Lab Tests In Construction

MINIMUM QUANTITIES REQUIRED TO BE SENT TO LABORATORIES FOR TESTING OF MATERIALS SR .No.

Name of Test

Minimum Quantities of Material Required for testing

CEMENT 1.

Fineness

Test samples of cement shall be made up of a 15 Kg.

2.

Specific Gravity

Cement approximately taken from each of number of bags on the site

3.

Standard Consistency

4. 5.

Setting Time (Initial & Final) Compressive Strength

6.

Soundness COARSE AGGREGATE

Size of metal

Quantity

7.

Sieve Analysis

60 mm

100 Kg

8.

Water absorption & Specific Gravity

40 mm

50 kg

a)

Water Absorption

25 mm

50 Kg

b)

Specific Gravity

20 mm

25 Kg

12.5 mm

12 kg

10 mm 6.3 mm

6 Kg 3 Kg

9.

Impact Value

10. Abrasion Value 11. Crushing Value 12. Flakiness Index FINE AGGREGATE 13. Fineness Modulus (Sieve Analysis)

One bag of 25 Kg.

14. Silt & Clay Content (Weight Seiving) BRICKS 15. Water Absorption

Five Bricks

16. Compressive Strength

Five Bricks

17. Efflorences

Five Bricks

FLOORING TILES 18. Flexural Test

Six Tiles

19. Water Absorption

Six Tiles

20. Resistance to wear

Six specimen of size 70 x 70 mm

MANGLORE TILES 21. Water Absorption

Six Tiles

22. Flexural Test

Six Tiles

23. Permeability Test

Six Tiles

GLAZED TILES 24. Water Absorption

Five Tiles

CONCRETE 25. Compressive Strength Three Nos of C. C. Cubes Size of C. C. Cube 15 x15x 15 cm. Per Set 26. Concrete Mix Design with all tests on basic materials

One full bag of each Aggregate , Sand & Cement

27. Concrete mix design only for mix (tests on basic materials have already been taken

for Mix Design of each Grade

MORTOR 28. Compressive Strength Three Nos of MorterCubes Size 7.07x 7.07x 7.07 CmsPer Set STONE 29. Crushing Value

50 Kg.

30. Water Absorption & Specific Gravity 31. Compressive Strength Six dressed Samples of Size (Dressing of Stone already Done) 10x 10x 10 Cms 32. Compressive Strength Six Samples from which six with dressing of stone specimen of dressed stone of in Laboratory Size 10 x10 x10 Cms can be achieved SOIL/ MURUM 33. Field moisture Content 34. Liquid limit & Plastic Limit

35. Compaction Test (Proctor Density)

One bag of 50 Kg.

36. C.B.R. Test (Lab.) 37. Field Density by sand replacement method BITUMEN 38. Extraction Test

Two Kg. Bituminus Mix

39. Marshall stability & flow measurements a)Moulds Testing

One Set of Three Standard MarshallMoulds of size Diametre 10 cm ,Height 6.5 cm.

40. Preparation of Marshall moulds & Testing

4 Kg. Mix

41. Penetration

Two Kg Bitumen

42. Asphaltic concrete Job One full bag of each Mix Design with all Aggregate , filler- 5 Kg.,Grit-10 tests on basic materials Kg., Bitumen-5 Kg. for DBM/SDBC/AC 43. Bituminus Macadam Job Mix Design

for each Mix Design

HOLLOW BLOCKS 44. Density test

Three Blocks

45. Compressive Strength

Eight Blocks

46. Water Absorption Test

Three Blocks

SOLID BLOCKS

S.N.

47. Density Test

Three Blocks

48. Compressive Strength

Eight Blocks

49. Water Absorption Test

Three Blocks

Name of Test

COARSE AGGREGATE

Minimum Quantities of Materials required for testing

1 2 3 4 5 6

Soundness Bulk Density FINE AGGREGATE CL2 & Sulphate Content Moisture Content Bulkage of sand CONCRETE Flexural Strength of beam

17 18

SOIL/ MURUM Sulphate & Chloride content Mechanical analysis BITUMEN Softening point Viscosity Flash & fire point Specific gravity Ductility Mastic Hardness No. WATER PH value Sulphate & Chloride content WOOD Density Moisture content

19 20

STEEL ANTI CORROSIVE TEST Resistance to applied voltage (1 Hr.test) Resistance to applied voltage (30 days.test)

21 22

Thickness of coating Chemical resistance Test

23

Hardness of coating Test

7 8 9 10 11 12 13 14 15 16

20 kg 25 kg 2 kg 2 kg 5 kg One set of three beams 2 kg 60 kg (IS 2720 Pt.4)

5 kg Bitumen

5 Moulds 1 Litre of Water

3 Samples of 450 x 300 mm Two bars of 90 cm. length of required diameter Eight bars of 30 cm. length of required diameter Two bars of 30 cm. length of required diameter

Control Tests & their frequency & specified limits for various construction materials: Sr.No

Material & Tests.

Specified Limit.

Frequency.

1.

CEMENT (OPC) 1) Initial setting time.

Not less than 30 minutes.

2) Final setting time.

Not more than 600 minutes.

3) Fineness by dry sieving.

Residue not more than 10% on 90micron sieve.

4) Specific gravity.

3.10 to 3.15

For each consignment of 50 M.T. or part thereof.

5) Compressive strength. 33 Grade. 43 Grade 53 Grade (in Kg/cm2.) a) 3 days ( +/- 1 hours )

a) 160 230 270

b) 7 days. ( + /-2 hours. ) b) 220 330 370

2)

6) Soundness by Lechatelier apparatus.

Expansion not more than 10 mm.

SAND

100% passing through 4.75 mm I.S. sieve.

1) Particle size. 2) Silt content.

Not more than 4%

3) Fineness modulus.

1) For concrete 2.6 to 3.6

Tests should be carried out in the beginning and if 2)For masonry and 1st coat of plaster. there is a change in source Not more than 3. 3) For pointing & IInd coat of plaster shall Not exceed 1.6

4) Bulkage.

Bulkage will have to be determined for applying correction to the qty. of sand as and when necessary.

5) Moisture content.

Will have to be determined to find quantity of free water in sand.

Sr.No Material & Tests. 3. COARSE AGGREGATE 1) Gradation. Size of metal.

Specified Limit.

80 mm. 60mm 50mm

100 % Passing through sieve size 100mm 80mm 60mm

50 mm 50 mm 40 mm

40mm

63mm

63 mm ( 0%)

Frequency.

100% Retained on sieve size

One test for per 100 Cubic metre

40mm 35 to 70%

40mm to50mm. For Bituminus Works 40mm Crushed Metal 25mm Crushed Metal 20mm Crushed Metal

63 mm

40mm (30 to 65%) 12.5mm (95 to 100%) 25 mm

50mm 40 mm 25 mm

25 mm 20 mm 12.5mm

12.5 mm Crushed Metal

20 mm

10 mm

10mm Crushed Metal

12.5 mm

6.3 mm

6.3 mm Crushed Metal

10 mm

4.75 mm

12.5mm 0 to 5 %

For concrete 2)Impact Value. 3.

Crushing value 4) Los Angles abrasion value

Shall not exceed 45% shall not exceed. 45% shall not exceed 16%.

5) Flakiness Index

Shall not exceed

For Road work (Heavy traffic) Shall not exceed 30% shall not exceed. 17 % shall not exceed. At the beginning & if 50% (for WBM) there is change in shall not exceed. source. 17%(B.T.works) shall not exceed. 15%

35% 6) Water absorption

7) Specific Gravity

Sr. No 4

Tests. BRICKS 4. Water absorption shall not exceed

shall not exceed 5% shall not exceed 5% for WBM shall not exceed 1% for BT work Not specified Not specified

Specified Limit. I class II class 20% 22%

Frequency.

· Compressive Strength 32.8 kg/cm2 29.52 kg/cm2 (wet condition ) minimum 3)Efflorescence

A set of 15 bricks for 50000 consignment or part there of.

NIL - when there is no percephible deposit of efflorescence Slight – when not more than 10% area is covered with deposit Serious – when there is heavy deposit of salt accompanied by powdering

1) Compressive Strength for 28 days

Propotion 28 days Strength 1:3 127 to 211 Kg/cm2 1:4 84 to 126 Kg/cm2 1 :5 56 to 84 Kg/cm2 1:6 35 to 56 Kg/cm2

6

CEMENT CONCRETE CUBE 1) Compressive Strength

Grade 7days 28 days

Quantity Min. No

(Min kg/cm2) (Min kg/cm2)

Of Concrete of Samples

M100 70 100

Cum.

M150 105 150

1–51

M200 135 200

6 – 15 2

M250 170 250

16 – 30 3

M300 200 300

31 –50 4

M350 235 350

50 & Above 4 plus

M400 270 400

additional samples for each addition 0f 50 m3 or part there of 1 Sample = 6 Cubes

MANGALORE TILES 1) Water absorption shall not exceed…

Class AA Class A 19% 24%

.

2) Breaking Load kg (minimum)

For Average For Average

1 set of 18 tiles for every 2000 tiles or part thereof.

100 (410 x 235) 80(410x235) 110(420x250) 90(420x250) 110(425x260) 90(425x260) Individual Individual 90(410x235) 68(410x235) 100(420x250) 78(420x250) 100(425x260) 78(425x260) 3) Permeability Test

8

The tile shall be considered as satisfying the test, if not water has coazed from the bottom at the tile after the test.

CEMENT FLOORING TILES 5. Water absorption 6. Transverse strength

Shall not exceed 10% Average wet shall not be less than

6 tiles shall be tested or every test for every 2000

3 N /mm2 (30 kg/cm2) tiles or part there of. 9

SOIL/MURUM 7. Proctor Density 1.44 gm/cc Embankment upto 3 mtr. Shall not be less Height than 1.5 to gm/cc for Embankment exceeding 3 mtr. Height

One test per 1000 m3 or soil.

1.65 gm/cc for top 0.5 mtr. Height of Embankment 8. C.B.R. Value

10

HARD MURUM 9. Gradation 2) Plasticity Index

The Embankment shall be designed on ascertaining the CBR value 95% passing through 80 mm seive One test for compaction of size 2% passing through 25 mm seive 1 layer in one km. and size Below 4 every change in source or type of murum.

11

SOFT MURUM 1) Plasticity Index

One test for compaction of 1 layer in one km. and every change in source or type of murum.

Below 8

1 Sr. No Tests. 12 STONE 10. Water Absorption

Specified Limit.

Frequency.

Maximum 5% 1530 kg/cm2 minimum

11. Compressive Strength

13

12. Specific Gravity GLAZED TILES

Not less than 3

Not more than 10%

One set of 5 tiles for every 5000 tiles or part thereof.

To ascertaion the correct grade of bitumen

Two samples per lot to be subjected to all some tests as directed by the Engineer.

1) Water Absorption

14

BITUMEN 1) Penetration

15

BITUMINI0U MIX 13. Extruction

To check correct binder content as per 2 test for each 100 tonnes the tender of mix subject to a minimum of two tests per day per plant.

Minimum stability 820 kg 2) Marshall Stability & Flow measurments Flow 2-4 mm

For each 100 tonnes of mix produced , a set of 3 marshall moulds to be prepared and tested as per MOST

CONTROL TESTS AND THEIR FEQUENCY AND SPECIFIED LIMITS FOR VARIOUS CONSTRUCTION MATERIALS

S.N. 1

2 3 4 5

Name of Test COARSE AGGREGATE Soundness

Bulk Density FINE AGGREGATE CL2 & Sulphate Content Moisture Content Bulkage of sand CONCRETE Flexural Strength of beam

7

8 9 10 11 12 13 14

SOIL/ MURUM Sulphate & Chloride content

Mechanical analysis BITUMEN Softening point Viscosity Flash & fire point Specific gravity Ductility Mastic Hardness No.

Specified Limit

Frequency

Loss with Before approving the Sodium – 12% Max. aggregates and every Magnesium Sulphate 18% Max. month subsequently Sulphate content – 500 mg/Lt Cl 2 content – 2000 mg/Lt. – For P.C.C. 1000 mg/Lt. – For R.C.C. Grade Modules of rupture Of By beam test min. Concrete 3 days 7 days N/mm2 N/mm2 M-10 1.2 1.7 M-15 1.5 2.1 M-20 1.7 2.4 M-25 1.9 2.7 M-30 2.1 3.0 M-35 2.3 3.2 M-40 2.5 3.4

2 beams/150 m3 or part there of (one for 7 days and other for 28 days) or minimum 6 beams per day’s work whichever is more

Sulphate content – 500 mg/Lt Chloride content – 2000 mg/Lt. for P.C.C. 1000 mg/Lt. for R.C.C.

40 to 550C 2 sample/lot to be subjected to all or some tests as directed 1750C by the Engineers 0.99 minimum 75 cm. Minimum 60 to 80 at 250C without coarse aggregate 10 to 20 at 250C after adding coarse aggregate

WATER 15 16

PH value Sulphate & Chloride content

Not less than 6 Sulphate content – 500 mg/Lt Chloride content – 2000 mg/Lt. for P.C.C. 1000 mg/Lt. for R.C.C.

Once for approval of source of supply subsequently in case of doubt

WOOD 17 18

19

20

Density Moisture content

STEEL ANTI CORROSIVE TEST Resistance to applied voltage (1 Hr.test)

Resistance to applied voltage (30 days.test)

21

Thickness of coating

22

Chemical resistance Test

23

Hardness of coating Test

Roof and floors/weather Boards 20% Joinery beams/staircase 16% floors 12%

There was no sign of any coating failure at cathode, due to evaluation of hydrogen gas of any lasting at anode No under cutting of coating shall occur at any holiday that develops during testing. If no holiday developed during 30 days single intentional hole of 6 mm. shall be made in both cathod in anode then test shall be continued for additional 24 hours in which no under cutting shall occur Minimum thickness CECRI – 200 – 400 Mic. FBEC – 100 – 300 Mic. CPCC – 125 Mic. Min.

The coating shall not blister, soften, lose bond, nor development holiday during 45 days. The intentionally made holes shall exhibit no under cutting during the 45 days period. Hardness of coating when measured using a pencil hardness tester shall be around 54 to 74.

TYPICAL LETTER FOR SAMPLE DESPATCH Date To,

At least 3 samples from lots containing upto 200 pieces

-

-

Coating thickness shall be tested at a frequency of not less than one full length bar every twenty bars for each size.

-

Sub.:- Testing of construction material Please find enclosed herewith the samples collected from the below mentioned work site and it is requested to please test the materiasl and communicate the test results to this office at an early date. 1. 2. 3. 4. 5.

Name of Work : ----------------------------------------------------------------------------Estimates cost of work :---------------------------------------------------------------------Tender No. & Cost :-------------------------------------------------------------------------Scheme of Work :-----------------------------------------------------------------------------Name of Agency :-----------------------------------------------------------------------------

6. Details of sample as below.

A. Aggregate/ Murum/ Bituminious mix. Sr.No.

Material its location chainage LHS/RHS

No. of samples

Tests to be conducted

1)

60 mm metal km 1/500 (RHS)

1 No.

1)Water Absorption 2) Impact Value 3) Gradation

B. C. Bricks/Tiles (Flooring/Manglore) /CC Blocks etc Sr.No

Material & its identification mark

No. of sets

Tests to be conducted

1

Bricks

1 set 1 set=10 bricks

1)Water Absorption 2) Compressive strength

D. E. CC Cube/Moter Cube/ Hallow Block/Soil Block :Sr.No Grade of concrete / member

Date of Casting

Mark Size in cm

1

12-5-2000

B-1 B-2 B-3

M-20 Beam No.B-4

No. of sets

15x15x15 2 sets 1 set= 3 No. cube

G. Concrete Mix Design 1. Grade of Concrete ----------------------------------------------------2. Size of Aggregate to be used ------------------------------------3. Details of fine Aggregate -------------------------------------------

Test Compressive Strength

4. Cement company and Grade ------------------------------------5. Maximum size of Aggregate --------------------------------------6. Required character stic strength --------------------------------7. Degree of workability ------------------------------------------------8. Type of exposer -------------------------------------------------------9. Degree of quality control --------------------------------------------10. Water cement ratio ----------------------------------------------------11. Required slump --------------------------------------------------------12. Minimum cement content specified -----------------------------E) Job Mix Design for Bituminus Work (SDBC/DBM/BC/BM) 1. 2. 3. 4. 5.

Wearing surface type -------------------------------------------------Thickness as per tender ---------------------------------------------Details of material to be used --------------------------------------Details of filler ------------------------------------------------------------Details of binder ---------------------------------------------------------

Identification slip as described below duly signed with seal shall be kept in the sample bag. Identification Slip 1) Name of Sub Dn. : ---------------------------------------------------------2) Name of work ---------------------------------------------------------------3) Date of sample ------------------------------------------------------------- dispacted to Laboratory 4) Details of sample --------------------------------------------------------Testing charges for the above tests will be paid by the agency in cash or Demand Draft. It is requested to send the results to the Executive Engineer ----------------Dn. Encl: Samples as Deputy Engineer, Mentioned above P.W/NH/ZP Sub Dn. Copy submitted to the Executive Engineer, P.W. Dn. ---------------------- for information Copy to Agency ---------------------------------------- for information & necessary action.

REGISTER OF QUALITY CONTROL TESTS A. Guidelines for maintaining the Register of Quality Control Tests. 1) On every work, this Register shall be maintained.

2) The Junior Engineer, in charge of the work, should maintain this Register under the guidance of his Deputy Engineer. 3) The entries in the register should be signed by the Deputy Engineer for authentication. 4) Register should be available on the site of work during the inspection and should be kept up-to-date. 5) This register shall form a part of the permanent record of work and its pages should not be torn off and erasured, changed etc. should be authenticated. 6) For special type of works involving large scale construction in Bituminous Macadam and Asphaltic concrete etc. a separate register may be kept for dayto-day tests. A. Samples of Materials of Testing 1) Samples should be adequately representative and should be takenafter receipt of each new consignment. 2) The number of samples to be tested and the quality of each sample etc. as also the frequency of the testing shall be as per the Standard Specification. 3) Samples should be properly identified by giving due identification marks and sent to the Laboratory carefully so that they do not get damaged in transit. A. Standard Results The prescribed standards and frequency are shown in separate chapter. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14)

Cement. … ... … Sand. … … … Bricks. … … … Stone. … … … Aggregates. … … … Concrete. … … … Steel. … … … Welded Joints/Electrodes. … … Flooring Tiles. … … … Mangalore Tiles. … … … Cement Mortar. … … … Soils … … … Bitumen … … … Hume pipes. … … …

PERFORMA FOR TESTING OF CEMENT

Sr. Date of No. Sampling

1

Age of Date of Sample identification cement at Testing No. including Name the time of of Factory, Lot Not. testing No. etc.

2

Soundness

8

3

4

5

Setting Time Initial Final (Minutes) (Minutes)

9

FINENESS

% of Residue Specific surface by by weight on Air Permeability 90 micron method cm2/gm. sieve. 6 7

Compressive Strength Name of Lab. Dated Remarks Age of Compressive & No. & Date Signature of letter No. of the cube strength in under which Deputy Kg/cm 2 the results are Engr. received. 11 12 13 14 15

10

PROFORMA FOR TESTING OF SAND Sr. No.

Date

Silt contents %

1

2

3

Fineness Condition of Modulus sand

6

7

Moisture content %

% Bulkage observed

8

9

Sieve Analysis Sieve size in mm. % Retained by weight 4 5

Action taken for reduction in silt content /F.M. Bulkage 10

Dated Signature of D.E.

Remarks

11

12

PROFORMA FOR TESTING OF BRICKS Sr. No.

No. of Bricks in one consignment

1

2

Compressive strenth Kg/cm2 Dry. Wet. 8 9

No. of samples selected for testing 3

Size of brick

Identification No. on sample

Date of testing

% of water absorption

4

5

6

7

Efflorance Test.

Reference No. from laboratory

Dated Signature of the Dy. Engineer

Remarks.

10

11

12

13

PROFORMA FOR TESTING MASONRY STONES. Sr. No.

Date of Testing

Source & details of Samples

Specific gravity

Water Absorption

1

2

3

4

5

Compre- Name of Dated ssive Lab. No.& Signature strength Dt. Under of Dy. Kg/cm2 which the Engr Kg/cm2 results received. 6 7 8

Remarks

9

PROFORMA FOR TESTING OF STONE AGGREGATE Sr. No. Nominal size of Date of testing metal 1 2 3

Impact value

Crushing value

4

5

Los Angles abrasing value test 6

Water Stripping SIEVE ANALYSIS Absorbtion value I.S. sieve % passing by weight 7

8

9

10

% No. & Dt. Under Dated flakiness which the results Signature Index are received from of the Dy. the laboratory Engr. 11 12 13

Remarks

14

PROFORMA FOR TESTING OF CEMENT CONCRETE CUBES Sr. Date of No. concreting.

1

2

Grade of concrete.

3

Date of Age Dimension Weight Testing of of cube of of Cube cube. Cube 9 10 11 12

Total Nos. of cubes Location Quantity of & where concrete laid identification concrete during the there on used. day. 4 5 6

Observed comp. Strength Kg/cm2 13

Water cement ratio

Slump observed.

7

8

Calculated Ref. No. Dated Comp. from Signature of strength Laboratory the Dy. Engr. 728 14 15 16

Remarks

17