CRUSHING VALUE OF AGGREGATE

Aim: To assess the strength of coarse aggregates used in the pavement components under
gradually applied load and to determine the aggregates crushing value of the given sample of
aggregates.

Apparatus Required:
Compression testing machine, Tamping Rod, Trowel, Weighing Machine, Cylindrical Mould
and Plunger.

Theory:

Different rock samples give different compressive strength varying from minimum of about
45Mpa to maximum of 545Mpa. The compressive strength of parent rock does not exactly
indicate the strength of aggregates in concrete. For this reason assessment of strength of the
aggregates are made by using a sample bulk aggregates in standardized manner. The test
conducted to know the compressive strength of aggregate is known as aggregates crushing
value test. The crushing value of aggregates is rather insensitive to variation in strength of
weaker aggregates. For this reason, a simple test known as 10 percent fine value is introduced.
When the aggregates crushing value become 30% or higher, the results are likely to be
inaccurate.

The aggregates crushing value provides a relative measure of resistance to crushing under a
gradually applied compressive load. The principal mechanical property of aggregate required
in any construction is (i) satisfactory resistance to crushing under the roller during construction
(ii) adequate resistance to surface abrasion under traffic. Aggregates used in road construction
should be strong enough to resist crushing under traffic wheel load. If aggregates are weak the
stability of pavement structure is adversely affected. The strong aggregates will have low
crushing value and weak aggregates have high crushing value. The aggregate crushing strength
for various types of surface course of pavements should be high enough to withstand the high
wheel load, including the steel tires of loaded bullock-carts. However, low strength aggregates
having lesser crushing strength are used in base and sub-base courses of pavements. IRC have
specified aggregates crushing values of the coarse aggregates used for cement concrete surface
should not exceed 30%. For aggregates used for concrete other than surfaces, the aggregates
crushing values should not exceed 45%.
Aggregate Crushing test mould

Flexible Pavements
Types of Roads/ Pavements Aggregate Crushing Value (ACV) Limit
Soiling 50
Water bound macadam 40
Bituminous macadam 40
Bituminous surface dressing or thin premix 30
carpet
Dense mix carpet 30

Rigid Pavements
Types of Roads/ Pavements Aggregate Crushing Value (ACV) Limit
Other than wearing course 45
Surface or wearing course 40

Procedure:

1. The material for the standard test shall consist of aggregate passing a 12.5 mm IS Sieve and
retained on a 10 mm IS Sieve, and shall be thoroughly separated on these sieves before
testing.

2. The aggregate shall be tested in a surface-dry condition. If dried by heating, the period of
drying shall not exceed four hours, the temperature shall be 100 to 110°C and the aggregate
shall be cooled to room temperature before testing.
3. The appropriate quantity may be found conveniently by filling the cylindrical measure in
three layers of approximately equal depth, each layer being tamped 25 times with the
rounded end of the tamping rod and finally levelled off, using the tamping rod as a straight-
edge.

4. The weight of material comprising the test sample shall be determined (Weight 2) and the
same weight of sample shall be taken for the repeat test.

5. The cylinder of the test apparatus shall be put in position on the base plate and the test
sample added in thirds, each third being subjected to 25 strokes from the tamping rod. The
surface of the aggregate shall be carefully levelled and the plunger inserted so that it rests
horizontally on this surface, care being taken to ensure that the plunger does not jam in the
cylinder.

6. The apparatus, with the test sample and plunger in position, shall then be placed between
the platens of the testing machine and loaded at as uniform a rate as possible so that the
total load is reached in 10 minutes. The total load shall be 400 kN.

7. The load shall be released and the whole of the material removed from the cylinder and
sieved on a 2.36 mm IS Sieve for the standard test. The fraction passing the sieve shall be
weighed (Weight 3).

Observations & Calculations:

1. Weight of empty cylinder, W1 = __________

Empty weight of Weight of cylinder Weight of aggregate passing Aggregate
the cylinder (W1) with the aggregates through 2.36 mm sieve (W3) Crushing
in (g) (W2) in (g) in (g) Value (%)

Average Aggregate Crushing Value =

Conclusion:
 IMPACT TEST ON AGGREGATE
Aim: To evaluate the toughness of aggregates to break down under application of impact and
to determine aggregate impact value of the given sample of aggregate.

Apparatus Required:

Impact Testing Machine, Temping Rod, Trowel, Cylindrical Mould, Levelling Rod and
Weighing Balance.

Theory:

Aggregates undergo significant wear and tear throughout their life. Aggregates must be hard
and tough enough to resist crushing, degradation and disintegration and be able to transmit
loads from the pavement surface to the underlying layers and eventually the sub grade. Testing
the strength of parent rock alone does not exactly indicate the strength of aggregates in
concrete. For this reason assessment of strength of the aggregates are made by using a sample
bulk aggregates in standardized manner. The principal mechanical property of aggregate
required in any construction is

1. Satisfactory resistance to crushing under the roller during construction

2. Adequate resistance to surface abrasion under traffic

Aggregates used in road construction should be strong enough to resist abrasion and crushing
and also the impact load. If aggregates are weak, then the stability of pavement structure will
be adversely affected. The toughness of aggregate is its ability to resist sudden load acting on
it. The movement of vehicles on the road sometimes gives rise to impact loading which results
in breaking of aggregates into smaller pieces. Therefore the aggregates should have sufficient
toughness to resist their disintegration due to impact. This characteristic of aggregate is
measured by impact value test.

In this test sample of standard aggregates kept in a mould which is subjected to fifteen blows
of metal hammer of weight 14 kg falling from the height of 38cms. The quantity of finer
materials resulting from pounding will indicate the toughness of the sample of aggregates. As
per IS 283-1970 Aggregates Impact Value is defined as the ratio of weight of fines formed to
weight of total sample taken and is expressed in percentage.

Aggregates Impact Value gives relative measure of resistance of aggregates to sudden shock or
impact, which in some aggregates differs from its resistance to slow compression load. Impact
Value should not be less than 45% for aggregates used for concrete other than wearing surface
and 30% for concrete used in wearing surface. Table below shows the classification of
aggregate with respect to aggregate impact value and limits of aggregate impact value for
different types of road construction suggested by Indian Road Congress.
Aggregate Impact Value Classification
< 10% Exceptionally Strong
10 – 20% Strong
20 – 30% Satisfactory for road surfacing
> 35% Weak for road surfacing
Procedure:

1. The test sample shall consist of aggregate (350.00 g) the whole of which passes a 12.5 mm
IS Sieve and is retained on a 10 mm IS Sieve. The aggregate comprising the test sample
shall be dried in an oven for a period of four hours at a temperature of 100 to 110°C and
cooled.
2. The measure shall be filled about one-third full with the aggregate and tamped with 15
strokes of the rounded end of the tamping rod. Further similar quantity of aggregate shall
be added and a further tamping of 15 strokes given. The measure shall finally be filled to
overflowing, tamped 15 times and the surplus aggregate struck off, using the tamping rod
as a straight edge. The net weight of aggregate in the measure shall be determined to the
nearest gram (Weight W2).
3. The impact machine shall rest without wedging or packing upon the level plate, block or
floor, so that it is rigid and the hammer guide columns are vertical.
4. The cup shall be fixed firmly in position on the base of the machine and the whole of the
test sample placed in it and compacted by a single tamping of 15 strokes of the tamping
rod.
5. The hammer shall be raised until its lower face is 380 mm above the upper surface of the
aggregate in the cup, and allowed to fall freely on to the aggregate. The test sample shall
be subjected to a total of 15 such blows each being delivered at an interval of not less than
one second.
6. The crushed aggregate shall then be removed from the cup and the whole of it sieved on
the 2.36 mm IS Sieve until no further significant amount passes in one minute. The fraction
passing the sieve shall be weighed to an accuracy of 0.1 g (Weight. W3).
7. The fraction retained on the sieve shall also be weighed (Weight W1) and, if the total
weight is less than the initial weight by more than one gram, the result shall be discarded
and a fresh test made. Two tests shall be made.

Observations:

Empty weight of Weight of cylinder with the Weight of aggregates passing through
the empty aggregates (W2) in (g) 2.36 mm sieve (W3) in
cylinder (W1) in (g)
(g)
Calculation:

The ratio of the weight of fines formed to the total sample weight in each test shall he expressed
as a percentage, the result being recorded to the first decimal place:

Aggregate Impact Value = {W3/ (W2 – W1)} X 100

Where, W1 = weight of empty cylinder

W2 = weight of empty cylinder and aggregates retained on IS 10mm sieve

W3 = weight of aggregate passing through 2.36 mm sieve

Aggregate Impact Value (ACV) =

Aggregate Impact Value (ACV) =

Therefore, the average value of Aggregate Impact Value

Conclusion:
 FLAKINESS INDEX TEST

Aim: To determining the flakiness index of the coarse aggregate.

Apparatus:

Metal gauge, Weighing Balance, Gauging Trowel, Sieves

Reference:

IS: 2386 (Part I) – 1963 Method of test for aggregates for concrete

IS: 383-1970 specification for coarse and fine aggregate from natural source for concrete

Theory:

The flakiness index of an aggregate is the percentage by weight of particles in it whose least
dimension (thickness) is less than three-fifths of their mean dimension. Particle shape and
surface texture influence the properties of freshly mixed concrete more than the properties of
hardened concrete. Rough-textured, angular, and elongated particles require more water to
produce workable concrete than smooth, rounded compact aggregate. Consequently, the
cement content must also be increased to maintain the water-cement ratio. Generally, flat and
elongated particles are avoided or are limited to about 15 % by weight of the total aggregate.

Procedure

1. A quantity of aggregate shall be taken sufficient to provide the minimum number of 200
pieces of any fraction to be tested.
2. The sample shall be sieved with sieves specified in Table.
3. Then each fraction shall be gauged in turn for thickness on a metal gauge of the pattern
shown in Fig or in bulk on sieves having elongated slots. The width of the slot used in the
gauge or sieve shall be of the dimensions specified in column 3 of Table for the appropriate
size of material.
4. The total amount passing the gauge shall be weighed to an accuracy of at least 0.1 percent
of the weight of the test sample.

Calculations:

∑𝑤
Flakiness Index = 100 x ∑𝑊

Where, w is the weights of material passing the various thickness gauges and W is the total
weights of aggregate passing and retained on the specified sieves.
Results: Flakiness index=........................................
 ELONGATION INDEX TEST

Aim: To determining the elongation index of the coarse aggregate.

Apparatus:
Metal gauge, weighing Balance, Gauging Trowel, Sieves.
Reference code:
IS: 2386 ( Part I) – 1963 Method of tst for aggregates for concrete
IS: 383-1970 specification for coarse and fine aggregate from natural source for concrete
Theory:
The elongation index of an aggregate is the percentage by weight of particles in it whose
greatest dimension (thickness) is greater than one and four-fifths of their mean dimension. The
test is not applicable to sizes smaller than 6.3mm.
Procedure:
1. A quantity of aggregate shall be taken sufficient to provide the minimum number of 200
pieces of any fraction to be tested.
2. The sample shall be sieved with sieves specified in Table.
3. Each fraction shall be gauged in turn for length on a metal gauge of the pattern shown in
Fig. The gauge length used shall be of the dimensions specified in column of Table for the
appropriate size of material.
4. The total amount of aggregate retained by the length gauge shall be weighed to an accuracy
of at least 0.1 percent of the weight of the test sample.
Calculations:
Elongation index=100 x (x/W) %
Where, x is the weight of materials retained on specified gauges and W is the total weights of
aggregate passing and retained on the specified sieves.
Results: Elongation Index:____________
 DETERMINATION OF SPECIFIC GRAVITY OF AGGREGATE
Aim: To determine specific gravity of a given sample of aggregate.
Apparatus:
Pycnometer bottle, Taping rod, Funnel
Procedure:
1. Take the empty pycnometer (W1).
2. Take a sample of fine aggregate for which specific gravity is to be find out and transfer
that to the pycnometer and weight (W2).
3. Pour distilled water into pycnometer.
4. Eliminate the entrapped air by rotating the pycnometer.
5. Wipe out the outer surface of pycnometer and weight it (W3).
6. Transfer the aggregate of the pycnometer into a try care being taken to ensure that all the
aggregate is transferred.
7. Refill the pycnometer with distilled water up to the mark and it should be
completely dry from outside and take the weight (W4).
Observation Table:
Sl. No. W1 W2 W3 W4
1
2
Calculation:

Result: The Specific Gravity of a given sample of fine aggregate is: __________
 WATER ABSORPTION TEST
Aim: To determine water absorption of a given sample of aggregate.
Apparatus:
Wire Mesh Bucket, Setup of Water Absorption Test

Fig 1: Wire mesh Bucket Fig 2: Setup of water absorption test

Reference Code:
IS 2386(Part 3):1963 Methods of Test for Aggregates
Procedure for Aggregate Coarser Than 6.3mm:
1. About 2 kg of aggregate sample is taken, washed to remove fines and then placed in the
wire basket. The wire basket is then immersed in water, which is at a temperature of 220C to
320C.
2. Immediately after immersion the entrapped air is removed from the sample by lifting the
basket 25 mm above the base of the tank and allowing it to drop, 25 times at a rate of about
one drop per second.
3. The basket, with aggregate are kept completely immersed in water for a period of 24 ± 0.5
hour. 4. The basket and aggregate are weighed while suspended in water, which is at a
temperature of 220C to 320C.
5. The basket and aggregates are removed from water and dried with dry absorbent cloth.
6. The surface dried aggregates are also weighed.
7. The aggregate is placed in a shallow tray and heated to 100 to 1100C in the oven for 24 ±
0.5 hours. Later, it is cooled in an airtight container and weighed.
Calculation
Weight of saturated aggregates in air, W1:
Weight of oven dry aggregates in air, W2:
Water Absorption (%): [(W1-W2)*100]/W2:
 GRADING ANALYSIS OF FINE AND COARSE AGGREGATES

Aim: To determine the particle size distribution of fine and coarse aggregates by sieving.

Apparatus

1. Balance: Accurate to 0.1% of the weight of the sample.

2. Sieves: Conforming to IS 460, with square openings of appropriate sizes (e.g., 80 mm,
40 mm, 20 mm, 10 mm, 4.75 mm for coarse aggregates and 2.36 mm, 1.18 mm, 600
µm, 300 µm, 150 µm for fine aggregates).
3. Sieve Shaker: Mechanically or manually operated.
4. Drying Oven: Capable of maintaining a temperature of 100°C to 110°C.
5. Brush: For cleaning sieves.
6. Trays: For collecting and weighing material.

Sample Preparation

1. Obtain a representative sample of the aggregate by quartering or riffling as per IS 2430.

2. Dry the sample to a constant weight in the oven at 100°C to 110°C.
3. Cool the sample to room temperature before testing.

Test Procedure

Coarse Aggregates

1. Weigh the Sample: Take approximately 5 kg for aggregates of maximum size up to 40

mm. For larger aggregates, increase the sample size as per IS 2386.
2. Arrange the Sieves: Stack the sieves in descending order of size, with the largest
opening at the top and a pan at the bottom.
3. Sieve the Sample:
o Place the sample on the top sieve.
o Secure the sieve stack on the sieve shaker.
o Operate the sieve shaker for 10 minutes or manually shake for an equivalent
duration.
4. Weigh the Retained Material:
o Remove and weigh the material retained on each sieve.
o Brush the sieves to ensure all particles are accounted for.
5. Calculate Percentages:
o Calculate the percentage retained on each sieve.
o Compute the cumulative percentage passing.

Fine Aggregates

1. Use a representative sample of approximately 1 kg.

2. Follow the same sieving and weighing procedure as for coarse aggregates.

Observations
Prepare a tabular format as below:

Sieve Size Weight Retained % Cumulative % Cumulative %

(mm) (g) Retained Retained Passing

Calculations

1. Percentage Retained:
2. Cumulative Percentage Retained: Sum of percentages retained on the current sieve
and all coarser sieves.
3. Cumulative Percentage Passing:

Results

1. Plot a graph of sieve size (log scale) vs. cumulative percentage passing.
2. Determine the grading of the aggregate (e.g., well-graded, poorly graded).
3. Check conformity with specifications as per IS 383.

Precautions

1. Ensure the sieves are clean and free from damage.

2. Dry the sample to a constant weight to avoid errors.
3. Avoid overloading individual sieves.
4. Use a balance with appropriate sensitivity.

References

• IS 2386 (Part I): 1963 – Methods of Test for Aggregates for Concrete – Part I: Particle
Size and Shape.
• IS 460: Specification for Test Sieves.

AIR PERMEABILITY TEST

Aim: To determine the fineness of cement by measuring the specific surface area using the air
permeability apparatus (Blaine apparatus).

Apparatus

1. Air Permeability Apparatus: Blaine type, conforming to IS 4031 (Part 2).

2. Manometer: U-tube type, filled with a suitable liquid.
3. Standard Cement Sample: For calibration purposes.
4. Balance: Sensitive to 0.001 g.
5. Stopwatch: For accurate timing.
6. Syringe: To introduce air into the apparatus.
7. Non-absorbent Filter Paper: To hold the cement bed in place.
8. Drying Oven: Capable of maintaining a temperature of 100°C to 110°C.
9. Desiccator: For cooling the sample.

Sample Preparation

1. Dry the Cement Sample:

o Place the cement in the oven at 100°C to 110°C until it reaches a constant
weight.
o Cool the sample in a desiccator.
2. Weigh the Sample:
o Weigh an appropriate amount of cement (e.g., 2.8 g) for the test.

Calibration of the Apparatus

1. Prepare the Apparatus:

o Assemble the air permeability apparatus.
o Ensure all connections are airtight.
2. Use a Standard Cement Sample:
o Use a sample of known specific surface area to calibrate the apparatus.
3. Measure the Time:
o Introduce air and record the time taken for a defined volume of air to pass
through the cement bed.
o Repeat until consistent readings are obtained.

Test Procedure

1. Assemble the Test Setup:

o Place a weighed quantity of the prepared cement sample in the cylindrical cell.
o Insert a layer of non-absorbent filter paper below and above the cement bed.
o Compress the cement using a plunger to a uniform height.
2. Measure Permeability:
o Connect the manometer to the apparatus.
o Introduce air at a constant pressure using the syringe.
o Measure the time required for a defined volume of air to flow through the
cement bed.
3. Repeat the Test:
o Conduct at least three trials and calculate the average time.
Calculations

1. Determine Specific Surface Area:

Where:

o = Specific surface area (cm²/g)

o = Calibration constant
o = Viscosity of air (poise)
o = Measured time (s)
o = Density of cement (g/cm³)
o = Pressure difference across the bed
2. Average Results:
o Compute the average specific surface area from repeated trials.

Observations

Prepare a tabular format as follows:

Trial Weight of Cement (g) Time (s) Specific Surface Area (cm²/g)

Results

The specific surface area of the cement sample is determined as the average value of the trials,
expressed in cm²/g.

Precautions

1. Ensure the apparatus is free from leaks.

2. Use dry and clean cement for accurate results.
3. Avoid over-compression of the cement bed.
4. Maintain a consistent air pressure during the test.
5. Record time accurately using a calibrated stopwatch.

References

• IS 4031 (Part 2): 1999 – Methods of Physical Tests for Hydraulic Cement – Part 2:
Determination of Fineness by Blaine Air Permeability Method.
• IS 4031 (Part 1): 1996 – Determination of Fineness by Dry Sieving.

MANUAL FOR CONSISTENCY OF CEMENT

Objective

To determine the standard consistency of cement paste, which is the percentage of water
required to produce a cement paste of standard consistency.

Apparatus

1. Vicat Apparatus: Conforming to IS 5513, equipped with a plunger of 10 mm diameter

and 50 mm length.
2. Balance: Accurate to 0.1 g.
3. Measuring Cylinder: For measuring water.
4. Mixing Tools: A trowel and a non-porous plate for mixing cement and water.
5. Stopwatch: To measure the time of mixing and testing.

Sample Preparation

1. Weigh the Cement:

o Take 400 g of cement for the test.
2. Prepare the Mixing Water:
o Use potable or distilled water for mixing.

Test Procedure

1. Mix Cement and Water:

o Take 400 g of cement and mix with a measured quantity of water to form a
uniform paste within 3 to 5 minutes.
2. Fill the Mould:
o Place the cement paste in the Vicat mould resting on a non-porous base plate.
o Level the surface of the paste.
3. Test for Consistency:
o Lower the plunger gently into the paste and release it to penetrate under its own
weight.
o Note the depth of penetration of the plunger.
4. Adjust Water Content:
o Repeat the test with varying water content until the plunger penetrates to a point
5 to 7 mm above the bottom of the mould.

Observations

Prepare a tabular format as follows:

Trial Weight of Cement (g) Water Added (ml) Penetration (mm)

Calculations

1. Determine Standard Consistency:

o Express the quantity of water added, as a percentage of the weight of cement,
as the standard consistency. \[ \text{Standard Consistency} = \frac{\text{Water
Added (ml)}}{\text{Weight of Cement (g)}} \times 100 \]

Results

The standard consistency of the cement sample is determined as the percentage of water
required to allow the plunger to penetrate 5 to 7 mm from the bottom of the mould.

Precautions

1. Ensure the apparatus is clean and free from previous cement paste.
2. Mix cement and water thoroughly and within the prescribed time.
3. Perform the test in a draught-free environment at a consistent temperature.
4. Record all measurements accurately.

References

• IS 4031 (Part 4): 1988 – Methods of Physical Tests for Hydraulic Cement – Part 4:
Determination of Consistency of Standard Cement Paste.
• IS 5513: 1976 – Specification for Vicat Apparatus.
 DETERMINATION OF INITIAL AND FINAL SETTING TIME OF
CEMENT

Aim: To determine the initial and final setting time of cement using the Vicat apparatus as
per IS 4031 (Part 5): 1988.

Apparatus

1. Vicat Apparatus: Comprising a frame with a movable rod, weighing 300 g, with a
needle for initial setting time and an annular attachment for final setting time.
2. Balance: Accurate to 1 g.
3. Measuring Cylinder: For measuring water.
4. Stopwatch: To record time intervals.
5. Glass Plate: Smooth, non-porous, and rigid.
6. Trowel: For mixing cement paste.
7. Standard Vicat Mould: Split type, cylindrical, 80 mm in height and 70 mm in
diameter.
8. Drying Oven: Capable of maintaining 100°C to 110°C.

Sample Preparation

1. Cement Sample:
o Use fresh cement, free from lumps, and stored under standard conditions.
2. Mixing Water:
o Use potable or distilled water.
3. Preparation of Cement Paste:
o Mix cement with water at a water-to-cement ratio of 0.85 times the standard
consistency (determined as per IS 4031 Part 4).
o Prepare the paste within 3-5 minutes, ensuring uniformity.

Test Procedure

Initial Setting Time

1. Preparation:
o Fill the Vicat mould with cement paste, ensuring no air pockets.
o Level the surface using a trowel.
2. Initial Setting Needle:
o Attach the 1 mm square needle to the Vicat apparatus.
o Allow the needle to freely penetrate the paste.
3. Observations:
o Repeat the test at regular intervals.
o The initial setting time is the time elapsed from adding water to the cement
until the needle penetrates to a depth of 33-35 mm from the top.

Final Setting Time

1. Final Setting Needle:

o Replace the initial setting needle with an annular attachment.
 2. Observations:
o The final setting time is the time elapsed from adding water to the cement until
the needle fails to leave an impression on the surface, but the annular
attachment does.

Observations

Prepare a tabular format as follows:

Time (Minutes) Penetration Depth (mm) Observation (Initial/Final)

Calculations

1. Initial Setting Time:

o The elapsed time in minutes from the addition of water to when the needle
penetration is 33-35 mm.
2. Final Setting Time:
o The elapsed time in minutes from the addition of water to when the needle
leaves no impression.

Results

1. Initial Setting Time: Reported in minutes.

2. Final Setting Time: Reported in minutes.
3. Compare results with IS 12269 for Ordinary Portland Cement (initial setting time ≥
30 minutes, final setting time ≤ 600 minutes).

Precautions

1. Conduct the test in a controlled environment with a temperature of 27°C ± 2°C and
relative humidity of 65% ± 5%.
2. Ensure all apparatus are clean and dry before use.
3. Prepare the cement paste quickly and uniformly.
4. Avoid vibration or disturbances during the test.
5. Record time accurately using a calibrated stopwatch.

References

• IS 4031 (Part 5): 1988 – Methods of Physical Tests for Hydraulic Cement –
Determination of Initial and Final Setting Times.
• IS 12269: 2013 – Specification for Ordinary Portland Cement, 53 Grade.
 MANUAL FOR DETERMINATION OF SOUNDNESS OF CEMENT

Aim: To determine the soundness of cement by measuring the expansion of cement paste or
mortar to ensure it does not undergo undue expansion after setting.

Apparatus

1. Le-Chatelier Mould: Consisting of a split brass mould of cylindrical shape with two
indicators.
2. Balance: Accurate to 0.01 g.
3. Measuring Cylinder: For measuring water.
4. Tamping Rod: 16 mm diameter and 60 cm long.
5. Glass Plate: To support the mould.
6. Drying Oven: Capable of maintaining a temperature of 100°C to 110°C.
7. Water Bath: Capable of maintaining a temperature of 27°C and boiling.

Materials

1. Cement Sample: Freshly prepared.

2. Water: Potable and free from impurities.

Sample Preparation

1. Take a representative cement sample conforming to IS 3535 for testing.

2. Ensure the sample is free from lumps and dried if necessary.

Test Procedure

A. Preparation of Cement Paste

1. Weigh 100 g of cement.

2. Prepare a paste by adding 0.78 times the water required for standard consistency
(determined as per IS 4031 Part 4).
3. Mix thoroughly to obtain a uniform paste.

B. Filling the Le-Chatelier Mould

1. Place the mould on a glass plate and fill it with the prepared cement paste.
2. Ensure there are no air gaps by tamping gently.
3. Cover the paste with another glass plate and gently press to ensure a level surface.
4. Prevent leakage by using clips to hold the mould together.

C. Initial Curing

1. Submerge the filled mould in water at 27°C ±2°C for 24 hours.

D. Boiling and Measurement

1. After 24 hours, remove the mould from the water.

2. Measure the distance between the indicators using a Vernier caliper (initial reading).
3. Submerge the mould in boiling water for 3 hours.
4. Remove the mould and allow it to cool to room temperature.
5. Measure the distance between the indicators again (final reading).

Observations

Prepare a tabular format as follows:

Trial Initial Distance (mm) Final Distance (mm) Expansion (mm)

Calculations

1. Expansion:
2. Average the results of multiple trials to obtain the soundness value.
3. Results

1. The soundness of the cement sample is reported as the average expansion in mm.
2. Compare the results with the permissible limits specified in IS 269 (33-grade OPC):
o Maximum Permissible Expansion: 10 mm.

Precautions

1. Ensure the mould is free from damage and properly assembled.

2. Use fresh cement paste to avoid hydration before testing.
3. Maintain accurate water and curing temperatures.
4. Avoid any disturbances during the test.

References

• IS 4031 (Part 3): 1988 – Methods of Physical Tests for Hydraulic Cement – Part 3:
Determination of Soundness.
• IS 269: 2015 – Ordinary Portland Cement, 33 Grade – Specification.
 MANUAL FOR SLUMP CONE TEST OF CONCRETE

Aim: To determine the consistency or workability of freshly mixed concrete using the slump
cone test.

Apparatus

1. Slump Cone: A frustum of a cone with the following dimensions:

o Bottom Diameter: 200 mm
o Top Diameter: 100 mm
o Height: 300 mm
2. Tamping Rod: 16 mm diameter and 600 mm long with a rounded end.
3. Measuring Scale: To measure the slump.
4. Base Plate: Non-porous and rigid surface.
5. Mixing Tools: Shovel and trowel for concrete preparation.

Test Procedure

1. Prepare the Concrete Mix:

o Mix the concrete as per the required proportions and ensure uniform
consistency.
2. Position the Slump Cone:
o Place the cone on a clean, level, and non-absorbent base plate.
o Hold the cone firmly in place.
3. Fill the Cone:
o Fill the cone in three equal layers by volume.
o For each layer:
▪ Tamp the layer 25 times using the rounded end of the tamping rod.
▪ Distribute the strokes evenly across the surface.
4. Level the Top:
o After filling the cone, strike off the excess concrete flush with the top of the
cone using a trowel.
5. Lift the Cone:
o Carefully lift the cone vertically and without twisting, within 5 to 10 seconds.
6. Measure the Slump:
o Measure the vertical difference between the top of the cone and the highest point
of the subsided concrete using a measuring scale.

Types of Slump

1. True Slump: The concrete subsides evenly, retaining its shape.

2. Shear Slump: A portion of the concrete shears off and slides down.
3. Collapse Slump: The concrete collapses completely, indicating high water content.
Observations

Prepare a tabular format as below:

Sample ID Slump (mm) Type of Slump Comments

Results

The workability of the concrete mix is indicated by the measured slump value: _____mm.

Precautions

1. Ensure the base plate is clean, level, and non-absorbent.

2. Fill the cone evenly and tamp each layer uniformly.
3. Lift the cone vertically without jerking.
4. Conduct the test immediately after mixing the concrete.
5. Perform the test in a sheltered environment to avoid wind or direct sunlight.

References

• IS 1199: 1959 – Methods of Sampling and Analysis of Concrete.

• IS 456: 2000 – Code of Practice for Plain and Reinforced Concrete.
 COMPACTING FACTOR TEST OF CONCRETE

Aim: To determine the workability of fresh concrete by measuring its compacting factor, which
is the ratio of the weight of partially compacted concrete to the weight of fully compacted
concrete.

Apparatus

1. Compacting Factor Apparatus:

o Consists of two conical hoppers (upper and lower) and a cylindrical container.
2. Tamping Rod:
o Circular cross-section, 16 mm in diameter and 600 mm in length.
3. Balance:
o Accurate to 0.1% of the weight of the sample.
4. Scoop:
o Suitable for handling concrete.
5. Trowel:
o For levelling concrete.
6. Measuring Container:
o Cylindrical, with known volume.

Procedure

1. Preparation:
o Ensure the apparatus is clean and assembled on a level, rigid base.
o Prepare the concrete mix as per the required proportions.
2. Filling the Apparatus:
o Fill the upper hopper gently with freshly mixed concrete using the scoop.
o Level the surface of the concrete in the upper hopper using the trowel.
3. Releasing Concrete:
o Open the trapdoor of the upper hopper to allow the concrete to fall into the lower
hopper.
o Ensure the concrete flows freely without manual assistance.
4. Filling the Cylinder:
o Open the trapdoor of the lower hopper to let the concrete fall into the cylindrical
container.
o Level the surface of the concrete in the cylinder using the trowel.
5. Weighing:
o Determine the weight of the partially compacted concrete in the cylinder (W1).
o Remove the concrete from the cylinder, refill it in layers, and compact each
layer thoroughly using the tamping rod.
o Level the surface and determine the weight of the fully compacted concrete
(W2).
o Record the weight of the empty cylinder (W).

Calculations

1. Compacting Factor:
2. Express the compacting factor as a decimal value (e.g., 0.85).
Observations

Prepare a tabular format as below:

Weight of Partially Weight of Fully

Weight of Empty Compacting
Trial Compacted Concrete Compacted Concrete
Cylinder (W) Factor
(W1) (W2)

Results

The workability of the concrete mix is assessed using the compacting factor, which typically
ranges between 0.75 and 0.95 for most practical mixes.

Precautions

1. Ensure the hoppers and cylinder are clean and dry before the test.
2. Prevent segregation of the concrete mix during handling and pouring.
3. Avoid vibration or excessive disturbance during the test.
4. Compact the concrete in the cylinder uniformly during the fully compacted weight
determination.
5. Calibrate the apparatus and balance before testing.

References

• IS 1199: 1959 – Methods of Sampling and Analysis of Concrete.

 VEE-BEE CONSISTOMETER TEST

Aim: To determine the workability of fresh concrete by measuring the time required to convert
a slump cone shape into a cylindrical shape using the Vee-Bee Consistometer.

Apparatus

1. Vee-Bee Consistometer: Including:

o Vibrating table
o Slump cone
o Removable sheet metal cylindrical container
o Graduated rod with a disc to measure concrete settlement
2. Trowel: For filling the slump cone.
3. Stopwatch: Accurate for timing.
4. Measuring scale: To measure slump height.
5. Metallic tamping rod: 16 mm diameter, 600 mm long.

Sample Preparation

1. Prepare fresh concrete mix as per the design proportion.

2. Ensure the concrete is homogenous by thoroughly mixing before the test.

Test Procedure

Step 1: Slump Test

1. Fill the Slump Cone:

o Place the cone on a non-absorbent surface.
o Fill the cone in three layers, each approximately one-third of the cone’s height.
o Tamp each layer 25 times using the tamping rod.
2. Lift the Cone:
o Carefully lift the cone vertically without lateral or torsional movement.
3. Measure Slump:
o Measure the height difference between the original cone height and the
displaced slump.

Step 2: Vee-Bee Time Measurement

1. Transfer the Concrete:

o Place the slump concrete carefully into the cylindrical container of the Vee-Bee
apparatus.
2. Insert the Graduated Rod:
o Attach the graduated rod with the disc on the top of the concrete surface.
3. Start Vibrating:
o Switch on the vibrator and start the stopwatch simultaneously.
o Continue vibrating until the concrete surface becomes fully cylindrical and the
disc just touches the concrete without sinking.
4. Record the Time:
o Stop the stopwatch as soon as the cylindrical shape is achieved.
o The recorded time is called the Vee-Bee time.
Observations

Prepare a table as below:

Slump (mm) Vee-Bee Time (s) Workability Classification

Results

1. Workability Classification:
o Vee-Bee time indicates the workability level:
▪ High workability: 0-3 seconds
▪ Medium workability: 3-8 seconds
▪ Low workability: >8 seconds
2. Interpret Results:
o High workability is suited for lightly reinforced sections.
o Low workability is suited for heavily reinforced or compacted sections.

Precautions

1. Ensure the vibrating table is level and securely fixed.

2. Operate the vibrator at consistent amplitude and frequency.
3. Avoid overfilling or under filling the cone.
4. Conduct the test immediately after mixing the concrete to prevent setting.
5. Clean the apparatus thoroughly after each test.

References

• IS 1199: 1959 – Methods of Sampling and Analysis of Concrete.

• IS 456: 2000 – Code of Practice for Plain and Reinforced Concrete.
 REBOUND HAMMER TEST OF CONCRETE

Aim: To assess the compressive strength of concrete indirectly using the rebound hammer test.

Apparatus

1. Rebound Hammer: Conforming to IS 13311 (Part 2), calibrated and in good working
condition.
2. Grinding Stone: For surface preparation of concrete.
3. Measuring Tape: To ensure correct spacing and layout of test points.
4. Reference Chart: Correlating rebound number with compressive strength.

Principle

The rebound hammer measures the surface hardness of concrete. The rebound number obtained
is empirically correlated to the compressive strength of concrete.

Test Procedure

1. Preparation:
o Ensure the surface of the concrete is clean, dry, and smooth.
o Use a grinding stone to remove loose particles, laitance, or coatings from the
test area.
2. Calibration of the Rebound Hammer:
o Before testing, check the calibration of the hammer using the test anvil provided
by the manufacturer.
3. Test Locations:
o Identify a minimum of 6 test locations on the concrete member.
o Ensure the spacing between test points is at least 20 mm.
4. Performing the Test:
o Hold the rebound hammer perpendicular to the test surface.
o Press the hammer firmly against the concrete surface until the plunger is fully
compressed.
o Record the rebound number displayed on the scale.
o Repeat the test at each of the marked points.
5. Recording the Readings:
o Take at least 10 readings for each test area.
o Discard any outlier values that deviate significantly from the average.
o Calculate the average rebound number for the test area.
Observations

Prepare a table as follows:

Test Location Rebound Numbers Average Rebound Number

Correlation with Compressive Strength

1. Use the reference chart provided by the rebound hammer manufacturer to correlate the
average rebound number with the compressive strength of concrete.
2. Note: The correlation chart is specific to the rebound hammer used and may vary.

Limitations

1. The test provides an approximate estimation of compressive strength.

2. Results are affected by:
o Surface texture and moisture.
o Type of cement and aggregate.
o Age of concrete.
o Curing conditions.

Reporting

The report should include:

1. Identification of the structure or member tested.

2. Date of testing and environmental conditions.
3. Average rebound numbers and corresponding compressive strength.
4. Calibration details of the rebound hammer.
5. Any observations regarding the condition of the concrete surface.

Precautions

1. Ensure the rebound hammer is calibrated before use.

2. Avoid testing on rough, honeycombed, or heavily textured surfaces.
3. Perform tests at uniform intervals on the same type of surface.
4. Discard outlier readings and use consistent test procedures.
5. Apply corrections for variations in orientation (e.g., horizontal, vertical).

References

• IS 13311 (Part 2): 1992 – Non-Destructive Testing of Concrete: Rebound Hammer.

• Manufacturer’s user manual for the rebound hammer.
 ULTRASONIC PULSE VELOCITY TEST OF CONCRETE

Aim: To assess the quality of concrete by measuring the velocity of ultrasonic pulses passing
through it.

Apparatus

1. Ultrasonic Pulse Velocity (UPV) Equipment:

o Pulse generator and receiver.
o Transducers (piezoelectric type) with appropriate frequency.
o Timing device (microsecond accuracy).
o Couplant (e.g., grease, petroleum jelly, or any material to eliminate air gaps).
2. Measuring Instruments:
o Vernier caliper or scale for measuring distances.
3. Reference Bar:
o For equipment calibration.

Principle

The ultrasonic pulse velocity (UPV) test measures the travel time of ultrasonic pulses through
concrete. The velocity depends on the elastic properties and density of the concrete, and it
indicates its quality, uniformity, and integrity.

Calibration

1. Use the reference bar provided with the UPV equipment to ensure accuracy.
2. Measure the travel time for a known length.
3. Adjust the equipment as per the manufacturer's instructions if discrepancies are
observed.

Test Procedure

1. Preparation

1. Clean the surface of the concrete where the transducers will be placed.
2. Apply couplant to ensure good acoustic coupling.
3. Ensure the concrete surface is free from dust and loose particles.

2. Testing Configurations

• Direct Transmission (preferred): Transducers are placed on opposite faces of the

concrete.
• Semi-Direct Transmission: Transducers are placed on adjacent faces.
• Indirect Transmission: Transducers are placed on the same face.

3. Measurement

1. Place the transducers on the concrete surface based on the chosen configuration.
2. Ensure firm contact between the transducers and the concrete.
3. Initiate the pulse and record the transit time displayed on the equipment.
 4. Measure the distance between the transducers.
5. Repeat measurements at multiple locations to ensure representative results.

Calculations

1. Pulse Velocity (V):

Where:

o = Pulse velocity (m/s)

o = Path length (m)
o = Transit time (s)
2. Interpretation of Results:
o Above 4500 m/s: Excellent quality.
o 3500 to 4500 m/s: Good quality.
o 3000 to 3500 m/s: Medium quality.
o Below 3000 m/s: Poor quality or presence of defects.

Observations

Prepare a tabular format as follows:

Test Transmission Path Length Transit Time Pulse Velocity Quality

Point Type (m) (µs) (m/s) Assessment

Results

• Average pulse velocity: __________ m/s.

• Quality assessment: __________.

Precautions

1. Ensure proper coupling between transducers and concrete to avoid signal loss.
2. Perform the test on a clean and flat surface.
3. Avoid testing near reinforcement to minimize inaccuracies.
4. Use consistent pressure while holding the transducers.
5. Calibrate the equipment before use.
Applications

1. Evaluate uniformity of concrete.

2. Identify cracks, voids, or honeycombing.
3. Assess concrete strength (in combination with other tests).
4. Monitor changes in concrete properties over time.

References

• IS 13311 (Part 1): 1992 – Non-destructive Testing of Concrete – Methods of Test – Part
1: Ultrasonic Pulse Velocity.