Remarks – Often problem encountered when soil mass is dry and cutter is not properly
filled up or looses soil while handling. In such case test is to be done by sprinkling
water and testing after suitable lapse of time. Core cutter shall be removed, trimmed

LABORATORY MANUAL
and kept in polythelene bag to take it to laboratory. It shall be weighed with cutter and
any loose soil mass collected in bag.
Calculations :
Bulk Density Yb of Wet Soil is as below:
Yb = ( Ws – Wc ) / Vc , gms /cm3
Dry Density Yd is as below:
Yd = 100 Yb / ( 100 + w ) , gms /cm3 Where w = Water content %
Report :
Dry Density to be recorded to 2nd place of decimal in gms/cm3.
Water Content % to two significant figures ( e.g.- 23, 2.3, 0.23 )
Format to be Used :
Format of Field Density of Soil by Core Cutter Method shall be used.

LABORATORY MANUAL
FIELD DRY DENSITY OF SOIL

BY CORE CUTTER METHOD
( IS : 2720- XXIX )
Name of Client : Location :
Name of Consultant : Layer No : from bottom

Thickness of layer : mm
MDD of Soil : g/cm3 OMC % :
Sr. Description Sample

I II III
A. Bulk Density of Soil
1. Weight of the cutter, Wc , g
2. Weight of Cutter + Soil , Ws, g
3. Volume of Cutter , Vc , cm3
4. Bulk Density of Soil Yb

= ( Ws –Wc ) /Vc , g / cm3
B. Water Content %
1. Weight of Container with Lid ,
W1 , g
2. W1 + Weight of wet Soil = W2 , g
3. W1 + Weight of Oven dried soil =

W3 , g
4. % of Water Content, w = 100x (
W2 –W3 ) / ( W3 –W1 )
C. Dry Density of Soil
1. Dry Density of Soil , Yd = 100
Yb / ( 100 + w ) , g / cm3
2. Average Field Dry Density, Yd‟ , g
/cm3
D. % Compaction Achieved,
100 x ( Yd avg / MDD )
Acceptable Limit =
RESULT ACCEPTED / REJECTED
ACTION TO BE TAKEN ( If Any ) :
Date Date

LABORATORY MANUAL
CHAPTER – 3
CALIBRATION OF TEST
EQUIPMENTS

LABORATORY MANUAL
1- GENERAL
Scope :
The scope of this Calibration Plan is pertaining to SPCL procedure Document No – SP-O-2.2.
This Plan deals with Calibration & /or Verification of test equipments and measuring
equipments used in testing and production.
Requirements :
All test equipments in lab shall be in proper condition of use. They shall be verified at some
defined frequency to achieve correct results and consistent performance. Measuring
equipments and Test equipments are required to be calibrated to show that these equipments
give correct results within the tolerances specified by BIS. This shall be done at defined
frequency or as required.

LABORATORY MANUAL
2 - CALIBRATION PLAN
Sr. Equipme Brand / Part to be Method of Frequenc Latest

No nt Make Calibrated Calibratio y Calibratio
n n on
1. Compressi Lawrence & Dial Gauge External Once a
on testing Mayo Agency Year
machine
2. Weigh ISI Mark Weights External Once a
Balance (Contass) Agency Year
&Weights
3. Batch Plant Dial Gauge In -House Once a six
or Load cell month
4. Oven Expo Thermostat In -House Once a
Year
5. Pan Eureka External Once a six
balance Agency month
(electronic)
6. Mechanical Dial Gauge External Once a six
Weigh or Load cell Agency month
Batcher
7. Cube ISI Mark Check on In -House Once a
moulds (Contass) edges and three
straightness month

LABORATORY MANUAL
3 - PROCEDURE FOR VERIFICATION OF EQUIPMENTS

(In House Test)
VERIFICATION OF CUBE MOULD
Aim : To check Cube Mould assembly for dimensional correct ness.
Apparatus : Platform flat and leveled, Set of spanners,Metallic scale,Vernier Caliper
Procedure :
Put Sr No on Cube moulds and base plates ( All plates )
Cube set assembly shall be kept on platform.
Check the joints which shall be tight and uniform. Thickness shall be hairline thick.
Check the bolts for tight fitting and cleanliness.
Remove the bolts and dis –assemble the side plates and bottom plate.
Check for cleanliness and straightness with help of straight edge.
Re-fit the assembly and again and check for dimensional accuracy.
Check for diagonals for right angles in plan.
Remove bottom plate if attached and check diagonals between top and bottom.
Put cube assembly on base plate and check level of adjacent plates.
Tolerances ( IS : 516 ) :
Dimensional tolerances shall not be more than 150 + /- 0.2 mm.
Angular Tolerances shall be 90 deg + /- 0.5 deg. ( +/- 0.2 mm ).
Reports :Keep records of verifications of dimensions Date and Serial wise.
VERIFICATION OF SIEVES
Aim : To visually inspect the sieves for condition
Procedure :
Check the sieves are properly secure at frame and no gap is seen between frame and sieve
when pressed little on sieve center by palm.
Check the sieve wires /flats for straightness, ruptures etc.
Records : Rejected sieves shall be marked and then dispose suitably.

LABORATORY MANUAL
VERIFICATION OF PAN BALANCE

Aim : To check the sensitivity of pan balance.
Apparatus : Weight of least count.
Procedure :
Check proper level of balance and cleanliness.
Keep the pan on balance and check for pointer.
Then apply slight pressure on pan and keep the balance in swing. Watch for any abrupt
stoppage of swing.
Then keep the least count weight lightly without shock in pan and check if it record swing.
Remove the weight lightly with forceps without shock and watch if pointer returns back to
original.
If it does not respond to the least count weight, use next higher weight and observe.
Conclusion : Weight to which balance responds and visually seen shall be the least count
of the balance.
VERIFICATION OF MECHANICAL WEIGH BALANCE
Aim : To check condition and sensitivity of weighing mechanism.
Apparatus : Weight of 3kgs. ( This will give tolerance of about 2% in weighing as against
3% specified ).
Procedure :
Put weigh balance on level ground. Empty the buckets completely.
Check weighing mechanism is showing zero reading.
Add 3 kg load in bucket and check the reading.
Add 20 kg weight and check the reading.
Add 3kg weight and check the reading and so on.

LABORATORY MANUAL
Conclusion :
If it shows the reading around 3 kgs for each increment , it is OK. If not check weighing
mechanism which may have jammed bearing. Clean, change and repeat procedure. If still
error persists then it is time to calibrate equipment which only can be done by manufacturer or
approved agency. ( One common problem with arm type weigh batcher is slotted weights. If
they get interchanged then weighing will show variation.)
VERIFICATION OF COMPRESSION TESTING MACHINE OIL LEAKAGE

Aim : To check performance of loading. This can be tested while performing above test
also.
Apparatus :
Test Cube for higher grade than normally tested.
Procedure :
Test method is same as Cube Testing but cube is not to be loaded till crushing.
Place the cube in machine and load the cube till first crack appears on surface.
Stop the loading.
Watch the black needle whether remains in position. This needle may come back slightly as
cube is getting strained but then remains in position.
Conclusions :
If the needle traced back slowly it means there is leakage in system particularly Oil seal inside
cylinder. Or visible leakage in line connecting dial gauge and cylinder.
Report :
Report the load applied and observation and file in Calibration File.
Consult manufacturer for Repairs if required.
VERIFICATION OF COMPRESSION TESTING MACHINE PLATEN FLATNESS

Aim : To check the condition of CTM for its performance- platen Flat ness.

LABORATORY MANUAL
Apparatus :
Test Cubes of grade at least M: 20 ( Extra Conc. Cubes which are not listed for checks of
work )
Plain Paper and New Carbon Paper- 2each
Procedure :
For carrying out this test, cube is required to load partially only say upto 25-30 kN and cube
shall be retrieve in whole piece. Method is same as Cube testing.
Check cube surface which will be contact with platens for flatness by straight edge.
Put carbon paper on bottom platen, carbon side facing top and then put plain paper
( Mark “Bottom Side” on the paper ) on top of carbon paper.
Slide the cube and center it correctly so that whole cube surface shall be in contact with plain
paper. Mark the cube edges on the paper by pen.
Slide one more plain paper ( Mark “ Top Side on the paper )on top surface of cube. Put
carbon paper on top of plain paper with carbon side touching plain paper. Mark the cube
edges on paper by pen after tightening platen on cube by jack.
Load the CTM partially say upto 25-30 kN. This should not break the cube.
Remove the load. Retrieve the cube and plain papers watch the carbon marks on the
papers.Complete the cube size marking with straight edge to show area of cube with respect
to carbon mark ( which will appear circular in shape).
Results :
Refer to the top side paper first.Match the diagonals of cube size and check if carbon mark is
concentric with center of cube dimensions. If this is not concentric then cubes are getting
loaded eccentrically and failures are occurring only on one side mostly.
Check the carbon marking on the paper with respect to size of cube. If this marking is less
than 75 mm in diameter, it means cube is getting loaded only as point load thereby most of
the cubes are getting cracks centrally.Refer to the Bottom side paper.On this side carbon
marking will on more area than top side. Check the consistency of shade of marks.It shall not
be varying too much in shade or blank spaces in between.
Conclusions:

LABORATORY MANUAL
If top markings are showing point or eccentric loading, it means top platen is bent ( Usually
this occurs in 100t CTM as per our experience).If bottom marking have large shade variance,
bottom platen surface has irregularities.Consult the Manufacturer for replacement or repairs of
platens.

LABORATORY MANUAL
4 - CALIBRATION OF BATCHING PLANT

(In-House Test)
Aim : To calibrate the weighing mechanism of batch plant to conform within weighing
tolerances.
Apparatus :
Calibrated Weight blocks of various designations 50 / 20 kgs / 10 kgs ( As decided and
required ).
Procedure :
 Clear the bucket of all loose and any sticking material shall be removed.
 Set the reading at zero on display for no load.
 Load the bucket with weights starting from 20 kg and increase at the increment of 50 kgs.
 At start and each increment record the load on dial or display ( Loading Condition ).
 Reach the total load upto 1.2 times the operating weight of material being used or to the
0.9 times of capacity.
 After this remove 50 kg load every time and record these decrement values as above (
Unloading Condition )
 Check the report for tolerances to + /- 3 %. If it is exceeding the same weighing
mechanism shall be adjusted suitably to give minimum errors.
Report :
Keep report of variance of actual weights and recorded weights. Give correction factors to
plant operator.

LABORATORY MANUAL
BATCHING PLANT CALIBRATION REPORT
Site : Date of Calibration :
Make and capacity of Batching Plant :
SP Code No :
Testing Condition : LOADING / UNLOADING
Actual Reading Reading Error% Error% Remarks

Weight before After before After
correctn Corretn correctn correctn
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1050
1100
1150
1200
1250
1300
1350
1400
1450
1500
Calibration Done By : Checked By :

LABORATORY MANUAL
5 - LIST OF ABBREVIATION
Amp : Ampere
Avg : Average
C : Centigrade
C.C. : Cement Concrete
CA : Coarse Aggregate
cc : Cubic Centimeter
cl. : Clause
CM : Cement Mortar ( Proportion )
cm : Centimeter
cm2 : Square Centimeter
cm3 : - do –
CTM : Compression Testing Machine
deg : Degree ( Temperature)
Dia : Diameter
DLBD : Dry Loose Bulk Density.
g : Gram
G.I. : Galvanized Iron
Hrs : Hours
IS : Indian Standard
ISI : Indian Standard Institution now BIS (Bureau of Indian Standards)
Kg : Kilogram
kN : Kilo-Newton ( Weight measure. 1kN = 1000 N = 100 kg )
LL : Live Load
M.S. : Mild Steel
m3 : Cubic meter
Max : Maximum
mcn : Micron ( 1000 micron = 1 mm )
MDD : Maximum Dry Density
Min : Minimum
mm : Millimeter
mm2 : Square Millimeter
Mpa : Mega Pascal ( Unit of Stress/ Pressure )
MT : Metric Ton ( 1 MT = 1000 Kgs)
MTC : Manufacturer‟s Test Certificate
N : Newton ( weight measure 10 N = 1 Kg approx )
No : Number
O.P.C : Ordinary Portland Cement
OMC : Optimum Moisture Content
Pg : Page
PPC : Portland Pozzolana Cement
PSC : Portland Slag Cement
Qty : Quantity
RMC : Ready Mix Concrete
S.D. : Standard Deviation
Sp.Gr. : Specific Gravity
SPCL : m/s Shapoorji Pallonji & Co. Ltd.
Sr. : Serial
Std : Standard
UTS : Ultimate Tensile Stress
wt : Weight
LABORATORY MANUAL
6 - DEFINITIONS
Newton : It is measure of weight in S.I. ( International Standard ) Unit. 10 N = 1kg.
Approximately.
Mpa : It is unit of Stress or Pressure in S.I. ( International Standard ) Unit. Equivalent to
N/mm2.
Optimum Moisture Content ( OMC ) : Calculated in %. It is the moisture content in soil
at which soil can be compacted to maximum Dry Density under given applied efforts (
Ramming with standard weight rammer through standard distance ).
Maximum Dry Density ( MDD ) : The maximum density to which soil can attain at given
parameters ( Like Moisture Content and efforts ). The value is calculated without the weight of
water content in specimen.
Gross Sample : Sample collected from stack of material which is representative and it is
further divided to make specimen for testing by specific method.
Liquid Limit ( LL ) : It is calculated in % for cohesive soils. It is the % of water at which soil
specimen flows under little effort applied. This gives undesirable conditions of water content in
cohesive soil mass.
Plastic Limit ( PL ) : It is calculated in % for cohesive soils. It is the % of water at which soil
specimen become plastic e.g. – moldable / compactable. OMC of soil is generally slightly less
than PL.
Plasticity Index ( PI ) : It is numerical difference bet LL & PL ( LL- PL ). For highly cohesive
soils PI is high. For Non-cohesive soils PI is less. Highly cohesive soils offers great resistance
to compaction and Non-cohesive soils are unstable in moist conditions.
Characteristic Strength ( of Concrete ) , Fck : This is the designated strength ( in
N/mm2 or kg /cm2 ) of cube cured for 28 days for given Grade of the concrete, below which
not more than 5% of the test results are expected to fall. This value shall not be considered as
accepted value of strength directly. Concrete strength acceptance criteria is based on value
of „Fck‟.
Mean Target Strength (of Concrete ) : This value is targeted when designing the mix of
concrete under strict control at laboratory. Hence under site conditions lower values will be
attained without any compromise on acceptance criteria.
Lot of Brick : A collection of bricks of same class and size, manufactured under relatively
similar conditions of production.

LABORATORY MANUAL
Batch of Cement : This is displayed on cement bags as a week number of the year. It
shows Week of production ( Whole year is divided in weeks and serial no of week is given.
E.g.- 4th week means 4th week of Jan. 9th week means 1st week of Mar ) along with Month and
year is also shown. The display is „ 9 / 03‟ or
W M Y
9 3 2003
0.2% Proof stress ( For steel ) - IS : 1608 : It is derived from graph force vs. extension.
Value of force is derived by drawing line at 0.2% of extension on graph and running it parallel
to the straight portion of graph. This line will intersect the graph and value of force will be
obtained. This force is divided by the original cross section area of specimen and thus 0.2 %
proof stress is arrived at.
Batch of Steel- IS 1786 : Any quantity of bars /wires of same size and grade whether in
coils or bundle presented for examination and test at one time.
Bundle of Steel – IS 1786 : Two or more coils or a number of lengths properly bound
together.
Notes ( As mentioned in this manual ) : These are authentic notes / comments
given from references.
Remarks ( As mentioned in this manual ) : These are added extra as per normal
practices and observations. These can not be quoted as authentic one as no proper
back up can be available.

LABORATORY MANUAL
LABORATORY MANUAL AMENDMENT REQUEST FORM

From :
Document Code :
Dept./Site : ISO Cell, SP Centre
Document Title : To :
Current Issue No. : Date :
Chapter No. Details Proposed Amendment Reason
SIGNATURE OF ORIGINATOR
Review Notes :
Signature of Original Approving Authority
P.S. The Amendment Request Form shall be approved Recommended Not Recommended
by the approving authority of the Document.
Document Amendment Date :
Document Approval Date :
Document Issued On : By :

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Quality Assurance & Quality Control - Laboratory Testing

A-2.2/09-10-1 - Laboratory Manual

Quality Control For

Shapoorji Pallonji And Co. Ltd.

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A-2.2/09-10-1 - Laboratory Manual

This laboratory manual was initiated by Corporate QA / QC Department( Head Office),

Corporate QA/ QC Department.

Second Edition Nov 2012.

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1. Scope of the Manual 6

1. Area of Laboratory Required 19 to 20

III - Calibration of Test Equipment’s :

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SCOPE OF THE MANUAL :

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List of Tests to be Conducted at Site Laboratory :

Sr.No Material to be tested Related IS Codes Tests to be Conducted

1. Soil 2720 part-1-2-29 In-situ core test.

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List of the Material & Tests to be Conducted at External Laboratory :

*Note : External Laboratory shall be as per requirement of the project or as

Sr. Material to Tests to be conducted Requirements

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8. Concrete Mix Design At start of project and /or

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Sr. Equipments Capacity/ Size Make

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18. Weigh Balance (10kg) Battery backup Eureka

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LIST OF REFERENCE IS CODES:

IS: 383 - Specifications for Coarse and Fine aggregate

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ACCEPTANCE CRITERIA FOR VARIOUS MATERIAL

Material Reference Clause Details of Acceptance Frequency

Coarse Inspection of in-coming material-

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IS:383 Table-2 % passing for Single size aggregate of

5454 cl. 5.2.1.1 Compressive Strength of any individual

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1077 Table-1 Classification on basis of average

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Acceptance Criteria Graph ' Zone Wise ' for Sand

600 mcn % passing

% PASSING 600 MCN SIEVE

10 mm 100 100 120

150 mcn 0 10 % Passing

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