CONCRETE

TECHNOLOGY
LAB MANUAL

Prof. SHINDE A M
DEPARTMENT OF CIVIL ENGINEERING
Sandipani Technical Campus, Faculty of Engineering, Kolpa, Latur.
 GENERAL INSTRUCTIONS

1. Students are instructed to come to Concrete Technology laboratory on time. Late comers
are not entertained in the lab.

2. Students should be punctual to the lab. If not, conducted experiments will not be repeated.

3. Students are expected to come prepared at home with the experiments which are going
to performed.

4. Students are instructed to display their identity cards and apron before entering into the lab.

5. Students are instructed not to bring mobile phones to the lab.

6. The equipment’s and other accessories used in Concrete Technology lab should be
handled with care and responsibility.

7. Any damage to the equipment’s during the lab session is student’s responsibility and penalty
or fine will be collected from the student.

8. Students should update the records and lab observation books session wise. Before
leaving the lab, the student should get his lab observation book signed by the faculty.

9. Students should submit the lab records 2/3 days in advance to the concerned faculty
members in the staffroom for their correction and return.

10. Students should not move around the lab during the lab session.

11. If any emergency arises, the student should take the permission from faculty
member concerned in written format.

12. The faculty members may suspend any student from the lab session on disciplinary grounds

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 SAFETY PRECAUTIONS

1. While working in the laboratory suitable precautions should be observed to prevent

accidents.

2. Always follow the experimental instructions strictly.

3. Use the first aid box in case of any accident/mishap.

4. Never work in the laboratory unless a demonstrator or teaching assistant in present.

5. When the experiment is completed, students should disconnect the setup made by
them, and should return all the components/instruments taken for the purpose.

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 BTCVL 510 Concrete Technology Laboratories
 List of Practical’s :-
1) Testing of Cement: Consistency, Fineness, Setting Time, Specific Gravity,
a) Normal Consistency and fineness of cement.
b) Initial setting time and final setting time of cement.
c) Specific gravity of cement
2) Soundness and Strength Test for Cement
a) Soundness of cement.
b) Compressive strength of cement.
3) Testing of Aggregates: Specific Gravity, Sieve Analysis, Bulking of Fine Aggregate,
Flakiness Index, Elongation Index and Percentage Elongation
a) Sieve Analysis And Gradation Zone
b) Bulking Of Sand
c) Sieve Analysis
d) Specific Gravity And Water Absorption Test
4) Placement Tests on Concrete: Workability Tests: Slump, Compaction,
e) Slump test
f) CF (compact factor stress)
5) Non-destructive Testing for Concrete.
(a) Rebound Hammer
(b) Ultrasound pulse velocity (UPV)

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1. TESTS ON CEMENT

1
 NORMAL CONSISTENCY OF CEMENT
AIM:
Normal consistency test is used to optimum percentage of water content required for a
cement paste.
APPARATUS:
1. Vicat apparatus (conforming to IS: 5513 - 1976) with plunger (10 mm in diameter)
2. Vicat mould
3. Gauging trowel
4. Measuring jar
5. Balance
6. Tray.
INTRODUCTION:
The standard consistency of a cement paste is defined as that consistency which will permit
the Vi-cat plunger to penetrate to a point 5 to 7 mm from the bottomofthe Vicat mould. For
finding out initial setting time, final setting time, soundness of cement and compressive
strength of cement, it is necessary to fix the quantity of water to be mixed in cement in each
case. This experiment is intended to find out the quantity of water to be mixed for a given
cement to give a cement paste of normal consistency and can be done with the help of Vi-cat
apparatus.

PROCEDURE:
1. Prepare a paste of weighed quantity of cement (300 grams) with a weighed quantity
of potable or distilled water, starting with 28% water of 300g of cement.
2. The percentage of water to be taken according to the room temperature 27 ± 50C.

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3. Take care that the time of gauging is not less than 3 minutes, not more than 5 minutes
and the gauging shall be completed before setting occurs.
4. The gauging time shall be counted from the time of adding the water to the dry cement
until commencing to fill the mould.
5. Fill the Vi-cat mould with this paste, the mould resting upon a non-porous plate.
6. After completely filling the mould, trim off the surface of the paste, making it in level with
the top of the mould. The mould may slightly be shaken to expel the air.
7. Place the test block with the mould, together with the non-porous resting plate, under the
rod bearing the plunger (10mm diameter), lower the plunger gently to touch the surface of
the test block and quickly release, allowing it to penetrate into the paste.
8. This operation shall be carried out immediately after filling the mould.
9. Prepare trial pastes with varying percentages of water and test as described above until the
amount of water necessary for making the standard consistency as defined above is
obtained.
10. Express the amount of water as a percentage by weight of the dry cement.

CALCULATIONS:

𝑊
1 gm per cc = 1 ml of water

𝑃 𝑋 100
Where P = percentage of water (b) = 𝐶
W = water required in ml
(c)
C = weight of cement required (a).
OBSERVATIONS:

Weight of
Water Plunger Consistency of
cement Water taken
S.No taken in ml penetration cement in % by
taken in gms in % (b)
(c) (mm) weight b/a * 100
(a)
1 400 28 112
2 400 30
3 400 32
4 400 34
5 400 36

RESULT: Normal consistency for the given sample of cement is .

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 FINENESS OF CEMENT

AIM:
To determine the fineness of the given sample of cement by sieving.
APPARATUS:
1. IS-90-micron sieve conforming to IS:460-1965
2. Standard balance
3. Weights
4. Brush.

INTRODUCTION:
The fineness of cement has an important bearing on the rate of hydration and hence on the
rate of gain of strength and on the rate of evolution of heat. Finer cement offers a greater
surface area for hydration and hence the faster and greater the development of strength.
Increase in fineness of cement is also found to increase the drying shrinkage of concrete.
Fineness of cement is tested either by sieving or by determination of specific surface by air-
permeability apparatus. Specific surface is the total surface area of all the particles in one
gram of cement.

FINENESS BY SIEVING:
PROCEDURE:
1. Weigh accurately 100 g of cement and place it on a standard 90 microns IS sieve.
2. Break down any air-set lumps in the cement sample with fingers.
3. Continuously sieve the sample giving circular and vertical motion for a period of 15 minutes.
4. Weigh the residue left onthe sieve. As per IS code the percentage residue should not
exceed 10%.
OBSERVATIONS:

S. No Weight of sample taken(g) Weight of residue(g) Fineness (%)

Average fineness of cement is .

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RESULT: Fineness of given sample of cement is .

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 INITIAL AND FINAL SETTING TIMES OF
CEMENT
AIM:
To determine the initial and final setting times for the given sample of cement.
APPARATUS:
1. Vicat apparatus (conforming to IS: 5513-1976) with attachments
2. Balance
3. Weights
4. Gauging trowel.
INTRODUCTION:
In actual construction dealing with cement, mortar or concrete, certain time is required for
mixing, transporting and placing. During this time cement paste, mortar, or concrete should be
in plastic condition. The time interval for which the cement products remain in plastic condition
is known as the setting time. Initial setting time is regarded as the time elapsed between the
moment that the water is added to the cement to the time that the paste starts losing its
plasticity. The final setting time is the time elapsed between the moment the water is added to
the cement, and the time when the paste has completely lost its plasticity and has attained
sufficient firmness to resist certain pressure. The constituents and fineness of cement is
maintained in such a way that the concrete remains in plastic condition for certain minimum
time. Once the concrete is placed in the final position, compacted and finished it should lose
its plasticity in the earliest possible time so that it is least vulnerable to damages from external
destructive agencies. This time should not be more than 10 hours which is referred to as final
setting time. Initial setting time should not be less than 30 minutes.

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PROCEDURE:
Preparation of Test Block:
1. Prepare a neat cement paste by gauging 300 grams of cement with 0.85 times the water
required to give a paste of standard consistency (0.85P).
2. Potable or distilled water shall be used in preparing the paste.
3. The paste shall be gauged in the manner and under the conditions prescribed in
determination of consistency of standard cement paste.
4. Start a stop-watch at the instant when water is added to the cement.
5. Fill the mould with the cement paste gauged as above the mould resting on a nonporous
plate.
Fill the mould completely and smooth off the surface of the paste making it level with the top
of the mould. The cement block thus prepared in the mould is the test block.
DETERMINATION OF INITIAL SETTING TIME:
1. Place the test blocks confined in the mould and rest it on the non-porous plate, under the
rod bearing initial setting needle, lower the needle gently in contact with the surface of the
test block and quickly release, allowing it to penetrate into the test block.
2. In the beginning, the needle will completely pierce the test block.
3. Repeat this procedure until the needle, when brought in contact with the test block and
released as described above, fails to pierce the block to a point 5 to 7 mm measured from
the bottom of the mould shall be the initial setting time.
DETERMINATION OF FINAL SETTING TIME:
1. Replace the needle of the Vicat apparatus by the needle with an annular attachment.
2. The cement shall be considered as finally set when, upon applying the needle gently to the
surface of the test block, the needle makes an impression there on, while the attachment
fails to do so.
3. The period elapsed between the time when water is added to the cement and the time at
which the needle makes an impression on the surface of test block while the attachment fails
to do so shall be the final setting time.
PRECAUTIONS:
Clean appliances shall be used for gauging. All the apparatus shall be free from vibration
during the test. The temperature of water and that of the test room, at the time of gauging shall
be 270C
+ 200C. Care shall be taken to keep the needle straight.
OBSERVATIONS:

Time in minutes

Height in mm fails to penetrate

RESULT:
Initial setting time for the given sample of cement =
Final setting time for the given sample of cement =

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 SPECIFIC GRAVITY OF CEMENT
AIM:
To determine the specific gravity of given sample of hydraulic cement.
APPARATUS:
1. Physical balance
2. Specific gravity bottle of 50ml capacity
3. Clean kerosene.
INTRODUCTION:
Specific gravity is defined as the ratio between weight of a given volume of material and
weight of an equal volume of water. To determine the specific gravity of cement, kerosene is
used which does not react with cement.

PROCEDURE:
1. Clean and dry the specific gravity bottle and weigh it with the stopper (W1).
2. Fill the specific gravity bottle with cement sample at least half of the bottle and weigh
with stopper (W2).
3. Fill the specific gravity bottle containing the cement, with kerosene (free of water) placing
the stopper and weigh it (W3).
4. While doing the above do not allow any air bubbles to remain in the specific gravity bottle.
5. After weighing the bottle, the bottle shall be cleaned and dried again.
6. Then fill it with fresh kerosene and weigh it with stopper (W4).
7. Remove the kerosene from the bottle and fill it with full of water and weigh it with
stopper (W5).
8. All the above weighing should be done at the room temperature of 27c + 10 c.

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OBSERVATIONS:

Description of item Trial 1 Trial 2 Trial 3

Weight of empty bottle W1 g
Weight of bottle + Cement W2 g
Weight of bottle + Cement + Kerosene
W3 g

Weight of bottle + Full Kerosene W4 g

Weight of bottle + Full Water W5 g

Specific gravity of Kerosene Sk = W4 - W1 / W5 - W1.

Specific gravity of Cement Sc = W2 - W1 / ((W4 - W1) - (W3-W2)) * SkSc

= (W2 - W1) * (W4 - W1) / ((W4 - W1) - (W3-W2)) * (W5 - W1)

PRECAUTION:
1. Only kerosene which is free of water shall be used.
2. At time of weighing the temperature of the apparatus will not be allowed to exceed the
specified temperature.
3. All air bubbles shall be eliminated in filling the apparatus and inserting the stopper.
4. Weighing shall be done quickly after filling the apparatus and shall be accurate to 0.1 mg.
5. Precautions shall be taken to prevent expansion and overflow of the contents resulting
from the heat of the hand when wiping the surface of the apparatus.

RESULT:
Average specific gravity of given sample of cement =

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 SOUNDNESS OF CEMENT
AIM:
To determine the soundness of the given sample of cement by "Le Chatelier" Method.

APPARATUS:
1. Le Chatelier apparatus conforming to IS 5514-1969
2. Balance
3. Weights
4. Water bath.
INTRODUCTION:
It is essential that the cement concrete shall not undergo appreciable change in volume after
setting. This is ensured by limiting the quantities of free lime, magnesia and sulphates in cement
which are the causes of the change in volume known as unsoundness. Unsoundness in cement
does not come to surface for a considerable period of time. This test is designed to accelerate
the slaking process by the application of heat and discovering the defects in a short time.
Unsoundness produces cracks, distortion and disintegration there by giving passage to water
and atmospheric gases which may have injurious effects on concrete and reinforcement. The
apparatus for conducting the test consists of small split cylinder of spring brass or other
suitable metal of 0.5mm thickness forming a mould 30 mm internal diameter and 30mm high.
On either side of the split mould are attached to indicators with pointed ends, the distance
from these ends to the centre of the cylinder being 165 mm. The mould shall be kept in good
condition with the jaws not more than 50mm apart.

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PROCEDURE:
1. Place the lightly oiled mould on a lightly oiled glass sheet and fill it with cement paste
formed by gauging cement with 0.78 times the water required to give a paste of standard
consistency.
2. The paste shall be gauged in the manner and under the conditions prescribed in
determination of consistency of standard cement paste, taking care to keep the edges of the
mould gently together
3. While this operation is being performed cover the mould with another piece of glass sheet,
place a small weight on this covering glass sheet and immediately submerge the whole
assembly in water at a temperature of 270C- 200C and keep there for 24 hours.
4. Measure the distance separating the indicator points.
5. Submerge the moulds again in water at the temperature prescribed above.
6. Bring the water to boiling, with the mould kept submerged for 25 to 30 minutes, and
keep it boiling for three hours.
7. Remove the mould from the water allow it to cool and measure the distance between the
indicator points.
8. The difference between these two measurements represents the expansion of the cement.
9. For good quality cement this expansion should not be more than 10mm.

OBSERVATIONS:
Initial distance between the indicator points in mm =
Final distance between the indicator points in mm =
Expansion in mm =
final length - initial length =

RESULT:
Expansion in mm.

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 COMPRESSIVE STRENGTH OF CEMENT
AIM:
To determine the compressive strength of standard cement mortar cubes compacted by means
of standard vibration machine.
APPARATUS:
1. Vibration machine and cube moulds of size 7.06 cms (Conforming to IS: 4031- 1988).
STANDARD SAND:
The standard sand to be used in the test shall conform to IS: 650-1991 or sand passing 100
percent through 2 mm sieve and retained 100 percent on 90 microns IS sieve. 2mm to 1mm
33.33 percent 1mm to 500 microns 33.33 percent 500mm to 90 microns 33.33 percent.
INTRODUCTION:
The compressive strength of cement mortars is determined in order to verify whether the
cement conforms to IS specifications and whether it will be able to develop the required
compressive strength of concrete. The average compressive strength of at least three mortar
cubes (area of the face 50 cm2) composed of one part of cement and three parts of standard
stand should satisfy IS code specifications.

PROCEDURE:
Mix proportions and mixing:
1. Clean appliances shall be used for mixing and the temperature of the water and that of the
test room at the time when the above operations are being performed shall be 27 ± 2oC.
2. Place in a container a mixture of cement and standard sand in the proportion of 1:3 by
weight mix it dry, with a trowel for one minute and then with water until the mixture is of
uniform colour.
3. The quantity of water to be used shall be as specified below.
4. In any element, it should not take more than 4 minutes to obtain uniform coloured mix.

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5. If it exceeds 4 minutes the mixture shall be rejected, and the operation repeated with a fresh
quantity of cement, sand and water.
6. The material for each cube shall be mixed separately and the quantity of cement standard
sand and water shall be as follows: Cement 200 gms Standard sand 600 gms, Water (P/4 +
3) percent of combined weight of cement and sand, where p is the percentage of water
required to produce a paste of standard consistency.
MOULDING SPECIMENS:
1. In assembling the moulds ready for use, cover the joints between the halves of the mould
with a thin film of petroleum jelly and apply a similar coating of petroleum jelly between
the contact surfaces of the bottom of the mould and its base plate in order to ensure that no
water escapes during vibration.
2. Treat the interior faces of the mould with a thin coating of mould oil.
3. Place the assembled mould on the table of the vibration machine and firmly hold it is
position by means of suitable clamps.
4. Securely attach a hopper of suitable size and shape at the top of the mould to facilitate
filling and this hopper shall not be removed until completion of the vibration period.
5. Immediately after mixing the mortar, place the mortar in the cube mould and rod with a rod.
6. The mortar shall be rodded 20 times in about 8 seconds to ensure elimination of entrained
air and honey combing.
7. Place the remaining quantity of mortar in the hopper of the cube mould and rod again as
specified for the first layer and then compact the mortar by vibrations.
8. The period of vibration shall be two minutes at the specified speed of 12,000 + 400
vibrations per minute.
9. At the end of vibration remove the mould together with the base plate from the machine
and finish the top surface of the cube in the mould by smoothing surface with the blade of
a trowel.

CURING SPECIMEN:
1. Keep the filled moulds at a temperature of 27 + 20 C in an atmosphere of at least 90 %
relative humidity for about 24 hours after completion of vibration.
2. At the end of that period remove them from the moulds.
3. Immediately submerge in clean fresh water and keep them under water until testing.
4. The water in which the cubes are submerged shall be renewed every 7 days and shall be
maintained at a temperature of 27 0C + 20C.
5. After they have been taken out and until they are tested the cubes shall not be allowed to
become dry.
TESTING:
1. Test three cubes for compressive strength at the periods mentioned under the relevant
specification for different hydraulic cements, the periods being reckoned from the
completion of vibration.
2. The compressive strength shall be the average of the strengths of three cubes for each
period of curing.

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3. The cubes shall be tested on their sides without any packing between the cube and the
steel plates of the testing machine.
4. One of the platens shall be carried base and shall be self-adjusting and the load shall be
steadily and uniformly applied starting from zero at a rate of 350 Kgs/Cm2/ min. The cubes
are tested at the following periods Ordinary Portland cement 3, 7 and 28 days. Rapid
hardening Portland cement 1 and 3 days. Low heat Portland cement 3 and 7 days.
CALCULATION:
Calculate the compressive strength from the crushing load and the average area over which the
load is applied.
Express the results in N/mm2 to the nearest 0.05 mm2.
Compressive strength in N/mm2 = P/A
Where P is the crushing load in N and
A is the area in mm2 (5000 mm2).
PRECAUTIONS:
Inside of the cube moulds should be oiled to prevent the mortar from adhering to the sides of
the mould.

RESULT:
The average compressive strength of the given cement at 3 days N/mm2 at 7 days N/mm2 at 28
days N/mm2.

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2.TESTS ON
AGGREGATE
(COARSE AND FINE)

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 SIEVE ANALYSIS AND GRADATION ZONE
AIM:

The gradation and size test are used to determine aggregate particle size distribution.

APPARATUS:

AASHTO T 27 and ASTM C 136: Sieve Analysis of Fine and Coarse Aggregates

INTRODUCTION:

In a gradation and size analysis, a sample of dry aggregate of known weight is separated
through a series of sieves with progressively smaller openings. Once separated, the weight of
particles retained on each sieve is measured and compared to the total sample weight. Particle
size distribution is then expressed as a percent retained by weight on each sieve size. Results
are usually expressed in tabular or graphical format. Graphical displays almost always use the
standard 0.45 power gradation graph.

PROCEDURE:

1. Obtain an aggregate sample of adequate mass from one of the following locations:
aggregate stockpiles, bins, dump trucks, conveyor belt, or the roadway.

2. Mix and reduce the sample to an amount suitable for testing. This process of reducing a
sample size is often referred to as “splitting” the sample.

3. Dry the test sample to a constant mass and determine the sample’s dry mass.

4. If using the washed procedure, place the dry sample in a container and cover with water.
Agitate the sample to completely separate all particles finer than the No. 200 (0.075 mm)
sieve from the coarser aggregate, and to bring the fine material into suspension. Immediately
decant the wash water containing the suspended solids over a nest of sieves consisting of a
No. 200 (0.075 mm) sieve and an upper sieve with openings in the range of No. 8 (2.36 mm)
to No. 16 (1.18 mm).

5. If using the washed procedure, repeat step 4 until the wash water is clear.

6. If using the washed procedure, return the material retained on the nested sieves to the
washed sample by flushing with water. Dry the washed sample to a constant mass and allow
to cool. Determine mass of the sample after washing.

7. Select applicable sieves to obtain the information required by the specifications covering
the material to be tested. Sieve sizes typically used for Super pave mix design are 1½ in,
1.0

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 inch, ¾ inch, ½ inch, 3/8-inch, No. 4, No. 8, No. 16, No. 30, No. 50, No. 100 and No. 200
(37.5, 25.0, 19.0, 12.5, 9.5, 4.75, 2.36, 1.18, 0.600, 0.300, 0.150 and 0.075 mm) sieves.
Assemble the sieves in order of decreasing size of opening from top to bottom and place
the nest of sieves over a pan.

8. Pour the sample into the top sieve in the nest.

9. Sieve the material in a mechanical sieve shaker.

10. Determine the mass of the material retained on each sieve size. Record the cumulative
mass retained for each sieve size (the mass retained on a specific sieve size and the mass
retained on all sieves with larger openings).

CALCULATIONS:

Gradation may be reported as either a percentage retained or percentage passing each sieve
size.

Percentage Retained on Each Sieve

Percent passing = 100 – percent

retained. Where:

M sieve = cumulative mass retained on a sieve, M total = total original sample mass

Percentage Passing Each Sieve

Percent passing = 100 – percent retained.

NOTE:

Report percentages to the nearest whole number, except for the percentage passing the No.
200 (0.075 mm) sieve which is reported to the nearest 0.1 %.

RESULT:

Percent retained or percent passing each sieve size by mass and material finer than the 0.075
(No. 200) sieve.

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 GRADATION OF AGGREGATE:

Coarse aggregates used in concrete making contain aggregates of various sizes. This particle
size distribution of the coarse aggregates is termed as “Gradation”. The sieve analysis is
conducted to determine this particle size distribution It is this matrix that is vulnerable to all
ills of concrete.

GRADATION CHARTS:

GRADATION EXAMPLE 1:

Sample: 5/8” gravel , Initial weight: 9920g .

Sieve Sieve Aggregate Cumulative Cumulative Cumulative

Sieve
weight weight weight weight percent percent
designation
empty (g) full (g) retained (g) retained (g) retained (g) passing (%)

1/2 in 471 471 0

3/8 in 428 918 490
No. 4 423 1973 1550
No. 8 422 2772 2350
No. 16 417 1757 1340
No. 30 390 2090 1700
No. 50 365 1125 760
No. 100 363 1113 750
Pan 330 1390 1060
TOTAL 10000 (must be within 0.3% of initial weight above)

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 GRADATION EXAMPLE 2:

Sample: 5/8” gravel , Initial weight: 9920g .

Sieve Sieve Aggregate Cumulative Cumulative Cumulative

Sieve
weight weight weight weight percent percent
designation
empty (g) full (g) retained (g) retained (g) retained (g) passing (%)
1/2 in 0 0.0 100.0
3/8 in 490 4.9 95.1
No. 4 2040 20.4 79.6
No. 8 4390 43.9 56.1
No. 16 5730 57.3 42.7
No. 30 7430 74.3 25.7
No. 50 8190 81.9 18.1
No. 100 8940 89.4 10.6
Pan 10000 100.0 0.0
TOTAL 10000 (must be within 0.3% of initial weight above)

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 BULKING OF SAND

AIM:

To ascertain the bulking phenomena of given sample of sand.

APPARATUS:

1000ml measuring jar, brush.

INTRODUCTION:

Increase in volume of sand due to presence of moisture is known as bulking of sand. Bulking
is due to the formation of thin film of water around the sand grains and the interlocking of air
in between the sand grains and the film of water. When more water is added sand, particles get
submerged and volume again becomes equal to dry volume of sand. To compensate the
bulking effect extra sand is added in the concrete so that the ratio of coarse to fine aggregate
will not change from the specified value. Maximum increase in volume may be 20 % to 40 %
when moisture content is 5 % to 10 % by weight. Fine sands show greater percentage of
bulking than coarse sands with equal percentage of moisture.

PROCEDURE:

1. Take 1000ml measuring jar.

2. Fill it with loose dry sand up to 500ml without tamping at any stage of filling.
3. Then pour that sand on a pan and mix it thoroughly with water whose volume is equal to
2% of that of dry loose sand.
4. Fill the wet loose sand in the container and find the volume of the sand which is in excess of
the dry volume of the sand.
5. Repeat the procedure for moisture content of 4%, 6%, 8%, etc. and note down the readings.
6. Continue the procedure till the sand gets completely saturated i.e. till it reaches the
original volume of 500ml.

OBSERVATIONS:

Volume of % moisture Volume of % Bulking V2

S. No
dry loose content added wet loose – V1 / V1
sand V1 sand V2
1 2%
2 4%
3 6%
4 8%
5
6

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GRAPH:

Draw a graph between percentage moisture content on X-axis and percentage bulking on
Y- axis. The points on the graph should be added as a smooth curve. Then from the graph,
determine maximum percentage of bulking and the corresponding moisture content.

PRECAUTIONS:

1. While mixing water with sand grains, mixing should be thorough and uniform.
2. The sample should not be compressed while being filled in jar.
3. The sample must be slowly and gradually poured into measuring jar from its top.
4. Increase in volume of sand due to bulking should be measured accurately.

RESULT:

The maximum bulking of the given sand is at % of moisture content.

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 SHAPE TEST (Flakiness Index)
AIM:
To determine the flakiness Index of a given aggregates sample.

APPARATUS:
(i) The apparatus consists of a standard thickness gauge, I.S. sieves of sizes 63, 50,
40, 31.5, 25, 20, 16, 12.5, 10 and 6.3 mm
(ii) Balance to weigh the samples.

THEORY AND SCOPE:

The particle shape of aggregate is determined by the percentages of flaky and elongated particles
contained in it. In case of gravel it is determined by its Angularity Number. Flakiness and Elongation
tests are conducted on coarse aggregates to assess the shape of aggregates. Aggregates which are flaky
or elongated are detrimental to the higher workability and stability of mixes. They are not conducive to
good interlocking and hence the mixes with an excess of such particles are difficult to compact to the
required degree. For base coarse and construction of bituminous and cement concrete types, the presence
of flaky and elongated particles are considered undesirable as they may cause inherent weakness with
probabilities of breaking down under heavy loads. Rounded aggregates are preferred in cement concrete
road construction as the
workability of concrete improves. Angular shape of particles are desirable for granular base coarse due
to increased stability derived from the better interlocking when the shape of aggregates deviates more
from the spherical shape, as in the case of angular, flaky and elongated aggregates, the void content in an
aggregate of any specified size increases and hence the grain size distribution of the graded aggregates
has to be suitably altered in order to obtain minimum voids in the dry mix or the highest dry density. It is
determined according to the procedure laid down in IS-2386 (PART- I).

FLAKINESS INDEX:
The flakiness index of aggregates is the percentage by particles whose least dimension (thickness) is less
than 3/5th (0.6) of their mean dimension. The test is not applicable to sizes smaller than 6.3 mm

Procedure:
• The sample is sieved with the sieves mentioned in the table.
• A minimum of 200 pieces of each fraction to be tested are taken and weighed (w1 gm).
• In order to separate flaky materials, each fraction is then gauged for thickness on thickness gauge, or in
bulk on sieve having elongated slots as specified in the table.
• Then the amount of flaky material passing the gauge is weighed to an accuracy of at least 0.1% of test

22
sample.
• Let the weight of the flaky materials passing the gauge be w1gm. Similarly the Weights of the
fractions passing and retained on the specified sieves be w1, w2, w3, etc. are weighed and the total
weight w1+w2+w3+………. = w gm is found.
▪ Also the weights of the materials passing each of the specified thickness gauges are found = W1, W2,
W3… and the total weight of the material passing the different thickness gauges = W1+W2+W3+
………. =W gm is found.
• Then the flakiness index is the total weight of the flaky material passing the various thickness gauges
expressed as a percentage of the total weight of the sample gauged.

Observation and Calculation:

RESULT: The flakiness index of the given sample of aggregates is _______________%.

23
 SHAPE TEST (Elongation Index)
AIM
To determine the Elongation Index of the given aggregate sample.

APPARATUS
(i) Length gauge, I.S-sieves as given in the table
(ii) Balance of accuracy 0.01 gm

THEORY AND SCOPE:

The particle shape of aggregate is determined by the percentages of flaky and elongated particles
contained in it. In case of gravel it is determined by its Angularity Number. Flakiness and Elongation
tests are conducted on coarse aggregates to assess the shape of aggregates. Aggregates which are flaky
or elongated are detrimental to the higher workability and stability of mixes. They are not conducive to
good interlocking and hence the mixes with an excess of such particles are difficult to compact to the
required degree. For base coarse and construction of bituminous and cement concrete types, the presence
of flaky and elongated particles are considered undesirable as they may cause inherent weakness with
probabilities of breaking down under heavy loads. Rounded aggregates are preferred in cement concrete
road construction as the workability of concrete improves. Angular shape of particles are desirable for
granular base coarse due to increased stability derived from the better interlocking when the shape of
aggregates deviates more from the spherical shape, as in the case of angular, flaky and elongated
aggregates, the void content in an aggregate of any specified size increases and hence the grain size
distribution of the graded aggregates has to be suitably altered in order to obtain minimum voids in the
dry mix or the highest dry density. It is determined according to the procedure laid down in IS-2386
(PART- I)

ELONGATION INDEX:
The elongation index of an aggregate is the percentage by weight of particles whose greatest dimension
(length) is greater than 1 and 4/5th times (1.8 times) their mean dimensions. The elongation test is not
applicable to sizes smaller than 6.3 mm.

Procedure:
• The sample is sieved through I.S-sieves specified in the table.
• A minimum of 200 aggregate pieces of each fraction is taken and weighed.
 Each fraction is thus gauged individually for length in a length gauge. The gauge length is used should
be those specified in the table for the appropriate material.
• The pieces of aggregates from each fraction tested which could not pass through the specified gauge
length with its long side are elongated particles and they are collected separately to find the total weight
24
of aggregate retained on the length gauge from each fraction.
• The total amount of elongated material retained by the length gauge is weighed to an accuracy of at
least 0.1% of the weight of the test sample.
• The weight of each fraction of aggregate passing and retained on specified sieves sizes are found –
W1, W2, W3 , …………. And the total weight of sample determined = W1 +W2+W3+……………. =
Wgm. Also the weights of material from each fraction retained on the specified gauge length are found =
x1, x2, x3 …and the total weight retained determined = x1 +x2 +x3 +…… = x gm.
• The elongation index is the total weight of the material retained on the various length gauges,
expressed as a percentage of the total weight of the sample gauged.

RESULT: The elongation index of a given sample of aggregate is ________________%.

Combined flakiness and elongation index:
Flakiness index of the given aggregate is found out.Then Elongation index of the nonflaky materials of
the given aggregate found out and combined flakiness and elongation index is calculated by adding both
the flakiness and elongation index of the aggregate sample.

25
 SPECIFIC GRAVITY AND WATER ABSORPTION TEST
AIM:
To determine the absorption and specific gravity of aggregates.

APPARATUS:
• A wire basket of not more than 6.3 mm mesh or a perforated container of convenient size with thin
wire hangers for suspending it from the balance.
• A thermostatically controlled oven to maintain temperature of 100 °C to 110 °C.
• A container for filling water and suspending the basket.
• An airtight container of capacity similar to that of the basket.
• A balance of capacity about 5 kg weight accurate to 0.5 gm, and of such a type and shape as to permit
weighing of the sample container when suspended in water.
• A shallow tray and two dry absorbent clothes.

THEORY AND SCOPE:

The specific gravity of an aggregate is considered to be a measure of strength or quality of the material.
The specific gravity test helps in the identification of stone. Water absorption gives an idea of strength
of aggregate. Aggregates having more water absorption are more porous in nature and are generally
considered unsuitable unless they are found to be acceptable based on strength, impact and hardness
tests.

PROCEDURE:

• About 2 kg of the aggregate sample is washed thoroughly to remove fines, drained and then placed in
the wire basket and immersed in distilled water at a temperature between 22 °C to 32 °C with a cover of
at least 50 mm of water above the top of the basket. Immediately after immersion the entrapped air is
removed from the sample by lifting the basket containing it 25mm above the base of the tank and
allowing it to drop 25 times at the rate of about one drop per second . The basket and the aggregate
should remain completely immersed in water for a period of 24 hours

• The basket and the sample are then weighed while suspended in water at a temperature of 22 °C to 32
°C. In case it is necessary to transfer the basket and the sample to a different tank for weighing. They
should be jolted 25 times as described above in the new tank to remove air before weighing. This
weight is noted while suspended in water W 1 gm. The basket and the aggregate are then removed from
water and allowed to drain for a few minutes. After which the aggregates are transferred to absorbent
26
clothes. The empty basket is then returned to the tank of water jolted 25 times and weight in water W2
gm.
• The aggregates placed on the absorbent clothes are surface dried till no further moisture could be
removed by this cloth. Then the aggregates are transferred to the second dry cloth spread in a single
layer covered and allowed to dry for at least 10 minutes until the aggregates are completely surface dry.
10 to 60 minutes drying may be needed. The aggregates should not be exposed to the atmosphere,
direct sunlight or any other source of heat while surface drying. A gentle current of unheated air may be
used during the first ten minutes to accelerate the drying of aggregate surface. The surface dried
aggregate is then weighed W 3 gm. The aggregate is placed in a shallow tray and kept in an oven
maintained at a temperature of 110 °C for 24 hours. It is then removed from the oven, cooled in an
airtight container and weighed W4 gm.
• Two tests are done and the average value to the nearest whole number is reported as aggregate
abrasion value.

Observation and calculation:

Weight of saturated aggregate suspended in water with the basket = W1 g

Weight of basket suspended in water= W2 g
Weight of saturated aggregate in water= (W1-W2) = Ws g.
Weight of saturated surface dry aggregate in air= W3 g
Weight of oven dried aggregate=W4 g
Weight of water equal to the volume of the aggregate = (W3-Ws) g

Specific Gravity= (Weight of aggregate/Weight of equal volume of water) = W4/ (W3-Ws)

Water absorption= percent by weight of water absorbed in terms oven dried weight of aggregates. =
[(W3-W4) / W4] x 100

27
RESULTS:

Specific gravity of given aggregate is………….& Water Absorption of given aggregate………….

28
3. TESTS ON FRESH CONCRET

29
 SLUMP TEST

AIM:

Concrete slump test is to determine the workability or consistency of concrete mix prepared
at the laboratory or the construction site during the progress of the work.

APPARATUS:

Mould for slump test, non-porous base plate, measuring scale, temping rod.

INTRODUCTION:
Concrete slump test is carried out from batch to batch to check the uniform quality of
concrete during construction. The slump test is the simplest workability test for concrete,
involves low cost and provides immediate results. Generally concrete slump value is used to
find the workability, which indicates water-cement ratio, but there are various factors
including properties of materials, mixing methods, dosage, admixtures etc. also affect the
concrete slump value.

1. Very low workability: slump value 0-25mm or 0-1 inch

2. Low workability: slump value 25-50mm or 1-2 inch
3. Medium workability: slump value 50-100mm or 2-4 inch
4. High workability: slump value 100-175mm or 4-7 inch

 True Slump – True slump is the only slump that can be measured in the test. The measurement
is taken between the top of the cone and the top of the concrete after the cone has been
removed as shown in figure.

30
 Zero Slump – Zero slump is the indication of very low water-cement ratio, which results in
dry mixes. These type of concrete is generally used for road construction.
 Collapsed Slump – This is an indication that the water-cement ratio is too high, i.e.
concrete mix is too wet or it is a high workability mix, for which a slump test is not
appropriate.
 Shear Slump – The shear slump indicates that the result is incomplete, and concrete to be
retested.

PROCEDURE:

1. Clean the internal surface of the mould and apply oil.

2. Place the mould on a smooth horizontal non- porous base plate.
3. Fill the mould with the prepared concrete mix in 4 approximately equal layers.
4. Tamp each layer with 25 strokes of the rounded end of the tamping rod in a uniform manner
over the cross section of the mould. For the subsequent layers, the tamping should penetrate
into the underlying layer.
5. Remove the excess concrete and level the surface with a trowel.
6. Clean away the mortar or water leaked out between the mould and the base plate.
7. Raise the mould from the concrete immediately and slowly in vertical direction.
8. Measure the slump as the difference between the height of the mould and that of height point
of the specimen being tested.

RESULT:

31
Slump for the given sample = mm.

32
 CF (COMPACT FACTOR STRESS) TEST

AIM:

Compaction factor test is the workability test for concrete conducted in laboratory.

APPARATUS:

Compaction factor apparatus consists of trowels, hand scoop (15.2 cm long), a rod of steel or
other suitable material (1.6 cm diameter, 61 cm long rounded at one end) and a balance.

INTRODUCTION:

The compaction factor test is used for concrete which have low workability for which slump
test is not suitable. The test is sufficiently sensitive to enable difference in workability arising
from the initial process in the hydration of cement to be measured. Each test, therefore should
be carried out at a constant time interval after the mixing is completed, if strictly comparable
results are to be obtained. Convenient time for releasing the concrete from the upper hopper
has been found to be two minutes after the completion of mixing.

PROCEDURE:

1. Place the concrete sample gently in the upper hopper to its brim using the hand scoop and
level it.
2. Cover the cylinder. Open the trapdoor at the bottom of the upper hopper so that concrete
fall into the lower hopper. Push the concrete sticking on its sides gently with the road.

33
3. Open the trapdoor of the lower hopper and allow the concrete to fall into the cylinder below.
4. Cut of the excess of concrete above the top level of cylinder using trowels and level it.
5. Clean the outside of the cylinder.
6. Weight the cylinder with concrete to the nearest 10 g. This weight is known as the weight of
partially compacted concrete (W1).
7. Empty the cylinder and then refill it with the same concrete mix in layers approximately 5
cm deep, each layer being heavily rammed to obtain full compaction.
8. Level the top surface.
9. Weigh the cylinder with fully compacted. This weight is known as the weight of
fully compacted concrete (W2).
10. Find the weight of empty cylinder (W).

CALCULATION:

The compaction factor is defined as the ratio of the weight of partially compacted concrete to
the weight of fully compacted concrete. It shall normally to be stated to the nearest second
decimal place.

Compaction Factor Value= (W1-W) / (W2-W)

RESULT:
Compaction factor of the concrete =

The Compaction factor values ranges from 0.7 to 0.95.

34
 VEE - BEE TEST
AIM:

To determine the workability of freshly mixed concrete by using of Vee – Bee consistometer
apparatus.

APPARATUS:

Cylindrical container, Vee-Bee apparatus (consisting of vibrating table, slump cone), Standard
tamping rod, stop watch and trowels.

INTRODUCTION:
Vee-bee test carries out the relative effort measurement to change the mass of the concrete
from a definite shape to the other. That is, as per the test, from the conical shape to the
cylindrical shape by undergoing vibration process. The measurement of the effort is done by
time measurement in seconds. The amount of work measured in seconds is called as
the remoulding effort. The time required for the complete remoulding is a measure of the
workability and is expressed in the Vee-Bee seconds. The experiment is named after the
developer V Bahrmer of Sweden. The method can be also applied for dryconcrete. For
concrete that have slump value more than 50mm, the remoulding activity will be so fast that
the measurement of time is not possible.

PROCEDURE:

1. Initially the sheet metal slump cone is placed inside the cylinder container that is placed in the
consistometer. The cone is filled with four layers of concrete. Each concrete layer is one
fourth the height of the cone. Each layer after pouring is subjected to twenty-five tamping
with the standard tamping rod. The tamping is done with the rounded end of the rod. The
strokes are

35
 distributed in uniform manner. This must be done in such a way theta the strokes conducted
for the second and the subsequent layers of concrete must penetrate the bottom layers. Once
the final layer has been placed and compacted, the concrete is struck off to make it in level
with the help of a trowel. This makes the cone to be exactly filled.

2. After the preparation of the concrete cone, the glass disc attached to the swivel arm is moved
and is placed on the top of the slump cone placed inside the cylindrical container. The glass
disc has to be placed such that it touches the top of the concrete level and the reading is
measured from the graduated rod.

3. Now the cylindrical cone is removed immediately by raising the cone slowly in the vertical
direction. The transparent disc on the top of the concrete is placed down to the new position
and the reading is determined.

4. The difference in the values measured from step 3 and step 4 will give the slump.

5. Now the electrical vibrator is switched on and at the same time we have to start the stop
watch. The concrete is allowed to spread out in the cylindrical container. Until the concrete is
remolded the vibration is continued. This stage is when the surface of the concrete becomes
horizontal and the concrete surface completely adheres uniformly to the transparent disc.

6. The time required for complete remoulding in seconds is recorded. This time in seconds gives
us the measure of workability of the fresh concrete. This time is expressed in Vee-Bee
seconds.

OBSERVATION AND CALCULATIONS:

1. Initial reading from the graduated rod, before unmoulding (a) in mm

2. The final reading on the graduated rod after removing the mould (b) in mm
3. Slump = a – b in mm
4. The time required for complete remoulding in seconds

RESULT:

Hence the consistency of the concrete is measured in vee-bee seconds.

36
STANDARD VALUES:

WORKABILITY DESCRIPTION VEE – BEE TIME (IN SECONDS)

Extremely dry 32 – 18

Very stiff 18 – 10

Stiff 10 – 5

Stiff plastic 5–3

Plastic 3–0

Flowing

37
5. NON-DESTRUCTIVE TEST
OF CONCRETE

38
 REBOUND HAMMER
AIM:

To determine the comprehensive strength of harden concrete by Rebound Hammer.

APPARATUS:
Rebound Hammer.

INTRODUCTION:

When the plunger of rebound hammer is pressed against the surface of the concrete, the
spring controlled mass rebounds and the extent of such rebound depends upon the surface
hardness of concrete. The surface hardness and therefore the rebound is taken to be related to
the compressive strength of the concrete. The rebound is read off along a graduated scale and
is designated as the rebound number or rebound index.

PROCEDURE:

1. Smoothen the concrete surface with the help of the carborundum stone removing any
loosely adhered scale to the concrete surface.
2. Rough surfaces resulting from incomplete compaction, loss of grout, spalled or
tooled surfaces do not give reliable results and should be avoided.
3. The point of impact should be at least 20 mm away from any edge or shape discontinuity.
4. The rebound hammer measurements can be taken at any angle, vertically upwards,
downwards, horizontal, or any intermediate angle as the situation demands Six readings
are taken about each point of observation and the average of these readings after deleting
outliners becomes the rebound index for the point of observation.

39
OBSERVATIONS:

COMPRESSIVE
REBOUND NUMBER (6 LOCATION OF
S.NO STRENGTH
READINGS) OBSERVATIONS
(KG/CM2)
1

RESULTS:

Compressive strength of the harden concrete surface is .

40
 ULTRASOUND PULSE VELOCITY (UPV)
AIM:

To determine the time of travel of an ultrasonic pulse passing through the concrete.

APPARATUS:
Ultrasound pulse velocity

INTRODUCTION:

This test is done to assess the quality of concrete by ultrasonic pulse velocity method as per IS:
13311 (Part 1) – 1992. The underlying principle of this test is – The method consists of measuring
the time of travel of an ultrasonic pulse passing through the concrete being tested. Comparatively
higher velocity is obtained when concrete quality is good in terms of density, uniformity,
homogeneity etc.

PROCEDURE:

1. Preparing for use: Before switching on the „V‟ meter, the transducers should be connected to
the sockets marked “TRAN” and ” REC”. The „V‟ meter may be operated with either:

a) the internal battery, b) an external battery or c) the A.C line.

2. Set reference: A reference bar is provided to check the instrument zero. The pulse time for the
bar is engraved on it. Apply a smear of grease to the transducer faces before placing it on the
opposite ends of the bar. Adjust the „SET REF‟ control until the reference bar transit time is
obtained on the instrument read-out.
3. Range selection: For maximum accuracy, it is recommended that the 0.1 microsecond range be
selected for path length up to 400mm.
4. Pulse velocity: Having determined the most suitable test points on the material to be tested,
make careful measurement of the path length „L‟.
5. Apply couplant to the surfaces of the transducers and press it hard onto the surface of the
material. Do not move the transducers while a reading is being taken, as this can generate
noise signals and errors in measurements. Continue holding the transducers onto the surface of
the material until a consistent reading appears on the display, which is the time in microsecond
for the ultrasonic pulse to travel the distance „L‟. The mean value of the display readings
should be taken when the units digit hunts between two values.

Pulse velocity = (Path length/Travel time).

6. Separation of transducer leads: It is advisable to prevent the two transducer leads from
coming into close contact with each other when the transit time measurements are being taken.
If this is not done, the receiver lead might pick-up unwanted signals from the transmitter lead
and this would result in an incorrect display of the transit time.

41
RESULT:

The quality of concrete in terms of uniformity, incidence or absence of internal flaws, cracks and
segregation, etc, indicative of the level of workmanship employed, can thus be assessed using the
guidelines given below, which have been evolved for characterizing the quality of concrete in
structures in terms of the ultrasonic pulse velocity.

PULSE/VELOCITY CONCRETE QUALITY

(KM/SECOND) (GRADING)

ABOVE 4.5 EXCELLENT

3.5 TO 4.5 GOOD

3.0 TO 3.5 MEDIUM

BELOW 3.0 DOUBTFUL

42