Lab Tests in Construction

MINIMUM QUANTITIES 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.

Stan Standa dard rd Cons Consis iste tenc ncy y

4.

Sett Settin ing g Time Time (Ini (Initi tial al & Final)

5.

Comp Compre ress ssiv ivee Stre Streng ngth th

6.

Soundness COARSE AGGREGATE

Size of metal

Quantity

7.

Sieve Analysis

60 mm

100 Kg

8.

Waterr abs Wate absor orp ptio tion & Specific Gravity

40 mm

50 kg

Water Absorption

25 mm

50 Kg

a) b)

Specific Gravity 9.

Impact Value

20 mm

25 Kg

12.5 mm

12 kg

10. Abrasion Value

10 mm

6 Kg

11. Crushing Value

6.3 mm

3 Kg

12. 12. Flak Flakin ines esss Index Index FINE AGGREGATE

13. Finene Fineness ss Modulu Moduluss (Sieve Analysis)

One bag of 25 Kg.

14. Silt Silt & Clay Clay Cont Content ent (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

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20. Resistance to to wear

Six speci ecimen 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. Compre Compressi ssive ve Stren Strength gth Three Nos of C. C. Cubes Size of C. C. Cube 15 x15x 15 cm. Per Set 26. Concre Concrete te Mix Mix Design Design with all tests on basic materials

One full bag of each Aggregate , Sand & Cement

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

for Mix Design of each Grade

MORTOR 

28. 28. Comp Compres ressi sive ve Stren Strengt gth h Three Three Nos Nos of of Morte MorterC rCub ubes es Size Size 7.07x 7.07x 7.07 CmsPer Set STONE

29. Cr C rushing Value

50 Kg.

30. Water Water Absorp Absorptio tion n& Specific Gravity 31. Compre Compressi ssive ve Stren Strength gth Six dressed Samples of Size (Dressing of Stone already Done) 10x 10x 10 Cms 32. Compre Compressi ssive ve Stren Strength gth 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 Field moist moisture ure Cont Content ent

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35. 35. Comp Compac acti tion on Test Test (Proctor Density)

One bag of 50 Kg.

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

38. Extraction Test

Two Kg. Bituminus Mix

39. Marsha Marshall ll stab stabili ility ty & flow measurements a)Moulds Testing

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

40. 40. Prep Prepar arat atio ion n of  Marshall moulds & Testing

4 Kg. Mix

41. Penetration

Two Kg Bitumen

42. Asphal Asphaltic tic concr concrete ete Job 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. Bitumi Bituminus nus Macada Macadam m 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

47. Density Test

Three Blocks

48. Compressive Strength

Eight Blocks

49. Water Absorption Test

Three Blocks

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1

Soundness

20 kg

2

Bulk Density

25 kg

FINE AGGREGATE

3

CL2 & Sulphate Content

2 kg

4

Moisture Content

2 kg

5

Bulkage of sand

5 kg CONCRETE

6

Flexural Strength of beam

One set of three  beams

SOIL/ MURUM

7

Sulphate & Chloride content

8

Mechanical analysis

2 kg 60 kg (IS 2720 Pt.4)

BITUMEN

9

Softening point

10

Viscosity

11

Flash ash & fire po point

12

Specific fic gravity

13

Ductility

14

Mastic Hardness No.

5 kg Bitumen

5 Moulds

WATER 

15

PH value

1 Litre of Water  

16

Sulp Sulpha hate te & Chlo Chlori ride de cont conten entt WOOD

17

Density

18

Moisture co content

3 Samples of

 

450 x 300 mm

STEEL ANTI CORROSIVE TEST

19

Resistance to applied voltage (1 Hr.test)

Two bars of 90 cm. length of required diameter 

20

Resist Resistanc ancee to to appl applied ied voltag voltagee (30 (30 days days.te .test) st)

21

Thick icknes ness of of co coatin ating g

22

Chemical resistance Test

Eight bars of 30 cm. length of required diameter 

23

Hardness of coating Test

Two bars of 30 cm. length of required diameter 

Control Tests & their frequency & specified limits for various construction construction materials:

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1.

CEMENT (OPC)

1) Initial setting time.

 Not less than 30 minutes.

2) Fi Final setting ti time.

Not mo more th than 600 mi 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 day dayss ( +/+/- 1 hour hourss )

a) 160 160 230 230 270 270

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

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) Fin Finenes enesss modu modulu luss.

1) For For con concret cretee 2.6 2.6 to 3.6 2)For masonry and 1st coat of plaster.  Not more than 3.

Tests should be carried out in the beginning and if  there is a change in source

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) Mois Moistu ture re con content tent..

Will ill hav havee to to be dete determ rmin ined ed to fin find quantity of free water in sand.

Sr.No

Material & Tests.

3.

COARSE AG AGGREGATE

Specified Limit.

1) Gradation. Size of metal.

80 mm.

100 % Passing through sieve size 100mm

100% Retained on sieve size 50 mm

Frequency.

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40mm 35 to 70%

40mm (30 to 65%)

12.5mm 0 to 5 %

12.5mm (95 to 100%)

63 mm

25 mm

40mm Crushed Metal

50mm

25 mm

25mm Crushed Metal

40 mm

20 mm

20mm Crushed Metal

25 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

40mm to50mm. For Bituminus Works

2)Impact Value. 3.

Crushing value

4) Los Angles abrasion value

For concrete

For Road work   (Heavy traffic)

Shall not exceed 45%

Shall not exceed 30%

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

5) Flakiness Index

Shall not exceed

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) W Waater ab absorption

7) Specific Gravity

Sr. No

4

Tests. BRICKS

shall no not exceed 5% 5% shall no not ex exceed 5% for WBM shall not exceed 1% for BT work  Not specified

Not specified

Specified Limit.

I class II class 20% 22%

Frequency.

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· 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

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.

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.

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11

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

SOFT MURUM

1) Plasticity Index

Below 8

1 Sr. No

12

Tests.

Specified Limit.

Frequency.

STONE

10. Water  Absorption

Maximum 5% 1530 kg/cm2 minimum

11. Compressive Strength  Not less than 3 12. Specific Gravity 13

GLAZED TILES

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

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S.N.

Name of Test

Specified Limit

Frequency

COARSE AGGREGATE

1

Soundness

Loss with Sodium – 12% Max. Magnesium Sulphate 18% Max.

2

Bulk Density

-

Before approving the aggregates and every month subsequently -

FINE AGGREGATE

3

CL2 & Sulphate Content

4

Moisture Co Content

5

Bulkage of sand

Sulphate content – 500 mg/Lt Cl 2 content –  2000 mg/Lt. – For P.C.C. 1000 mg/Lt. – For R.C.C.

CONCRETE

Flex Flexu ural ral Str Stren eng gth of beam eam

Grad Gradee Mo Module duless of of ru ruptu pture 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

SOIL/ MURUM

7

Sulphate & Chloride content

8

Mechanical an analysis

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

BITUMEN

9

Softening point

10

Viscosity

11

Flash & fire point

12

Specific gravity

40 to 550C 1750C 0.99 minimum

2 sample/lot to be subjected to all or  some tests as directed  by the Engineers

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WOOD

17

Density

18

Moisture content

-

-

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

At least 3 samples from lots containing upto 200 pieces

STEEL ANTI CORROSIVE TEST

19

20

Resi Resist stan ance ce to appl applied ied volta voltage ge (1 Hr.test)

Resi Resist stan ance ce to appl applied ied volta voltage ge (30 days.test)

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 

21

Thickness of coating

Minimum thickness CECRI – 200 – 400 Mic. FBEC – 100 – 300 Mic. CPCC – 125 Mic. Min.

22

Chemical resistance Test

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.

23

Hardness of coating Test

Hardness of coating when measured using a pencil hardness

-

-

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

-

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

6. Detai Details ls of of samp sample le as as belo below. w.

A. Aggregate/ Aggregate/ Murum/ Murum/ Bitumin Bituminious ious mix. Sr.N Sr.No. o.

Mate Materi rial al its its loca locati tion on chai chaina nage ge 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 Bricks/Tiles (Flooring/ (Flooring/Manglo Manglore) re) /CC Blocks Blocks etc Sr.No

Material & its identification mark

No. of sets

Tests to be conducted

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

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

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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) Cement. Cement. … ... … 2) Sand. … … … 3) Bricks. Bricks. … … …

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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

3

4

Setting Time Initial Final (Minutes) (Minutes)

8

9

10

5

FINENESS

% of Residue  by weight on 90 micron sieve.

Specific surface by Air Permeability method cm2/gm.

6

7

Compressive Strength Age of  cube

11

Name of Lab. Dated Remarks Compressive & No. & Date Signature of letter No. of the strength in under which Deputy Kg/cm 2 the results are Engr. received. 12

13

14

15

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PROFORMA FOR TESTING OF BRICKS

Sr. No No.

No. of of Br Bricks in in one consignment

 No. of samples selected for  testing

1

2

3

Compressive strenth Kg/cm2 Dry.

Wet.

8

9

Size of  Identification  brick   No. on sample 4

5

Date of  testing

% of water  absorption

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  Source & Testing details of  Samples

Specific gravity

Water  Absorption

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

Remarks

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Water  Stripping SIEVE ANALYSIS Absorbtion value I.S. I.S. siev sievee % pass passin ing g  by weight 7

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

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Remarks

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PROFORMA FOR TESTING OF CEMENT CONCRETE CUBES

Sr.  No.

Date of  concreting.

Grade of  concrete.

Total  Nos. of cubes Quantity of  & concrete laid identification during the there on day.

Location where concrete used.

Water  cement ratio

Slump observed.