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

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

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.

Shapoorji Pallonji E&C

Page 2 of 82

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

LABORATORY MANUAL

INDEX Page No. I - General : 1. 2. 3. 4. 5. 6. 7.

Scope of the Manual Table-1.- List of tests to be conducted at Site Table-2.- List of tests to be conducted at External Lab. Table-3.- List of lab equipment‟s Table-4.- List of reference IS codes Table-5.- Acceptance Criteria for material Acceptance Criteria Graph „Zone wise‟ for SanD

6 7 8 to 9 10 to 11 12 13 to 15 16 to 17

II - Procedures : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Area of Laboratory Required Precautionary measures for testing equipment‟s Procedure for Sampling of Material Slump test RMC Inspection/testing for Concrete Cube filling from fresh concrete Compressive strength of concrete Procedure for Standard deviation Field Test for Silt Content in Sand Sieve Analysis of Fine aggregate Sieve analysis of coarse aggregate Specific Gravity and water Absorption of Aggregates Flakiness Index Elongation Index Aggregate Crushing Value Determination of Aggregate Impact Value Tests for Common Burnt Clay Bricks (Strength, Water Absorption) Soil – Water Content Soil – Field density by Core- cutter.

19 to 20 21 to 22 23 to 26 27 28 to 30 31 to 32 33 to 35 36 to 37 38 39 to 41 42 to 44 45 to 48 49 to 50 51 to 52 53 to 55 56 to 58 59 to 62 63 to 65 65 to 68

III - Calibration of Test Equipment’s : 1. 2. 3. 4. 5. 6. 7.

General Calibration Plan Procedure for Verification of Equipment‟s Calibration of Batching Plant List of Abbreviations Definitions Amendment

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70 71 72 to 76 77 to 78 79 80 to 81 82 Page 3 of 82

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

LABORATORY MANUAL

CHAPTER – 1 GENERAL

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

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

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

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 (1975)

In-situ core test. Moisture Content

2.

Concrete

Compressive strength Slump Test

a.

Coarse Aggregate

1199(1959) 456(2000) 10262(1982) 8112 (1989) 2430(1986) 2386 part-1-3-4 (1963) 383 (1970)

b.

Fine aggregate

3.

Bricks

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1542 (1992) 2116 (1980) 383 (1972) 3495 part-1-2 (1992) 1077 (1992) 5454 (1978)

Sieve Analysis Aggregate Crushing Value/Impact Value Specific Gravity Water absorption Sieve Analysis Silt Content Specific Gravity Compressive Strength Water Absorption Test Dimension Efflorescence

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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. No.

Material to be Tested

1.

Construction Water

2.

Cement

a.

Physical

b.

Chemical

3.

Reinf Steel

a.

Physical

b.

Chemical

4. a.

Structural Steel Physical

b.

Chemical

c.

Weld tests

5.

Concrete Admixtures C.C. Block/ Paver blocks Aggregate Physical

6. 7. a.

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Tests to be conducted Potability, Sulphates, Chlorides

Strength, Fineness, Initial / Final setting Time, Standard Consistency, Soundness by Le-chatelier method Loss on ignition, Insoluble residue

Yield stress/UTS, Elongation, bend- rebend, Weight per meter % of Carbon , Sulphur, Phosphorus

Requirements As per Requirements of IS : 456 which shall be done at the start of project or change of source. As per respective IS codes for OPC, PPC, PSC and for Grades 43 /53 For every batch if MTC is not available. If MTC is available at Random frequency. In case cement is old or for new brand along with above tests For respective IS codes for Fe: 415/500/550 At given Frequency ( Project Specific) For new manufacturer or problem in physical tests

Yield stress/UTS, Elongation, bend- rebend, Weight per meter % of Carbon , Sulphur, Phosphorus Butt full strength jointsRadiography Compatibility with cementMarsh cone testing Compressive strength, water absorption, Density

At given Frequency ( Project Specific)

Routine tests Abrasion value

If specified by Client Critically for road works

For new manufacturer or problem in physical tests As per provision in tender or requirements. New admixture or admixture is giving performance problems. At given Frequency ( Project Specific)

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

LABORATORY MANUAL

8.

Concrete

Mix Design Non Destructive Tests like Ultra sonic or Rebound hammer Core Test

9.

10.

11.

Soil

RCC PipesNP ( NonPressure ) class. Galvanized Steel

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Max dry density and water content relationship ( proctor test ) Gradation, Plastic Limit, Liquid Limit Soluble sulphate contents Three edge test, Water absorption

Zinc coating thickness

At start of project and /or change of cement . When cube strengths are below acceptance criteria or as required by client. As specified by IS : 456 or as per Client requirement At the start of the activities and change of source. As required. As required As required ( Normally test setup available with manufacturer ) As required.

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LABORATORY MANUAL

TABLE – 3 List of Laboratory Equipments :

Sr. No

Equipments

1.

Compression Testing machine Cube Moulds Slump Cone

2. 3.

4.

Capacity/ Size 100 /200 tonne 150x150x150 mm Top Diameter – 100 mm, Bottom Diameter – 200 mm,Height – 300 mm, SheetThickness – 1.6 mm min. 40,20,16,12.5,10,6.32,4.75,2.36 mm 10mm & 4.75, 2.36, 1.18mm, 600mcn, 300mcn,150mcn Accuracy 1g

a

G.I.Coarse Aggregate Sieves- 300 mm dia Brass Fine Aggregate sieves- 200 mm dia Weigh Balance 10kg ( Pan ) C.I. Weights

b

S.S. Weights in box

100g, 50g, 20g, 10g, 5g, 2g, 1g

7. 8. 9.

Flakiness Index Gauge Elongation Gauge Measuring Cylinders a) Glass b) Plastic (nontransparent) Pycnometer Bottle Aggregate Crushing test apparatus Oven with Thermostat

--250 ml Height 335mm

5. 6.

10. 11. 12. 13 14. 15. 16. 17.

G.I. Trays Thermometer Vernier Caliper Wire gauge Core cutter ( For fine grained soils)

Shapoorji Pallonji E&C

5,2,1,500g, 200g, 100g, 50g

Make Lawrence & Mayo / Universal ISI Mark (Contass)

ISI Mark (Contass) ISI Mark (Contass) ISI Mark (Contass) Duly calibrated and stamped by Weight and Measure Dept. Duly calibrated by Weight and Measure Dept.

Borosil

Capacity 1 litre approx. -45x45cm size (2 tray) aluminium chamber Large / med 200 deg range (Indian Glass) --3 cutters Cutter – Int. Dia – 100mm Height – 130 mm Dolly – Height – 25 mm Rammer –Dia – 140 mm Thickness – 75mm

Expo

ISI Mark ISI Mark ISI Mark

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LABORATORY MANUAL

18. 19. 20.

Weigh Balance (10kg) Electronic Circular Spring Balance Misc.- Brush, duster, Trowel, scoop, Spanners, Sample metal containers, gunny bags

Shapoorji Pallonji E&C

Battery backup Platform 345x 225mm 50kg , 100 kg

Eureka ISI Mark

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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)

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LABORATORY MANUAL

TABLE – 5 ACCEPTANCE CRITERIA FOR VARIOUS MATERIAL Material

Reference

Clause /Pg

River Sand

IS:383

Table 4/pg-11

Table1/pg-8

Table1/pg-8

Coarse aggregat e

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Details of Acceptance

Frequency

Inspection of in-coming material Sand shall be free from clay lumps. Sand shall be free from organic matters Physical Testing As per Grading zone-I- III. 4.75 mm passing 90-100%. 150 mcn passing 010%. 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-IV80-100 Limit of Deleterious material( % by weight) Coal & Lignite – 1%, Clay lumps – 1%, 75mcn passing – 3%, Shale-1% Total % of deleterious material – 5% Limit of Deleterious material ( % by weight) 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 Inspection of in-coming materialShall be of angular shape and not flaky. Shall be free from deleterious material Shall be free from mud and soil.

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LABORATORY MANUAL

IS:383

Table-2 /pg-9

3.3/pg-6

3.4 /pg-6

Table1/pg-8

Common Clay Bricks

5454

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% passing for Single size aggregate of 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 Aggregate Crushing Value – 45% for concrete other than wearing surface. 30% for concrete for wearing surface. Aggregate Impact Value-Alt to 3.3 45% for concrete other than wearing surface. 30% for concrete for wearing surface. Limit of Deleterious material ( % by weight) Coal & Lignite- 1%, Clay lumps- 1%, 75 micron passing – 3%, Total % of deleterious material – 5% Flakiness Index: 30% for concrete. Inspection of in-coming material – Shall be of specified size and shape 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.

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%.

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LABORATORY MANUAL

1077

Table-1 /pg-1

cl.6.2 /pg-1

cl.7.2 /pg-3

cl.7.3/pg3 Concrete

456

Shapoorji Pallonji E&C

cl. 15.4 /pg-29

Classification on basis of average 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. Tolerances Non-modular: For 20 bricks Length – 4600 +/- 80 mm Width – 2200 +/- 40 mm Height – 1400 +/- 40 mm Water Absorption : Should not be more than 20% by weight upto class 12.5 and 15% by weight for higher classes. Efflorescence: „Moderate‟ upto class 12.5 and „Slight‟ for higher classes. The test results shall be average of 3 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.

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LABORATORY MANUAL

Acceptance Criteria Graph ' Zone Wise ' for Sand

600 mcn % passing Lower Limit Upper limit Zone-I 15 34 Zone-II 35 59 Zone-III 60 79 Zone-IV 80 100

ZONE DESIGNATION FOR FINE AGGREGATES

90 80 70 60 50 40 30 20 10

% PASSING 600 MCN SIEVE

100

600 mcn % passing Upper limit

Zone-IV

Zone-III

Zone-II

Zone-I

0

600 mcn % passing Lower Limit

ZONES

ZONE - I GRADING % Passing

10 mm

4.75 mm

2.36 mm

1.18 mm

120 100 80 60 40 20 0

600 mcn

100 100 95 70 34 20 10

300 mcn

100 90 60 30 15 5 0

150 mcn

10 mm 4.75 mm 2.36 mm 1.18 mm 600 mcn 300 mcn 150 mcn

ZONE-I GRADING CURVE

% PASSING

Sieves

SIEVES SIZES

ZONE -II GRADING CURVE

Sieves

120 100 80 60 40 20

SIEVE SIZES

Shapoorji Pallonji E&C

10 mm

4.75 mm

2.36 mm

1.18 mm

600 mcn

0

150 mcn

% PASSING

limit 100 100 100 90 59 30 10

300 mcn

ZONE - II GRADING % Passing Lower Limit Upper 10 mm 100 4.75 mm 90 2.36 mm 75 1.18 mm 55 600 mcn 35 300 mcn 8 150 mcn 0

% Passing Lower % Passing Upper

% Passing Lower % Passing Upper

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LABORATORY MANUAL

ZONE - III GRADING % Passing Lower Limit Upper limit 10 mm 100 100 4.75 mm 90 100 2.36 mm 85 100 1.18 mm 75 100 600 mcn 60 79 300 mcn 12 40 150 mcn 0 10

ZONE -III GRADING CURVE

Sieves

120

% PASSING

100 80 60 40 20

10 mm

4.75 mm

2.36 mm

1.18 mm

600 mcn

300 mcn

150 mcn

0

SIEVE SIZES

ZONE -IV GRADING CURVE 120 100

% PASSING

ZONE - IV GRADING Sieves % Passing Lower Limit Upper limit 10 mm 100 100 4.75 mm 95 100 2.36 mm 95 100 1.18 mm 90 100 600 mcn 80 100 300 mcn 15 50 150 mcn 0 15

% Passing Lower % Passing Upper

80 60 40 20

10 mm

4.75 mm

2.36 mm

1.18 mm

600 mcn

300 mcn

150 mcn

0

% Passing Lower % 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.

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

LABORATORY MANUAL

CHAPTER – 2 PROCEDURES

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

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.

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

LABORATORY MANUAL Sample of Laboratory :5.0 M PLATFORM FOR SAMPLES TILES, BRICKS ETC,.

DISPLAY BOARD (3.0X1.2M)

DOWN BELOW DOCUMENTATION SHELVES

CURING TANK

CHAIR

W

TABLE

4.0 M

X

1.5X1.5M COMP. TESTING MACHINE

CHAIR

WASH BASIN

CHAIR

W X'

PLATFORM FOR SOIL CONC. TESTING EQUIP.

PLATFORM FOR TESTING AGG / SAND EQUIP.

1.0 M

W

W

LAB PLAN 5.0 M ROOF

FILING RACK

1.2 M

RACKS

FOR

APPRATUS

FILING RACK

RACKS

FOR

APPRATUS

LAB SECTION XX'

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

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. Shapoorji Pallonji E&C

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

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.

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

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

15

25

Min wt. Of Gross sample, kg

10

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. Shapoorji Pallonji E&C

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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)

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

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. Shapoorji Pallonji E&C

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

LABORATORY MANUAL Sample size – For Visual / Dimensional Characteristics –

Lot Size of bricks Sample size for Individual brick

Sample size For group of

Check 2001 – 10000

20

10001 – 35000 35001- 50000

20 bricks Check

40 32

50

60 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

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

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. Shapoorji Pallonji E&C

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

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.

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

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.

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LABORATORY MANUAL

FORMAT FOR RMC CUBE REGISTER NAME OF PROJECT : Name of Client : Name of Consultant : S Name r of N Suppli o er .

Date of Testing for 28 days

Vide Delivery Challan/ Date

Weight of Cubes in Kg

Time Mixer Left Mixin g Plant

Area of Cube Surface cm2

Time discharg e complet ed

Stren gth at 7days in kg /cm2

Grad e of Conc rete

7 days Avg Strength in Kg/cm2

Locat ion of Use

ID of Cube s

Strength at 28 days in kg/cm2

Slum p in mm

28 days Avg strength in kg/cm2

Temp of fresh Concret e recd.

Sign of Contract or

Random testing of Aggrega te OK? Yes / No

Sign of Client / Consulta nt

Date of Testin g for 7 days

Remarks

Remarks : This format shall be used as Register. Preferably 7 days and 28days readings shall be entered in different rows.

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

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.

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

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

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

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. Shapoorji Pallonji E&C

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

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 :

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To be recorded in Cube Register.

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

LABORATORY MANUAL

FORMAT FOR CONCRETE CUBE REGISTER NAME OF PROJECT : Name of Client : Name of Consultant : Sr No

ID Mark of Cube

Area of Cube Surface Cm2

Location

Strength at 7days in kg /cm2

Grade of Concre te

7 days Avg Strength in Kg/cm2

Slump in mm

Strength at 28 days in kg/cm2

Date of casting cubes

28 days Avg strength in kg/cm2

Date of Testing for 7 days

Sign of Contract or

Date of Testing for 28 days

Sign of Client / Consulta nt

Weight of Cubes in Kg

Remarks

Remarks : This format shall be used as Register. Preferably 7 days and 28days readings shall be entered in different rows.

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

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 Cube strength 3 Cubes in N/mm2 Xi

Sr. No

( Xi- Xbar ) ^2

1 2 3

30 Total Xi =

Total Xn =

Xbar

n = 30 S.D. =

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(I)

(I)

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

LABORATORY MANUAL

UPDATING THE SD FOR SUBSEQUENT SETS OF RESULTS

Site :

Name of Client :

Concrete Grade : Period : Individual Avg Result ofXi- Xbar Sr. No Cube strength 3 Cubes in N/mm2 Xi 31 32 33

( Xi- Xbar ) ^2

55 Total Xi =

Total Xn =

Xbar

n = 25 S.D. =

( II )

( 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 ).

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

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.

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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 anticlockwise 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. Shapoorji Pallonji E&C

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

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.

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LABORATORY MANUAL

FORMAT FOR SIEVE ANALYSIS FOR FINE AGGREGATE NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name Of Consultant : Type of Aggregate : Source

River Sand / Crushed Sand

:

Name of Supplier :

IS Sieve Size

Date of sample Collected :

Wt retained on each sieve, g

Sample size :

Wt retained %

Cumulative wt retained %

Cumulative Passing %

grams

Remarks

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

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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 anticlockwise 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.

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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.

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LABORATORY MANUAL

FORMAT FOR SIEVE ANALYSIS FOR COARSE AGGREGATE NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name of Consultant : Size of CA

:

mm

Date of sample Collected :

Source : Name of Supplier :

IS Sieve Size

Wt retained on each sieve, g

Sample size :

Wt retained %

Cumulative wt retained %

Cumulative Passing %

grams

Remarks

40 mm 20 mm 16mm 12.5 mm 10 mm 4.75 mm 2.36 mm Pan Total

Dry Loose Bulk Density

:

Water Absorption % Specific Gravity

kg / m3 :

:

% Fines passing 4.75% :

% gms/cc

SAMPLE ACCEPTED / REJECTED Tested By :

Checked By:

Date

Date

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

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 )

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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)

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LABORATORY MANUAL

FORMAT FOR DETERMINATION OF WATER ABSORPTION OF COARSE & FINE AGGREGATE ( IS : 2386-III ) NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name Of Consultant : Type of Aggregate : Source

Date of sample Collected :

:

Name of Supplier :

Sr.No . 1.

2.

3. 4.

Sample size :

Description

Sample-1

grams

Sample-2

Weight of material after fan drying for 4-5 hrs to Surface Saturated Dry condition ( A, g ) Weight of Oven dry material for 24 hrs ( D, g ) % Water absorption in SSD condition 100 x ( A – D ) / D Average of % Water Absorption

SAMPLE ACCEPTED / REJECTED

Tested by :

Checked by :

Date

Date

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LABORATORY MANUAL

FORMAT FOR DETERMINATION OF SPECIFIC GRAVITY ( IS 2386- III ) NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name of Consultant : Size of CA

:

mm

Date of sample Collected :

Source : Name of Supplier : Sr

Sample size :

Description

Sample I

1.

2.

3. 4. 5.

6.

II

Weight of Saturated Surface-dry sample, A in g Weight of Pychn. Bottle + Sample + Water , B in g Weight of Pychn. Bottle + Water, C in g Weight of Oven Dried Sample, D in g Sp. Gravity = D / A – ( B –C) Average Sp. Gravity

Tested By :

Checked By :

Date

Date

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Page 47 of 82

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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.

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LABORATORY MANUAL

FORMAT FOR FLAKINESS INDEX OF COARSE AGGREGATE NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name Of Consultant :

Size of CA

:

mm

Date of sample Collected :

Source : Name of Supplier : Size of Aggregate

63 – 50 mm 50- 40 mm 40 – 31.5 mm 31.5 – 25 mm 25 – 20 mm 20 – 16 mm 16 – 12.5 mm 12.5- 10 mm 10- 6.3 mm

Individual wt of aggregates retained between sieves , g W1 = W2 = W3 = W4 = W5 = W6 = W7 = W8 = W9 =

Sample size :

grams

Weight of Aggregate passing through respective slot of the gauge , g w1 = w2 = w3 = w4 = w5 = w6 = w7 = w8 = w9 =

Actual Flakiness Index = 100 x ( w1 +w2 + w3 + ----- / W1 + W2 + W3 --- ) Actual Flakiness Index = Acceptable Flakiness Index = SAMPLE ACCEPTED / REJECTED

Tested by :

Checked By :

Date

Date

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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.

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FORMAT FOR ELONGATION INDEX OF COARSE AGGREGATE NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name Of Consultant :

Size of CA

:

mm

Date of sample Collected :

Source : Name of Supplier :

Size of Aggregate

63 – 50 mm 50- 40 mm 40 – 31.5 mm 31.5 – 25 mm 25 – 20 mm 20 – 16 mm 16 – 12.5 mm 12.5- 10 mm 10- 6.3 mm

Individual wt of aggregates retained between sieves , g W1 = W2 = W3 = W4 = W5 = W6 = W7 = W8 = W9 =

Sample size :

grams

Weight of Aggregate passing through respective slot of the gauge , g w1 = w2 = w3 = w4 = w5 = w6 = w7 = w8 = w9 =

Elongation Index = 100 x ( w1 +w2 + w3 + ----- / W1 + W2 + W3 --- ) Actual Elongation Index = Acceptable Elongation Index = SAMPLE ACCEPTED / REJECTED

Tested by :

Checked By :

Date

Date

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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.

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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.

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FORMAT FOR AGGREGATE CRUSHING VALUE NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name of Consultant : Size of CA

:

mm

Date of sample Collected :

Source : Name of Supplier :

Sample size :

Description

grams

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

SAMPLE ACCEPTED / REJECTED

Tested By : Date

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Checked By : Date

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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.

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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

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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) SAMPLE ACCEPTED / REJECTED

Tested By : Date

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Checked By : Date

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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.

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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 )

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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.

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LABORATORY MANUAL

FORMAT FOR TESTING OF COMMON BURNT CLAY BRICKS ( IS : 3495-I ) NAME OF PROJECT :

DATE OF TESTING:

Name of Client : Name of Consultant : A. Compressive Strength :

Sr.

Date of Receipt of Sample

Area of Brick sample

Load as per dial gauge in kN

Frog Mark (Sketch)

Calibrated load in kN

B. Water Absorption : Sr Date of Frog I.D. receipt mark of Sketch sample

I.D.

Strength in N /mm2

Date of Testing

Average Strength

Date of Wt of oven testing dried brick in g

Wt of Brick in gms

Sign of SPCL engr.

Sign of Client Consultan t

Wt of brick Water immersed Absorpti for 24 hrs on % in water in g

SAMPLE ACCEPTED / REJECTED

Tested By : Date Shapoorji Pallonji E&C

Checked By Date Page 61 of 82

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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

1000

500

300

200

50

More than 90% passing

Min qty of soil specimen For test in g

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 )

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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 6080 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.

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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 overheating. 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.

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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 Shapoorji Pallonji E&C

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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.

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LABORATORY MANUAL FIELD DRY DENSITY OF SOIL BY CORE CUTTER METHOD ( IS : 2720- XXIX ) NAME OF PROJECT :

DATE OF TESTING:

Name of Client :

Location :

Name of Consultant :

Layer No : from bottom Thickness of layer : mm

MDD of Soil :

OMC % :

Sr.

g/cm3

Description I

A. 1.

Bulk Density of Soil 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 Water Content % Weight of Container with Lid , W1 , g W1 + Weight of wet Soil = W2 , g

B. 1. 2. 3. 4. C. 1. 2. D.

Sample II

III

W1 + Weight of Oven dried soil = W3 , g % of Water Content, w = 100x ( W2 –W3 ) / ( W3 –W1 ) Dry Density of Soil Dry Density of Soil , Yd = 100 Yb / ( 100 + w ) , g / cm3 Average Field Dry Density, Yd‟ , g /cm3 % Compaction Achieved, 100 x ( Yd avg / MDD )

Acceptable Limit = RESULT ACCEPTED / REJECTED ACTION TO BE TAKEN ( If Any ) :

Tested By : Date Shapoorji Pallonji E&C

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LABORATORY MANUAL

CHAPTER – 3 CALIBRATION OF TEST EQUIPMENTS

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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.

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2 - CALIBRATION PLAN Sr. Equipme No nt

Brand / Make

Part to be Calibrated

Method of Calibratio n

Frequenc y

1.

Lawrence & Mayo

Dial Gauge

External Agency

Once a Year

ISI Mark (Contass)

Weights

External Agency

Once a Year

3.

Compressi on testing machine Weigh Balance &Weights Batch Plant

In -House

4.

Oven

Expo

Dial Gauge or Load cell Thermostat

5.

Pan balance (electronic) Mechanical Weigh Batcher Cube moulds

Eureka

External Agency

Once a six month Once a Year Once a six month

Dial Gauge or Load cell

External Agency

Once a six month

Check on edges and straightness

In -House

Once a three month

2.

6.

7.

Shapoorji Pallonji E&C

ISI Mark (Contass)

In -House

Latest Calibratio n on

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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. Shapoorji Pallonji E&C

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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.

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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.

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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:

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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.

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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.

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LABORATORY MANUAL BATCHING PLANT CALIBRATION REPORT Site :

Date of Calibration :

Make and capacity of Batching Plant : SP Code No : Testing Condition : LOADING / UNLOADING

Actual Weight

Reading before correctn

Reading After Corretn

Error% before correctn

Error% After correctn

Remarks

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 : Shapoorji Pallonji E&C

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

LABORATORY MANUAL

5 - LIST OF ABBREVIATION Amp Avg C C.C. CA cc cl. CM cm cm2 cm3 CTM deg Dia DLBD g G.I. Hrs IS ISI Kg kN LL M.S. m3 Max mcn MDD Min mm mm2 Mpa MT MTC N No O.P.C OMC Pg PPC PSC Qty RMC S.D. Sp.Gr. SPCL Sr. Std UTS wt

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

Ampere Average Centigrade Cement Concrete Coarse Aggregate Cubic Centimeter Clause Cement Mortar ( Proportion ) Centimeter Square Centimeter - do – Compression Testing Machine Degree ( Temperature) Diameter Dry Loose Bulk Density. Gram Galvanized Iron Hours Indian Standard Indian Standard Institution now BIS (Bureau of Indian Standards) Kilogram Kilo-Newton ( Weight measure. 1kN = 1000 N = 100 kg ) Live Load Mild Steel Cubic meter Maximum Micron ( 1000 micron = 1 mm ) Maximum Dry Density Minimum Millimeter Square Millimeter Mega Pascal ( Unit of Stress/ Pressure ) Metric Ton ( 1 MT = 1000 Kgs) Manufacturer‟s Test Certificate Newton ( weight measure 10 N = 1 Kg approx ) Number Ordinary Portland Cement Optimum Moisture Content Page Portland Pozzolana Cement Portland Slag Cement Quantity Ready Mix Concrete Standard Deviation Specific Gravity m/s Shapoorji Pallonji & Co. Ltd. Serial Standard Ultimate Tensile Stress Weight

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

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.

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

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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.

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