STANDARD METHODS OF TEST AND

SPECIFICATIONS FOR
CEMENT, WATER & SP

Lecture by:
G. K. Tike’, Scientist E-II,& Head
Rigid Pavements Division, CRRI
 What is cement? How it is manufactured?
1/26

BUILDER’S CEMENT
IS AN INORGANIC GREY COLOURED FINE POWDER
CAPABLE OF REACTION WITH WATER TO PRODUCE
STRENGTH GIVING COMPOUNDS, WHICH SET AND
HARDEN WITHOUT ANY APPRECIABLE CHANGE WITH
REGARD TO ITS PROPERTIES IN COURSE OF TIME
PORTLAND CEMENT CLINKER
IS PRODUCED BY BURNING AT ABOUT 1200 O TO 1450 O C A MIX
OF - CALCIUM CARBONATE (LIMESTONE OR CHALK) AND
AN ALUMINOSILICATE(CLAY OR SHALE)
LSF = CaO
2.80 Si O2 + 1.18 Al2O3 + 0.65 Fe2O3
 What is cement? How it is manufactured?
2/26

ASH FROM THE COAL INSOLUBLE RESIDUE I R;

“WHITE CEMENT CLINKER”, THE RAW MEAL IS TOTALLY IRON-FREE;

GAS OR FURNACE OIL FIRED SYSTEM

C3S, C2S, C3A, C4AF ALONG WITH SOME PERICLASE IN CLINKER FORM

INTER-GRINDING GYPSUM WITH CLINKER TO NEUTRALIZE THE C3A

CaSO4.2H2O IS GYPSUM AND CaSO4. ½H2O IS PLASTER OF PARIS

 COMPOSITION OF PORTLAND CEMENT
3/26

Grey White Factors Grey White

Oxides Cement Clinker Clinker Cement Clinker Clinker
% % %
Si O2 18-24 21.7 23.8 LSF % 88-102 98.4 97.2
Al2 O3 4-8 5.3 5.0 LCF % - 96.2 93.8
Fe2 O3 1.5-4.5 2.6 0.2 S/R 1.5-4 2.7 4.6
Total CaO 62-67 67.7 70.8 A/F 1-4 2.0 25
Incl. Free
Lime
MgO 0.5-4.0 1.3 0.08 C 3S % - 65.4 59.4
(max. limit)
K2 O 0.1-1.5 0.5 0.03 C 2S % - 12.9 23.5
Na2 O 0.1-1.0 0.2 0.03 C 3A % - 9.6 12.9
S O3 2.0-3.0 0.7 0.06 C4AF % - 7.9 0.6
(max. limit)
LOI 3.0 - -
(max. limit)
IR 1.5 - -
(max. limit)
Free Lime 0.5-1.5 1.5 2.5
 COMPOSITION OF PORTLAND CEMENT
4/26

LOI = LOSS ON IGNITION (CO2 + H2O);

IR = ACID INSOLUBLE RESIDUE;
S/R= Si O2 / (Al2 O3 + Fe2 O3 );
A/ F = Al2 O3 / Fe2 O3 ;
LSF = LIME SATURATION FACTOR
LCF = LIME COMBINATION FACTOR.

BOUGE EQUATIONS 1955; WEIGHT % OF EACH OXIDE

C4AF = 3.04 Fe2 O3
C3 A = 2.65 Al2 O3 – 1.69 Fe2 O3
C2 S = 8.60 Si O2 + 1.08 Fe2 O3 + 5.07 Al2 O3 – 3.07 CaO
C3 S = 4.07 CaO – 7.60 Si O2 – 1.43 Fe2 O3 – 6.72 Al2 O3
 COMPOSITION OF PORTLAND CEMENT
5/26

33 GRADE 43 GRADE 53 GRADE LOW

ORDINARY MEDIUM HIGH HEAT
(IS : 269) (IS: 8112) (IS : 12269) ( IS: 269)

C3S 45 % 50 % 55 % 30 %
C2S 27 % 22 % 17 % 46 %
C3A 11 % 11 % 11 % 5%
C4AF 10 % 10 % 9% 13 %
WHAT IS UNDERSTOOD BY CHARACTERISTIC
PROPERTIES OF CEMENT? 6/26
• FINENESS, (m 2 / kg)

• WATER FOR NORMAL CONSISTENCY, (%)

• INITIAL AND FINAL SETTING TIME, (min.)

• STRENGTH, (COMPRESSIVE - 3 , 7, 28 DAY) (N /mm 2 )

• DRYING SHRINKAGE, (%)

• SOUNDNESS, (PASS / FAIL)

• PERMEABILITY, ( ml / cm / sec.)
IS: 4031 – 1988 INDIAN STANDARD METHODS OF
PHYSICAL TESTS FOR HYDRAULIC CEMENT
7/26

PART 1 DETERMINATION OF FINENESS BY DRY SIEVING (FIRST

REVISION) FIRST REPRINT APRIL 1992

PART 2 DETERMINATION OF FINENESS BY SPECIFIC SURFACE BY AIR

PERMEABILITY METHOD (FIRST REVISION) FIRST REPRINT
MARCH 1992

PART 3 DETERMINATION OF SOUNDNESS (FIRST REVISION) FIRST

REPRINT NOVEMBER 1991

PART 4 DETERMINATION OF CONSISTENCY OF STANDARD CEMENT

PASTE (FIRST REVISION) FIRST REPRINT AUGUST 1993

PART 5 DETERMINATION OF INITIAL AND FINAL SETTING TIMES (FIRST

REVISION) FIRST REPRINT NOVEMBER 1991
IS: 4031 – 1988 INDIAN STANDARD METHODS OF
PHYSICAL TESTS FOR HYDRAULIC CEMENT
8/26

PART 6 DETERMINATION OF COMPRESSIVE STRENGTH OF HYDRAULIC

CEMENT OTHER THAN MASONRY CEMENT (FIRST REVISION) FIRST
REPRINT JUNE 1992

PART 7 DETERMINATION OF COMPRESSIVE STRENGTH OF MASONRY CEMENT

(FIRST REVISION) FIRST REPRINT MARCH 1992

PART 8 DETERMINATION OF TRANSVERSE AND COMPRESSIVE STRENGTH OF

PLASTIC MORTAR USING PRISM (FIRST REVISION) FIRST REPRINT
JANUARY 1993

PART 9 DETERMINATION OF HEAT OF HYDRATION (FIRST REVISION) FIRST

REPRINT AUGUST 1993

PART 10 DETERMINATION OF DRYING SHRINKAGE (FIRST REVISION) FIRST

REPRINT AUGUST 1993
IS: 4031 – 1988 INDIAN STANDARD METHODS OF
PHYSICAL TESTS FOR HYDRAULIC CEMENT
9/26

PART 11 DETERMINATION OF DENSITY (FIRST REVISION)

PART 12 DETERMINATION OF AIR CONTENT OF HYDRAULIC

CEMENT MORTAR (FIRST REVISION) FIRST REPRINT MARCH,
1992.

PART 13 MEASUREMENT OF WATER RETENTIVITY OF MASONRY

CEMENT (FIRST REVISION) FIRST REPRINT SEPTEMBER 1992

PART 14 DETERMINATION OF FALSE SET (FIRST REPRINT

JANUARY 1993)

PART 15 DETERMINATION OF FINENESS BY WET SIEVING (FIRST

REPRINT JULY 1994)
IS:2386-1983 INDIAN STANDARD METHODS OF
TEST FOR AGGREGATES FOR CONCRETE 10/26

• PART - I: PARTICLE SIZE AND SHAPE

• PART - II: ESTIMATION OF DELETERIOUS MATTER
• PART - III: SPECIFIC GRAVITY, DENSITY, VOIDS AND
BULKING
• PART-IV: MECHANICAL PROPERTIES

• PART - V: SOUNDNESS
• PART - VI: MEASURING MORTAR MAKING PROPERTIES
OF FINE AGGREGATES
• PART - VII: ALKALI AGGRGATE REACTIVITY
• PART - VIII: PETROGRAPHIC EXAMINATION
IS: 2386-1963 [PART-III] SPECIFIC GRAVITY, DENSITY,
VOIDS, ABSORPTION AND BULKING 11/26

SPECIFIC GRAVITY= OVEN DRIED WT

[SSD WT IN AIR- SSD WT IN WATER]

APPARENT SPECIFIC GRAVITY = OVEN DRIED WT

OVEN DRIED WT - SSD WT IN WATER

WATER ABSORPTION = 100 X [SSD WT IN AIR-OVEN DRIED WT]

OVEN DRIED WT

BULK DENSITY = WT/ VOLUME IN kg / liter

VOIDS % = [SPECIFIC GRAVITY- BULK DENSITY] X 100

IS: 2386-1963 [PART-IV] MECHANICAL PROPERTIES
12/26

AGGREGATE CRUSHING VALUE=

[Fr. PASSING 2.36mm] x 100
WT OF AGGREG. SAMPLE
10% FINES VALUE, LOAD REQD. TO PRODUCE 10 % FINES=
[14 x x] where x = load in tonnes, and
[y + 4] y = mean % of fines at
x- tonnes load
AGGREGATE IMPACT VALUE =
[Fr. PASSING 2.36mm] x 100
WT OF SAMPLE
AGGREGATE ABRASION VALUE [LOS ANGELES] =
[WT OF SAMPLE - WT RET. ON 1.70mm] x 100
WT OF SAMPLE
QUALITY SPECIFICATION OF WATER FOR MIXING
& CURING IS: 456- 2000 Indian Standard Plain and
Reinforced Concrete – Code of Practice 13/26

A)TO NEUTRALIZE 100 ML OF SAMPLE, USING PHENOLPHTHALEIN INDICATOR,

SHOULD NOT REQUIRE MORE THAN 5 ML OF 0.02 NORMAL NaOH SOLUTION
[DETAILS ARE AS PER IS 3025 (PART 22).]
B)TO NEUTRALIZE 100 ML OF SAMPLE, USING MIXED INDICATOR, SHOULD NOT
REQUIRE MORE THAN 25 ML OF 0.02 NORMAL H 2SO4 SOLUTION [DETAILS ARE
AS PER IS 3025 (PART 23).]
C) PERMISSIBLE LIMITS OF SOLIDS –
SL. TESTED AS PER PERMISSIBLE LIMIT, MAX.
NO.
1. ORGANIC IS 3025 (PART 18) 200 mg / l
2. INORGANIC IS 3025 (PART 1) 3000 mg / l
3. SULPHATES (AS SO3) IS 3025 (PART 24) 400 mg / l
4. CHLORIDES (AS CL ) IS 3025 (PART 32)
2000 mg / l for concrete
not containing embedded
steel and reinforced
concrete work
5. SUSPENDED MATTER IS 3025 (PART 17) 2000 mg / l
IS: 4032 – 1985 INDIAN STANDARD METHOD OF
CHEMICAL ANALYSIS OF HYDRAULIC CEMENT
14/26

IS 3812 : SPECIFICATION FOR FLY ASH FOR USE AS

POZZOLANA AND ADMIXTURE

Fly Ash Grade I For incorporation in cement mortar and

concrete and in lime-pozzolana mixture, and for
manufacture of Portland Pozzolana cement.

Fly Ash Grade II For incorporation in cement mortar and

concrete and in lime –pozzolana mixture (may be
used for PPC if IS 1489-1976 is permitting it.)
 CHEMICAL REQUIREMENTS OF FLY ASH
15/26

SR. CHARACTERISTIC REQUIREM

NO. ENT
1 SiO2 + Al2O3 + Fe2O3 , % Min. 70.0

2 SiO2 , % Min. 35.0

3 MgO , % Max. 5.0

4 SO3 , % Max. 2.75

5 Alkalis as Na2O , % Max.* in case of reactive 1.5

aggregates, IS 4032 : 1968.
6 Loss on Ignition, % Max. 12.0
PHYSICAL REQUIREMENTS GRADE OF FLY ASH

I II
16/26

1 FINENESS- SP. SUR. IN m2/kg BY 320 250

BLAINE’S PERMEABILITY METHOD, min.
2 LIME REACTIVITY – N/mm2 , min. 4.0 3.0

3 COMPRESSIVE STRENGTH AT 28 DAYS, NOT LESS THAN 80

N/mm2 , min. % OF THE
STRENGTH OF
CORRESPONDING
PLAIN CEMENT
MORTAR CUBES
4 DRYING SHRINKAGE, % max. 0.15 0.10

5 SOUNDNESS (AUTOCLAVE), % max. 0.8 0.8

EXPANSION
CHARACTERISTICS GRADE OF CEMENT
33- 43- 53- PPC-I PPC-II
FLY ASH CALCINED CLAY
CHEMICAL REQUIREMENTS 17/26

1. CAO/ OXIDES RATIO NOT NOT NOT FLY ASH (OF CALCINED
MORE MORE MORE FINENESS CLAY
THAN THAN 1.02 THAN MIN. 320 M2 / POZZOLANA
1.02 AND AND 1.02 KG AND LIME (OF FINENESS
NOT NOT LESS AND REACTIVITY MIN. 320 M2 / KG
LESS THAN 0.66 NOT VALUE NOT AND LIME
THAN LESS LESS THAN REACTIVITY
0.66 THAN 4.0 MPA; VALUE NOT
0.80 UNIFORMLY LESS THAN 4.0
BLENDED OR MPA;
INTERGROUN UNIFORMLY
D WITH OPC - BLENDED OR
IS 269: 1989; INTERGROUND
HOMOGENEI WITH OPC - IS
TY OF MIX + 269: 1989;
3 %) HOMOGENEITY
MIN. 15 % OF MIX + 3 %)
AND MAX. 35 MIN. 15 % AND
% BY MAX. 35 % BY
WEIGHT OF WEIGHT OF
OPC OPC
CHARACTERISTICS GRADE OF CEMENT
33- 43- 53- PPC-I PPC-II
FLY ASH CALCINED CLAY

CHEMICAL REQUIREMENTS: 18/26

2. ALUMINA/IRON OXIDE RATIO

NOT LESS THAN 0.66 0.66 0.66 - -

3.INSOL. RESIDUE, %
NOT MORE THAN 4.0 % 3.0 % 3.0 % X + 4.0(100-X) X + 4.0(100X)
100 100
WHERE X IS % WHERE X IS %
OF FLY ASH IN OF CAL. CLAY
PPC POZZ. IN PPC
4. MgO %
NOT MORE THAN 6.0 % 6.0 % 6.0 % 6.0 % 6.0 %
CHARACTERISTICS GRADE OF CEMENT
33- 43- 53- PPC-I PPC-II
FLY ASH CALCINED CLAY

CHEMICAL REQUIREMENTS: 19/26

5. TOTAL SULPHUR AS SO3 % FOR C3A 5 % OR LESS :- SO3 NOT MORE THAN 3.0 %
SO3 NOT MORE THAN 2.5 %
FOR C3A MORE THAN 5 %:-
SO3 NOT MORE THAN 3.0 %

6. TOTAL LOSS ON
IGNITION,
NOT MORE THAN 5.0 % 5.0 % 4.0 % 5.0 % 5.0 %
CHARACTERISTICS GRADE OF CEMENT
33- 43- 53- PPC-I PPC-II
FLY ASH CALCINED CLAY

PHYSICAL REQUIREMENTS: 20/26

FINENESS
NOT LESS THAN, m2 / kg 225 225 225 300 300

SOUNDNESS
EXPANSION NOT MORE
THAN, mm 10 10 10 10 10
LE- CHATELIER’S :-
AUTOCLAVE: - % 0.8 0.8 0.8 0.8 0.8
IF IT FAILS THEN :-
AERATION (KEEP 75 MM
DEPTH OF LAYER AT 50 TO
80 % RH, FOR 7 DAYS).
RE-TEST FOR SOUNDNESS.
RE-TEST – NOT MORE THAN
LE- CHATELIER’S :- mm 5 5 5 5 5
AUTOCLAVE: - % 0.6 0.6 0.6 0.6 0.6
CHARACTERISTICS GRADE OF CEMENT
33- 43- 53- PPC-I PPC-II
FLY ASH CALCINED CLAY
PHYSICAL REQUIREMENTS: 21/26

SETTING TIME
INITIAL, NOT LESS 30 30 30 30 30
THAN, min.
FINAL, NOT MORE 600 600 600 600 600
THAN, min.
FOR FALSE SET: REMIX
AND BREAK THE FALSE
SET, RE-TEST.

COMPRESSIVE STRENGTH,
PROGRESSIVE INCREASE
IN STRENGTH, NOT LESS THAN
72+1 HR. 16 MPA 23 MPA 27 MPA 16 MPA 16 MPA
168+2 HR. 22 MPA 33 MPA 37 MPA 22 MPA 22 MPA
672+4 HR. 33 MPA 43 MPA 53 MPA 33 MPA 33 MPA

TRANSVERSE STRENGTH MUTUALLY AGREED BETWEEN PURCHASER & SUPPLIER.

(IS 4031 PT.8:1988)

DRYING SHRINKAGE
NOT MORE THAN - - - 0.15 % 0.15 %
 IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR
STRENGTH OF CONCRETE: COMPRESSIVE STRENGTH 22/26
SAMPLE PREPARATION
• VOLUME OF CONCRETE- surplus by 10 percent

• WORKABILITY – IS 1199-1959,

• CUBE-MOULDS SIZE – 15 cm or 10 cm cube

• CYLINDERS SIZE - 15 cm dia. x 30 cm length,

• TAMPING BAR: 16 mm dia. 60 cm long bullet pointed at lower end.

• COMPACTION- 35 strokes per layer for 15 cm cubes and

25 strokes per layer for 10 cm cubes,
3-layers filling, finishing with trowel and cover.

• CURING - at 27 + 2 oC in fresh water or saturated lime solution till the

time of testing.
IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR
STRENGTH OF CONCRETE: COMPRESSIVE STRENGTH 23/26
CORE SPECIMEN
• Height prior to capping less than 95 percent of the diameter shall be rejected,
after capping the H/D ratio should be at least one,
Correction factor for H/D ratio between 1 and 2 as per the relationship given,
• CORE CAPPING – Neat cement and Sulphur capping,
• EQUIVALENT CUBE STRENGTH FROM CORE STRENGTH – multiply by 5 / 4.
• AGE AT TEST: 7 and 28 days, 13 weeks and 1 year.

• EQUIVALENT CUBE STRENGTH FROM BROKEN BEAM SPECIMEN

Bearing plates of thickness 6.5 to 19 mm metal plates, 10 cm square or 15 cm
square as per beam specimen depth, rate of loading 140 kg / sq. cm / min, result
is 5 percent greater than cube strengths.

• REPORTING – identification mark, date of test, age of specimen, curing

conditions, including date of manufacture of specimen in the field, weight of the
specimen, dimensions of the specimen, cross sectional area, maximum load,
compressive strength and appearance of fractured faces of concrete and type of
fracture.
 IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR
STRENGTH OF CONCRETE: FLEXURAL STRENGTH
24/26
SAMPLE PREPARATION
Coarse and fine aggregates, proportioning, weighing, mixing concrete- minimum 2
minutes in machine till concrete is uniform.

• VOLUME OF 10 percent in excess over and above the

CONCRETE: requirement.

• WORKABILITY: IS 1199-1959,

• BEAM-MOULD SIZE : 15 x 15 x 70 cm beam, OR

10 x 10 x 50 cm beam

• TAMPING BAR : Weight 2 kg, 25-mm sq. ramming flat face, 40-cm long.
Casting, Curing the same way.
 IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR
STRENGTH OF CONCRETE: FLEXURAL STRENGTH 25/26

CALCULATION

fs = [ p x l ] / [ b x d2 ]
If ‘a’ = distance between line of fracture and the nearer support measured
on the center- line of tensile side of specimen, in cm,
When ‘a’ is greater than 20 cm for 15 cm specimen, or
greater than 13.3 cm for a 10 cm specimen,
fs = [3p x a ] / [b x d2 ]
When ‘a’ is less than 20 cm but greater than 17 cm
for 15 cm specimen, or
less than 11 cm for a 10 cm specimen
Where b = measured width in cm of the specimen,
d = measured depth in cm of the specimen
l = length n cm of the span on which the beam is supported,
p = maximum load in kg applied to the specimen.

IF ‘a’ IS LESS THAN 17 CM (FOR 15-CM BEAM) OR 11 CM (FOR 10-CM BEAM)

THEN THE RESULTS SHALL BE DISCARDED.
 IS 516-1959 INDIAN STANDARD METHODS OF TESTS FOR
STRENGTH OF CONCRETE: MODULUS OF ELASTICITY 26/26
SIZE OF SPECIMEN: Cylinders of 15-cm dia. and 30 cm length. Or cores of
H/D ratio at least 2.
PREPARATION OF SPECIMEN: Same As above, age of testing at 28 days.
TESTING MACHINE AND EXTENSOMETERS: Two extensometers of gauge length not
less than 10.2 cm and not more than half the length of the specimen
capable of measuring strains to an accuracy of 2 x 10 –6.
PROCEDURE: average Compressive strength of 3 specimens, C = 1/3 Av. C.S.
nearest 5 kg/ sq. cm. Extensometers on opposite sides parallel to axis,
load applied @ 140 kg / sq. cm / min. till (C+5) kg/sq. cm Maintain this
load for a minute and then gradually reduc e to 1.5 kg / sq. cm when
extensometer reading is taken. Load is again applied to repeat the
reading. Then the third time repeat load and reading taken. The last two
readings should be in agreement to 5 percent of each other and repeat
that once more till the reading difference is less than 5 percent.

CALCULATION: The stress – strain curves (straight lines) for the two-extensometer
readings for the last two load-cycles are plotted. The slopes give the
average ‘E’-value expressed in kg/ sq. cm nearest to 1000 kg / sq. cm.