MINIMUM QUANTITIES REQUIRED TO BE SENT TO LABORATORIESFOR TESTING OF MATERIALS

SR .No. Name of Test Minimum Quantities of Material Required for testing

CEMENT

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

2. Specific Gravity Cement approximately taken from each of number of bags on the site

3. Standard Consistency

4. Setting Time (Initial & Final)

5. Compressive Strength

6. Soundness

COARSE AGGREGATE

Size of metal Quantity

7. Sieve Analysis 60 mm 100 Kg

8. Water absorption & Specific Gravity

40 mm 50 kg

a) Water Absorption 25 mm 50 Kg

b) Specific Gravity 20 mm 25 Kg

9. Impact Value 12.5 mm 12 kg

10. Abrasion Value 10 mm 6 Kg

11. Crushing Value 6.3 mm 3 Kg

12. Flakiness Index

FINE AGGREGATE

13. Fineness Modulus (Sieve Analysis)

One bag of 25 Kg.

14. Silt & Clay Content (Weight Seiving)

BRICKS

15. Water Absorption Five Bricks

16. Compressive Strength Five Bricks

17. Efflorences Five Bricks

FLOORING TILES

18. Flexural Test Six Tiles

19. Water Absorption Six Tiles

20. Resistance to wear Six specimen of size 70 x 70 mm

MANGLORE TILES

21. Water Absorption Six Tiles

22. Flexural Test Six Tiles

23. Permeability Test Six Tiles

GLAZED TILES

24. Water Absorption Five Tiles

CONCRETE

25. Compressive Strength of C. C. Cube

Three Nos of C. C. Cubes Size 15 x15x 15 cm. Per Set

26. Concrete Mix Design with all tests on basic materials

One full bag of each Aggregate , Sand & Cement

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

for Mix Design of each Grade

MORTOR

28. Compressive Strength Three Nos of MorterCubes Size 7.07x 7.07x 7.07 CmsPer Set

STONE

29. Crushing Value 50 Kg.

30. Water Absorption & Specific Gravity

31. Compressive Strength (Dressing of Stone already Done)

Six dressed Samples of Size

10x 10x 10 Cms

32. Compressive Strength with dressing of stone in Laboratory

Six Samples from which six specimen of dressed stone of Size 10 x10 x10 Cms can be achieved

SOIL/ MURUM

33. Field moisture Content

34. Liquid limit & Plastic Limit

35. Compaction Test (Proctor Density)

One bag of 50 Kg.

36. C.B.R. Test (Lab.)

37. Field Density by sand replacement method

BITUMEN

38. Extraction Test Two Kg. Bituminus Mix

39. Marshall stability & flow measurements a)Moulds Testing

One Set of Three Standard MarshallMoulds of size

Diametre 10 cm ,Height 6.5 cm.

40. Preparation of Marshall moulds & Testing

4 Kg. Mix

41. Penetration Two Kg Bitumen

42. Asphaltic concrete Job Mix Design with all tests on basic materials for DBM/SDBC/AC

One full bag of each Aggregate , filler- 5 Kg.,Grit-10 Kg., Bitumen-5 Kg.

43. Bituminus Macadam Job Mix Design

for each Mix Design

HOLLOW BLOCKS

44. Density test Three Blocks

45. Compressive Strength Eight Blocks

46. Water Absorption Test Three Blocks

SOLID BLOCKS

47. Density Test Three Blocks

48. Compressive Strength Eight Blocks

49. Water Absorption Test Three Blocks

S.N. Name of Test Minimum Quantities of Materials

required for testing

COARSE AGGREGATE

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 2 kg

8 Mechanical analysis 60 kg (IS 2720 Pt.4)

BITUMEN

9 Softening point

5 kg Bitumen10 Viscosity

11 Flash & fire point

12 Specific gravity

13 Ductility

14 Mastic Hardness No. 5 Moulds

WATER

15 PH value 1 Litre of Water

16 Sulphate & Chloride content

WOOD

17 Density 3 Samples of

450 x 300 mm18 Moisture content

STEEL ANTI CORROSIVE TEST

19 Resistance to applied voltage (1 Hr.test) Two bars of 90 cm. length of required

diameter20 Resistance to applied voltage (30 days.test)

21 Thickness of coating

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 materials:

Sr.No Material & Tests. Specified Limit. Frequency.

1. CEMENT (OPC)

1) Initial setting time.

Not less than 30 minutes.

2) Final setting time. Not more than 600 minutes.

3) Fineness by dry sieving.

Residue not more than 10% on 90micron sieve.

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

4) Specific gravity. 3.10 to 3.15

5) Compressive strength.(in Kg/cm2.)

33 Grade. 43 Grade 53 Grade

a) 3 days ( +/- 1 hours ) a) 160 230 270

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

6) Soundness by Lechatelier apparatus.

Expansion not more than 10 mm.

2) SAND

1) Particle size.

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

2) Silt content. Not more than 4%

3) Fineness modulus. 1) For concrete 2.6 to 3.6

2)For masonry and 1st coat of plaster. Not more than 3.

3) For pointing & IInd coat of plaster shall Not exceed 1.6

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

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

5) Moisture content. Will have to be determined to find quantity of free water in sand.

Sr.No Material & Tests. Specified Limit. Frequency.

3. COARSE AGGREGATE

1) Gradation.

Size of metal. 100 % Passing through

sieve size

100% Retained on sieve size

80 mm. 100mm 50 mm

60mm 80mm 50 mm

50mm 60mm 40 mm One test for per 100 Cubic metre

40mm 63mm 63 mm ( 0%)

40mm 35 to 70% 40mm (30 to 65%)

12.5mm 0 to 5 % 12.5mm(95 to 100%)

40mm to50mm. 63 mm 25 mm

For Bituminus Works

40mm Crushed Metal 50mm 25 mm

25mm Crushed Metal 40 mm 20 mm

20mm Crushed Metal

12.5 mm Crushed Metal

10mm Crushed Metal

6.3 mm Crushed Metal

25 mm

20 mm

12.5 mm

10 mm

12.5mm

10 mm

6.3 mm

4.75 mm

For concrete For Road work(Heavy traffic)

2)Impact Value. Shall not exceed 45%

Shall not exceed 30%

3. Crushing value

shall not exceed.45%

shall not exceed.17 %

4) Los Angles abrasion value

shall not exceed

16%.

shall not exceed. 50% (for WBM) shall not exceed. 17%(B.T.works)

At the beginning & if there is change in source.

5) Flakiness Index Shall not exceed

35%

shall not exceed.15%

6) Water absorption shall not exceed 5% shall not exceed 5% for WBM

shall not exceed 1% for BT work

7) Specific Gravity Not specified Not specified

Sr. No Tests. Specified Limit. Frequency.

4 BRICKS

4. Water absorption shall not exceed

I class II class 20% 22%

· Compressive Strength (wet condition )

32.8 kg/cm2 29.52 kg/cm2minimum

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

3)Efflorescence 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

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

M100 70 100

M150 105 150

M200 135 200

M250 170 250

M300 200 300

M350 235 350

M400 270 400

Quantity Min. No

Of Concrete of Samples

Cum.

1 – 5 1

6 – 15 2

16 – 30 3

31 –50 4

50 & Above 4 plus

additional samples for each addition 0f 50 m3 or part there of

1 Sample = 6 Cubes

MANGALORE TILES

1) Water absorption shall not exceed…

Class AA Class A

19% 24%

. 2) Breaking Load kg (minimum)

3) Permeability Test

For Average For Average

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)

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

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

8 CEMENT FLOORING TILES

5. Water absorption

6. Transverse strength

Shall not exceed 10%

Average wet shall not be less than

3 N /mm2 (30 kg/cm2)

6 tiles shall be tested or every test for every 2000

tiles or part there of.

9 SOIL/MURUM

7. Proctor Density Shall not be less than

8. C.B.R. Value

1.44 gm/cc Embankment upto 3 mtr. Height

1.5 to gm/cc for Embankment exceeding 3 mtr. Height

1.65 gm/cc for top 0.5 mtr. Height of Embankment

The Embankment shall be designed on ascertaining the CBR value

One test per 1000 m3 or soil.

10 HARD MURUM

9. Gradation

2) Plasticity Index

95% passing through 80 mm seive size 2% passing through 25 mm seive size Below 4

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

11 SOFT MURUM

1) Plasticity Index

Below 8

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

1

Sr. No Tests. Specified Limit. Frequency.

12 STONE

10. Water Absorption

11. Compressive Strength

12. Specific Gravity

Maximum 5%

1530 kg/cm2 minimum

Not less than 3

13 GLAZED TILES

1) Water Absorption

Not more than 10% One set of 5 tiles for every 5000 tiles or part thereof.

14 BITUMEN

1) Penetration

To ascertaion the correct grade of bitumen

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

15 BITUMINI0U MIX

13. Extruction

2) Marshall Stability & Flow measurments

To check correct binder content as per the tender

Minimum stability 820 kg

Flow 2-4 mm

2 test for each 100 tonnes of mix subject to a minimum of two tests per day per plant.

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

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

S.N. Name of Test Specified Limit Frequency

COARSE AGGREGATE

1 Soundness Loss withSodium – 12% Max.Magnesium Sulphate 18% Max.

Before approving the aggregates and every month subsequently

2 Bulk Density - -

FINE AGGREGATE

3 CL2 & Sulphate Content Sulphate content – 500 mg/LtCl 2 content –2000 mg/Lt. – For P.C.C.1000 mg/Lt. – For R.C.C.

4 Moisture Content

5 Bulkage of sand

CONCRETE

Flexural Strength of beam Grade Modules of ruptureOf By beam test min.Concrete 3 days 7 daysN/mm2 N/mm2M-10 1.2 1.7M-15 1.5 2.1M-20 1.7 2.4M-25 1.9 2.7M-30 2.1 3.0M-35 2.3 3.2M-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 Sulphate content – 500 mg/LtChloride content –2000 mg/Lt. for P.C.C.1000 mg/Lt. for R.C.C.

8 Mechanical analysis

BITUMEN

9 Softening point 40 to 550C 2 sample/lot to be subjected to all or

some tests as directed by the Engineers

10 Viscosity -

11 Flash & fire point 1750C

12 Specific gravity 0.99 minimum

13 Ductility 75 cm. Minimum

14 Mastic Hardness No. 60 to 80 at 250C without coarse aggregate

10 to 20 at 250C after adding coarse aggregate

-

WATER

15 PH value Not less than 6 Once for approval of source of supply

subsequently in case of doubt

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

WOOD

17 Density - -

At least 3 samples from lots containing

upto 200 pieces

18 Moisture content Roof and floors/weatherBoards 20%

Joinery beams/staircase 16% floors 12%

STEEL ANTI CORROSIVE TEST

19 Resistance to applied voltage (1 Hr.test)

There was no sign of any coating failure at cathode, due to

evaluation of hydrogen gas of any lasting at anode

-

20 Resistance to applied voltage

(30 days.test)

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 thicknessCECRI – 200 – 400 Mic.FBEC – 100 – 300 Mic.CPCC – 125 Mic. Min.

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

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 tester shall be around 54 to 74.

TYPICAL LETTER FOR SAMPLE DESPATCH

Date

To,

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. Name of Work : ----------------------------------------------------------------------------- 2. Estimates cost of work :---------------------------------------------------------------------- 3. Tender No. & Cost :-------------------------------------------------------------------------- 4. Scheme of Work :------------------------------------------------------------------------------ 5. Name of Agency :-----------------------------------------------------------------------------

6. Details of sample as below.

A. Aggregate/ Murum/ Bituminious mix.

Sr.No. Material its location chainage LHS/RHS

No. of samples Tests to be conducted

1) 60 mm metal km 1/500 (RHS) 1 No. 1)Water Absorption2) Impact Value3) Gradation

B. C. Bricks/Tiles (Flooring/Manglore) /CC Blocks etc

Sr.No Material & its identification mark No. of sets Tests to be conducted

1 Bricks 1 set1 set=10 bricks

1)Water Absorption2) Compressive strength

D.

E. CC Cube/Moter Cube/ Hallow Block/Soil Block :-

Sr.No Grade of concrete / member

Date of Casting

Mark Size in cm

No. of sets Test

1 M-20Beam No.B-4

12-5-2000 B-1B-2B-3

15x15x15 2 sets1 set= 3 No. cube

Compressive Strength

G. Concrete Mix Design

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

4. Cement company and Grade ------------------------------------- 5. Maximum size of Aggregate --------------------------------------- 6. Required character stic strength --------------------------------- 7. Degree of workability ------------------------------------------------- 8. Type of exposer -------------------------------------------------------- 9. Degree of quality control --------------------------------------------- 10. Water cement ratio ----------------------------------------------------- 11. Required slump --------------------------------------------------------- 12. Minimum cement content specified ------------------------------

E) Job Mix Design for Bituminus Work (SDBC/DBM/BC/BM)

1. Wearing surface type -------------------------------------------------- 2. Thickness as per tender ---------------------------------------------- 3. Details of material to be used --------------------------------------- 4. Details of filler ------------------------------------------------------------- 5. Details of binder ---------------------------------------------------------

Identification slip as described below duly signed with seal shall be kept in the sample bag.

Identification Slip

1) Name of Sub Dn. : ----------------------------------------------------------

2) Name of work ----------------------------------------------------------------

3) Date of sample ------------------------------------------------------------- dispacted to Laboratory

4) Details of sample ---------------------------------------------------------

Testing charges for the above tests will be paid by the agency in cash or Demand Draft. It is requested to send the results to the Executive Engineer ----------------Dn.

Encl: Samples as Deputy Engineer,

Mentioned above P.W/NH/ZP Sub Dn.

Copy submitted to the Executive Engineer, P.W. Dn. ---------------------- for information

Copy to Agency ---------------------------------------- for information & necessary action.

REGISTER OF QUALITY CONTROL TESTS

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

2) The Junior Engineer, in charge of the work, should maintain this Register under the guidance of his Deputy Engineer.3) The entries in the register should be signed by the Deputy Engineer for authentication.4) Register should be available on the site of work during the inspection and should be kept up-to-date.5) This register shall form a part of the permanent record of work and its pages should not be torn off and erasured, changed etc. should be authenticated.6) For special type of works involving large scale construction in Bituminous Macadam and Asphaltic concrete etc. a separate register may be kept for day-to-day tests.

A. Samples of Materials of Testing1) 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. … ... …

2) Sand. … … …

3) Bricks. … … …

4) Stone. … … …

5) Aggregates. … … …

6) Concrete. … … …

7) Steel. … … …

8) Welded Joints/Electrodes. … …

9) Flooring Tiles. … … …

10) Mangalore Tiles. … … …

11) Cement Mortar. … … …

12) Soils … … …

13) Bitumen … … …

14) Hume pipes. … … …

PERFORMA FOR TESTING OF CEMENT

Sr.No.

Date of Sampling

Age of cement at the time of

testing

Date of Testing

Sample identification No. including Name of Factory, Lot Not.

No. etc.

FINENESS

% of Residue by weight on

90 micron sieve.

Specific surface by Air Permeability method cm2/gm.

1 2 3 4 5 6 7

Soundness Setting Time Compressive Strength Name of Lab. & No. & Date of letter No. under which

the results are received.

Dated Signature

of the Deputy Engr.

Remarks

Initial (Minutes)

Final (Minutes)

Age of cube

Compressive strength in Kg/cm 2

8 9 10 11 12 13 14 15

PROFORMA FOR TESTING OF SAND

Sr. No. Date Silt contents % Sieve Analysis

Sieve size in mm. % Retained by weight

1 2 3 4 5

Fineness Modulus

Condition of sand

Moisture content %

% Bulkage observed

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

Bulkage

Dated Signature of

D.E.

Remarks

6 7 8 9 10 11 12

PROFORMA FOR TESTING OF BRICKS

Sr. No. No. of Bricks in one consignment

No. of samples selected for

testing

Size of brick

Identification No. on sample

Date of testing

% of water absorption

1 2 3 4 5 6 7

Compressive strenth Kg/cm2

Efflorance Test. Reference No. from laboratory

Dated Signature of the Dy. Engineer

Remarks.

Dry. Wet.

8 9 10 11 12 13

PROFORMA FOR TESTING MASONRY STONES.

Sr. No.

Date of Testing

Source & details of Samples

Specific gravity

Water Absorption

Compre-ssive

strength Kg/cm2 Kg/cm2

Name of Lab. No.& Dt. Under which the

results received.

Dated Signature

of Dy. Engr

Remarks

1 2 3 4 5 6 7 8 9

PROFORMA FOR TESTING OF STONE AGGREGATE

Sr. No. Nominal size of metal

Date of testing Impact value Crushing value Los Angles abrasing value test

1 2 3 4 5 6

Water Absorbtion

Stripping value

SIEVE ANALYSIS % flakiness

Index

No. & Dt. Under which the results are received from

the laboratory

Dated Signature of the Dy.

Engr.

Remarks

I.S. sieve % passing by weight

7 8 9 10 11 12 13 14

PROFORMA FOR TESTING OF CEMENT CONCRETE CUBES

Sr. No.

Date of concreting.

Grade of concrete.

Total Quantity of

concrete laid during the

day.

Nos. of cubes &

identification there on

Location where

concrete used.

Water cement

ratio

Slump observed.

1 2 3 4 5 6 7 8

Date of Testing

of Cube

Age of

Cube

Dimension of cube

Weight of

cube.

Observed comp.

Strength Kg/cm2

Calculated Comp.

strength728

Ref. No. from

Laboratory

Dated Signature of the Dy. Engr.

Remarks

9 10 11 12 13 14 15 16 17