Highway Material Testing Manual: V. K. L. Rao V. K. L. Rao V. K. L. Rao V. K. L. Rao

HIGHWAY MATERIAL
TESTING MANUAL
By
V. K. L. Rao
M.Tech (GTE), MIE., MIRC., MIIBE., MICI., MIGS., CE
Senior Quality cum Material Expert
Highway Material Testing Manual
HIGHWAY
MATERIAL TESTING
MANUAL
Page 2 of 362 VKL Rao, M.Tech (Geotechnical)

PREFACE
While designing a structure, engineer assumes certain value of strength for each of
material being used therein. When the structure is being constructed, it is the bounden
duty of the field engineers to get the same validated by regular testing of material. The
quality of materials used in any infrastructure does play a vital role with regard to its
ultimate strength and durability in the long run. Hence, the materials need to be tested
according to certain standard procedures developed by AASHTO, ASTM, BIS, and BS to
give a clear picture of material strength.
The “Highway Material Testing Manual” is an attempt by VKL Rao to bring together
the standard test procedures for materials frequently used in the civil engineering
infrastructure of Highways. It is hoped that this will be a helpful guide to the field
engineers.
Serge Droogmans
Senior Pavement Expert

Scott-Wilson, UK

ACKNOWLEDGEMENT
Strength and durability of any infrastructure is a reflection of the quality of materials used. Quality
control of materials can only be ensured through certain standard test procedures designed by
AASHTO, ASTM, BIS, BS and others.
The “Highway Material Testing Manual” is an attempt towards this aim, of creating a collection of
standard test procedures for materials, commonly used in civil engineering infrastructure on the
Highways. This will serve as a guide to the field engineers. The readers are advised in their interest to
refer to the latest standards to avoid any omission, due to changes/amendments in the standards.
The support rendered by the faculty and staff of Scott-Wilson, UK in this endeavour, needs mention.
Shri Janathan West, Resident Engineer and Shri Ravi Shankar, Technical Assistant, have been of
technical assistance and Shri Dayananda Sarth Kumar, my Personal Assistant, has been extremely
useful in the task of word processing.
I am thankful to Shri Serge Droogmans, Senior Pavement Expert, Scott-Wilson, UK, for his guidance
and encouragement.
VKL Rao
Senior Quality cum Material Expert

CONTENTS
S. No Description Page
I SOILS 10 – 101
1 Preparation of Dry Soil Samples for various Tests 12
2 Classification of Soils 16
3 Grain Size Analysis 23
4 Specific Gravity of Soil 34
5 Moisture Content Test 36
6 Free Swell Index Test 38
7 Consistency Limits of Soils 40
8 Compaction Test 46
9 Field Density Test by Sand Replacement Method 51
10 Field Density Test by Core Cutter Method 55
11 California Bearing Ratio Test 58
12 Shear Test by Triaxial Method 66
13 Shear Test by Direct Shear Method 71
14 Unconfined Compressive Strength of Cohesive Soils 75
15 Permeability Test 79
16 Bearing Capacity of Soil by Plate Bearing Test 85
17 Standard Penetration Test 87
18 Sand Equivalent Test 89
19 Deleterious Contents of Soil – Determination of Total Soluble Sulphates 92
20 Deleterious Contents of Soil – Determination of Organic Matter 97
21 Deleterious Contents of Soil – Determination of Chloride and Salinity 100

II ROAD AGGREGATES 102 – 140
1 Aggregates Sampling 103
2 Aggregate Impact Value Test 107
3 Los Angles Abrasion Value Test 110
4 Aggregate Crushing Value Test 113
5 Flakiness & Elongation Index 115
6 Soundness Test 119
7 Specific Gravity and Water Absorption Test 124
8 Ten Percent Fines value Test 127
9 Bulkage & Silt Content of Fine Aggregates 130
10 Stone Polishing value Test 131
11 Deleterious Contents of Aggregates – Determination of Clay Lumps 134
Deleterious Contents of Aggregates – Determination of Clay, Fine Silt and Fine
12
Dust 136
13 Deleterious Contents of Aggregates – Determination of Light Weight Pieces 138
14 Deleterious Contents of Aggregates – Determination of Soft Particles 140

III BITUMEN AND BITUMINOUS MATERIALS 141 – 191
1 Penetration Test 143
2 Specific Gravity Test 146
3 Softening Point Test (Ring & Ball Test) 148
4 Viscosity Test 151
5 Flash and Fire Point Test 158
6 Ductility Test 160
7 Loss on Heating of Bituminous Materials 162
8 Stripping Value of Aggregates 164
9 Binder Content of Paving Mixtures 166
10 Test for Control Rate of Spread of Binder 168
11 Test for rate of Spread of Grit in Surface Dressing 170
12 Marshall Stability Test 171
13 Elastic Recovery Test 183
14 Separation Test 185
15 Indirect Tensile Strength of Asphalt Mixes 187

IV CEMENT AND CONCRETE 192 – 218
1 Determination of Normal Consistency 193
2 Determination of Initial and Final Setting Time of Cement 194
3 Determination of Soundness of Cement by the Le Chatelier Method 196
4 Determination of Fineness of Cement 197
5 Determination of Compressive Strength of Cement 199
6 Determination of Compressive Strength of Concrete 201
7 Determination of Workability of Concrete by Slump Test 204
8 Determination of Workability of Concrete by Compacting Factor Test 205
9 Determination of Workability of Concrete by Vee-Bee Test 206
10 Determination of Specific Gravity of Cement 208
11 Determination of Flexural Strength of Concrete 210
12 Determination of Permeability of Concrete 212
13 Determination of Entrained Air Content of Concrete 213
14 Determination of Flow of Concrete 214
15 Tests on Hardened Concrete (Rebound Hammer Test) 215
16 Ultrasonic Pulse Velocity 216
17 Determination of Fluidity of Cement Grout 218

V OTHER TESTS 219 – 247
1 Determination of Surface Irregularities (Unevenness) by Straight edge method 220
2 Determination of Surface Unevenness by Automatic Road Unevenness Recorder 222
Determination of Strengthening of Flexible Road Pavements using Benkelman
3
Beam Deflection Technique 225
Determination of Strengthening of Flexible Road Pavements using Falling
4
Weight Deflectometer Technique 235
5 Determination of Microtexture of Milled Pavement 244
VI APPENDIX 248 – 360
1 APPENDIX – I (General Formats for Highway) 248
2 APPENDIX – II (Check Lists) 287
3 APPENDIX – III (List of Essential Laboratory Equipments) 326
4 APPENDIX – IV (Test Requirements, Frequency & Limits) 331
5 APPENDIX – V (Laboratory Plan) 360

SOILS.

INTRODUCTION:
Soil is very essential material for highway constructions.
In view of the wide diversity in soil type, it is desirable to classify the sub grade soil into groups
possessing similar physical properties. Many methods have been in use for this purpose. Soils are
normally classified on the basis of simple laboratory tests such as grain size analysis and consistency
tests.
Soil compaction is important phenomenon in highway construction as compacted sub grade improves
the load supporting ability of pavement; in turn resulting in decreased pavement thickness
requirement. Compaction of earth embankments would result in decreased settlement. Thus the
behavior of soil sub grade material could be considerably improved by adequate compaction under
controlled conditions. The laboratory compaction test results are useful in specifying the optimum
moisture content at which a soil should be compacted and the dry density that should be aimed at the
construction site. The in-situ density of prepared sub grade as well as other pavement layers has to
be determined by a field density test for checking the compaction requirements and as a field control
test for compaction.
There are a number of tests for measuring soil strength; some of them give the strength parameters
of the soil, other methods are empirical and give only arbitrary strength values. The types of the
strength tests may be classified as shear test, bearing tests and penetration tests. The triaxial test
results are useful to find the strength parameters, viz: cohesion and angle internal friction and
modulus deformation of soils. The California Bearing Ratio test is essentially a penetration test, which
is carried out either in the laboratory or in the field. This test is suitable for the evaluation of strength
of soil and aggregates. The method has an important place among highway material testing
programme, as it has been extensively correlated with flexible pavement design and performance.
North Dakota Cone Test is another penetration test, which may also be carried out either in the
laboratory or on in-situ soil in the field, but its use is restricted to fine grained soils free from coarse
particles. Plate bearing test is carried out either on subgrade to find the modulus of subgrade reaction
or on a pavement component layer for pavement evaluation.
There are several soils, which are unsuitable as highway materials, since they cannot be used as such
in the base course, sub-base or the subgrade. The strength and durability characteristics of these soils
can be improved to the desired extent by adopting a stabilization technique. One of the widely used
methods of stabilization is soil-cement and soil-lime, which are applicable to a fairly wide range of soil
types. The cement and lime stabilization soil can be used in sub-base and base course layers of
pavement.

1. PREPARATION OF DRY SOIL SAMPLES FOR VARIOUS TESTS

(IS: 2720 – PART – 1 – 1983)
OBJECT:
It covers the method of preparation of dry samples from the bulk soil samples received from the field
for various test.
APPARATUS:
1. Wooden-mallet – for breaking soil clods.

2. Trays – for air drying of soil of suitable size and of non-rusting material.
3. Pulverizing Apparatus – Either mortar and rubber covered pestle or a mechanical device consisting
of mortar and a power-driven rubber covered pestle suitable for breaking up the aggregation of
soil particles without reducing the size of the individual grains. Pestle and mortar made of
softwood way also be used.
4. Sample – A suitable riffle sampler or sample splitter for quartering the samples.
5. Sieves – of sizes 75mm, 63mm, 37.5mm, 19mm, 13.2mm, 9.5mm, 4.75mm, 2mm and 425micron.
6. Drying Apparatus – (a) Drying over thermostatically controlled with interior of non-corroding
material to maintain the temperature between 1050C and 1100C. (b) Other suitable drying
apparatus.
7. Balances – (a) Capacity 10 kg.and minimum sensitivity 100g. (b) Capacity 1kg.and minimum
sensitivity 1g. (c) Capacity 250g.and minimum sensitivity 0.01g.
PREPARATION OF SAMPLE FOR TESTS:
• General – Soil sample as received from the field shall be dried in the air or in sun. In wet weather
a drying apparatus may be used in which case the temperature of the sample should not exceed
600C. The clods may be broken with a wooden-mallet to hasten drying. The organic matter like,
tree roots and pieces of bark should be removed from the sample. Similarly matter other than soil
like shells should also be separated from the main soil mass. A nothing shall be made of such
removals and their percentage of the total soil sample. When samples are to be taken for
estimation of organic content, lime content etc., total sample should be taken for estimation
without removing shell, roots and barks etc.
• Drying of the sample – The amount of drying depends upon the proposed test to be conducted on
the particular sample. The type, temperature and duration of during of soil samples for different
tests are given in Table-1. When oven is used for drying, the temperature in the oven shall not
exceed 1100C. Chemical drying of samples should not be adopted for any tests.
• Soil containing organic or calcareous matter should not be dried at temperature above 600C.
• Degree of Pulverization – The big clods may be broken with the help of wooden-mallet. Further
pulverization may be done in pestle and mortar. The pulverized soil shall be passed through the
specified sieve for the particular test and the soil retained on that sieve shall be again pulverized

for sieving. This procedure should be repeated until on further attempts at pulverizing very little
soil passes through the specified sieve. Care should be taken not to break up the individual soil
particles.
QUANTITY OF SAMPLE:
The quantities of soil sample required for conducting various laboratory tests are given in Table-1 for
guidance.
When a smaller quantity has to be taken out of a bigger soil mass the representative sampling shall
be done by quartering or riffling.
In the case of coarse gravel or gravelly soils quartering by forming a cone shall not be done. The
entire sample shall be thoroughly mixed and spread on a flat surface. The sample so spread shall be
divided into four quadrants and diagonally opposites quadrants mixed. This process shall be repeated
till the desired quantity of sample is obtained.
TABLE - 1
QUANTITY OF SOIL SAMPLE REQUIRED FOR CONDUCTING THE TEST
Degree of
Amount of soil Ref.to
Type, Temp. and pulverization
S.No. Test sample required Part of
Duration of Drying (Passing IS sieve
for test. IS:2720
size)
1 Water content Oven, 24h As given in Table-2 - Part - 2
50g.for fine grained

0 soils, 400g.for medium
2 Specific gravity Oven 105-110 C,24h 2 mm Part - 3
and coarse grained
soils.
3 Grain size analysis Air drying As given in Table-3 - Part - 4
4 Liquid Limit Air drying 270 g 425 micron Part - 5
5 Plastic Limit Air drying 60 g 425 micron Part - 5
6 Shrinkage factor Air drying 100 g 425 micron Part - 6
Compaction
6 kg.(15kg if soil is
Part - 7
a) Light compaction Air drying susceptible to 19 mm
7 crushing)
b) Heavy compaction Part - 8
c) Constant mass Air drying 2 kg 4.75 mm Part - 9

for test. IS:2720
size)
Unconfined
8 Oven 1100C +/- 50C 1 kg - Part - 10
Comp.Strength
Triaxical Compression
9 Oven 1100C +/- 50C 1 kg, 5 kg - Part - 11
(Un - Consolidated)
Triaxical Compression
10 Oven 1100C +/- 50C 1 kg, 5 kg - Part - 12
(Consolidated)
Air drying / oven 1100C

11 Direct Shear 1 kg 4.75 mm Part - 13
+/- 50C
Density index
(Relative density)
75 mm 45 kg
Oven 1050C - 1100C,
12 37.5 mm 12 kg - Part - 14
24 h
19 mm 12 kg
9.5 mm 12 kg
4.75 mm 12 kg
Consolidation Air drying / oven 1100C
13 500 g - Part - 15
Properties +/- 50C
14 CBR Air drying 6 kg 19 mm Part - 16
Oven, 1050C -1100C, 2.5kg(100mm dia), 5

15 Permeability 9.5 mm Part - 17
24h kg(200mm dia)
Field moisture
16 Air drying 15 g 425 micron Part - 18
Equivalent
Centrifuge moisture
17 Air drying 10 g 425 micron Part - 19
Equivalent
18 Linear Shrinkage Air drying 450 g 425 micron Part - 20
Chemical Test
Oven, 1050C -1100C,
a)Total soluble solids 10 g 2 mm Part - 21
24h
b)Organic matter Air drying 100 g 2 mm Part - 22
Oven, 1050C -1100C,
c)Calcium Carbonate 5g 2 mm Part - 23
24h
19 d)Cation Exchange Oven, 1050C -1100C,
80 - 130 g 2 mm Part - 24
capacity 24h
e)Silica-sesquioxide Oven, 1050C -1100C,
15 g - Part - 25
ratio 24h
f)PH Value do 30 g 425 micron Part - 26
g)Total soluble
do 30 g 425 micron Part - 27
Sulphates

Degree of
for test. IS:2720
size)
Air drying / oven 1100C
20 Vane - Shear 250 g - Part - 30
+/- 50C
Negative Pore Water Air drying / oven 1100C

21 1 kg, 5 kg - Part - 35
Pressure +/- 50C
Permeability of Air drying / oven 1100C

22 1 kg, 5 kg - Part - 36
granular soils +/- 50C
23 Direct Shear Air drying Upto 120 kg Above 4.75 mm Part - 39
24 Free swell index Oven dry 20 g 425 micron Part - 40
25 Swelling Pressure Air dry / Oven dry 2 kg 2 mm Part - 41
TABLE – 2
QUANTITY OF SAMPLE REQUIRED FOR DETERMINATION OF WATER CONTENT
Size of Particles more than 90 percent Minimum Quantity of soil Specimen to be
passing taken for the test Mass in gm.
425 micron IS.Sieve 25 g
2 mm IS.Sieve 50 g
4.75 mm IS.Sieve 200 g
19 mm IS.Sieve 500 g
TABLE – 3
QUANTITY OF SOIL REQUIRED FOR GRAIN SIZE ANALYSIS
Maximum size of material present in

Mass to be taken for test (kg)
substantial quantities (mm)
75 mm 60 kg
37.5 mm 25 kg
19 mm 6.5 kg
13.2 mm 3.5 kg
9.5 mm 1.5 kg
6.7 mm 0.75 kg
4.75 mm 0.4 kg

2. CLASSIFICATION OF SOILS.
(IS: 1498 – 1970)
INTRODUCTION:
The purpose of soil classification is to arrange various types of soils into groups according to their
engineering properties and various other characteristics. From engineering point of view, the
classification may be done with the objective of finding the suitability of the soil for construction of
highway foundations.
For general engineering purposes, soils may be classified by the following systems.
i) Particle size classification.
ii) Textural classification.
iii) Highway Research Board (HRB) classification.
iv) Unified soil classification and IS classification system.
i) Particle size classification: In this system, soils are arranged to the grain size. Terms such as
gravel, sand, silt and clay are used to indicate grain sizes. There are various grain size
classifications in use, but the more commonly used systems are (i) U.S.Bureau of soil and Public
Road Administration (PRA) system of United States.(ii) International soil classification, proposed at
the International Soil Congress at Washington,D.C (iii) Massachusetts Institute of Technology (MIT)
classification and (iv) Indian Standard classification.
Indian standard classification:
> 300mm - Boulders

300 – 80mm - Cobble
80 – 20mm - Coarse Gravel
20 – 4.75mm - Fine Gravel
4.75 – 2mm - Coarse Sand
2mm – 425micron - Medium Sand
425mic. – 75mic. - Fine Sand
75mic – 2micron - Silt
< 2 micron - Clay.
ii) Textural classification: Soils occurring in nature are composed of different percentage of
sand, silt and clay size particles. Soil classification of composite soils exclusively based on the
particle size distribution is known as textural classification. The classification is based on the
percentages sand, silt and clay sizes making up the soil.

To use the chart, for the given percentages of the three constituents forming a soil, lines are drawn
parallel to the three sides of the equilateral triangle; the three lines intersect at one point. That
point in the sector designated as the classification of that soil.
Textural classification chart:

0 100
10 90
20 80
30 70
Sand ( 2 - 0.05mm) 40 60 Clay ( < 0.005 mm)

Clay
50 50
60 40
Sandy Silty
70 Clay Clay 30
Sandy Clay
Clay Loam Silty Clay Loam
80 Loam 20
Loamy Sand
90 Sandy Loam Loam Silty Loam 10
Sand Silty
100 0
0 10 20 30 40 50 60 70 80 90 100
Silt ( 0.05 - 0.005 mm )
iii)Highway Research Board (HRB) classification: This system is based on both the particle-size
composition as well as the plasticity characteristics. This system is mostly used for pavement
construction. Soils are divided into 7 primary groups, designated as A-1, A-2…A-7. Group A-1 is
divided into two sub-groups and group A-2 into four sub-groups. A characteristic ‘group index’ is
used to describe the performance of the soils when used for pavement construction. The group
index of a soil depends upon (i) the amount of material passing the 75 micron IS sieve, (ii) the
liquid limit, and (iii) the plastic limit, and is given by the following equation:
Group index = 0.2 a + 0.005 ac + 0.01 bd
Where, a = that portion of percentage passing 75 micron sieve greater than 35 and
not exceeding 75 expressed as a whole number (0 to 40).
b = that portion of percentage passing 75 micron sieve greater than 15 and
not exceeding 75 expressed as a whole number (0 to 40).
c = that portion of the numerical liquid limit greater than 40 and not
exceeding 60 expressed as positive whole number (0 to 20).
d = that portion of the numerical plasticity index greater than 10 and not
exceeding 30 expressed as a positive whole number (0 to 20).

HRB – Classification of soils :
Granular material Silt clay materials ( > 35%

General Description
( 35% or less passing 75 micron IS sieve ) passing 75 mic.sieve)
A -1 A-3 A-2 A-4 A-5 A-6 A-7
Group classifiation A-7-5
A-1-a A-1-b A-2-4 A-2-5 A-2-6 A-2-7
A-7-6
% passing
2.0mm IS sieve > 50
425 micron sieve > 30 < 50 < 51
75 micron sieve > 15 > 25 > 10 > 35 > 35 > 35 > 35 < 36 < 36 < 36 < 36
Characteristics of
fractions
>6 NP
Liquid Limit > 40 < 41 > 40 < 41 > 40 < 41 > 40 < 41
Plasticity Index > 10 > 10 < 11 > 11 > 10 > 10 < 21 < 11
Group Index Zero >4 >8 > 12 > 16 > 20
Stone
Fine sand
Usual type of
fragments
significant constituent Silty or clayey gravel and sand Silty soil Clayey soil
gravel and
materials
sand
General rating as
Excellent to good Fair to poor
subgrade
Group classification A-7 A - 7a A - 7b A - 7c
% passing
upto 75 55 - 95 80 - 95 84-100
75 micron sieve
Characteristcs of
fraction
Liquid Limit < 55 < 65 < 65 > 65
Plasticity Index < 25 < 42 < 42 > 42
Group index > 20 20 - 30 30 - 40 40 - 50
Usual type of
significant constat Clayey soils
constituent
Fair to
poor
General rating as
Poor
subgrade

iv)Unified soil classification and Indian standard classification: The system is based on both
grain size and plasticity properties of the soil.
Soils are broadly divided into three divisions
i) Coarse grained soils: In these soils, more than half the total material by weight is larger than 75
micron IS sievs size.
Coarse-grained soils are further divided into two sub-divisions:
a)Gravels (G): In these soils, more than half the coarse fraction is larger than 4.75mm IS sieve size.
This sub-division includes gravels and gravelly soils, and is designated by symbol ‘G’.
b) Sands (S): In these soils, more than half the coarse fraction is smaller than 4.75mm IS sieve size.
This sub-division includes sands and sandy soils, and is designated by symbol ‘S’.
Each of the above sub-divisions are further sub-divided into four groups depending upon grading
and inclusion of other materials:
W : Well graded, clean.

C : Well graded with excellent clay binder.
P : Poorly graded, fairly clean.
M : Containing fine materials not covered in other groups.
These symbols used in combination designate the type of coarse-grained soils. For example, GC
means clayey gravels.
ii) Fine grained soils: In these soils, more than half the material by weight is smaller than 75
micron IS sieve size.
Fine-grained soils further divided into three sub-divisions:
a) Inorganic silt and very fine sands – designated by ‘M’.
b) Inorganic clays – designated by ‘C’.
c) Organic silts and clays, and organic matter – designated by ‘O’.

The fine-grained soils are further divided into the following groups on the basis of the liquid limit.
i) Silts and clays of low compressibility, having a liquid limit less than 35, and represented by symbol
‘L’.
ii) Silts and clays of medium compressibility, having a liquid limit greater than 35 and less than 50,
and represented by symbol ‘I’.
iii) Silts and clays of high compressibility, having a liquid limit greater than 50, and represented by a
symbol ‘H’.
Combination of these symbols indicates the type of fine-grained soil. For example, ML means
inorganic silt with low to medium compressibility.
Laboratory classification of fine-grained soil is done with the help of plasticity chart. The A-line,
dividing inorganic clay from silt and organic soil has the following equation:
Ip = 0.73 (wL – 20)
Where, Ip = Plasticity Index.

WL = Liquid Limit.
Plasticity chart:
60
50 WL = 50 CH
40
IP
30 WL=35
MH & OH
20 Cl
CL
10
CL-ML ML&OL MI & OI
0
10 20 30 40 50 60 70 80 90 100
WL

iii) Highly organic soils and other miscellaneous soil materials: These soils contain large
percentages of fibrous organic matter, such as peat, and the particles of decomposed vegetation.
IS Soil classification: Laboratory classification criteria for Coarse-grained soils

Symbols
Groups
Laboratory Classification Criteria
Cu Greater than 4
GW
Cc Between 1 and 3
Determine percentages of gravel and sand from
grain size curve depending on percetage of fines
GP Not metting all gradation requirements for GW ( fraction smaller than 75 micron sieve size );
coarse-grained soils are classified as follows:
Less than 5% = GW,GP,SW,SP.
Atterberg limits below "A" line above "A" line with Ip More than 12% = GM,GC,SM,SC.
GM
or Ip less than 4 etween 4 and 7 are 5% to 12% = borderline cases requiring use of
border line cases dua symbols.
Atterberg limits above "A" requiring use of dual
GC symbols.
line with Ip greater than 7
Cu Greater than 6
SW
Cc Between 1 and 3
SP Not metting all gradation requirements for SW

Cu (uniformity coefficient) = D60 / D10 Cc
(coefficient of curvature) =
Atterberg limits below "A" line
SM Limits plotting above (D30)2 / (D10 x D60)
or Ip less than 4
"A" line with Ip between
4 and 7 are border line
Atterberg limits above "A" cases reqiring use of
SC dual symbols.
line with Ip greater than 7

Soil suitability for Roads in different layers.
base when not

to frost action
Value as base
not subjected
Value as sub-
Value as sub-
subjected to
subjected to
grade when
frost action
frost action
Soil Group
when not
Unit Dry
Drainage Compressibility
weight
characteristics and Expansion
g/cm3
GW Excellent Excellent Good Excellent Almost none 2.00 - 2.24

Good to
GP Good Fair to good Excellent Almost none 1.76 - 2.24
Excellent
Good to
GM Good Fair to good Fair to poor Very slight 1.84 - 2.32
Excellent
Poor to not Poor to
GC Good Fair Slight 2.08 - 2.32
suitable impervious
Fair to
SW Good Poor Excellent Almost none 1.76 - 2.08
good
Poor to not
SP Fair to good Fair Excellent Almost none 1.68- 2.16
suitable
Fair to
SM Fair to good Poor Fair to poor Very slight 1.60- 2.16
good
Poor to Slight to
SC Poor to fair Poor Not suitable 1.60 - 2.16
impervious medium
ML, Not Slight to
Poor to fair Not suitable Fair to poor 1.44 - 2.08
MI suitable medium
Not
CL, CI Poor to fair Not suitable Impervious Medium to high 1.44 - 2.08
suitable
OL, Not
Poor Not suitable Poor Medium to high 1.44 - 1.68
OI suitable
Not
MH Poor Not suitable Fair to poor High 1.28 - 1.68
suitable
Poor to very Not
CH Not suitable Impervious High 1.44 - 1.84
poor suitable
Poor to very Not
OH Not suitable Impervious High 1.28 - 1.76
poor suitable
Not
Pt Not suitable Not suitable Very poor Very high -
suitable

3. GRAIN SIZE ANALYSIS.

(IS: 2720 – PART – 4)
INTRODUCTION:
Most of the methods for soil identification and classification are based on certain physical properties of
the soils. The commonly used properties for the classification are the grain size distribution, liquid limit
and plasticity index. These properties have also been used in empirical design methods for flexible
pavements, and in deciding the suitability of sub grade soils.
Grain size analysis also known as mechanical analysis of soils is the determination of the percent of
individual grain sizes present in the sample.
The mechanical analysis consists of two parts:
(i) the determination of the amount and proportion of coarse material by the use of sieves.
(ii) the analysis for the fine grained fraction by sedimentation method.
The sieve analysis is a simple test consisting of sieving a measured quantity of material through
successively smaller sieves. The weight retained on each sieve is expressed as a percentage of the
total sample. The sedimentation principle has been used for finding the grain size distribution of fine
soil fraction; two methods are commonly used (i) Pipette method and (ii) Hydrometer method.
The grain size distribution of soil particles of size greater than 75 micron is determined by sieving the
soil on a set of sieves of decreasing sieve opening placed one below the other and separating out the
different size ranges. Two methods of sieve analysis are as follows:
(i) wet sieving applicable to all soils and

(ii) dry sieving applicable only to soils, which have negligible proportion of clay and silt.
The soils received from the field is divided into two parts: one, the fraction retained on 2mm sieve
and the other passing 2mm sieve. The sieve analysis also may be carried out separately for these two
fractions. The fraction retained on 2mm sieve may be subjected to dry sieving using bigger sieves and
that passing 2mm sieve may be subjected to wet sieving; however if this fraction consists of single
grained soil with negligible fines passing 0.075mm size, dry sieving may be carried out.

Apparatus:
Various apparatus include set of standard sieves of different sieve sizes, balance, rubber covered
pestle and mortar, oven, riffle and sieves shaker.
Procedure:
(a) For the fraction retained on 2.0mm sieve: Sufficient quantity of the dry soil retained on
2.0mm sieve is weighed out. The quantity of sample taken may be increased when the maximum size
of particles is higher. The sample is separated into various fractions by sieving through the set of
sieves of sizes 100, 63, 20, 6, 4.75 and 2 mm IS sieves. Additional sieve size may also be introduced if
necessary. After initial sieving, the material retained on each sieve is collected, the lumps broken
down using mortar and rubber covered pestle and is re-sieved thus the soil fraction retained on each
sieve is carefully collected and weighed.
(b) For the fraction passing 2.0mm sieve and retained on 0.075mm sieve: Dry sieving may
be done in the case of soils which are cohesion less, single grained and without lumps. Rifling or
quartering method takes the required quantity of soil sample, dried in oven at 1050 to 1100C and is
subjected to dry sieve analysis using a set of sieves with sieve openings 2.0, 0.6, 0.425, 0.15 and
0.075 mm, pan and lid, additional sieves may be used or any of the sieves removed, depending upon
the requirement of the test. The material retained on each sieve and on the pan are separately
collected and weighed.
Wet sieving may be adopted in the case of clayey or cohesive soils. Required quantity of sample taken
by riffling is weighed. The sample is spread in a tray or bucket and covered with water. In case of
soils having fractions that are likely to flocculate a dispersing agent like sodium hexametaphosphate
(2.0g) or sodium hydroxide (1.0g) and sodium carbonate (1.0g) per liter of water may be added to
the water. The mix is stirred and left for soaking. The soaked soil specimen is placed over the set of
sieves of sizes with the finest sieve and pan at the bottom and washed thoroughly. Washing is

continued till the water passing each sieve is substantially clean. The fraction of each sieve is emptied
carefully without loss of material in separate trays, oven dried at 1050 to 1100C and each fraction
weighed separately.
Calculations:
The weight of dry soil fractions retained on each sieve is calculated as a percentage of the total dry
weight of the sample taken.
Results:
The results are plotted on a semi-logarithmic graph with the grain size or sieve size on the X-axis in
log. scale and the percentage finer of each sieve on the Y-axis in ordinary scale. The smooth curve
joining the points thus obtained is known as the particle size distribution curve or diagram.
Uniformity coefficient of soil, Cu = D60 / D10

Coefficient of curvature, Cc = (D30)2 / (D10 X D60)
Where, D60, D30 and D10 are particle sizes corresponding to 60, 30 and 10 percent finer.

(c) For the fraction passing 0.075mm sieve: Two methods are in use based on sedimentation
principle that the larger grains settle more rapidly than the smaller ones. The Stoke’s law is made use
of according to which the velocity of settlement of spherical particles is proportional to the square of
their diameters. Thus if the depth and the duration of settlement are known, the velocity and hence
the diameter of particles at that depth can be estimated. The percentage of particles finer than this
diameter should be found using any one of the two methods viz; (i) Pipette method and (ii)
Hydrometer method.
Hydrometer method.
Apparatus:
a) Density hydrometer confirming to IS: 3104-1965 –(Range 0.995 –
1.030), b) Two glass-measuring cylinders of 1000ml capacity with ground
glass or rubber stoppers about 7cm diameter and 33cm high marked at
1000ml volume, c) Thermometer to cover the range 0 to 500C, accurate
to 0.500C, d) Water bath or constant temperature room, e) Stirring
apparatus, f) 75 micron sieve, g) Balance accurate to 0.01g, h) Stop
watch, i) Wash bottles containing distilled water, j) Glass rod, about 15
to 20 cm long and 4 to 5 mm in diameter, k) Reagents: Hydrogen
peroxide, Hydrochloric acid N solution and Sodium hexametaphosphate,
l) Conical flask of 1000ml capacity m) Funnel, filter paper, measuring
cylinder of 100ml capacity and blue litmus papers.
Procedure:
(A) Calibration of Hydrometer:
1.Determination of volume of the hydrometer bulb (Vh): Pour about 800ml of distilled water in the
1000ml-measuring cylinder and note the reading at the water level. Immerse the hydrometer in water
and note the water reading. The difference between the two readings is recorded as the volume of
the hydrometer bulb plus the volume of that part of the stem, which is submerged. For practical
purposes, the error due to the inclusion of this stem volume may be neglected. Alternatively, weigh
the hydrometer to the nearest 0.2g. This weight in grams is recorded as the volume of the
hydrometer in ml. This includes the volume of the bulb plus the volume of the stem. For practical
purposes the error due to the inclusion of the stem may be neglected.
2. In order to find the area of cross-section (A) of the measuring cylinder in which the hydrometer is
to be used, measure the distance, in cm, between two graduations of the cylinder. The cross-section
area (A) is then equal to the volume included between the two graduations divided by the distance
between them.
3. Measure the distance (h) from the neck to the bottom of the bulb, and record it as the height of
the bulb.

4. With the help of an accurate scale, measure the height (H) between the necks of the hydrometer to
each of the other major calibration marks (Rh).
5. Calculate the effective depth (He) corresponding to each of the major calibration marks (or
hydrometer readings, Rh) by the following expression:
He = H + ½(h – Vh/A)
6. Draw a calibration curve between He and Rh, which may be used for finding the effective depth (He)
corresponding to hydrometer readings (Rh) obtained during the test.
7. Meniscus correction (Cm) : Insert the hydrometer in the measuring cylinder containing about 700ml
of water. Take the readings of the hydrometer at the top and bottom of the meniscus. The difference
between two readings is taken as the meniscus correction (Cm), which is a constant for hydrometer.
During the actual sedimentation test, the readings should be taken at the bottom of the meniscus but
since the soil suspension is opaque, readings are taken at the top of meniscus. The meniscus
correction is always positive.
(B) Pre- treatment of soil:
1. Weigh accurately (to 0.01g) 50 to 100 g of oven dried soil sample (Wd) passing the 0.075mm IS
sieve. If the percentage of soluble salts is more than one percent, the soil should be washed with
water before further treatment, taking care to see that the soil particles are not lost.
2. Add 150ml of hydrogen peroxide to the soil sample placed in a wide mouth conical flask and stir it
gently for few minutes with a glass rod. Cover the flask with glass and leave it to stand overnight.
3. Next morning, the mixture in the conical flask is gently heated in an evaporating dish, stirring the
contents periodically. Reduce the volume to about 50ml by boiling. With very organic soils additional
peroxide may be required to complete the oxidation.
4. If the soil contains insoluble calcium compounds, add about 50ml of hydrochloric acid to the cooled
mixture of soil obtained in step 3. The solution is stirred with a glass rod for a few minutes and
allowed to stand for one hour or for longer periods, if necessary. The solution will have an acid
reaction to litmus.
5. Filter the mixture and wash it with warm water until the filtrate shows no acid reaction to litmus.
Transfer the damp soil on the filter paper and funnel to the evaporating dish using a jet of distilled
water. Place the dish and its contents to the oven. Take the weight (Wb) of the oven-dried soil
remaining after pre-treatment and find the loss of weight due to pre-treatment.

(C) Dispersion of soil:
1. To the oven-dried soil, add 100ml of sodium hexametaphosphate solution and warm the mixture
gently for about 10 minutes. Transfer the mixture to the cup of the mechanical mixer using a jet of
distilled water, and stir it well for about 15 minutes. The sodium hexametaphosphate solution is
prepared by dissolving 33 g of sodium hexametaphosphate and 7 grams of sodium carbonate in
distilled water to make one liter of solution. This solution is unsuitable and should be freshly prepared
approximately once in a month.
2. Transfer the soil suspension to the 75 micron IS sieve placed on a receiver and washes the soil on
this sieve using jet of distilled water from a wash bottle. The amount of distilled water used during
this operation may be about 500ml.
3. Transfer the soil suspension passing the 75-micron IS sieve to the 1000ml-measuring cylinder, and
adds more water to make the volume to exactly 1000ml in the cylinder.
4. Collect he material retained on 75-micron sieve and put it in the oven for drying. Determination the
dry weight of soil retained on 75-micron sieve.
(D) Sedimentation test with hydrometer:
1. Insert a rubber bung or any other suitable cover on the top of the 1000ml-measuring cylinder
containing the soil suspension and shake it vigorously end over end. Stop shaking and allow it to
stand. Immediately, start the stopwatch, and remove the top cover from the cylinder.
2. Immerse the hydrometer gently to a depth slightly below its floating position and then allow it to
float freely. Take the hydrometer readings after periods of 0.5, 1, 2 and 4 minutes. Take out the
hydrometer, rinse it with distilled water and allow it to stand in a jar containing distilled water at the
same temperature as that of the test cylinder.
3. The hydrometer is re-inserted in the suspension and readings are taken after periods of 8, 15 and
30 minutes; 1, 2 and 4 hours after shaking. The hydrometer should be removed, rinsed and placed in
the distilled water after each reading. After the end of 4 hours, readings should be taken once or
twice within 24 hours.
4. Composite correction (C): In order to determine the composite correction, put 100ml of dispersing
agent solution in another 1000ml measuring cylinder and make it to 1000ml
by adding distilled water. The cylinder should be maintained at the same temperature as that of the
test cylinder containing soil specimen. Insert the hydrometer in this comparison cylinder containing
distilled water and the dispersing agent and take the reading corresponding to the top of the
meniscus. The negative of the hydrometer reading so obtained gives the composite correction (C).

The composite correction is found before the start of the test, and also at every time intervals of 30
minutes, 1 hour, 2 hours and 4 hours after the beginning of the test, and afterwards, just after each
hydrometer reading is taken in test cylinder.
5. The temperature of the suspension should be observed and recorded once during the first 15
minutes and then after every subsequent reading.
Calculations:
(1) The loss in weight in pre-treatment of the soil in percentage is calculated from the following
expression:
P = (1 – Wb/Wd)x100
Where, P = loss in weight in percentage

Wd = weight of dry soil sample taken from the soil passing 2mm
Sieve
Wb = weight of the soil after pre-treatment
(2) The diameter of the particle in suspension at any sampling time t is calculated from:
D = 10-5 M ( He / t ) 0.5
Where, M = poise constant factor

He = effective depth of the hydrometer
t = elapsed time, minutes
(3) The percentage finer N/ based on the weight Wd is calculated from:
N/ = {(100xG)/[Wd x(G – 1)]} x R
Where, N/ = percentage finer, based on the weight of dry soil sample Wd

Wd = weight of dry soil sample taken from the soil sample passing
2mm sieve.
G = specific gravity of the soil passing 75 micron sieve.
R = corrected hydrometer reading
R = Rh/ + C
Rh = Rh/ + Cm
Where, Rh/ = observed hydrometer reading

Rh = hydrometer reading, corrected for meniscus
correction
(4) The percentage finer (N) based on the total weight of dry soil sample (W) is obtained from the
relation:

N = N/ X (W/ / W)
Where, W/ = cumulative weight passing 2mm sieve.
Values of Factor ‘M’

0 µ Factor 'M'
Temp. C
( poise) G = 2.50 G = 2.60 G = 2.65 G = 2.70 G = 2.75 G = 2.80
15 0.01145 1528 1479 1458 1435 1414 1305
16 0.01116 1508 1460 1438 1417 1396 1377
17 0.01088 1490 1442 1420 1399 1379 1360
18 0.01060 1470 1423 1402 1381 1361 1342
19 0.01034 1452 1406 1384 1364 1344 1325
20 0.01009 1434 1389 1367 1347 1328 1309
21 0.00984 1417 1372 1351 1331 1311 1294
22 0.00961 1400 1355 1335 1315 1296 1278
23 0.00938 1383 1339 1318 1291 1280 1262
24 0.00916 1367 1323 1305 1284 1265 1248
25 0.00896 1351 1308 1288 1269 1251 1233
26 0.00875 1335 1293 1273 1254 1236 1219
27 0.00855 1321 1279 1259 1241 1224 1206
28 0.00836 1305 1264 1244 1226 1208 1191
29 0.00818 1291 1250 1231 1213 1195 1178
30 0.00800 1277 1236 1217 1199 1182 1165
31 0.00783 1264 1224 1205 1187 1170 1154
32 0.00767 1251 1211 1193 1175 1158 1142
33 0.00751 1238 1199 1180 1163 1146 1130
34 0.00736 1225 1186 1168 1151 1134 1118
35 0.00721 1212 1174 1156 1139 1120 1107
36 0.00706 1199 1161 1144 1127 1110 1095
37 0.00692 1188 1150 1133 1116 1100 1084
38 0.00679 1176 1139 1122 1105 1089 1074
39 0.00666 1165 1128 1110 1094 1079 1064
40 0.00654 1155 1118 1101 1084 1069 1055

GRAIN SIZE ANALYSIS OF SOIL/COARSE AND FINE AGGREGATE

( IS : 2386 - PART - 1 )
Lab Ref.No:____________________ Mass of Dry Sample Before Washing:____________________ Date of Sampling:___________
Date of Sample:_________________ Mass of Dry Sample After Washing:______________________ Date of Testing:____________
Type of Material :________________ Loss of Sample:______________________________________
Source Km.:____________________ Weight of the Sample (W1):_____________________________
Cumulative Cumulative
Weight Percentage Passing
Sieve Size Weight Percentage
Retained in (%) - Specification Limits (%)
(mm) Retained in Retained (%) -
(gm) - W2 (100 - Col.4)
(gm) - W3 W3/W1X100
53.00
40.00
37.50
26.50
20.00
19.00
13.20
12.50
11.20
10.00
9.50
5.60
4.75
2.36
1.18
0.600
0.425
0.300
0.150
0.075
Pan
Wash
Loss
Total
Remarks :________________________________________________________________________________

TEST : DETERMINATION OF SAND CONTENT

( IS : 2720 - PART - 4 )
Frequency of Tests Permissible Limits

Embankment 2 Tests / Embankment
3 60 - 80 %
Subgrade 3000m Subgrade
Lab Ref No :_________________ Date of Sampling :____________
Type of
Material :_________________ Date of Testing :____________
Source :_________________ Oven / Air dried :___________
RETAINED ON SEIVE
PERCENTAGE
SIEVE SIZE
WEIGHT RETAINED CUM.Wt. CUM. % PASSING
( mm )
( gms ) - W2 RETAINED ( RETAINED ( ( 100 - Col.4 )
gms ) - W3 W3 /W1 X 100 )
1 2 3 4 5
4.75mm
600 mic.
200 mic.
150 mic.
75 mic.
TOTAL WEIGHT OF SAMPLE ( W1) =
WET WEIGHT OF SAMPLE =
DRY WEIGHT OF SAMPLE =
WASH RET. ON 75 mic. SIEVE =
PERCENTAGE OF SAND CONTENT =
Remarks: __________________________________________________________________________________

HYDROMETER ANALYSIS
Sample No: Specific gravity of soil particles of minus 75 micron G :
Weight of dry soil sample ( W ) : Meniscus correction Cm : + 0.5
Weight of fraction passing 2 mm sieve ( W ' ) :
Weight of dry sample taken from minus 2 mm sieve ( W d) :
-5 N’ = 100GR/[W d (G - 1)]
Calculations: D = 10 M ( He / t)
Hydro- % finer
Elapsed %finer (N) based
meter Temp. Rh = Eff.Depth Factor Particle size R = Rh' + (N')
Date Time time "t" 0 C on whole N =
Reading C Rh' + Cm He (cm) M D (mm) C based
(min) N'XW'/W
( Rh' ) on Wd
0.5
1
2
4
8
15
30
60
120
240
540
1440
Remarks:______________________________________________

4. SPECIFIC GRAVITY TEST FOR SOILS.

(IS: 2720 – PART – 3)
Object:
To determine the specific gravity of soil fraction passing 4.75 mm sieve by density bottle.
Apparatus:
1) Density bottle of 50ml / 100ml capacity.

2) Balance sensitive to 0.01g.
3) Wash bottle with deaired distilled water
4) Vacuum source
Procedure:
To clean and dry the density bottle, wash it thoroughly with distilled water and allow it to drain.
Weigh the empty cleaned bottle (W1) accurate to 0.01g with its stopper. Take about 10 to 20 grams
of oven dried soil sample; find the weight (W2) of the bottle and the soil, with the stopper. Put about
10ml of deaired distilled water in the bottle, so that the soil is fully soaked. Leave it for a period of 2
to 10 hours. Add more distilled water so that the bottle is about half full. Remove the entrapped air by
subjecting the contents to a partial vacuum, then find out the weight (W3). Clean the bottle
thoroughly and fill it with distilled water and weighed (W4). Temperature should be maintained 270C
through out the test.
Calculations:
Specific gravity of the soil = G = (W2 – W1)/[(W2 – W1) – (W3 – W4)]
Where, W1 = weight of the empty bottle with stopper.

W2 = weight of the bottle + Soil sample with stopper.
W3 = weight of the bottle + sample + water with stopper.
W4 = weight of the bottle + water with stopper.

TEST : SPECIFIC GRAVITY OF FINE AGGREGATES / SOIL

( IS : 2720 - PART 3 )
Pycnometer Method
Lab Ref.No :______________________
Type of Material :______________________
Source Km. :______________________ Date of Tested :_____________
TEST NUMBER MEAN

S.NO DESCRIPTION
1 2 3 VALUE
1 Weight of Pycnometer. W1
2 Weight of Pycnometer + Sample. W2
3 Weight of Pycnometer + Sample + Water. W3
4 Weight of Pycnometer + full of water. W4
5 Weight of Sample ( W2 - W1 )
6 Sp.Gr = ( W2 - W1 ) / [(W4 - W1) - (W3 - W2)]
7 Saturated Surface Dry Weight of Sample W5
8 Oven Dried Sample Weight W6
9 App.Sp.Gr. = W6 / [(W4-W1) - (W3-W2) - (W5-W6)]
10 Water Absorption (W5 - W6) X100 / W6
Remarks :_____________________________________________________________________________________

5. MOISTURE CONTENT TEST.

(IS: 2720 – PART – 2)
Object:
To determine the water content of a soil sample by oven drying method / sand bath method / Rapid
moisture meter method.
Apparatus:
1) Non-corrodible airtight containers.
2) Heat resistant tray – 5 to 7 cm deep.
3) Rapid moisture meter and absorbent (calcium carbide).
4) Oven, balance and heater / stove etc.
Procedure:
(A) Oven drying method:
Take about 30 to 50 gms of soil sample if it is fine
grained and about 250 to 300 gms if it is coarse
grained soil in to the container and weigh it (W1).
Place the container in the oven and dry for 24 hours
at temperature of 1050 to 1100C. Remove the
container from the oven replace the lid and cool it,
after cooling weigh the container along with lid
(W2). Clean and dry the container and weigh it
(W3).
Calculations:
Water content, w % = [(W1 – W2)/(W2 – W3)] X 100
(B) Sand bath method: Clean the container with lid or the tray, as the case may be dry and weigh
(W1). Take the required quantity of the soil specimen in the container crumbled and placed loosely
and weigh (W2). Add a few pieces of white paper if necessary. Place the container with the lid
removed or the tray on the sand bath and heat the sand bath. Care shall be taken not to get the sand
bath too hot. During heating, the specimen shall be turned frequently and thoroughly with the palette
knife to assist the evaporation of water, care being taken to see that no soil is lost in the process.
When drying is complete, remove the container from the sand bath, cool and weigh (W3).
Calculations:
Water content, w % = [(W2 – W3)/(W3 – W1)] X 100
Note: Avoid overheating, A convenient method of detecting overheating of the soil is by the use of
small pieces of white paper mixed the soil. Overheating is indicated if the paper turns brown.

(C) Rapid Moisture Meter:

Set up the balance, place sample in pan till the mark on the balance
arm mass lines up with the index mark (taken approximately 6 grams of
soil). Unclamp the clamping screw of the instrument sufficiently to
move the U-clamp off the cup. Lift off the cup, check that cup and body
are clean; otherwise clean it by using a brush. Hold the body horizontal
and gently deposit one level scoopful of absorbent (calcium carbide)
halfway inside the chamber. Then lay the chamber down without
disturbing the absorbent charge. Transfer the soil weighed out as above
from the pan to the cup. Holding cup and chamber approximately
horizontal bring them together without disturbing sample or absorbent,
bring the U-clamp round and clamp the cup tightly into place.
With gauge downwards (except when the steel balls are used) shake
the moisture meter up and down vigorously for 5 seconds, then quickly
turn it so that the gauge is upwards, give a tap to the body of the
moisture meter to ensure that all the contents fall into the cup. Hold
the rapid moisture meter downwards, again shake for 5 seconds then
turn it with gauge upwards and tap. Hold for one minute and repeat
this, when the needle comes to rest on the reading. The reading on the meter is the percentage of
water content of the wet mass.
Calculations: From the water content (m) obtained on the wet mass basis as the reading on the
rapid moisture meter, the water content (w) on the dry mass basis shall be calculated as follows:
w, % = [m/(100 – m)]x100, percent.
where, m = moisture content on the wet mass basis, obtained from rapid moisture meter.
w = moisture content on the dry mass basis
DETERMINATION OF MOISTURE
(IS: 2720 – PART – 2)
Container No.
1 Wt.of Wet Soil + Container (gms)
2 Wt.of Dry Soil + Container (gms)
3 Wt.of Water = (s) - (t) (gms)
4 Weight of Container (gms)
5 Wt.of Dry Soil = (t) - (v) (gms)
Moisture Content = (u)x100/w (%)
Remarks :______________________________________________________________________________

6. FREE SWELL INDEX TEST.

(IS: 2720 – PART – 40)
Object:
To determine the free swell index of soils.
Apparatus:
1) 425 micron IS sieve, 2) Glass graduated cylinders – 2 nos 100ml capacity, 3) Distilled water and
kerosene.
Procedure:
Take two 10 grams soil specimens of oven dry
soil passing through 425-micron IS sieve. Each
soil specimen shall be poured in each of the two
glass graduated cylinders of 100ml capacity. One
cylinder shall then be filled with kerosene oil and
the other with distilled water up to the 100ml
mark. After removal of entrapped air the soils in
both the cylinders shall be allowed to settle.
Sufficient time (not less than 24 hours) shall be
allowed for the soil sample to attain equilibrium
state of volume without any further change in the
volume of the soils. The final volume of soils in
each of the cylinders shall be read out.
Calculations:
The level of the soil in the kerosene-graduated cylinder shall be read as the original volume. The soil
samples, kerosene being a non-polar liquid does not cause swelling of the soil. The level of the soil in
the distilled water cylinder shall be read as the free swell level. The free swell index of the soil shall be
calculated as follows:
Free swell index, percent = [(Vd – Vk)/Vk]x100
Where, Vd = the volume of soil specimen read from the graduated cylinder containing
Distilled water.
Vk = the volume of soil specimen read from the graduated cylinder containing
kerosene.
Limits:
FSI in % Expansiveness
< 20 % Low
20 – 30 % Moderate
35 – 50 % High
> 50 % Very High

DETERMINATION OF FREE SWELL INDEX OF SOIL

( IS : 2720 - PART - 40 )
As required by Engineer Max. 50%
Type of Material :_________________ Date of Testing :____________

Total Wt.of Dry
Source :_________________ sample:____________
(Passing
0.425mm sieve)
Swell Index =
Volume in Volume in Water Swell Average
Sample No. (Vd - Vk) / Vk X 100
Kerosene - Vk - Vd (Vd - Vk) Value
(%)
1
3
Remarks :_____________________________________________________________________________________

7. CONSISTENCY LIMITS OF SOILS.

(IS: 2720 – PART – 5)
INTRODUCTION:
The physical properties of fine-grained soils, especially of clay differ much at different water contents.
Clay may be almost in liquid state, or it may show plastic behavior or may be very stiff depending on
the moisture content. Plasticity is a property of outstanding importance for clayey soils, which may be
explained as the ability to undergo changes in shape without rupture.
Atterberg in 1911 proposed a series of tests, mostly empirical, for the determination of the
consistency and plastic properties of fine soils. These are known as Atterberg limits and indices.
Liquid limit: defined as the minimum water content at which the soil will flow under the application
of a very small shearing force.
Plastic limit: defined as the minimum moisture content at which the soil remains in a plastic state.
Plasticity Index (PI): is defined as the numerical difference between the liquid limit and plastic
limits. PI thus indicates the range of moisture content over which the soil is in a plastic condition.
Shrinkage limit: is the maximum moisture content at which further reduction in water content does
not cause reduction in volume. It is the minimum water content that can occur in a clayey soil sample,
which is completely saturated.
Consistency limits and the plasticity index vary for different soil types. Hence these properties are
generally used in the identification and classification of soils.
Liquid limit test:(Mechanical liquid limit device)

Object:
Determination of the liquid limit of soil by mechanical liquid limit device.
Apparatus:
i) Mechanical liquid limit device consists of a cup and
arrangement for raising and dropping through a specified
height and standard grooving tools.
ii) Balance of 200 g capacity and sensitive to 0.01 g.
iii) Oven to maintain 1050 to 1100C.

Procedure:
About 120 g of dry pulverized soil sample passing 425 micron IS sieve is weighed, and mixed
thoroughly with distilled water in the evaporating dish to form a uniform thick paste. The liquid limit
device is adjusted to have a free fall of cup through 10 mm. A portion of the paste is placed in the cup
above the lowest spot, and squeezed down with the spatula to have a horizontal surface. The
specimen is trimmed by firm strokes of spatula in such a way that the maximum depth of soil sample
in the cup is 10 mm. The soil in the cup is divided along the diameter through the center line of the
cam followed by firm strokes of the grooving tool so as to get a clean sharp groove. Grooving tool (b)
may be used for all soils, where as grooving tool (a) may be used only in clayey soils free from sand
particles or fibrous materials.
The crank is rotated at the rate of two revolutions per second (either by hand or electrically operation)
so that the cup is lifted and dropped. This is continued till the two halves of the soil cake come into
contact at the bottom of the groove along a distance of about 10 mm, and the number of blows given
is recorded. A representative soil is taken, placed in the moisture container, lid placed over it and
weighed. The container is dried in oven and the dry weight determined the next day for finding the
moisture content of the soil. The operations are repeated for at least three more trials with slightly
increased moisture contents each time, noting the number of blows so that there are at least four
uniformly distributed readings of number of blows between 10 and 40 blows.
Calculations:
Taking the number of blows in the log scale on the X-axis, and the water content in arithmetic scale
on the Y-axis plots the flow curve. The flow curve is straight line drawn on this semi-logarithmic plot,
as nearly as possible through three or more plotted points. The moisture content corresponding to 25
blows is read from this curve, rounding off to the nearest whole number and is reported as the liquid
limit (LL or wl) of the soil.
The slope of the straight-line flow curve is the flow index. It may be calculated from the following
formula:
Flow Index (If) = (w1 – w2)/(log n2 – log n1)
= (w10 – w100)/(log 100 – log 10)
Where, w10 = water content at 10 blows.

w100 = water content at 100 blows.

Liquid limit test: (Cone penetration)
Object:
To determine the liquid limit of the soil by cone penetration

apparatus.
Apparatus:
i) Cone penetration apparatus confirming to IS: 11196-1985
(cone angle 300+/-0.50) and weight of assemble is 80 +/-
0.5 g including all), ii) Balance of 200 g capacity and
sensitive to 0.01 g, iii) Oven to maintain 1050 to 1100C.
Procedure:
About 150 g of dry pulverized soil sample passing 425

micron IS sieve is weighed, and mixed thoroughly with
distilled water in the evaporating dish to form a uniform
thick paste. The soil paste shall then be transferred to the
cylindrical mould of the cone penetrometer apparatus and
leveled up to the top of the cup. The penetrometer shall be so adjusted that the cone point just
touches the surface of the soil paste in the trough. The scale of the penetrometer shall then be
adjusted to zero and the vertical rod released so that the cone is allowed to penetrate into the soil
paste under its weight. The weight should be 80 +/- 0.5 g and the penetration shall be noted after 5
seconds from the release of the cone.
If the difference in penetration lies between 14 and 28 mm the test is repeated with suitable
adjustments to moisture either by addition of more water or exposure of the spread paste on a glass
plate for reduction in moisture content. The test shall be repeated at least to have four sets of values
of penetration in the range 14 and 28 mm. The exact moisture content of each trial shall be
determined.
Calculations:
A graph representing water content on the Y-axis and the cone penetration value on the X-axis shall
be prepared. The best fitting straight line is then drawn. The moisture content corresponding to cone
penetration of 20 mm shall be taken as the liquid limit of the soil and shall be expressed to the
nearest first decimal place.

Liquid Limit Graph (Mechanical Device Method):
26
25 WL
WATER CONTENT
24
23
22
21
20
10 20 25 30 40 50 60 70 80 90 100
NO OF BLOWS
Liquid Limit Graph (Cone Penetration Method):
26
25
WATER CONTENT
24
23
22 WL
21
20
10 20 30 40 50 60 70 80 90 100
DEPTH F PENETRAION (mm)

Plastic limit test:
Object:
Determination of the plastic limit of the soils.
Apparatus: Evaporating dish, spatula, glass plate, moisture containers, rod of 3 mm diameter,
balance sensitive to 0.01 g and oven controlled at temperature 1050 to 1100C.
Procedure:
About 20 g of dry pulverized soil passing 425 micron IS
sieve is weighed. The soil is mixed thoroughly with distilled
water in the evaporating dish till the soil paste is plastic
enough to be easily moulded with fingers. A small ball is
formed with the fingers and this is rolled between the
fingers and the glass plate to a thread. The pressure just
sufficient to roll into a thread of uniform diameter should
be used. The rate of rolling should be between 80 to 90
strokes per minute counting a stroke as one complete
motion of hand forward and back to the starting position
again. The rolling is done till the diameter of the thread is 3
mm. Then the soil is kneaded together to a ball and rolled
again to form thread. This process of alternate rolling and
kneading is continued until the thread crumbles under
pressure required for rolling and the soil can no longer be
rolled into a thread.
If the crumbling starts at diameter less than 3 mm, then moisture content is more than plastic limit
and if the diameter is greater while crumbling starts, the moisture content is lower. By trial, the
thread that starts crumbling at 3 mm diameter under normal rolling should be obtained and this
should be immediately transferred to the moisture container, lid placed over it and weighed. The
container is kept in the oven for about a day and dry weight found to determine the moisture content
of the thread. The above process is repeated to get at least three consistent values of the plastic limit
(PL or wp).
Calculations:
Plasticity Index (PI or Ip) = Liquid limit – Plastic limit.
= LL - PL
= wl - wp
Toughness Index (TI or IT) = Ip / If
Liquidity Index ( LI or Il) = (w – wp) / Ip where, ‘w’ is the natural moisture
content of the soil.
Consistency Index (CI or Io) = (wp – w) / Ip

TEST : DETERMINATION OF LIQUID AND PLASTICITY INDEX OF SOILS

( IS : 2720 (PART - 5)
Embankment 2 Tests / Embankment

3 LL ≤ 50 % & PI ≤ 25 %
Subgrade 3000m Subgrade
1Test / Granular Sub
Granular Sub Base 3 LL ≤ 25% & PI ≤ 6%
400m Base
S.No LIQUID LIMIT PLASTIC LIMIT

a Determination Number 1 2 3 4 5 6
B Number of Blows
c Container Number
D Container + Wet Soil - gms.
e Container + Dry Soil - gms.
F Moisture Loss ( d - e ) - gms.
G Container Weight - gms.
H Dry Soil Weight ( e - g ) - gms.
I Moisture Content ( f /h ) X 100
Average(%)
Test Obtained Limits
Liquid Limit
Plastic Limit
Plasticity
Index
Remarks :_____________________________________________________________________________________

8. COMPACTION TEST.
(IS: 2720 – PART – 7 & 8)
INTRODUCTION:
Compaction of soil is mechanical processes by which the soils particles are constrain to be packed
more closely together by reducing the air voids. Soil compaction causes decrease in air voids and
consequently an increase in dry density. This may result in increase in shearing strength. The
possibility of future settlement or compressibility decreases and also the tendency for subsequent
changes in moisture content decreases. Degree of compaction is usually measured quantitatively by
dry density.
Increase in dry density of soil due to compaction mainly depends on two factors – (i) the compacting
moisture content and (ii) the amount of compaction. For practically all soils it is found that with
increase in the compaction moisture content, the dry density first increases and then decreases if
compacted by any method. This indicates that under a given compactive effort every soil has optimum
moisture content (OMC) at which the soil attains maximum dry density (MDD). R.R.Proctor first
recorded this fact in 1933.
The compaction test is divided into two parts (i) light compaction (IS: 2720 – Part - 7) and (ii) heavy
compaction (IS: 2720 – Part – 8).
Object:
To determine the compaction test by light / heavy compaction test method.
Apparatus:
a) Cylindrical mould of capacity 1000 cc, with an internal
diameter of 10cm and height 12.73 cm or a mould of capacity
2250 cc, with an internal diameter of 15 cm and height of 12.73
cm. The mould is fitted with a detachable base plate and
removable collar or extension of about 6 cm high.
b) For light compaction, a metal rammer having 5 cm diameter

circular face, and weight 2.6 kg is used which has a free drop of
31 cm.
For heavy compaction, the rammer has 5 cm diameter circular

face, but having weight 4.89 kg and free drop of 45 cm.
c) Steel straight edge having be leveled edge for trimming the top
of the specimen.

d) Other accessories include moisture containers, balances of capacity 10 kg and 200 g , oven, sieves
and mixing tools.
Procedure:
Preparation of samples:
For light compaction, about 20 kg of the representative

soil is air-dried, mixed pulverized and sieved through 19
mm IS sieve. The fraction retained on 19 mm sieve is
not used in this test. If there is note worthy proportion
of materials retained on 19 mm sieve, allowance for
larger size materials is made by replacing it by an equal
weight of material passing 19 mm sieve and retained on
4.75 mm sieve.
For heavy compaction, about 45 kg of the representative

soil is air-dried, mixed pulverized and sieved through
37.5 mm IS sieve. The fraction retained on 37.5 mm is
not used in this test. If there is note worthy proportion
of materials retained on 37.5 mm sieve, allowance for large size materials is made by replacing it by
an equal weight of material passing 37.5 mm and retained on 4.75 mm sieve.
For compacting the soil in the mould every time the required quantity will depend on the soil type,
size of the mould, moisture content and amount of compaction. As a rough guidance, for each test
2.5 kg of soil may be taken for light compaction and 5.8 kg for heavy compaction. The estimated
weight of water to be added to the soil every time may be measured with a graduated jar in cc.
Enough water is added to the specimen to bring the moisture content to about 7% less than the
estimated OMC for sandy soils and 10% less for clayey soils. The processed soil is stored in an airtight
container for about 18 to 20 hours to enable moisture to spread uniformly in the soil mass.
The mould with base plate fitted in is weighed. The process soil-water mixture is mixed thoroughly
and divided into eight equal parts.
(i) For light compaction the wet soils is compacted into the mould in three equal layers, each layer
being given 25 blows of the 2.6 kg hammer, if 10 cm diameter mould is used. When the 15 cm
diameter mould is used, 56 blows are given to each of the three layers by the 2.6 kg hammer.
(ii) For heavy compaction, the wet soil mix is compacted in the mould in five layers each layer being
given 25 blows of 4.89 kg hammer when the 10 cm diameter of mould is used. When the 15 cm
diameter mould is used, 56 blows are given to each of the five layers by 4.89 kg hammer.

The blows should be uniformly distributed over the surface of each layer. Each layer of the compacted
soil is scored with a spatula before placing the soil for the succeeding layer. The amount of soil used
should be just sufficient to fill the mould leaving about 5mm to be struck off on the top after
compacting the final layer.
The collar is removed and the compacted soil is leveled off to the top of the mould by means of the
straight edge. The mould and the soil is then weighed. The soil is then ejected out of the mould and
cut in the middle and a representative sample is taken in airtight container from the cut surface. The
moisture content of this representative specimen is determined by finding the wet weight, keeping in
the oven at 1050 to 1100C and finding the dry weight the next day.
This procedure is repeated five to six times using fresh part of the soil specimen and after adding a
higher water content than the preceding specimen every time so that the last compaction is carried
out at moisture 7 to 10 percent higher than estimated optimum moisture content.
Calculations:
Let the weight of mould with moist compacted soil = Wg
Weight of empty mould = Wm g
Volume of the mould = Vm cc
Moisture content = w%
Specific gravity of the soil = G
Wet density, Ƴm = (W – Wm)/Vm, g/cc
Then dry density, Ƴd = Ƴm/(1 + w/100) = (W – Wm)/[Vm(1 + w/100)], g/cc
Porosity, n = 100 x (Vv/V), % = (1 – Ƴd/GƳw) x 100, %
Voids ratio, e = (GƳw/Ƴd – 1)
Results:
Points are plotted with moisture content on the X-axis and dry density on the Y-axis and a smooth
curve is drawn connecting the points. From this curve, the maximum dry density (MDD) is noted and
the corresponding value of moisture content taken as optimum moisture content (OMC) of the soil.

MDD & OMC Graph.
1.93
1.91
1.87
MDD
1.85
1.83
DRY DENSITY
1.81
1.79
1.77
1.75
1.73
OMC
5
6 7 8 9 10 11 12 13 14 15 16
WATER CONTENT

TEST : MOISTURE - DENSITY RELATIONSHIP OF SOILS

( IS : 2720 PART - 7/8 - *LIGHT / *HEAVY COMPACTION)

Embankment up to 3m
Embankment Min. 1.52 g/cc
3 height
2 Tests / 3000m
Embankment more than
Subgrade Min. 1.60 g/cc
3m height
3
Granular Sub Base 1Test / 3000m Sub Grade Min. 1.75 g/cc

Location :Km______________
S.No. Test No. 1 2 3 4 5 6
Water Added. (ml)
a Weight of Mould + Sample. (gms)
b Weight of Mould. (gms)
c Weight of Sampl (a) - (b) (gms)
d Volume of Mould (cc)
e Wet Density = ( c ) / d (gms/cc)
* * Tare No.
f Weight of Tare + Wet Sample (gms)
g Weight of Tare + Dry Sample (gms)
h Weight of Water = (f) - (g) (gms)
I Weight of Tare* * (gms)
j Weight of Dry Sample = (g) - (I) (gms)
k Moisture Content = (h) / (j) x 100 (%)
l Dry Density = (e) / ( 1 + k/100) (gms/cc)
Light /
Method used
Heavy
1000 /
Volume ( cc )
2250
2.6 /
Rammer Wt.
4.9 Kg
No. of Layers 3 / 5
Blows / Layer 25 / 56
Max.Dry Density
(gms/cc)
O.M.C ( % )
Remarks :_____________________________________________________________________________________

9. FIELD DENSITY TEST BY SAND REPLACEMENT METHOD.

(IS: 2720 – PART – 28)
INTRODUCTION:
The dry density of the compacted soil or pavement material is a common measure of the amount of
the compaction achieved during the construction. Knowing the field density and field moisture
content, the dry density is calculated. Therefore field density test is importance as a field control test
for the compaction of soil or any other pavement layer.
There are several methods for the determination of field density of soils such as core cutter method,
sand replacement method, rubber balloon method, heavy oil method etc. One of the common
methods of determining field density of fine-grained soils is core cutter method; but this method has a
major limitation in the case of soils containing coarse-grained particles such as gravel, stones and
aggregates. Under such circumstances, field density test by sand replacement method is
advantageous, as the presence of coarse-grained particles will adversely affect the test results.
The basic principle of sand replacement method is to measure the in-situ volume of hole from which
the material was excavated from the weight of sand with known density filling in the hole. The in-situ
density of material is given by the weight of the excavated material divided by the in-situ volume.
Object:
To determination of field density by sand replacement method.
Apparatus:
a) Sand pouring cylinder equipment:
(i) Small pouring cylinder: suitable for fine and medium
grained soils. This consists of a metal cylinder of capacity 3 liters,
100mm in diameter and 380 mm length with an inverted funnel or
cone at one end and a shutter to open and close the entry of
sand and a cap on the other end. Metal tray to excavate the hole
with suitable shape and size. Calibration container of the small
pouring cylinder (size 100X150mm)
(ii) Large pouring cylinder: suitable for fine, medium and
coarse grained soils. This consists a metal cylinder of capacity
16.5 liters, 200mm in diameter and 610mm length with all
arrangements mentioned above. Calibration container size
200X250mm
(iii) Medium pouring cylinder: suitable for fine, medium and
coarse grained soils. This cylinder with 150mm diameter and
length 450mm. The calibration container size is 150X200mm.
b) Tools for leveling and excavating: Hand tools such as scraper with handle for leveling the
surface; a dibber or an elongated trowel for digging and excavating the material.

c) Containers: Metal containers of any convenient size (about 150mm diameter and 200mm depth)
with removable lid for collecting the excavated material.
d) Sand: Dry and clean test sand of uniform gradation, passing 1.0mm and retained 600-micron
sieve.
e) Balance: A suitable balance of capacity 15 or 30 kg accuracy 1.0 g and necessary set of weights.
Procedure:
The test may be conducted in two stages: (i) calibration of apparatus and (ii) measurement of field
density.
(i) Calibration of apparatus:
The determination of volume of the excavated hole is based on the weight of sand filling the hole and
the cone and the density of the sand. Calibration of apparatus includes (a) determination of density of
test sand used in the experiment under identical height and pouring conditions of the sand into the
test hole and (b) determination of the weight of the sand occupying the cone of the sand-pouring
cylinder.
Clean and dry test sand passing 1.0mm sieve and retained 600-micron sieve is collected in sufficient
quantity required for at least three to four sets of tests. The top cap of the sand-pouring cylinder is
removed, the shutter is closed, the cylinder is filled with dry test sand up to about 10mm from the top
and the cap is replaced. The weight of the cylinder with the sand is determined accurate to one gram
and is recorded = W1. In all the subsequent tests for calibration as well as for the field density tests,
every time the sand is filled into the cylinder such that the initial weight of the cylinder with sand is
exactly W1. The sand pouring cylinder is placed over the calibration cylinder or one of the test holes
already excavated, the shutter is opened and the sand equal to the volume of the calibration cylinder
or the excavated test hole is allowed to flow out and the shutter is closed.
The sand pouring cylinder is now placed on a clean plane surface (glass or Perspex plate), the shutter
is kept open till the sand fills up the cone fully and there is no visible movement of sand as seen from
the top of the cylinder by removing the cap. The shutter is closed, the cylinder is removed and the
sand which occupied the cone is carefully collected from the plate and weighed = W2.
The sand pouring cylinder is refilled with sand such that the initial weight is again W1. Now the
cylinder is placed centrally on the top of the calibration container and the shutter
is opened. When the sand fills up the calibration container and the cone completely and there is no
movement of sand, the shutter is closed and the sand pouring cylinder and the remaining sand is
weighed = W3.

The above steps are repeated three times and the mean values of W2 and W3 are determined such
that the mean value of the weight of sand required to fill the calibration container up to the level top
can be determined.
The volume of the calibrating container, V is determined either by measuring the internal dimensions
or by filling with water and weighing. From the weight of sand Wa and its volume V in the calibrating
container, the density of sand, is determined.
(ii) Measurement of field density:
The site where the field density test is to be conducted is cleaned and leveled using a scraper for an
area of about 450 mm square. The metal tray central hole is placed on the prepared surface. Using
this central hole as pattern, the soil/material is excavated using a dibber or a trowel up to a required
depth and the loose material removed is carefully collected in the metal container and is weighed =
W. The sand-pouring cylinder is refilled with sand such that its weight is again W1. The metal tray
with central hole is removed and the sand-pouring cylinder is placed centrally over the excavated
hole. The shutter is opened till the sand fills the excavated hole and the cone completely and there is
no further movement of sand in the cylinder. The shutter is closed and the cylinder is weighed again
= W4, so that the weight of sand filling the excavated hole alone = Wb can be found.
The moisture content of the excavated soil, w% is determined by taking a sample of soil from it in a
moisture content dish, weighing, drying in oven at 1100C and re-weighing. Alternatively, the moisture
content (w%) is determined by placing the entire excavated soil collected from the hole (of weight W)
in the oven and finding its dry weight = Wd.
The above steps for the determination of the weights of excavated soil, the weight of the sand filling
the hole and the weights of samples for the moisture content determination are repeated at least
three times and the average values taken for the determination of field density (wet and dry) values.

Calculations and Results:

W1 = weight of sand pouring cylinder and sand filled up to 10mm from top edge, gms
W2 = weight of sand in the cone, mean value, gms
W3 = weight of cylinder and sand after pouring into the calibration container and cone, gms
W4 = weight of cylinder and sand after pouring into the excavated hole and cone, gms
Va = volume of the excavating container, cm3
W = weight of the soil from the excavated hole, gms
Wd = oven dry weight of the soil excavated from the hole, gms
w = moisture content of the soil, %
The weight of sand filling the calibrating container only = Wa = (W1 – W3 – W2), gms
(i) Bulk density of sand, Ƴs = Wa/Va, g/cm3
Weight of sand filling the excavated hole alone = Wb = (W1 – W4 – W2), gms
Volume of sand filling the excavated hole alone = V = Wb/Ƴs , cm3
(ii) In-situ bilk density of the wet excavated soil, Ƴ = W/V , g/cm3
(iii) Moisture content of soil, w% = 100(W – Wd)/Wd, %
(iv) In-situ dry bulk density of the excavated soil, Ƴd = ƳxWd/W = 100Ƴ/(100+W), g/cm3
The results are reported as the average value of at least three sets of tests in the following:
(i) In-place wet density of soil in g/cm3, correct to second decimal place or in kg/m3, correct to
nearest whole number.
(ii) In-place dry density of soil in g/cm3 or in kg/m3 (as above).
(iii) Moisture content of the soil in percent, correct to first decimal place.

10. FIELD DENSITY TEST BY CORE CUTTER METHOD.

(IS: 2720 – PART – 29)
Object:
To determination of field density by Core Cutter Method.
Apparatus:
Cylindrical Core Cutter

a) Steel Dolly
b) Steel Rammer
c) Balance, with an accuracy of 1 gm
d) Straightedge
e) Square metal tray – 300mm x 300mm x 40mm
f) Trowel
Procedure:
1) The internal volume (V) of the core cutter in cc
should be calculated from its dimensions which
should be measured to the nearest 0.25mm.
2) The core cutter should be weighed to the nearest gram (W1).
3) A small area, approximately 30cm square of the soil layer to be tested should be exposed and
levelled. The steel dolly should be placed on top of the cutter and the latter should be rammed
down vertically into the soil layer until only about 15mm of the dolly protrudes above the
surface, care being taken not to rock the cutter. The cutter should then be dug out of the
surrounding soil, care being taken to allow some soil to project from the lower end of the
cutter. The ends of the soil core should then be trimmed flat in level with the ends of the cutter
by means of the straightedge.
4) The cutter containing the soil core should be weighed to the nearest gram (W2).
5) The soil core should be removed from the cutter and a representative sample should be placed
in an air-tight container and its water content (w) determined.
Reporting Results:
Bulk density of the soil ‘Ƴ’ = (W2 – W1)/V - g/cc
Dry Density of the Soil ‘Ƴd’ = (100Ƴ)/(100 + w) – g/cc
Average of at least three determinations should be reported to the second place of decimal in g/cc.

TEST : FIELD COMPACTION TEST BY SAND REPLACEMENT METHOD

( IS : 2720 PART - 28 )

2
Embankment 10Tests/3000m Embankment Min. 95 %
2
Subgrade 10 Tests/2000m Subgrade Min. 97 %
2
Granular Sub Base 1Test /1000m Granular Sub Base Min. 98 %
2
Wet Mix Macadam 3 Tests/1000m Wet Mix Macadam Min. 98 %
Lab Ref No :_________________ Date of Sampling:_________
Type of Material :_________________ Date of Testing:_________
Location :Km______________
Determination of Weight of Sand in Cone

S.No Test No. : 1 2 3
a Intial weight of container and sand, ( gms )
b Final weight of container and sand after filling cone, ( gms )
Weight of sand in cone = (a) - (b), (gms )
c
Average Value, ( gms )
Note : 1. Before test, remove from initially filled container a vplume of sand approximately equal to that
of the
2. Use density plate in each test.
3. Place container with cone on level ground / glass plate.
Determination of Bulk Density of Sand :

S.No Test No. : 1 2 3
c Weight of sand in cone, ( gms )
d Weight of sand before pouring, ( gms )
e Weight of sand after pouring, ( gms )
f Weight of sand in calibration cylinder [ ( d ) - ( c ) - ( e ) ], ( gms )
g Volume of calibration cylinder, ( cc )
h Bulk density of Sand ( f ) / ( g ), ( gms/cc )
Average Value ( gms / cc )
Remarks :___________________________________________________________

TEST : FIELD COMPACTION TEST BY SAND REPLACEMENT METHOD

( IS : 2720 PART - 28 )

2
Embankment 10 Tests/3000m Embankment Min. 95 %
2
Subgrade 10 Tests/2000m Subgrade Min. 97 %
2
Granular Sub Base 1Test / 1000m Granular Sub Base Min. 98 %
2
Wet Mix Macadam 3 Tests/1000m Wet Mix Macadam Min. 98 %
Date
Contract :___________________________________________ :__________
Source _____________________________________________
Location / Layer______________________________________
Sample Description___________________________________
WET DENSITY DETERMINATION
Test No. 1 3 4 5 6
S.No.
Location of Test - Chainage
I Thickness ( cm )
j Wt.of Soil from hole + container (gms)
k Wt.of Container (gms)
L Wt.of Soil from hole = (j) - (k) (gms)
m Wt.of Sand before pouring (gms)
n Wt.of Sand after pouring (gms)
o Wt.of Sand in hole = (m) - ( c ) - (n) (gms)
p Ratio of ( L / o )
q Bulk Density of Sand ( gms/cc )
r Wet Density of Soil ( gms/cc )
DETERMINATION OF MOISTURE
Container No.
s Wt.of Wet Soil + Container (gms)
t Wt.of Dry Soil + Container (gms)
u Wt.of Water = (s) - (t) (gms)
v Weight of Container (gms)
w Wt.of Dry Soil = (t) - (v) (gms)
x Moisture Content = (u)x100/w (%)
Dry Density (gms/cc)
Maximum Dry Density (MDD) (gms/cc)
Optimum Moisture Content (OMC) (%)
Compaction (%)
Required Deg.of Compaction (%)
Remarks :______________________________________________________________________________

11. CALIFORNIA BEARING RATIO TEST.

(IS: 2720 – PART – 16)
INTRODUCTION:
The California Bearing Ratio (CBR) test was developed by the California Division of Highway as a
method of classifying and evaluating soil-sub grade and base course materials for flexible pavements.
The CBR is a measure of resistance of a material to penetration of standard plunger under controlled
density and moisture conditions. The test procedure should be strictly adhered if high degree of
reproducibility is desired. The CBR test may be conducted in re-moulded or undisturbed specimens in
the laboratory. The test has been extensively investigated for field correlation of flexible pavement
thickness requirement.
Briefly, the test consists of causing a cylindrical plunger of 50mm diameter to penetrate a pavement
component material at 1.25mm/minute. The loads, for 2.5mm and 5mm are recorded. This load is
expressed as a percentage of standard load value at a respective deformation level to obtain CBR
value. The standard load values were obtained from the average of a large number of tests on
different crushed stones and are given.
Penetration, mm Standard Load, kg. Unit standard load, kg/cm2

2.5 1370 70
5.0 2055 105
7.5 2630 134
10.0 3180 162
12.5 3600 183
Laboratory CBR test:
Apparatus:
a) Loading Machine: Any compression machine, which can
operate at a constant rate of 1.25mm/minute, can be used. A
metal penetration piston or plunger of diameter 50mm is attached
to the loading machine. b) Cylindrical moulds: Moulds of
150mm diameter and 175mm height provided with a collar of
about 50mm length and detachable perforated base are used for
this purpose. A spacer disc of 148mm diameter and 47.7mm
thickness is used to obtain a specimen of exactly 127.3mm height.
c) Compaction Rammer: The material is usually compacted as
specified for the work, either by dynamic compaction or by static
compaction. The details for dynamic compaction suggested by the
ISI are given.

Type of compaction No.of layers Hammer Wt. Kg Fall, cm No.of blows

Light compaction 3 2.6 31 56
Heavy compaction 5 4.89 45 56
d) Adjustable stem, perforated plate, tripod and dial gauge: The standard procedure requires
that the soil sample before testing should be soaked in water to measure swelling. For this purpose
the above listed accessories are required.
e) Annular weight: In order to simulate the effect of the overlaying pavement weight, annular
weights each of 2.5 kg weight and 147mm diameter are placed on the top of the specimen, both at
the time of soaking and testing the samples, as surcharge.
Procedure:
The CBR test may be performed either on undisturbed soil

specimens obtained by fitting a cutting edge to the mould or
on remoulded specimens. Remoulded soil specimens may be
compacted either by static compaction or by dynamic
compaction. When static compaction is adopted, the batch of
soil is mixed with water to give the required moisture
content; the correct weight of moist soil to obtain the desired
density is placed in the mould and compaction is attained by
pressing in the spacer disc using a compaction machine or
jack. The preparation of soil specimens by dynamic
compaction or ramming is more commonly adopted and is
explained below.
About 45 kg of material is dried and sieved through 19mm

sieve. If there is note worthy proportion of materials retained
on 19mm sieve, allowance for larger size materials is made
by replacing it by an equal weight of material passing 19mm
sieve and retained on 4.75mm sieve. The optimum moisture content and maximum dry density of the
soil are determined by adopting either light compaction or heavy compaction as per the requirement.
Each batch of soil (of at least 5.5 kg weight for granular soil and 4.5 to 5.0 kg weight for fine grained
soils) is mixed with water up to the optimum moisture content or the field moisture content if
specified so. The spacer disc is placed at the bottom of the mould over the base plate and a coarse
filter paper is placed over the spacer disc. The moist soil sample is to be compacted over this in the
mould by adopting either the light compaction or heavy compaction.
(i) For IS light compaction or Proctor compaction the soil to be compacted is divided into three equal
parts; the soil is compacted in three equal layers, each of compacted thickness about 44mm by
applying 56 evenly distributed blows of the 2.6 kg rammer.

(ii) For IS heavy compaction or the modified Proctor compaction, the soil is divided into five equal
parts; the soil is compacted in five equal layers, each of compacted thickness about 26.5mm by
applying 56 evenly distributed blows of the 4.89 kg rammer. After compacting the last layer, the collar
is removed and the excess soil above the top of the mould is evenly trimmed off by means of the
straight edge. It is important to see if the excess soil to be trimmed off while preparing each specimen
is of thickness about 5.0mm; if not the weight of soil taken for compacting each specimen is suitably
adjusted for the repeat tests so that the thickness of the excess layer to be trimmed off is about
5.0mm. Any hole that develops on the surface due to the removal of coarse particles during trimming
may be patched with smaller size material. Three such compacted specimens are prepared for the
CBR test. About 100g of soil samples are collected from the each mould for moisture content
determination, from the trimmed off portion.
The clamps are removed and the mould with the compacted soil is lifted leaving below the perforated
base plate and the spacer disc, which is removed. The mould with the compacted soil is weighed. A
filter paper is placed on the perforated base plate, the mould with compacted soil is inverted and
placed in position over the base plate (such that the top of the soil sample is now placed over the
base plate) and the clamps of the base plate are tightened. Another filter paper is placed on the top
surface of the sample and the perforated plate with adjustable stem is placed over it. Surcharge
weights of 2.5 or 5.0 kg weight are placed over the perforated plate and the whole mould with the
weights is placed in a water tank for soaking such that water can enter the specimen both from the
top and bottom. The swell measuring device consisting of the tripod and the dial gauge are placed on
the top edge of the mould and the spindle of the dial gauge is placed touching the top of the
adjustable stem of the perforated plate. The initial dial gauge reading is recorded and the test set up
is kept undisturbed in the water tank to allow soaking of the soil specimen for four full days or 96
hours. The final dial gauge reading is noted to measure the expansion or swelling of the soil specimen
due to soaking.
The swell measuring assembly is removed, the mould is taken out of the water tank and the sample is
allowed to drain in a vertical position for 15 minutes. The surcharge weights, the perforated plate with
stem and the filter paper are removed. The mould with the soil sample is removed from the base
plate and is weighed again to determine the weight of water absorption.
The mould with the specimen is clamped over the base plate and the same surcharge weights are
placed on the specimen centrally such that the penetration test could be conducted. The mould with
base plate is placed under the penetration plunger of the loading machine. The penetration plunger is
seated at the center of the specimen and is brought in contact with the top surface of the soil sample
by applying a seating load of 4.0 kg. The dial gauge for measuring the penetration values of the
plunger is fitted in position. The dial gauge of the proving ring (for load readings) and the penetration
dial gauge are set to zero. The load is applied through the penetration plunger at a uniform rate of
1.25 mm/min. The load readings are recorded at penetration readings of 0.0, 0.5, 1.0, 1.5, 2.0, 2.5,
3.0, 4.0, 5.0, 7.5, 10.0 and 12.5 mm. In case the load readings start decreasing before 12.5mm
penetration, the maximum load value and the corresponding penetration value are recorded. After the
final reading, the load is released and the mould is removed from the loading machine. The proving
ring calibration factor is noted so that the load dial values can be converted into load in kg. About 50g

of soil is collected from the top three cm depth of the soil sample for the determination of moisture
content.
Calculations:
The swelling or expansion ratio is calculated from the observations during the swelling test using the
formula:
Expansion ratio or swelling = 100 (df – di)/h
Where, df = final dial gauge reading after soaking, mm
di = initial dial gauge reading before soaking, mm
h = initial height of the specimen (127.3 mm), mm
The load values noted for each penetration level are divided by the area of the loading plunger
(19.635cm2) to obtain the pressure or unit load values on the loading plunger. The load-penetration
curve is then plotted in natural scale for each specimen. If the curve is uniformly convex upwards, no
correction is needed. In case there is a reverse curve or the initial portion of the curve is concave
upwards, necessity of a correction is indicated. A tangent is drawn from the steepest point on the
curve to intersect the base at point, which is the corrected origin corresponding to zero penetration.
The unit load values corresponding to 2.5 and 5.0 mm penetration values are found from the graph.
The CBR value is calculated from the formula:
Unit load carried by soil sample at defined penetration level

CBR, % = X 100
Unit load carried by standard crushed stones at above penetration level
Results:
The CBR values at 2.5mm and 5.0mm penetrations are calculated for each specimen from the
corresponding graphs. Generally the CBR value at 2.5mm penetration is higher and this value is
adopted. However if higher CBR value is obtained at 5.0mm penetration, the test is to be repeated to
verify the results; if the value at 5.0mm is again higher, this is adopted as the CBR value of the soil
sample. The average CBR values of three specimens are reported to the first decimal place.

Field CBR Test.
Apparatus:
A reaction load like a truck, tractor or truss is required for

applying the load by means of a mechanical screw jack.
The other equipment needed are 5 cm diameter loading
plunger, extension rods, jacks, proving ring assembly, dial
gauge, datum frame, annular surcharge plate 25 cm in
diameter and 5 kg in weight, with a central hole and slot
width 5.3 cm and two circular slotted weights of 10 kg and
diameter about 25 cm with central hole and slot width of
5.3 cm.
Procedure:
A circular area of about 30 cm in diameter is trimmed and

leveled. Particular care should be taken at the center where
the plunger is to be seated. The surcharge load of 15 kg is
placed on this surface and the plunger is seated properly.
The dial gauge to measure the penetration is attached to
the plunger from an independent datum frame. A seating
load of 4 kg is applied and the load and penetration dials
are set to zero.
The load is applied to the plunger by means of the jack such that the rate of penetration is
approximately 1.25 mm/minute. The load readings are noted for at penetrations 0.0, 0.5, 1.0, 1.5,
2.0, 2.5, 3.0, 4.0, 5.0, 7.5, 10.0 and 12.5 mm. The load is released and moisture content specimen is
taken from underneath the plunger.
Calculations:
The load – penetration curve is plotted, and the CBR value is calculated as in the case of laboratory
CBR.

CBR Graph:
300
280 Spe.1(No Correction)
260
240
220
LOAD (Kg/cm )
2
200
180 Spe.2(Correction Required)
160
140
120
100
80
60
40
20
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PENETRATION (mm)

TEST : CALIFORNIA BEARING RATIO

(IS : 2720 - PART - 16)
3
Embankment 1 Test / 3000m Embankment Min. 2 %
3
Subgrade 1 Test / 3000m Subgrade Min. 6 %
3
Granular Sub Base 1 Test / 3000m Granular Sub Base Min. 30%
Type of
Location :Km______________ Condition of Test : MDD = _______& OMC_______

Soaked/Unsoaked
MOISTURE CONTENT AND UNIT WEIGHT OF TEST SAMPLES
Mould No.
No.of Layers 5 5 5
No.of Blows per Layer
After
Condition of Sample Before Soaking Soaking Before Soaking After Soaking Before Soakiong After Soaking
Wt.of Wet
sample+Mould
Wt.of Mould
Wt.of Wet sample
Volume of Sample
Wet Unit Weight
MOISTURE After
DETERMINATION Before Soaking Before Soaking After Soaking Before Soaking After Soaking
Soaking
Can No.
Wt.of Wet sample+can
Wt.of Dry sample+can
Wt.of Water
Wt.of Can
Wt.of Dry Sample
% Moisture Content
Avg.Moisture Content
Dry Unit Weight
SWELL DATA
Speciman 1 Speciman 2 Speciman 3
Elapsed Time
In.RDG Fi.RDG swell % swell In.RDG Fi.RDG swell %swell In.RDG Fi.RDG swell %swell

CBR DATA
Time Elapsed Std. Speciman 1 Speciman 2 Speciman 3
in mins. Load Pr.Ring Force Corr. CBR Pr.Ring Force Corr. CBR Pr.Ring Force Corr. CBR
KGF
RDG Kg. Force % RDG Kg. Force % RDG Kg. Force %
0
0.5
1
1.5
2
2.5 1370
3
4
5 2055
7.5
10
Remarks:______________________________________________________________________

11. SHEAR TEST BY TRIAXIAL METHOD.

(IS: 2720 – PART – 12)
INTRODUCTION:
Shear tests are generally carried out on small soil samples in the laboratory to evaluate the strength
properties of the element in the soil mass. The strength parameters, namely the cohesion and angle
of shearing resistance are usually found from these tests. The two methods of shear tests commonly
used are the direct shear test and the triaxial test.
Apparatus:
The triaxial machine consists of a pressure cell assembly and equipment for loading and measuring
the load and deformation.
Triaxial pressure cell: Cylindrical soil specimen inserted in a thin rubber membrane and kept sealed
to prevent the entry of lateral fluid, can be placed in position in the cell. There is provision to apply
radial fluid pressure and vertical stress through a piston. There is also facility to allow or prevent
drainage of specimen during the application stresses. A pressure gauge may be used to measure the
fluid pressure in the cell.
Loading equipment: Usually strain controlled equipment is used; stress controlled equipment is also
used in some tests. A proving ring assembly may measure the vertical load applied on the piston. A
dial gauge attached to the piston measures the deformation of specimen.

Procedure:
Preparation of specimen: Either undisturbed or

remoulded specimens may be prepared as desired. Larger
size of undisturbed soil sample may be taken and trimmed
to desired size. But undisturbed soil sample can be
prepared only from soils having sufficient cohesion.
Remoulded samples of cohesive soils may be prepared
either by compacting first in large mould and by pressing
hollow cutters or in constant volume moulds. Special care
is needed while preparing specimens of cohesion less soil,
in special mould after placing the membrane in proper
position. The cylindrical specimens usually have height to
diameter ratio equal to two; this ratio does not however
exceed 2.5.
Test type: Three types of triaxial tests may be performed

in partially or fully saturated specimens. These are (i)
undrained or quick test, (ii) consolidated – undrained test
and (iii) drained or slow test.
In the undrained or quick test the out let valve is closed and no drainage is allowed from the
specimen during the test, from the time of application of lateral pressure ơ3 till the specimen fails
under gradually increasing vertical load. In the consolidated undrained test, the drainage valve is kept
open and the specimen is allowed to fully consolidate under the applied lateral pressure ơ3; but no
further drainage is allowed during the application of the vertical load, till failure.
In the drained or slow test the drainage is allowed during all stages of testing. First the specimen is
allowed to fully consolidate under the applied lateral pressure ơ3 and later the vertical load is also
applied in such a way that there is enough time for the drainage of pore water pressure developed
from time to time.
There are two methods of applying the lateral or confining pressure. Usually the lateral pressure ơ3 is
maintained constant throughout the test. But in some studies the volume of the specimen is
maintained constant by adjusting the lateral pressure.
Procedure: The specimen enveloped properly in the membrane is kept in the triaxial cell and a
desired lateral pressure ơ3 is applied. Then the vertical load is increased till the specimen fails noting
the vertical deformation and load readings at desired intervals. The experiment is repeated for various
other values of lateral pressure. To find the values of cohesion and angle of internal friction, tests
should be carried out with at least two or three different lateral pressure values. Soils may be tested
with lateral pressures of 0, 0.75 and 1.5 kg/cm2.

Calculations: The triaxial test specimen is subjected to the all round pressure equal to the lateral
pressure ơ3 and the applied vertical stress or deviator stress ơd such that the total vertical stress ơ1 =
ơd+ơ3. Mohr stress circles are plotted at normal stress intercepts ơ3 and ơ1 or with diameters equal to
deviator stresses. Mohr rupture envelope is then obtained by drawing a tangent to the circles. The
intercept of this line with Y-axis represents the cohesion (C) and the inclination with X-axis represents
the angle of internal friction (ɸ) of the soil.
Correction for area of cross section: It is necessary to correct the deviator stress values for the
increased area of cross section due to loading. Assuming that the volume of specimen remains
constant and the area of cross section of the specimen increases uniformly, the corrected value of
deviator stress d is calculated from the relation:
ơd = P1/A0 x (1 – ∆/l0)
Where, P1 = applied load.
A0 = original area of cross section.
∆ = deformation of specimen.
l0 = original length of specimen.
The shearing resistance is found the following equation:
S = C + ơ tanɸ
Mohr’s Envelope from Triaxial Test.

SHEAR STRESS
σ3 σd
σ1 NORMAL STRESS

TRIAXIAL SHEAR TEST

(IS: 2720 Part -12 : 1986)
Sample No:_______________ Sample Location :___________ Date of Sampling:___________

Type of Material:___________ Grid Reference:____________ Date of Testing: ____________
ɸ value required:____________ Proving Ring Constant:_______
Method of Test:____________
Preparation of Test Specimen:
OMC (%(from Modified Proctors test):__________ Wt.of wet sample Required(grms)Ƴd x90x(1+w/100):_______________
MDD(g/cc)(from Modified Proctor test):_________ Wt.of dry sample required in case of UU test(grms):________________
Wt. of dry sample taken (grms): 200
Required Max.dry density Ƴd(g/cc):____________
(95% of MDD)
Volume of water added (ml):____________
Volume of the mould/specimen: 82.83 cc
(H=75mm, D=37.5mm) :
Cross sectional Area - A (cm2): 11.04 Rate of strain: 0.125 mm/min.
Original Length of Specimen (l0): 37.5

Test Observations:
Normal Stress / Lateral Pressure (σ3) Normal Stress / Lateral Pressure (σ3) Normal Stress / Lateral Pressure (σ3)
(Kg/cm2 )=1 (Kg/cm2 )=1.5 (Kg/cm2 )=2
Deformation
of
S.No Vertical/Deviator
Specimen
δ (mm) Load Corr.Deviator Shear Load from Shear Load from
from Proving Ring Proving Ring Corr.Deviator Stress Proving Ring Corr.Deviator Stress
Stress
(P) (σd) = P/A(1 - δ/l0) (σd) = P/A(1 - δ/l0)
(σd) = P/A(1 - δ/l0)
Kg/cm2 Kg/cm2
Kg/cm2
Divisions Kg Divisions Kg Divisions Kg
1 0.0
2 0.2
3 0.4
4 0.6
5 0.8
6 1.0
7 1.2
8 1.4
9 1.6
10 1.8
Normal Stress (σ3) Results:
S.No Vertical / Deviator Stress (σd) (Kg/cm2)
(Kg/cm2)
1 1.00 Angle of Internal Friction (ɸ) in degrees from
2 1.50 the Graph
3 2.00 Cohesion (C)
Remarks:______________________________________________________________________________________

Toatl
Normal
Deviator
Stress
Stress (σ1)=
(σ3)
(σ3+σd)
0
Angle of Internal Friction (ɸ) in degrees
1
1.5
Cohesion ( C)
2

13. SHEAR TEST BY DIRECT SHEAR METHOD (SHEAR BOX).

(IS: 2720 – PART – 13 – 1986)
Object:
To determine the shearing strength of the soil using the direct shear apparatus.
Need and Scope: In many engineering problems such as design of foundation, retaining walls, slab
bridges, pipes, sheet piling, the value of the angle of internal friction and cohesion of the soil involved
are required for the design. Direct shear test is used to predict these parameters quickly. The
laboratory report cover the laboratory procedures for determining these values for cohesionless soils.
Apparatus:
1) Direct shear box apparatus. 2) Loading frame
(motor attached). 3) Dial gauge. 4) Proving ring. 5)
Tamper. 6) Straight edge. 7) Balance to weigh upto
200 mg. 8) Aluminum container. 9) Spatula.
Procedure:
1. Check the inner dimension of the soil container.
2. Put the parts of the soil container together.
3. Calculate the volume of the container. Weigh the
container.
4. Place the soil in smooth layers (approximately 10
mm thick). If a dense sample is desired tamp the
soil.
5. Weigh the soil container, the difference of these
two is the weight of the soil. Calculate the density of
the soil.
6. Make the surface of the soil plane.
7. Put the upper grating on stone and loading block
on top of soil.
8. Measure the thickness of soil specimen.
9. Apply the desired normal load.
10.Remove the shear pin.
11. Attach the dial gauge which measures the
change of volume.
12. Record the initial reading of the dial gauge and calibration values.
13. Before proceeding to test check all adjustments to see that there is no connection between two
parts except sand/soil.
14. Start the motor. Take the reading of the shear force and record the reading.
15.Take volume change readings till failure.
16. Add 5 kg normal stress 0.5 kg/cm2 and continue the experiment till failure.
17. Record carefully all the readings. Set the dial gauges zero, before starting the experiment.

General Remarks:
1. In the shear box test, the specimen is not failing along its weakest plane but along a
predetermined or induced failure plane i.e. horizontal plane separating the two halves of the shear
box. This is the main draw back of this test. Moreover, during loading, the state of stress cannot
be evaluated. It can be evaluated only at failure condition i.e Mohr’s circle can be drawn at the
failure condition only. Also failure is progressive.
2. Direct shear test is simple and faster to operate. As thinner specimens are used in shear box, they
facilitate drainage of pore water from a saturated sample in less time. This test is also useful to
study friction between two materials, one material in lower half of box and another material in the
upper half of box.
3. The angle of shearing resistance of sands depends on state of compaction, coarseness of grains,
particle shape and roughness of grain surface and grading. It varies between 28o(uniformly
graded sands with round grains in very loose state) to 46o(well graded sand with angular grains in
dense state).
4. The volume change in sandy soil is a complex phenomenon depending on gradation, particle
shape, state and type of packing, orientation of principal planes, principal stress ratio, stress
history, magnitude of minor principal stress, type of apparatus, test procedure, method of
preparing specimen etc. In general loose sands expand and dense sands contract in volume on
shearing. There is a void ratio at which either expansion contraction in volume takes place. This
void ratio is called critical void ratio. Expansion or contraction can be inferred from the movement
of vertical dial gauge during shearing.
5. The friction between sand particle is due to sliding and rolling friction and interlocking action.
The ultimate values of shear parameter for both loose sand and dense sand approximately attain the
same value so, if angle of friction value is calculated at ultimate stage, slight disturbance in density
during sampling and preparation of test specimens will not have much effect.
Calculations: Draw the values on graph, Normal Stress on X – axis and Shear Stress on Y – axis.
The intercept of this line with Y-axis represents the cohesion (C) and the inclination with X-axis
represents the angle of internal friction (ɸ) of the soil.

DIRECT SHEAR TEST

(IS: 2720 Part -13-1986)
Sample No:____________ Sample Location:__ Date of Sampling:_____
Grid Reference:___ Date of Testing:______
Type of Material:_________
Preparation of Test Specimen: ɸ value required:
OMC (%(from Modified Proctors test):_____________ Wt.of wet sample Required(grms)Ƴdx90x(1+w/100):____
MDD(g/cc)(from Modified Proctor test):____________ Wt.of dry sample required in case of UU test(grms):_______
Required Max.dry density Ƴd(g/cc) (95% of MDD):____ Wt. of dry sample taken (grms): 200 gms
Volume of the mould / specimen (6x6x2.5): 90cc Volume of water added (ml):___________
2
Cross sectional Area - A (cm ): 36 Rate of strain: 0.125 mm/min.:___________
Test
Observations:
Normal Stress (Kg/cm2)= 0.5 Normal Stress (Kg/cm2)= 1.0 Normal Stress (Kg/cm2)= 1.5
Corrected
Horizontal
Area = Shear Load from Shear Load from Shear Load from
S.No Displacement Shear Shear Shear
A(1-δ/30) Proving Ring Proving Ring Proving Ring
δ (mm) Stress Stress Stress
cm2
Divisions Kg Kg/cm2 Divisions Kg Kg/cm2 Divisions Kg Kg/cm2
1 0.0 36.00
2 0.2 35.76
3 0.4 35.52
4 0.6 35.28
5 0.8 35.04
6 1.0 34.80
7 1.2 34.56
8 1.4 34.32
9 1.6 34.08
10 1.8 33.84
11 2.0 33.60
12 2.2 33.36
13 2.4 33.12
14 2.6 32.88
15 2.8 32.64
S.No Max.Normal Stress (Kg/cm2) Max.Shear Stress (Kg/cm2) Results:
1 1.50
Angle of Internal Friction (ɸ) in
2 2.00
degrees from the Graph
3 2.50
Remarks:_______________________________________________________________________________________

Normal Shear
Stress Stress
0.5
1.0 Angle of Internal Friction (φ) in degrees = Inverse Tan(m)
1.5

14. UNCONFINED COMPRESSIVE STRENGTH OF COHESIVE SOIL.

(IS: 2720 – Part – 10)
INTURDUCTION:
Unconfined compressive strength is the load per unit area at which an unconfined cylindrical specimen
of cohesive soil will fail in a simple compression test.
Object:
Determination of unconfined compressive strength.
Apparatus: a) Compression Device, b) Sample Ejector, c) Test sample mould (Circular cross sectionv
with diameter of 38mm and height 75mm), d) Deformation Dial Gauge (0.01mm sensitivity), e)
Vernier Calipers, f) Timer
Preparation of test Specimen:
The specimen size for the test shall have a minimum diameter of 38mm and the height 75mm. The
soil specimen to be used for test may be undisturbed, compacted or remolded.
a) Undisturbed Specimens: Undisturbed specimen shall be prepared from large undisturbed

samples by means of sample ejector without loosing the moisture. The specimen shall be handled
carefully to prevent disturbance, change in cross section or loss of water. The specimen shall be
uniform circular cross section with ends perpendicular to the long axis of the specimen.
b) Remolded Specimens: The specimen may be prepared either from a failed undisturbed
specimen or from a disturbed soil samples. In case of failed undisturbed specimen, the material shall
be wrapped in a thin rubber membrane and thoroughly worked with the fingers to assure complete
remolding. Care shall be taken to avoid entrapped air to obtain a uniform density, to remold to the
same void ratio as that of the undisturbed specimen, and to preserve the natural water content of the
soil.

c) Compacted Specimens: when compacting disturbed material, it shall be done using a test
sample mould. Compacted specimen may be prepared at any predetermined water content and
density.
Procedure:
The initial length, diameter and weight of the specimen shall be measured and the specimen placed
on the bottom plate of the loading device. The upper plate shall be adjusted to make contact with the
specimen. The deformation dial gauge shall be adjusted to zero. Force shall be applied so as to
produce axial strain at a rate of 1.25mm per minute. Force and deformation readings shall be
recorded at suitable intervals.

The specimen shall be compressed until failure surfaces have definitely developed or the stress-strain
curve is well past its peak or until an axial strain of 20 percent is reached.
The failure pattern shall be sketched carefully and shown on the data sheet or on the sheet
presenting the stress-strain plot. The angle between the failure surface and the horizontal may be
measured, if possible, and reported.
Calculations:
Stress and strain values shall be calculated as follows:
1. The axial strain, ε shall be determined from the following relationship:
ε = ∆L/L0
Where, ∆L = the change in the specimen length as read from the strain dial indicator
L0 = the initial length of the specimen.
2. The average cross-sectional area, A, at a particular strain shall be determined from the following
relationship:
A = A0 / (1 – ε)
Where, A0 = the initial average cross-sectional area of the specimen.
3. Compressive strength, ơc, shall be determined from the following relationship:
ơc = P/A
Where, P = the compressive force

A = average cross-sectional area.

UNCONFINED COMPRESSIVE STRENGTH

(IS: 4332 Part -5)
Sample No:_____________ Sample Location:________________ Date of Sampling:__________
Type of Material:_________ Grid Reference:_________________ Date of Testing:____________
Method of Test:__________ Proving Ring Constant:______
Preparation of Test Specimen:

Moisture Content(%):________ Wt.of dry sample Required(gms):_________
Wet Desnity (g/cc):_________ Volume of water added (ml):_____________
Dry density Ƴd(g/cc) :________ Rate of strain: 1.25 mm/min.
Volume of the mould/specimen (Ht: 75mm,Dia:37.5mm): 82.83 cc
2
Cross sectional Area - A0 (cm ): 11.04
Test Observations:
Proving Corrected Corrected

Time
S.No Ring value value
elapsed
Reading (N) (Kg) Calculations:
1 30 sec
2 60 sec 1. Intial Length of the Specimen (cm) - L0 : 7.5
3 90 sec 2. Change in length of the Specimen (cm) - ∆L: 0.17
4 120 sec 3. Axial strain - ε = ∆L/L0 : 0.023
2
4. Ave.Cross sectional Area (cm ) - A =
5 150 sec
(A0/1-ε): 11.30
6 180 sec 5. Applied Load (Kg) – P:_______________________
2
7 210 sec 6. Load per unit area (Kg/cm )= σc = P/A:___________
8 240 sec
9 270 sec
Safe Bearing Capacity of the Soil (SBC) -
10 300 sec 2
Kg/cm
Remarks:_______________________________________________________________________________________

15. PERMEABILITY TEST.

(IS: 2720 – Part –17)
INTURDUCTION:
Permeability is a measure of the ease in which water can flow through a soil volume. It is one of the
most important geotechnical parameters. However, it is probably the most difficult parameter to
determine. In large part, it controls the strength and deformation behavior of soils. It directly affects
the following:
1. Quantity of water that will flow toward an excavation
2. Design of cutoffs beneath dams on permeable foundations
3. Design of the clay layer for a landfill liner.
For fine grained soil Falling head permeability test is done, whereas constant head permeability test is
done for the coarse grained soil.
Object: Determination of soil permeability for following applications:

1. Estimation of quantity of underground seepage water under various hydraulic conditions.
2. Quantification of water during pumping for underground construction.
3. Stability analysis of slopes, earth dams, and earth retaining structures.
4. Design of landfill liner.
Apparatus: a) Equipment Combination Permeability meter assembly, b) Stop watch, c) Graduated

cylinder (250 or 500 ml), d) Balance sensitive to 0.01 g, e) Moisture cans, f) Drying oven and
g) Thermometer.
Constant Head Apparatus Falling Head Apparatus

Preparation of test Specimen: Mix sufficient water into the sample to prevent segregation of
particle sizes during placement into the Permeability meter. Enough water should be added to allow
the mixture to flow freely, forming layers.
Constant Head Permeability test
Procedure: The following steps are to be done:

a) Remove both the chamber cap and upper chamber from the unit by unscrewing the three
knurled cap nuts and lifting them off the tie rods.
b) Position one porous stone on the inner support ring in the base of the chamber.
c) Using a scoop or funnel, pour the prepared specimen into the lower chamber, using a circular
motion to fill the lower chamber to a depth of 1.5 cm. A uniform layer should be formed.
d) Use an appropriate tamping device to compact the layer of soil to the desired density. Repeat
the compacting procedure until the sample is within 2 cm of the top of the lower chamber
section.
e) Replace the upper chamber section, placing the rubber gasket between the chamber sections.
Be careful not to disturb the test specimen. Continue the sample placement operation until the
level of compacted material is about 2 cm below the rim of the upper chamber. Carefully level
the surface of the specimen and place the upper porous stone on it.
f) Place the compression spring on the porous stone. Replace the chamber cap and sealing
gasket, securing it firmly with the cap nuts. The spring will restrict upward sample movement.
g) Measure and record the sample length.
h) Assemble the constant head funnel, rod and meter stick. Use the rod clamp the funnel's lower
portion.
i) Adjust the level of the funnel to allow the constant water level in it to remain a few inches
above the top of the specimen.
j) Connect the flexible tube from the tail of the funnel to the bottom outlet of the Permeability
meter. Keep the valves on top of the Permeability meter open.
k) Place a receiver at the top outlet to collect any water that may come out.
l) If preferred, a piece of tubing may be connected to the outlet, leading the water to a sink.
m) Open the bottom outlet valve and allow water to flow into the permeability meter.
n) As soon as water begins to flow out of the top control (deairing) valve, close the control valve,
letting the water flow out the outlet for a time.
o) Close the bottom outlet valve and disconnect the flexible tubing at the bottom. Connect the
constant head funnel to the top side port.
p) Open the bottom outlet valve and raise the constant level head (funnel) to a convenient height
to get a reasonable steady flow of water.
q) Accurately measure the vertical distance between the funnel overflow level and the chamber
outflow level.
r) Measure and record the length of the specimen, L.
s) Allow adequate time for the flow pattern and/or specimen to stabilize.
t) After equilibrium flow has been established, measure the time taken to have specified volume
of water flowing out. Use a measuring cylinder and a stop watch. Repeat three or more times,
calculating the average time.

Calculations: Coefficient of permeability (k) shall be calculated by use following equation:
k = VL/Aht
Where, k = Coefficient of permeability

V = Collected volume of water
L = Length of soil column (13.25 cm)
A = Area of the soil column (31.65 cm2 )
h = Head difference (34.3 cm)
t = Time required to get ‘V’ volume
Falling Head Permeability test
Procedure:
The following steps are to be done:

a) Compact the sample in the lower chamber section of the Permeability meter, in layers
approximately 1.5 cm deep, to within about 2 cm of the lower chamber rim. Use an
appropriate tamping device to compact the sample to the desired density.
b) Remove the upper section of the chamber tie rods and place the upper porous stone on the
specimen, securing the upper section of the chamber with spring to the unit.
c) Measure and record the length of the specimen.
d) Use the clamp to attach the falling head burette to the support rod. Position the burette as
high as is possible for practicality. Place the meter stick directly behind the burette, so the
height of water in the burette above the chamber outflow port may be read.
e) Saturate the specimen, following the steps outlined above.
f) Measure the heights of the two levels from the outflow level.
g) After a stable flow has been established, note the drop in head (∆h) in 2 hours. (use a stop
watch).
Calculations: Coefficient of permeability (k) shall be calculated by use following equation:
k = (aL/At)xIn(h0/h1)
Where, k = Coefficient of permeability

a = Area of the burette (1.695 cm2 )
L = Length of soil column (13.25 cm)
A = Area of the soil column (31.65 cm2 )
h0 = Initial height of water (56 cm)
h1 = Final height of water = (h0 – ∆h)
t = Time required to get head drop of ∆h

Temperature Correction
k200C = kT0C (ɳT0C/ɳ200C)
Where, kT0C = measured permeability at the actual water temperature in the lab
k200C = permeability at the standard temperature of 200C.
Table 1: Correction Factors for Water Temperature

Test Water Temperature, T0C ɳT0C/ɳ200C
15 1.135
16 1.106
17 1.077
18 1.051
19 1.025
20 1.000
21 0.976
22 0.953
23 0.931
24 0.910
25 0.889
26 0.869
27 0.850
28 0.832
29 0.814
Table 2: Typical permeability coefficients for different Soils

Type of Soil Typical Permeability,
k (cm/sec)
Gravel and Coarse Sands > 10-1
Fine Sands 10-1 to 10-3
Silty Sands 10-3 to 10-5
Silts 10-5 to 10-7
Clay < 10-7

HYDRAULIC CONDUCTIVITY OF SOIL BY CONSTANT HEAD METHOD

(ASTM D2434)
Test Data:
2
Specimen Diameter, D: 6.35 cm Specimen Area, A: 31.65 cm
Specimen Length, L:_________ Volume of Soil, V:_____________
Dry Mass of Soil, Ms :________ Specific Gravity of Soil, Gs:____________
Dry Unit Weight, ϒd:_________ Void Ratio, e:___________
Saturation Duration: 48 hrs.
Test Observations:
Head Hydraulic Flow Hydraulic

Time Flow Rate
S.No Difference Gradient Volume Conductivity
(t) (q)
(h) (i) (Q) (k)
Remarks:_______________________________________________________________________________________

HYDRAULIC CONDUCTIVITY OF SOIL BY FALLING HEAD METHOD

(ASTM D2434)
Test Data:
2
Specimen Diameter, D: 6.35 cm Specimen Area, A: 31.65 cm
Specimen Length, L:_________ Volume of Soil, V:_____________
Dry Mass of Soil, Ms :________ Specific Gravity of Soil, Gs:____________
Dry Unit Weight, ϒd:_________ Void Ratio, e:___________
2
Saturation Duration: 48 hrs. Burette Area, a: 1.695cm
Test Observations:
Initial
Initial Head Hydraulic Final Head Time Hydraulic Conductivity
S.No
(H0) Gradient (Ht) (t) (k)
(ii)
Remarks:_______________________________________________________________________________________

16. BEARING CAPACITY OF SOIL BY PLATE LOAD BEARING TEST.

(IS: 1888 – 1982)
INTRODUCTION:
This is the method of conducting the load test on soils and the evaluation of bearing capacities and
settlement from this test. This method assumes that down to the depth of influence of stresses the
soil strata is reasonably uniform. This should be verified by boring or sounding.
Apparatus:
The apparatus consists of bearing plates, loading equipment and instruments to measure the applied
loads and resulting settlement.
a) Bearing plates: Consist of a mild steel 75 cm in diameter and 1.5 to 2.5 cm thickness, and few
other plates of same thickness, but smaller diameters (usually 60, 45, 30 and 22.5 cm dia.) used as
stiffeners.
b) Loading equipment: Consist of a reaction or dead load and a hydraulic jack. The reaction frame
may suitable be loaded to give the needed reaction load on the plate. The load applied may be
measured either by a proving ring and dial gauge assembly or a pressure gauge connected to the
output end of the hydraulic jack.
c) Settlement measurements: May be made by means of three or four dial gauges fixed on the
periphery of the bearing plate from an independent datum frame. The datum frame should be
supported far from the loaded area.
Procedure: The test site is prepared and loose material is removed so that the 75 cm diameter plate
rests horizontally in full contact with the soil sub-grade. If the modulus of sub-grade reaction of
natural ground is needed, the topsoil may be removed up to a depth of about 20 cm before testing.
The plate is seated accurately and then a seating load equivalent to a pressure of 0.07 kg/cm2 (320
kg for 75 cm diameter plate) is applied and released after a few seconds. The settlement dial readings
are now noted corresponding to zero load. A load is applied by means of the jack, sufficient to cause
an average settlement of about 0.25 mm. When there is no perceptible increase in settlement or
when the rate of settlement is less than 0.025 mm per minute (in the case of soils with high moisture
content or in clayey soils) the load dial reading and the settlement dial readings are noted. The

average of the three (or four) settlement dial readings is taken as the average settlement of the plate
corresponding to the applied load.
The load is then increased till the average settlement increase to a further amount of about 0.25 mm,
and the load and average settlement readings are noted as before. The procedure is repeated till the
settlement is about 1.75 mm or more.
Bearing pressure-settlement curve:

Mean Bearing Pressure (Kg/cm2)
0.5
0 0.1 0.2
Mean Settlement (cm)
Calculations: A graph is plotted with the mean settlement versus bearing pressure (load per unit
area) as shown in above. The pressure ‘p’ (kg/cm2) corresponding to a settlement ∆ = 0.125 cm is
obtained from the graph. The modulus of sub grade reaction ‘K’ is calculated from the relation.
K = p/0.125, kg/cm2/cm (or) kg/cm3.

17. STANDARD PENETRATION TEST.

(IS: 2131 - 1981)
INTURDUCTION:
Standard Penetration Test conducted by means of the split spoon, specified in this standard, furnishes
data about resistance of the soils to penetration which can be used to evaluate standard strength
data, such as N values (number of blows per 30cm of penetration using standard split spoon) of the
soil and calculation of bearing capacity of the soils.
Object: This standard specifies a standard procedure for conducting the Standard Penetration Test
(SPT) for soils.
Apparatus: a) Drive Weight Assembly (the drive weight assembly shall consist of a driving head and
a 63.5 kg weight with 75 cm free fall).
b) Split Spoon Sampler
Procedure: The Standard Penetration Tests are carried out at 2.0m interval alternate to the
undisturbed sampling or as dictated by soil strata existing. Before testing, the borehole is cleaned
properly and Split Spoon Sampler is centrally seated in borehole. In case of SPT to be conducted
below water table care is taken that casing position is above the borehole depth. The water level in
borehole is maintained above or at least at the water table.
A standard hammer of 63.5 Kg. is dropped from a height of 75 cms and the no of blows for
penetration of Split Spoon Sampler for 0 - 15, 15 - 30 and 30 - 45 cms are noted. Standard
Penetration Test value N is considered for 15 - 45 cms penetration values. Sample for moisture
content is collected in moisture cans. For non-plastic silts and fine sands N value is corrected for
effective overburden pressure and dilatancy correction is added for tests conducted below water table
Results are recorded.

Disturbed and Undisturbed Samples: Disturbed samples from shell or from Split Spoon Sampler
is collected in polythene bags with proper levels such that we shall get the data of 0.5m interval or
change in strata. Undisturbed samples in 38mm dia Shelby tubes are collected alternate to SPT at
2.0m interval. The sampling tube is connected to the rod by jarring link in case of 38mm dia Shelby
tube or otherwise in case of 75 or 100mm dia tube, 'A' drill rods are connected by suitable adopter
with ball check value. Two or three undisturbed samples are collected at same depth in case of 38mm
dia tube to get sufficient sample for physical property tests. Before lowering the sampler, the bore is
cleaned properly and sampling tube is lightly oiled from inner and outer side. Sampling tube is pushed
into the borehole by pressure hammering as per the soil stiffness. The sampling tube is immediately
waxed after covering with aluminum foil. In case of medium to coarse, non-cohesive, sand samples,
where sampling is unsuccessful, Standard Penetration Test is carried out on cleaning the borehole.
Report: Data obtained in borings shall be recorded in the field and shall include the following:
1) Date of boring, 2) Reference datum, 3) Job identification, 4) Boring number, 5) Sample number,
6) Type of sampler, 7) Drilling method, 8) Sample elevation and recovery ratio, 9) Limits of stratum
10) Water Table information, 11) Soil identification, including condition of samples, 12) Penetration
records, 13) Casing used, 14) Weather data.
The data obtained shall be prepared in a final form as a soil profile to show the nature and extent of
the soil strata over the area under consideration.
Corrections:
1. Due to Overburden: The N value for cohesion less soil shall be corrected for overburden
according to Standard graph (N’).
2. Due to Dilatancy: The value obtained from the graph shall be corrected for dilatancy if the
stratum consists of fine sand and silt below water table for values of N’ greater than 15 as under (N”):
N” = 15 + ½(N’ – 15)

18. SAND EQUIVALENT TEST.

(IS: 2720 – PART – 37)
INTRODUCTION:
This test is intended to serve as a rapid field test to show the relative proportions of fine dust or clay
like material in soils or graded aggregates.
Apparatus:
1) A graduated plastic cylinder, rubber stopper, irrigator tube, weighted foot assembly, and siphon
assembly, all confirming to their respective specifications and dimensions. Fit the siphon assembly to a
4 liters bottle of working calcium chloride solution placed on a shelf 915 +/- 25mm above the work
surface. In lieu of the specified 4liter bottle, a glass or plastic vat having a larger capacity may be
used providing the liquid level of the working solution is maintained between 915 to 1175mm above
the work surface. 2) A 85 ml tinned box approximately 57mm in diameter, with gill style cover and
having a capacity of 85 +/- 5ml. 3) A wide mouth funnel approximately 100mm in diameter at the
mouth. 4) A clock or watch reading in minutes and seconds. 5) A mechanical shaker having a throw of
203.2 +/- 1.02mm and operating at 175 +/- 2 cycles per minute. 6) Stock calcium chloride solution.
7) Working calcium chloride solution
Preparation of Stock/Working Calcium Chloride Solution:
a) Stock Calcium Chloride Solution: Dissolve the 480.4 g of calcium chloride in 2 liters of distilled
water. Cool and filter through ready pleated rapid filtering filter paper. Add 2179 g of glycerin and the
49.7 g of formaldehyde to the filtered solution mix well and dilute to 4 liters.

b) Working Calcium Chloride Solution: Prepare the working calcium chloride solution by diluting
90 ml of the stock calcium chloride solution to 4 liters with water.
Sample preparation:
The sand equivalent test shall be performed on soils or graded aggregate materials passing the
4.75mm sieve. All aggregates of fine-grained soil material shall be pulverized to pass the 4.75mm
sieve, and all fines shall be cleaned from the particles retained on the 4.75mm sieve and included with
the material passing the 4.75mm sieve. Split enough of the original sample to yield slightly more than
85ml tin measures of material passing the 4.75mm sieve. Use extreme care to obtain a truly
representative portion of the original sample.
Procedure:
Siphon 101.6 +/- 2.5ml of working calcium chloride solution into the paste cylinder. Pour the prepared
test sample from the measuring tin into the plastic cylinder using the funnel to avoid spillage. Tap the
bottom of the cylinder sharply on the heel of the hand several times to release air bubbles and to
promote thorough wetting of the sample. Allow the wetted sample to stand undisturbed for 10
minutes. At the end of the 10-minute soaking period, stopper the cylinder, then loosen the material
from the bottom by partially inverting the cylinder and shaking it simultaneously. Hold the cylinder in
a horizontal position and shake it vigorously in a horizontal linear motion from end to end. Shake the
cylinder 90 cycles in approximately 30 seconds using a throw of 229 +/- 25mm. A cycle is defined as
a complete back and front motion. To properly shake the cylinder at this speed, it will be necessary
for the operator to shake with the forearms only, relaxing the body and shoulders.
Allow the cylinder and contents to stand undisturbed to 20 minutes, read the level of the top of the
clay suspension. This is referred to as the ‘clay reading’. After the clay reading has been taken, the
‘sand reading’ shall be obtained by the following method:
When using the weighted foot assembly having the sand indicator on the rod of the assembly, place
the assembly over the cylinder and gently lower the assembly towards the sand. Do not allow the
indicator to hit the mouth of the cylinder as the assembly is being lowered. As the weighted foot
comes to rest on the sand, tip the assembly toward the graduations on the cylinder until the indicator
touches the inside of the cylinder. Subtract 254mm from the level indicated by the extreme top edge
of the indicator and record this value as the ‘sand reading’.
Calculations:
Sand equivalent (SE) to the nearest 0.1 using the following formula:
SE = (Sand Reading/ Clay Reading) x 100

SAND EQUIVALENCY TEST

( IS : 2720 - PART - 37 )
As required by Engineer Min. 50%

Type of
Source :_________________ Total Wt.of Dry sample:____________
Temperature of working solution:______ Material Passing 4.75mm sieve:_____
Sand Equivalency
Trial No. Clay Reading in mm. Sand Reading in mm
Actual Say
1
Average S.E.Value.
Sand Readingx100
S.E Value = Clay Reading
Remarks:________________________________________________________________________________

19. DELETERIOUS CONTENTS OF SOILS - Determination of Total Soluble Sulphates

(IS: 2720 – Part – 27)
A. By Precipitation Method:
Object:
Determination of total soluble sulphate content of soil by precipitation method.
Apparatus:
1) Analytical Balance – sensitive to 0.001 g , 2) Glass Beaker – 250 ml capacity, 3) Glass Funnel – 50
mm diameter, 4) Glass Bottle – 250 ml capacity with a rubber cork, 5) Crucible – 50 ml capacity, 6)
Pipette – 25 ml, 7) Burette – 50 ml with 0.1 ml graduation, 8) Filter paper – Whatman No.42, 9)
Heating equipment, Muffle furnace, Mechanical shaker, Drying oven and A Mortar with rubber-covered
pestle.
Reagents:
1. Phenolphthalein Indicator Solution: Dissolve 0.1 g of phenolphthalein in 60 ml of rectified spirit and
dilute with distilled water to 100 ml.
2. Concentrated Hydrochloric Acid: Specific gravity 1.18 (conforming to IS:265-1976)
3. Barium Chloride Solution: 5 percent. Dissolve 5 g of barium chloride in 100 ml of distilled water.
4. Silver Nitrate Indicator Solution: 0.5 percent. Dissolve 500 mg of silver nitrate in 100 ml of distilled
water.
Procedure:
a) Soil Sample: The soil sample shall be brought to a state in which it may be crumbled if necessary,
by drying it in an oven maintained at 105 to 1100C. The aggregations of particles shall be broken up
in mortar with rubber-covered pestle or the mechanical device. The sample shall be thoroughly mixed
and then sub-divided by quartering.
b) Procedure: Take 10 g of soil from the sample prepared as above in a 250 ml bottle with 100 ml
of distilled water. Give occasional shaking for 2 hours by means of the mechanical shaker. Allow the
soil suspension to stand overnight. Filter and take 25 ml of filtrate in a beaker and add concentrated
hydrochloric acid to just neutralize the solution if it is found alkaline to phenolphthalein indicator. Add
further 4 ml concentrated hydrochloric acid to make the solution acidic. Boil the soil suspension and
add barium chloride filter it. The precipitation shall be wash free from chloride ions. The filteration
mass also done through a preheated with sintered glass crucible. In the case of filter paper after
drying ashing shall be done on a low flame and the precipitate then ignited over a burner or in a
muffle furnace at 600 to 7000C for half an hour cool in a desiccator weigh and note the weight of the
residue. This is the weight of barium sulphate. A corresponding weight of sodium sulphate should be
calculated and thus its percentage determined.

Note: To check whether the residue is free of chloride ions, collect the washings in a separate test
tube at different time intervals and a drop of 0.5 percent silver nitrate solution to it. The formation of
white cloudy precipitate shows the presence of chloride ions in the precipitate. Continue washing until
the white precipitation is not formed in the washings by the addition of silver nitrate solution. Hot
water may be used for washing.
Calculations:
Sulphates (as SO4), by mass = 41.15 x (W1/W2)
Sulphates (as Na2 S04), by mass = 60.85 x (W1/W2)
Where, W1 = mass in g of the precipitation and

W2 = mass in g of the soil contained in the solution taken for precipitation.
B. Volumetric Method:
Reagents:
1. Barium Chloride Solution: N/4. Dissolve 30.54 g of barium chloride in one litre of distilled water.
2. Potassium Chromate Solution: N/4. Dissolve 24.275 g of potassium chromate in a small amount of
distilled water. Add a few drops of silver nitrate solution to it to remove any chloride, filter and dilute
to 250 ml.
3. Silver Nitrate Indicator Solution: 0.5 percent. Dissolve 500mg of silver nitrate in 100 ml of distilled
water.
4. Dilute Solution of Ammonium Hydroxide: Sp.Gr.0.888. Mix ammonium hydroxide and distilled water
in the ratio of 1:2.
5. Concentrated Hydrochloric Acid: Sp.Gr.1.11 (conforming to IS:265-1976).
Procedure:
Weigh 10 g of the soil specimen obtained by the method specified in above, in a beaker and add
about 50 ml water. Stir well, allow to decant, filter, wash the soil on filter paper with a small quantity
of water and make the filtrate to 100-ml. Pipette out 10 ml of the water extract in a conical flask,
make it slightly acidic by adding concentrated hydrochloric acid and heat to boiling. While boiling, add
barium chloride solution (N/4) from the burette till the precipitation is complete and barium chloride
solution is in slight excess.
Neutralize the solution with ammonium hydroxide and titrate the excess of barium chloride against
potassium chromate solution (N/4). The end point may be confirmed, if considered necessary, by
using silver nitrate solution as an external indicator.

Calculations:
Sulphates as sodium sulphate in soil, percent by mass = 0.0177 X 100 (x – y)
Where, x = volume of N/4 barium chloride added in ml.

y = volume of N/4 potassium chromate solution used in back titration in ml.
Limits: Max. 1000 ppm (or) 0.5% by weight of mass.

DELETERIOUS CONTENT TEST

(TOTAL SOLUBLE SULPHATE CONTENT)
BY VOLUMETRIC METHOD
( IS : 2720 - PART - 27 )
Date of Sampling
Lab Ref No :_________________ :____________
Type of Date of Testing
Material :_________________ :____________
Source :_________________
1 Mass of Precipitate in gms - (W1)
Mass of soil contained in the solution taken for

2
precipitation in gms - (W2)
3 Sulphates as (SO4) percent by mass = 41.15 (W1 / W2)
4 Sulphates as (Na2SO4) percent by mass = 60.85 (W1 / W2)
Remarks:________________________________________________________________________________


(TOTAL SOLUBLE SULPHATE CONTENT)
( IS : 2720 - PART - 27 )
Type of
Source :_________________
Determination No. 1 2 3
Weight of specimen, gm
Volume of N/4 Barium Chloride Added (x), ml
Volume of N/4 Potassium Chromate Solution Used in Back Titration

(y), ml.
N/4 Barium Chloride Actually Used for Precipitating Sulphate
Sulphate as Sodium Sulphate in Soil, % by mass = 0.0177 ( x - y )
Remarks
:___________________________________________________________________________________

20. DELETERIOUS CONTENTS OF SOILS – Determination of Organic Matter

(IS: 2720 – Part – 22)
Apparatus:
1) Oven – thermostatically controlled (105 to 1100C), 2) Balance – sensitive to 0.001 g, 3) Volumetric
Flask – 2 nos of one litre capacity, 4) Burette – 2 nos of 25 ml with 0.1 ml graduation, 5) Pipette – 10
ml, 6) Conical Flask – 2 nos of 500 ml capacity, 7) Graduated Measuring Cylinders – 200 ml & 25 ml
capacities, 8) Desiccator – with any desiccating agent other than sulphuric acid, 9) Glass Weighing
Bottle – 25 mm diameter & 50 mm height fitted with a ground glass stopper, 10) Wash Bottle, 11)
Sieves – 10mm & 425 micron.
Reagents:
1. Potassium Dichromate Normal Solution: Dissolve 49.035 g of potassium dichromate in one litre of
distilled water.
2. Ferrous Sulphate Solution: 0.5 N – Dissolve approximately 140 g of ferrous sulphate in 0.5 N
sulphuric acid to make one litre of solution (add 14 ml of concentrated sulphuric acid to distilled water
to make one litre of solution for 0.5 N sulphuric acid).
3. Sulphuric Acid, Concentrated: sp.gr. 1.83 (conforming to IS : 266-1977).
4. Orthophosphoric Acid, 85 percent: sp.gr. 1.70 to 1.75.
5. Indicator Solution: 0.25 g of sodium diphemylamine-sulphonate dissolved in 100 ml of distilled
water.
Soil sample preparation:

The portion of the air-dried sample selected and weighed (W1). It shall then be sieved on a 10 mm IS
sieve and all particles other than stones crushed to pass through the sieve. The equivalent weight on
oven-dry basis of the material passing 10 mm IS sieve (W2) shall be calculated and recorded to the
nearest 0.1 percent of its total weight. A sample weighing approximately 100 g shall be obtained from
the material passing 10 mm IS sieve by quartering. This sample shall then be pulverized so that it
passes the 425 micron IS sieve.
Standardization of ferrous sulphate solution:
10 ml of the normal potassium dichromate solution will be run from a burette into a 500 ml conical
flask. 20 ml concentrated sulphuric acid shall then be added carefully and the mixture swirled and
allowed to cool for some minutes. 200 ml of distilled water shall then be added to the mixture
followed by 10 ml of phosphoric acid and 1 ml of the indicator and the mixture shall be shake
thoroughly. Ferrous sulphate solution shall then be added from the second burette in 0.5 ml
increments, the contents of the flask being swirled, until the color of the solution changes from blue
to green. A further 0.5 ml of potassium dichromate shall then be added, changing the color back to
blue. Ferrous sulphate solution shall then be added drop by drop with continued swirling until the
color of the solution changes from blue to green after the addition of a single drop. The total volume
of ferrous sulphate solution used (x) shall be noted to the nearest 0.05 ml (one ml ferrous sulphate
solution is equivalent to 10.5/x ml potassium dichromate).

Procedure:
A 5-gram soil sample shall be taken from the thoroughly mixed portion of the material passing the
425-micron IS sieve and used for the test.
The sample shall be placed in a glass weighing bottle and weighed to 0.001 g. A small quantity, from
5 g to 0.2 g depending on the organic content shall be transferred to a dry 500 ml conical flask, the
weighing bottle reweighed (W3).
10 ml of N potassium dichromate solution shall be run into the conical flask from a burette, and add
20 ml of concentrated sulphuric acid very carefully from a measuring cylinder. The mixture shall be
thoroughly swirled for about one minute and allowed to stand on a heat-insulating surface, such as
asbestos or wood for 30 min to allow oxidation of the organic matter to proceed. During this period,
the flask shall be protected from draughts. Distilled water, 200 ml, shall then be added along with 10
ml of orthophosphoric acid and one ml of the indicator. The mixture shall be shaken vigorously. If the
indicator is absorbed by the soil, a further one ml of the solution shall be added. Ferrous sulphate
solution shall then be added from the second burette in 0.5 ml increments, the contents of the flask
being swirled, until the color of the solution changes from blue to green. A further 0.5 ml of potassium
dichromate shall then be added, changing the color of the solution back to blue. Ferrous sulphate
solution shall then be added drop by drop with continued swirling until the color of the solution
changes from blue to green after the addition of a single drop. The total volume of the ferrous
sulphate solution used (y) shall be noted to the nearest 0.05 ml.
Calculations:
The volume (V ml) of potassium dichromate used to oxidize the organic matter in the soil is given by
the following formula:
V = 10.5 (1 – y/x)
Where, x = total volume of ferrous sulphate used in the standardization test.

y = total volume of ferrous sulphate used in the test.
The percentage of organic matter (OM) present in the oven-dried sample shall be calculated from the
following formula:
Percentage of Organic Matter (OM) = (0.6 W2 V) / (W1 W3)
Where, W1 = total weight of original sample.

W2 = weight of soil passing 10 mm IS sieve.
W3 = weight of dry soil specimen used in the test.
V = volume of potassium dichromate solution used to oxidize organic.
Limits: Max. 1% by weight of mass.

DETERMINATION OF ORGANIC MATTER(SOIL)

( IS : 2720 - PART - 22 )
Type of
Source :_________________
Total Weight of Original Sample (W1), gm
Weight of Soil Passing 10mm Sieve (W2), gm
Weighing Bottle No.
Weight of Weighing Bottle and Dry Soil After Taking Specimen for Test,
gm
Weight of Weighing Bottle and Dry Soil Before Taking Specimen for
Test, gm
Weight of Dry Soil Specimen Used (W3), gm
Volume of Ferrous Sulphate Solution Added to Standardize Potassium

Dichromate Solution (x), ml
Volume of Ferrous Sulphate Solution Used to Oxidize Excess (y), ml
Volume of Potassium Dichromate Solution Used to Oxidize Organic.

V = 10.5( 1 - y/x ), ml
Percentage of Organic Matter in Soil = ( 0.6 W2 V ) / ( W1 W3)
Remarks:________________________________________________________________________________

21. DELETERIOUS CONTENTS OF SOILS – Determination of Chloride and Salinity in Soils

By Volumetric Method
Object:
Determination of Chloride content and Salinity in Soils. Salinity is nothing but excess of chlorides.
Preparation of Reagents:
1. Chloride free distilled water.

2. Potassium Chromate – Color Indicator.
3. Standard Silver Nitrate (0.0141N/0.0156N): Dissolved 2.395 grams of Silver Nitrate in one liter
of hot distilled water to prepare 0.0141N solution. Alternatively, dissolve 2.65 grams of Silver
Nitrate in one liter of hot distilled water to prepare 0.0156N solution.
Procedure:
1. Take 25 ml of filtered sample in a conical flask.

2. Adjust the PH in the range of 7 to 8 by adding Sulphuric acid or Sodium Hydroxide solution.
3. Add 1 ml of Potassium Chromate – Yellow color develops.
4. Take 0.0165N Silver Nitrate solution in burette and titrate till brick red color develops.
Measure the volume in ml and recorded it as ‘X’.
Calculations:
1. Chloride (mg/l or ppm) Y = (X x 35.46 x 1000 x 0.0156)/(ml of sample taken)
2. Salinity (ppt or gms/lt) = 0.03 + 1.806 + Chlorides in g/lt.
3. Total Chlorides in Soil sample = 5 x Y
Limits: Max. 200ppm.


(CHLORIDE CONTENT AND SALINITY)
Type of
Source :_________________
Weight of specimen, gm
Volume of 0.0156N Silver Nitrate solution Added (X), ml
Chloride Content ‘Y’ (mg/lt or ppm) =

(X x 35.36 x 1000 x 0.0156)/(ml of sample taken)
Salinity (ppt or gms/lt) = (0.03 + 1.806 + Chlorides in g/lt)

Total Chlorides in Soil Sample = 5 x Y
Remarks
:___________________________________________________________________________________

ROAD AGGREGATES.

1. AGGREGATES SAMPLING
(IS: 2430-1986)
LOT:
The quantities of the Aggregate of the same class, Nominal size, source and offered for inspection at
one time. The lot may consist of the whole or a part of the quantity ordered for.
SUB-LOT:
The quantity of aggregates in each of the parts into which a lot is divided for the purpose of sampling.
The sub lots should be of equal size as for as possible.
UNIT SAMPLE:
The quantity of aggregates collected at one point in sectional sampling or at one time from the
conveyer.
GRASS SAMPLE:
Sample as collected from a sub lot, that is the quantity of aggregate consisting or one of several
increments or unit samples taken from a sub lot.
LABORATORY SAMPLE:
The quantity of aggregate obtained by reducing a gross sample following a specified procedure and
intended for laboratory testing.
COMPOSITE SAMPLE:
The quantity of aggregates obtained by mixing together equal quantities from each of the laboratory
samples.
SAMPLING OF MATERIAL ON THE SITE OF WORK & FOR INSPECTION OF MATERIAL:

Samples shall be selected and examined from each lot separately. For obtaining reliable conclusions
the samples be obtained while in motion as for as possible i.e. from convenes and during loading un-
loading.
SAMPLING FROM STACKS OR STOCK PILES:
• For sampling material from stockpiles or stacks, it is very difficult to ensure unbiased samples, due
to the segregation, which often occurs when material is stacked, with coarser particles rolling to
the outside face of the pile. For coarse or all in aggregates every effort should be made to procure
a power equipment to develop a separate small sampling pile composed of materials drawn from

various levels and locations in the main pile after which several increments may be combined to
compose the gross sample. If it is necessary to indicate the degree of variability existing within the
main pile, separate samples should be drawn from separate areas of the pile.
• Where power equipment is not available, samples from stock piles should be made up of the
required number of increments taken equally from top, third, at the midpoint and at the bottom
third of the volume of the pile. A board put vertically into the pile just above the sampling point
helps in preventing further segregation. In sampling stock pile of the aggregates the outer layer,
which may have become segregated, should be removed and the sample taken from the material
beneath.
• Sub-lots: For the purpose of sampling, the quantity of aggregates in a stack shall be divided into a
suitable number of sub-lots. A representative gross sample shall be drawn from each of the sub-
lots sampling of aggregates from stacks shall be carried out as for as possible during the making
or breaking of the stack.
• A minimum of ten increments shall be taken from a sub-lot for making up a gross sample. The
weight of increment shall not be less than 1 Kg. The number of increments shall be equally
distributed over the sub-lot. Increments shall be drawn with the help of a suitable scoop at regular
intervals in the course of making or unmaking of the stacks.
REDUCTION OF A GROSS SAMPLE:
Each gross sample shall be reduced a separately to the required size for each test by way of repeating
the methods given as under.
• Reduction by Riffle divider: The aggregates shall be well mixed and poured into the riffle
divider according to the size of the aggregates.
• Coning and Quartering Method: The aggregates shall be mixed and then scooped into a cone
shaped pile, care being taken to drop each scoop full exactly over the same spot to avoid the
uneven distribution of the particles. After the cone is formed it shall be flattened by pressing the
top of the cone with the smooth surface of the scoop and it is than cut into quarters by two lines
which intersect at right angles at the center of the cone. The two diagonally opposite quarters are
rejected and the process repeated till the required size of sample is obtained.

DETAILES OF TESTS AND TEST SAMPLES
Details of Quantity of Samples

S. No. Name of Test Min. weight of
Min. weight of Sample
Sample taken for
dispatched for Testing
Sieving
Particle Size
63 mm 100 Kg 50 Kg
50 mm 100 Kg 35 Kg
40 mm or 31.5 mm 50 Kg 15 Kg
25 mm 50 Kg 5 Kg
20 mm 25 Kg 2 Kg
1 16 mm 25 Kg 2 Kg
12.5 mm 12 Kg 1 Kg
10 mm 6 Kg 500 Gms
6.3 mm 3 Kg 200 Gms
4.75 mm - 200 Gms
2.36 mm - 100 Gms
Quantity of Aggregates Sufficient to provide the min.

2 Flakiness Index
of 200 pieces of each fraction.
Quantity of Aggregates Sufficient to provide the min.
3 Elongation Index
of 200 pieces of each fraction.
4 Deleterious Materials & Organic Impurities
For Determination of Clay links
Over 40 mm 5000 Gms
40 – 20 mm 3000 Gms
a
20 – 10 mm 2000 Gms
10 – 4.75 mm 1000 Gms
4.75 – 1.18 mm 100 Gms
For Determination of Clay, Fine silt & Fine Dust by Sedimentation Method
64 – 25 mm 6000 Gms
b 20 – 12.5 mm 1000 Gms
10 – 6.3 mm 500 Gms
300 Gms
Less than 4.75 mm
c For Determination of Light weight pieces (Coal & Lignite)

80 mm 10000 Gms
40 mm 5000 Gms
20 mm 3000 Gms
Less than 6.3 mm 200 Gms
For Determination of Soft Particles
50 – 40 mm 12000 Gms
40 – 25 mm 4500 Gms
d
25 – 20 mm 1500 Gms
20 – 12.5 mm 600 Gms
12.5 – 10 mm 200 Gms
Estimation of Organic
e 200 Gms
Impurities
5 Specific Gravity 2000 Gms
Bulk Density & Voids
More than 40 mm 30 Liters
6
40 – 4.75 mm 15 Liters
Less than 4.75 mm 2 Liters
Determination of Surface
7 200 Gms
Moisture in Fine Aggregates
8 Aggregate Crushing Value 6500 Gms
9 Aggregate Impact Value 500 Gms/Test
Aggregate Abrasion Value
More than 2.8 mm 5500 Gms
10 2.8 – 2.4 mm 5000 Gms
2.39 – 2.2 mm 4500 Gms
Less than 2.2 mm 4000 Gms
Aggregate Soundness Test
11 For Coarse Aggregates 3000 Gms
For Fine Aggregates 1000 Gms
12 Alkali Aggregate Reactivity 1000 Gms

2. AGGREGATE IMPACT VALUE TEST.

(IS: 2386 – PART – 4)
INTRODUCTION:
Toughness is the property of a material to resist impact. Due to traffic loads, the road stones are
subjected to the pounding action or impact and there is possibility of stones breaking into smaller
pieces. The road stones should therefore be tough enough to resist fracture under impact. A test
designed to evaluate the toughness of stones i.e., the resistance of the fracture under repeated
impacts may be called an impact test for road stones.
Object:
To determine the toughness of road stone materials by Impact test.
Apparatus:
a) Impact testing machine: The machine consists of a

metal base with a plane lower surface supported well on a
firm floor, without rocking. A detachable cylindrical steel cup
of internal diameter 102mm and depth 50mm is rigidly
fastened centrally to the base plate. A metal hammer of
weight between 13.5 and 14.0 kg having the lower end
cylindrical in shape, 100mm in diameter and 50mm long, with
2mm chamfer at the lower edge is capable of sliding freely
between vertical guides, and fall concentric over the cup.
There is an arrangement for raising the hammer and allowing
it to fall freely between vertical guides from a height of
380mm on the test sample in the cup, the height of fall being
adjustable up to 5mm. A key is provided for supporting the
hammer while fastening or removing the cup.
b) Measure: A cylindrical metal measure having internal
diameter 75mm and depth 50mm for measuring aggregates.
c) Tamping rod: A straight metal tamping rod of circular
cross section, 10mm in diameter and 230mm long, rounded at
one end.
d) Sieve: IS sieve of sizes 12.5mm, 10mm, and 2.36mm for sieving the aggregates.
e) Balance: A balance of capacity not less than 500 gm to weigh accurate up to 0.1 gm.
f) Oven: A thermostatically controlled drying oven capable of maintaining constant temperature
between 1000C to1100C.
Procedure:
The test sample consists of aggregates passing 12.5mm sieve and retained on 10mm sieve and dried
in an oven for four hours at a temperature 1000C to 1100C and cooled. Test aggregates are filled up

to about one-third full in the cylindrical measure and tamped 25 times with rounded end of the
tamping rod. Further quantity of aggregates is then added up to two-third full in the cylinder and 25
stocks of the tamping rod are given. The measure is now filled with the aggregates to over flow,
tamped 25 times. The surplus aggregates are struck off using the tamping rod as straight edge. The
net weight of the aggregates in the measure is determined to the nearest gram and this weight of the
aggregates is used for carrying out duplicate test on the same material. The impact machine is placed
with its bottom plate flat on the floor so that the hammer guide columns are vertical. The cup is fixed
firmly in position on the base of the machine and the whole of the test sample from the cylindrical
measure is transferred to the cup and compacted by tamping with 25 strokes.
The hammer is raised until its lower face is 380mm above the upper surface of the aggregates in the
cup, and allowed to fall freely on the aggregates. The test sample is subjected to a total 15 such
blows, each being delivered at an interval of not less than one second. The crushed aggregate is then
removed from the cup and the whole of it sieved on the 2.36mm sieve until no further significant
amount passes. The fraction passing the sieve is weighed accurate to 0.1gm. The fraction retained on
the sieve is also weighed and if the total weight of the fractions passing and retained on the sieve is
added it should not be less the original weight of the specimen by more than one gram, if the total
weight is less than the original by over one gram the results should be discarded and a fresh test
made.
Calculations:
The aggregate impact value is expressed as the percentage of the fines formed in terms of the total
weight of the sample.
Aggregate Impact Value = 100 x W2/W1
Where, W1 = Original weight of the sample.

W2 = Weight of fraction passing 2.36mm IS sieve.
Results:
The mean of the three results is reported as the AIV(Aggregate Impact Value) of the specimen to the
nearest whole number.
Limits:
< 10% Exceptionally strong.
10 – 20% Strong.
20 – 30% Satisfactory for road surfacing.
> 35% Weak for road surfacing.

TEST : AGGREGATE IMPACT VALUE

( IS : 2386 PART - 4 )
Wet Mix 3 Wet Mix
1Test/1000m Max.30%
Macadam Macadam
3
DBM / BC 1 Test/350m DBM = Max. 27% BC = Max.24%
Mix Seal Surface 3 Mix Seal Surface /
1 Test/200m Max.30%
/ BM BM
Concrete 1 Test/day Concrete Max. 30%
Height of Drop 380mm
No.of Blows 15 Blows
Lab Ref.No :______________________

Type of Material :______________________
Date of Sample :______________
Date of Tested :______________
Source Km. :______________________
Test Original Wt.of Material Wt.of Material Retained Wt.of Material Passing AIV Average
No. (gm) on Sieve 2.36mm (gm) on Sieve 2.36mm (gm) (%) Value ( % )
A B C C/A X 100
Remarks:______________________________________________________________________________

3. LOS ANGLES ABRASION VALUE TEST.

(IS: 2386 – PART – 4)
INTRODUCTION:
Due to the movement of traffic, the road stones used in the surfacing course are subjected to wearing
action at the top. Resistance to wear or hardness is hence an essential property for road aggregates,
especially when used in wearing course. Thus road stones should be hard enough to resist the
abrasion due to the traffic. When fast moving traffic fitted with pneumatic tyres move on the road, the
soil particles present between the wheel and road surface causes abrasion on the road stone. Steel
tyres of animal drawn vehicles, which rub against the stones, can cause considerable abrasion of the
stones on the road surface. Hence in order to test the suitability of road stones to resist the abrading
action due to traffic.
Object:
To determine the aggregates abrasion test by Los Angles Abrasion method.
Apparatus:
a)Los Angles Abrasion Machine: The Los Angles
Machine consists of a hollow steel cylinder, closed at both
ends, having an inside diameter 700mm and an inside
length of 500mm, mounted on stub shafts about which it
rotates on a horizontal axis, and rotating arrangement for
speed of 30 to 33 revolutions per minute. An opening is
provided in the cylinder for the introduction of the test
sample. A removable cover of the opening is provided in
such a way that when closed and fixed by bolts and nuts, it
is dust-tight and the interior surface is perfectly cylindrical.
A removable steel shelf projecting radially 88mm in to the
cylinder and extending to the full length of it, is mounted
on the interior surface of the cylinder rigidly, parallel to the
axis. The shelf is fixed at a distance of 1250mm from the
opening, measured along the circumference in the direction of rotation. Abrasion charge, consisting of
cast iron spheres approximately 48mm in diameter and 390 to 445gm in weight are used.
b) Balance -10 kg capacity – sensitivity 0.1 gm.
c) Test Sieve – 1.70 mm IS sieve.
d) Oven.
Procedure:
Clean aggregates dried in an oven at 105 – 1100C to constant weight, confirming to any one of the
grading A, to G, is used for test. The grading or gradings used in the test should be nearest to the
grading to be used in the construction. Aggregates weighing 5 kg for gradings A, B, C or D and 10 kg
for gradings E, F or G may be taken as test specimen and placed in the cylinder. The abrasion charge
is also chosen, depending on the grading of the aggregate and is placed in the cylinder of the

machine. The cover is then fixed dust-tight. The machine is rotated at a speed of 30 to 33 revolutions
per minute.
The machine is rotated for 500 revolutions for gradings A, B, C and D, for gradings E, F and G, it shall
be rotated for 1000 revolutions. The machine should be balanced and driven in such a way as to
maintain uniform peripheral speed.
After the desired number of revolutions, the machine is stopped and the material is discharged from
the machine taking care to take out entire stone dust. Using a sieve of size 1.70mm IS sieve, the
material is first separated into two parts and the finer portion is taken out and sieved further on a
1.70mm IS sieve. The portion of material coarser than 1.70mm size is washed and dried in an oven at
105 – 1100C to constant weight and weighed correct to one gram.
Calculations:
The difference between the original and final weights of the sample is expressed as a percentage of
the original weight of the sample is reported as the percentage wears.
Loa Angles Abrasion Value = 100 x (W1 – W2)/W1
Where, W1 = Original weight of the sample.

W2 = Weight of aggregate retained on 1.70mm IS sieve.
(W1 – W2) = Los in weight due to wear.
Results:
The result of the Los Angles Abrasion is expressed as a percentage wear and the average value of
three tests.
Limits:
Loa Angles Abrasion for road aggregates = Maximum 40%.
Types of Grading and Abrasion charges:

Abrasion charge
Weight in grams of each test sample in size range, mm (Passing
Grading
spheres
Number
nd retained on square holea)

Weight of
of
80 to 63 to 50 to 40 to 25 to 20 to 12.5 10 to 6.3 to 4.75 to charge, gm

63 50 40 25 20 12.5 to 10 6.3 4.75 2.36
A - - - 1250 1250 1250 1250 - - - 12 5000+/-25
B - - - - - 2500 2500 - - - 11 4584+/-25
C - - - - - - - 2500 2500 - 8 3330+/-20
D - - - - - - - - - 5000 6 2500+/-15
E 2500 2500 5000 - - - - - - - 12 5000+/-25
F - - 5000 5000 - - - - - - 12 5000+/-25
G - - - 5000 5000 - - - - - 12 5000+/-25

TEST : LOS ANGELES ABRASION TEST

( IS : 2386 PART - 4 )
Permissible Limits Max. 30 %
Sieve No.of Sieve Freaction No.of Spheres

Gradation Freaction Wt. Spheres Wt. Gradation
Fraction Spheres Fraction Wt. Spheres Wt.
40-25mm 1250gm 80 - 63mm 2500gm

25 20mm 1250gm 5000 +/-
E - Gradation 63 - 50mm 2500gm 12
A - Gradation 12 5000 +/-25gm 25gm
20 - 12.5mm 1250gm 50 - 40mm 5000gm
12.5 - 10mm 1250gm 50 - 40mm 5000gm 5000 +/-
F - Gradation 12
20 - 12.5mm 2500gm 40 - 25mm 5000gm 25gm
B - Gradation 11 4584 +/- 25gm
12.5 - 10mm 2500gm 40 - 25mm 5000gm 5000 +/-
G - Gradation 12
10 - 6.3mm 2500gm 25 - 20mm 5000gm 25gm
C - Gradation 8 3330 +/- 20gm
6.3 - 4.75mm 2500gm
2500 +/-
D - Gradation 4.75-2.36mm 5000gm 6
15gm
Lab Ref.No :______________________

Type of Material :______________________
Date of Sample :________
Source Km. :______________________ Date of Sample :__________
S.No. DESCRIPTION TEST - 1 TEST - 2 TEST - 3 AVERAGE
1 Weight of the Sample before Test ( A ) gms.
Weight of the Sample Passing IS:Sieve 1.70mm after

2
Test ( B ) gms.
3 Aggregate Abrasion Value ( % ) = B/AX100
Remarks :_________________________________________________________________________

4. AGGREGATE CRUSHING VALUE TEST.

(IS: 2386 – PART – 4)
INTRODUCTION:
The principal mechanical properties required in stones are (i) satisfactory resistance to crushing under
the roller during construction and (ii) adequate resistance to surface abrasion under traffic.
Aggregates used in road construction, should be strong enough to resist crushing under traffic wheel
loads. If the aggregates are weak, the stability of the pavement structure is likely to be adversely
affected. The strength of coarse aggregates is assessed by aggregates crushing test. The aggregate
crushing value provides a relative measure of resistance to crushing under a gradually applied
compressive load. To achieve a high quality of pavement, aggregate possessing low aggregate
crushing value should be preferred.
Object:
To determine the aggregate crushing value by compressive testing machine.
Apparatus:
a) Steel cylinder with open ends, and internal diameter
152mm, square base plate, plunger having a piston of
diameter 150mm, with a hole provided across the stem of
the plunger so that a rod could be inserted for lifting or
placing the plunger in the cylinder.
b) Cylindrical measure having internal diameter of

115mm and height 180mm.
c) Steel tamping rod with one rounded end, having a

diameter of 16mm and length 450 to 600mm.
d) Balance of capacity 3 kg with accuracy up to 1gm.
e) Compressive testing machine capable of applying load of 40 tonnes, at a uniform rate of loading of
4 tonnes per minute.
Procedure:
The aggregate passing 12.5mm IS sieve and retained on 10mm IS sieve is selected for standard test.
The aggregate should be in surface dry condition before testing. The aggregate may be dried by
heating at a temperature 1000C to 1100C for a period of 4 hours and is tested after being cooled to
room temperature.

The cylindrical measure is filled by the test sample of aggregate in three layers of approximately equal
depth, each layer being tamped 25 times by the rounded end of the tamping rod. After the third layer
is tamped, using the tamping rod as a straight edge levels off the aggregate at the top of the
cylindrical measure. About 6.5kg of aggregate is required for preparing two test samples. The test
sample thus taken is then weighed. The same weight of the sample is taken in the repeat test.
The cylinder of the test apparatus is placed in position on the base plate; one third of the test sample
is placed in this cylinder and tamped 25 times by the tamping rod. Similarly, the other two parts of
the test specimen are added, each layer being subjected to 25 blows. The total depth of the material
in the cylinder after tamping shall however be 100mm. The surface of the aggregates is leveled and
the plunger inserted so that it rests on this surface in level position. The cylinder with the test sample
and the plunger in position is placed on compression testing machine. Load is then applied through
the plunger at a uniform rate of 4 tonnes per minute until the total load is 40 tonnes, and then the
load is released. Aggregates including the crushed portion are removed from the cylinder and sieved
on a 2.36mm IS sieve. The material, which passes this sieve, is collected.
The above crushing test is repeated on second sample of the same weight in accordance with above
test procedure. Thus two tests are made for the same specimen for taking an average value.
Calculation:
The aggregate crushing value is defined, as a ratio of the weight of fines passing the specified IS
sieve to the total weight of the sample expressed as a percentage.
Aggregate crushing value = 100 x W2/W1
Where, W1 = Total weight of dry sample.

W2 = Weight of the portion of crushed material passing 2.36mm IS sieve.
Results:
The mean of the crushing value obtained in the two tests is reported as the aggregate crushing value.
Limits:
The aggregate crushing value for cement concrete pavement shall not exceed 30%.
The aggregate crushing value for wearing surfaces shall not exceed 45%.

5. FLAKINESS & ELONGATION INDEX TEST( SHAPE TEST ).

(IS: 2386 – PART – 1)
INTRODUCTION:
The particle shape of aggregates is determined by the percentages of flaky and elongated particles
contained in it. For base course 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 possibilities of breaking down under heavy loads. The angularity number i.e., flaky and
elongation has considerable importance in the gradation requirements of various types of mixes such
as bituminous concrete, cement concrete and soil aggregate mixes.
Object:
To determine the flakiness and elongation of the aggregates by standard flakiness gauge and
elongation gauges.
Apparatus:
a) Flakiness gauge (Thickness gauge):
The Flakiness index of aggregates is the

percentages by weight of particles whose least
dimension is less than three-fifths (0.6) of their
mean dimension. The test is not applicable to
sizes smaller than 6.3mm. The apparatus
consists of a standard thickness gauge of IS
sieve sizes 63, 50, 40, 31.5, 25, 20, 16, 12.5,
10 and 6.3mm and a balance to weigh the
samples.
b) Elongation gauge (Length gauge):
The elongation index of aggregate is the

percentage by weight of particles whose
greatest dimension (length) is greater than one
and four fifth times (1.8) their mean dimension.
The elongation test is not applicable to sizes
smaller than 6.3mm. The apparatus consists of
a standard length gauge of IS sieve sizes 50,
40, 31.5, 25, 20, 16, 12.5, 10 and 6.3mm.
Procedure:
a) Flakiness Index: The sample is sieved with the sieves mentioned in above. A minimum of 200
pieces of each fraction to be tested is taken and weighed. In order to separate flaky materials, each
fraction is then gauged for thickness on a thickness gauge. The amount of flaky material passing the
gauge is weighed to an accuracy of at least 0.1 percent of the test sample.

Calculation:
In order to calculate the flakiness index of the entire sample of aggregates first the weight of each
fraction of aggregate passing and retained on the specified set of sieves is noted (X1, X2, X3… etc).
Each of the particle from this fraction of aggregate is tried to be passed through the slot of the
specified thickness of the thickness gauge are found and weighed (x1, x2, x3…etc). 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.
Flakiness Index = [(x1 + x2 + x3 + …)/(X1 + X2 + X3 + …)] x 100
b) Elongation Index: The sample is sieved through the IS sieves specified as above. A minimum of
200 pieces of each fraction is taken and weighed. In order to separate elongated material, each
fraction is then gauged individually for length in a length gauge. 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 are collected separately to find the total weight of aggregates 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 percent of the weight of the sample.
Calculation:
In order to calculate the Elongation index of the entire sample of aggregates first the weight of each
fraction of aggregate passing and retained on the specified set of sieves is noted (Y1, Y2, Y3… etc).
Each piece of these are tried to be passed through the specified length of the gauge length with its
longest side and those elongated pieces which do not pass the gauge are separated and weighed (y1,
y2, y3…). Then 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.
Elongation Index = [(y1 + y2 + y3 +…)/(Y1 + Y2 + Y3 + …)] x 100
Combined Flakiness & Elongation Index: To determine this combined proportion, the flaky stone
from a representative sample should first be separated out. Flakiness index is weight of flaky stone
metal divided by weight of stone sample. Only the elongated particle is separated out from the
remaining (non flaky) stone metal. Elongation index is weight of elongated particles divided by total
non-flaky particles. The value of flakiness index and elongation index so found are added up.
Limits:
(i) Flakiness Index for Bituminous and Non-bituminous Mixes = Max. 15%
(ii) Elongation Index for Bituminous and Non-bituminous mixes = Max. 15%
(iii) Combined Flakiness and Elongation Index for Bituminous and Non-bituminous mixes = Max.30%
(iv) Flakiness Index for Concrete mixes = Max.35%

TEST : DETERMINATION OF FLAKINESS / ELONGATION INDEX OF COARSE AGGREGATE

( IS : 2386 PART - 1 )
3
Wet Mix Macadam 1 Test/500m Wet Mix Macadam
DBM / BC 1 Test/350m3 DBM / BC FI & EI =35 %
( FI=EI=15%)
Mix Seal Surface / BM 1 Test/100m3 Mix Seal Surface / BM
3
Concrete 1 Test/50m Concrete FI = 35%
0.6 times of the mean sieve

Thickness Gauge Dimension
size
1.8 times of the mean sieve
Length Gauge Dimension
size
Lab Ref.No :______________________ Date of Sample :____________________
Type of Material :______________________ Date of Tested :____________________
Source Km. :______________________
FLAKINESS INDEX ELONGATION INDEX
Weight of Aggregate in
S.No. Passing through Retained Weight of Aggregate Weight of Non-Flaky Weight of the Aggregate in each
each fraction passing
IS sieve on IS sieve taken in each Aggregate taken in each fraction not passing the length
the Thickness Gauge
(mm) (mm) Fraction (gms) fraction (gms) Gauge (gms)
(gms)
1 50 40
2 40 25
3 25 20
4 20 16
5 16 12.5
6 12.5 10
7 10 6.3
W= w= W1= w1=
(w / W)X100 = (w1 / W1)X100 =
Remarks:_____________________________________________________________________________________________________________________

TEST : DETERMINATION OF FLAKINESS / ELONGATION INDEX OF COARSE AGGREGATE

( IS : 2386 PART - 1 ) - Amended
Wet Mix Macadam 1 Test/200m3 Wet Mix Macadam
DBM / SDBC / BC 1 Test/50m3 DBM / SDBC / BC FI & EI = 30 %
( FI=EI=15%)
Mix Seal Surface / BM 1 Test/50m3 Mix Seal Surface / BM
Concrete 1 Test/50m3 Concrete FI = 35%
0.6 times of the mean
Thickness Gauge Dimension
sieve size
1.8 times of the mean
Length Gauge Dimension
sieve size
Lab Ref.No :_________________ Date of Sample:_______________________
Type of Material:_____________ Date of Test:________________________
Source Km.:________________
IS Sieve Determination of Elongation
Size Determination of Flakiness Index Index
No of pieces Mass of total

Total Aggregates
passing the no. of pieces Weight % of Weight of Non Weight of
weight of Sieve fraction passing in flaky
Retained
Passing
flaky guage in each the mass of flaky aggregates

fractions quarted to achieve guage (Quarted
as % of total sieve pieces aggregates retained on
for not less than 200 sample passing
no. of pieces fraction as passing the retained on Elongation
materials pieces for testing through each
tested in % of whole flaky guage flaky guage guage
sieved Gauge
each sieve sample
W2 N1 W3 N2 X= Y= W4 = W5 =
mm mm W1 (gms) W6 (gms)
(gms) (nos) (gms) (nos) (N2/N1)x100 (W1/W)x100 (XxY)x100 W2-W3 (gms)
63 50
50 40
40 31.5
31.5 25
25 20
20 16
16 12.5
12.5 10
10 6.3
Total W= Σ W4 = Σ W5 = Σ W6 =
Flakiness Index = (Σ W4 ) = Elongation Index = (Σ W6 /Σ W5)x100 =
Combined FI & EI = Specification Limits (Max %) =

Remarks :_____________________________________________________________________________________

6. SOUNDNESS TEST.
(IS: 2386 – PART – 5)
INTRODUCTION:
This test is intended to study the resistance of aggregates to weathering action.
In order to quicken the effect of weathering due to alternate wet-dry and or freeze-thaw cycles in the
laboratory, the resistance to disintegration of aggregate is determined by soaking the specimen in
saturated solution of sodium sulphate or magnesium sulphate.
Object:
Determination of the soundness of aggregates.
Apparatus:
The apparatus required for the test are containers for aggregates, sieves (63, 50, 40, 31.5, 20, 16,
10, 8, 4.75 and 4mm), balance of capacity 5kg to weight accurate to at least 0.1g and oven to
maintain 1050C to 1100C.
Procedure:
Saturated solution of Sodium sulphate (the anhydrous Na2SO4 or the crystalline Na2SO4 10H2O) is
prepared in water at a temperature of 250 to 300C. The solution is maintained at a temperature of
270C+/-20C and stirred at frequent intervals, until it is used. At the time of using the solution should
have a specific gravity of not less than 1.151 and not more than 1.171, and discolored solution should
not be used. It may be necessary to use not less than 420g of anhydrous salt or 1300g of the
crystalline decahydrate salt per liter of water.
Alternatively saturated solution of Magnesium sulphate may be prepared by dissolving either

anhydrous (MgSO4) or crystalline (MgSO47H2O) magnesium sulphate. At the time of using, the
solution should have a specific gravity of not less than 1.295 and not more than 1.308. Not less than
400g of the anhydrous salt or 1600g of the crystalline heptahydrate may be used per liter of water.
The specimen of coarse aggregate for the test may be prepared after removing the fraction finer than
4.75mm IS sieve. The sample should be of such a size that it would yield not less than the following
amounts of the different sizes, which should be available in amount of 5 percent or more.
(i) 20mm to 10mm - 1000 g

10mm to 4.75mm - 300 g
consisting of 20 to 12.5mm – 67%
2.5 to 10mm – 33%

(ii) 40mm to 20mm - 1500 g

consisting of 40 to 25mm – 67%
25 to 20mm – 33%
(iii) 63mm to 40mm - 3000 g

consisting of 63 to 50mm – 50%
50 to 40mm – 50%
(iv) 80mm and large sizes by

20mm spread in sieve size, - 3000 g
each fraction
The sample of coarse aggregate should be thoroughly washed and dried to a constant weight at 1050
to 1100C and is separated to different size ranges, as given above, by sieving. The proper weight of
the sample for each fraction is weighed and placed in separate containers for the test. In the case of
fraction coarser than 20mm, the particles are also counted. The samples are immersed in the
prepared solution of sodium sulphate or magnesium sulphate for 16 to 18 hours in such a manner
that the solution covers them to a depth of at least 15mm. The containers are kept covered to reduce
evaporation and during the period of immersion, the temperature of the solution is maintained at 270
+/- 10C.
After the immersion period, the aggregates are removed from the solution, drained for about 15
minutes, and placed in the drying oven maintained at a temperature of 1050 to 1100C. The samples
are dried to a constant weight at this temperature by checking the weights after 4 hours up to 18
hours. When the successive weights differ by less than 1 g, it may be considered that constant weight
has been attained and then it may be allowed to cool to room temperature. Then the aggregates are
again immersed in the prepared solution, for the next cycle of immersion and drying. The number of
cycles of alternate immersion and drying are minimum 5 for road aggregates.
After completion of the final cycle, the sample is cooled washed free from the sulphat. This may be
determined when there is no more reaction of the wash water with barium chloride (i.e., when there
is no white precipitation when barium chloride is added to wash water, it can be said that there is no
sulphate with wash water). Each fraction of the sample is then dried to constant temperature of 1050
to 1100C and weighed. Coarse aggregate fractions are sieved by IS sieves of sizes indicated below:
Size of Aggregate Sieve Size used to determine Loss

63 – 40 mm 31.5 mm
40 – 20 mm 16 mm
20 – 10 mm 8 mm
10 – 4.75 mm 4 mm

Each fraction of aggregate is examined visually to see if there is any evidence of excessive splitting,
crumbling or disintegration of the grains. A combined sieve analysis of all the materials subjected to
the above test cycles, may also be carried out to note the variation from the original grain size
distribution of the sample.
Limits:
Soundness of aggregates: Loss with Sodium Sulphate – Max.12% (5 cycles).

Loss with Magnesium Sulphate – Max.18% (5 cycles).

TEST : AGGREGATE SOUNDNESS TEST

( IS : 2386 - PART 5 )
COARSE AGGREGATE
Frequency of Test Sample Permissible Limits
Test Sieve
Wt.(gm)
1 Test / Each Source & As and When Size of Aggregate
Loss with Na2 Max 12%
Required . 31.5mm 3000
63mm - 40mm SO4
40mm - 20mm 16mm 1500
Loss with Mg Max 18%
20mm - 10mm 8mm 1000 SO4
10mm - 4.75mm 4mm 300
Lab Ref. NO:_________________

Type of Re-Agent used : Na2SO4 / MgSO4 Date of Sampling:______________
No.of Cycles : 5 Date of Testing:_______________
Sieve Size ( mm ) Weight of

Weight of Test Percentage Passing Finer
Grading of Orignal Test Fraction Weighted Average
Fraction After Test Sieve After Test
Sample Percent Before Test ( Corrected Percent Loss )
Passing Retained (gm) ( Actual Percentage Loss )
(gm)
63 40
40 20
20 10
10 4.75
Total
Remarks :_______________________________________________________________________________________________

TEST : AGGREGATE SOUNDNESS TEST

( IS : 2386 - PART 5 )
FINE AGGREGATE
Frequency of Test Size of Test Sample Permissible Limits
Aggregate Sieve Wt.(gm)
1 Test / Each Source & As and When Required . Loss with Na2 SO4 Max 10%
10 - 4.75mm 100
4.75 - 2.36mm 100
Loss with Mg SO4 Max 15%
2.36 - 1.18mm 100
1.18 - 0.600mm 100
0.600 - 0.300mm 100
0.300 - 0.150mm 100
< 0.150mm 100 Lab Ref. No : ________
Type of Re-Agent used : Na2SO4 / MgSO4
Date of Sampling :_____
No.of Cycles : 5
Date of Testing :______
Sieve Size ( mm ) Percentage Passing

Grading of Weight of Test Weight of Test Weighted Average
Finer Sieve After Test
Orignal Sample Fraction Before Test Fraction After Test ( Corrected Percent
( Actual Percentage
Passing Retained Percent (gm) (gm) Loss )
Loss )
10 4.75
4.75 2.36
2.36 1.18
1.18 0.6
0.6 0.3
0.3 0.15
0.15
Total
Remarks :________________________________________________________________________________________

7. SPECIFIC GRAVITY AND WATER ABSORPTION TEST.

(IS: 2386 – PART – 3)
INTRODUCTION:
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.
Object:
To determine the specific gravity and water absorption of aggregates by perforated basket.
Apparatus:
a) A wire basket of not more than 6.3mm mesh or a perforated
container of convenient size with thin wire hangers for
suspending it from the balance. b) A thermostatically controlled
oven to maintain temperature of 1000 to 1100C. c) A container for
filling water and suspending the basket. d) An airtight container
of capacity similar to that of the basket. e) A balance of capacity
about 5 kg, to weigh accurate to 0.5 g, and of such a type and
shape as to permit weighing of the sample container when
suspended in water. f) A shallow tray and two dry absorbent
clothes, each not less than 750 X 450 mm.
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 220 to 320C
with a cover of at least 50mm 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 +/- 0.5 hours afterwards.
The basket and the sample are then weighed while suspended in water at a temperature of 220 to
320C. 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 W1 g. 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 one

of the dry absorbent clothes. The empty basket is then returned to the tank of water, jolted 25 times
and weight in water W2 g.
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 W3 g. The aggregate is placed in a shallow tray and kept
in an oven maintained at a temperature of 1100C for 24 hours. It is then removed from the oven,
cooled in an airtight container and weighed W4 g. At least two tests should be carried out, but not
concurrently.
Calculations:
Weight of saturated aggregate suspended in water with the basket = W1 gms
Weight of basket suspended in water = W2 gms
Weight of saturated aggregate in water = (W1-W2) = Ws gms
Weight of saturated surface dry aggregate in air = W4 gms
Weight of water equal to the volume of the aggregate = (W3-Ws) gms
(i) Specific gravity = Dry weight of aggregate/Weight of equal volume of water
= W4/(W3 – Ws) = W4/[W3 – (W1 – W2)]
(ii)Apparent Sp.gr. =
Dry weight of aggregate/Weight of equal volume of water excluding air voids in aggregates
= W4/(W4 – Ws) = W4/[W4 – (W1 – W2)]
(iii) Water absorption = percent by weight of water absorbed in terms oven dried weight
of aggregates.
= 100 x (W3 – W4)/W4
Limits: The specific gravity of aggregates ranges from 2.5 to 3.0

The water absorption of aggregates ranges from 0.1 to 2.0 %.

TEST : SPECIFIC GRAVITY OF COARSE AGGREGATES

( IS : 2386 - PART 3 )
Basket Method
Lab Ref.No :______________________
Type of Material :______________________

Date of Sample :__________
Source Km. :______________________ Date of Tested :___________
TEST NUMBER MEAN

S.NO DESCRIPTION
1 2 3 VALUE
Weight of Saturated Aggregate and Basket in
1
Water. W1 ( gms )
2 Weight of Basket in Water. W2 ( gms )
Weight of Saturated Surface Dry Aggregates in Air.

3
W3 ( gms )
4 Weight of Oven Dried Aggregates in Air.W4 (gms )
5 Specific Gravity = W3 / [W3 - ( W1 - W2 )]
6 Apparent Specific Gravity = W4 / [W4 - (W1 - W2)]
7 Water Absorption = ( W3 - W4 ) X 100 / W4
Remarks :_____________________________________________________________________________________

8. TEN PERCENT FINES VALUE.

(BS: 812 – PART – 111)
INTRODUCTION:
The ‘Ten percent fines’ value is a measure of resistance of the aggregates to the crushing.
Object:
To determine the ten percent value of aggregates by crushing machine apparatus.
Apparatus:
a) Steel cylinder with open ends, and internal

diameter 152mm, square base plate, plunger
having a piston of diameter 150mm, with a hole
provided across the stem of the plunger so that a
rod could be inserted for lifting or placing the
plunger in the cylinder.
b) Cylindrical measure having internal diameter of

115mm and height 180mm.
c) Steel tamping rod with one rounded end,

having a diameter of 16mm and length 450 to
600mm.
d) Balance of capacity 3 kg with accuracy up to 1gm.
e) Compressive testing machine capable of applying load of 40 tonnes, at a uniform rate of loading of
4 tonnes per minute.
Procedure:
The aggregate passing 14mm IS sieve and retained on 10mm IS sieve is selected for test. The
aggregate should be in surface-dry condition before testing. The aggregate may be dried by heating
at a temperature 1000C to 1100C for a period of 4 hours and is tested after being cooled to room
temperature.
The cylindrical measure is filled by the test sample of aggregate in three layers of approximately equal
depth, each layer being tamped 25 times. The same sample poured in to the cylinder with three equal
layers, each layer being tamped 25 times. The test sample in the cylinder with the plunger in position
is placed in the compression-testing machine. The load is applied at a uniform rate so as to cause a
total penetration of the plunger of about 20mm for normal crushed aggregates in 10 minutes. But for

rounded or partially rounded aggregates, the load required to cause a total penetration of 15mm is
applied where as for honeycombed aggregate like expanded shale or slag that for a total penetration
of 24mm is applied in 10 minutes. After the maximum specified penetration is reached, the load is
released and the aggregate from the cylinder is sieved on a 2.36mm IS sieve. The fines’ passing this
sieve is weighed and is expressed as a percentage by weight of the test sample. This percentage
normally falls in the range of 7.5 to 12.5; but if it does not fall in this range, the test is repeated with
necessary adjustment of the load.
Two tests are carried out at the load ‘X tonnes’, which give the percentage fines between 7.5 to 12.5
and let the mean of the percent fines be ‘Y’ for calculating the load required for ten percent fines.
Load for 10 percent fines = 14 X/(Y + 4)
Results:
The 10 percent fines value of Granular Sub base material is should be more than 50 KN.

TEST : 10 PERCENT FINES VALUE

( BS : 812 PART - 111 )
1 Test / Each Source &
> 50 KN.
As and When Requiored
Type of Material :______________________

Date of Sample :_____________
Weight of Surface dry

Compressive Load
aggregate Weight of fines Mean % of
Applied for 10
Sl.No. Passing 12.5mm & passing 2.36mm IS % of fines fines
minutes (tones)
Retained 10mm IS Sieve (gm) "y"
"x"
Sieve (gm)
14 * x
Load Required for 10 Percent Fines = y+4
Where x = Load in tones.

y = Mean Percentage fines from two tests at x tones load.
Remarks
:_____________________________________________________________________________________

9. BULKAGE & SILT CONTENT OF FINE AGGREGATE.

(IS: 2386 – PART – 3)
INTRODUCTION:
Sand brought on to a building site or other works may contain an amount of moisture, which will
cause it, when loosely filled into a container, to occupy a large volume than it would occupy if dry. If
the sand is measured by loose volume, it is necessary in such a case to increase the measured volume
of the sand, in order that the amount of sand put into the concrete may be the amount intended for
the nominal mix used (based on dry sand). It will be necessary to increase the volume of sand by the
‘percentage’ bulking. The correction to be made is only a rough approximation because the system of
measurement by loose volume is a rough method at the best, but a correction of the right order can
easily be determined and should be applied in order to keep the concrete uniform.
Object:
This method of test covers the field method for determining the necessary adjustment for the bulking
& silt content of fine aggregate.
Apparatus:
250ml measuring cylinder, tray and water cane etc.
Procedure:
In a 250ml-measuring cylinder, pour the damp sand (consolidated
by shaking) until it reached the 200ml mark. Then fill the cylinder
with water and stir the sand well (the water shall be sufficient to
submerge the sand completely). It will be seen that the sand
surface is now below its original level. Suppose the surface is at the
mark ‘Y’ml the percentage of bulking of the sand due to moisture
shall be calculated from the formula.
Percentage bulking = 100 x [(200/Y) – 1)]
Silt content = 100 x (X – Y)/Y
Where, X = the level of top surface of material i.e., sand + sedimentation of silt.
Y = the level of top surface of sand layer.
Results: Report the percentage bulking of the sand to the nearest whole number.
Limits: Bulkage and silt content is allow maximum 10%

10. STONE POLISHING VALUE

(BS: 812 – PART – 114)
INTRODUCTION:
The object of this test is to determine the polished stone value which gives a relative measure of the
extent to which different types of road stone in the wearing surface will polish under traffic.
Object:
To determine the Stone Polishing Value of aggregates by accelerated action in a special machine and
by suitable friction tester.
Apparatus: The apparatus shall consist of the following:

a) An accelerated polishing machine which shall be rigidly mounted on a firm, level and non-resilient
base of stone or concrete and shall include:
1) A road wheel having a flat periphery, and of such a size and shape as to permit 14 of the
specimens to be clamped on the periphery so as to form a continuous surface of stone particles 45
mm wide and 405 mm in diameter.
2) Means for rotating the road wheel about its own axis at a speed of 320 to 325 rev/min.
3) Means for bringing the surface of a rubber-tyred wheel of 20 cm diameter and 5 cm breadth to
bear on the stone surface of the road wheel with a total load of 40 kg. The tyre shall be an industrial
8 x 2 pneumatic 4-ply rating smooth hand-truck tyre with a hardness of 55 ± 5 and shall be inflated to
a pressure of 3.15 ± 0.15 kg/cm2. It shall be free to rotate on its own axis, which shall be parallel with
the axis of the road wheel; the plane of rotation of the tyre shall be accurately in line with that of the

road wheel. Before a new tyre is used on an actual test, it shall be given a preliminary run of 3 hours
with sand and 3 hours with emery flour, as in an actual test, but using spare specimens. The tyre
shall be discarded after 30 test runs have been made with it, or sooner if it shows signs of irregular
wear.
Preparation of Specimens and Testing Procedure:

1. The standard specimens shall be prepared with 10 mm passing IS Sieve and be retained on the 8
mm IS Sieve and shall be neither flaky nor elongated. These shall be clean and free from dust.
2. Each specimen shall consist of a single layer of 40 to 50 of the particles spaced as closely as
possible and covering an area of 90.5 x 44.5 mm, set in a sand-cement mortar with their exposed
surfaces proud of the mortar. The surface of the specimen shall be flat across the shorter
dimension but shall be curved in the arc of a circle of 400 mm diameter along the longer
dimension.
3. The individual particles shall be mounted in such a way that the surfaces exposed to wear are as
nearly flat as possible, and in any case present no sharp edges to the polishing tyre.
4. The specimens shall be not less than 12.5 mm thick, and shall be of such a shape as to permit
their being clamped round the flat periphery of the road wheel of the accelerated polishing
machine so as to form a continuous outer surface of particles with an outer diameter of 405 mm.
5. At least two specimens shall be made from each material to be tested.
6. The specimens shall be rigidly clamped round the periphery of the road wheel of the accelerated
polishing machine. The wheel will accommodate 14 specimens.
7. The pneumatic tyred wheel shall be brought to bear on the surface of the specimens with a total
load of 40 kg and the road wheel started up and brought to a speed of 320 to 325 rev/min.
8. At the rate of 20g/min Water, and 12g/min of specified sand shall be fed continuously for a period
of 3 hours. The specification of feeding sand as follows:
Feeding Sand Gradation

Passing IS Sieve Percentage by Weight
425 micron 100
300 micron 85 – 100
212 micron 20 – 50
150 micron 0–5
9. The specimens thoroughly cleaned by washing so that all traces of sand are removed and the
machine operated for a further 3 hours with feeding of water and emery powder with following
rates. Rate of spread of water is 5g/min and rate of spread of emery powder is 2g/min. The
specification of feeding emery powder as follows:
Feeding Emery Powder Gradation

Passing IS Sieve Percentage by Weight
60 micron 100
2 micron 70 – 100
10. Stop the polishing machine and cleaned by washing the specimens. The specimens shall then be
tested on the friction tester.

11. The test shall be made at a temperature of 20 ± 20C.

12. The tester shall rest upon a firm level surface and leveling screws shall be adjusted so that the
column is vertical.
13. The axis of suspension of the pendulum shall then be raised so that the arm swings freely, and
the friction in the pointer mechanism shall be adjusted so that when the pendulum arm and
pointer are released from the right hand horizontal position the pointer comes to rest at the zero
position on the scale.
14. The specimen shall then be rigidly located with its longer dimension lying in the track of the
pendulum, and centrally with respect to the rubber slider and to the axis of suspension of the
pendulum.
15. The height of the axis of suspension of the pendulum shall then be adjusted so that in traversing
the specimen the rubber slider is in contact with it over the whole width of the slider and over a
length of 75 ± 1.5 mm of the specimen under a normal load of 2.25 ± 0.05 kg.
16. The surface of the specimen and the rubber slider shall then be wetted with a copious supply of
clean water, care being taken not to disturb the slider from its set position.
17. The pendulum and pointer shall then be released from the horizontal position and the reading of
the pointer recorded to the nearest whole number.
18. The procedure shall then be repeated with a second specimen of the same material.
19. If the values obtained from the two specimens differ by more than 3 percent, a further specimen
or specimens shall be tested until two values agree with in this limit.
Reporting of Results:
The mean of the two values of the coefficient of friction, expressed as a percentage, shall be reported
to the nearest whole number as Polished Stone Value.
Limits: Permissible Limit = Minimum 55%

11. DELETERIOUS CONTENT OF AGGREGATES – Determination of Clay Lumps.

(IS: 2386 – PART – 2)
Apparatus:
1) Balance – sensitive to 0.001 g, 2) Containers – size and shape that will permit the spreading of the
sample on the bottom in a thin layer, 3) Sieves – conforming to IS : 460-1962.
Sampling:
Samples shall be obtained by quartering or by the use of a sampler, from a representative sample
selected from the material to be tested. They shall be handled in such a manner as to avoid breaking
up clay lumps, which may be present. Samples shall be dried to constant weight at a temperature not
exceeding 1100C.
Samples of fine aggregate shall consist of particles coarser than 1.18 mm IS sieve and shall weigh not
less than 100 g.
Samples of coarse aggregate shall be separated into different sizes using 4.75mm, 10mm, 20mm and
40mm IS sieves. The weight of the sample for different sizes shall be not less than those indicated
below:
Size of Particles Making Up

Weight of Sample Min. (g)
the Samples (mm)
4.75 - 10 1000
10 - 20 2000
20 - 40 3000
Over 40 5000
In the case of mixtures of fine and coarse aggregates, the material shall be separated into two sizes
on 4.75mm IS sieve, and the samples of fine and coarse aggregates shall be prepared as described
above.
Procedure:
The sample shall be spread in a thin layer on the bottom of the container and examined for clay
lumps. Any particles, which can be broken into finely divided particles with the fingers, shall be
classified as clay lumps. After all discernible clay lumps have been broken, the residue from the clay
lumps shall be removed by the use of sieves indicated below:

Size of Particles Making up the Size of Sieve for Sieving Residue of

Sample Clay Lumps
Fine aggregate (retained on 1.18mm
850 - micron
IS sieve)
4.75 to 10 mm 2.36 mm
10 mm to 20 mm 4.75 mm
20 mm to 40 mm 4.75 mm
Over 40 mm 4.75 mm
Calculations:
The percentage of clay lumps shall be calculated to the nearest 0.1 percent in accordance with the
following formula:
L = 100 x (W – R)/W
Where, L = percentage of clay lumps.

W = weight of sample.
R = weight of sample after removal of clay lumps.

12. DELETERIOUS CONTENT OF AGGREGATES –

Determination of Clay, Fine Silt and Fine Dust
Apparatus:
1) A watertight screw-topped glass jar of dimensions similar to a 1-kg fruit-preserving jar, 2) A device
for rotating the jar about its axis, with this axis horizontal, at a speed of 80 +/- 20 rev/min, 3) A
sedimentation pipette of the Andreason type of approximately 25 ml capacity. This consists mainly of
a pipette fitted at the top with a two way tap and held rigidly in a clamp which can be raised or
lowered as required, and which is fitted with a scale from which the changes in height of the pipette
can be read, 4) A 1000 ml measuring cylinder, 5) A scale or balance of capacity not less than 10 kg,
readable and accurate to one gram, 6) A scale or balance of capacity not less than 250 g, readable
and accurate to 0.001 g, 7) A well ventilated oven, thermostatically controlled, to maintain a
temperature of 100 to 1100C.
Chemicals:
A solution containing 8 g of sodium oxalate per litre of distilled water shall be taken. For use, this
stock solution is diluted with distilled water to one tenth (that is 100 ml diluted with distilled water to
one litre).
Test sample:
The sample for test shall be prepared from the main sample taking particular care that the test
sample contains a correct proportion of the finer material. The amount of sample taken for test shall
be in accordance with below table.
Maximum size present in Approximate weight of sample

substantial proportions (mm) for test (kg)
63 to 25 6
20 to 12.5 1
10 to 6.3 0.5
4.75 or smaller 0.3
All in aggregates shall be separated into fine and coarse fractions by sieving on a 4.75 mm IS sieve
and the two samples so obtained shall be tested separately.
Procedure:
Method for fine aggregate: Approximately 300 g of the sample in the air dry condition, passing the
4.75 mm IS sieve, shall be weighed and placed in the screw topped glass jar, together with 300 ml of
the diluted sodium oxalate solution. The rubber washer and cap shall be fixed, care being taken to

ensure water tightness. The jar shall then be rotated about its long axis, with this axis horizontal, at a
speed of 80 +/- 20 rev/min for a period of 15 minutes. At the end of 15 minutes, the suspension shall
be poured into the 1000 ml measuring cylinder and the residue washed by gentle swirling and
decantation of successive 150 ml portions of sodium oxalate solution, the washings being added to
the cylinder until the volume is made up to 1000 ml. The determination shall be completed as
described below.
Method for coarse aggregate: The weighed sample shall be placed in a suitable container, covered
with a measured volume of sodium oxalate solution (0.8 g per litre), agitated vigorously to remove all
adherent fine material and the liquid suspension transferred to the 1000 ml measuring cylinder. This
process shall be repeated as necessary until all clayey material has been transferred to the cylinder.
The volume shall be made up to 1000 ml with sodium oxalate solution and the determination
completed as described below.
The suspension in the measuring cylinder shall be thoroughly mixed by inversion and the tube and
contents immediately placed in position under the pipette. The pipette shall then be gently lowered
until the tip touches the surface of the liquid, and then lowered a further 10 cm into the liquid. Three
minutes after placing the tube in position, the pipette and the bore of tap shall be filled by opening
and applying gentle suction. A small surplus may be drawn up into the bulb between tap and tube,
but this shall be allowed to run away and any solid matter shall be washed out with distilled water
from top end. The pipette shall then be removed from the measuring cylinder and its contents run
into a weighed container, any adherent solids being washed into the container by distilled water from
top end. The contents of the container shall be dried at 100 to 1100C to constant weight, cooled and
weighed.
Calculations: The proportion of fine silt and clay or fine dust shall then be calculated from the
following formula:
Percentage of clay and fine silt or fine dust = (100/W1) x [(1000 x W2/V) – 0.8]
Where, W1 = weight in g of the original sample.

W2 = weight in g of the dried residue.
V = volume in ml of the pipette
0.8 = weight in g of sodium oxalate in one litre of the diluted solution.

13. DELETERIOUS CONTENT OF AGGREGATES – Determination of Light – Weight Pieces
Apparatus:
1) Balances – for weighing fine aggregates, a balance having a capacity of not less than 500 g,
sensitive to at least 0.1 g; for weighing coarse aggregates, a balance having a capacity of not less
than 5000 g, sensitive to at least 1 g.
2) Containers – containers suitable for drying the aggregate sample, and containers suitable for
holding the heavy liquid during the sink-float separation.
3) Skimmer – a piece of 300-micron sieve cloth of suitable size and shape for separating the floating
pieces from the heavy liquid.
4) Hot-plate or oven.
Heavy liquid:
The heavy liquid shall consist of a mixture of carbon tetrachloride, and 1, 1, 2, 2-tetrabromoethane,
bromoform, and monobromobenzene, or bromoform and benzene, in such proportions that the
desired specific gravity will be obtained. Bromotrichloromethane may be used as a heavy liquid having
a specific gravity of 2.00. The specific gravity shall be maintained within +/- 0.01 of the specified
value at all times during the test.
The approximate volumes of materials to be combined to produce a mixture of the desired specific
gravity may be computed from the following specific gravities of the different liquids:
Liquid Specific gravity

1,1,2,2-tetrabromoethane 2.97
Benzene 0.88
Bromoform 2.88
Carbon tetrachloride 1.58
Monobromobenzene 1.49
For determining coal and lignite, the heavy liquid used shall have a specific gravity of 2.00 +/- 0.01.
Test Sample: The minimum size of test sample shall be as follows:
Maximum size of Minimum weight of

aggregate (mm) sample (grms)
6.3 (fine aggregate) 200
20 3000
40 5000
80 10000

Procedure:
1) Fine aggregate: Allow the dried sample of fine aggregate to cool to room temperature and then
sieve over a 300-micron IS sieve until less than one percent of the retained material passes the sieve
in one minute of continuous sieving. Weigh the material coarser than the 300-micron IS sieve to the
nearest 0.1 g; then introduce it into the heavy liquid in a suitable container, the volume of liquid being
at least three times the absolute volume of the aggregate. Pour the liquid off into a second container;
passing it through the skimmer and taking care that only the floating pieces are poured off with the
liquid and that none of the sand is decanted onto the skimmer. Return to the first container the liquid
that has been collected in the second container and, after further agitation of the sample by stirring,
repeat the decanting process just described until the sample is free of floating pieces. Wash the
decanted pieces contained on the skimmer in carbon tetrachloride, until the heavy liquid is removed,
and then dry. The pieces will dry very quickly, but may be placed in an oven at 1050C for a few
minutes if desired. Brush the dry decanted pieces from the skimmer onto the balance pan and
determine the weight to the nearest 0.1 g.
2) Coarse aggregate: Allow the dried sample of coarse aggregate to cool to room temperature and
sieve over a 4.75 mm IS sieve. Weigh the material coarser than the 4.75 mm IS sieve to the nearest 1
g; then introduce it into the heavy liquid in a suitable container, the volume of the liquid being at least
three times the absolute volume of the aggregate. Using the skimmer, remove the pieces that rise to
the surface, and save them. Repeatedly agitate the remaining pieces and remove the floating pieces
until no additional pieces rise to the surface. Wash the decanted pieces in carbon tetrachloride until all
of the heavy liquid is removed, and allow to dry. Determine the weight of the decanted pieces to the
nearest 1-gram.
Calculations: Calculate the percentage of lightweight pieces as follows:
For fine aggregate: L= 100 x (W1/W2)
For coarse aggregate: L= 100 x (W1/W3)
Where, L = percentage of lightweight pieces.

W1 = dry weight in g, of decanted pieces.
W2 = dry weight in g, of portion of sample coarser than 300-micron IS sieve.
W3 = dry weight in g, of portion of sample coarser than 4.75 mm IS sieve.

14. DELETERIOUS CONTENT OF AGGREGATES – Determination of Soft Particles
Apparatus:
The apparatus shall consist of a brass rod, having a Rockwell hardness of 65 RHB to 75 RHB. A brass
rod of about 1.6mm diameter and of proper hardness inserted into the wood shaft of an ordinary lead
pencil is a convient tool for field or laboratory use.
Test Sample:
Aggregates for the test shall consist of material from which the sizes finer than the 10mm IS sieve
have been removed. The sample tested shall be of such size that it will yield not less than the
following amount of the different sizes, which shall be available in amounts of 10 percent or more:
Sieve size (mm) Sample Weight (grms)

10 to 12.5 200
12.5 to 20 600
20 to 25 1500
25 to 40 4500
40 to 50 12000
Procedure:
Each particle of aggregate under test shall be scratched with the brass rod with a small amount of
pressure (about 1 kg). Particles are considered to be soft if during the scratching process, a groove is
made in them without deposition of metal from the brass rod or if separate particles are detached
from the rock mass.
Calculations: The report shall include the following information.
a) Weight and number of particles of each size of each sample tested with the brass rod.
b) Weight and number of particles of each size of each sample classified as soft in the test.
c) Percentage of test sample classified as soft by weight and by number of particles.
d) Weighed average percentage of soft particles calculated from percentage in item (c) and based on
the grading of sample of aggregate received for testing.

BITUMEN & BITUMINOUS

MATERIALS.

Bitumen: Bitumen is a petroleum product obtained by the distillation of petroleum crude.
Tar: Tar is obtained by the destructive distillation of coal or wood.
Both bitumen and tar have similar appearance, as both are black in color, both these materials can be
used for pavement works, but they have different characteristics.
The bitumen is brought to sufficient fluidity or viscosity before use in pavement construction by any
one of the following three methods:
a) by heating, in the form of hot bitumen binder.
b) by dissolving in light oils, in the form of cutback bitumen.
c) by dispersing bitumen in water, in the form of bituminous emulsion.
The paving bitumen available in India is classified into two categories:
i) paving bitumen from Assam petroleum denoted as A-type and designated as A35, A45, A55, A65,
A90 & A200.
ii) paving bitumen from other sources denoted as S-type and designated as S35, S45, S55, S65, S90 &
S200.
Cutback bitumen: is defined as the bitumen, the viscosity of which has been reduced by a volatile
diluents. For use in surface dressings, some types of bituminous macadam. Cutback bitumens are
available in three types, namely (i) Rapid curing (RC), (ii) Medium curing (MC) and (iii) Slow
curing(SC).
Bitumen Emulsion: is a liquid product in which a substantial amount of bitumen is suspended in a

finely divided condition in an aqueous medium and stabilized by means of one or more suitable
materials. The main advantages of emulsions are that (i) they can be used, without heating for
preparing mixes, (ii) they are particularly useful for patch repair works and can be used even when
the surface is wet or it is raining. Three types of emulsified bitumen can be prepared (i) Rapid Setting
(RS)- is a setting emulsified bitumen used for penetration and surface treatment, (ii) Medium Setting
(MS)- is used for plant mixes with coarse aggregate, (iii) Slow Setting (SS)- is used for fine aggregate
mixes.
Foamed Bitumen: is an alternative to cutback bitumen or bitumen emulsion and has the
advantage of higher initial set up strength because it contains no cutter, and only about 3% water.
The process is in the development stage and is not widely used at present.

1. PENETRATION TEST
(IS: 1203 – 1978)
INTRODUCTION:
Penetration test is the test on bitumen to grade the material in term of its hardness.
Object:
To determine the penetration of bitumen by penetration test.
Apparatus:
a) Container: A flat-bottomed cylindrical metallic

container 55mm in diameter and 35mm or 57mm in
height.
b) Needle: A straight, highly polished hard steel needle.
c) Water bath: A water bath is maintained at 25 +/- 10C

containing not less than 10 liters of water, the sample is
immersed to depth not less than 100mm from the top
and supported on a perforated shelf not less than 50mm
from the bottom of the bath.
d) Penetrometer: Electrically operated automatic

penetrometer / Manually operated penetrometer. It is an
apparatus, which allows the needle assembly of gross
weight 100gm to penetrate without appreciable friction
for the desired duration of time 5 sec. The dial is
accurately calibrated to give penetration value in units of
one tenth of an mm.
e) Transfer tray: A small tray, which can keep the container fully immersed in water during the test.
f) Stop Watch.
Procedure:
The bitumen is softened to a pouring consistency between 750C and 1000C above the approximate
temperature at which bitumen softens. The sample material is thoroughly stirred to make it
homogenous and free from air bubbles and water. The sample material is then poured into the
containers to a depth at least 15 mm more than the expected penetration. The sample containers are

cooled in atmosphere temperature not lower than 130C for one hour. Then they are placed in
temperature controlled water bath at a temperature of 250C for a period of one hour.
The sample container is placed in the transfer tray with water from the water bath and placed under
the needle of the penetrometer. The weight of needle, shaft and additional weight are checked. The
total weight of this assembly should be 100gm.
Using the adjusting screw, the needle assembly is lowered and the tip of the needle is made to just
touch the top surface of the sample, the needle assembly is clamped in this position. The contact of
the tip of the needle is checked using the mirror placed on the rear of the needle. The initial reading
of the penetrometer dial is either adjusted to zero or the initial reading is taken before releasing the
needle. The needle is released exactly for a period of 5 sec. by pressing the knob and the final
reading is taken on the dial. At least three measurements are made on this sample by testing at
distance of not less than 10mm apart. After each test the needle is disengaged and cleaned with
benzene and carefully dried. The sample container is also transferred in the water bath before next
testing is done so as to maintain a constant temperature of 250C. The test is repeated with sample in
the other containers.
Results:
The difference between the initial and final penetration readings is taken as the penetration value.
Paving Bitumen Grade VG – 10 VG – 20 VG – 30 VG – 40

Penetration Value, mm Min. 80 mm Min. 60 mm Min. 45 mm Min. 35 mm

PENETRATION OF BITUMEN
( IS : 1203 - 1978 )

Grade VG – 30 Min.45mm
2 Samples / Consignment
Grade VG – 40 Min.35 mm
Lab Ref. No :________________ Date of Sampling :__________
Grade of Sample :____________ Date of Testing :__________
Test Load 100 + / - 0.25 gms

0 0
Test Temp. 25 C + / - 1 C
Test Duration 5 Seconds.
TRIAL NO. PENETRATION 1/10 mm. SPECIFICATION 1/10 mm.
AVERAGE =
Remarks :________________________________________________________________

2. SPECIFIC GRAVITY TEST.

(IS: 1202 – 1978)
Object:
To determine the specific gravity of the bitumen by specific gravity bottle.
Apparatus:
a) Pycnometer / specific gravity bottle – 50 ml capacity. b)
Balance – sensitivity 0.1mg.
Procedure:
The specific gravity bottle is cleaned, dried and weighed
along with the stopper. It is filled with fresh distilled water,
stopper placed and the same is kept in water container for
at least half an hour at temperature 270C +/- 10C. The
bottle is then removed and cleaned from outside. The
specific gravity bottle containing distilled water is now
weighed.
The bituminous material is heated to a pouring temperature and is poured in the above empty bottle
taking all the precautions that it is clean and dry before filling sample materials. The material is filled
up to the half taking care to prevent entry of air bubbles. To permit an escape of air bubbles, the
sample bottle is allowed to stand for half an hour at suitable temperature cooled to 270C and then
weighed. The remaining space in the specific gravity bottle is filled with distilled water at 270C,
stopper placed and is placed in water container at 270C. The bottle containing bituminous material
and remaining water is removed, cleaned from outside and is again weighed.
Calculations:
The specific gravity of the bituminous material is calculated as follows:
Specific gravity = (Weight of bituminous material)/(Weight of equal volume of water at 270C)
= (c – a)/[(b – a) – (d – c)]
Where, a = weight of the specific gravity bottle

b = weight of the sp.gravity bottle filled with distilled water.
c = weight of the sp.gravity bottle about half filled with bitumen.
d = weight of the sp.gravity bottle about half filled with bitumen and
the distilled water.
Limits: Specific gravity of Bitumen at 270C is Minimum 0.99.

SPECIFIC GRAVITY OF BITUMEN

( IS : 1202 - 1978 )

Grade VG – 30 0.99
Grade VG – 40 0.99
Lab Ref. No :________________ Date of Sampling:__________
0 0
Test Temp. 27 C + / - 1 C
S.NO DESCRIPTION NOTATION WEIGHT ( gms )
Weight of Empty bottle with stopper

1 A
( gms )
Weight of Bottle + Distilled watyer
2 B
( gms )
Weight of Bottle + Half filled material
3 C
( gms )
Weight of Bottle + Half filled material +
4 D
Distilled water ( gms )
(C-A)
5 Specific Gravity
[( B - A ) - ( D - C )]
Remarks :________________________________________________________________

3. SOFTENING POIN TEST ( RING AND BALL TEST ).

(IS: 1205 – 1978)
INTRODUCTION:
Bitumen does not suddenly change from solid to liquid state, but as the temperature increases, it
gradually becomes softer until it flows readily. All semi-solid state bitumen grades need sufficient
fluidity before they are used for application with the aggregate mix. For this purpose bitumen is
sometimes cutback with a solvent like kerosene. The common procedure however is to liquefy the
bitumen by heating. The softening point is the temperature at which the substance attains particular
degree of softening under specified condition of test. For bitumen, it is usually determined by ‘Ring
and Ball’ test.
Object:
To determine the softening point of the bitumen by ‘Ring and Ball’ apparatus.
Apparatus:
a) Ring and Ball apparatus – It consists
(i) Steel Balls – 2 nos.each has a diameter of 9.5mm and

weight is 2.5+/-0.05gm.
(ii) Brass Rings – 2 nos. each 6.4mm depth, inside diameter
at top 17.5mm, inside diameter at bottom 15.9mm and
outside diameter 20.6mm and three equally spaced ball
guides.
(iii) Support - The metallic support is used for placing pair of
rings. The upper surface of the rings is adjusted to be 50mm
below the surface of water or liquid contained in the bath. A
distance of 25mm between the bottom of the rings and top
surface of the bottom plate of support is provided. It has a
housing for a suitable thermometer.
b) Thermometer – 00C to 3500C – sensitivity 0.10C.
c) Bath and stirrer – A heat resistant glass container of 85mm diameter and 120mm depth is used.

Procedure:
Sample material is heated to a temperature between 75 and

1000C above the approximate softening point until it is
completely fluid and is poured in heated rings placed on
metal plate. To avoid sticking of the bitumen to metal plate,
coating is done to this with a solution of glycerin and dextrin.
After cooling the rings in air for 30 minutes, the excess
bitumen is trimmed and rings are placed in the support as
mentioned in item(iii) above. At this time the temperature of
distilled water is kept at 50C. This temperature is maintained
for 15 minutes after which the balls are placed in position.
The temperature of water is raised at uniform rate of 50C per
minute with a controlled heating unit, until the bitumen
softens and touches the bottom plate by sinking of balls. At
least two observations are made.
Results:
The temperature at the instant when each of the ball and sample touches the bottom plate of support
is recorded as softening value.
Limits:

0 0 0 0
Softening Point, C Min. 40 C Min. 45 C Min. 47 C Min. 500C

SOFTENING POINT OF BITUMEN

( IS : 1205 - 1978 )

0
Grade VG – 30 Min. 47 C
2 Samples / Consignment 0
Grade VG – 40 Min. 50 C
TYPE DATE DATE Temperature at which sample

SUPPLIED 0
touches bottom plate ( C)
S.NO OF MANUFACTURER OF OF
QUANTITY
BITUMEN ARRIVAL TESTING 1st.RING 2nd.RING AVERAGE
1
Remarks :________________________________________________________________

4. VISCOSITY TEST.
(IS: 1206 – 1978)
INTRODUCTION:
Viscosity is defined as inverse of fluidity. Viscosity thus defines the fluid property of bituminous
material. The degree of fluidity at the application temperature greatly influences the ability of
bituminous material to spread, penetrate into the voids and also coat the aggregates and hence
affects the strength characteristics of the resulting paving mixes.
Object:
To determine the viscosity of bitumen by Tar Viscometer.
Apparatus:
Tar Viscometer with 4mm and 10mm orifices – The apparatus

consists of main parts like cup, valve, water bath, sleeves, stirrer,
receiver and thermometers etc.
Procedure:
The tar cup is properly leveled and water in the bath is heated to
the temperature specified for the test and is maintained
throughout the test. Stirring is also continued. The sample
material is heated at the temperature 200C above the specified
test temperature, and the material is allowed to cool. During this
the material is continuously, stirred. When material reaches
slightly above test temperature, the same is poured in the tar cup, until the leveling peg on the valve
rod is just immersed. In the graduated receiver (cylinder), 25ml of mineral oil or one percent by
weight solution of soft soap is poured. The receiver is placed under the orifice. When the sample
material reaches the specified testing temperature within +/- 0.10C and is maintained for 5 minutes,
the valve is opened. The stopwatch is started, when cylinder records 25ml. The time is recorded for
flow up to a mark of 75ml.(i.e., 50ml of test sample to flow through the orifice).
Results:
The time in seconds for 50ml of the test sample to flow through the orifice is defined as the viscosity
at a given test temperature.

Limits:
Type of Orifice size, Viscosity
Test temp,0C
material mm range, sec.
A35 & S35 10mm 600C 90 - 100
A45 & S55 10mm 600C 80 - 90
A55 & S55 10mm 600C 70 - 80
A65 & S65 10mm 600C 60 - 70
A90 & S90 10mm 600C 50 - 60
A200 & S200 10mm 600C 40 - 50
Cutback -
RC,MC&SC - 4mm 250C 25 - 75
Grade - 0
Grade - 1 4mm 250C 50 - 150
Grade - 2 10mm 250C 10 - 20
Grade - 3 10mm 250C 25 - 75
Grade - 4 10mm 400C 14 - 45
Grade - 5 10mm 400C 60 - 140
Viscosity conversion chart:

Required Viscosity
sec. sec. sec. sec. sec. sec.
Known Viscosity cs. 0
Engler Redw. Redw. STV. STV. Saybolt. Saybolt.
Vk
I II 10 mm 4 mm Univ. Furol.
Centi Stock, Vk 1 0.132 4.10 0.41 0.0025 0.076 4.70 0.47
0
Engler 7.58 1 31.10 3.11 0.019 0.576 35.63 3.563
sec. Redw. I 0.244 0.0322 1 0.10 0.00061 0.0185 1.12 0.112
sec. Redw. II 2.44 0.322 10 1 0.0061 0.185 11.2 1.12
sec. STV. 10 mm 400 52.80 1640 164 1 30.40 1880 188
sec. STV. 4 mm 13.20 1.74 54.10 5.41 0.033 1 62.04 6.204
sec. Saybolt. Univ. 0.213 0.028 0.873 0.0873 0.00053 0.0162 1 0.10
sec. Saybolt. Furol. 2.13 0.28 8.73 0.873 0.0053 0.162 10 1

VISCOSITY TEST OF BITUMEN

( IS : 1206 - 1978 )
Grade VG- 30 2400 – 3600 Poises / Min.70 sec.
Grade VG- 40 3200 – 4800 Poises / Min.90 sec.
Test Run 50 ml Collection.
0
Test Temp. 60 C
Viscosity (η) (Units) Seconds / Poises / Centistokes

Viscosity (η) = pa.s Flow time x ρ (gm/ml) x constant
1 Poise 10 pa.s
For 4 mm orifice = 0.0132
Constants (STV)
For 10 mm orifice = 0.400
2
Stock cm / sec.
1 Centistock 10 Stocks
4 mm Orifice 1cst = 0.076 sec.
10mm Orifice 1cst = 0.0025sec.
Mean
S.NO DESCRIPTION Test -1 Test -2 Test -3 Test -4
Value
0
1 Specific Test Temp. C
2 Size of Orifice in mm
0
3 Actual Test Temp. C
4 Test Run.
5 Viscisity in Seconds.
Remarks
:________________________________________________________________

Absolute Viscosity (IS: 1206 – Part 2) & Kinematic Viscosity (IS: 1206 – Part3):
Absolute Viscosity (IS: 1206 – Part 2)

Absolute or Dynamic Viscosity is an internal friction, such that a tangential force of one dyne (0.00001
N) acting on planes of unit area separated by unit distance of the liquid produces unit tangential
velocity, the cgs unit for the viscosity of the liquid is one Poise.
Kinematic Viscosity (IS: 1206 – Part3):
It is defined as the quotient of the absolute or dynamic viscosity divided by the density of the liquid of
the liquid under test. The cgs unit of kinematic viscosity is the stoke which has the dimensions square
centimeter per second. For kinematic viscosity is generally expressed in centistokes (cSt) which is
1/100th of a stoke.
Object:
Absolute Viscosity (IS: 1206 – Part 2) Kinematic Viscosity (IS: 1206 – Part3)
To determine the Absolute viscosity of bitumen by To determine the Kinematic viscosity of bitumen
Cannon Manning Vacuum Viscometer as per IS: by U-Tube Reverse Flow Viscometer as per IS:
1206-Part 2 1206-Part 3
Apparatus:
1. Constant Temperature Bath – A 1. Constant Temperature Bath – A

suitable bath for immersion of at least 6 suitable bath for immersion of at least 6
vacuum capillary viscometer tubes with a vacuum capillary viscometer tubes with a
digital temperature controller. The digital temperature controller. The
accuracy of the temperature in the bath accuracy of the temperature in the bath
should be +/- 0.1 C throughout the bath. should be +/- 0.1 C throughout the bath.
2. Silicone Bath Oil - suitable up to 1500 C 2. Silicone Bath Oil - suitable up to 1500 C
3. Timing Device – A stop watch or stop 3. Timing Device – A stop watch or stop
clock capable of reading up to ½ second. clock capable of reading up to ½ second.
4. Cannon-Manning Vacuum 4. U-Tube Reverse Flow Viscometers –

Viscometers – With manufacturers’ with manufacturers’ calibration certificate,
calibration certificate, viscometer holder viscometer holder and silicone cork. Size 5
and silicone cork. Size 12 and Size 13 (one and Size 6 (one each) [Size 5 is suitable
each) [Size 12 is suitable for testing VG-10 for testing VG-10 and Size 6 is suitable for
and Size 13 is suitable for testing VG-20, testing VG-20, VG-30 and VG-40
VG-30, and VG-40 bitumen.] bitumen.]

Cannon-Manning Viscometer (Absolute) U-Tube Reverse Flow Viscometer (Kinematic)
Viscometer Silicon Bath

Procedure:
U-Tube Reverse Flow Viscometer (Kinematic

Cannon-Manning Viscosity (Absolute Viscosity)
Viscosity)
Sample Preparation Sample Preparation
1. Heat the bitumen sample to a temperature 1. Heat the bitumen sample to a temperature not
not more than 900 C approx. softening point more than 900 C approx. softening point until is
until is has become sufficiently fluid. has become sufficiently fluid.
2. Transfer about 20 ml into a suitable container 2. Transfer about 20 ml into a suitable container
and maintain at a temperature of 135 ± 5.50C and maintain at a temperature of 135 ± 5.50C
stirring occasionally to allow entrapped air to stirring occasionally to allow entrapped air to
escape. escape.
3. Pour the hot bitumen in the Canning-Manning 3. Pour the hot bitumen in the U-Tube Reverse
vacuum viscometer with the help of special Flow viscometer with the help of special pipette
pipette and fill bitumen is within ± 2 mm of and fill bitumen is within ± 2 mm of the fill line
the fill line E & F. Place the charged G & H. Place the charged viscometer in an oven
viscometer in an oven or bath maintained at or bath maintained at 135 ± 5.50C for a period
135 ± 5.50C for a period of 10 ± 2 minutes to of 10 ± 2 minutes to allow larger air bubbles to
allow larger air bubbles to escape. escape.
Testing Testing
1. Maintain the test bath temperature at 60 ± 1. Maintain the test bath temperature at 135 ±
0.10 C. Place the charged viscometer vertically 0.10 C. Place the charged viscometer vertically
in the test bath with the help of a holder so in the test bath with the help of a holder so
that that the uppermost timing mark is at that that the uppermost timing mark is at least
least 2 cm below the surface of the bath 2 cm below the surface of the bath liquid.
liquid.
2. Establish a vacuum of 30 ± 0.05 cm of 2. Establish a vacuum of 30 ± 0.05 cm of mercury

mercury in the vacuum system and connect to in the vacuum system and connect to the
the viscometer with the valve closed. After viscometer with the valve closed. After the
the viscometer has been in the bath for 30 ± 5 viscometer has been in the bath for 30 ± 5
min, open the valve and allow the bitumen to min, open the valve and allow the bitumen to
flow in the viscometer. flow in the viscometer.
3. Measure the time required (to within ± 0.5 3. Measure the time required (to within ± 0.5 sec)
sec) for the leading edge of the meniscus to for the leading edge of the meniscus to pass
pass between successive pairs of timing between successive pairs of timing marks.
marks.
4. Report the first flow time which exceeds 60 4. Report the first flow time which exceeds 60 sec
sec between a pair of timing marks, noting between a pair of timing marks, noting the

the identification of the pair of the timing identification of the pair of the timing marks.
marks.
Calculation and Report:
Cannon-Manning Viscosity (Absolute Viscosity) U-Tube Reverse Flow Viscometer (Kinematic

Viscosity)
Calculate and report the absolute viscosity in poises Calculate and report the Kinematic viscosity in
to three significant figures centistokes to significant figure
Viscosity in Poises @ 600C = Kt Viscosity in Centistokes @ 1350C = Kt

Where, Where,
K = Calibration factor in poise per second K = Calibration factor in centistokes per second
t = Flow time in seconds. t = Flow time in seconds.
Limits:
Characterstics Paving Grades

VG – 10 VG – 20 VG – 30 VG – 40
0
Absolute Viscosity at 60 C, Poises 800 - 1200 1600 - 2400 2400 - 3600 3200 - 4800
Kinematic Viscosity at 1350C, cSt, Min. 250 300 350 400

5. FLASH AND FIRE POINT TEST.

(IS: 1209 – 1978)
INTRODUCTION:
Bituminous materials leave out volatiles at high temperatures depending upon their grade. These
volatile catch fire causing a flash. This condition is very hazardous and it is therefore essential to
qualify this temperature for each bitumen grade.
Flash point:
The flash point of a material is the lowest temperature at which the vapour of substance momentarily
takes fire in the form of a flash under specified condition of test.
Fire point:
The fire point is the lowest temperature at which the material gets ignited and burns under specified
condition of test.
Object:
To determine the flash and fire point of bitumen by Pensky-Martens closed tester.
Apparatus:
a) Pensky-Martens closed tester consist of cup, lid, stirrer
device, shutter, flame exposure device.
b) Thermometer ( 0 – 3500C) – sensitivity – 0.10C.
Procedure:
The material is filled in the cup up to a filling mark. The lid is
placed to close the cup in a closed system. All accessories
including thermometer of the specified range are suitably
fixed. The bitumen sample is then heated. The test flame is lit
and adjusted in such a way that the size of a bleed is of 4mm
diameter. The heating is done at the rate of 50C to 60C per
minute. The stirring is done at a rate of approximately 60
revolutions per minute. The test flame is applied at intervals
depending upon the expected flash and fire points. First
application is made at least 170C below the actual flash point
and then at every 10C to 30C. The stirring is discontinued
during the application of the test flame.
Results:
The flash point is taken as the temperature read on the thermometer at the time of the flame
application that causes a bright flash in the interior of the cup in closed system. For open cup it is the
instance when flash appears first at any point on the surface of the material. The heating is continued
until the volatiles ignite and the material continues to burn for 5 seconds. The temperature of the
sample material when this occurs is recorded as the fire point.
Limits: The flash point for all grades of bitumen materials is 2200C, minimum.

FLASH AND FIRE POINT TEST OF BITUMEN

( IS : 1209 - 1978 )

0
Flash point : Min.220 C
2 Samples / Consignment For All Grades 0
Fire Point : Min.220 + 5 C
Lab Ref. No :________________ Date of Sampling:_________
0 0
Heating 5 C - 6 C / Min.
Stirring 60 Rev / Min.
Mean
S.NO DESCRIPTION Test -1 Test -2 Test -3 Test -4
Value
1 Grade of Bitumen
2 Rate of Heating Time ( Minutes )
0
3 Temperature ( C ).
4 Flash Point.
5 Fire Point.
Remarks :________________________________________________________________

6. DUCTILITY TEST.
(IS: 1208 – 1978)
INTRODUCTION:
In the flexible pavement construction where bitumen binders are used, it is of significant importance
that the binders form ductile thin films around the aggregates. This serves as a satisfactory binder in
improving the physical interlocking of the aggregates.
Object:
To determine the ductility of the bituminous material.
Apparatus:
a) Ductility machine.
b) Briquette moulds.
c) Knife.
Procedure:
The bitumen sample is melted to
a temperature of 75 to 1000C
above the approximate
softening point until it is fluid. It
is strained through 90 micron
sieve, poured in the mould
assembly and placed on a brass
plate, after a solution of glycerin and dextrin is applied at all surfaces of the mould exposed to
bitumen. After 30 to 40 minutes, the plate assembly along with the sample is placed in water bath
maintained at 270C for 30 minutes. The sample and mould assembly are removed from water bath
and leveling the surface using hot knife cuts off excess bitumen material. After trimming the
specimen, the mould assembly-containing sample is replaced in water bath maintained at 270C for 85
to 95 minutes. The sides of the mould are now removed and the clips are carefully hooked on the
machine with out causing any initial strain.
The pointer is set to zero, the machine is started and the two clips are pulled apart horizontally at a
uniform speed of 50 +/- 2.5mm per minute. While the test is in operation, it is checked whether the
sample is immersed in water at depth of at least 10mm. The distance, at which the bitumen thread of
each specimen breaks, is recorded (in cm) to report as ductility value.
Results: The distance stretched by the moving end of the specimen up to the point of breaking of
thread measured in centimeters is recorded as ductility value.
Limits:
Ductility at 250C, cm Min. 75 cm Min. 50 cm Min. 40 cm Min. 25 cm

DUCTILITY TEST OF BITUMEN

(IS : 1208 - 1978 )

Grade VG - 30 Min. 40 cm.
Grade VG - 40 Min. 25 cm.
0
Test Temp. 27 + / - 1 C.
50 + / -
Rate of Pulling
2.5mm/Min.
BRIQUETTE NUMBER
TEST PROPERTY MEAN VALUE
1 2 3
Remarks :________________________________________________________________

7. LOSS ON HEATING OF BITUMINOUS MATERIALS.

(IS: 1205 – 1978)
INTRODUCTION:
The loss in weight (exclusive of water) of bituminous materials when heated is called loss on heating
of bituminous materials.
Object:
To determine the loss on heating of bituminous materials.
Apparatus:
a) Oven – heating capacity is minimum
1800C and interior dimensions
min.330X330mm. b) Aluminum Rotating
shelf - the self shall be suspended by
vertical shaft and centered with respect to
the horizontal interior dimensions
minimum diameter of 250mm, and shall
be provided with a mechanical means of
rotating it at the rate of 5 to 6 rpm. c)
Thermometer – 0 to 3600C – sensitivity
0.10C. d) Containers- Metal or glass
cylindrical containers shall have a flat
bottom and diameter 55mm, 35mm depth
minimum. e) Balance – sensitivity 0.01gm.
Procedure:
Heat the sample with care, stirring constantly to prevent local overheating, until the sample has
become sufficiently fluid to pour. Place the sample in container and cool the sample to room
temperature and then weigh to the nearest 0.01gm. Bring the oven to a temperature of 1630C and
place the container in oven for period of 5 hr. Remove the sample from the oven, cool to room
temperature, and weigh to the nearest 0.01gm. And calculate the loss due to heating.
Limits:
Loss on heating of all grades of bitumen is maximum 1% by mass.

LOSS ON HEATING OF ASPHALTIC COMPOUNDS.

( IS : 1212 - 1978 )
2 Samples / Consignment For All Grades Max. 1 %.
SAMPLE NO. 1 2 3 4 5 6 7 8
WEIGHT OF CONTAINER.
WEIGHT OF SAMPLE
BEFORE HEATING.
WEIGHT OF SAMPLE
AFTER HEATING.
WEIGHT LOSS.
LOSS ON HEATING ( % )
AVERAGE VALUE.
Remarks :________________________________________________________________

8. STRIPPING VALUE OF AGGREGATES.

(IS: 6241 – 1959)
INTRODUCTION:
Bitumen and tar adhere well to all normal types of aggregates provided they are dry and are not
exceptionally dusty. Largely the viscosity of the binder controls the process of binding. When the
viscosity of the binder is high, coating of aggregates by the binder is slower. In the absence of water
there is practically no adhesion problem in bituminous road construction. Two problems are observed
due to the presence of water. First, if aggregate is wet and cool it is normally not possible to coat with
a bituminous binder. This problem can be dealt with by removing the water film on aggregate by
drying, and by increasing the mixing temperature. Second problem is stripping of coated binder from
the aggregate due to the presence of water. This problem of stripping is experienced only with
bituminous mixtures, which are permeable to water.
Object:
To determine the stripping value of aggregates by static immersion method.
Apparatus:
Thermostatically controlled water bath, beaker.
Procedure:
This method covers the procedure for determining the stripping value of aggregates by static
immersion method, when bitumen and tar binder are used. 200gm of dry and clean aggregates
passing 20mm IS sieve and retained on 12.5mm sieve are heated up to 1500C when these are to be
mixed with bitumen and the aggregates are heated up to 1000C when these are to be mixed with tar.
5% by weight of bitumen / tar binder is heated to 1600C (1100C in the case of tar binder). The
aggregate and binder are mixed thoroughly till they are completely coated and the mixture is
transferred to a 500ml beaker and allowed to cool at room temperature for about two hours. Distilled
water is then added to immerse the coated aggregates. The beaker is covered and kept in a water
bath maintained at 400C, taking care that the level of water in the water bath is at least half the
height of the beaker. After 24 hours the beaker is taken out, cooled at room temperature and the
extent of stripping is estimated visually while the specimen is still under water.
The stripping value is the ratio of the uncovered area observed visually to the total area of aggregates
in each test, expressed as a percentage.
Limits:
The maximum stripping value is 5%( i.e., minimum retained coating is 95%).

STRIPPING VALUE OF AGGREGATES.

( IS : 6241 - 1971) / AASHTO - T – 182
As and When Required. Min. Retained Coating = 95 %.

20mm passing &
Test Sample
12.5mm Retained.
Binder Content 5%
0 0
25 C - 40 C @
Test Temp.
24 - 48 hrs.
BEAKER % OF AGG.THAT RETAINED COATED
OBSERVATION AFTER THE SPECIFIED TIME.
S.NO NO. AND REMARKS
NUMBER.
TEMP. 1 Hrs. 3 Hrs. 24 Hrs. 48 Hrs.
1
2
NO.
1 @ 3
0
25 C
4
MEAN
2
NO.
2 @ 3
0
40 C
4
MEAN
Remarks :________________________________________________________________

9. BINDER CONTENT OF PAVING MIXTURES.

(SP 11 / ASTM D 2172)
Object:
To determine the binder content in the mix by cold solvent extraction.
Apparatus:
a) Centrifugal extraction machine
electrically operated. b) Balance – 15 kg
capacity – sensitivity 0.1gm. c) Cold solvent
– Commercial grade of Benzene. d) Filter
paper – Wat 60. e) Oven.
Procedure:
A representative sample about 1000gm is
exactly weighed and placed in the bowl of
the extraction apparatus and covered with
commercial grade of benzene. Sufficient
time (not more than 1 hour) is allowed for
the solvent to disintegrate the sample
before running the centrifuge.
The filter paper of the extractor is dried,
weighed and then fitted around the edge of
the bowl. The cover of the bowl is clamped tightly. A beaker placed under to collect the extract.
The machine is revolved slowly and then gradually increases the speed, maximum of 3600 rpm. This
speed is maintained till the solvent ceases to flow from the drain. The machine is allowed to stop and
200ml of benzene is added and the above procedure is repeated. A number of 200ml solvent
additions (not less than three) are used till the extract is clear and not darker than a light straw
colour.
The filter paper removed from the bowl, dried in air then in oven to constant weight at 1150C and
weighted the fine materials that might have passed through the filter paper are collected back from
the extract preferably by centrifuging. The material is washed and dried to constant weight as before.
The percentage of binder in the sample is calculated as below.
Percentage of binder = 100 x [W1 – (W2 + W3) + W4]/W1
Where, W1 = Weight of sample.

W2 = Weight of the sample after extraction.
W3 = Weight of Fine material recovered from the extract.
W4 = Increase in weight of the filter paper.

BITUMEN EXTRACTION TEST

( ASTM - D - 2172 )
Lab Ref. No :________________ Date of Sampling:_______
Grade of Sample :____________ Date of Testing :_________
Location :____________________
Type of (A) (B) (C) (D) (E)

Wt. Before Wt. After Wt. Diff. Total Ash Bitumen in Mix Percentage of Bitumen
Material Extraction Extraction (A-B) in Mix (C-D-F) in Mix = ( E / A X 100 )
Tested (Gms.) (Gms.) (Gms.) ( From L ) ( Gms )
FILTER PAPER ( OVEN DRIED ) ASH CORRECTION
(G)
Wt.Before Wt.After Wt.of Wt.of Wt.of
(F) ( L ) Wt. Of Ash on Total
Extraction Extraction
Wt.Diff. Gms.
crucible & crucible Ash
Solution = G / 100 X Tot.Sol.
Gms. Gms. Ash Gms. Gms. per
100cc
Measure total Bitumen solution in cc. Record Total solution here _____________________cc. Take 100cc from total solution for
correction.
Weight After Washed ( Gms ) =
Sieve No.
Wt.
Retained
Cum. Wt.
Retained
Cum.%
Retained
%
Passing
Limits
JMF
Remarks :________________________________________________________________

10. TEST FOR CONTROL OF RATE OF SPREAD OF BINDER.

(SP: 11 – 1976)
Object:
To determine the rate of spread of binder by tray test.
Apparatus:
a) 20cmX20cm and 3cm deep metal trays – 5 nos.
b) Balance – 0.1gm sensitivity.
Procedure:
Light metal trays of about 20cmX20cm and 3cm deep previously weighed and numbered, are placed
at intervals along the road in the path of the binder distributor between the wheel tracks. After the
distributor has passed, the trays are removed and wrapped in weighed sheets of paper so that they
can be handled stocked and weighed as soon as convenient. The spacing and the number of trays can
be varied to suit the circumstances of the particular site, but at least five trays shall normally be used.
The tray test gives a measure of the variation in rate of spread along the road and a good
approximation to the average rate of0 spread.
Precautions:
The trays shall be weighed correct to first place of decimal in gram. The maximum longitudinal
distribution error shall be within 10% of the specification.
Transverse distribution by the machine can be checked by placing a number of trays to collect the
binder sprayer over each 5cm of the width of the spray bar. The variation in transverse distribution
shall not be more than 20% from the man (not counting the extreme 15cm at either side of sprayed
area).

APPLICATION OF BITUMINOUS PRIME / TACK COAT
Lab.Ref.No:_________________ Date of testing:______________

Location:___________________
Tested by:__________________
A. Kind of Bituminous Material:___________________________________

B. Application Temperature of Prime / Tack coat:_____________________
C. Observed Temperature of Prime / Tack coat:_____________________
D. Unit Weight of Prime / Tack coat:______________________________
E. Correction Factor at Observed Temperature:______________________
F. Speed of Distributor (kmph):___________________________________
G. Height of Spray Bar (m):______________________________________
1.Tray No
2. Weight of Tray (g)
3. Weight of Tray + Bitumen (g)
4. Weight of Bitumen (g) ( 3 - 2 )

2
5. Area of Tray (cm )
2
6. Rate of Spray (g/cm ) ( 4 / 5)
2
7. Rate of Spray (Kg/m ) ( 6 / 0.10 )
2
8. Rate of Application (L/m ) ( 7 / D )
2
9. Average Rate of Application (L/m )
2
10. Goverining Specification (L/m )
Remarks :________________________________________________________________

11. TEST FOR RATE OF SPREAD OF GRIT IN SURFACE DRESSING.

(SP: 11 – 1976)
Object:
To determine the rate of spread of grit by measuring the area covered by each lorry load of known
capacity.
Procedure:
Measuring the area covered by each lorry load of known capacity can check the rate of spread of grit
by gritters.
Removing the chippings from small areas of the road and weighing them can also check this. A small
square metal frame is laid on the new dressing and all the chippings within the enclosed area which is
10cm square are collected and washed in solvent to remove the binder, weighed and the rate of
spread is measured at points along the road at intervals of between 1 meter to 4 meters.
The transverse variation shall be less than +/- 20 percent of the mean.

12. MARSHALL STABILITY TEST.

(ASTM – D – 1559 & MS-2)
INTRODUCTION:
Bruce Marshall, a former Bituminous Engineer with the Mississippi State Highway Department,
formulated the concepts of the Marshall method of designing paving mixtures. The U.S.Army Crops of
Engineers, through extensive research and correlation studies, improved and added certain features
to Marshall’s test procedure, and ultimately developed mix design criteria.
The original Marshall method is applicable only to hot-mix asphalt paving mixtures containing
aggregates with maximum sizes of 25mm or less. A modified Marshall has been proposed for
aggregates with maximum size up to 38 mm.
This method covers the measurement of the resistance to plastic flow of cylindrical specimens of
bituminous paving mixture loaded on the lateral surface by means of the Marshall apparatus.
Object:
To determine the stability, flow, voids, voids in mineral aggregates, voids filled with asphalt and
density of the asphalt mixture by Marshall stability test.
Apparatus:
a) Specimen Mould Assembly – For Standard Marshall,
Mould cylinders 101.6mm (4 in.) in diameter by 75mm (3
in.) in height, base plates, and extension collars. For
Modified Marshall, mould cylinders 152.4mm (6 in.) in
diameter by 95.2mm (3.75 in.) in height.
b) Specimen Extractor – Steel disk with a diameter

100mm/150mm, and 12.7mm thick for extracting the
compacting specimen from the specimen mould with the
use of the mould collar. A suitable bar is required to
transfer the load from the proving ring adapter to the
extension collar while extracting the specimen.
c) Compaction Hammer – The compaction hammer

shall have a flat, circular tamping face and a 4.5kg (10 lb)
sliding weight with a free fall of 457mm (18 in.) for
Standard Marshall Method. For Modified Marshall Method,
the weight of hammer is 10.2kg (22.5 lb) and height of fall
is 457mm (18 in.). Two compaction hammers are
recommended for each method.
d) Compaction Pedestal – The compaction pedestal

shall consist of 200X200X460mm(8X8X18 in.) wooden post capped with a 305X305X25mm(12X12X1

in.) steel plate. The pedestal should be installed on concrete slab so that the post is plumb and the
cap is level. Mould holder provided consisting of spring tension device designed to hold compaction
mould centered in place on compaction pedestal.
e) Breaking Head – It consists of upper and lower cylindrical segments or test heads having an
inside radius of curvature of 50 mm. The lower segment is mounted on a base having two vertical
guide rods, which facilitate insertion in the holes of upper test head.
f) Loading Machine – The loading machine is provided with a gear system to lift the base in upward
direction./ on the upper end of the machine, a calibrated proving ring of 5 tonne capacity is fixed. In
between the base and the proving ring, the specimen contained in test head is placed. The loading
machine produces a movement at the rate of 50mm per minute. Machine is capable of reversing its
movement downward also.
g) Flow meter – One dial gauge fixed to the guide rods of a testing machine can serve the purpose.
Least count of 0.25mm(0.01 in.) is adequate.
h) Oven or hot plates
i) Mixing apparatus.
j) Thermostatically control water bath.
k) Thermometers of range 0 – 3600C with 10C sensitivity.
Procedure: In the Marshall method each compacted test specimen is subjected to the following tests
and analysis in the order listed below:
i) Bulk density determination
ii) Stability and flow test
iii) Density and voids analysis
At least three samples are prepared for each binder content.
Preparation of test specimens:

The coarse aggregates, fine aggregates and the filler material should be proportioned and mixed in
such a way that final mix after blending has the gradation with in the specified range.
The aggregates and filler are mixed together in the desired proportion as per the design requirements
and fulfilling the specified gradation. The required quantity of the mix is taken so as to produce a
compacted bituminous mix specimen of thickness 63.5mm, approximately.
Preparation of Mixtures: Weigh into separate pans for each test specimen the amount of each size
fraction required to produce a batch that will result in a compacted specimen 63.5 +/- 1.27mm(2.5
+/-0.05 in.) in height. This will normally be about 1200gm(2.7 lb.). It is generally to prepare a trial
specimen prior to preparing the aggregate batches. If the trial specimen height falls outside the limits,
the amount of aggregate used for the specimen may be adjusted using:

Adjusted mass of aggregate = 63.5 (mass of aggregate used)/Specimen height (mm) obtained
Take the sample as mentioned above, and heated to a temperature of 1750 to 1900C. The compaction
mould assembly and hammer are cleaned and kept pre-heated to a temperature of 1000C to 1450C.
The bitumen is heated to temperature of 1210 to 1380C and the required quantity of first trial
percentage of bitumen (say, 3.5% by weight of mineral aggregates) is added to the heated aggregate
and thoroughly mixed using a mechanical mixer or by hand mixing with trowel. The mixing
temperature may be 1530 to 1600C. The mix is placed in a mould and compacted by hammer, with 75
blows on either side (for light compaction it is 50 blows) for Standard Marshall Method. For Modified
Marshall Method, number of blows will be 1.5 times of Standard Marshall Method. The compaction
temperature may be 1380 to 1490C. The compacted specimen should have a thickness of 63.5 +/-
3.0mm. Three specimens should be prepared at each trial bitumen content, which may be varied at
0.5 percent increments up to about 7.5 or 8.0 percent.
Determination of mixing and Compaction
Temperature – The temperature to which the
asphalt must be heated to produce viscosities of 170
± 20 centistokes kinematic and 280 ± 30 centistokes
kinematic shall be established as the mixing
temperature and compaction temperatures
respectively. These temperatures can be estimated
from a plot of the viscosity (log-log centistokes
scale) versus temperature relationship for the
asphalt cement to be used.
Marshall Stability and Flow values: The
specimens to be tested are kept immersed under
water in a thermostatically controlled water bath
maintained at 600 +/- 10C for 30 to 40 minutes. The
specimen are taken out one by one, placed in the
Marshall test head and the Marshall Stability value
(maximum load carried in kg. before failure) and the
flow value (the deformation the specimen undergoes
during loading up to the maximum load in 0.25mm
units) are noted. The corrected Marshall stability
value of each specimen is determined by applying
the appropriate correction factor.
The following tests are determined first, to find out

the density, voids, VMA and VFB.
Tests:
The specific gravity and apparent specific gravity values of the different aggregates, filler and bitumen
used are determined first.
i) Bulk specific gravity of aggregate ‘Gsb’ is given by:
Gsb = (P1 + P2 +. ……+ Pn)/(P1/G1 + P2/G2 +. ……+ Pn/Gn)

Where, Gsb = Bulk specific gravity for the total aggregate.

P1, P2, Pn = Individual percentages by weight of aggregate.
G1, G2, Gn = Individual bulk specific gravities of aggregate.
ii) Effective specific gravity of aggregate ‘Gse’ is given by:

Gse = (100 – Pb)/[(Pmm/Gmm) – (Pb/Gb)]
Where, Gse = Effective specific gravity of aggregate, constant for all at 5% bitumen
content.
Gmm = Maximum specific gravity of paving mixture (no air voids), determine
by Vacuum pump test (ASTM – D – 2041).
Pb = Bitumen content, percent by total weight of mixture.
Gb = Specific gravity of Bitumen.
iii) Maximum specific gravity of mixture ‘Gmm’ is given by:

Gmm = 100/[(Ps/Gse) + (Pb/Gb)]
Where, Gmm = Maximum specific gravity of paving mixture (no air voids)
Ps = Aggregate content, percent by total weight of mixture
Pb = Bitumen content, percent by total weight of mixture
Gse = Effective specific gravity of aggregate
Gb = Specific gravity of bitumen
iv) Bitumen absorption ‘Pba’ is given by:

Pba = [(100 x Gb) x (Gse – Gsb)]/(Gse x Gsb)
Where, Pba = Absorbed bitumen, percent by weight of aggregate

Gse = Effective specific gravity of aggregate
Gsb = Bulk specific gravity of aggregate
Gb = Specific gravity of bitumen
v) Effective bitumen content of a paving mixture ‘Pbe’ is given by:

Pbe = Pb – [(Pba x Ps)/100]
vi) Voids in mineral aggregate in compacted paving mixture ‘VMA’ is given by:
VMA = 100 – [(Gmb x Ps)/Gsb]
Where, VMA = Voids in mineral aggregate, percent of bulk volume

Gsb = Bulk specific gravity of total aggregate
Gmb = Bulk specific gravity of compacted mixture
Ps = Aggregate content, percent by total weight of mixture

vii) Air voids in compacted mixture ‘Va’ is given by:

Va = 100 x (Gmm – Gmb)/Gmm
Where, Va = Air voids in compacted mixture, percent of total volume

Gmm = Maximum specific gravity of paving mixture
Gmb = Bulk specific gravity of compacted mixture
viii) Voids filled with bitumen in compacted mixture ‘VFB’ is given by:
VFB = 100 x (VMA – Va)/VMA
Where, VFB = Voids filled with bitumen, percent of VMA
VMA = Voids in mineral aggregate, percent of bulk volume
Va = Air voids in compacted mixture, percent of total volume
Determination of Optimum Bitumen Content:

Six graphs are plotted with values of bitumen content against the values of:
a) Density ‘Gmb’ g/cc. b) Marshall Stability, S kg. c) Voids in total mix, Va %. d) Flow value, F
(0.25mm units). e) Voids filled with bitumen, VFB %. f) Voids in mineral aggregate, VMA %.
Let the bitumen contents corresponding to maximum density be B1, corresponding to maximum
stability be B2 and that corresponding to the specified voids content Va (4.0% in the case of dense AC
mix) be B3. Then the Optimum Bitumen Content is given by:
Optimum Bitumen Content (OBC) = (B1 + B2 + B3)/3
The values of flow and VFB are found from the graphs, corresponding to bitumen content OBC. All the
design values of Marshall stability, flow, voids and VFB are checked at the Optimum Bitumen Content,
with the specified design requirements of the mix.
Design Requirements of the mix:

Design Requirements
S.No Property
Standard Modified
1 Marshall Stability Value, kN 9.0 2.25 times of Std.
2 Flow Value, mm 2–4 1.5 times of Std.
3 Voids in Total Mix, Va, % 3–5 3–6
4 Voids in Mineral Aggregate (VMA), % Min. 12 Min. 12
5 Voids Filled with Bitumen (VFB), % 65 – 75 65 – 75
6 Marshall Quotient 2–5 2–5
7 Fines to Bitumen Ratio 0.6 – 1.2 0.6 – 1.2
8 Tensile Strength Ratio Min. 80% Min. 80%
9 Coating of Aggregate Particle Min. 95% Min. 95%
The highest possible Marshall stability values in the mix should be aimed at consistent with the other
four requirements mentioned above. In case the mix designed does not fulfill any one or more of the
design requirements, the gradation of the aggregates or filler content or bitumen content or
combination of these are altered and the design tests are repeated till all the requirements are
simultaneously fulfilled.

Job Mix Formula:

The proportions in which the different aggregates, filler and bitumen are to be mixed are specified by
weight or by volume for implementation during construction.
Caution:
Mixes with high Marshall stability values and very low Flow values are not desirable as the pavements
of such mixes may be brittle and are likely to crack under heavy traffic.
Correction Factors
Standard Marshall Method Modified Marshall Method
Approximate Approximate
Volume of Volume of
Thickness of Correction Thickness of Correction
Specimen in Specimen in
Specimen in Factors Specimen in Factors
cc cc
mm mm
200 - 213 25.4 5.56 1608 - 1636 88.9 1.12
214 - 225 27.0 5.0 1637 - 1665 90.5 1.09
226 - 237 28.6 4.55 1666 - 1694 92.1 1.06
238 - 250 30.2 4.17 1695 - 1723 93.7 1.03
251 - 264 31.8 3.85 1724 - 1752 95.2 1.00
265 - 276 33.3 3.57 1753 - 1781 96.8 0.97
277 - 289 34.9 3.33 1782 - 1810 98.4 0.95
290 - 301 36.5 3.03 1811 - 1839 100.0 0.92
302 - 316 38.1 2.78 1840 - 1868 101.6 0.90
317 - 328 39.7 2.50
329 - 340 41.3 2.27
341 - 353 42.9 2.08
354 - 367 44.4 1.92
368 - 379 46.0 1.79
380 - 392 47.6 1.67
393 - 405 49.2 1.56
406 - 420 50.8 1.47
421 - 431 52.4 1.39
432 - 443 54.0 1.32
444 - 456 55.6 1.25
457 - 470 57.2 1.19
471 - 482 58.7 1.14
483 - 495 60.3 1.09
496 - 508 61.9 1.04
509 - 522 63.5 1.00
523 - 535 65.1 0.96
536 - 546 66.7 0.93
547 - 559 68.3 0.89
560 - 573 69.8 0.86
574 - 585 71.4 0.83
586 - 598 73.0 0.81
599 - 610 74.6 0.78
611 - 625 76.2 0.76

Swell test:
Apparatus: a) Moulds with internal diameter 101.6mm(4 in.) and length 127mm(5 in.), b)
Perforated, 98.4mm diameter x 3.2mm thick with adjustable stem, for swell measurement, c) Dial
gauge, mounted on tripod, with reading accuracy to 0.025mm, d) Aluminum pans, 190mm diameter x
64mm deep.
Procedure:
Allow compacted swell test specimen to stand at room temperature for at least one hour. Place the
mould and specimen in 190mm diameter x 64mm deep aluminum pan. Place the perforated disk on
specimen, position the tripod with dial gauge on mould, and set the adjustable stem to give a reading
of 2.54mm on the dial gauge. Introduce 500ml of water into the mould on top of the specimen and
the measure distance from the top of the mould to the water surface with the graduated scale. After
24 hours, read the dial gauge to the nearest 0.025mm and record the change as swell. Also, measure
the distance from the top of the mould to the water surface with the graduated scale and record the
change as permeability or the amount of water in ml that percolates into and/or through the test
specimen.
Acceptance Criteria of Job Mix Formula:
i) Water Sensitivity: The loss of stability on immersion in water at 600C. The allowable limit is
minimum 85% retained strength.
ii) Marshall Quotient (Stiffness): is the ratio of stability and flow.

Allowable limit, for base course = 350
for wearing surfaces = 400.
iii) Filler and Binder Ratio: is the ratio of 75µ sieve passing and Binder Content.
Allowable Limit, 0.6 – 1.2
iv) Thickness of Bitumen Film (F): acceptable range is 7 – 8 µ.
F = Pbe/(100-Pb) x 1/A x 1/Pb x 1/S x 106
Where, Pbe = Effective Bitumen

A = Surface area of the Blended Aggregate – m2/Kg
= (2+0.02a+0.04b+0.08c+0.14d+0.3e+0.6f+1.6g) x 0.20482
Where, a = percentage passing 4.75mm sieve
b = percentage passing 2.36mm sieve
c = percentage passing 1.18mm sieve
d = percentage passing 600µ sieve
e = percentage passing 300µ sieve
f = percentage passing 150µ sieve
g = percentage passing 75µ sieve
Pb = Bitumen content, percent by total weight of mixture
S = Bitumen Density – Kg/m3

Marshall Curves:
Bitumen(%) ’vs’ Stability(kg) Bitumen(%) ‘vs’ Density (g/cc)
1500 2.5
1200
900 2.4
600
300 2.3
3.5 4 4.5 5 5.5 6 3.5 4 4.5 5 5.5 6
Bitumen(%) ‘vs’ Flow(mm) Bitumen (%) ‘vs’ Voids(%)
10 10
8 8
6 6
4 4
2 2
3.5 4 4.5 5 5.5 6 3.5 4 4.5 5 5.5 6
Bitumen(%) ‘vs’ VFB(%) Bitumen(%) ‘vs’ VMA(%)
80 20
70 18
60 16
50 14
40 12
3.5 4 4.5 5 5.5 6 3.5 4 4.5 5 5.5 6

Type of Mix :_________________ Date of Sampling:____________________

Compaction : 75 Blows ( Both Sides ) Date of Testing:______________________
Specific Gravity of Bitumen :______________ Grade of Bitumen::___________________
Bulk Sp.Gr. Of Aggregates:_______________ Absorbed Bitumen of Aggregate:________
Effective Sp. Gr. Of Aggregate:_________
Mass in grams. Stability in kg.
% AC % AC
Spec.
by Wt. by Wt.of SSD
Ht. In In Bulk Bulk Max. Air Corr. Flow
Of Mix. in VMA VFA Measured Adjusted
(mm) Air. Water. Volume Sp.Gr. Sp.Gr. Voids factor (0.25mm)
Agg. & Air.
Spec.No
5
Remarks :__________________________________________________________________________________________________________

HOT - MIX DESIGN DATA BY THE MARSHALL METHOD

( Asphalt Institute MS - 2, ASTM - D - 1559 )
Location / Source :_______________ Date of Sampling:________

Date of Testing :_________
Description of Sample :___________ % Asp. Cem.by Wt.of mix:_________
Sp.Gr.of Asp.Cem (Gb):____________ Pen.Grade:____________ Ave.Bulk Sp.Gr.of Agg. (Gsb):____________
SET I SET II
SAMPLE Average Average
1 2 3 4 5 6
a Sample Height, mm
b Wt.of Sample in Air, g
c Wt.of SSD Sample in Air, g
d Wt.of Sample in Water, g
e Bulk Volume, cc (c-d)
f Bulk Density, g/cc (b / e)
g Agg.by.wt.of mix. %
h Asp.Cem.by wt.of mix %
I Vol.of Asp.Cem % hxf / Gb
k Vol.of Agg.Cem % (100 - h)xf / Gsb
L Vol.of Voids % (100 - I - k)
100
m Max.Sp.Gravity
[(g/Gsb) + (h/Gb)]
n Voids in Mineral Agg. % (100 - k)

p Voids Filled with Asp % (I / n) x 100
(m - f) x 100
q Air Voids in Total mix %
m
r Stability (Measured) kg
s Correl.Ratio
t Stability (Adjusted) kg
u Loss of Stability %
v Flow mm
w Rigidity Ratio (t / v)
y Swell %
Remarks :____________________________________________________________________________________

Worksheet for Volumetric Analysis of Compacted Paving Mixture

( Analysis by weight of aggregate / by weight of Mix )
Sample : Date
Compaction of Paving Mixture : Identification :
Specific Gravity., G Mix Composition, % by wt.of Total Mix, P
Material Ingredients Mix or Trial Number
Bulk
1 2 3 4 5
1. Coarse Aggregate G1 P1
2. Fine Aggregate G2 P2
3. Mineral Filler G3 P3
4. Total Aggregate Gs Ps
5. Asphalt Cement Gb Pb
(P1+P2+……….)
6. Bulk Sp.Gr.(Gsb),total aggregate
(P1/G1+P2/G2+……….)
100
7. Max.Sp.Gr.(Gmm),paving mix
(Ps / Gse) + (Pb / Gb)
8. Bulk Sp.Gr.(Gmb),compacted mix
(100 - Pb)
9. Eff.Sp.Gr.of total aggregate (Gse)
(100 / Gmm) - (Pb /Gb)
100(Gse - Gsb)XGb
10. Absorbed Asphalt(Pba),% by wt.total agg.
Gse X Gsb
CALCULATIONS :
Line5Pb – [(Line10 x Line4 Ps)/100]

11. Eff.Asphalt Content (Pbe)
12. VMA 100 – [(Line8 x Line4 Ps)/Line6]
13. Va 100 x [(Line7 – Line8)/Line7]
14. VFA 100 x [(Line12 – Line13)/Line12]
Remarks:____________________________________________________________________________________________________

CORE TEST OF BITUMINOUS LAYER
SSD
CORE THICK'SS Wt.IN Wt.IN VOLUME BULK LAB % OF AGE OF
S.NO. Wt.IN REMARKS
LOCATION (mm) AIR WATER OF CORE DENSITY DENSITY COMP. PAVEMENT
AIR
Remarks :__________________________________________________________________________________________________________

13. ELASTIC RECOVERY TEST

(IRC: SP – 53)
Introduction:
The Elastic Recovery of Modified Bitumen is intended to assess degree of bitumen modification.
Object:
Determination of elastic recovery of modified bitumen.
Apparatus:
1) Ductility Machine, 2) Thermometer (Range 630C), 3) Scissors, 4) Scale.
Procedure:
Prepare the test specimens and condition as prescribed in Test method IS: 1208 (Ductility Test).
Elongate the test specimen at the rate of 5±0.25 cm/minute up to 10 cm long. Immediately cut the
test specimen into two halves at the midpoint using scissors. Keep the test specimen in the water
bath in an undisturbed condition for 1 hour at 150C.
After the 1 hr. time period, move the elongated half of the test specimen back into position near the
fixed half of the test specimen so the two pieces of modified bitumen just touch. Record the length of
the recombined specimen as ‘X’.
Calculations:
Calculate the percent elastic recovery by the following formula:
Elastic Recovery, (%) = 100 x (100 – X)/X
Limits: For Elastomeric Thermoplastic PMB – 40 = Min. 50%

For Elastomeric Thermoplastic PMB – 70 = Min. 60%
For Elastomeric Thermoplastic PMB – 120 = Min. 70%
For Plastomeric Thermoplastic PMB – 40 = Min. 40%
For CRMB – 60 = Min. 30%

ELASTIC RECOVERY TEST OF MODIFIED BITUMEN

( IS : 1208 - 1978 )
Permissible Limits
Frequency of Tests
Polymer Modified Bitumen (PMB)
PMB – Elastomeric Thermoplastics PMB – Plastomeric Thermoplastics
PMB – 40 Min. 50 % PMB – 40 Min. 40 %
PMB – 70 Min. 60 % PMB – 70 Min. 50 %
PMB – 120 Min. 70 % PMB – 120 Min. 60 %
1 Test/Each Consignment
Crumb Rubber Modified Bitumen (CRMB)
CRMB – 60 Min. 30 %
CRMB – 55 Min. 35 %
CRMB – 50 Min. 40 %
Test 0
15 + / - 1 C.
Temp.
Rate of
5 + / - 2.5 mm/Min.
Pulling
0
Note: 1. Prepare the test specimens and conditioning for 1hr at 15 C.
2. Elongate the test specimen up to 10 cm at the rate of 5 ± 2.5 mm/Min.
3. Cut the test specimen into two halves at the mid point using scissors.
4. Keep the test specimen in the water bath in an undistrubed condition for 1 hour.
5. After 1hr. Time period, move the elongated half of the test specimen back into position near the fixed half
of the test specimen so the two pieces of modified bitumen just touch. Record the length of the recombined
specimen as 'X'.
BRIQUETTE NUMBER
TEST PROPERTY
1 2 3 MEAN VALUE
Deformation/
10 cm 10 cm 10 cm
Elongation
Recombined
length = X
Elastic Recovery = [( 10 - X)x100]/10
Remarks:_______________________________________________________________________

14. SEPARATION TEST

(IRC: SP – 53)
Introduction:
The Separation of Modifier and Bitumen during hot storage is evaluated by comparing the Ring and
Ball Softening point of the top and bottom samples.
Object:
Determination of separation of modifier and bitumen.
Apparatus:
1) Ring and Ball Softening Apparatus, 2) Aluminum Tubes – 25.4mm (1 in.) diameter and 139.7mm
(5.5 in.) length, 3) Oven – capable of maintaining 163±50C, 4) Freezer – capable of maintaining
-6.7±50C.
Procedure:
Place the empty tube, with sealed end down in the rack. Heat the sample carefully until sufficiently
fluid to pour. Care should be taken to prevent localized over-heating. Pass the molten sample through
a No.50 (IS 300 micron) sieve. After thorough stirring, pour 50g into the vertically held tube. Fold the
excess tube over two times, and crimp and seal.
Place the rack containing the sealed tube in a 163±50C oven. Allow the tubes to stand undisturbed in
the oven for a period 24±4 hours. At the end of the period, remove the rack from the oven, and
placed immediately in the freezer at -6.7±50C, taking care to keep the tube in a vertical position at all
times. Leave the tube in the freezer for a minimum of 4 hours to solidify the sample completely.
Remove the tube from the freezer, place it on a flat surface cut the tube into three equal length
portions. Discard the central portion and place the top and bottom portions of the tube into separate
beakers. Place the beakers into a 163±50C oven until the bitumen is sufficiently fluid. Prepare the test
specimens according to Test Method IS: 1205 (Softening Point by Ring and Ball Method) and tested
the softening points.
Calculations:
Calculate the difference, in 0C, between the softening points of the respective top and bottom
samples.
Limits: For Elastomeric Thermoplastic PMB – 40, PMB – 70, PMB – 120 = Max. 40 C.
For Plastomeric Thermoplastic PMB – 40, PMB – 70, PMB – 120 = Max. 30 C.

SEPARATION TEST OF MODIFIED BITUMEN

( IS : 1205 - 1978 / ASTM : D5976 - 1996)
0
Elastomeric Thermoplastics – PMB-40, PMB-70, PMB-120 Max. 4 C
1 Test/Each Consignment 0
Plastomeric Thermoplastics – PMB-40, PMB-70, PMB-120 Max. 3 C
Note: 1. The separation of modified bitumen during hot storage is evaluated by comparing the ring and ball softening
point of the top and bottom samples taken from a conditioned, sealed tube of modified bitumen.
2. Place the empty aluminium tube of 25.4 mm (1 in) diameter and 139.7 mm (5.5 in.) length, with sealed end
down in rack.
3. Pour the 50 gms of molten sample in to the vertical held tube. Fold the excess tube over two times, and crimp
and seal.
0
4. Conditioning the specimen i.e. the vertical tube place in the oven at 163 ± 5 C for 24 ± 4 hours.
0
5. After conditioned the sample take out from the oven and placed immediately in the freezer at - 6.7 ± 5 C for
minimum 4 hours, taking care to keep the tubes in a vertical position at all times.
6. After freezing period, specimen removing from the freezer, place it on a flat surface and cut it in three equal
portions. Discard the central portion, and place the top and bottom portions of the tube in to separate beakers
and heat the sample portions until the bitumen is sufficiently fluid.
7. Conduct the Softening point of the two specimens according to test method IS: 1205-1978. Report the
difference in ° C, between the softening points of the respective top and bottom samples.
Temperature at which sample touches

Test Specimen
TYPE OF
MANUFACTURER
DATE OF SUPPLIED DATE OF bottom plate ( 0C)
BITUMEN ARRIVAL QUANTITY TESTING
1st.RING 2nd.RING AVERAGE
Top portion of the test
specimen
Bottom portion of the

test specimen
Separation, Difference in Softening point
Remarks :_______________________________________________________________________

15. INDIRECT TENSILE STRENGTH OF ASPHALT MIXES

(AASHTO T 283)
Introduction:
Moisture damage, caused by a loss of bond between the asphalt binder or the mastic and the
aggregate under traffic loading, can cause a decrease of strength and durability in asphalt mixtures.
Moisture damage is relatively prone to produce the separation and removal of asphalt binder from the
aggregate surface, thus, leading to stripping in the asphalt pavement and ultimately causing
premature failure.
The Indirect Tensile Strength (ITS) Test is often used to evaluate the moisture susceptibility and
rutting quality of an asphalt mixture.
Object:
This method sets out the procedures for carrying out the Indirect Tensile Strength (ITS) test on
prepared asphalt specimens using the Marshall Loading Frame. Asphalt specimens are conditioned in
a medium water bath and suitable water level. It is applicable to asphalt mixes not exceeding 25 mm
nominal size or equivalent mix.
Apparatus:
1) Marshall equipment, 2) vacuum pump equipment, 3)

Balance, 4) Water bath capable of maintaining a
temperature of 60 ± 10 C, 5) Freezer maintained at -18 ±
30C, 6) Heavy duty leak proof plastic bags, 7) Loading
Strips 12.7 mm wide, 70 mm long and 10 mm thickness,
8) Aluminum pans.
Procedure:
Preparation of laboratory test specimens:

Specimens 101.6 mm in diameter and 63.5 mm thick are
usually used. Specimens prepared using a Marshall
compactor and compacted as per the Marshall Method.
Evaluation of Test Specimens and Grouping:

Determine theoretical maximum specific gravity of mixture
by AASHTO T 209. Determine the specimen thickness by
ASTM D 3549. Determine the bulk specific gravity by
AASHTO T 166 and calculate the air voids by AASHTO T
269. Prepare six specimens and sort into two sets of three
specimens each.

Preconditioning of Test Specimens:
One set will be tested dry and the other will be conditioned before testing.
The dry set will be stored at room temperature until testing. The specimens shall be placed in a heavy
duty leak proof plastic bag. The specimens shall then be placed in a 250C water bath for a minimum
of 2 hours and then tested as described in Testing.
The other set shall be conditioned as follows:
Place the specimen in the vacuum container, apply a vacuum 13 – 67 kPa absolute pressure for a
short time (5 to 10 minutes). Remove the vacuum and leave the specimen submerged in water for a
short time (5 to 10 minutes).
Cover the vacuum saturated specimens tightly with a plastic film and place each wrapped specimen in
a heavy duty leak proof plastic bag. Place the plastic bag containing specimen in a freezer at -18±30C
for a minimum of 16 hours. After removal from the freezer, place the specimens into a 60±10C water
bath for 24±1 hours.
After 24±1 hours in the 600C water bath, remove the specimens and place them in a water bath at
25±0.50C for 2±1 hours. It may be necessary to add ice to the water bath to prevent the water
temperature from rising above 250C. As soon as possible after placement in the water bath, remove
the plastic bag and film from the specimens and test the specimens as described in Testing.

Testing:
Determine the Indirect Tensile Strength (ITS) of dry and conditioned specimens at 250C.
Measure the diameter of the specimen at two evenly distributed points around the specimen
circumference and record to the nearest 0.1 mm. measure the height of the specimen at four evenly
distributed points around the specimen height and record to the nearest 0.1 mm.
Asphalt specimens shall be only tested within the mean height tolerance of 57 to 70 mm or volume
tolerance of 460 to 570 cm3.
Position the loading strip in the testing machine to allow the specimen to be centered with lower
loading strip and loading rod and ensure that the steel ball is placed on the top of the loading strip.
Remove the test specimen from the water bath after the designated period, then quickly wipe down
with cloth and place the specimen centrally on its side into the loading strips.
Commence loading the specimen within 30 seconds, without shock; at the specified constant rate
51 ± 3 mm/min. Record the maximum reading on the proving dial gauge prior to the Indirect Tensile
splitting failure of the test specimen.

Calculations:
The Indirect Tensile Strength (ITS) of the test specimen shall be calculated as follows:
ITS = 2(GR x RF) X 106

∏ Have Dave
Where,
ITS = Indirect Tensile Strength, in kilopascals (kPa)

GR = Gauge Reading
RF = Ring Factor
GR x RF = Maximum applied force indicated by gauge reading, in kilonewtons (kN)
Have = Specimen Mean Height, in mm
Dave = Specimen Mean Diameter, in mm.
Limits:
ITSdry at 250C = > 225 kPa
ITSwet at 250C = > 100 kPa
TSR (Tensile Strength Ratio) = ITSwet at 250C ≥ 80%

ITSdry at 250C
Indirect Tensile Strength (kPa) Rut Resistance
> 440 Excellent
320 – 440 Good
200 – 320 Fair
< 200 Poor

INDIRECT TENSILE STRENGTH OF ASPHALT MIXES

(AASHTO T 283)
ITSdry > 225 kPa
1 Test per Required/Design ITSwet > 100 kPa
TSR (ITSwet/ITSdry) ≥ 80%
Proving Ring Factor:
Dry Set Specimen Conditioned Set Specimens

Description Average Average
1 2 3 1 2 3
Diameter
Height
Max. Theoretical
Specific Gravity
Bulk Specific Gravity
Air Voids
Gauge Reading (GR)
Applied Force (kN) =

(GR x RF)
Indirect Tensile
Strength (ITS), kPa
Remarks :_______________________________________________________________________

CEMENT & CONCRETE.

1. DETERMINATION OF NORMAL CONSISTENCY

(IS: 4031 – part – 4)
Object:
Determination of the quantity of water required to produce a cement paste of standard consistency.
Apparatus:
Vicat apparatus (confirming to IS : 5513 – 1968) with plunger ( 10mm in dia ).
Theory:
The standard consistency of a cement paste is defined as that
consistency which will permit the vicat plunger to penerate to a
point 5 to 7 mm from the bottom of the vicat mould, when the
cement paste is tested as described in the following procedure.
Procedure:
Prepare a paste of weighted quantity of cement ( 350 gms) with
a weighted quantity of water, start with 30% water of 350 gms
of cement taking care that the time of gauging is not less than 3
minutes and not more than 5 minutes and the gauging shall be
completed before any sign of setting occurs. The gauging time
shall be counted from the time of adding the water to the dry
cement until commencing to fill the mould. Fill the vicat mould
with this paste, the mould resting upon a non-porous plate. 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.
Place the test block with the mould, together with the non-porous resting plate, under the rod bearing
the plunger ( 10mm dia ) lower the plunger gently to touch the surface of the test block and quickly
release, allowing it to penetrate into the paste. This operation shall carried out immediately after
filling the mould.
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. Express the
amount of water as a percentage by weight of the dry cement.
Precautions:
Use clean appliances for gauging. The temperature of cement and water and that of test room, at the
time when the above operations are being performed, shall be 270C +/- 20C. the room temperature
shall be maintained at 270C +/- 20C.

2. DETERMINATION OF INITIAL AND FINAL SETTING TIMES OF CEMENT.

(IS: 4031 – part – 5)
Object:
Determination of the Initial and Final setting times of cement.
Apparatus:
The vicat apparatus ( conforming to IS : 5513 – 1968 ).
Sample:
350 gms of cement is taken.
Procedure:
Preparation of Test Block

Prepare a neat cement paste by gauging 350 gms of cement with 0.85 times the water required to
give a paste of standard consistency. The paste shall be gauged in the manner and under the
conditions prescribed in determination of consistency of standard cement paste. Start a stopwatch at
the instant when water is added to the cement. Fill the mould with the cement paste gauged as
above, the mould resting on a non-porous 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.
Use clean appliances for gauging. The temperature of water and that of the test room, and the time
gauging, shall be 270C +/- 20C.
During the test, the block shall be kept at a temperature of 270C +/- 20C and at not less than 90%
relative humidity.
Determination of Initial Setting Time:

Place the test block confined in the mould and resting 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. In the beginning the needle will completely pierce
the test block. Repeat this procedure until the needle, when brought in contact with the test block and
released as described above, fails to pierce the block for 5 +/- 0.5 mm measured from the bottom of
the mould. The period lapsing between the time water is added to the cement and the time at which
the needle fails to pierce the test block by 5 +/- 0.5 mm shall be the initial setting time.

Determination of Final Setting Time:
Replace the needle of the vicat apparatus by the needle with an annular ring. 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 thereon, while the outer ring fails to do so. The period elapsing between
the time when water is added to the cement and the time at which the needle makes an impression
on the surface of the test block while the attachment fails to do so, shall be the final setting time.
Limits:
Initial Setting Time, minimum - 30 minutes.
Final Setting Time, maximum - 600 minutes.

3. DETERMINATION OF SOUNDNESS OF CEMENT

BY THE LE CHATELIER METHOD.
(IS: 4031 – part – 3)
Object:
Determination of the Soundness of cement by the Le Chatelier method.
Apparatus:
The apparatus for conducting the test consists of

small split cylinder of spring brass or other suitable
metal of 0.5 mm thickness, forming a mould 30 mm
internal diameter and 30 mm high. On either side of
the split mould are attached two indicators with
pointed ends, the distance from these ends to the
center of the cylinder being 165 mm. The mould
shall be kept in good condition with the Jaws not
more than 0.50 mm apart.
Procedure:
Place the mould on a 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. 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 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 +/- 20C
and keep there for 24 hours.
Measure the distance separating the indicator points. Submerge the moulds again in water at the
temperature prescribed above. Bring the water to boiling, with the mould kept submerge, in 25 to 30
minutes, and keep it boiling for three hours. Remove the mould from the water, allow it to cool and
measure the distance between the indicator points. The difference between these two measurements
represents the expansion of the cement.
Limits: Expansion should not be more than 10 mm.

4. DETERMINATION OF FINENESS OF CEMENT.

(IS: 4031 – part – 3)
Object:
To determine the fineness of cement by dry sieving.
Apparatus:
a) Standard balance with 100 gm.

weighing capacity.
b) IS : 90 micron sieve confirming
to IS : 460 – 1962 and a Brush.
Procedure:
a) Break down any air-set lumps in
the cement sample with fingers.
b) Weigh accurately 100 gms of
the cement and place it on a
standard 90 micron IS.sieve.
c) Continuously sieve the sample
for 15 minutes. d) Weigh the residue left after 15 minutes of sieving. This completes the test.
Result: The percentage weight of residue over the total sample is reported.
% Weight of Residue = (Wt.of Sample Retained on the Sieve/Total Weight of the Sample)
Limits:
The percentage residue should not exceed 10%.
Precautions:
Sieving shall be done holding the sieve in both hands and gentle wrist motion, this will involve no
danger of spilling the cement, which shall be kept well spread out on the screen. More or less
continuous rotation of the sieve shall be carried out throughout sieving.
Washers, shots and slugs shall not be used on the sieve. The underside of the sieve shall be lightly
brushed with a 25 or 40 mm bristle brush after every five minutes of sieving.
Mechanical sieving devices may be used, but the cement shall not be rejected if it meets the fineness
requirement when tested by the hand method.

INITIAL & FINAL SETTING TIME OF CEMENT

( IS : 4031 - 1968 )

Not < 30
Initial Setting Time
Minutes
1 Test / Each Consignment
Not > 600
Final Setting Time
Minutes
Finess Value Not > 10%
Soundness Value Not > 10mm
Lab. Ref. No :________________ Date of Sampling:________
Brand of Cement :____________ Date of Testing:__________
Age of Cement :______________
S.NO. DESCRIPTION RESULTS
1 Normal Consistency
2 Time at the moment adding water in Cement
3 Time at Initial Setting
4 Total Time taken for Initial Setting
5 Time at Final Setting
6 Total Time taken for Final Setting
7 Finess of Cement ( through 90 Micron Sieve )
8 Soundness of Cement
Remarks :_______________________________________________________

5. DETERMINATION OF COMPRESSIVE STRENGTH OF CEMENT.

(IS: 4031 – Part – 6)
Object:
Determination of the compressive strength of standard cement mortar cubes compacted by means of
a standard vibration machine.
Apparatus:
Vibration machine, cube moulds of size 7.06 cms(confirming to IS : 4031 – 1968), and Standard Sand
to be used in the test shall be confirm to IS : 650 – 1966.
Procedure:
Mix Proportions and Mixing: 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 270 +/- 20C.
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. The quantity of water to
be used shall be as specified below. In any
event, it should not take more than 4 minutes to obtain uniform coloured mix. If it exceeds 4 minutes,
the mixture shall be rejected and the operation repeated with a fresh quantity of cement, sand and
water.
The material for each cube shall be mixed separately and the quantity of cement, standard sand and
water shall be as follows:
Percentage of water to be added to the cement and sand in ( 1:3 ) cm (P/4 + 3) X % combined
weight of cement and sand = (P/4 + 3) X 800/100.
Cement 200 gms, standard sand 600 gms, water (P/4 + 3) per cent of combined weight of cement
and sand, where P is the percentage of water required to produce a paste of standard consistency.
Moulding Specimens:
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.
Treat the interior faces of the mould with a thin coating of mould oil.
Place the assembled mould on the table of the vibration machine and firmly hold it in position by
means of suitable clamps.
Securely attach a hooper of suitable size and shape at the top of the mould to facilitate filling and this
hooper shall not be removed until completion of the vibration.
Immediately after mixing the mortar, place the mortar in the cube mould and rod with a rod. The
mortar shall be rodded 20 times in about 8 seconds to ensure elimination of entrained air and honey
combing. Place the remaining quantity of mortar in the hooper of the cube mould and rod again as
specified for the first layer and then compact the mortar by vibration.
The period of vibration shall be two minutes at the specified speed of 12000 +/- 400 vibrations per
minutes.
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 Specimens: Keep the filled moulds at a temperature of 270C +/- 20C in an atmosphere of
atleast 90% relative humidity for about 24 hours after completion of vibration. At the end of that
period remove them from the moulds immediately submerge in clean fresh water and keep them
under water until testing. The water in which the cubes are submerged shall be renewed every 7 days
and shall be maintained at a temperature of 270C +/- 20C. After they have been taken out and until
they are tested, the cubes shall not be allowed to become dry.
Testing: Test three cubes for compressive strength at the periods mentioned under the relevant
specifications for different hydraulic cements, the periods being reckoned from the completion of
vibration. The compressive strength shall be the average of the strengths of the three cubes for each
period of curing. The cubes shall be tested on their sides without any packing between the cube and
the steel platens of the testing machine. 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.
Calculation:
Calculate the compressive strength from the crushing load and the average area over which the load
is applied. Express the results in kgs/cm2 to the nearest 0.5 kg/cm2.
Compressive strength, kg/cm2 = P/A, where ‘P’ is the crushing load in kg, and ‘A’ is the area in cm2.

6. DETERMINATION OF COMPRESSIVE STRENGTH OF CONCRETE.

(IS: 516 – 1959)
Object:
Determination of compressive strength of concrete.
Apparatus:
Testing Machine: The testing machine may

be of any reliable type of sufficient capacity
for the tests and capable of applying the load
at the specified rate. The permissible error
shall not be greater than 2 percent of the
maximum load. The testing machine shall be
equipped with two steel bearing platens with
hardened faces. One of the platens shall be
fitted with a ball seating in the form the
portion of a sphere, the center of which
coincides with the central point of the face of
the platen. The other compression platen
shall be plain rigid bearing block. The bearing
faces of both platens shall be at least as
larger as, and preferably larger than the
nominal size of the specimen to which the
load is applied. The bearing surface of the
platens, when new, shall not depart from a
plane by more than 0.01mm at any point, and
they shall be maintained with a permissible variation limit of 0.02mm. the movable portion of the
spherical seated compression platen shall be held on the spherical seat, but the design shall be such
that the bearing face can be rotated freely and tilted through small angles in any direction.
Age at test: Tests shall be made at recognized ages of the test specimens, the most usual being 7
and 28 days. The ages shall be calculated from the time of the addition of water of the dry
ingredients.
Number of Specimens: At least three specimens, preferably from different batches, shall be made
for testing at each selected age.
Procedure:
Specimens stored in water shall be tested immediately on removal from the water and while they are
still in the wet condition. Surface water and grit shall be wiped off the specimens and any projecting

find removed specimens when received dry shall be kept in water for 24 hours before they are taken
for testing. The dimensions of the specimens to the nearest 0.2mm and their weight shall be noted
before testing. Placing the specimen in the testing machine the bearing surface of the testing machine
shall be wiped clean and any loose sand or other material removed from the surface of the specimen,
which are to be in contact with the compression platens. In the case of cubes, the specimen shall be
placed in the machine in such a manner that the load shall be applied to opposite sides of the cubes
as cast, that is, not to the top and bottom. The axise of the specimen shall be carefully aligned with
the center of thrust of the spherically seated platen. No packing shall be used between the faces of
the test specimen and the steel platen of the testing machine. As the spherically seated block is
brought to bear on the specimen the movable portion shall be rotated gently by hand so that uniform
seating may be obtained. The load shall be applied without shock and increased continuously at a rate
of approximately 140 kg/cm2/min.until the resistance of the specimen to the increasing load breaks
down and no grater load can be sustained. The maximum load applied to the specimen shall then be
recorded and the appearance of the concrete and any unusual features in the type of failure shall be
noted.
Calculation:
The measured compressive strength of the specimen shall be calculated by dividing the maximum
load applied to the specimen during the test by the cross sectional area, calculated from the mean
dimensions of the section and shall be expressed to the nearest kg per cm2. Average of three values
shall be taken as the representative of the batch provided the individual variation is not more than +/-
15 percent of the average. Otherwise repeat tests shall be made.
A correction factor according to the height / diameter ratio of specimen after capping shall be
obtained from the curve shown in Fig.1 of IS:516-1959. The product of this correction factor and the
measured compressive strength shall be known as the corrected compressive strength this being the
equivalent strength of a cylinder having a height/diameter ratio of two. The equivalent cube strength
of the concrete shall be determined by multiplying the corrected cylinder strength by 5/4.

COMPRESSIVE STRENGTH OF CONCRETE / MORTAR CUBE SAMPLES

( IS : 516 )
Frequency of Tests
1 - 5m3 Concrete 6 Cubes
3
16 - 30m Concrete 12 Cubes
15 + 3 Cubes for every
> 50m3 Concrete
50m3
Compressive Strength
Lab. Location Age at Load at
Qty. of Grade of Weight of Density Date of Date of ( Kg/cm2 )
Ref. & Part of Test Failure
Concrete Concrete Specimen ( Kg/m3 ) Casting Testing
No Structure ( Days ) ( Tons ) 3 7 28
Days Days Days
Remarks :______________________________________________________________________________________________________________________

7. DETERMINATION OF WORKABILITY OF CONCRETE ( By Slump Test)

(IS: 1199 – 1959)
Object:
This method of test specifies the procedure to be adopted, either in the laboratory or during the
progress of work in the field, for determining, by the slump test, the consistency of concrete.
Apparatus:
a) Mould: the mould for the test specimen shall be in the
form of the frustum of a cone having the following
internal dimensions:
Dimensions cm
Bottom diameter. 20
Top diameter. 10
Height. 30
b) Tamping Rod: The tamping rod shall be of steel or
other suitable material, 16 mm in diameter, 0.6m long
and rounded at one end.
Procedure:
The internal surface of the mould shall be thoroughly
cleaned and freed from superfluous moisture and any set
concrete before commencing the test. The mould shall
be placed on a smooth, horizontal, rigid and non-absorbent surface, such as a carefully leveled metal
plate, the mould being firmly held in place while it is being filled. The mould shall be filled in four
layers, each approximately one-quarter of the height of the mould. Each layer shall be tamped with 25
strokes of the rounded end of the tamping rod. The strokes shall be distributed in a uniform manner
over the cross-section of the mould and for the second and subsequent layers shall penetrate into the
underlying layer. The bottom layer shall be tamped throughout its depth. After the top layer has been
rodded, the concrete shall be struck off level with a trowel or the tamping the rod, so that the mould
is exactly filled. Any mortar, which may have leaked out between the mould and the base plate, shall
be cleaned away. The mould shall be removed from the concrete immediately by raising it slowly and
carefully in a vertical direction. This allows the concrete to subside and the slump shall be measured
immediately by determining the difference between the height of the mould and that of the highest
point of the specimen being tested. The above operation shall be carried out at a place free from
vibration or shock, and within a period of two minutes after sampling.
The slump measured shall be recorded in terms of millimeters of subsidence of the specimen during
the test. Any slump specimen which collapses or shears off laterally gives incorrect result and if this
occurs the test shall be repeated with another sample.

8. DETERMINATION OF WORKABILITY OF CONCRETE (By Compacting Factor Test)

(IS: 1199 – 1959)
Object:
To determine the workability of fresh concrete by compacting factor test as per IS: 1199 - 1959.
Apparatus:
Compacting factor apparatus
Procedure:
1) The sample of concrete is placed in the upper hopper upto the
brim.
2) The trap-door is opened so that the concrete falls into the lower
hopper.
3) The trap-door of the lower hopper is opened and the concrete is
allowed to fall into the cylinder.
4) The excess concrete remaining above the top level of the
cylinder is then cut off with the help of plane blades.
5) The concrete in the cylinder is weighed. This is known as weight
of partially compacted concrete.
6) The cylinder is filled with a fresh sample of concrete and
vibrated to obtain full compaction. The concrete in the cylinder is
weighed again. This weight is known as the weight of fully
compacted concrete.
REPORTING OF RESULTS:
Compacting Factor =
(Weight of Partially Compacted Concrete)/(Weight of Fully Compacted Concrete)

9. DETERMINATION OF WORKABILITY OF CONCRETE (By VEE-BEE Test)

(IS: 1199 – 1959)
Object:
To determine the workability of fresh concrete by Vee-Bee Consistometer as per IS: 1199 - 1959.
Apparatus:
Vee-Bee Consistometer
Procedure:
1) A conventional slump test is performed, placing the

slump cone inside the cylindrical part of the
consistometer.
2) The glass disc attached to the swivel arm is turned
and placed on the top of the concrete in the pot.
3) The electrical vibrator is switched on and a stop-
watch is started, simultaneously.
4) Vibration is continued till the conical shape of the
concrete disappears and the concrete assumes a
cylindrical shape.
5) When the concrete fully assumes a cylindrical shape,
the stop-watch is switched off immediately. The time
is noted.
REPORTING OF RESULTS:
The consistency of the concrete should be expressed in VB-degrees, which is equal to the time in
seconds, recorded in Para v), above.

SLUMP CONE TEST

( IS : 1199 )
Lab. Ref. No :________________ Date of Testing :________
Grade of Concrete :___________ Day Weather :_________
Designed Slump :____________ W / C Ratio :__________
( * ) Weather details includes Bright Sun, Normal, Cloudy, Rainy, Fog etc.
LOCATION IN
TIME OF ( * ) OBSERVATION OBSERVED
S.NO. STRUCTURE WHERE REMARKS
WITH WEATHER DETAILS SLUMP ( mm )
CONE LAID
Remarks :_______________________________________________________

10. DETERMINATION OF SPECIFIC GRAVITY OF CEMENT.

(IS: 2720 – Part – 3)
Object: To determine the specific gravity of cement using Le Chatelier Flask or Spcefic Gravity Bottle.
Apparatus:
a) Le Chatelier Flask or Specific Gravity Bottle – 100 ml

capacity.
b) Balance capable of weighing accurately upto 0.1gm.
Procedure:
Weigh a clean and dry Le Chatelier Flask or Specific

Gravity Bottle with its stopper (W1). Place a sample of
cement upto half of the flask (about 50 gm) and weight
with its stopper (W2). Add kerosene (polar liquid) to
cement in flask till it is about half full. Mix thoroughly
with glass rod to remove entrapped air. Continue stirring
and add more kerosene till it is flush with the graduated mark. Dry the outside and weigh (W3).
Entrapped air may be removed by vacuum pump, if available. Empty the flask, clean it refills with
clean kerosene flush with the graduated mark wipe dry the outside and weigh (W4).
Calculations:
Specific gravity = (W2 – W1)/[( W2 – W1) – ( W3 – W4)] x 0.79
Where, W1 = weight of empty flask.

W2 = weight of flask + cement.
W3 = weight of flask + cement + kerosene.
W4 = weight of flask + kerosene.
0.79= specific gravity of kerosene.
Limit: Specific gravity of cement = 3.15 g/cc .

TEST : SPECIFIC GRAVITY OF CEMENT

( IS : 2720 - PART 3 )
1 Test/ Each Consignment Min. 3.15 g/cc
Lab Ref.No :______________________ Date of Sampling:_________
Source of Cement:____________________ Date of Testing:___________
Grade of Cement:_____________________ Week:___________________
TEST NUMBER MEAN

S.NO DESCRIPTION
1 2 3 VALUE
1 Weight of empty flask, W1
2 Weight of flask + Cement, W2
3 Weight of flask + Cement + Kerosene, W3
4 Weight of flask + full of Kerosene, W4
5 Weight of Cement, ( W2 - W1 )
Specific Gravity of Cement =

6
(W2 – W1)/[( W2 – W1) – ( W3 – W4)] x 0.79
Remarks:______________________________________________________________________________

11. DETERMINATION OF FLEXURAL STRENGTH OF CONCRETE.

(IS: 516 – 1959)
Introduction:
Concrete is not normally designed to resist direct tension, the

knowledge of tensile strength is used to estimate the load under
which cracking will develop. This is due to its influence on the
formation of cracks and its propagation to the tension side of
reinforced concrete flexural member. Shear, torsion and other
actions also produce tensile stresses to the particular section of
concrete member. In most cases member behavior changes upon
cracking. So flexural strength of concrete is also considered in
proportioning concrete member. This strength is of interest in
designing of highway and airfield slabs as shear strength and
resistance to cracking are very important to sustain such loading.
The flexural strength of concrete is about 10 to 15% of the
compressive strength, occasionally 20%.
Object:
Determination of the flexural strength of concrete specimen.
Apparatus:
a) Standard moulds of size 15 X 15 X 70 cms for preparing the specimen.

b) Tamping bar. c) Testing Machine.
Procedure:
Test specimens stored in water at a temperature of 250C to 300C for 48 hours before testing shall be
tested immediately on removal from the water, whilst they are still in a wet condition. The dimensions
of each specimen shall be noted before testing. No preparation of the surface is required. Placing the
specimen in the testing machine: The bearing surfaces of the supporting and loading rollers shall be
wiped clean, and any loose sand or other material removed from the surfaces of the specimen where
they are to make contact with the rollers. The specimen shall then be placed in the machine in such a
manner that the load shall be applied to the upper most surface as cast in the mould, along two lines
spaced 20 or 13.30 cms apart. The axis of the specimen shall be carefully aligned with the axis of the
loading device. No packing shall be used between the bearing surface of the specimen and the rollers.
The load shall be applied with shock and increasing continuously at a rate such that the extreme fiber
stress increases at approximately 7 kgs/cm2/mm for the 10 cm specimens, the load shall be increased
until the specimen falls, and the maximum load applied to the specimen during the test shall be
recorded. The appearance of the fractured faces of the concrete and any unusual features in the type
of failure shall be noted.

Calculation:
The flexural strength of the specimen shall be expressed as the modules of rapture ‘ fb’ which if ‘a’
equals the distance between the line of fracture and the nearer support measured on the centerline of
the tensile side of the specimen, in cm, shall be calculated to the nearest 0.5 kg/cm2 as follows.
fb = ( p X l ) / ( b X d2 )
When ‘a’ is greater than 20.0 cm . for 15.0 cm specimen or greater than 13.30 cm for a 10.0 cm
specimen, or
fb = ( 3p X a ) / ( b X d2 )
When ‘a’ is less than 20.0 cms. but greater than 17.0 cms for 15.00 cms specimen, or less than 13.30
cms but greater than 11.0 cms for a 10.0 cms specimen, where b = measured width in cms of the
specimen, d = measured depth in cms of the specimen at the point of failure, l = length in cm. of
the span on which the specimen was supported, and p = maximum load in kg. applied to the
specimen.
If ‘a’ is less than 17.0 cm. for a 15 cm specimen or less than 11.0 cm for a 10.0 cm specimen, the
result of the test shall be discarded.

12. DETERMINATION OF PERMEABILITY OF CONCRETE.

(MOSRTH: 1716.5)
Object: Determination of the Permeability of concrete specimen.
Apparatus:
a) Standard Cube moulds of size 150 X 150 X 150 mm or

Cylindrical moulds 150mm dia and 160mm height for
preparing the specimen. b) Tamping bar. c) Testing
Machine.
d) Permeability equipment.
Procedure:
At least three specimens prepared with cubic moulds or
cylindrical moulds as per the design mix and placed in curing
tank for 28 days.
After 28 days curing, the test specimen is fitted in a machine

such that the specimen can be placed in water under
pressure up to 7 bars.
At first a pressure of one bar is applied for 48 hours, followed by 3 bars for 24 hours and 7 bars for
next 24 hours.
After the passage of the above period, the specimen is taken out and split in the niddle by
compression applied on two round bars on opposite sides above and below.
The water penetration in the broken core is to be measured with a scale and the depth of penetration
assessed in mm.
Calculation: The depth of penetration in the broken core is the permeability of the particular
concrete mix and reported in mm.
Limits: The maximum permissible limit for the concrete is 25mm.

13. DETERMINATION OF ENTRAINED AIR CONTENT OF CONCRETE

(AASHTO: T 152-74)
Object: Determination of the air content of freshly mixed concrete from observation of the change in
volume of concrete with a change in pressure.
Apparatus: a) Air Meter, b) Measuring bowl, c) Spray tube,

d) Trowel, e) Tamping Rod, f) Rubber Mallet
Procedure:
Place a representative sample of the concrete in the
measuring bowl in three equal layers. Compact each layer of
concrete by 25 strokes of the tamping rod and evenly
distributed over the cross section. After consolidation of the
concrete strike off the excess concrete by trowel and leveled
up to the given marking. And then the sides of the bowel
sharply tapped 10 to 15 times with rubber mallet to remove
the large air bubbles.
Thoroughly clean the flanges or rims of the bowel and cover

the bowel with pressure tight clamps. Assemble the apparatus and add the water over the concrete by
means of the tube until it rises to about the halfway mark in the standpipe. Incline the apparatus
assembly about 300 from vertical and using the bottom of bowel as a pivot. Tapping the cover lightly
to remove any entrapped air bubbles above the concrete sample. Return the apparatus assembly to a
vertical position and fill the water column slightly above the zero mark.
Apply slightly more than the desired test pressure (about 0.2 psi) by hand pump to relieve local
restraints and record the water level on the standpipe as “h1”. Then the ultimate pressure (14.7 psi)
is apply on the test specimen until no change in the indicated air content (about 1 min) and record
the water level on the standpipe as “h2”. The apparent air content “A1” is equal to “h1-h2”.
Calculation: Calculate the air content of the concrete in the measuring bowl as follows:
Air content of the sample tested = As = A1 – G
Where, As = air content of the sample tested, percent

A1 = apparent air content of the sample tested, percent
G = aggregate correction factor, percent.

14. DETERMINATION OF FLOW OF CONCRETE

(AASHTO: T 120 - 42)
Object: Determination of the flow of concrete.
Apparatus:
a) Mould (bottom dia.= 254mm, top dia.= 171mm and height = 127mm). b) Flow Table
c) Tamping Rod.
Procedure:
Sample of concrete for test specimens shall be taken at the

mixer. The flow table top shall be wetted and cleaned of all
gritty material and the excess water removed with a rubber
squeegee. The mould shall be placed in centered on the
flow table and fill the concrete sample in two layers. Each
layer shall be rodded with 25 strokes of the tamping rod.
The excess concrete trimmed with trowel and cleans the
table again. The mould shall be immediately removed from
the concrete by a steady, upward pull. The table shall then
be raised and dropped (drop is 12.7mm) 15 times in about
15 seconds by revolving the actuating cam continuously at a
uniform rate. The diameter of the spread concrete shall be
the average of six symmetrically distributed caliper
measurements read to the neares 6.4mm.
Calculation:
The flow of the concrete shall be recorded as the percentage increase in diameter of the spread
concrete over the base diameter of the molded concrete.
Flow percent = Spread diameter – Original diameter x 100

Original diameter
Where, As = air content of the sample tested, percent

A1 = apparent air content of the sample tested, percent
G = aggregate correction factor, percent.

15. TESTS ON HARDENED CONCRETE

REBOUND HAMMER TEST
(IS: 13311 – Part 2 – 1992)
Object: Determination of Compressive strength/Quality of concrete by using Rebound Hammer Test.
Apparatus: Rebound Hammer
Principle:
The rebound of an elastic mass
depends on the hardness of the
surface against which its mass strikes.
When the plunger of the rebound
hammer is pressed against the surface
of the concrete, the spring-controlled
mass rebounds and the extent of such
a rebound depends upon the surface
hardness of the concrete. The surface
hardness and therefore the rebound is taken to be related to the compressive strength of the concrete.
The rebound value is read from a graduated scale and is designated as the rebound number or
rebound index. The compressive strength can be read directly from the graph provided on the body of
the hammer.
Procedure:
1) Before commencement of a test, the rebound hammer should be tested against the test anvil,
to get reliable results, for which the manufacturer of the rebound hammer indicates the range
of readings on the anvil suitable for different types of rebound hammer.
2) Apply light pressure on the plunger - it will release it from the locked position and allow it to
extend to the ready position for the test.
3) Press the plunger against the surface of the concrete, keeping the instrument perpendicular to
the test surface. Apply a gradual increase in pressure until the hammer impacts. (Do not touch
the button while depressing the plunger. Press the button after impact, in case it is not
convenient to note the rebound reading in that position.)
4) Take the average of about 15 readings.
Interpretation of Results: The rebound reading on the indicator scale has been calibrated by the
manufacturer of the rebound hammer for horizontal impact, that is, on a vertical surface, to indicate
the compressive strength. When used in any other position, appropriate correction as given by the
manufacturer is to be taken into account.

16. ULTRASONIC PULSE VELOCITY

(IS: 13311 – Part 1 – 1992)
Object: Determination of homogeneity of the concrete/Changes in the structure of the concrete

which may occur with time.
Apparatus: Ultrasonic Pulse Velocity Meter.
Principle:
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 upto 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’. 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)

5) 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.
Interpretation of Results:
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 – 4.5 Good
3.0 – 3.5 Medium
Below 3.0 Doubtful

17. FLUIDITY OF CEMENT GROUT

(ASTM C 939)
Object: Determination of Fluidity of Cement Grout by using Flow Cone as per ASTM C 939.
Apparatus: Flow Cone as per ASTM C 939, Receiving Container – 2000 ml capacity, Ring Stand and
Stop Watch.
Principle:
For determination the time of efflux of a specified

volume of fluid hydraulic cement grout through a
standardized flow cone.
Calibration of Apparatus:
Mount the flow cone firmly in such a manner that it is

free of vibration. Level the top to assure vertically.
Close the outlet and fill the 1725 ± 5 ml of water and
measure the discharge time of water. If this time is 8
± 0.2 sec, the cone may be used for determining the
time of efflux of grout.
Procedure:
1. Moisten the inside of the cone by filling the cone with water and, 1 min before introducing the
grout sample.
2. Drain out the water and close the outlet of the discharge tube.
3. Introduce the grout into the cone until the grout surface rises to contact the point gauge.
4. Start the stop watch, and simultaneously release the stopper and measure the time for full
discharge of grout.
5. The time indicated by the stop watch is the time of efflux of the grout.
Results:
Repeat the test 2 – 3 times and report the average time as a efflux of the grout. Average time of efflux
to nearest 0.2 sec.
Limits:
Efflux time of cement grout for post-tensioned cables in prestressed concrete bridge is less than 35
Sec.

OTHER TESTS.

1. DETERMINATION OF SURFACE IRREGULARITIES (UNEVENNESS)

(IRC: SP: 11)
Object:
Checking the surface unevenness using a straight edge and wedge.
Apparatus:
1) 3-metre straight edge may be made of steel or seasoned hard wood with the dimensions of 75mm
wide and 125mm deep.
2) Graduated wedge – with a least count of at least 3mm.
Procedure:
For recording undulations in the longitudinal profile

the straight edge is to be placed longitudinally
parallel to the center line of the road measurements
along two parallel lines may normally the sufficient
for a single lane pavement and along three lines for
the two lane pavement one additional line may be
covered for each additional lane.
The straight edge has limitations for as regards the

measurement of undulations at vertical curves.
Additional templates may be made for this purpose
especially if the curves are sharp.
The straight edge may be placed at the starting point, wedge inserted between it and the test surface
where the gap is maximum and reading taken. The edge may then be slide by about ½ length i.e.
1.5m, and the wedge reading repeated. This process should be continued. The straight edge need not
always be moved forward but may be moved backward and forward to record the maximum
undulation existing at a location. Locations with undulations in excess of the specified magnitude
should be marked on the surface.

LONGITUDINAL AND TRANSVERSE SURFACE UNEVENNESS

Max.Permissible no.of Undulations in 300m Length Max. allowable
Tolerances in Levels difference between
Type of Layer Type of Layer BC Surfaces Other than BC Road surface and
Sub-grade +20mm / - 20mm Undulation 4mm 7mm 4mm 7mm stright edge.
GSB +10mm / -10mm National Highway / For Bituminous Base
15 2 40 4
CRB / WMM +10mm / -10mm Expressway Courses = 6 mm
BM / DBM + 6mm / - 6mm For Granular Sub-

Roads of Lower
40 4 60 6 base / Base Courses
+ 6mm / - 6mm Category
AC = 8 mm
LONGITUDINAL IN LONGITUDINAL IN Transverse dip
"mm" "mm" readings
CHAINAGE CHAINAGE
R at Camber %
L at M L at R at M
C 0.6 C Left Right
0.6 M 0.6 M 0.6 M
M
150 TO 155 0
155 TO 160 10
160 TO 165 20
165 TO 170 30
170 TO 175 40
175 TO 180 50
180 TO 185 60
185 TO 190 70
190 TO 195 80
195 TO 200 90
200 TO 205 100
205 TO 210 110
210 TO 215 120
215 TO 220 130
220 TO 225 140
225 TO 230 150
230 TO 235 160
235 TO 240 170
240 TO 245 180
245 TO 250 190
250 TO 255 200
255 TO 260 210
260 TO 265 220
265 TO 270 230
270 TO 275 240
275 TO 280 250
280 TO 285 260
285 TO 290 270
290 TO 295 280
295 TO 300 290
300

2. DETERMINATION OF SURFACE UNEVENNESS BY AUTOMATIC ROAD UNEVENNESS

RECORDER / ROUGHOMETER.
Automatic road unevenness recorder also known as BUMP INTEGRATOR or ROUGHOMETER gives
speedily a quantitative integrated evaluation of surface irregularities on an electromagnetic counter. It
comprises of a trailer of single wheel with a pneumatic tyre mounted on a chassis over which on
integrating device is fitted. The machine has a panel board fitted with two sets of electromagnetic
counters for counting the uneven index value. The operating speed of the machine is 30 +/- ½
km/hr. A vehicle, usually a jeep, towed the machine and tyre pressure is 2.1 kg/cm3 (30 PSI).
Operation of the Bump integrator:
The Bump integrator should towed by a vehicle at a speed of 30 km/hr. A jeep with a canvass body is
eminently suitable because it affords opportunities for the driver to keep a watch on the unit. The
jeep should have sound suspension and damping system. The tyres pressure in the rear wheels of the
jeep should be same.
Before carrying out tests it is advisable to check the following items:
1) Integrator-cord terminals are in parked position i.e. the cord joining the integrator unit to the wheel
axle should be fathered to the chassis in a non-operational position.
2) Tyre pressure is 2.1 kg/cm3 (30 PSI).
3) Level of fluid in dashpots is up to top mark of the dipstick (check and maintain level to 3 cms below
the cylinder cap).
4) The electromagnetic counters are working in this is simply checked by running a short distance in
operational mode.
5) All the bolts of the towing hitch and the bracket fixed with the towing vehicle are tight.
6) The caster-wheel adjustable jacks are removed from the Bump integrator.
7) Tyre pressure gauge and foot pump kept in towing vehicle.

8) The control-knob (if provided) of the wheel-revolution contact is screwed down to disengage the
counter (this knob is located on top of the small box positioned where the wheel is bolted to the axle).
9) Spare like integrator cords, tool-kit, dipstick and fluid for the dashpots kept in the towing vehicle.
10) The relevant result-recording forms are also kept with the counter-board.
Comprehensive notes should be taken giving particulars of test length, width of road, type of
surfacing and any other relevant details needed.
The machines driver over the test section of road at a speed of 30 +/- ½ kmph. Normally in the
nearside wheel track of the nearside lane (position of machine on road is dependent on purpose of
measurements).
At the beginning of the section, the observer having set the counters to zero operates the on/off
switch to on-position on the instrument board.
At the end of the section the observer changes over to the second set of counters, which are then set
to zeros thus allowing continuous measurements. The readings of the integrating and wheel-
revolution counters are entered. The test section should not be less than 500m. Bump integrator is
run on two parallel lines (on each wheel track) on single lane carriageway and on three parallel lines
(one on each wheel track and the third on the central line) for double lane carriageway.
Processing of results obtained with Bump integrator:
The results obtained with Bump integrator are the following for a test section over which it has been
run to evaluate its riding quality:
i) Integrator value of irregularities in inches (BI counter reading).
ii) The number of wheel revolutions (wheel revolution counter).
Each set of readings (BI reading and corresponding number of wheel-revolutions) are required to be
converted to the unevenness index value (UI value) in terms of cms/km.
The unevenness index value for the test section is arrived at by taking mean of UI values
corresponding to the three sets of readings.
The unevenness index value is calculated by dividing the BI counter values (in cms.) by the distance
traveled in kms.
Integrator counter value (cms)
= ---------------------------------------
Distance traveled (km)
Limits: The riding quality of bituminous concrete wearing surface, as measured by a standard towed
fifth wheel bump integrator, shall not be more than 2000 mm per Km.

RIDING QUALITY MEASURMENT WITH BUMP INTEGRATOR / ROUGHOMETER
1 Name of the Road 8 Tyre Pressure : 2.1 kg/cm2(30psi)
: 500m
2 Length of Test Section Km ……to Km……. 9 Test Speed : 30 + / - 0.5 km/hr.
3 Single / Double Carriageway 10 No.of wheel Revolutions / km : 1000
4 Width of Carriageway 11 Name of the Instrument / Model :
5 Type of Surface
12 Calibration Equation at 30 km/hr ( From - CRRI ) =
6 New Construction / Last renewal
Period of Construction / Last 13 Name of the Testin Team

7
renewal
PERMISSIBLE LIMITS
BI Counter reading No of Wheel Revolutions UI Values ( cms / km )

Test Section and Location of Test Average Correct UI
Direction of line 1st 2nd 3rd 1st 2nd 3rd 1st 2nd 3rd UI Value
Measurment Left/Central/Right Set Set Set Set Set Set Set Set Set (cms/km) (cms/km)
Remarks :

3. DETERMINATION OF STRENGTHENING OF FLEXIBLE ROAD PAVEMENTS USING

BENKELMAN BEAM DEFLECTION TECHNIQUE.
(IRC: 81-1997)
Introduction:
Ever since Benkelman devised the simple deflection beam for measurement of pavement surface
deflection on WASHO test road in 1953, its use has become quite popular for evaluation of
strengthening requirements of flexible pavements quickly and conveniently, Benkelman beam has
been in use in India for more then a decade by different organizations. Since no uniform procedure
was available for the design of flexible overlays by using the deflection technique, the specifications
and standards committee of the IRC flat the necessity for preparing tentative guidelines.
Basic principles of the deflection method:
The deflection method is based on the concept that pavement sections, which have been conditioned
by traffic, deform elastically under a load. The deformation of elastic deflection under given load
depends upon the sub grade soil type and its conditions of moisture and compaction, thickness and
quality of the pavement courses, drainage condition, pavement surface temperature etc. Extensive
studies in other countries have shown that performance and life of flexible pavements are closely
related to the pavement elastic deflection caused by the passage of wheel loads.
The Benkelman Beam measures pavement deflection under a wheel load. It consists of a slender
beam 3.66m long pivoted at a distance of 2.44m, from the tip by suitable placing the probe between
the dual wheels of a loaded truck; it is possible to measure the rebound and residual deflections of
the pavement structure. While the rebound deflection is the one related to pavement performance,
the residual deflection may be due to non-recoverable deflection of the pavement or because of the
influence of the deflection bowl on the front legs of the beam.

Procedure for deflection survey:
The deflection survey essentially consists of two sets of operation, namely,

i) conditions survey for collecting basic information about the road structure and based on this
demarcation of the road into sections of more or less equal performance, and
ii) actual deflection measurements.
i) Pavement condition survey: This phase of operation, which should precede the actual deflection
measurements, consists primarily of visual observations supplemented by simple measurements for
rut depth using a 3-meter straight edge. Based on these, the road should be classified into sections of
equal performance with the criteria given as under.
Classification Pavement conditions

Good No cracking, rutting less than 10mm.
No cracking or cracking confined to single crack in wheel track
Fair
with rutting between 10mm and 20mm.
Poor Extensive cracking and/or rutting greater than 20mm.
As it is inexpedient to modify the overlay design at frequent intervals, it will be preferable if length of
each section is kept minimum of 50m.
During condition survey, information should also be collected about drainage characteristics,
topography, climatic condition and other relevant features. Test pits should be dug approximated
every 250 –500m depending on the uniformity in performance or pavement structure to determine
the thickness and composition of the pavement layers as also the sub grade soil characteristics.
Where it is intended to compare the results with the CBR design method. CBR of the sub grade soil
should also be determined on the lines recommended in IRC:37-1970.
The data collected at the condition survey should be recorded a proforma for which is suggested in
below.
Format for the collection of field information during test.
Pavement condition survey.
Name of Road:
Section:
Pavement Condition Existing Pavement Details

Sl. Section Surfacing Base
Riding Overall
No. or Km. Cracking Patching Rutting
quality rating Type Thickness Type Thickness
1 2 3 4 5 6 7 8 9 10 11

Continuation of this table is given below.

Existing Pavement Details
Sub-base Subgrade Soil
Field Moisture Field dry
Type Thickness Total Thickness LL PI CBR @ Remarks
content density
12 13 14 15 16 17 18 19 20
@ This test may be conducted where it is desired to compare the overlay design with that given by
CBR method. The test condition of the CBR specimens should be as recommended in IRC: 37.
ii) Deflection measurements: In each road section of uniform performance minimum ten
equidistant points should be marked in each lane of traffic for making the deflection observations in
the outer wheel path. The interval between the points might vary from as low as 50m depending on
the length of section under investigation. On roads with more than one lane, the points marked on
adjacent lanes should be staggered. In the transverse direction, the measurement points should be
60cm from the pavement edge where the lane width is less than 3.5 and 90cm for wider lane width.
For measuring the pavement deflection, several procedures are available and fall under two main
categories, (i) testing under static load, and (ii) testing under creep speed. For the purpose of these
guidelines, either the CGRA procedure, which is based on testing under static load, or the WASHO
procedure, based on creep load test may be made. In both cease methods; a standard truck having
the rear axle equipped with dual tyres inflated to a pressure of 5.60 kg/cm2 and transmitting a load of
8170 kg is used for loading the pavement. During actual tests, the load and tyre pressure are
maintained within a tolerance of +/- 1% and +/- 5% respectively.
The pavement temperature also influences deflections measured by Benkelman Beam. For design
purpose therefore, all deflection values should be related to a single common temperature, which is
recommended to be 350C. Measurement made when the pavement temperature is other than 350C
should be corrected in accordance with the procedure. Pavement deflections are also affected by the
seasonal variation in climate. For the purpose of these guidelines, it is intended that the pavement
deflections should pertain to the period when the sub grade is at its weakest condition. In India, this
period occurs during the monsoon season and immediately thereafter. It is desirable to conduct the
deflection measurements during such periods, but where this is not feasible a correction factor may
be applied to the deflection value.
The deflection measurements and other information collected during the deflection survey should be
recorded; for this a proforma is given below. This table also has columns for working out overlay
thickness.

Format for recording and analysis of pavement deflection data.
Name of road: Date and time of observation:

Section: Climatic conditions:
Lane or road: Ambient temperature:
Pavement deflection - mm Mean
Standard
Sl.N Pavement Correction Correction deflec-
Location Concreated deflection
o temp. Measured for for tion.
deflection …….
temperatur season mm
1 2 3 4 5 6 7 8 9
Continuation of this table is given below.
Charactreristic
Design.(Traffic), Permissible Overlay
deflection - Remarks
Com.Veh./Day deflection. required
mm
10 11 12 13 14
Correction for temperature variations:The stiffness of bituminous layers charges with

temperature of the binder and consequently the surface deflections of a given pavement will vary
depending on the temperature of the constituent bituminous layers. For purpose of design, therefore
it is necessary that the measured deflection be corrected to a common standard temperature of 350C.
Correction for temperature is not applicable in case of roads with thin bituminous surfacing (such as
premix carpet or surface dressing over a non-bituminous base) since these are usually unaffected by
changes in temperature. But temperature correction will be required for pavement having a
substantial thickness of bituminous construction (i.e. minimum 40mm). Correction need not however
be applied in the later case if road is subject to severe cracking or bituminous layer is substantially
stripped.
The deflection pavement temperature relationship is linear above temperature of 300C. For
convenience in the application of temperature correction it is recommended that deflection
measurements should be taken when pavement temperature is greater than 300C.
Correction for temperature variation on deflection values for pavement temperature greater than 300C
should be 0.0065mm for each degree centigrade change from standard temperature of 350C. The
correction will be positive for pavement temperature lower than 350C and vice versa. For example if
deflection is measured at 370C. The correction factor will be (2X0.0065 = 0.013mm). The correction
should be subtracted from measured deflection to obtain corrected value corresponding to standard
pavement temperature of 350C. The deflection measurement should take when pavement
temperature is uniform and near about 350C, so measurements should be made during morning or
evening hours.

In colder areas, the areas of altitude greater than 1000m where the average day temperature is less
than 200C for more than 4 months, it is recommended that deflection measurements be made when
ambient temperature is above 200C and no correction for temperature is required.
In cases, where temperature correction is required, pavement temperature should be measured,

during deflection survey. The measurement should be made at depth of 40mm using short stem
mercury thermometer. A hole of about 10mm dia and 40mm deep should be dug in pavement and
filled with enough glycerol.
Correction for seasonal variation of deflection: Since the pavement deflection is dependent
upon change in the climatic season of the year, it is always desirable to take deflection reading during
the season when the pavement is in its weakest condition, because permanent deformation and
consequent pavement distress occurs in this period of the year. Since in India this period occurred
during and after monsoon, deflection measurements should confined to this period only as far as
possible. When deflections are measured during summer they require a correction factor (which is
defined as the maximum deflection during or immediately after monsoon to that of minimum
deflection in summer). This correction and other factors due to large variations in subgrade soil
composition and climatic conditions prevailing in India, it is difficult to give single value to this factor.
It is, however, recommended that for dry clayey subgrade soils it may be taken as 2 where as for
sandy subgrade it may be taken as 1.2 to 1.3.
Analysis of deflection data: Deflection values as corrected above should be plotted against the
chainages. For each section mean and standard deviation should be obtained using the following
formula.
Mean deflection = x¯ = Σ X/n

Where, X = Individual deflections.
n = Number of measurements.
x¯ = Mean deflection.
Standard deviation= ơ = Σ(X – x¯2)/(n – 1)

Where, ơ = Standard deviation.
X = Individual deflection.
n = Number of measurements.
x¯ = Mean deflection.
Characteristic deflection = ( x¯ + ơ)

Allowable deflection:
Based on the limited experience available in this country following tentative limits are set for allowable
deflection corresponding to two methods of deflection measurements.
Allowable deflections where the deflections are

Traffic Intensity measured by :
CGRA method WASHO method
250 - 450 commercial vehicles/day 1.50 mm 1.40 mm
450 - 1500 commercial vehicles/day 1.25 mm 1.10 mm
1500 - 4500 commercial vehicles/day 1.00 mm 0.80mm
Determination of overlay thickness: Having obtained the characteristic deflection and permissible
deflection for a given section, following relationship may be used for obtaining overlay thickness:
h = R log10 (∆a/∆)
where, h = thickness of granular overlay in mm

∆a = characteristic deflection.
∆ = allowable deflection.
R = constant which may be taken as 550.
Evaluation of overlay thickness by CGRA curves:
The overlays to be provided can be assessed with the help of CGRA curves. The deflection having
known and the traffic intensity known the overlay can be directly read on Y-axis. The various curves
give the allowable deflection in the particular type of load for particular traffic intensity. The X-axis
shows or read the observed deflection. The Y-axis reading will get us the thickness of overlays to be
laid on the existing crust to meet the traffic demand.

CGRA – DEFLECTION TEST PROCEDURE.
Object:
This method of test covers a procedure for the determination of the static rebound deflection of
pavement under a standardized axle load, tyre size, tyre spacing and tyre pressure.
Equipment:
The equipment shall include:-
1) Benkelman Beam:
a) Length of probe arm from pivot to probe point. - 244 cm.

b) Length of measurement arm from pivot to dial. - 122 cm.
c) Distance from pivot to front legs. - 25 cm.
d) Distance from pivot to rear legs. - 166 cm.
e) Lateral spacing of front support legs. - 33 cm.
2) A 5-ton truck is recommended as the reaction. The vehicle shall have an 8170 kg. rear axle load
equally distributed in two wheels, equipped with dual tyres. The tyres shall be 10.00X20-12 ply
inflated to a pressure of 5.60 kg/cm2. The use of tyres with tubes and rib treads is recommended.
3) Tyre pressure measuring gauge.
4) Thermometer (0 – 1000C) with 10 division.
5) A mandrel for making 4.5 cm deep hole in the pavement for temperature measurement. The
diameter of the hole at the surface shall be (1.25 cm) and at bottom 1 cm.
Procedure:
1) The point on the pavement to be tested is selected and marked. For highways, the points are
located 60 cm from the pavement edge if the lane width is less than 350 cm, 90 cm from pavement
edge if lane width is 350 cm or more.
2) The dual wheels of the truck are centered above the selected point.
3) The probe of the Benkelman Beam is inserted between the duals and placed on the selected point.
4) The locking pin is removed from the beam and the legs are adjusted so that the plunger of the
beam is in contact with the stem of the dial gauge. The beam pivot arms are checked for free
movement.

5) The dial gauge is at approximately 1 cm. The initial reading is recorded when the rate of
deformation of the pavement is equal or less than 0.025 mm per minute.
6) The truck is slowly driven a distance of 270 cm and stopped.

7) An intermediate reading is recorded when the rate of recovery of the pavement is equal to or less
than 0.025 mm per minute.
8) The truck is driven forward a further 9 m.
9) The final reading is recorded when the rate of recovery of pavement is equal to or less than 0.025
mm per minute.
10) Pavement temperature is recorded at least once every hour, inserting thermometer in the
standard hole and filling up the whole with water. At the same time air temperature is recorded.
11) The tyre pressure is checked at two to three hour intervals during the day and adjusted to the
standard, if necessary.
Calculations:
1) Subtract the final dial reading from the initial dial reading. Subtract the intermediate dial reading
from the initial dial reading.
2) If the differential readings obtained compare within 0.025 mm, the actual deflection is twice the
final differential reading.
3) If the differential readings obtained do not compare to 0.025 mm, twice the final differential dial
reading represents the apparent pavement deflection.
4) Apparent deflections are corrected by means of the following formula:-
XT = XA + 2.91 Y
Where, XT = True pavement deflection.

XA = Apparent pavement deflection.
Y = Vertical movement of the front legs i.e., twice the difference
between the final and intermediate dial readings.

WASHO – DEFLECTION TEST PROCEDURE.
Equipment:
1) Benkelman Beam
2) 5-tonne truck with 8170 kg. rear axle load equally distributed on the two wheels. The 10X20-12 ply
tyres should be inflated to 5.60-kg/cm2 pressure.
3) Tyre pressure measuring gauge & other equipments are given in CGRA test procedure.
Procedure:
1) The point on the pavement where deflection measurement is desired will be selected and marked.
2) Move the truck so that its rear wheel is about 1.2m behind the selected point.
3) Insert probe arm between dual tyres of the vehicle to a distance of about 1.2m. lining up arm by
eye in such a position that rubbing of probe arm and tyre walls does not occur.
4) While truck is standing, record initial reading of dial. Turn on vibrator buzzer before taking first
reading.
5) Vehicle should be moved slowly (2 Kmph) and smoothly forward to at least 3m past the tip of the
beam. The beam operator should catch to see that the probe arm does not rub. The maximum dial
reading will occur when wheels are opposite the contact point, record this value.
6) After a reasonable length of time or when the dial needle has come to rest final reading should be
recorded.
Calculations:
1) The maximum deflection is the difference between the initial and maximum readings multiplied by
two.
2) The rebound deflection is the difference between the second reading and the final reading
multiplied by two.
3) The residual deflection is the difference between the initial reading and final reading multiplied by
two.

ADDITIONAL PAVEMENT THICKNESS (mm)

C.G.R.A.Curves:
875
0.635mm(0.025")
750
0.762mm(0.03")
625 0.889mm(0.035")
500 1.020mm(0.04")
375 1.270mm(0.05")
250
1.520mm(0.06")
125
0
0.75
1.25
1.75
2
2.25
5
0.5
1.5
2.5
7.5
BENKELMAN DEFLECTION (mm)
CBR Curve for Flexible Pavement Design:
100
120
10
15
20
30
40
50
60
80
2
4
5
6
7
8
9
10
20
30
A
40
B
50 No of Commercial Vehicles per
Curve
C day exceeding 3T.load
60 D
A 0 - 15
70 E
B 15 - 45
80 F
C 45 - 150
90 G
D 150 - 450
100 E 450 - 1500
F 1500 - 4500
G ABOVE 4500

4. DETERMINATION OF STRENGTHENING OF FLEXIBLE ROAD PAVEMENTS USING

FALLING WEIGHT DEFLECTOMETER TECHNIQUE
(IRC: 115-2014)
Introduction:
Significant developments have taken place during the past few decades in terms of the equipment
and the analytical tools adopted for structural evaluation of pavements. Impulse loading equipment
commonly known as Falling Weight Deflectometer (FWD) have been developed, which closely
simulates the duration and amplitude of the load pulses.
These guidelines are meant for evaluating the structural condition of in-service flexible road
pavements using deflection data from FWD as well as other pavement data as inputs to a
backcalculation model for determining the elastic moduli of pavement layers, and, thereafter, using
these moduli as inputs to a pavement design model for estimating the overlay requirement. The
backcalculation software used in these guidelines is the one developed as a result of the research
carried out under MoRTH Research study “Structural Evaluation of Pavements using Falling Weight
Deflectometer” and other studies conducted by the Transportation Engineering Section of IIT
Kharagpur. The pavement design model used in these guidelines is the one prescribed in IRC: 37-
2012.
Principle of Pavement Evaluation using FWD:
Performance of flexible pavements can be evaluated by applying loads on the pavements that
simulate the traffic loading, recording the response to such loading by measuring the elastic deflection
under such loads, and analyzing these data duly considering the factors influencing the performance
such as subgrade strength, thickness and quality of each of the pavement layers, drainage conditions,
pavement surface temperature etc.
When a moving wheel load passes over the pavement it produces load pulses. Normal stresses
(vertical as well as horizontal) at a location in the pavement will increase in magnitude from zero to
peak value as the moving wheel load approaches the location. The time taken from the stress pulse to
vary from zero to peak value is termed as ‘rise time of pulse’. As the wheel moves away from the
location, magnitude of stress reduces from peak to zero. The time period during which the magnitude
of stress pulse varies from ‘zero-to-peak-to-zero’ is the pulse duration. Peak load and the
corresponding pavement responses are of interest for pavement evaluation.
The resulting load-deflection data can be interpreted through appropriate analytical techniques, such
as backcalculation technique, to estimate the elastic moduli of the pavement layers. The computed
moduli are, in turn, used for
(i) the strength evaluation of different layers of in-service pavements
(ii) the estimation of the remaining life of in-service pavement

(iii) determination of strengthening requirement, if any and

(iv) evaluation of different rehabilitation alternatives (overlay, recycling, partial reconstruction,
etc.)
Falling Weight Deflectometer:
The Falling Weight Deflectometer (FWD) is an impulse-loading device in which a transient load is
applied to the pavement and the deflected shape of the pavement surface is measured. The working
principle of a typical FWD is illustrated in below figure.

Different magnitudes of impulse load can be obtained by selection of a suitable mass and an
appropriate height of fall. Under the application of the impulse load, the pavement deflects. Velocity
transducers are placed on the pavement surface at different radial locations to measure surface
deflections. Geophones or seismometers are used as displacement transducers. Load and deflection
data are acquired with the help of a data acquisition system.
The typical FWD is a circular loading plate of 300 or 450 mm diameter. A rubber pad of min. 5 mm
thickness should be glued to the bottom of the loading plate for uniform distribution of load.
A falling mass in the range of 50 to 350 kg is dropped from the height of fall in the range of 100 to
600 mm to produce load pulses of desired peak load and duration. Heavier models use falling mass in
the range of 200 to 700 kg. The target peak load to be applied on bituminous pavements is 40 kN ± 4
kN, which corresponds to the load on one dual wheel set of a 80 kN standard axle load.
Typical geophone position configurations (number and radial distances measured from center of load
plate) commonly used for flexible pavement evaluation are:
(i) 7 sensors at 0, 300, 600, 900, 1200, 1500 and 1800 mm radial distances
(ii) 7 sensors at 0, 200, 300, 450, 600, 900 and 1500 mm radial distances
(iii) 6 sensors at 0, 300, 600, 900, 1200 and 1500 mm radial distances and
(iv) 6 sensors at 0, 200, 300, 600, 900 and 1200 mm radial distances.
Steps for measuring deflection at a test point:

The following steps may be followed for measuring deflections at each test point. The exact sequence
of operations may be different for different models of FWD.
a) Mark the test point on the pavement
b) Centre the load plate of the duly calibrated FWD over the test point
c) Lower the loading plate onto the pavement. There should be no standing water (surface
texture completely filled with water) on the pavement surface. The loading plate should be in
proper contact with pavement surface.
d) Lower the frame holding the displacement transducers (geophone) so that the transducers are
in contact with pavement surface.
e) Raise the mass to a pre-determined height required for producing a target load of 40 kN.
f) Drop one seating load. Load and deflection data for seating load drop need not be recorded.
g) Raise the mass and drop. Record load and deflection data into the computer through data
acquisition system. While peak load and peak deflections at different selected radial positions
must be recorded, complete time history of load and deflections can be stored for each load
drop if feasible.
h) Repeat step (g) atleast two more times.

i) If, during steps (g) and (h), the deflections measured are too large or too small, the test may
be repeated by changing the peak load.
j) Raise the geophone frame and load plate and move to the next test location.
k) Record air temperature at half hourly interval.
l) Record pavement surface temperature (optional) if non-contact temperature sensors are
available.
m) Measure pavement surface layer temperature at half-hourly intervals by drilling holes of 40
mm depth into the pavement surface layer. Fill the hole with a drop of glycerol. Insert the
thermometer into the hole and record the temperature after three minutes.
n) Deflection measurements should not be made when the pavement temperature is more than
450C.
Over Lay Design:

The following are the steps to be followed for design of overlays based on FWD evaluation.
1) Measurement of surface deflections of homogeneous section of the in-srvice pavement using
FWD.
2) Normalization of the deflections to correspond to a standard load of 40 kN.
3) Collection of information about layer type and layer thickness.
4) Backcalculation of pavement layer moduli from the normalized deflections using an appropriate
backcalculation software. Backcalculation will be by considering the pavement to be a three
layer system. All bituminous layers will be combined together. Similarly granular base and
subbase layers may be combined. For pavements with modified subgrades, the modified layer
may be treated as part of subgrade. Cemented subbases may be treated to be part of granular
layer.
5) Adjustment of the bituminous layer modulus (backcalculated) to a standard temperature of
350C using the correction factors given by following equations:
ET1 = λ ET2
Where, λ = temperature correction factor
λ = 1 – 0.238 In T1
1 – 0.238 In T2
Where, ET1 = backcalculated modulus (MPa) at temperature T1 (0C)
ET2 = backcalculated modulus (MPa) at temperature T2 (0C)

6) Adjustment of the subgrade and granular layer moduli to correspond to post-monsoon

condition using following equations:
Esub_mon = 3.351 x (Esub_win)0.7688 – 28.9
Esub_mon = 0.8554 x (Esub_sum) – 8.461
Egran_mon = -0.0003 x (Egran_sum)2 + 0.9584 x (Egran_sum) – 32.989
Egran_mon = 10.5523 x (Egran_win)0.624 – 113.857
Where, Esub_mon = subgrade modulus in monsoon (MPa)

Esub_win = subgrade modulus in winter (MPa)
Esub_sum = subgrade modulus in summer (MPa)
Egran_mon = granular layer modulus in monsoon (MPa)
Egran_mon = granular layer modulus in monsoon (MPa)
Egran_sum = granular layer modulus in summer (MPa)
Egran_win = granular layer modulus in winter (MPa)
7) Selection of 15th percentile modulus (15% of the values will be less than this value) of each of
the three layers considered for analysis.
8) Analysis of the in-service pavement using linear elastic layer theory with the backcalculated
(corrected) moduli and layer thicknesses collected from field as inputs. This includes
computation of critical strains (a) Horizontal Tensile Strain at the bottom fiber of bituminous
layer and (b) Vertical Compressive Strain on top of subgrade. The loading configuration and
the locations of critical strains considered for analysis will be similar to those adopted in IRC:
37-2012.
9) Estimation of the remaining life of the pavement using the fatigue in bituminous layer and
subgrade rutting performance criteria adopted in IRC: 37-2012 given by equations as follows:
Fatigue model for 90 percent reliability
Nf = 0.711 x 10-4 x [1/εt]3.89 x [1/MR]0.854
Where, Nf = fatigue life in standard axle load repetitions
Εt = maximum tensile strain at the bottom of bituminous layer
MR = Resilient modulus of bituminous mix, MPa.

Rutting model for 90 percent reliability

N = 1.41 x 10-8 x [1/εv]4.5337
Where, N = number of cumulative standard axle
εv = vertical strain in the subgrade
The strain values obtained in step (8) will be used to estimate the remaining lives from fatigue
and rutting consideration. Remaining life of the pavement will be the shortest of the lives
obtained from bituminous layer fatigue, subgrade rutting and cemented base fatigue criteria.
10) For design of bituminous overlay, a trial thickness of overlay of an appropriate material has to
be selected and the critical strains have to be evaluated. The modulus value of the bituminous
overlay material may be selected as per the guidelines given in IRC:37-2012. Design overlay
thickness can be selected by trial in such a way that the computed critical strains are less than
the permissible limits given by the performance criteria for the design traffic level considered.

PAVEMENT CONDITION SURVEY FOR IDENTIFYING SELECTIONS OF UNIFORM PERFORMANCE (FOR ESTIMATING SAMPLE
SIZE FOR FWD DEFLECTION MEASUREMENT)
Name of the Road: Date of Survey:
Section: Traffic Intensity:_________cv/day_______Year
No. of Lanes & Carriageway Type: Annual Rainfall: High/Low
Subgrade Soil Type
Pavement Details
Embankment/Depth of
Depth of Water Table

Pavement Condition
Drainage Condition
Type of Shoulder
Bituminous Granular Granular Sub
Lane Position
cutting (m)
Surfacing Base Base

Height of
Remarks
S.No From To
(m)
Thickness
Thickness
Thickness
(mm)
(mm)
(mm)
Type
Type
Type
Note 1 : Identify the Carriageway / Lane position / Paved Shoulder
Note 2 : Classify as “Good”, “Fair” or “Poor” - Min. length of sub section is 1.0 km. in case of localized failures requiring closer examination should be 0.3 km.
Note 3 : Record any special or abnormal conditions such as flooding, submergence, failed section, previous failure history (if any) etc.
Note 4 : It is advised that distress data may also be collected separately using suitable mapping formats

PROFORMA FOR RECORDING PAVEMENT DEFLECTION DATA

Name of the Road: Date and Time of Observation:
Section: Climatic Conditions: (Hot / Humid / Cold)
No. of Lanes & Carriageway Type:
Peak Load Applied (kN)

Location of Test
Air Temperature (0C)
Temperature (0C) Peak Deflection (mm) observed at a radial distance (mm)

Point
Load Drop No
Lane Position
Pavement
Remarks
S.No
carriageway
edge (m)
Chainage
Distance
1200
1500
1800
from
300
600
900
0
Note 1 : Identify the Carriageway / Lane Position / Paved Shoulder
Note 2 : Other Sensor Configurations

ANALYSIS OF DATA FOR DIFFERENT HOMOGENEOUS SECTIONS

Name of the Road: Date and Time of Observation:
Homogeneous Section: From__________ To____________ Climatic Conditions: (Hot / Humid / Cold)
No. of Lanes & Carriageway Type:
Backcalculated Corrected
Location of test Peak Normalised Deflection (mm) observed at a radial
Backcalculated
point distance (mm) Moduli (MPa)
Lane Position
Moduli (MPa)
Remarks
S.No
Bituminous
Bituminous
y edge (m)
carriagewa
Subgrade
Subgrade
Chainage
Granular
Granular
Distance
Layer
Layer
Layer
Layer
Layer
Layer
1200
1500
1800
from
300
600
900
0
Note 1 : Identify the Carriageway / Lane Position / Paved Shoulder

Note 2 : Deflections may be normalized as subgrade
Note 3 : Other Sensor Configurations
Note 4 : Bituminous Layer Modulus may be corrected for Temperature . Granular and Subgrade layers may be corrected for season

5. DETERMINATION OF MICROTEXTURE OF MILLED PAVEMENT.
INTRODUCTION:
This test is used to determine the macrotexture of a pavement surface to meet the requirements of
the texture of a milled surface prior to an overlay. The micro-milled surface can provide smooth, safe
and comfortable riding surfaces for vehicles travelling at the highway speed.
Object:
This test method covers the procedure to evaluate the macrotexture of a milled pavement surface.
Apparatus:
(a) Filler: Type 1 glass beads in accordance with AASHTO M 247.

(b) Spreader: A flat, stiff hard disk
made from methyl methacrylate
(Plexiglas) with a thickness of 13 ±
3 mm, diameter of 200 ± 50 mm
and a round handle affixed in the
center used to spread the filler.
(c) Graduated Cylinder: A class-B or
better, style III, 250 ml capacity
graduated cylinder in accordance
with ASTM E 1272, used to measure
the volume of filler for the test.
(d) Brushes: A stiff wire brush and a
soft bristle brush used to clean the
pavement.
(e) Container: A small container with a
secure and easily removable cover used to store 200 ml of filler.
(f) Screen: A shield used to protect the test area from air turbulence by the wind or traffic.
Laboratory Preparation:
(a) Prepare one container with 200 ml of filler for each sample location.
(b) Fill the graduated cylinder to the specified volume.
(c) Gently tap the side of the graduated cylinder to level the surface of the filler.
(d) Place the measured volume of filler in the container.
(e) Label the container with the type and quantity of filler.

Procedure:
Randomly determine a sample location on the milled pavement surface. Inspect the sample location
and ensure the location is a dry, homogeneous site, free of unique or localized features such as
cracks, joints, stripping and patching. If localized features are present, move up-station at the same
transverse offset until a suitable site is located. Clean the sample location using the brushes to
remove any residue, debris or loosely bonded material.
Place the screen on the milled pavement surface to protect the sample location from air turbulence.
Hold the container with filler above the pavement at the sample location at a height not greater than
100 mm. Pour the measured volume of filler from the container onto the milled pavement surface into
a conical pile. Place the spreader lightly on top of the conical pile of filler being careful not to compact
the filler. Move the spreader in a slow, circular motion to disperse the filler in a circular area and to
create a defined crest around the perimeter. Continue spreading the filler until the filler is well
dispersed and the spreader rides on top of the high points of the milled pavement surface.
Measure and record the diameter of the circular area four times, at intervals of 45º and to the nearest
5 mm, as shown in Figure1. Measure the diameter of the circular area from the crest of the slope on
one side, through the center, and to the crest of the slope on the other side of the circular area.
Calculations: Calculate the average diameter of the circular area covered by the filler as follows:
Da = (D1+D2+D3+D4)/4
where:
Da = average diameter of the filler area, mm

D1, D2, D3, D4 = diameters of the filler area, mm

Results: Calculate the Macrotexture Ratio from the following table using the average diameter of the
area covered by the filler.
Limits: The acceptance Microtexture ratio is greater than or equal to 2.2.
Frequency of test: 1 test per 10000 sqm.

MICROTEXTURE REPORT
( ITM: 812-08T)
Permissible Limit Frequency of Test
2
≥ 2.2 1 Test per 10000 m

Date of Testing :__________
Road: ________________
D1 D2 D3 D4 Da Microtexture
Station Offset
(mm) (mm) (mm) (mm) (mm) Ratio
Remarks :_______________________________________________________

(APPENDIX – I)
GENERAL FORMATES FOR HIGHWAYS

GRADATION FOR COARSE & FINE AGGREGATE FOR CONCRETE WORKS

( IS : 383 - 1970 )
Lab Ref.No :______________________ Frequency of Tests : 1 Test / Week / Day
Type of Material :______________________ Date of Sample :__________________
Source Km. :______________________ Date of Tested :__________________
20mm Aggregate wt.of Sample =W1= Limits
Limits asa per Limits asa per
Sieve Size Weight Cum.Wt. Cum.% Remarks
% Passing IS:383 for IS:383 for
Retained Retained Retained
( 100 - col.4 ) Single size Graded
(gm) W2 (gm) W3 W3/W1X100
aggregate. aggregate.
40mm 100 100
20mm 85 - 100 95 - 100
10mm 0 - 20 25 - 55
4.75mm 0-5 0 - 10
12.5mm Aggregate wt.of Sample =W1= Limits

Limits asa per Limits asa per
Sieve Size Weight Cum.Wt. Cum.% Remarks
% Passing IS:383 for IS:383 for
Retained Retained Retained
( 100 - col.4 ) Single size Graded
(gm) W2 (gm) W3 W3/W1X100
aggregate. aggregate.
20mm 100 100
16mm 100 100
12.5mm 85 - 100 90 - 100
10mm 0 - 45 40 - 85
4.75mm 0 - 10 0 - 10
River Sand wt.of Sample =W1= Limits
Sieve Size Weight Cum.Wt. Cum.%

% Passing
Retained Retained Retained ZONE I ZONE II ZONE III
( 100 - col.4 )
(gm) W2 (gm) W3 W3/W1X100
10mm 100 100 100
4.75mm 90 - 100 90 - 100 90 - 100
2.36mm 60 - 95 75 - 100 85 - 100
1.18mm 30 - 70 55 - 90 75 - 100
600micr. 15 - 34 35 - 59 60 - 79
300micr. 5 - 20 8 - 30 12 - 40
150micr. 0 - 10 0 - 10 0 - 10
Remarks :________________________________________________________________________________

ALKALI AGGREGATE REACTIVITY TEST DATA

(IS: 2386 Part 7)(Mortar Bar Method)
Lab Ref.No:_____________________ Type of Aggregate:____________________ Source of Aggregate:_______________ Date of Sampling::_______
Type of Portland Cement:__________ Source of Cement:____________________ Date of Testing:________
Alkali Content of Cement : %K3O:…………………..%Na3O…………………..%Na2O…………………….
Specimen No. 1 2 3 4 Remarks
Intial Measurement Date
0
Temp., C………….. Time
Rel. Humidity, %...... Length, mm
Measurement at 1 month Date
Temp., 0C………….. Time
Ave.Expansion, mm
0
Ave.Expansion, mm
0
Ave.Expansion, mm
Ave.Expansion, mm
0
Ave.Expansion, mm
Ave.Expansion, mm
Examination at End of Test:
Description of wrapping:…………………………………………………………………………………………………….
Pattern & Location of Cracking:……………………………………………………………………………………………
Superficial Deposit / Exudations:………………………………………………………………………………………….
Remarks :__________________________________________________________________________

CONCRETE PIPES TEST

(IS : 3597 - 1998)
Manufacturer :___________________________________________ Lot No:_____________________
Pipe Classification:_______________________________________ Date of Testing:______________
Pipe Overall Length Internal Diameter Thickness Workmanship and finish

Remarks
No. Actual Limits Actual Limits Actual Limits Cl.8.1.1 Cl.8.1.2 Cl.8.1.3 Cl.8.2
THREE EDGE BEARING TEST
Three Edge Bearing Test

Pipe
Load Produce to 0.25mm
No. Crack
Limits Ultimate Load Limits
Remarks:_______________________________________________________________________________________

DAILY MIX DESIGN ( M-_____) AT BATCHING PLANT

Date:
Adjustments
Aggregate SSD weight Correction Net weight after
Moisture content
Type (Kgs) Factor adjustment (Kg)
(Kg)
20 mm
16 mm
10 mm
Sand
Cement
Water
Plastcizer
Water Absorption Batch weight for ______Cum.

Plant
Batch Weight Used
Agg. Size % age Agg. Size Roundup (Kg)
(Kg)
20 mm 20 mm (kg)
16 mm 16 mm (kg)
10 mm 10 mm (kg)
Sand Sand (kg)
Cement (kg)
Daily Moisture Content Water (kg)

Plasticizer
20 mm
(Ltr)
16 mm
10 mm
Sand Material Engineer

CONCRETE DELIVERY & POUR RECORD

(IRC-SP-47)
Date:_______________
S.No: :
Location of Pour :
Transit Truck No : Quantity Loaded in Truck :
Dispatch Time : Maximum ambient temperature :
Chainage :
Type of Structure :
Grade of Concrete : Slump as per design :
Lift :
From:
RL
To:
W/C Ratio : Cement Content (Kg/m3) :
Brand:
Cement Grade:
Batch:
3
Admix Dosage per m :
: 40mm 20mm 10mm Stone Dust Sand Water

Quantity of Aggregate at batching location:
Slump recorded at Batching Plant : Temperature of Concrete :
Dispatch Time : Maximum ambient temperature :
Time of arrival at Pouring : Slump at site :
No. of cubes cast :
No. Marks on Cubes :
Remarks: ____________________________________________________________________________
Checked & Despatched Checked for Consultant

TEMPERATURE DETAILS REGISTER

(PLANT SITE)
Location:___________________
Tested by:__________________
Temperature Temperature
0 0
Description of Activity ( C) Required ( C) Maintained
VG-30 VG-40 VG-30 VG-40
1. Aggregate temperature 150-170 160-175
2. Bitumen Temperature 150-165 160-170
3. Mixing Temperature 150-165 160-170
4. Room temperature
5. Discharge Temperature
Vehicle Temp. Vehicle Temp.
Sl.No. Material 0 Time Sl.No. Material 0 Time
No C No C
1 21
2 22
3 23
4 24
5 25
6 26
7 27
8 28
9 29
10 30
11 31
12 32
13 33
14 34
15 35
16 36
17 37
18 38
19 39
20 40
Remarks :________________________________________________________________

TEMPERATURE DETAILS REGISTER

(WORK SITE)
Location:___________________
Tested by:__________________
Temperature Temperature
0 0
Description of Activity ( C) Required ( C) Maintained
VG-30 VG-40 VG-30 VG-40
1. Laying temperature Min.140 Min.150
2. Rolling Temperature Min. 90 Min.100
Work Details Temp. while
Vehicle
Sl.No. discharging to Remarks
No. Location Material Layer paver
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Remarks :________________________________________________________________

TEST : GRANULAR SUB BASE - CLOSE GRADATION

( MORTH - Sec.400 - Table - 400 - 1 ) Grading- V
GRANULAR SUB BASE 1 TEST / 400m3

Type of
WEIGHT OF THE SAMPLE = ( W1 ) = LIMITS

PERCENTAGE
SIEVE SIZE
PASSING
( mm ) WEIGHT CUM.Wt.
CUM. % RETAINED ( 100 - Col.4 )
RETAINED RETAINED
(W3 /W1 X 100) MAX. MIN.
( gms) - W2 (gms) - W3
1 2 3 4 5
75 mm 100 100
53mm 100 80
26.5mm 90 55
9.5mm 65 35
4.75mm 50 25
2.36mm 20 10
0.850 mm 10 2
0.425mm 5 0
0.075mm - -
Remarks:______________________________________________________________________________________________________________

TEST : GRANULAR SUB BASE - DRAINGE LAYER

( Table - 400 - 1A ) Grading-1
3
GRANULAR SUB BASE 1 TEST / 400m

PERCENTAGE
SIEVE SIZE
WEIGHT CUM.Wt. CUM. % PASSING
( mm )
RETAINED RETAINED RETAINED ( 100 - Col.4 )
( gms ) - W2 ( gms ) - W3 ( W3 /W1 X 100 ) MAX. MIN.
1 2 3 4 5
75mm 100 100
53mm 100 80
26.5mm 90 55
9.5mm 65 35
4.75mm 55 25
2.36mm 15 10
0.850mm 10 4
0.425mm 3 0
Remarks :________________________________________________________________________________________

TEST : WET MIX MACADAM – GRADATION

(MORTH - Sec.400 - Table - 400 - 13)
3
WET MIX MACADAM 1 TEST / 250m

PERCENTAGE
SIEVE SIZE
WEIGHT CUM.Wt. CUM. % PASSING
( mm )
RETAINED RETAINED RETAINED ( 100 - Col.4 )
(gms) - W2 (gms) - W3 ( W3 /W1X100) MAX. MIN.
1 2 3 4 5
53mm 100 100
45mm 100 95
22.4mm 80 60
11.2mm 60 40
4.75mm 40 25
2.36mm 30 15
0.600mm 22 8
0.075mm 8 0
Remarks:_____________________________________________________________________________________

TEST : CRUSHED RUN MACADAM – GRADATION

( MORTH - Sec.400 - Table - 400 - 14 )
3
CRUSHED RUN MACADAM 1 TEST / 250m
SIEVE PERCENTAGE
SIZE WEIGHT CUM.Wt. CUM. % PASSING
( mm ) RETAINED RETAINED RETAINED ( 100 - Col.4 )
(gms) - W2 (gms) - W3 (W3 /W1 X100) MAX. MIN.
1 2 3 4 5
63mm 100 100
45mm 100 87
22.4mm 85 50
5.6mm 45 25
0.710mm 25 10
0.090mm 5 2
Remarks :________________________________________________________________________________________

TEST : BITUMINOUS MACADAM – GRADATION

( MOST - Sec.500 - Table - 500 - 7 ) (Grading – 1)
2
BITUMINOUS MACADAM
TEST/Day/Plant
Lab Ref No:_________________ Date of Sampling:__________
Type of Material:_________________ Date of testing:_____________
Source:_______________________ Oven / Air Dried:____________
LIMITS
WEIGHT OF THE SAMPLE = ( W1 ) = (Nominal Size of Agg. 40mm)
SIEVE PERCENTAGE
(Layer Thickness 80-100mm
SIZE PASSING
WEIGHT CUM.Wt. CUM. %
( mm ) (100 - Col.4)
RETAINED RETAINED RETAINED
(gms) - W2 (gms) - W3 (W3 /W1 X 100) MAX. MIN.
1 2 3 4 5
45 mm 100 100
37.5 mm 100 90
26.5 mm 100 75
13.2 mm 61 35
4.75 mm 22 13
2.36 mm 19 4
300 micron 10 2
75 micron 8 0
Remarks :_______________________________________________________________________________________

TEST : BITUMINOUS MACADAM – GRADATION

2
BITUMINOUS MACADAM
TEST/Day/Plant
LIMITS
SIEVE PERCENTAGE
SIZE PASSING
( mm ) (100 - Col.4)
1 2 3 4 5
26.5 mm 100 100
19 mm 100 90
13.2 mm 88 56
4.75 mm 36 16
2.36 mm 19 4
300 micron 10 2
75 micron 8 0
Remarks :_______________________________________________________________________________________

TEST : DENSE BITUMINOUS MACADAM – GRADATION

2
DENSE BITUMINOUS MACADAM
TEST/Day/Plant
LIMITS
SIEVE PERCENTAGE
SIZE PASSING
( mm ) (100 - Col.4)
1 2 3 4 5
45 mm 100 100
37.5 mm 100 95
26.5 mm 93 63
13.2 mm 75 55
4.75 mm 54 38
2.36 mm 42 28
300 micron 21 7
75 micron 8 2
Remarks:___________________________________________________________________________

TEST : DENSE BITUMINOUS MACADAM – GRADATION

2
DENSE BITUMINOUS MACADAM
TEST/Day/Plant
LIMITS
SIEVE PERCENTAGE
SIZE PASSING
( mm ) (100 - Col.4)
1 2 3 4 5
37.5 mm 100 100
26.5 mm 100 90
19 mm 95 71
13.2 mm 80 56
4.75 mm 54 38
2.36 mm 42 28
300 micron 21 7
75 micron 8 2
Remarks:___________________________________________________________________________

TEST : BITUMINOUS CONCRETE – GRADATION

2
BITUMINOUS CONCRETE
TEST/Day/Plant
LIMITS
SIEVE PERCENTAGE
SIZE PASSING
( mm ) (100 - Col.4)
1 2 3 4 5
26.5 mm 100 100
19 mm 100 79
13.2 mm 79 59
9.5 mm 72 52
4.75 mm 55 35
2.36 mm 44 28
1.18 mm 34 20
600 micron 27 15
300 micron 20 10
150 micron 13 5
75 micron 8 2
Rmarks:___________________________________________________________________________

TEST : BITUMINOUS CONCRETE – GRADATION

2
BITUMINOUS CONCRETE
TEST/Day/Plant
LIMITS
SIEVE PERCENTAGE
SIZE PASSING
( mm ) (100 - Col.4)
1 2 3 4 5
19 mm 100 100
13.2 mm 100 90
9.5 mm 88 70
4.75 mm 71 53
2.36 mm 58 42
1.18 mm 48 34
600 micron 38 26
300 micron 28 18
150 micron 20 12
75 micron 10 4
Rmarks:___________________________________________________________________________

REQUEST FOR INSPECTION

Project :
: National Highways Authority of ndia
Client
Independent Consultant :
Concessionaire :
EPC Contractor :
Sub-Contractor :
RFI No: Date:
We request you kindly arrange for the inspections / survey checking / approval of following materials / works
Highway Structure Survey Material Others
Contract B.O.Q. Item No: Highway / Structure work:
Specification Clause No: Structure No:
1. Section / Chainage: Safety Precaution taken
2. LHS / RHS: YES / NO
3. Brief Description of work:
Requested By: Received By:
Name: Name:
For Subcontractor / EPC: For Concessionaire:
Date: Date:
Time: Time:
Enclousers : Level Sheet / Field Density Report / Pre Concrete check list / Post Concrete check list /
Test Reports / Others if any
Comments / Recommendations of Concessionaire's / IC's Representative
Sr.Highway / Bridge / Material Engr. of Concessionaire Highway / Bridge / Material / Survey Dept. of IC.
APPROVED / NOT APPROVED
Concessionaire's Representative IC's Representative

Project:
Client: National Highways Authority of India
Consultant:
Contractor / Concessionaire:
NON CONFORMANCE REPORT (NCR)
Date:________________ NCR No.__________
Non-Compliance :
Location:__________________________________________________________________________
Details:___________________________________________________________________________
Signature of Contractor: Signature of Consultant:
Proposed Corrective Action :
Details:___________________________________________________________________________
_________________________________________________________________________________
Proposed Completion Date: Actual Completion Date:
Proposed Preventive Action :
Details:___________________________________________________________________________
_________________________________________________________________________________
Closing Out of NCR :
Rectification works accepted : Yes / No
Preventive Action accepted : Yes / No
Date of Closing Out NCR : :______________________
Signature of Contractor: Signature of Team Leader:

STAGE APPROVALS
PART - I
Approval is hereby requested for execution of ________________________________________
Location : From Km:________________________ to Km:______________________( LHS / RHS)
The previous layer (____________________________) has been constructed as per requirements

of technical specification and approved drawings. The following have been checked for:
1 Levels OK NOT OK
2 Field density OK NOT OK
3 Width and thickness OK NOT OK
4 Surface regularity OK NOT OK
Methodology
5 approved OK NOT OK
6 Mix design approved OK NOT OK
Materials
7 confirmation OK NOT OK
8 Frequency of tests OK NOT OK
Contractor's
Date :________________________ ___________________ Representative
PART - II
Checking of works as mentioned in Part - I above have been verified. Yes / No
Remarks:
Approved / Rejected
Date:______________________ Engineer

RELEASE FORM
Client : National Highway Authority Of India

Consultant :
Contractor :
Location:___________________________________Date:______________________
Contractor:_________________________________Contract No:________________
Additional Comments
Embankment / Sand
Material : 1 Filling
2 Subgrade
3 Granular Sub-base
4 Wet Mix Macadam
Dense Bituminous
5 Macadam
Bituminous
6 Concrete
Location : Left Right

From station:________________________________
To station:__________________________________
Cheched by Contractor Checked by RE
1) Compaction (test results)
2) Survey (template check data)
3) Identification of soft spot
4) Soft Spot Repairs (re-test results)

Engineer : Contractor :
Received
Date of Relase:_____________Time:_______________ by:_______________________________________

Project:
Month :
WEATHER RECORD
LOCATION TEMPERATURE WEATHER
DATE 0 0
Rain fall in mm Max C Min C Status
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Average
Total Tempature
Rain fall
Average Rain fall
Legend : C – Cloudy R – Rain S – Sunny
SUMMARY ( Rain Fall in mm )
Till Previous Month During The Month Cummlative
Checked by
……………………….

Client :
Project:
Engineer :
REQUEST FOR INSPECTION / WITNESS OF LAB TESTS

The following Field / Lab tests / Programme are to be inspected / Witnesed on_____________
1 Soil Tests :
(a) C.B.R: Chainage :
_________________________________________________________________________
(b) Heavy / Light compaction :
________________________________________________________________
( c) Atterbergs Limits : ________________________________________________________________
________________________________________________________________
(d) Gradation :
_________________________________________________________________________
(e) Sample collection : ________________________________________________________________
2 Concrete Cube Testing : ________________________________________________________________
3 Aggregate : _________________________________________________________________________
_________________________________________________________________________
4 Others : __________________________________________________________________________________
Request Subbmitted By______________________on________________ Signature____________________________

for
Contractor for Engineer
________________________________________________________________________________________________
Engineer's
Comments:
No of tests / programmes for which request given________________________
No of tests / programmes carried out _________________________________
Reason, if any
Signed ( for Engineer )________________________________ on _____________________( date )
Received ( for Contractor )________________________________ on __________________( date )

DAILY REPORT SHEET

PROJECT: DATE:
CLIENT: Weather :
CONSULTANT: Name :
CONTRACTOR: Designation :
Description of work Done
Specific Location of
Work REMARKS (Plant &
Type of Work
Labour)
From To
Difficulties Encountered and Delays
Instructions given to Contractor - Information received from Contractor
Signature Signature
Deputy Resident Engineer Engineer's Representative

DAILY PROGRESS REPORT

DATE :
Name of Site Incharge : Milestone : Day / Night
Embankment / Subgrade / Excavation / GSB / CRB / SD / DBM / BC / Concrete / Others.
Chainage Quantity
S.No. Side No.of Trips Remarks
From To Theoritical Actual
Machinery Utilised
S.No. Type of Machinery No.of Hours Worked Remarks
Labour Engauged
No.of persons
S.No. Name of the Gang Remarks
Male Female Total
Next Day's Programme
Chainage
S.No. Side Remarks
From To
Requirements Remarks

DAILY WORK PLAN

Date :
Road Works
Chainage Nature of
S.No. Side Layer No. Remarks
From To Work
Concrete Works
Structure Type of Grade of Structural

S.No. Lift No. Remarks
Chainage Structure Concrete Component
Project Manager's Signature

TEST : BENTONITE SLURRY

( MORTH: 1115.2.3)

Min. 1.05
Density
g/cc
Mars Cone Viscosity 30 - 40
pH Value 9.5 - 12
1 Test per Source/ As and When Required
Less than
Silt Content
1%
More than
Liquid Limit
400%
Source :_________________ Date of Testing :____________
Pile No. :_________________ Quantity of Sample:___________
Mars Cone
Sample No Density pH Value Silt Content Liquid Limit
Viscosity
Mean Value
Remarks :__________________________________________________________________________
Tested by :_______________________ Checked by :________________ __________________

( For
( For Contractor ) Contractor ) ( For Engineer )

TEST : DETERMINATION OF pH VALUE, CHLORINE AND SULPHATE CONTENT IN WATER

( IS : 3025 )
pH Not < 6
1 Test per Source / As and When 2000 mg/l (PCC)
Chlorine
Required 1000 mg/l (RCC)
Sulphate 500 mg/l

Source :_________________ Date of Testing :____________
To be used in Quantity of Sample:___________
Structure: _________________
A. pH Value (Using pH Strips)
Sl. No. of Strips pH Value Acceptable Value
3
B. Chloride Content (Using Test Kit)
Qty. of Water
Qty. of Reagent 'A' Qty. of Regent 'B' Chloride Content (mg/l)
taken
C. Sulphate Content (Using Test Kit)
Qty. of Water
Qty. of Reagent 'A' Qty. of Regent 'B' Sulphate Content (mg/l)
taken
Remarks :_____________________________________________________________________________________
Tested by :_______________________ Checked by :________________ __________________

( For Contractor ) ( For Contractor ) ( For Engineer )

VERTICAL LOAD TEST ON PILES

(IS: 2911 - Part 4)
Lab Ref No :_________________ Date of Testing :____________
Test Pile No. :_________________
Jack Details: Incremental Load = 20% of Safe load on the pile
Make & Type :_________________
Last Calibration on________________
Ram Dia. =____________ Divisions =____________
Recording of Deflection
Date Pressure Dial Gauge Reading (in mm) Average Average
Load
and Applied Reading Settlement Remarks
2 (in MT) A B C D
Time (Kg/cm ) (in mm) (in mm)
Pressure Building up
Pressure Released
Recommended Value: Maximum Deflection = 12 mm

Note: (For maintain the load in each stage of loading)
Displacement in each stage of loading is maintained till rate of displacement is either 0.1 mm in first 30 minutes or
0.2 mm in first 1 hr. or till 2hrs. whichever occur first.
Remarks :_____________________________________________________________________________________
Checked by
Tested by :_______________________ :________________ __________________
( For Contractor ) ( For Contractor ) ( For Engineer )

THE TESTING OF THE PLASTICISER

(IS: 9103-1999)
Lab Ref.No :______________________
Quantity of Plasticiser:____________________ Date of Sample :____________
To be used in
Structure:____________________
1 Compressive Strength (Percentage of Control Sample)
a) Grade of Concrete = M..…
b) Age of Concrete Cubes =…….Days
c) Size of Cube = ……mm x …….mm x ……..mm
Sample No. Compressive Strength of Concrete
Control Concrete Concrete with Plasticiser
S. No Concrete Compressive
Control
with Load at Compressive Load at Compressive Strength as
Concrete
Plasticiser Failure Strength Failure Strength percentage of control
sample
1
2
3
4
5
6
Recommended value of the compressive strength as percentage of control sample:
3 days = 125% minimum 7 days = 125% minimum 28 days = 115% minimum
2 Loss of Workability Slump in mm, (Deviation from Control Sample)

a) Grade of Concrete = M..…
Slump of Concrete (in mm)
S. No.
Control Concrete after 15 minutes Concrete with Plasticiser after 2 hrs.
1
2
3
4
5
6
Recommended value of the deviation in slump from control sample:
The Slump at the end of 2 hrs should not be lesser than that of control concrete after 15 minutes.
Results: Accepted / Not Accepted =………….
Remarks (if any)……………………………………………………………………………………………………………….

GROUTING RECORD IN SHEATHING

(MOSRTH: Appendix 1800/IV)
Name of Work:__________________________ Lab Ref.No:________________________

Span No:_______________________________ Cable No._________________________
Date of Pre-Stressing:_____________________ Date of Grouting:____________________
Type of Cement:_________________________ Date of Manufacture:________________
Water Cement Ratio (Max. 0.45):___________
Name & amount of Admixture (if used):________
Temperature: Mixing Water________________ Grout_______________________
Time: Start____________________________ Finish______________________
Equipment: Grout Mixer___________________ Grout Pump_________________
Cable Duct: Diameter___________________ Length_____________________
Volume of Grout (in lts)_________________ Regrouting__________________
Grouting Pressure______________________
Cement Consumption: Theoretical___________ Actual___________________
Pregrouting Checks:
Free of Blockage: 1. Inlet (Yes / No)______ 2. Outlet (Yes / No)_____________
3. Vents (Yes / No)_____ 4. Cable Ducts (Yes / No)__________
Leakage Observed (Yes / No)______________ Sealed________________________

If cable duct blocked: Remedial measures________________________________________
Grouting Observations:
Passage of grouts through vents (Yes / No)________________________
Passage of grouts through outlets (Yes / No)________________________
Any equipment failure:_______________________________________________________
Post Grouting Checks:_______________________________________________________
Probing by Stiff Wire_________________________________________________________
Checked by
Tested by :_____________ :___________ ____________
for Contractor for Contractor for Engineer

TESTING THE EPOXY BONDING AGENT
Lab Ref.No :______________________ Date of Sample :_____________

Quantity of Epoxy:______________________ Date of Tested :_____________
Source Km. :______________________
To be Used in Structure:_________________
1 Pot Life of Epoxy Bonding Agent
0
a) Ambient Temperature During Testing = ……………………………. C
b) Duration of Mixing =…………………..minutes
Time since completion of Mixing Remarks

(in Minutes) (Workable/Stiff/Not Workable)
Pot Life of Sample of Epoxy = ………….. Minutes

Recommended Pot Life =Minimum 20 Minutes
Results : Accepted / Not accepted =………………………
Remarks (if any):………………………………………………………………………..
Open Time of Epoxy Bonding

2 Agent
0
Time since Remarks

Specimen No. completion of Mixing (Concrete Failure/Joint
(in Minutes) Failure)
Open time os sample of Epoxy = ………….. Minutes

Recommended Open Time = Minimum 60 Minutes
Remarks (if any):………………………………………………………………………..

3 Thixotropy of Epoxy Bonding Agent

0
b) Sample filled in gutter of Daniel's gauge after 10 minutes of 3 minutes mixing
Time Reckoned from
Sag
S. No start
(in mm)
(in Minutes)
1
2
3
Sag flow of Epoxy =……………Minutes
Recommended sag flow = Minimum 30 Minutes
Remarks (if any):………………………………………………………………………..
4 Angle of Internal Friction (Squeezability)

0
3
b) Quantity of Bonding Agent 3140 mm
Acceptable Values of the Area
Area of Spread
S. No Load (in Kg) of Spread
2
(in mm ) 2
(inmm )
1 15 Minimum 3000
2 200 Minimum 7500
3 400 Minimum 10000
Remarks (if any):………………………………………………………………………..
Curing Rate of Epoxy Bonding

5 Agent
0
b) Size of Cubes = 50 mm x 50 mm x 50 mm
Failure Load (in kN) Mean

Curing Compressive Acceptable
Load at
time Strength Values
Specimen Specimen Specimen Failure 2 2
(hrs) (N/mm ) (N/mm )
1 2 3 (kN)
12 Minimum 20
24 Minimum 60
168 Minimum 75
Remarks (if any):………………………………………………………………………..

6 Compressive Strength of Epoxy Bonding Agent

0
b) Size of Cubes = 50 mm x 50 mm x 50 mm
Failure Load (in kN) Mean

Age of Compressive Acceptable
Load at
Specimen Specimen Specimen Specimen Strength Values
Failure 2 2
(hrs) 1 2 3 (N/mm ) (N/mm )
(kN)
24 Minimum 60
168 Minimum 75
Remarks (if any):………………………………………………………………………..
7 Bonding of Cured Bonding Agent to Concrete Surface

0
2
b) Compressive Strength of Prism should be approx. 40 N/mm
Specimen No. Remarks (Concrete Failure / Joint Failure)
Recommendations: Total fracture of concrete paste should occur (Concrete Failure) with no evidence
of bonding agent failure (Joint Failure)
Remarks (if any):………………………………………………………………………..
8 Tensile Bending Strength of Epoxy Bonding Agent

0
2
b) Compressive Strength of Prism should be approx. 40 N/mm
Specimen No. Remarks (Concrete Failure / Joint Failure)
Recommendations: Total fracture of concrete paste should occur (Concrete Failure) with no evidence
of bonding agent failure (Joint Failure)
Remarks (if any):………………………………………………………………………..

9 Shear Strength of Epoxy Bonding Agent

0
2
Specimen No. Load at Failure (kN) Shear Stress (N/mm )
2
Recommendations: Minimum Shear Stree = 12 N/mm
Remarks (if any):………………………………………………………………………..
10 Heat Resistance of Epoxy Bonding Agent

0
2
Specimen No. Load at Failure (kN) Shear Stress (N/mm )
2 0
Recommendations: Minimum Shear Stree = 10 N/mm at 50 C
Remarks (if any):………………………………………………………………………..
11 Colour of Epoxy Bonding Agent
0
Colour of Epoxy Bonding Agent = ……………………………. C
Recommendations: Colour should be similar to adjoining concrete
Remarks (if any):………………………………………………………………………..
Tested by Checked by
:____________________ :____________________ ____________________
for
for Contractor for Contractor Engineer

TESTING THE MIS SHEATHING DUCT

(IRC: 18, Appendix-1A)
Date of Sample
Lab Ref.No :______________________ :_____________
Date of Tested
Length of Sheathing:______________________ :_____________
Source Km. :______________________
1 Workability Test of Sheathing
Length of Sheathing test piece = 1100 m
Dia. Of Sheathing =………mm
Radius of Bent = 1800 mm
No of cycles =3
Condition of Sheathing joint after 3 cycles (any failure or opening of joints)…………………………………..

………………………………………………………………………………………………………………………..
Recommendations: No failure or opening joints after 3 cycles
Remarks (if any):………………………………………………………………………..

2 Transverse Load Rating Test
Applied Load =………..N
Permanent Deformation =………..%
Recommendations: Permanent Deformation is less than 5%

Remarks (if any):………………………………………………………………………..

3 Tension Load Test

Applied Load =………..N
Condition of joints and couplers (any deformation of Joints or Slippage of Couplers)………...……………..

………………………………………………………………………………………………………………………..
Recommendations: No deformation of Joint or slippage of Couplers is to be noticed
Remarks (if any):………………………………………………………………………..
4 Water Loss Test

Applied Pressure = 0.05 Mpa
Duration of Applied Pressure = 5 Minutes
Loss of Water =…………
Recommendations: Maximum losses of Water = 1.5 %

Remarks (if any):………………………………………………………………………..
Remarks
:_____________________________________________________________________________________
_________________
Tested by :____________________ Checked by :____________________ ___
for Contractor for Contractor for Engineer

TESTING THE HDPE SHEATHING DUCTS

(IRC: 18, Appendix-1B)
Lab Ref.No :______________________ Date of Sample :_____________
Date of Tested
Length of Sheathing:______________________ :_____________
Source Km. :______________________
1 Bond Test
Data Sample - 1 Sample - 2 Sample - 3

Dia. Of Duct (mm)
Length of Duct (in mm, 40 times the dia. Of duct)
2 2
Strength of Grout (in N/mm , Minimum 27 N/mm )
Anchorage Efficiency
Failure Capacity of tendon (in MPa)
95% of failure capacity (in Mpa)
Load at failure (in Mpa)
Mean Load at Failure (in Mpa)
Recommendations: Failure capacity of bond shall be at least equal to the anchorage efficiency or 0.95 of
failure capacity of the tendon
Remarks (if any):………………………………………………………………………..
2 Compressive Test for the loss of Wall Thickness
Data Sample - 1 Sample - 2 Sample - 3

Measurement of the indentation formed
Mean value of the indentation formed
Recommendations: The residual thickness of the duct shall not be less than 1.5 mm
Remarks (if any):………………………………………………………………………..
Checked by
Tested by :____________________ :____________________ _____________________
for Contractor for Contractor For Engineer

(APPENDIX – II)
CHECK LISTS

Wet Mix Macadam (WMM)

S. No. Description Yes/No/NA Remarks
1 Are all the Ingredients for WMM with required physical properties are collected?
2
Are all the Ingredients are mixed as per JMF by Mechanical means?
3
Is the GSB top levels and density are checked?
4 Is the WMM is prepared at OMC +1% moisture and sample are tested for gradation
test at specified intervals?
5
Is the light sprinkling of water on GSB surface is done?
6
Is the One pass of 8 - 10 T smooth wheel roller is done?
7 Is the approved mix is transported and properly dumped, max.thickness of one layer
should not be more than 200 mm?
8
Are the Width and levels are marked on level pegs?
9
Is the Material is spreaded by motor grader / paver?
10
Is the Moisture content of mix is checked?
11
Are the Water is sprinkled uniformly to achieve OMC +1% moisture?
12 Is the Final grading as per required level and grade including allowance for
compaction?
13
Is the Compaction is done at moisture content +1% to -2% of OMC?
14
Is the Compaction is done by 8 - 10T vibratory compactor?
15 Is the Rolling should start from outer edge and proceeds towards centre
longitudinally?
16
Is the Speed of roller should be with in 3 - 5 kmph?

17 Each pass of roller shall overlap atleast 1/3 rd width of track made in
previous pass?
18
Rolling is done till 98% compaction is achieved.
19 Surface irregularity / segregation is corrected during compaction, if found any

where.
20
Max.permissible undulation +/- 8mm.
21
Field density should not be less than 98% of MDD.
22
Density and levels of compacted layer is checked
23
Tolerances in levels should be in +/- 10mm.
For Contractor For Consultant
Name: Name:
Designation: Designation:
Signature: Signature:
Date: Date:

Asphaltic Concrete
1 Location of Work:
2 Chainage:
Materials
Is the Aggregates approved as per Clause 507.2.2 of MOSRTH? If yes,
reference of approval………………
1 Is the Filler material approved as per Clause 507.2.4 of MOSRTH? If yes,
reference of approval……………..
Is the Bitumen approved as per Clause 507.2.1 of MOSRTH?
If yes, reference of approval……………..
Mix
2
Is the mix as per the approved Job Mix?
Is the Hot Mix Plant (HMP) of adequate capacity and can produce a uniform mix
3 and approved?
Reference of approval…………………………………….
Is the surface on which Bituminous Concrete is to be laid is prepared to start the
4
work?
0 0
5 Temperature of Binder during mixing (140 C to 170 C)
0 0
6 Temperature of Aggregate during mixing (155 C to 175 C)
0 0
7 Temperature of Mix (155 C to 170 C)
Temperature difference between the Aggregates and the Binder not more than
8 0
14 C?
9 Whether the mixing is homogenous?
Whether the mix is transported from the mixing plant to the point of use in
10
suitable tipper vehicles?
11 Whether the tippers are clean and covered?
12 Whether Tack Coat has been applied?

Spreading
13
Whether the mix is spread by means of a sensor paver?
Rolling
Is the Initial/Breakdown rolling done by 8 to 12 MT, 3 wheeled steel roller or a
vibratory roller with vibration switched off?
14 Is the Intermediate rolling done with a 8 to 10 MT vibratory roller or 12 to 15 MT
Pneumatic Smooth Wheeled Roller (with 9 wheels, and tyre pressure minimum
2
5.6kg/cm )?
Is the final rolling done with a 8 to 10 MT vibratory roller or smooth wheeled
tandem roller?
Density
15
Is the relative density equal to at least 98%
Name: Name:
Date: Date:

Bore Cast-in-situ concrete piles

1 Unique Identification No. of Piles
2 Pile Group
Sketch for Pile Group No.
Layout
1 Has the layout been checked as per the coordinates

with a total survey station?
Whether found Correct?
Vertical Alignment
2
Is the Vertical Alignment Correct?
Piling Equipment
Whether piling equipment as approved?
3 Specify the Ref. of Approval…………………………….
Whether dia of cutting tool is as per the required bore
opening?
Liner
Is the thickness of liner as specified in the method
4 statement?
Is the depth of liner from existing ground level as per
the drawing? Specify the depth……………..
Bentonite Slurry
5 Whether bentonite tested as per Clause 1115.2.3 of
MOSRTH?
Flushing of Bore
Is the Sp. gravity of bottom slurry after cleaning of
6 bore not more than 1.2? Specify the Sp.
Gravity……………..
Has the bore been cleaned?

Reinforcement
Is the reinforcement checked as per checklist?
7 Whether the cage has been reasonably stiffened as
observed during lifting of reinforcement?
Whether length for construction of pile cap available?
Concreting
Whether checklist for concrete pour has been
approved?
If yes. Reference of
approval…………………………………….
Has the cut off level been checked?
8 Specify…………
Does the funnel have adequate holding capacity?
Whether tremmie pipe was continuously embedded
in Concrete?
Is the pile shift within permissible limit?
Specify the shift……………….
Name: Name:
Date: Date:

RCC Work (Staging)

1 Nomenclature of Item:
2 Dimensions Drawing No.:
S.
Description Yes/No/NA Remarks
No.
Has staging been designed and got
1
approved in advance?
Is the base preparation done as per the
2
approved methodology?
Is the placing of Concrete Block as per
3
drawing?
Is the Erection of V.T. Columens true to
4
plumb?
Are the Connection of horizontal and
5
diagonal bracing as per drawing?
Are all the joints benn properly made
6
and stiffened?
Is the placing of longitudinal girder and
7
transverse girders as per drawing?
Has staging been done as per approved
8
design?
Is the spacing of V.T. Column according
9
to approved design?
Name: Name:
Date: Date:

RCC Work (Form Work)

2 Dimensions Drawing No.:
1 Is the shuttering material (wood/steel) as approved?

2 Is the thickness of shuttering plates as approved?
3 Is the thickness of stiffener as approved?
Is pre assembly of shuttering checked and elements of individual
4
shuttering checked before use?
Is arrangement of the formwork as per the approved dimension
5
drawing?
6 Has the alignment and levels of the shuttering/formwork checked?
7 Is the verticality checked (Max. limit 1 in 1000)?
8 Is shuttering watertight and whether foam and rubber sheet provided?
Are shuttering plates suitable to give shutter finish of concrete, i.e. free
9
from dents, scales or pitting etc.?
10 Is the shuttering adequately supported and braced?
Are the sectional dinensions correct to ± 5mm & level correct
11
to ± 3mm?
12 Are shutter vibrators provided as approved?
13 Are joints between panels flush (no steps/lips)?
14 Are spacers between shutters adequately provided wherever required?
15 Are End Stoppers provided?
16 Is the Oiling of forms done with approved release oil?
17 Are the water stops fixed as required?
Name: Name:
Date: Date:

RCC Work (Reinforcement)

2 Structural Drawing No.:
3 Shop Drawing No.:
1 Is the drawing in use latest issued for construction purpose?
2 Is Bar Bending Schedule approved? Ref. of approval……………..
3 Is Bar Bending and Cutting satisfactory?
4 Has Corrosion Treatment of Bars carried out in case of scaling of Bars?
5 Are Bar sizes correct as per BBS?
6 Are Bar spacing correct as per BBS?
7 Are Bar Lap lengths correct as per the Structural Drawing?
8 Are Bar Laps at correct locations as per the Structural Drawing?
9 Are all joints tied properly with binders using double knot?
Is Bar assembly rigid and adequately supported (including spacers/chairs

10
supports)?
11 Is the concrete for cover blocks of the same grade as the main concrete?
12 Are the cover blocks adequately fixed?
13 Is the cover to bottom reinforcement correct?
14 Is the cover to top reinforcement correct?
15 Is the cover to side reinforcement correct?
16 Are the cover blocks of proper size and fixed at proper spacing?
Name: Name:
Date: Date:

RCC Work (Concrete Pour)

2 Structural Drawing No.:
3 Date of Casting:
Staging
1
Is the staging approved as per checklist as given?
Formwork
2
Is the Formwork approved as per checklist as given?
Reinforcement
3
Is the reinforcement approved as per checklist as given?
Embedded Parts
4 Are the embedded parts provided as per the requirement?
Is the alignment and fixing of inserts correct?
Arrangement of Concreting
Are construction joints provided as approved?
Has the old concrete surface been roughened?
Are materials/ingredients approved as per relevant code?
Is Batching Plant calibration checked?
Has the concreting sequence been approved?
5
Has arrangement for protection from extreme weather during or after
concreting been made?
Are the platforms and access for materials and labour movement provided?
Is adequate illumination arrangements provided?

Are safety measures as per safety assurance record taken?
During Concreting
Is the Slump of concrete meets the requirement?
Number of cube specimens taken
6
Is the previously placed layer of concrete green to receive the succeeding
layer for amalgamation?
Is proper vibration done to ensure compaction?
Name: Name:
Date: Date:

RCC Work (Post Concrete Inspection)

2 Date of Casting:
3 Date of De-shuttering:
4 Date of Inspection:
Alignment / Dimensions of the member
1 Is the alignment correct?
Are the dimensions correct?
2 Is any bulging noticed?
Appearance of Surface
Is there any honey combing?
3 Are there any bubbles?
Are there any cold joints?
Is shutter finish obtained?

Are there any cracks
4 noticed? If yes, nature of
cracks (depth & width)
5 Any other defects?
6 Any Non conformations?
Name: Name:
Date: Date:

Bearing Installation
Seating of Bottom Plate

Has the bearing been placed in proper position and
level?
Is the grouting material sieved through 1.18mm sieve
available?
1
Is mixing arrangement checked?
Is the pouring arrangement for grout checked?

Has the grout evenly spread all around and below the
bottom plate?
Fixing of Top Plate
Is the pier segment properly placed over the pier and
secured on the jacks/crib supports around the pier?
Are all the pockets properly cleaned and soaked in
water?
Is the grouting material sieved through 1.18mm sieve
2 available?
Is mixing arrangement checked?
Is the pouring arrangement for grout checked?

Has the Epoxy mortar applied all around the top plate
set?
Name: Name:
Date: Date:

Expansion Joint Installation

Whether the width of expansion gap required as per approved drawing

1
is available?
Whether the concrete and reinforcement in the recess of the joint has
2
been cleaned?
Whether the reinforcement has been suitably adjusted to allow
3
unhindered joint lowering?
4 Whether the formwork has been checked for shape and tightness?
Whether the temperature of the structure at the time of fixing of the

5
joint checked?
Is there any difference in the ambient temperature and the temperature
6
considered for pre-setting of the joint?
Whether the pre-setting has been corrected for any difference in the
7 ambient temperature and the temperature considered for pre-setting of
the joint?
8 Whether the brackets have re-tightened after pre-setting?
9 Whether the lowered joint checked for alignment and level?
10 Whether the welding of the anchor loops has been checked?
11 Whether the auxiliary brackets have been released?
Is the grade of concrete poured in the recess same as that of main

12
structure?
Is the wearing course on the carriage-way flush with the top of the steel
13
surface?
Name: Name:
Date: Date:

Thermoplastic Paint
Whether the paint to be used has been tested as per Clause 803.4 of
1
MOSRTH?
2 Whether the road surface approved for road marking?
Whether the road surface has been thoroughly cleaned of
3
dust/dirt/grease/oily matter or other foregin matter?
Whether the pavement temperature checked and found to more than
4 0
10 C?
5 Whether arrangements for diversion of traffic made?
Whether temperature of the paint at the time of application checked as

6
per specification of the manufacturer?
Is the time duration during which the paint remains in molten state
7
checked to be not more than 4 hours?
Whether the paint has been maintained within the manufacturers
8
specified range during the application?
Is the painting process manual or mechanical (whether approved by the
9
Engineer)?
Whether thickness of applied paint checked as per BS-3262 (part 3) and
10
found to be minimum 2.5 mm?
Whether additional glass beads of grading type 2 as per Clause
803.4.3.3 of MOSRTH specification for Road & Bridge works have been
11
sprayed in case of manual application for Arrows & Letters etc @ 250
2
g/m of area?
Whether the finished work is free from ruggedness on sides and ends
12
and parallel to general alignment of the carriageway?
13 Whether the surface is level, uniform and free from streaks?
Name: Name:
Date: Date:

Launching Girder
Fabrication of Launching Girder
Are the approved shop drawings showing details of location, type,

1
size and extent of all welds available?
Are all the structural members marked with a unique identification
2
number?
Are templates, jigs and other appliances available for ensuring
3
accuracy of work?
4 Are properly calibrated measuring devices available?
5 Are the templates used for drilling inspected and approved?
Is the pressure applying device for straightening or flattening

6
injuring the material?
Is a programme indicating identification and erection marks and
7
details of fabrication and welding available?
Preparation of the edges and ends
Is the approved arrangement of end/edge planning and cutting
available?
8 Is the machining arrangement of edges 12mm or more thick
plates available?
Is the shearing arrangement for less than 12mm thick plates
available?
Preparation of holes
9 Is the punching and drilling arrangement available?
Is the arrangement for clamping the plates available?
Name: Name:
Date: Date:

Testing of Launching Girder

1 Whether fabrication all different parts complete?
2 Is the shop drawing showing loading points available at site?
3 Is the testing scheme approved?
4 Is the site properly barricaded and warning signals installed?
5 Are safety precautions like safety helmets, safety betls available?
6 Has adequate lighting arrangement been made?
7 Are the mobile machineries registered and insured?
Do the operators possess proper licence from the concerned

8
authority?
9 Are the first aid facilities available?
10 Are properly calibrated deflection gauges available?
Name: Name:
Date: Date:

Shifting of Launching to Site

1 Is a crane of adequate capacity available?
2 Are licensed crane operator and grade present?
3 Are warning signals installed while using the crane?
4 Is the trailer of adequate capacity available?
5 Is the trailer insured?
6 Is the trailer operator licensed?
7 Is the permission from traffic police available?
8 Has the trailer made a successful Dry Run?
9 Is the segment securely fastened to the trailer?
10 Are unloading arrangements available at the site?
11 Is the stacking area the site demarcated and barricaded?
Name: Name:
Date: Date:

Shifting of Launching to Next Location

Is the crane movement area properly barricaded and

1
signaled?
Is the crane of adequate capacity available in good
2
running condition?
Is the crane operator licensed and the crane registered
3
with the concerned authorities?
4 Is the crane insured?
5 Is the movement area identified and clear?
Name: Name:
Date: Date:

Launching Operations
Whether proper placement, alignment and level of each Trestle

1
on firm ground done?
Whether proper placement of 100 MT jacks with lock nut safety
2 device under LG supporting crossbeams with ram extension of
100 - 125 mm ensured?
Whether alignment and levels of truss and beams of LG on each
3
trestle ensured?
4 Whether temporary locking of LG done?
5 Whether proper installation of Crab Trolley ensured?
6 Whether free movement of Crab Trolley ensured?
7 Whether free movement of Cross Beams ensured?
Whether arrangement for movement of transverse beam on

8
wooden packing ensured?
Whether proper hanging of working platform on both sides of the
9
pier ensured?
10 Whether surveying arrangements in order?
Whether transverse locking, rotational locking and longitudinal

11
locking checked?
Name: Name:
Date: Date:

Placement of Segment
1 Whether centre line marked on the segments?
2 Whether unique identification marking done on segments?
3 Whether pre-stressing ducts checked and cleaned?
Whether sand blasting of the segments on match cast faces

4
done?
5 Whether lifting Hangers fixed on the segments?
Whether turn buckle fixing done properly on every

6
segment?
Whether temporary pre-stressing frames fixed on each
7
segment?
Whether all the segments checked for any damage caused
8
in carriage and necessary repairs carried out?
Whether segments placed below the launching girder in
9
right order and sequence of lifting?
Name: Name:
Date: Date:

Placement of Pier Segment

Whether the levels of all the corners of top and bottom

1
identified?
2 Whether the centre line marked on the segments?
Whether the position of four corners dropped and

3 marked on the ground for conforming its location by
plumb?
4 Whether the crib support fixed on the ground?
Whether the jacks of required capacity placed on the

5
crib support for taking the load from pier segment?
Whether the lifting machinery like crane and crab trolley
6
checked for their being in order?
Whether the working area demarcated and barricaded
7 along with sufficient warning signals and proper lighting
arrangements?
Whether the fixing arrangements of bearing for pier
8
segment checked and found in order?
Name: Name:
Date: Date:

Lifting of Segments
1 Whether the working area demarcated?
Is the site properly barricaded and warning signals

2
installed?
Are safety precautions like safety helmets, safety belts
3
available?
4 Has adequate lighting arrangement been made?
5 Are the mobile machineries registered and insured?
Do the operators possess proper license from the

6
concerned authority?
7 Are all the segments placed as per the lifting sequence?
Are all the machineries and crab trolley in working order

8
and checked prior to its use?
9 Is well trained manpower is deployed on the job?
Name: Name:
Date: Date:

Dry Matching of Segments

Is each segment movement in all the directions globally

1
under control?
Has a mock up for ensuring the control over the movement
2
of segment done earlier?
Is the control machanism for segment moving like turn
3 buckle, jacks, pumps, huck-chuk arrangement well tested
for controlled movements?
Are the predetermined levels of the segments at corners or
4
at other point available at site?
Are the leveling instruments for taking precise levels (like
5 total station survey instrument), steel tape, available for
taking the levels of the segment while dry matching?
6 Is the trained manpower available at site?
Are the different jacks, gauges, pumps etc, required for use
7 in work listed and calibrated instruments/equipment
available?
8 Is the centerline marked on the segment?
Whether minor repairing to edges or elsewhere (if required)

9
has been done to the segment?
Name: Name:
Date: Date:

Epoxy Application and Jointing Segments

Whether 1mm thick washers to prevent entry of epoxy around sheathing

1
provided on both segments?
2 Whether dry matching of segments completed?
3 Whether both faces of segments cleaned using wet cloth?
Is the ambient temperature at the time of application within acceptable

4
limits?
5 Are arrangements for recording of time satsfactory?
6 Is sufficient amount of epoxy available at the site?
7 Are sufficient number of gloves and aprons available at the site?
8 Are trained workers available at the site?
9 Are arrangements for emergency removal of epoxy available at the site?
10 Was the uniform application of epoxy completed within Pot Life?
Whether the temporary prestress for jointing the segments applied within
11
the open time?
Whether sheathing ducts cleaned from either end by using dollies to
12
remove any epoxy going into the ducts?
13 Has all the excess epoxy from the ducts removed?

Whether the epoxy squeezing out on sides smoothly finished in the
14
groove?
15 Whether epoxy visible on the segment surface rendered?
Name: Name:
Date: Date:

Prestressing
1 Whether Sheathing ducts cleaned with compressed air?

Whether assembly of Anchor heads to the threaded strands concentric
2
with the bearing plate hole?
Whether wedges inserted on to the strands and firmed well onto the
3
anchor heads?
4 Whether assembly of wedge plate on face of anchor head done?
Whether assembly of calibrated hydraulic jacks on either side of the
5
cable done with the help of stressing plate?
Whether hydraulic connection from pump to the hydraulic jack and
6
wedge seating assembly done?
7 Whether placing of temporary props done?
8 Whether pre-stressing proforma filled up?
9 Whether corrected elongations calculated?
Whether longitudinal locking of the bearing unlocked as per the

10
construction sequence?
11 Whether structural shortening at abutment measured?
12 Has the predetermined elongation and forces been achieved?
Any corrective steps required if the required elongation and force are
13
not achieved?
Whether wedge properly seated by operating wedge seating device
14
(indicate wedge seating value……………)?
15 Whether wedge seating checked after 24 hts. (indicate ………)?
Name: Name:
Date: Date:

Detaching from the Launching Girder

Is the pre-stressing complete in respects with satisfactory results of

1
elongation and pressure?
Is the post pre-stressing inspection done and ensured that no damage of
2 any kind has been caused to any component of the launching girder
including the hangers of the segments?
Are all the levels of the segments at various points recorded after pre-
3
stressing and ensured that hogging of the girder is in order?
4 Is the sequence of the release of hangers predetermined?
Is the arrangement for taking the levels of the segment after detachment
5
from the launching girder available at site?
Is the area for placing the launching girder after detachment
6
demarcated?
Are all the precautions like barricading the area, lighting the area and
7
installing warning signals taken?
Is the mobile machinery like crane registered and in perfect working
8
conditions?
Is the manpower deployed on the job is well trained/licensed and
9
authorized?
Name: Name:
Date: Date:

Checklist for Source/Agency Approval
Coarse Aggregate
S. No. Particular Remarks
1 Name and Address of the Supplier
Information regarding the other ongoing works

2
where the material is being supplied by this supplier
3 Report obtained from the clients referred at S. No.2
What is the Petrography of the parent rock?

4
Is it acceptable?
Will adequate quantity be available for the complete
5
project?
Have the aggregates got tested from reputed
6 laboratory as per IS:383?
(a copy of test certificate may be attached)
Are adequate crushing and transporting facilities
7
available with the supplier/crusher?
Name & Designation: Name & Designation:
Signature & Date: Signature & Date:

Fine Aggregate
Information regarding the other ongoing works where the

2
material is being supplied by this supplier
What is the type of aggregates?

4 (i) Crushed Rock
(ii) River Sand
5 Will adequate quantity be available for the complete project?
Have the aggregates got tested from reputed laboratory as per

6 IS:383?
(a copy of the test certificate may be attached)
Are adequate washing and transporting facilities available with
7
the supplier?

Water
What is source of supply?

(i) Bore Well
1
(ii) Supply of local body
(iii) Tankers
Have the water got tested from reputed laboratory as per

2 IS:3025?
Will adequate quantity be available from the source for the
3
duration of construction?

Cement
1 Name and Address of the Manufacturer/Supplier
Whether the Supplier/Manufacurer among the approved list of

2
clients?
Information regarding the other ongoing works where the material is
3
being supplied by this supplier
Whether the material satisfies the test requirement as per IS: 4031?
5
Whether the supplier can supply the material in desired size of the
6
lot as per the site schedule?

Reinforcement/Strands

2
clients?
3
Whether the material satisfies the test requirement as per relevant

5 code?
6

Epoxy

2
clients?
3
Whether the material satisfies the test requirement as per relevant

5 code?
6
Whether the manufacturer has given the method statement for its
7 application?
(attach the copy of the method statement)
8 Has the manufacturer furnished any guarantee?
Will manufacturer's authorised representative be present during the

9
application of epoxy?

Plasticiser
1 Name of the Product
Type of the Product (Super Plasticiser / Water Reducing Admixture /

2
Retarder etc.)
4 Period for which the product is in use.

5
Whether the material satisfies the test requirement as per IS: 9103?
7
Can the agency supply the required quantities in the stipulated time
8
as per the site requirement?

Backfilling Material (Earth)

2 Source of the Earth and its distance from the site.
Is the source approved by the Engineer-in-charge?

3
(Indicate the reference of approval)
Information regarding the other ongoing works where the
4
material is being supplied by this supplier
Whether the material satisfies the test requirement as per

6 relevant code?
Whether the supplier can supply the material in desired quantity
7
as per the site schedule?

Prestressing System
1 Name and Address of the Prestressing System Agency
2 Whether the agency among the approved list of clients?
Information regarding the other ongoing works where the agency

3
has done the prestressing
Whether the system has been tested as per FIP recommendations

5 for acceptance of prestressing system as per relevant Code?
Whether the prestressing hardware like anchorage system,

wedges, barrels, bearing plate, trumpet cone etc. have been tested
6
as per relevant code?
Whether the supplier can supply the hardware including jacks and
7 pumps duly calibrated and in adequate numbers so as to met the
target progress of the work?

Thermoplastic Paint
1 Name and Address of the Agency
Information regarding the other ongoing works where the work of

2
this kind has been done by this agency.
Whether the material satisfies the test requirement as per

4 relevant code?
Whether the supplier can supply the material in desired size of
5
the lot as per the site schedule?
Does the agency have machanized facilities for checking the
6
quality of paint?
Is atomatic lane marking machine available with the agency for
7
use in the work?
Will the agency furnish the performance guarantee as per the
8
MOSRTH requirement?
9 Does the agency has specialized staff for laying the paint?

Bearings
1 Type of Bearing
Name and address of the manufacturer/supplier including the

2
loaction of workshop including the forging facilities (foundary)?

MOSRTH for the particular type of bearing as per the latest
3
circular?
(a copy of the MOSRTH approval may be attached)
Information regarding the other ongoing works where the bearing of
4
this type has been supplied by this supplier.
6 Has the manufacturer submitted has QAP?
Whether the material satisfies the test requirement as per QAP of

7 the manufacturer and/or as per relevant code?
Whether the supplier can supply the material in desired numbers as
8 per the site schedule so that the progress of the work is not
hampered?
9 Has the agency agreed to furnish a perfarmance bond for 10 years?
Will the manufacturer's authorized representative be available while

10
the joint is being installed?

Expansion Joints
1 Type of Expansion Joint

Name and address of the manufacturer/supplier including the
2
loaction of workshop.

3 MOSRTH for the particular type of joint as per the latest circular?
(a copy of the MOSRTH approval may be attached)
Information regarding the other ongoing works where the expansion

4
joint of this type has been supplied by this supplier.
6 Has the manufacturer submitted has QAP?
Whether the material satisfies the test requirement as per QAP of

7 the manufacturer and/or as per relevant code?
Whether the supplier can supply the material in desired numbers as
8 per the site schedule so that the progress of the work is not
hampered?
9 Has the agency agreed to furnish a perfarmance bond for 10 years?
Will the manufacturer's authorized representative be available while

10
the joint is being installed?

(APPENDIX – III)
LIST OF ESSENTIAL LABORATORY
EQUIPMENTS

Sl.
Name of the Equipment Req. Nos
No
A) GENERAL
1) Weigh Balances
a) 5 – 20 kg capacity Electronic type – Accuracy 1 gm 1 No.
b) 500 gm capacity – Electronic type Accuracy 0.01 gm 1 No.
c) Electronic 5 kg capacity Accuracy 0.5 gm 1 No.
d) Platform Balance scale -300 kg capacity 1 No.
e) Chemical Balance 100 gm capacity-accuracy 0.001gm --
Oven-electrically operated, thermostatically controlled (including
2)
thermometer), stainless steel interior
From 00C to 2000C Sensitivity 10C 1 No.
3) Sieves : as per IS:460-1962
I.S. sieves 450 mm internal dia of sieve sets as per BIS of
a) 1 set
required sieve sizes complete with lid and pan
I.S. sieve 200 mm internal dia (brass frame and steel/or brass
b) wire cloth mesh) consisting of sieve sets as of required sieve 2 sets
sizes complete with lid
Sieve shaker capable of aking 200 mm and 450 mm dia sieves-eclectically
4) 1 No
operated with time switch
5) 200 tonnes compression testing machine 1 No
6) Stop watches 1/5 sec. accuracy 1 No
Glassware comprising beakers, pipettes, dishes, measuring cylinders (100
7) to 1000 cc capacity) glass rods and funnels, glass thermometers range 2 No. each
00C to 1000C and metallic thermometers range up to 3000C
8) Hot plates 200 mm dia (1500 watt.) 1 No
9) Enamel trays
a) 600 mm x 450 mm x 50 mm 2 Nos
b) 450 mm x 300 mm x 40 mm 2 Nos
c) 300 mm x 250 mm x 40 mm 2 Nos
d) Circular plates of 250 mm dia 2 Nos
10) Water Testing Kit 1 No
B) FOR SOILS
1) Water still --
2) Liquid limit device with ASTM grooving tools as per IS:2720 1 No
3) Sampling pipettes fitted with pressure and suction inlets, 10 ml. capacity 1 set
Compaction apparatus (Proctor) as per IS:2720 (Part 7) complete with
4) 1 No
collar, base plate and hammer and all other accessories
Modified AASHTO Compaction apparatus as per IS:2720 (Part 8) 1974 or
5) Heavy Compaction 1 No
Apparatus as per IS complete with collar, base plate and hammer and all

other accessories
Sand pouring cylinder with conical funnel and tap and complete as per
6) 2 Nos
IS:2720 (Part 28) 1974 including modern eqyupment.
7) Ennore Standard Sand As required
Sampling tins with lids 100 mm dia x 75 mm ht. ½ kg capacity and
8) 4 Nos
miscellaneous items like moisture tins with lid 50 grams etc.
Lab CBR testing equipment for conducting CBR testing, load frame with 5
9) Tonne capacity, electrically operated with speed control as per IS:2720 1 Set
(Part 16) and consisting of following:
a) CBR moulds 150 mm dia – 175 mm ht. 6 Nos
b) Tripod stands for holding dial gauge holder 4 Nos
c) CBR plunger with settlement dial gauge holder 1 No
d) Surcharge weight 147 mm dia 2.5 kg wt. 6 Nos
e) Spacers disc 148 mm dia 47.7 mm ht. with handle 2 Nos
f) Perforated plate (Brass) 2 Nos
g) Soaking tank for accommodating 6 CBR moulds 2 Nos
h) Proving rings of 1000 kg, 2500 kg capacity 1 No each
i) Dial gauges 25 mm travel – 0.01 mm/division 2 Nos
10 Standard penetration test equipment 1 No
11) Nuclear moisture Density meter or equivalent --
12) Speedy moisture meter complete with chemicals 1 No
13) Unconfined Compression Test Apparatus 1 No
C) FOR BITUMEN AND BITUMINOS MIXES
Constant temperature bath for accommodating bitumen test specimen,
1) electrically operated, and thermostatically controlled (to accommodate 1 No
minimum six Specimens)
Penetrometer automatic type, including adjustable weight arrangement
2) 1 No
and needles as per IS:1203-1958
Soxhlet extraction or centrifuge type apparatus complete with extraction
3) 1 No
thimbles with solvent and filter paper
4) Bitumen laboratory mixer including required accessories (20lt) 1 No
Marshall compaction apparatus automatically operated as per ASTM 1559-
5) 1 set
62 T complete with accessories (with 180 N Marshall Moulds)
6) Furol viscometer 1 No
7) Ductility meter 1 No
8) Softening point (Ring and Ball app) 1 No
9) Distant reading thermometer --
10) Rifle box 1 No
11) Automatic Asphalt content Meter 1 No
Thin film oven test apparatus for modified binder either with PMB or
12) --
CRMB
13) Mastic Asphalt Hardness testing apparatus --
14) Sand Equivalent test apparatus 1 set

15) Core cutting machine suitable for upto 150 mm dia core 1 set
16) thermometers 4 Nos
D) FOR CEMENT, CEMENT CONCRETE AND MATERIALS
1) Water still 1 No
2) Vicat needle apparatus for setting time with plungers as per IS:269-1967 1 No
3) Moulds
150 mm x 300 mm ht. cylinder with capping component along
a) As required
with the capping set and compound as per IS
b) Cube 150 mm, and 100 mm (each size) As required
4) Concrete permeability apparatus --
5) High frequency mortar cube vibrator for cement testing --
6) Concrete mixer power driven, 1 cu.ft. capacity --
Variable frequency and amplitude vibrating table size 1m x 1m as per the
7) --
relevant British Standard
8) Flakiness index test apparatus 1 No
9) Aggregate impact test apparatus as per IS:2386 (Part 4) 1963 1 No
10) Los-angeles abrasion test apparatus as per IS:2386 (Part 4) 1963 1 No
11) Flow table as per IS:712-1973 --
12) Equipment for slump test 1 No
Equipment for determination of specific gravity on fine and coarse
13) 1 No
aggregate as per IS:2386 (Part 3) 1963
Compression and Flexural strength testing machine of 200 T capacity with
14) 1 No
additional dial for flexural testing
15) Core cutting machine with 10 cm dia diamond cutting edge 1 No
16) Needle vibrator 2 Nos
17) Air entrainment meter --
0.5 Cft, 1 Cft cylinder for checking bulk density of aggregate with tamping
18) As required
rod
19) Soundness testing apparatus for cement (Lee chattlier) 1 set
E) FOR CONTROL OF PROFILE AND SURFACE EVENNESS
1) Total Station 1 No
2) Precision automatic level with micrometer attachment 1 set
3) Distomat or equivalent 1 set
4) Theodolite – Electronically operated with computerized output attachment 1 set
5) Precision staff 2 sets
6) 3 meter straight edge and measuring wedge 1 set
7) Camber template 2 Lane
a) Crown type cross-section 1 set
b) Straight run cross-section 2 sets
8) Steel tape
a) 5 m long 2 Nos
b) 10 m long 2 Nos
c) 20 m long 2 Nos

d) 30 m long 2 Nos
e) 50 m long 1 No
1 No. (when
9 Roughometer (Bump Integrator)
required)
F) CHEMICALS
1) Calcium Carbide
2) Sodium Carbonate
3) Sodium Oxalate
4) Carbon Tetrachloride
5) 1, 1, 2, 2 – tetrabromoethane
6) Benzene
7) Bromoform
8) Monobromobenzene
9) Sodium Sulphate
10) Magnesium Sulphate
11) Sodium Hexametaphosphate
12) Sodium Hydroxide
13) Hydrogen peroxide
14) Hydrochloric Acid
15) Sulphuric Acid
16) Sodium Acetate
17) Asetic Acid
18) Calcium Chloride
19) Formaldehyde
20) Glycerin
G) REAGENTS
1) Phenolphthalein solution
2) Barium Chloride solution
3) Silver Nitrate solution
4) Potassium Chromate
5) Ammonium Hydroxide
H) OTHERS
1) Filter Papers – Whatman 40 & 60
2) Litmus Papers – Blue & Red

(APPENDIX-IV)
TEST REQUIREMENTS,
FREQUENCY AND LIMITS

FREQUENCY
NAME OF THE TEST RELEVENT CODE REQUIREMENTS
OF TEST
EARTH WORK FOR EMBANKMENT & SUBGRADE: BORROW MATERIAL

2 TESTS /
a) SAND CONTENT TEST IS : 2720 - PART 4 60 - 80%
3000 m3
L.L = Not > 50% 2 TESTS /
b) PLASTICITY TEST IS : 2720 - PART 5
P.I = Not > 25% 3000 m3
for Emb. > 1.52g/cc

2 TESTS /
c) DENSITY TEST IS : 2720 - PART 8 for SG. > 1.60g/cc
3000 m3
High.Emb.>1.75g/cc
2 TESTS /
d) MOISTURE CONTENT TEST IS : 2720 - PART 2 9 - 18%
3000 m3
for Emb.=Min 2% 1 TEST / 3000
e) CBR TEST IS : 2720 - PART 16
for SG =Min 6% m3
1 TEST /
f) FREE SWELLING INDEX IS : 2720 - PART 40 Not > 50%
SOURCE
10 TESTS /
for Emb.= 95%
3000 m2
g) DENSITY OF COMPACTED LAYER IS : 2720 - PART 28
10 TESTS /
For SG = 97%
2000 m2
2 TESTS /
h) MOISTURE CONTENT PRIOR TO COMPACTION IS : 2720 - PART 2 OMC +/- 1%
2000 m2
AS & WHEN
I) DELETERIOUS CONTENT IS : 2720 - PART 27
REQ.
Density = 1.96 g/cc
As & When
j) C & ɸ (Cohesion & Angle of Internal Friction) For High Embankment C = 0.10 kg/m2
Required
ɸ = 340

FREQUENCY OF
TEST
GRANULAR SUB BASE :

As per MOST-
As per MOST-T-400-1/
a) GRADATION T-400-1 /As per 1 TEST / 400m3
As per Tech. Spec.
Tech. Spec.
L.L = Not > 25%
b) ATTERBERG LIMITS IS : 2720 - PART 5 1 TEST / 400m3
P.I = Not > 6%
c) DENSITY TEST IS : 2720 - PART 8 Not < 1.95 g/cc 1 TEST / 3000m3
d) DENSITY OF COMPACTED LAYER IS : 2720 - PART 28 98 % of MDD 1 TEST / 1000m2
e) MOISTURE CONTENT PRIOR TO COMPACTION IS : 2720 - PART 2 OMC +/- 1% 2 TESTS / 1000m2
For all Grades =

f) CBR IS : 2720 - PART 16 AS REQUIRED
30%Min.
1 TEST / EACH
g) 10 PERCENT FINES VALUE BS : 812 - PART 111 > 50 KN
SOURCE
h) DELETERIOUS CONSITUENTS IS : 2720 - PART 27 NIL AS REQUIRED
1 TEST / EACH
I) WATER ABSORPTION OF THE C. AGGREGATES IS : 2386 - PART 3 Not > 2 %
SOURCE

FREQUENCY OF
TEST
WET MIX MECADAM :

As per MOST-
GRADATION As per MOST-T-400-13 /
a) T-400-13 /As per 1 TEST / 250m3
( COMBAINED & INDIVIDUAL ) As per Tech. Spec.
Tech. Spec.
L.L = Not > 25%
b) ATTERBERG LIMITS IS : 2720 - PART 5 1 TEST / 200 m3
P.I = Not > 6%
AGGREGATE IMPACT VALUE
/ Max.= 30%( AIV)
c) IS : 2386 - PART 4 1 TEST / 1000m3
LOS ANGLES ABRASION Max.= 40% ( LAA)
VALUE
FLAKINESS & ELONGATION Max.= 30%(Comb) &
d) IS : 2386 - PART 1 1 TEST / 500m3
INDEX Max.=15% each.
e) CBR IS : 2720 - PART 16 > 100% AS REQUIRED
AS & WHEN
f) DENSITY TEST IS : 2720 - PART 8 AS PER DESIGN.
REQUIRED
DENSITY OF COMPACTED
g) IS : 2720 - PART 28 98% of MDD 3 TESTS / 1000m2
LAYER
MOISTURE CONTENT PRIOR
h) IS : 2720 - PART 2 OMC +/- 1% 3 TESTS / 1000m2
TO COMPACTION
WATER ABSORPTION OF
I) IS : 2386 - PART 3 Not > 2% 1 TEST / SOURCE
AGGREGATES
Max.=12% (Na2So4) /
j) SOUNDNESS TEST IS : 2386 - PART 5 1 TEST / SOURCE
Max.=18% (MgSo4)

FREQUENCY
OF TEST
BITUMINOUS MECADAM :
2 SAMPLES /
a) QUALITY OF BINDER IS : 73 - 1961 AS PER TECH.SPEC.
LOT.
AGGREGATE IMPACT VALUE / Max.= 30%( AIV)

b) IS : 2386 - PART 4 1 TEST / 200m3
LOS ANGLES ABRASION VALUE Max.= 40% ( LAA)
Max.= 30%(Comb) &

c) FLAKINESS & ELONGATION INDEX IS : 2386 - PART 1 1 TEST / 100m3
Max.=15% each.
STRIPPING VALUE OF ( IS : 6241)/ Min. Retained AS & WHEN
d)
AGGREGATES AASHTO - T - 182 coating 95% REQUIRED
WATER ABSORPTION OF 1 TEST /
e) IS : 2386 - PART 3 Not > 2%
AGGREGATES SOURCE
Max.=12% (Na2So4) / 1 TEST /
f) SOUNDNESS TEST IS : 2386 - PART 5
Max.=18% (MgSo4) SOURCE
As per MOST- As per MOST- 2
g) GRADATION T-500-4 /As per T-500-4 / As per Tech. TESTS/DAY/PLA
Tech. Spec. Spec. NT
2
3 - 3.5 % (+/-)/
h) BINDER CONTENT ASTM - D - 2172 TESTS/DAY/PLA
As per Tech. Spec.
NT
BINDER = 150- 1650C

CONTROL OF TEMPERATURE OF
AGG.= 150 - 1700C AT REGULAR
BINDER AND AGGREGATE FOR
I) MIX = Max. 1650C CLOSE
MIXING AND OF THE MIX AT THE
LAYING = Min. 1250C INTERVALS
TIME OF LAYING AND ROLLING
ROLLING= Min. 900C
REGULAR
RATE OF SPREAD OF MIXED
j) CONTROL THR'H
MATERIAL
CHECK LEVELS
1 TEST / 700m2
Min. 95% of (10% of density
k) DENSITY OF COMPACTED LAYER
Lab Density. tests will be
done at edges)

FREQUENCY OF
TEST
DBM / BC :
a) QUALITY OF BINDER IS : 73 – 1961 AS PER TECH.SPEC. 2 SAMPLES / LOT.

AIV for DBM =27%
AGGREGATE IMPACT VALUE / AIV for BC = 24%
b) IS : 2386 - PART 4 1 TEST / 350m3
LOS ANGLES ABRASION VALUE LAA for DBM = 35%
LAA for BC = 30%
Max.= 30%(Comb) &
c) FLAKINESS & ELONGATION INDEX IS : 2386 - PART 1 1 TEST / 350m3
Max.=15% each.
( IS : 6241) / Min. Retained AS & WHEN
d) STRIPPING VALUE OF AGGREGATES
AASHTO - T - 182 coating 95% REQUIRED
WATER ABSORPTION OF
e) IS : 2386 - PART 3 Not > 2% 1 TEST / SOURCE
AGGREGATES
Max.=12% (Na2So4) /
f) SOUNDNESS TEST IS : 2386 - PART 5 1 TEST / SOURCE
Max.=18% (MgSo4)
MOST-T-500.9 - for
DBM, T-500.20 - for As per MOST / Tech.
g) GRADATION 2 TESTS/DAY/PLANT
SDBC, T- Spec.
500.18 - for BC
h) BINDER CONTENT ASTM - D - 2172 As per JMF +/- 0.3% 2 TESTS/DAY/PLANT
BINDER = 150 - 1700C

CONTROL OF TEMPERATURE OF
AGG.= 155 - 1750C
BINDER AND AGGREGATE FOR AT REGULAR CLOSE
I) MIX = 150 - 1700C
MIXING AND OF THE MIX AT THE INTERVALS
LAYING = 140 - 1500C
TIME OF LAYING AND ROLLING
ROLLING=Not <1000C
RATE OF SPREAD OF MIXED REGULAR CONTROL

j)
MATERIAL THR'H CHECK LEVELS
Min. 92% of Gmm 1 TEST / 700m2 (10%
k) DENSITY OF COMPACTED LAYER (Max. Theoretical Sp. of density tests will be
Gr.) done at edges)
Stability = 9 kN Min.
Flow = 2 - 4 mm. 1 Set /400 T of mix
Air voids = 3 - 6 %. production
L) STABILITY OF MIX ASTM - D - 1559
VMA = 10 - 13% Min. OR
VFB = 65 - 75 %. 2 Sets / plant / day.
Binder =4% Min.
AS & WHEN
m) SAND EQUIVALENT TEST IS : 2720 - PART 37 Not < 50 %
REQUIRED

AS & WHEN
n) STONE POLISHING VALUE BS : 812 - PART 114 Not < 55 %
REQUIRED
WATER SENSTIVITY TEST
Min.75% retained AS & WHEN
o) ( Stability on Immersion in Water @ ASTM - D - 1075
strength REQUIRED
600C)
AS & WHEN
p) SWELL TEST Asph.Instt. MS - 2 Max.1.5%
REQUIRED
BITUMEN
RELEVENT FREQUENCY OF
NAME OF THE TEST REQUIREMENTS
CODE TEST
BITUMEN :
Grade = VG – 10 Min. 80
PENETRATION Min. 60
Grade = VG – 20 2 SAMPLES /
a) ( AT 250C, 100G, 5SEC - IS : 1203 - 1978
Grade = VG – 30 Min. 45 LOT
1/10mm)
Grade = VG – 10 0.99
SPECIFIC GRAVITY Grade = VG – 20 0.99 2 SAMPLES /
b) IS : 1202 - 1978
( AT 270C - Min. ) Grade = VG – 30 0.99 LOT
Grade = VG – 40 0.99
Grade = VG – 20 Min. 45 2 SAMPLES /
c) SOFTENING POINT- 0C IS : 1205 - 1978
Grade = VG – 30 Min. 47 LOT
Ab.Vis = 800-1200
Grade = VG – 10
Kin.Vis = Min. 250
ABSOLUTE VISCOSITY AT Ab.Vis = 1600-2400
600C Grade = VG – 20
IS : 1206 - 1978 Kin.Vis = Min. 300 2 SAMPLES /
d)
(PART 2) Ab.Vis = 2400-3600 LOT
KINEMATIC VISCOSITY AT Grade = VG – 30
Kin.Vis = Min. 350
1350C
Ab.Vis = 3200-4800
Grade = VG – 40
Kin.Vis = Min. 400
Flash=2200C Min.
Grade = VG – 10
Fire=220+ 50C Min.
Flash=2200C Min.
Grade = VG – 20
Fire=220+ 50C Min. 2 SAMPLES /
e) FLASH & FIRE POINT IS : 1209 - 1978 0
Flash=220 C Min. LOT
Grade = VG – 30
Fire=220+ 50C Min.
Flash=2200C Min.
Grade = VG – 40
Fire=220+ 50C Min.

Grade = VG – 10 Min. 75 cm
0
DUCTILITY ( AT 27 C ) - Grade = VG – 20 Min. 50 cm 2 SAMPLES /
f) IS : 1208 - 1978
cm. Grade = VG – 30 Min. 40 cm LOT
Grade = VG – 40 Min. 25 cm
Grade = VG – 10 1% Min.
Grade = VG – 20 IS : 1212 - 1978 1% Min. 2 SAMPLES /
g) LOSS ON HEATING - %
Grade = VG – 30 1% Min. LOT
Grade = VG – 40 1% Min.
FREQUENCY OF
TEST
CONCRETE :
Consistancy IS : 4031 - PART 4
Initial Setting Time Not < 30 Minutes.
IS : 4031 - PART 5
Final Setting Time Not > 600 Minutes.
1 TEST /
a) CEMENT Soundness Not > 10mm.
IS : 4031 - PART 3 CONSIGNMENT
Finess Not > 10 %
Compressive
IS : 4031 - PART 6 As per Grade.
Strength
Coarse Aggregates. IS : 383 - 1970 / As per Design
b) GRADATION 1 TEST / DAY
Fine Aggregates. IS : 2386 - PART 1 Requirement.
REGULAR AS
c) IS : 2386 - PART 3 Not > 2 %
WATER ABSORPTION REQ.
Max.=12% (Na2So4)
d) SOUNDNESS TEST IS : 2386 - PART 5 1 TEST / SOURCE
/ Max.=18% (MgSo4)
AGGREGATE IMPACT VALUE / Max.= 30%( AIV)

e) IS : 2386 - PART 4 1 TEST / DAY
LOS ANGLES ABRASION VALUE Max.= 40% ( LAA)
f) FLAKINESS IS : 2386 - PART 1 Max.= 35%. 1 TEST / DAY

1 - 5 m3 = 6
Cubes.
6 - 15m3 = 9
Cubes.
16 - 30 m3 = 12
As per Design
g) STRENGTH OF CONCRETE IS : 516 Cubes.
Requirement.
31 - 50 m3 = 15
Cubes.
>50m3 = 15 +
3Cubes for ever
50m3

1 TEST / EACH
h) WORKABILITY / SLUMP IS : 1199 As per Design Req.
MIXER
IS : 2386 - PART 2 & 1 TEST / EACH
i) BULKAGE & SILT CONTENT Max. = 10%
3 SOURCE
CHEMICAL PROPERTIES
IS : 269 - IS : 8112 - IS : 12269 -
PROPERTY 1989 1989 1987
33 Grade 43 Grade 53 Grade
Not more than Not more than Not more than

Lime Saturation (CaO – 0.7 SO3)
1 1.02 and Not 1.02 and Not 1.02 and Not less
Factor (2.8 SiO2 + 1.2 Al2O3 + 0.6 Fe2O3)
less than 0.66 less than 0.66 than 0.80
Ratio of Alumina & Not less than Not less than

2 Fe2O3 / Al2O3 Not less than 0.66
Iron oxide 0.66 0.66
Not more than Not more than
3 Insoluble Residue Not more than 2 %
4% 2%
Not more than Not more than
4 Magnesia % by mass MgO Not more than 6 %
6% 6%
Total Sulphur content SO3 = not more SO3 = not more SO3 = not more
For C3A less than or equal to 5%
( SO3 ) than 2.5 % than 2.5 % than 2.5 %
5
C3A = SO3 = not more SO3 = not more SO3 = not more
2.65Al2O3-1.69Fe2O3 For C3A more than 5%
than 3% than 3% than 3%
7 Loss on Ignition Not > 5 % Not > 5 % Not > 4 %
8 Na2O For Reactive Aggregates - - Not > 0.6 %
PHYSICAL REQUIREMENTS
Not less than Not less than Not less than
1 Specific Surface Area
225m2 / kg. 225m2 / kg. 225m2 / kg.
I) Le Chatelier's Test
2 Soundness 10mm 10mm 10mm
ii) Autoclave Test 0.80% 0.80% 0.80%
Not less than 30 Not less than 30 Not less than 30
Initial Setting Time
min. min. min.
3 Setting Time
Final Setting Time
600min 600min 600min
Compressive 3 - Days Strength 16 23 27
4 Strength 7 - Days Strength 22 33 37
N/mm2 28 - Days Strength 33 43 53

CD WORKS
FREQUENCY
OF TEST
Compressive strength IS : 1121 - PART 1 Min.210 Kg/cm2 1 TEST/SOURCE
a) STONE MASONARY & As and When
Water Absorption IS : 1124 Max. 5% Required
Compressive strength IS : 3495 - PART 1 Min.100 Kg/cm2 1 TEST/SOURCE
b) BRICK MASONARY & 5 Bricks /
Water Absorption IS : 3495 - PART 2 Max. 10% 50000 Bricks.
Acidity( to neutralise with Not > 2 ml (or)
0.1N NaOH) 50 mg/l
Alkalinity( to neutralise with Not > 10 ml (or)
0.1N HCL) 250 mg/l
2000mg/l - PCC
Chlorides ( Cl )
1000mg/l - RCC 1 TEST/SOURCE
c)
WATER ( POTABLE ) Sulphates ( SO4 ) IS : 3025 - 1964 500 mg/l & As and When
Required
Organic Solids 200 mg/l
Inorganic Solids 3000 mg/l
Suspended Matter 2000 mg/l

PH Not < 6
Wt. per meter length-kg. 0.00785 kg/mm2(PRM)
Actual diameter-mm. √(w/0.00785L)

10% more than Yield
Average Ultimate tensile
stress, not less than 1 TEST/SOURCE
strength - kg/cm2
485N/mm2 & As When
STEEL Yield strength - kg/cm2 Min.415 N/mm2 Required
d) REINFORCEMENT IS : 1786 - 1988
( Fe = 415 ) % Elongation Min. 5.65√A
0.12 ɸ for ɸ <10mm
Mean Rib area - mm2/mm 0.15 ɸ for ɸ 10-16mm
0.17 ɸ for ɸ > 16mm
Bend to Included angle
of 1350 Rebend to
Bend & Re-bend test
Included angle of
157.50

RELEVENT
S.NO NAME OF THE TEST REQUIREMENTS FREQUENCY OF TEST
CODE
REINFORCEMENT BARS (CTD, TMT)
Chemical Tests
a) Carbon 0.30 Max.
1 Test for every source
b) Sulphur 0.06 Max. approval
IS: 1786 - 1985
c) Phosphorus 0.06 Max. 1 Test for every Lot
1 Test every 3 months
d) Sulphur + Phosphorus 0.11 Max.
Physical Tests
10% more than the actual

a) Ultimate Tensile Strength 0.2% proof stress but not
less than 485 MPa
b) 0.02% Proof Stress 415 MPa Min.
c) % Elongation 14.5 Min. 1 Test for every source

d) Bend Test To be Satisfactory approval
IS: 1786 - 1985
1 Test for every Lot
e) Rebend Test To be Satisfactory 1 Test every 3 months
6.31±3% for 32mm dia

3% for 25mm dia
f) Mass per meter run (Kg)
1.58±5% for a6 mm dia
0.888±5% for 12mm dia

FREQUENCY OF
S.NO NAME OF THE TEST RELEVENT CODE REQUIREMENTS
TEST
H.T. STRANDS (Uncoated Stress Relieved Low Relaxation Seven Ply Strand)
Chemical Tests
a) Sulphar IS: 228 - PART 3 Not more than 0.05% 1 Test for every Source
approval
b) Phosphorus IS: 228 - PART 9 Not more than 0.05% 1 Test for every Lot
Dimension, Tolerance and Mass
12.7mm = +0.66, - 0.15
a) Tolerance in diameter 15.2mm = +0.66, - 0.15
2
12.7mm = 98.7 mm
b) Nominal Area 15.2mm = 140 mm
2
12.7 mm = 775Kg/Km 1 Test for every Source

c) Nominal Mass of Strands
IS: 14268 - 1995 15.2mm = 1102Kg/Km approval
Centre wire at least 1.5%
Difference in dia of central course and
d) greater in dia than the
surrounding wires surrounding wires
12 to 16 times the nominal
e) Length of Lay diameter
Physical Properties
12.7 mm = 183.7 (kN)
a) Breaking Strength of Strands 15.2mm = 260.7 (kN)
1 Test for every Source
12.7 mm = 165.3 (kN)
b) 0.2% Proof Load IS: 14268 - 1995 15.2mm = 234.6 (kN)
approval
Min. 3.5% on Min. gauge
c) Elongation length of 600mm
Relaxation Properties
Relaxation losses not more

than 1.8% when loaded to
a) 100 hours IS: 14268 - 1995 70% of specified min.
approval
breaking load.
Relaxation losses not more 1 Test for every Source

than 2.5% when loaded to approval
b) 1000 hours IS: 14268 - 1995 70% of specified min. 1 Test in the project for
breaking load. each source

c) Modulus of Elasticity IS: 14268 - 1995 18870 to 20910 kg/sqmm approval

S.NO NAME OF THE TEST REQUIREMENTS
CODE TEST
CAST STEEL FOR BEARINGS(Grade 280 - 520 W)
Chemical Tests
a) Carbon ( C) Max. 0.25%
b) Manganese (Mn) Max. 1.20%
c) Silicon (Si) Max. 0.60%
d) Phosphorus (P) Max. 0.10%

1 Test for every
e) Sulphar (S) Max. 0.035% Source approval
IS: 1030 - 1989
f) Nickel (Ni) Max. 0.40% 1 Test for project for
each source
i) Chromium (Cr) Max. 0.35%
j) Copper (Cu) Max. 0.40%
k) Molybdenum (Mo) Max. 0.15%
l) Vanadium (V) Max. 0.05%
Physica Tests
a) Ultrasonic Test
1 Test for every
b) Magnetic Particle Examination No deformation should Source approval
IS: 1030 - 1989
c) Liquid Penetrate Examination be observed 1 Test for project for
each source
d) Radiographic Examination

S.NO NAME OF THE TEST RELEVENT CODE REQUIREMENTS FREQUENCY OF TEST
MILD STEEL
Chemical Tests
Carbon = 0.23%
Manganese = 1.5%
Sulphar = 0.05%
Phosphorus = 0.05%
a) Grade - A (Fe 410 WA) Silicon = 0.04%
CE = Max. 0.42%
Nitrogen = 0.012%
Niobium(Nb), Vanadium(V) &
Titanium(Ti) (all or any) = 0.2%
Carbon = 0.22%
Manganese = 1.5%
Sulphar = 0.046%
approval
IS: 206 – 1999 Phosphorus = 0.045%
b) Grade - B (Fe 410 WB) 1 Test for project for
Silicon = 0.04%
each source
CE = Max. 0.41%
Carbon = 0.20%
Manganese = 1.5%
Sulphar = 0.040%
Phosphorus = 0.04%
c) Grade - B (Fe 410 WC)
Silicon = 0.04%
CE = Max. 0.39%

FREQUENCY OF
TEST
STAINLESS STEEL
Chemical Tests
a) Carbon ( C) 0.08 % (Max ± 0.01%)
b) Silicon (Si) 1 % (Max ± 0.05%)
c) Manganese (Mn) 2 % (Max ± 0.04%)

1 Test for every
d) Nickel (Ni) 10 - 14% (Max ± 0.15%)
Source approval
IS: 6911 - 1992
e) Chromium (Cr) 16 - 18% (Max ± 0.2%) 1 Test for project for
each source
f) Molybdenum (Mo) 2 - 3 % (Max ± 0.1%)
g) Sulphar (S) 0.03 % (Max ± 0.05%)
h) Phosphorus (P) 0.045 % (Max ± 0.01%)
Physica Tests
a) Tensile Test IS: 1663 - 1972 Min. 440 MPa
b) Yield Strength IS: 1609 - 1972 Min. 200 MPa 1 Test for every
Source approval
Brinell = Max. 192 1 Test for project for
c) Hardness Test IS: 1500 - 1983
Rockwell = Max. 95 each source
d) Elongation IS: 1501 - 1984 Min. 40% in 50mm

FREQUENCY OF
TEST
GALVANIZING
400 g/m2 minimum total mass of Zinc
a) Mass of Zinc Coating IS: 6745 - 1972 (inside & outside) of the coated
surface
Zinc coating shall be free from

imperfection like flux, ash and dross
b) Visual Test IS: 2629 - 1985 inclusions, bare patches, black spots,
pimples, lumpiness, rums, rust stain,
blister, white deposite etc.
A 230mm long shall be passed

through the tube to ensure a free bore.
Nominal bore of tube after gal./dia of
rod=
c) Free Bore Test IS: 2633 - 1986 8mm/4mm
10mm/6mm
15mm/11mm
20mm/16mm
1 Test per Lot
25mm/21mm
Uniformity of Galvanized The galvanized coating shall withstand

d) IS: 4736 - 1986 4 one minute dips.
Coating
Galvanized tubes upto and including

50mm nominal bore when bent cold
through 900 round grooved, former
having radius at the bottoms of groove
e) Adhesion Test IS: 2629 - 1985 equal to 8 times its outer dia shall not
develop any crack in the coating. For
tubes more than 50mm nominal bore,
this shall be tested by pivoted hammer
test.

RELEVENT
S.NO NAME OF THE TEST REQUIREMENTS FREQUENCY OF TEST
CODE
EPOXY
a) Pot Life
Min. 20 minutes. Not less than 60

Open time minutes at upper Temp. Limits
Sag flow should not exceed 30mm in

Thixotropy 10 minutes at at upper Limit of
specified application.
For 15kg = 3000 mm2

Angle of Internal Friction For 200kg = 7500 mm2
(Squeezibility) For 400kg=10000 mm2
For 12hrs = 20 N/mm2

Curing Rate Curing Rate (for 50mm x
b) For 24hrs = 60N/mm2
50mm x 50mm size cubes) For 168hrs=75N/mm2
Compressive Strength
For 24hrs = 60 N/mm2
c) (for 50mm x 50mm x 50mm size For 168hrs = 75N/mm2
cubes) 1 Test for every Source
approval
Should have concrete failure with no
Bonding of Cured Bonding agent to FIP 1 Test for every lot
d) evidence of joint with concrete of
Concrete surface to be joined strength 40 MPa 1 Test for project for
each source
Should have concrete failure with no
e) Tensile Bonding Strength evidence of joint with concrete of
strength 40 MPa
Should have 12 N/mm2 higher than

f) Shear Strength the concrete strength
Shear strength at failure should have

g) Heat Resistance a strength 10 N/mm2 higher than the
concrete strength
h) Colour Should match the colour of concrete
Max. 0.4% after 7 days at the upper

i) Shrinkage limit of specified temperature range.

FREQUENCY OF
TEST
SEALANTS
Polysulphide Sealant
a) Pot Life/Work Life Min. 2 hrs.
Total area of failure should

3
not exceed 100m and the
b) Adhesion & Tensile Modulus force required to produce
the extension shall be
between 25 N and 270 N.
c) Plastic Deformation Not more than 25 %
Average peel strength of

four strips of backing 1 Test for approval
material should not be less of source
IS: 12118 - PART 1
d) Adhesion in Peel than 25N and the material 1 Test for every
shall not fail in adhesion change of source
over more than 25% of the
test area.
e) Loss of mass after heat ageing Not more than 6 %
The sealant shall produce

f) Staining no staining on the surface
of test mortar.

FREQUENCY OF
TEST
SEALANTS
0 0
a) Service Temperature 50 C - 100 C
0 0
b) Application Temperature 10 C - 40 C
c) Shore 'A' Hardness 18 - 32

2
d) Tensile Strength 0.5 N/mm 1 Test for approval of
source
e) Elongation at Rupture BS: 5889 Min. 400% 1 Test for every
ASTM-C-920-87
change of source
f) Modulus at 100% Elongation Min. 0.35 MPa
g) Tooling Time Min. 30 Minutes
Permanently elastic and
h) Curved State
modulus
Neutral cure reactive with
i) Base
atmospheric moisture

S.NO NAME OF THE TEST REQUIREMENTS
CODE TEST
RCC HUME PIPES
1) Up to 30mm, ± 2mm
2) 30mm - 50mm, ± 3mm
3) 50mm-65mm, ± 4mm
a) Tolerances in Wall Thickness
4) 65mm-80mm, ± 5mm
5) 80mm-95mm, ± 6mm
6) Over 95mm, ± 7mm
1) Up to 300mm, ± 3mm
Tolerances in Internal Dia of 2) 300-600mm, ± 5mm
b)
Pipe or Socket 3) 600-1200mm, ± 7mm
4) Over 1200mm, ± 10mm
c) Tolerances in Overall Length ± 1% of standard Length

1 Test for approval
d) Three Edge Bearing IS: 458 - 1988 Shall with stand the design Load of source
IS: 3597 - 1985 After 10 minutes, 2.5% of dry mass 1 Test for every Lot
e) Water Absorption Total at the end of 24 hrs, not more for each size
than 6.5% of dry mass
No leakage under the design
f) Hydrostatic Pressure pressure
The deviation from straightness when
tested by means of rigid straight edge
g) Straightness parallel to the longitudinal axis of the
pipe shall not exceed 3mm for every
'm' length
As per Code provision. On breaking
h) Reinforcement the pipe and extracting the
reinforcement.
i) Cube Strength As per the Design Strength

FREQUENCY OF
TEST
HDPE PIPES
No localized swelling, leakage,

weeping or bursting during
a) Hydraulic Characteristics subjecting to internal pressure
creep test.
Longitudinal reversion shall

b) Reversion Test not more than 3%
3 0
940.5 to 946.4 kg/m at 27 C
and shall not differ from the
c) Density nominal value by more than
3 1 Test for approval of
3kg/m
IS: 4984 - 1995 source
0.41 - 1.10 at 1900C with
nominal load of 5kg and shall
d) Melt Flow Rate (MFR) be with in 20% of the value
declared by the manufacturer.
Carbon Black Content & 2.5 ± 0.5 % with uniform

e) dispersion
Dispersion

FREQUENCY OF
TEST
THERMOPLASTIC PAINTS
a) Binder Content Min. 18 % by weight
b) Glass Beads 30 - 40 %
c) Titanium Dioxide Min. 10 %
Max. 42 % for white

d) Calcium Carbonate & Inert Fillers
paint
As per manufacturer
e) Yellow Pigments
recommendation
For White paint - at

0 1 Test for approval of
45 , Min. 65%
f) Luminance (Day Light) BS: 3262 source
MOSRTH, Cl.803 For Yellow paint - at 1 Test for every
0
45 , Min. 45% change of source
g) Drying Time Max. 15 Minutes
No cracking on
h) Skid Resistance application to concrete
blocks
0
i) Softening Point 102.5 ± 9.5 C
j) Flow Resistance Not more than 25 %
k) Yellowness Index Not more than 0.12

FREQUENCY
OF TEST
CHLOROPRENE ELASTOMER
60 ± 5 IRHD for Elastomeric

bearings,
a) Hardness
50 ± 5 IRHD for
POT-PTFE bearings
Min. 17 Mpa for

Elastomeric bearings,
b) Minimum Tensile Strength 15.5 Mpa for
POT-PTFE bearings
c) Minimum Elongation at Break 400%

1 Test for
0
35 % (Temp. 100±1 C, approval of
d) Maximum Compression Set source
duration 24 hrs.)
MOSRTH, Cl. 2005
1 Test for every
Max. change in change of
± 15 IRHD
Hardness source
0
Max. change in - 15 % (Temp. 100±1 C,
e) Accelerated Ageing
Tensile strength duration 70 hrs.)
Max. change in
- 40 %
Elongation
f) Shear Modulus 0.8 to 1.20 Mpa
g) Ash Content Not more than 5 %

FREQUENCY OF
TEST
POLY TETRA FLURO ETHYLENE (PTFE)
Without dimples or the ratio of

dimples (lubrications cavities) to
a) Foam the gross area should not be more
than 25%, depth of cavity not
more than 2 mm.
0
b) Density at 23 ± 2 C 2.13 to 2.19 g/cc
1 Test for approval of
BS: 3784
source
BS: 6564 - PART 2
1 Test for every
c) Tensile Strength at Break MOSRTH, Cl. 2006 Min. 24 Mpa change of source
d) Elongation at Break Min. 300%
No sign of melting & loss in mass

e) Resistance to Heat shall not exceed 0.5%
Mass change shall not exceed

f) Dimensional Stability 0.5%

FREQUENCY OF
TEST
STRIP SEAL EXPANSION JOINT
a) Hardness 63 ± 5 shore A
b) Tensile Strength Min. 11 Mpa
c) Elongation at Break Min. 350 %
Longitudinal Min. 10 N/mm

d) Tar Propagation Strength
Transverse Min. 10 N/mm
e) Shock Elasticity Min. 25 %

3
f) Abrasion Min. 220 mm
Residual Compressive Strain (22h/70deg.C/30%
g) Max. 28 %
Strain)
Max. change in
5 shore A 1 Test for approval
Hardness MOSRTH, Cl. 2607
of source
Max. change in 1 Test for every Lot
h) Ageing in Hot Air Tensile Strength 20%
Max. change in
Elongation 20%
Ageing in Ozone (24h/50pphm/25 deg.C/20%
i) No cracks
strain)
Volume change Max. 5 %
j) Swelling Behaviour in Oil
Change in Hardness Max. 10 shore A
Volume change Max. 25%

k) ASTM Oil No.3
Change in Hardness Max. 20 shore A
l) Cold Hardening Point Min. -35 deg C

FREQUENCY OF
TEST
POT-PTFE BEARINGS
Plan Dimensions 0 to +5 mm
Overall Height 0 to +3 mm
Height of any Steel
Dimensional 0 to +1 mm
a) component - Machined
Tolerance
Height of any Steel
component - Class 2 of IS: 4897
Unmachined All Bearings to be
Height of Elastomer ± 5% tested
Stainless steel
Flatness 0.0004L
b)
sliding surface Surface Finish Ra < 0.25 pm
IRC: 83 - PART 1
MOSRTH, Cl. 2006 A test load of 1.25 times the
Load Test (Vertically & Horizontally
c) design head there shall be
including Rotation capacity 100% recovery
The sufficient of friction shall

d) Friction Test be less than or equal to 0.05 2 Nos per Lot
at the design load
e) Ultrasonic Test Level 3 as per IS: 9565 All castings to be tested
There shall be no holes or

f) Dye Penetration Test flaws
All weldings to be tested
g) Raw Material Testing As per code 1 Test/source (approval)

FREQUENCY OF
TEST
ELASTOMERIC BEARINGS
There shall be no visible
a) Visual Inspection defects in surface finish,
shape or any other defects.
Overall Plan
- 0, + 6 mm
Dimensions
Total Bearing
- 0, + 5 %
Thickness
Parallelism of top surface
with respect to the 1 in 200
bottom surface as datum
Parallelism of one side
surface with respect to 1 in 100
the other as datum All Bearings to be
Dimensional Thickness of individual tested
b) internal layer of ± 20% (Max. 2 mm)
Tolerance
elastomer
Thickness of individual
outer layer of elastomer
- 0, + 1 mm
Plan dimension of
laminates IRC: 83 - PART 2 - 3 mm, + 0
Thickness of laminates
MOSRTH, Cl. 2005 ± 10%
Parallels ion of laminate
w.r.t bearing base as 1 in 100
datum
Deflection under axial load of
5 - 15Mpa for individual
c) Axial Load Test bearings shall not vary by
more than 20% of the mean
value for the entire lot.
Shear modulus shall be
d) Shear Modulus 1 ± 0.2 Mpa
Elastic modulus shall be 2 Tests/Lot
e) Elastic Modulus (Short term loading) 1 ± 0.2
f) Adhesion Strength No cracking or petting
g) Ultimate Compressive Strength Not less than 60 Mpa
h) Tests on Elastomer As per code

NAME OF THE
S.NO RELEVENT CODE REQUIREMENTS FREQUENCY OF TEST
TEST
PILING
Initial Tests
The vertical load shall be minimum of

(a) 50% of the final load corresponding
to displacement of 1/10th pile dia.
(b) 2/3rd of final load at which 2 Tests for each size of
a) Vertical Load Test IS: 2911 - PART 4
displacement is 12 mm. pile
(c ) Load corresponding to any other
specified displacement as per
performance requirements
Routine Tests
2% of Total piles
Maximum settlement at a test load of the
a) Vertical Load Test subjected to minimum 2
working load shall not exceed 12 mm.
tests for each size
Maximum displacement at 1.5 times the

b) Lateral Load Test IS: 2911 - PART 4 Upto 2% of Total piles
Force should be 5 mm.
There shall be no unacceptable flaws in

c) Integrity Test concrete as per the recommendation of 20% of Total piles
the specified agency carry out the test.

(APPENDIX – V)
FIELD LABORATORY PLAN.

General Plan for Field Laboratory
W1 W W W W W W W W1
WASHING
SME BENCHES CUM RACKS - 800mm WIDE
CURING
TANK &
W/C
BITUMEN
SOIL,AGG &
LAB
CONCRETE
ROOM LAB
D2 D1 D1 D D1 D1 D2
0
W W
VERANDAH VERANDAH
CONCRETE WORKING FLOOR
ENGINEER'S LABORATORY
( Min. FLOOR AREA 90 Sq.m.( INTERIOR )
( Min. COVERED VERANDAH 15 Sq.m. )
( Min. COVERED 150 mm. CONCRETE WORKING FLOOR 35 Sq.m. )
7 UNITS DOUBLE 80W FLOURSCENT LIGHT FITTINGS COMPLETE WITH TUBES etc.
1 UNIT A2 - MIN. 2.7KW AIR-CONDITIONER.
1 UNIT EXTERNAL TOILET (WESTERN STYLE) WITH HAND BASIN etc.
TYPE - W, W1 - WINDOWS AND D, D1 AND D2 - DOORS AS SHOWN.
W1 = 600 mm HIGH X 500mm WIDE TRASPARENT GLASS, OUTWARD OPENING.
D = 2100mm HIGH X 2100mm WIDE DOUBLE PANNEL DOOR
D1 = 2100mm HIGH X 1200mm WIDE SINGLE PANNEL DOOR.
D2 = 2100mm HIGH X 900mm WIDE SINGLE PANNEL DOOR.
18 POWER POINTS AS SHOWN
800 mm. WIDE BENCHES IN LABORATORY AND BOTTOM SHOULD BE RACKED.

THE END

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HIGHWAY MATERIAL

Page 2 of 362 VKL Rao, M.Tech (Geotechnical)

Senior Pavement Expert

Page 3 of 362 VKL Rao, M.Tech (Geotechnical)

Page 4 of 362 VKL Rao, M.Tech (Geotechnical)

Page 5 of 362 VKL Rao, M.Tech (Geotechnical)

Page 6 of 362 VKL Rao, M.Tech (Geotechnical)

Page 7 of 362 VKL Rao, M.Tech (Geotechnical)

Page 8 of 362 VKL Rao, M.Tech (Geotechnical)

Page 9 of 362 VKL Rao, M.Tech (Geotechnical)

Page 10 of 362 VKL Rao, M.Tech (Geotechnical)

Soil is very essential material for highway constructions.

Page 11 of 362 VKL Rao, M.Tech (Geotechnical)

1. PREPARATION OF DRY SOIL SAMPLES FOR VARIOUS TESTS

1. Wooden-mallet – for breaking soil clods.

PREPARATION OF SAMPLE FOR TESTS:

Page 12 of 362 VKL Rao, M.Tech (Geotechnical)

50g.for fine grained

3 Grain size analysis Air drying As given in Table-3 - Part - 4

4 Liquid Limit Air drying 270 g 425 micron Part - 5

5 Plastic Limit Air drying 60 g 425 micron Part - 5

6 Shrinkage factor Air drying 100 g 425 micron Part - 6

Page 13 of 362 VKL Rao, M.Tech (Geotechnical)

Air drying / oven 1100C

14 CBR Air drying 6 kg 19 mm Part - 16

Oven, 1050C -1100C, 2.5kg(100mm dia), 5

18 Linear Shrinkage Air drying 450 g 425 micron Part - 20

Page 14 of 362 VKL Rao, M.Tech (Geotechnical)

Negative Pore Water Air drying / oven 1100C

Permeability of Air drying / oven 1100C

23 Direct Shear Air drying Upto 120 kg Above 4.75 mm Part - 39

24 Free swell index Oven dry 20 g 425 micron Part - 40

25 Swelling Pressure Air dry / Oven dry 2 kg 2 mm Part - 41

Maximum size of material present in

Page 15 of 362 VKL Rao, M.Tech (Geotechnical)

Indian standard classification:

> 300mm - Boulders

Page 16 of 362 VKL Rao, M.Tech (Geotechnical)

Textural classification chart:

Sand ( 2 - 0.05mm) 40 60 Clay ( < 0.005 mm)

Group index = 0.2 a + 0.005 ac + 0.01 bd

Page 17 of 362 VKL Rao, M.Tech (Geotechnical)

HRB – Classification of soils :

Granular material Silt clay materials ( > 35%

Group Index Zero >4 >8 > 12 > 16 > 20

Group classification A-7 A - 7a A - 7b A - 7c

Group index > 20 20 - 30 30 - 40 40 - 50

Page 18 of 362 VKL Rao, M.Tech (Geotechnical)

Soils are broadly divided into three divisions

Coarse-grained soils are further divided into two sub-divisions:

W : Well graded, clean.

Fine-grained soils further divided into three sub-divisions:

a) Inorganic silt and very fine sands – designated by ‘M’.

b) Inorganic clays – designated by ‘C’.

c) Organic silts and clays, and organic matter – designated by ‘O’.

Page 19 of 362 VKL Rao, M.Tech (Geotechnical)

Ip = 0.73 (wL – 20)

Where, Ip = Plasticity Index.

Source Km. :__________ Date of Tested :_