Limak Soma (JV) Pkg-I

TESTS ON CEMENT
 DETERMINATION OF FINENESS OF CEMENT

1.0 PURPOSE

To establish the procedure for the determination of fineness of cement by dry sieving.

2.0 SCOPE

The fineness of cement has an important bearing on the rate of hydration and ultimately the rate of
gain of strength.

3.0 REFERENCE DOCUMET: IS: 4031 (Part-1)

4.0 APPARATUS

1. 90 micron sieve with lid & pan

2. Balance 0.01 accuracy
3. Brush

5.0 PROCEDURE

1. Weigh 100 (g) cement and sieve from a standard sieve 90 micron

2. Sieve continuously cement sample giving circular and vertical motion for a period of 15
minutes.

3. Weigh the retained mass left on sieve.

4. After sieving the residue by weight on an IS 90 micron shall be weighed.

Acceptance criteria = Residue on the 90 micron sieve shall not exceed 10% of the total
weight of sample.

2
 DETERMINATION OF NORMAL CONSISTENCY FOR CEMENT

1.0 PURPOSE:

To find out normal consistency of cement.

2.0 SCOPE:

The SOP works method of find out normal consistency of cement as per IS: 4031 Part-4

3.0 REFERENCE DOCUMET: IS: 4031 (Part-4)

4.0 APPARATUS:

1. Vicat Apparatus
2. Balance
3. Gauging trowel
4. Standard weights
5. Non porous plate

5.0 DETAILED PROCEDURE:

1. Take 500 gms of cement

2. Add 24% of water into cement
3. The paste must be prepared in a standard manner and filled into vicat mould within 3-5 minutes.
4. After filling the mould shake the mould to expel air.
5. A standard plunger is brought down to touch the surface of the paste in the test block & quickly
released allowing it to sink into paste by its own weight.
6. Take the reading.
7. Conduct 2nd trial with % of water at 25 & take the reading.
8. Conduct similar trials with higher w/c ratio till plunger penetrates for a depth of 33-35 mm from
the top.
9. The percentage of water at which penetration gives 33-35 from the top or 5 to 7 mm from the
bottom is a standard consistency.

Acceptance criteria: Amount of water as a % by mass of the dry cement.

3
 DETERMINATION OF SETTING TIMES FOR CEMENT

1.0 PURPOSE
To determine Initial & final setting time.

2.0 SCOPE
The time interval is retained for the cement paste/mortar/concrete for its workability while mixing,
transporting and placing.

3.0 REFERENCE DOCUMENTS: IS-4031-1988 (Part-5)

4.0 APPARATUS:

1. Vicate needle apparatus

2. Trowel
3. Balance
4. Weights
5. Stop watch

1.0 DETAIL PROCEDURE :

I. INITIAL SETTING TIME

a. Take 500(g) cement sample

b. Add 85% of consistency water to produce paste.
c. Fill paste in vicat mould within 2.5 minutes.
d. In the beginning needle will pierce through test block but after sometime when the paste
starts losing its plasticity, the needle may penetrate only to a depth 33-35 mm from the
top.
e. Interval of time at which the needle penetrate to test block to a depth equal to 33-35 mm
from the top is taken as initial setting time.

II. FINAL SETTING TIME:

a. Replace vicat needle by a circular attachment

b. The cement shall be considered as finally set when upon lowering the attachment gently
cover the surface of the test block the concrete needle makes an impression.
c. The circular arrangement impression not seen on the mould it considered as final setting
time.
Acceptance criteria: Initial Setting time should not be less than 30minutes
Final Setting time should not be more than 600minutes

4
 DETERMINATION OF COMPRESSIVE STRENGTH OF CEMENT

1.0 PURPOSE:
To establish the compressive strength of cement mortar.

2.0 SCOPE:
The scope is to determine compressive strength of hardened cement.

3.0 REFERENCE DOCUMENTS: IS –4031 (Part-6) & IS: 8112-1989

4.0 APPARATUS:
1. High frequency mortar cube vibrator.
2. Mixing tools, frogs, trowels
3. Ennore sand confirming IS-650-1960
4. Moulds of size 7.06x7.06x7.06 cm
5. Poking rod
6. Balance and graduated glass cylinder

1.0 DETAILS PROCEDURE :

1. Take Ennore sand class – I, II & III with cement sample and mix with (1:3) proportion in tray.
Mix the same for 1 minute in dry condition.
2. Add water (P/4 + 3.0)% and mix thoroughly uniform upto 3.5 minute
3. Immediately after mixing fill mortar in 7.06 x 7.06 mm moulds 9 Nos.
4. Compact the filled cube mould by cube vibration machine up to 2 minutes at the specified speed
12000+/-400 vibrations per minute.
。
5. Keep mortar cube mould at a temperature of 27+ 2C for 24 hours (may be kept under wet
gunny bag to simulate 90% relative humidity.
6. After 24 hours the cubes are removed from the mould and immersed in clean water, until takes
out for testing.
7. Three moulds shall be treated at age 3 days (72+/- 1 hour)
Three moulds shall be treated at age 7 days (168+/- 2 hours)
Three moulds shall be treated at age 28 days (672+/-4 hours)
Comp. Strength of cement cube = Load (N)
Area (mm2)
Acceptance criteria as per IS- 8112 (For OPC 43 grade): The average compressive strength
for cube not less than 23MPa for 3 days, 33MPa for 7 days & 43MPa for 28 days.

5
 DETERMINATION OF SOUNDNESS FOR CEMENT

1.0 PURPOSE:

To establish the procedure for the cement shows any appreciable subsequent expansion.

2.0 SCOPE:

Cement shall not go a large expansion after setting and this will cause serious difficulty to the
structure.

3.0 REFERENCE DOCUMENTS: IS – 4031 -1988(Part-3)

4.0 APPARATUS:

1 Le-Chatelier apparatus
2 Water bath
3 Measuring scale
4 Trowel
5 Graduated glass cylinder

5.0 DETAILS PROCEDURE:

1. Take 500 gm. Cement sample

2. Add water 78% of consistency water and make a well mixed paste with in 5 minutes.
3. Paste filled into the moulds kept on a glass plate and moulds are closed on the top
with another glass plate and keep weight as given in set. Measure the distance
between two indicator points before put in to the water.
4. Whole assembly is immersed in water at a temperature of 27 +/-2 0 c and kept for 24
hours and measure the distance between two indicators.
5. Submerge the mould again water & heat the water at boiling point in @ 25-30
minutes & keep it boiling for 3 hours.
6. Remove the mould from water, allow it to cool and measure the distance between
indicator points. The distance between indicator points represent the expansion of
cement.
7. It must not exceed 10 mm for OPC.
Acceptance criteria: For OPC cement shall not have an expansion more than 10mm
(tested by Lechatelier’s apparatus)

6
 DETERMINATION OF TEN PERCENT FINES VALUE FOR AGGREGATE

1.0 PURPOSE
To find out 10% fines value.
2.0 SCOPE
The SOP covers to find out 10% fines value, which gives a measure of the resistance of an
aggregate to crushing.
3.0 REFERENCE DOCUMENTS : BS:812 Part-3 & IS:2386 (Part-IV)
4.0 APPARATUS
1. Loading Machine
2. 15 cm dia cylinder
3. Plunger
4. IS sieves 12.5 mm, 10 mm & 2.36 mm.
5. Tamping rod 16 mm dia
6. Balance with 1 gm accuracy and 3kg capacity

5.0 DETAIL PROCEDURE :

1. Take sample from 12.5 mm passing & 10 mm retained & put that sample into soaked condition (i.e.
in water) for 24 hrs.
2. Fill the 10% fines mould with sample in 3 layers & tamped each layer 25 strokes with tamping rod.
3. Weight the mould with aggregate Reading A.
4. Put that mould into compressive loading machine & give load upto 15 mm penetration for rounded
aggregates & 20 mm penetration for angular aggregates.
5. Note the load value at specified penetration. X
6. Take out the sample from the mould & sieved through 2.36 mm size. Take out of sample passing
through.-B
7. Take reading of empty mould – C
8. Now, find out % passing from 2.36 mm by formula.
B
Y = ---------- x 100
A-C
9. If, y is between 7.5 and 12.5 % then apply given formula to find out 10% times value.
10. Load required for 10% fines = 14 x X
4+Y

Where X- Load in tones

Y- Mean % fines from two tests at “X” tones load

Acceptance criteria = Minimum 50KN (for sample in soaked condition for GSB)

7
 DETERMINATION OF FLAKINESS INDEX OF AGGREGATE

1. PURPOSE

This method of test lays down the procedure for determining the flakiness index of coarse
aggregate.

2. SCOPE

To find out particle size distribution of fine, coarse and all-in-aggregate by sieving and screening..

3. REFERENCE DOCUMENTS : IS-2386 (Part-I) - 1968

4. APPARATUS

1. Balance (0.1 of accuracy of the weight of the test sample)

2. Metal thickness Gauge
3. I.S. Sieves (given in table-I) conforming to IS:460-1962 (i.e, 63, 50, 40, 31.5, 25, 16,
12.5, 10 and 6.3mm)
4. Container

5. PROCEDURE:

I. SIEVING : The sample shall be sieved as per IS-2386 (Part-I) Table – V in a fraction 63-50
mm, 50-40 mm, 40-25 mm, 31.5 – 25 mm, 25-20 mm, 20-16 mm, 16-12.5 mm, 12.5 – 10
mm & 10-6.3 mm.
II. SEPRATION OF FLAKY MATERIALS: Each fraction shall be gauged in turn for thickness
on a metal gauge of the pattern. The width of slot used in the gauge or sieve shall be of the
dimensions specified in column-3 of Table V of IS-2386 (Part-I) 1963.
III WEIGHING OF FLAKY MATERIAL: The total amount passing the gauge shall be weigh
to an accuracy of at least 0.1% of the weight of the test sample.
IV REPORTING OF RESULTS: The flakiness index is the total weight of the material passing
the various thickness gauge, expresses as a % of the total weight of the sample gauged.

Acceptance criteria: For concrete - 35% max.

For WMM,DBM & BC - 30% max.
(Flaki & Elongation combined)

8
 DETERMINATION OF ELONGATION INDEX FOR AGGREGATE

I PURPOSE:

Method covers to determining the elongation index of coarse aggregate.

II SCOPE:

The SOP covers for determining the elongation index of coarse aggregate.

III REFERENCE DOCUMENTS: IS – 2386 (Part – I) 1963

IV APPARATUS:
1. Balance – 0.1g accuracy
2. Metal length gauge
3. IS – Sieves
4. Containers

V PROCEDURE:

1. SEIVING : The sample shall be sieved as per IS-2386 (Part-I) Table – V in fraction 63-50 mm,
50-40 mm, 40-25 mm, 31.5 – 25 mm, 25-20 mm, 20-16 mm, 16-12.5 mm, 12.5 – 10 mm & 10-
6.3 mm.
2. SEPERATION OF ELONGATED MATERIALS: Each fraction shall be gauged individually for
length on a metal length of the pattern. The gauge length used shall be that specified in column
– 4 of Table – IV of IS-2386 (Part-I) 1965.
3. WEIGHING OF ELONGATION MATERIAL: The total amount retained by the length gauge
shall be weighed.
4. REPORT OF RESULTS: The elongation index is the total weight of the material retained on the
various length gauge, expressed as a percentage of the total weight of the sample gauged.
Acceptance criteria: For concrete - Not applicable
For WMM,DBM & BC - 30% max.
(Flaki & Elongation combined)

9
TESTS ON CONCRETE

10
 DETERMINATION OF COMPRESSIVE STRENGTH OF CONCRETE CUBES

1.0 PURPOSE:

To determine the compressive strength of concrete.

2.0 SCOPE :

The SOP covers test for determination of compressive strength of concrete.

3.0 RESPECTIVE DOCUMENTS: IS: 516

4.0 APPARATUS
i. Compressive strength Test Machine (CTM-200MT)
ii. Balance
iii. Measuring scale

5.0 DETAILS PROCEDURE:

1. Specimen (CUBE) stored in water shall be tested immediately after removing from water tank.
2. Size and Weight shall be noted before testing.
3. Cube shall be placed in the machine in such a way that the load shall be applied to opposite
sides of the cubes as cast that is not to the top and bottom.
4. The Axis of the cube shall be carefully aligned with the center of thrust of the spherically seated
platen.
5. The spherically seated block is brought to bear on cube and the movable portion shall be rotated
gently by hand.
6. The load shall be applied continuously without shock and at the rate of 140 kg/Sq.cm/ min. until
the resistance of cube to the increasing load breaks down and no greater load can be sustained.
The maximum applied load is recorded.
7. Compressive strength is calculated by maximum load applied during the test divided by the
cross section area.
Comp. Strength of concrete cube = Load / Area (N / mm2)
Acceptance criteria as per MoRT&H clause: 1716.2.5

a) The mean strength determined from any group of four consecutive samples should
exceed the specified characteristic compressive strength.
b) Strength of any sample is not less than the specified characteristic compressive
strength minus 3MPa.

11
 DETERMINATION OF WORKABILITY OF CONCRETE BY SLUMP

1. SCOPE

To determine workability of the concrete mix.

2. REFERENCE DOCUMENTS: IS: 1199

3. APPARATUS

1. Slump cone apparatus (With complete set)

2. M.S Tray for concrete sample.
3. Float, Trowel.

4. PROCEDURE:

1. The internal surface of the mould shall be thoroughly cleaned.

2. The mould shall be placed on a smooth, horizontal, rigid & non- absorbent leveled surface.

3. The operator shall hold the mould firmly in place while it is being filled with test specimen
of concrete.

4. The mould shall be filled in four layers each layer shall be tamped with twenty-five strokes
of the rounded end of the tamping rod.

5. After the top layer has been rodded the surplus concrete shall be struck off by trowel.

6. Clean the concrete around the mould.

7. Mould shall be removed form the concrete immediately after filling by raising it slowly and
carefully in a vertical direction.

8. The moulded concrete shall be allowed to subside and slump shall be measured immediately
by determining the difference between the height of the subsided mould and that horizontal
flat of the mould.

Note: Above operation shall be carried out a place free from vibration or shock.

RESULT: The slump shall be measured in terms of millimeters.

Acceptance criteria: As per MoRT&H table 1700-4 and as observed in design mix
trials, it varies with different grade of concrete.

12
 DETERMINATION OF WORKABILITY OF CONCRETE BY COMPACTION FACTOR

1.0 PURPOSE: - To determined the workability of the concrete mix.

2.0 SCOPE: - To know the workability of the Mix for required level compaction factor.

3.0 REFERENCE DOCUMENTS: IS: 1199-1959

4.0 APPARATUS:

1. Compaction Factor apparatus

2. Steel float – Nos.2
3. 25 mm Needle vibrator – No.1
4. M.S.Tray – 600 x 600 x 50 mm
5. Electronic balance – 30 kg Capacity

Apparatus consist of two hoppers 1 & 2 , bottom of the hoppers consists of hinged doors. Distance of the
hoppers from the base are fixed. Below the lower hopper 2 , one cylindrical mould having (30 cm ht. & 15
cm dia) is fitted.

5.0 DETAILS OF PROCEDURE :

a. Fill the hopper No.1 & release the bottom door, the concrete falls from a specified height into the
lower hopper No.2
b. Release the door of the lower hopper No.2 concrete will fall in cylindrical mould placed below.
c. Remove the surplus concrete from mould by using steel floats.
d. Take weight of concrete in mould– “W1”
e. Make empty the cylindrical mould and refilled with concrete from the same sample in layers
approximate 5cm deep. Layers being compacted by vibrator – Remove surplus concrete & get
weight– “W2”
Compaction factor = W1/W2

13
 METHOD OF TEST FOR SURFACE TEXTURE

1. PURPOSE

To find out texture depth of rigid pavement concrete.

2. SCOPE

The SOP covers the method to determine depth of texture for rigid pavement concrete.

3. APPARATUS : REFERENCE DOCUMENT –MoRT&H Clause – 602.12

2. Cylinderical container 25 ml capacity.

3. Flat wooden disc (with hard rubber disc at bottom) with handle
4. Measuring Scale
5. Dry natural sand passing IS Sieve 300 micron and retained on 150micron sieve.

4. PROCEDURE:

1. Surface to be measured shall be dried.

2. Any extraneous mortar or loose material shall be removed by wire brush (Both-longitudinal
& Transverse direction).
3. The cylindrical container shall be filled with the sand, tamp its bottom – 3 times on surface
and ensure sand level up to the required mark.
4. The sand in container shall be poured into a heap on the surface to be treated.
5. The sand shall be spread over the surface, rotating the disc over sand in a circular motion so
that the sand is spread into a circular patch with the surface depressions filled with sand to
the level of peaks.
6. The diameter of the patch shall be measured to the nearest 5 mm and five reading are to be
taken for a particular location of a panel.
7. Select – 4 location in diagonally & one in centre of panel.
8. The texture depth of concrete surface shall be calculated by formula 31000/(D x D) where D
= Dia of patch in mm.
9. Two times observations to be done for a particular panel.
a. Between 24 hrs to 7 days
b. Between 7 days to before 6 weeks.

Acceptance criteria:
i. Between 24hours and 7 days 1+/-0.25mm.
ii. Not later than 6 weeks before the road is opened to public traffic
1+0.25mmand 1-0.35mm

14
 FLEXURAL STRENGTH OF CONCRETE BEAM

1.0 PURPOSE: - To determined flexural strength of “Pavement Concrete Beam”.

2.0 SCOPE: -This deals with the procedure for determining the flexural strength of moulded concrete
flexure test specimen (i.e. beam) to represent PQC Strength.

3.0 REFERENCE DOCUMENTS: IS: 516

4.0 APPARATUS: -

1. Flexural Strength M/c

5.0 DETAILS OF PROCEDURE:-

a. Take out specimen from curing tank, clean it with water.

b. Make a 5 cm mark vertically, on specimen on either ends.
c. Specimen shall be placed in machine such a way that the load shall be applied to the upper most
surface as cast in mould.
d. The axis of the specimen shall be carefully aligned with the axis of the loading device.
e. Load shall be applied continuously and without shock.
f. The load shall be increased until the specimen fails and load applied is recorded at the failure.
g. The appearance of the fractured faces is observed.
h. Fractured line is measured to the nearest ends of specimen.

Fractured face

5cm 60 cm 5cm

If a > 20 cm, use this formula for modulus rupture fb = p x l

bxd2
If a < 20 cm, use this formula for modulus rupture fb = 3p x l
bxd2
P = Applied Load (KN), l = Supported Length 60 cm
b = Width of the Beam, d = depth of the beam

Acceptance criteria: Characteristic flexural strength at 28 days 4.0MPa (As per Technical
Specification sub clause 602.3.5)

15
TESTS ON AGGREGATE

16
 DETERMINATION OF AGGREGATE IMPACT VALUE FOR AGGREGATES

1.0 Purpose: To find out Aggregates Impact Value.

2.0 The SOP covers the finding out of aggregate Impact Value of the coarse aggregate.

3.0 Reference Document : IS – 2386 (Part-IV)

4.0 Apparatus :
2. Aggregate Impact value machine
3. IS sieve size 12.5 mm 10 mm size & 2.36 mm dize
4. Aggregate Impact Jar.
5. Tamping rod with nose of cylinder 16 mm dia
6. Balance with 0.01 gm capacity.
5.0 Detailed Procedure
1. Take aggregate from source/ stock piles
2. Make test sample of aggregates passing 12.5 mm IS sieve & retained on 10 mm IS sieve
3. Put the sample in to oven for four hours at 1000 c – 1100 c temperature & cool it.
4. The aggregates are filled in measuring cylinder in 3 equal layer with 25 strokes by tamping rod.
5. Weight the impact Jar with material. Take Reading A
6. Now place the Impact cup into impact machine & set the bottom plate without deviating such
that hammer falls from 380 + 5 mm height.
7. Total 15 blows are carried out each being delivered at an interval of not less than the second.
8. The crushed aggregate are taken out & sieved through 2.36 mm sieve & weigh the fraction
passing out 2.36 mm IS Sieve.
9. Take the Empty Wt. of impact cup – Reading C

Calculation:
Aggregate Impact Value
B
= -------- x 100
A-C
Conclusion
B
Aggregate Impact Value = ------- x 100
A–C
Acceptance criteria:
Specification limits as per For Concrete
For DBM For BC
MoRT&H & WMM
Maximum ( % ) 30 27 24

17
 DETERMINATION OF SPECIFIC GRAVITY AND WATER ABSORPTION FOR AGGREGATE
LARGER THAN 10MM

1.0 Purpose: To find out water absorption & Specific gravity of aggregate greater than 10 mm size.
2.0 SCOPE: The SOP covers the procedure for testing of aggregate for its water absorbing
property & specific gravities.
3.0 Apparatus : Ref. Document : IS – 2386 (Part – III) : 1963
1. Wire basket.
2. Oven
3. Balance
4. Water Container
5. Suspension rod or ring
6. Two clothes of cotton
4.0 Detailed Procedure :
1. Take about 2 kg of aggregate sample & washed to remove fines & dust from it.

2. Place the aggregates in wire basket & immersed wire basket in distilled water container with the
help of suspension rod ring. Such that wire basket get a cover of at least 5 cm above. The
temperature at this time should be between 220 C & 320 c.

3. After immersions to remove entrapped air from sample, jerk the wire basket for 25 times.

4. The basket & aggregate should removed completing immersed in water for period of 24 + ½
hours.

5. Weigh after 24 hrs the sample with basket in water with use of suspension ring – Reading A.

6. Sample is taken out from basket & weigh the basket in water – Reading B.

7. The aggregates made surface dry with use of dry cotton cloths.

8. The aggregate should be weight – Reading C.

9. Then after, aggregate placed in oven for 24 hours at 110’ C then it is cooled & weight, Reading – D.

(I) Specific Gravity = D

---------------
C – (A-B)

(II) Apparatus Gravity = D

-----------
D – (A-B)

(III) Water Absorption =

(C-D)
-------------- x 100
D
Acceptance criteria for water absorption = Maximum 2% for all types of works

18
 DETERMINATION OF SPECIFIC GRAVITY AND WATER ABSORPTION FOR AGGREGATE
SMALLER THAN 10MM

I PURPOSE:
To find out water absorption and specific gravity of aggregate smaller than 10 mm.

II SCOPE:
The SOP covers for determining specific gravity of aggregate based on SSD, Oven dried and
apparent specific gravity.

III REFERENCE DOCUMENTS : IS-2386 (Part-III) 1963

IV APPARATUS:
1. Balance
2. Oven
3. Pycnometer
V PROCEDURE:
1. A sample of about 1 kg for 10 mm- 4.75mm or 500 g. if finer than 4.75 mm, shall be placed in
the tray and covered with the distilled water at a temperature of 22-320 C.
2. Soon after immersion, air entrapped in or bubbles on the surface of the aggregate shall be
removed by gentle agitation with a rod.
3. The sample shall remain immersed for 24 + ½ Hrs.
4. The water shall then be drained out carefully from the sample by cotton cloth / filter paper.
5. Surface moisture can be evaporated by rubbing cotton cloth on the aggregate. The saturated and
surface dry sample shall be weighed say weight (A).
6. The aggregate shall be then placed into pycnometer which shall be filled with distilled water.
7. Any trapped air shall be eliminated by rotating the pycnometer on its sides, the hole in the apex
of the cone being covered with a finger.
8. The pycnometer shall be filled up with distilled water up to top to remove if any air bubbles
from the surface and so that the surface of the water in the hole is flat. The pycnometer shall be
dried on the outside and weighed (B).
9. The content of the pycnometer shall be emptied into the tray, care being taken to ensure that all
the aggregate is transferred.
10. The pycnometer shall be refilled with distilled water to the same level as before, drained on the
outside and weighed say (C).
11. The water shall be carefully drained from the sample by cotton cloth.
12. The sample shall be placed in oven in the tray at a temperature 1000 to1100C for 24 hrs. Then the
same is cooled in airtight container – and get weight (D). Two tests shall be made.

VI CALCULATION:
D
Specific gravity ------------ Where A = Weight of SSD condition (g)
A - (B-C) B = Weight of Pycnometer filled with water and sample (g)

D C = Weight of pycnometer filled with distilled water (g)

Apparent Sp. Gr. ------------ D = Weight of oven dried sample (g)
D - (B-C)
Acceptance criteria for water absorption = Maximum 2% for all types of works
19
 DETERMINATION OF STRIPPING VALUE OF AGGREGATES

STANDARD

IS: 6241-1971.

DEFINITION

The stripping value of aggregates is determined as the ratio of the uncovered area observed visually
to the total area of aggregates, expressed as a percentage.

APPARATUS

Heat resistant glass beaker of 500 ml capacity.

20mm and 12.5mm IS sieves.

Mixer.

Balance of capacity 10Kg and sensitivity 1gram.

Water bath preferably with a thermostat.

PROCEDURE

Take 200 grams of dry and clean aggregates passing 20mm and retained on 12.5mm sieves and heat
up to 1500C.

Take five percent by weight of bitumen binder and heat up to 1600C.

Mix the aggregates and the binder till they are completely coated and transfer the mixture in to a
500ml beaker and allow to cool at room temperature for about 2 hours.

Add distilled water to immerse the coated aggregates.

Cover the beaker and keep 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 24hours take the beaker out, cool at room temperature and estimate the extent of stripping
visually while the specimen is still under the water.
REPORT
 Express the stripping value as the ratio of the uncovered area observed visually to the total area of
aggregates in each test.
 Report the mean of three results as stripping value of the tested aggregates to the nearest whole
number.

Acceptance Criteria = Minimum 95% retained coating

20
 DETERMINATION OF SAND EQUIVALENT VALUE

STANDARD

IS: 2720 (Part-3)-1976

SCOPE

The SOP covers the method for the determination of sand equivalent value of the soils and this
method is intended to serve as a rapid field-correlation test.

APPARATUS

Sand equivalent test, Graduated cylinder

Irrigator tube, Flat pan

Trimming device, Siphon assembly

Weighted foot assembly, Measuring can

IS Sieves, Funnel

Calcium chloride solution

PROCEDURE

 Fill the prepared calcium chloride solution up to 100+/-2mm indicated on the graduated cylinder.
 Pour the test specimen (4.75mm sieve passing) into the graduated cylinder using the funnel to avoid
spillage.
 Tap the bottom of the cylinder sharply on the palm of the hand several times to replace air bubbles
and to promote thorough wetting of the specimen.
 Allow the wetted specimen and cylinder to stand undisturbed for 10+/- 1 minute.
 At the end of the 10minutes soaking period, stopper the cylinder, then loosen the material from the
bottom by partially inverting the cylinder and shaking it simultaneously.
 After loosening the material from the bottom of the cylinder, shake the cylinder and contents by
hand.
 Hold the cylinder in the horizontal position and shake it vigorously in a horizontal linear motion
from end to end.
 Shake the cylinder 90 cycles in approximately 30seconds using a throw of 230+/-5mm.
 Following the shaking operation, set the cylinder upright on the work table and remove the stopper.

21
 Insert the irrigator tube in the top of cylinder, remove the spring clamp from the hose and rinse the
material from the cylinder wall as the irrigator is lowered.
 Continue to apply a stabbing and twisting action which flushing the fines upwards until the cylinder
is filled to the 380mm graduation.
 Regulate the flow just before the irrigator tube is entirely with drawn and adjust the final level to the
above 380mm graduation.
 Allow the cylinder and contents to stand undisturbed for 20minutes +/-15 seconds. After 20minutes
sedimentation period read and record the level of the top of the clay suspension “as clay reading”.
 After the clay reading has been taken place the weighed foot assembly over cylinder and gently
lower the assembly until it comes to rest on the sand.
 Subtract 250mm from the level indicated by the extreme top edge of the indicator and record this
value as “sand reading”.
Sr
 Calculate the sand equivalent (SE) = ---- x 100
Cr
Where Sr- Sand reading
Cr- Clay reading

Acceptance Criteria = Minimum 50%

22
TESTS ON SOIL

23
 DETERMINATION OF MOISTURE – DENSITY RELATION FOR SOIL

1.0 PURPOSE
To establish the relation between the Moisture content and Density by heavy compaction.
2.0 SCOPE
The SOP covers the method for determination of the relation between the water content and the dry
density of soil.
3.0 REFERENCE DOCUMENTS
IS-2720 (Part-VIII)
4.0 APPARATUS
i. Cylindrical metal mould.
ii. Chisel & hammer
iii. Balances – 0.1 gm & 0.2 gm accuracy
iv. Oven & Containers
v. Steel Straightedge
vi. Sieve – 19 mm IS size
vii. Metal Rammer – 4.9 Kg & Mixing Tools
6.0 DETAIL PROCEDURE :
i. Take 5.0 Kg of air dried soil (passing from 19 mm sieve and replaced retained particle by
4.75 mm)
ii. Thoroughly mix the soil by adding uniform increments of water content.
iii. 1000 cm3 capacity mould with base plate & extension attached shall be placed on plain floor.
iv. Soil specimen is approximately divided in five equal parts, each layer being given 25 blows
by 4.9 kg rammer dropped from height of 450 mm.
v. The extension shall be removed after 5 layers and compacted soil shall be leveled off
carefully by straightedge.
vi. Weigh the compacted soil with mould.
vii. Take approximate 50 gm soil sample in aluminum container from that mould after weighing
and put container in oven for 24 hours.
viii. Repeat the same procedure with new soil sample with adding 2% of increments of water
content for at least 5 times.
ix. Moisture content should be optimum of which the maximum DRY DENSITY occurs.
x. Plot the graph with DRY DENSITY & MOISTURE CONTENT and derive MDD, OMC
from the graph.
Acceptance criteria
Specification limits as per Embankment Embankment Subgrade&
MoRT&H table 300-1 upto3m height exceeding 3m Eart. shoulders
Minimum (gm/cc) 1.52 1.60 1.75

24
 DETERMINATION OF LIQUID LIMIT FOR SOIL

1.0 PURPOSE
To establish the procedure for the Determination of Liquid Limit.
2.0 SCOPE
Liquid Limit is defined as the water content at which the soil changes from liquid state to plastic
state.
3.0 REFERENCE DOCUMENTS: IS: 2720 (Part 5) 1985.
4.0 APPARATUS
1. Casagrande apparatus confirming to IS: 9259-1979.
2. Grooving tool.
3. Balance of capacity 500 grams and sensitivity 0.01gram.
4. Thermostatically controlled oven with capacity up to 2500 C.
5. Porcelain evaporating dish about 12 to 15cm in diameter.
6. Spatula flexible with blade about 8cm long and 2cm wide.
7. Palette knives with the blade about 20cm long and 3cm wide.
8. Wash bottle or beaker containing distilled water.
9. Containers airtight and non- corrodible for determination of moisture content.
DETAIL PROCEDURE:
 Take representative soil sample of approximately 120gms passing through 425 micron IS sieve and
mix thoroughly with distilled water in the evaporating dish to a uniform paste.
 The paste shall have a consistency that will require 30 to 35 drops of the cup to cause the required
closure of the standard groove.
 Leave the soil paste to stand for 24 hours to ensure uniform distribution of moisture through out the
soil mass. Remix the soil thoroughly before the test.
 Place a portion of the paste in the cup above the spot where the cup rests on the base, squeeze down
and spread in to position with a few strokes of the spatula as possible and at the same time trim to a
depth of 1cm at the point of maximum thickness.
 Make a clean, sharp groove by a grooving tool along the diameter through the centerline of the cam
follower.
 Drop the cup from a height of 10 + 0.25 mm by turning the crank at the rate of two-revolutions/ sec,
until the two halves of the soil cake come in contact with the bottom of the groove along the
distance of about 12mm.
 Record the number of drops required to cause the groove close for the length of 12mm.

25
 Collect a representative slice of sample of soil approximately the width of spatula, extending from
about edge to edge of the soil cake at right angle to the groove in to an air tight container and keep
in the oven for 24hrs, maintained at a temperature of 105 0 to 1100C and express its moisture content
as the percentage of the oven dried weight.
 Transfer the remaining soil in the cup to the evaporating dish and clean the cup and the grooving
tool thoroughly.
 Repeat the operation specified above for at least three more additional trials (minimum of four in
all) with soil collected in evaporating dish to which sufficient water has been added to bring the soil
to more fluid condition.
 In each case record the number of blows and determine the moisture content as before.
 The specimens shall be of such consistency that the number of drops required to close the groove
shall not be less than 15 or more than 35.
REPORT
 Plot a flow curve with the points obtained from each determination on a semi logarithmic graph
representing water content on the arithmetical scale and the no of drops on the logarithmic scale.
 The flow curve is a straight line drawn as nearly as possible through the four or more plotted points.
 The moisture content corresponding to 25 drops as read from the curve shall be rounded off to the
nearest second decimal and is reported as liquid limit of the soil.

Acceptance criteria

Specification limits as per MoRT&H Embankment &

GSB
clause 305.2.1.1 Subgrade
Maximum ( % ) 70 25

26
 DETERMINATION OF PLASTIC LIMIT & PLASTICITY INDEX FOR SOIL

2.0 PURPOSE
To establish the procedure for the determination of plastic limit / plasticity index
3.0 SCOPE
The SOP covers the determination of plastic limit of soils
4.0 REFERENCE DOCUMENTS : IS – 2720 (Part-5) : 1985
4.0 APPARATUS
1. Porcelain dish Appx. 100 mm dia
2. Flat glass – 10 mm thick & 45 cm square
3. Spatula – flexible, cm in length & 2 cm in width
4. Containers – 2 Nos. at least
5. Balance 0.01 g accuracy
6. Oven
5.0 DETAIL PROCEDURE:
a. A soil sample 20 gm aging through 425 micron sieve is taken in parceling dish and added
known volume of distilled water until soil mass be comes plastic enough to be easily
moulded into a ball with fingers.
b. Take a portion of the ball and roll it on glass plate at the rate of 80 to 90 strokes /minutes by
fingeres.
c. Care should taken while rolling soil mass to form a thread (Between fingers and glass plate)
be uniform in diameter thought its length.
d. Rolling shall be done till the threads are of 3 mm diameter, the soil is remolded again into a
ball.
e. This process of rolling and remolding is repeated until the thread starts just crumbling at a
diameter of 3 mm, and soil can no longer be rolled into a thread.
f. The crushed thread are kept for water cement determination
g. Repeat the test with two more sample
h. The plastic limit is then taken as average of the three water content value
PLASTICITY INDEX (Ip) = Liquid limit (WL) – Plastic limit (Wp)
Acceptance criteria for PI:

Specification limits as per MoRT&H Embankment &

GSB & WMM
clause 305.2.1.1 Subgrade
Maximum ( % ) 45 6

27
 DETERMINATION OF GRAIN SIZE ANALYSIS FOR SOIL

2.0 PURPOSE

To establish the procedure for the quantities determination of grain size distribution.

3.0 SCOPE

The SOP covers the determination the percentage of various size particles in a soil sample.

4.0 REFERENCE DOCUMENTS : IS-2720 (Part-4) : 1985

5.0 APPARATUS

1. I.S. Sieve (size 19mm, 4.75 mm, 2.0 mm, 1.18 mm, 425 micron, 300 micron, 150 and 75
micron with lid & pan)
2. Oven
3. Balance 0.01 g accuracy
4. Tray
5. Brush
6. Mechanical sieve shaker

5.0 DETAIL PROCEDURE:

1. Take 500 gm of oven dried soil passing 4.75 mm sieve.

2. Put this soil in a tray containing water for a period of 2-4 hours
3. Wash the soil on 75 micron sieve by stirring the soil on sieve.
4. Continue to pour the water till water passing the sieve is substantially clear.
5. Oven dry soil mass is sieved on above sieve as per apparatus and record the weight get passing
of on 75 micron sieve.
6. The percentage of soil retained on each sieve shall be calculated on the bases of the total mass
of soil sample taken.

Acceptance criteria: Soil having different % variation in grain size gives identification of
different types.

28
 DETERMINATION OF FREE SWELL INDEX FOR SOIL

1.0 PURPOSE :

To establish the procedure for the Free Swell Index

2.0 SCOPE :

The SOP covers the test for the determination of free swell index of soils which help to identify /
further detailed investigation.

3.0 REFERENCE DOCUMENTS: IS-2720 (Part XL – 1977

5.0 APPARATUS :

1. 425 microns sieve

2. Graduated cylinders – 2 Nos. 100 ml capacities.

5.0 DETAIL PROCEDURE:

a. Take two – 10 (g) soil specimen of oven dry soil passing through 425 micron IS sieve.
b. Each soil specimen shall be poured in each of the two glass (gradated) cylinder of 100
ml capacity.
c. One cylinder shall be filled with kerosene oil and other with distilled water up to 100 ml
mark.
d. By gentle shaking the soil in both the cylinder shall be allowed to settle up to 24 hrs to
attain equilibrium state of volume without disturbing the both cylinder.
e. The final volume of soil in each of the cylinder shall be noted.
Vd - Vk
The free swell index = --------- x 100
(FSI) Vk
Where Vd = Volume of soil read from cylinder with distilled water
Vk – Volume of soil read from cylinder with kerosene.
Acceptance criteria = Maximum 50%

29
 DETERMINATION OF CBR FOR SOIL

1.0 PURPOSE:
Laboratory determination of CBR to establish the procedure for the testing of CBR
2.0 SCOPE:
The SOP covers the mould preparation for CBR, Testing of CBR & interpretation of CBR reports.
3.0 REFERENCE DOCMENTS: IS – 2720 (Part 16) - 1987
4.0 APPARATUS
1. Moulds with Base plate, stay rod & wing
nut with collar. 9. Graduated cylinder
2. Spacer Disc. 10. CBR Apparatus
3. Metal Rammer 8. Perforated plate
4. Expansion Measuring Apparatus (Swelling)
5. Weights
6. Loading Machine with plunger
7. Dial gauges
5.0 PROCEDURE:
(A) MOULD PREPARATION
a. First find out moisture density relation of soil, as per IS:2720 (Part-8)
b. Take soil sample of about 5000 gms & add water in it as per OMC found.
c. Fill the 3 CBR mould in 5 layers with 55 blows with 4.9 kg hammer.
d. Put filter paper on mould with spacer disc on it.
e. Put surcharge weigh of 5 kg on prepared mould & put those mould into water tank for
soaking.
f. Put Expansion Measuring apparatus on those moulds & take initial reading.
(B) TESTING OF CBR:
a. Take out CBR moulds after 4 days soaking & get air dried for 15 minutes, check swelling
gauge reading.
b. Place the CBR mould into CBR Testing machine & give the sitting load as per IS-2720
(Part-16) with penetration plunger.
b. Take the reading of loading proving ring (CBR machine) at 0,0.5,1.0,1.5,2.0,2.5,
3.0,4.0,5.0,7.5,10 & 12.5 mm penetration for all three moulds respectively.
c. Multiply the proving ring reading with proving ring factor (from calibration of loading
machine) which gives load values for diff penetration & mould.
d. Draw a graph between load v/s penetrations & make a smooth curve of it.
e. Take out the load values at 2.5 mm & 5.0 mm penetration for different moulds.
f. With use of formula.
PT
CBR = ------- x100
PS
Where PT- Corrected unit test load corresponding to the chosen penetration from the load penetration
curve and
PS – Unit standard load for the same depth of penetration as for PT taken from the standard
table.
Generally the CBR value at 2.5mm penetration will be greater than that at 5mm penetration and the
same value of CBR taken for design.

Acceptance criteria = Minimum 8 for soil & 30 for GSB

30
 DETERMINATION OF MOISTURE CONTENT BY RAPID MOISTURE METER

1.0 PURPOSE: To determine moisture content of soil

2.0 SCOPE: This SOP covers a method for rapid determination of water content from the gas pressure
developed by the reaction of calcium carbide with the free water of soil

3.0 REFERENCE DOCUMENTS: IS-2720 (Part-II) 1973

4.0 APPARATUS: -
1. Metallic Pressure vessel
2. Counterpoised Balance
3. Scoop
4. Calcium Carbide
5. Cleaning brush
6. Steel Balls

PROCEDURE:
1. Set up the balance. Place the sample in pan till the mark on the balance arm mark lines up with the
index mark.
2. Unclamp the clamping screw of the instrument sufficient to move the U-clamp off the Cup, Lift off
the cup & check that cup and body are clean, otherwise clean it using a brush.
3. Hold the body horizontal and gently deposit one level scoop full calcium carbide half – way inside
the chamber.
4. Transfer the soil weighed out as above from the pan to the cap.
5. Place the 3-smaller balls into the cup along with the soil and larger one in the body along with the
calcium carbide and clamp the U-clamp tightly.
6. Hold moisture meter vertical so that the material in the cup falls into the body. Now holding the unit
horizontal rotate it for 10 seconds so that the balls are rolled round the i/s circumstances of the body.
Rest for 20 seconds.
7. Repeat the rotation – rest cycle until the gauge reading constant – Note the reading.
8. Finally release the pressure slowly (away from the operator) opening the clamp screw and taking
cup out, empty the contents clean the instrument with a brush.
Acceptance criteria: The water content of the soil from the calibrated rapid moisture meter gives the
actual moisture content available in soil.

31
 DETERMINATION OF FIELD DENSITY BY SAND REPLACEMENT METHOD

1.0 PURPOPSE:

To determine the field density by sand replacement method.

2.0 SCOPE:

The method covers the determination, in-place of dry density (in g/cc) of natural or compacted soil.

3.0 REFERENCE DOCUMENS: IS – 2720 (Part – 28) 1974

6.0 APPARATUS

1. Sand Pouring cylinder

2. Tools for excavating holes – chisels, hammer, clamps, bent spoon and scrappers tools.
3. Balance - 30 Kg capacity
4. Metal tray with hole
5. Standard sand.
6. Rapid Moisture meter

7.0 PROCEDURE

a. Approx 450 mm square flat area shall be exposed and leveled.

b. The metal tray with central hole shall be laid on the prepared surface.
c. The hole in the soil shall be excavated using scrapped tools put excavated soil in tray to the depth of
the layer to be tested (max. depth up to 150mm)
d. Excavated soil shall be removed and weigh carefully.
e. Pour the sand in excavated trench and weight the remain sand in pouring cylinder.
f. After weighing cylinder is to be placed on excavated pit and shutter is opened till the sand fills the
excavated hole.
g. Care should be taken that there’s no further movement of sand in the cylinder then shutter is closed.
h. Weigh the sand pouring cylinder again and noted.
i. Moisture from excavated soil is checked by moisture meter.
j. Put all data in tabular format and get % of compaction.

Acceptance criteria:
Specification limits as per Subgrade & WMM, DBM
Embankment
MoRT&H Eart. Shoulder & BC
Minimum ( % ) 95 98 98

32
TESTS ON BITUMEN

33
 DETERMINATION OF SPECIFIC GRAVITY OF BITUMEN

STANDARD

 IS: 1202 – 1978

DEFINITION

 Specific gravity is the ratio of the mass of a given volume of the substance to the mass of an
equal volume of water.

APPARATUS

 Specific gravity bottle of 50ml capacity

 Constant temperature bath having a depth greater than that of Pycnometer capable of being
maintained within 0.2 0C.
 Balance of capacity 500grams and sensitivity 0.01gm.
PROCEDURE
 Clean dry and weigh the specific gravity bottle together with the stopper (A).
 Fill it with freshly boiled and cooled distilled water and insert the stopper firmly.
 Keep the bottle up to its neck for not less than half an hour in beaker of distilled water at a
temperature of 27 + 0.10C or any other temperature at which specific gravity is to be determined.
 Wipe all surplus moisture from the surface with a clean, dry cloth and weigh it (B).
 Bring the bituminous material to the fluid condition by gentle application of heat, care being taken
to prevent loss by evaporation.
 When the material is sufficiently fluid, pour the bitumen in to the clean, dry specific gravity bottle
to fill at least half.
 Slightly warm the bottle before filling the material
 Keep the material away from touching the sides above the final level of bottle and avoid the
inclusion of air bubbles.
 The use of small funnel will prevent contamination of the neck of the bottle.
 To permit escape of entangled air bubbles, allow the partly filled bottle to stand for half an hour at a
suitable temperature, then cool to the specified temperature, and weigh with the stopper (C).
 Fill the specific gravity bottle containing the asphalt with freshly boiled and cooled distilled water
placing the stopper loosely in the specific gravity bottle.
 Do not allow any air bubbles to remain in the specific gravity bottle.
 Place the specific gravity bottle in the water bath and press the stopper firmly in place.
34
 Allow the specific gravity bottle to remain in the water bath maintained at a temperature of 27 +
0.10C for a period of not less than 30 minutes.
 Remove the specific gravity bottle from the water bath, wipe all surplus moisture from the surface
with a clean dry cloth and weigh it along with the stopper (D.

Calculations
C -A
 Specific gravity = -----------------
(B-A) - (D-C)
A = Weight of specific gravity bottle
B = Weight of specific gravity bottle filled with distilled water.
C = Weight of specific gravity bottle about half filled with the bituminous material
D = Weight of specific gravity bottle about half filled with the material and the rest with distilled
water.

Report

 Express the ratio of mass of a given volume of the bituminous material to the mass of an equal
volume of water.

Acceptance criteria: Minimum 0.99 at 270C for 60/70 grade.

35
 DETERMINATION OF PENETRATION OF BITUMEN

STANDARD

 IS: 1203 – 1978

DEFINITION

 Penetration of a bituminous material is the distance in tenths of millimeter that standard needle will
penetrate vertically into a sample under standard conditions of temperature, load and time.

APPARATUS

 Standard Penetration apparatus

 A metal or glass cylindrical flat-bottomed container essentially with the following dimensions

For penetration below 225

Diameter 55mm
Internal depth 35mm
 Needle shall be made up of straight, highly polished, cylindrical, hard steel rod.
 Water bath 10 liters capacity thermostatically Controlled and maintained within the temperature of
25 + 0.10C.
 Thermometer capable of reading temperature up to 250 0C.
PROCEDURE
 Soften the material to a pouring consistency at a temperature not more than 60 0C for tars and
pitches and not more than 90 0C for bitumen above the approximate respective softening points.
 Stir it thoroughly until it is homogeneous and free from air bubbles and water.
 Pour the melt in to the container to a depth of at least 10mm in excess of the expected penetration.
 Protect the sample from dust and allow it to cool in atmosphere at a temperature between 15 to 30
0
C for 11/2 to 2hours for 45mm deep container and 1 to 11/2 hours for 35mm deep container.
 Unless otherwise specified carry out testing at a temperature of 25 + 0.1oC.
 Place it along with the transfer dish in the water bath at 25 + 0.10C and allow it remain for 11/2 to
2hours for 45mm deep container and 1 to 11/2 hours for 35mm deep container.
 Fill the transfer dish with water from the water bath to a depth sufficient to cover the mould
completely.
 Remove the transfer dish along with the mould from water bath after specified period of time and
put it upon the stand of penetration apparatus.
36
 Adjust the needle (previously washed, cleaned well with benzene and dried) just to make contact
with the surface of the sample.
 The sum of the weights of the needle, carrier and super imposed weights i.e. the total moving
weight shall be 100  0.25grams.
 Bring the pointer to zero.
 Release the needle for five seconds and measure the distance penetrated.
 Make at least three determinations at points on the surface of the sample not less than 10mm apart
and not less than 10mm from the side of the dish.
 After each test, return the sample and transfer dish to the water bath and wash the needle with
benzene and dry.
 In case of material of penetration greater than 225 make three determinations on each of two
identical test specimens using a separate needle for each determination, leaving the needle in the
sample on completion of each determination to avoid disturbance of the specimen.

REPORT

 Express the depth of penetration of the needle in tenths of mm. The value of penetration reported
shall be the mean of not less than three determinations whose values.
Acceptance criteria: Between 60 to 70 at 250C for 60/70 grade.

37
 DETERMINATION OF SOFTENING POINT OF BITUMEN

STANDARD

 IS: 1205 – 1978.

DEFINITION

 Softening point is the temperature at which the substance attains a particular degree of softening
under specified conditions of test.

APPARATUS

 Standard Ring and Ball Apparatus.

 Steel balls 2 No, each 9.5mm in diameter and weighing 3.5 + 0.05 grams.
 Brass rings 2 No, the rings shall be tampered and shall confirm to the following
Depth : 6.4 + 0.1mm
Inside diameter at bottom : 15.9 + 0.1mm
Inside diameter at top : 17.5 + 0.1mm
Outside diameter : 20.6 + 0.1mm
 Thermometer capable of reading temperature up to 0 to 250 0 C.
 Water bath should be a heat resistant glass vessel not less than 85mm in diameter and 120mm in
depth.
 Stirrer shall be manual or mechanical to ensure uniform heat distribution at all times throughout the
water bath.
PROCEDURE
 Heat the material to a temperature between 75 to 100 0C above its softening point.
 Stir until it is completely fluid and free from air bubbles and water, and filter if necessary, through
IS sieve 30.
 Place the rings, previously heated to a temperature approximately to that of molten material on a
metal plate, which has been coated with a mixture of equal parts of glycerin and dextrin.
 Fill the mould with sufficient melt to give excess above the level of the ring.

Remove the excess material with a warmed sharp knife after cooling in air for 30 minutes.

Assemble the apparatus with the rings, thermometer and ball guides in position

38

Fill the bath to a height of 50mm above the upper surface of the rings with the freshly boiled
distilled water or pure glycerin at a temperature of 5 0C.

The water bath liquid shall be freshly boiled distilled water when testing materials having softening
points below 80 0C and pure glycerin for material having softening points above 80 0C.
 There shall be exactly 25mm difference between the bottom of the rings and the top surface of the
bottom plate of the support, if any, or the bottom of the bath.
 Maintain the bath at a temperature of 5 0C for 15 minutes after which place the balls previously
cooled to a temperature of 5 0C by forceps in each ball guide.
 Apply heat to the bath and stir the liquid so that the temperature rises at a uniform rate of 5 + 0.5 0 C
per minute until the material softens and allow the balls to pass through the ring.
 Record the temperature shown by the thermometer for each ring and ball at the instant the sample
surrounding the ball touches the bottom plate of the support, if any or the bottom of the bath.

Report
 Report to the nearest 0.5 0C the mean of the temperature recorded in duplicate as the softening point.
Acceptance criteria: Between 45 to 55 for 60/70 grade.

39
 DETERMINTION OF DUCTILITY OF BITUMEN
STANDARD
 IS: 208-1978.
DEFINTION
 The ductility of bituminous material is the distance in centimeters to which it will elongate before
breaking when a briquette specimen of the materials is pulled at a specified speed and at specified
temperature.
APPARTUS
 Testing machine
 Mould made up of brass
 Water bath preferably with a thermostat, 10lit capacity and maintained with in 0.1 0C of the specified
temperature
 Thermometer 2500C capable of reading up to 0.010C.
PROCEDURE
 Unless otherwise specified this test shall be conducted at a temperatures of 27 + 0.50C and at a rate
of pull of 50 + 2.5mm /min.
 Melt the bitumen to be tested to a temperature of 75 to 100 0C above its approximate softening point
till it becomes fluid.
 Assemble the mould on a brass plate and coated on all the sides with a mixture glycerin and dextrin
of equal parts to avoid sticking of the material.
 Fill the mould until it is more than level full.
 In filling the mould, pour the material in a thin stream back and forth from end to end of the mould.
 Leave it to cool room temperature for 30 to 40 minutes and than place it in water bath maintained at
a specific temperature for 30 minutes.
 Cut off excess bitumen by means of hot straight edged putty knife level full.
 Place the brass plate and mould with briquette specimen, in the water-bath and keep at the specified
temperature for about 85 to 95 minutes.
 Remove the briquette from the plate, detach sidepieces and test the briquette immediately.
 While the test is being conducted, make sure that the water in the tank of the testing machine covers
the specimen above by at least 25mm and is maintained continuously with in +0.50C of specified
temperature.

40
 Attach rings at each end of the clips to the hooks in the testing machine and pull the two clips apart
horizontally at a uniform speed as specified until the briquette ruptures.
 Measure the distance in centimeters through which the clips have been pulled to produce rupture.
 At least three determinations shall be made for each test.

REPORT
 Report the average of three normal tests as ductility of the sample, provided that, the three
determinations be with in + 5% of their mean value.
 If the value of three determinations do not lie with in + 5% of their mean but the two higher value
are with in + 5% of their mean, then record the mean of the two higher values as the test result.

Acceptance criteria: Minimum 75 cm at 270C for 60/70 grade.

41
 DETERMINATION OF FLASH POINT FOR BITUMEN

STANDARD

 IS: 1209 – 1978 (3).

DEFINITION

Flash Point
 The flash point of a material is the lowest temperature at which the application of test flame cause
the vapors from the material momentarily catch fire in the form of a flash under specified conditions
of test.

APPARTUS

 Pensky Martens Closed Tester consisting of cup, lid, stirring device, cover shutter and flame
exposure device etc.
 Low range thermometer -7 to +1100C and capable of reading up to 0.50C.
 High range thermometer 90 to 3700C and capable of reading up to 2 0C.

PROCEDURE

 Clean and dry all parts of the cup and its accessories thoroughly before the test.
 Take particular care to avoid the presence of any solvent used to clean the apparatus.
 Fill the cup with the material to be tested up to the level indicated by the filling mark.
 Place the lid on the cup and set the latter in the stove.
 Take care that the locating devices are properly engaged.
 Insert the thermometer, high or low range, as required.
 Light and adjust the test flame so that it is of the size of a bead of 4mm in diameter.
 Apply heat at such a rate that the temperature recorded by the thermometer increases between 5 to
60C per minute.
 Start stirring at a rate of 60 revolutions per minute.
 Apply the test flame at each temperature reading, which is a multiple of 10C up to 1040C.
 For the temperature range above 1040C, apply the test flame at each temperature reading, which is a
multiple of 20C

42
 Apply initial test flame at least 170C below the expected flash point.
 Apply the test flame by operating the device controlling the shutter and test flame burner so that the
flame is lowered in 0.50 seconds, left in its lowered position for one second, and quickly raised to
its high position.
 Discontinue stirring during the application of test flame.
 Carefully observe the surface of the material during heating.

REPORT

Flash Point

 The flash point shall be taken as the temperature read on the thermometer at the time of the flame
application that causes a distinct flash in the interior of the cup.

Acceptance criteria: Minimum 1750C for 60/70 grade.

43
 DETERMINATION OF ELASTIC RECOVERY TEST ON CRMB

SCOPE
This procedure is mainly intended to access degree of bitumen modification and quality of modified
bitumen.

PURPOSE
Test intended to optimize dose of polymeric and/or rubber additive in bitumen and help in accessing
quality of PMB/RMB in laboratory.

APPARTUS

 Ductility machine with moulds

 Thermometer
 Scissors
 Scale
 Hot plate
 Water bath

PROCEDURE

 Prepare three test specimens for one sample by heating CRMB at 163+/- 50C on hot plate.
 Pour the heated sample of CRMB in the moulds for test and keep at room temperature for 30 to 40
minutes and than place it into water bath at 150C trimming up to 30minutes.
 Place brass plate and moulds after with briquette specimen up to about 85 to 95 minutes at 15 0C
after trimming.
 Elongate the test specimen in specified rate to a deformation 10cm at a rate of 5+/-0.25cm per
minute at 150C temperature.
 Immediately cut the test specimen in to two halves at the midpoint using the scissors.
 Keep the test specimen in the water bath in an undisturbed condition for one hour at 15 0C
temperature.
 After one hour time period, move the elongated half of the test specimen back position near the
fixed half of the test specimen so that the two pieces of modified bitumen just touch.
 Record the length of the recombined specimen as X.
 Calculate the percentage/elastic recovery by the following procedure.
10-X
 Elastic recovery (%) =-------- x 100
10
Acceptance Criteria: Minimum 50%

44
 DETERMINATION OF SEPERATION TEST ON CRMB

SCOPE
The separation of modifier and bitumen during hot storage is often seen and this can be evaluated
by comparing the ring and ball softening point of the top and bottom portion of sample taken from
crumbed rubber modified bitumen in a sealed tube.

REFERENCE DOCUMENTS
IRC-SP: 53-2002

APPARTUS
 Softening point apparatus
 Aluminium tube, Freezer, Rack
 Oven, thermometer, Spatula & Hammer

PROCEDURE

 Place the empty tube (with sealed one end down) in rack.
 Heat the CRMB sample at 163+/-50C and pass the molten sample of CRMB through IS sieve
600microns.
 Pour the sample of 50 (g) into vertically held tube.
 Fold the excess tube over two times and crimp and seal.
 Place the rack containing the sealed tubes in a oven at 163+/-50C temperature for 48+/-4 hours.
 After 48+/-4 hours remove the rack from the oven and put it into freezer at 6.70+/-50C.
 After remove the tube from the freezer place the tube on the flat surface and cut the tube into three
equal lengths with knife.
 Discard the center portion of the sample and place the top & bottom in position of the tube into
separate beakers.
 Place the beakers into a 163+/-50C in oven until the bitumen is sufficiently fluid and after
thoroughly stirring, pour the samples into appropriately marked rings, for ring and ball softening
point test.
 Prepare the ring and ball apparatus accordingly to test method IS: 1205 and top & bottom sample
from the same tube should be tested at the same time.
 Difference in the o
C temperature, between the softening points of the respective top & bottom
samples in average of three specimens.
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Acceptance Criteria: Difference between softening points between top & bottom sample
should not be more than 40C.

TESTS ON ASPHALT MIX

46
 DETERMINATION OF BINDER CONTENT FOR ASPHALT MIX

STANDARD
 IRC: SP 11 –1988 (Appendix - 5), ASTM D 2172.
OBJECTIVE
 To determine the binder content in the asphalt mix by cold solvent extraction
APPARTUS
 Centrifuge
 Balance of capacity 500 gram and sensitivity 0.01grams.
 Thermostatically controlled oven with capacity up to 2500C.
 Beaker for collecting extracted material.

PROCEDURE

 Take exactly 500 grams of representative sample and place in the bowl of extraction apparatus
(W1).
 Add benzene to the sample until it is completely submerged.
 Dry and weigh the filter paper and place it over the bowl of the extraction apparatus containing the
sample ( F1 ) .
 Clamp the cover of the bowl tightly.
 Place a beaker under the drainpipe to collect the extract
 Sufficient time (not more than an hour) is allowed for the solvent to disintegrate the sample before
running the centrifuge.
 Run the centrifuge slowly and then gradually increase the speed to a maximum of 3600 rpm
 Maintain the same speed till the solvent ceases to flow from the drainpipe.
 Run the centrifuge until the bitumen and benzene are drained out completely.
 Stop the machine, remove the cover and add 200ml of benzene to the material in the extraction
bowl and the extraction is done in the same process as described above.
 Repeat the same process not less than three times till the extraction is clear and not darker than a
light straw colour.

47
 Collect the material from the bowl of the extraction machine along with the filter paper and dry it to
constant weight in the oven at a temperature of 1050C to 1100C and cool to room temperature.
 Weigh the material ( W2 ) and the filter paper ( F2 ) separately to an accuracy of 0.01grams.
 Weight of extracted filler shall be note as (W4) grams.

Calculations
W1 – (W2 + W3+ W4)
 Percentage of binder in the total mix = ---------------------------- x 100
W1
W1 = Weight of sample taken
W2 = Weight of sample after extraction
W3 = Increased weight of filter paper ( F2 – F1 )
W4 = Weight of extracted filler

REPORT

 The result obtained shall be reported as the percentage of binder content in the mix to the nearest
second decimal.
Acceptance Criteria: For DBM (Grade-II) - 4.5% min.
For BC (Grade-I) - 5-6%
For BC (Grade-II) - 5-7%

48
 DETERMINATION OF STABILITY ON ASPHALT MIX

STANDARD
 MS-4 1989, ASTM D 1559 and AASHTO Designation: T 166 – 78.

OBJECTIVE

 To determine the stability and flow of compacted asphalt mix.

APPARATUS
 Marshall Testing Machine
 Compaction pedestal consisting of a 200x460x460mm wooden post capped with a 305x305x25mm
steel plate.
 Compaction mould consisting of a base plate, forming mould and color extension. The internal
diameter of forming mould should be 101.60mm and a height of approximately 75mm.
 Compaction hammer consisting of flat circular tamping face 98.40mm diameter and equipped with
4.50 Kilogram weight constructed to obtain a specified 457mm height of drop.
 Mould holder consisting of a spring tension device designed to hold compaction mould in place on
compaction pedestal.
 Pans, metal, round, approximately 4 liters capacity for mixing of asphalt and aggregates.
 Thermostatically controlled oven and electrical hot plate.
 Scoop, mixing spoon, trowel and spatula.
 Mechanical mixer (optional) of 4lits capacity equipped with two metal mixing bowls and two wire
stirrers.
 Thermostatically controlled water bath
 Gloves and welders for handling hot equipment.
 Marking crayons.
 Extrusion jack for extruding compacted specimens from mould.
 Balance of capacity 10 kg’s and sensitivity 0.5 gms and of such a type and shape so as to permit the
basket containing the sample to be suspended from the beam and weighed in water.

49
 Wire basket of not more than 6.3mm mesh or a perforated container of convenient size preferably
chromium plated and polished, with wire hangers thickness not less than 1mm.
 A stout watertight container in which the basket may be freely suspended
 Two dry soft absorbent clothes each not less than 650 cm2

PROCEDURE

 Prepare test specimens either from Laboratory mix or from plant mix or from paved surface.

Preparation of Mix in the Laboratory

 Take representative sample of aggregates and dry to constant weight at 1050 to 1100C.
 Separate the aggregates by dry sieving in to desired size of fraction.
 Weigh in to separate pans for each test specimen the amount of each size of fraction required to
produce a batch that will result in a compacted specimen of height 63.5 + 1.3 mm which is
generally of 1.20kg including asphalt percentage.
 It is generally desirable to prepare a trial specimen prior to preparing aggregate batches.
 If the trial specimen height falls out side the limits, the amount of aggregate used for the specimen
may be adjusted as follows
63.50 (Mass of aggregate used)
Adjusted mass of aggregate = -------------------------------------------

Specimen height (mm) obtained

 Place the pans in the oven or on the hot plate and heat the aggregates to a temperature of
approximately 280C above the mixing temperature
 Heat the asphalt cement to a temperature not more than 1600C.
 Charge the mixing bowl with heated aggregates and dry mix thoroughly.
 From a carter in the dry blended aggregates and weigh the required amount of asphalt cement in to
the mixture accordance with the accumulative batch weights.
 The temperature to which the asphalt must be heated to produce viscosity of 170 + 20 centistokes
shall be taken as the mixing temperature.
 Care shall be taken to maintain temperature of aggregates and asphalt cement be with in the limits
of the mixing temperature.
 Mix aggregates and asphalt cement, preferably with a mechanical mixer or by hand with a trowel as
quickly and thoroughly as possible to yield a mixture having a uniform distribution of asphalt
through out.

50
Preparation of Mould and Hammer

 Thoroughly clean the mould assembly and heat the face of the compaction hammer in a boiling
water bath or on the hot plate to a temperature between 930C and 1490C.

Compaction of Specimens

 Place a piece of waxed paper cut to size in the bottom of the mould before the mix is placed in the
mould.
 Place the entire batch in the mould.
 Spade the mix vigorously with a heated spatula or trowel 5 times round the perimeter and 10 times
over the interior.
 Remove the collar and smoothen the surface to a slightly rounded shape.
 The temperature of the mix immediately prior to compaction shall be with in the limits of the
compaction temperature.
 Replace the collar, place the mould assembly on the compaction pedestal in the mould holder.
 Apply either 75 blows as specified according to the design traffic category with the compaction
hammer using a free fall of 457mm. Hold the axis of the compaction hammer as nearly
perpendicular to the base of the mould assembly during compaction.
 Remove the base plate and collar, reverse and reassemble the mould.
 Apply the same number of compaction blows to the face of the reversed specimen.
 After compaction, remove the base plate and allow the specimen to cool in air until no deformation
will result while removing it from the mould.
 Remove the specimen from the mould by means of extrusion jack and then place on a smooth level
surface until ready for testing.
 Marking shall be done on the specimens for identification.
 Leave the specimens to cool over night.

Stability and Flow

 Immerse the test specimens in a water bath maintained at 60 0C + 10C for 30 to 40 minutes before
commencing the test.
 Thoroughly clean the inside surface of the testing head.
 Temperature of the testing head shall be maintained within 21 0C to 37.800C using a water bath
whenever required.
 Lubricate guide rods with a thin film of oil so that upper test head will slide freely without binding.
51
 Check the dial indicator of the dial gauge to be firmly fixed and set to zero load position.
 With testing apparatus ready, remove test specimen from water bath and carefully wipe the surface.
 Place the specimen in the lower testing head and center, and then fit the upper testing head into
position and center complete loading device.
 Place flow meter over marked guide rod and set the needle to zero.
 Apply load on the specimen at the constant rate of deformation 51mm per minute.
 The point of failure is defined by the maximum load reading obtained.
 Maximum load taken by the specimen at 600C shall be recorded as its Stability value.
 Note the flow meter reading immediately when the load begins to decrease in load meter.
 This reading is the flow value of the specimen, expressed in units of 0.25mm.
 The entire procedure, both Stability and Flow tests, starting with removal of specimen from the
water bath and testing shall be completed within a period of 30 seconds.
 Measured Stability values for specimens that depart from the standard 63.50mm thickness shall be
converted to an equivalent 63.50mm value by means of conversion factor from the Table.
 Average the flow values and the converted Stability values for all specimens.
Table: Stability Correlation Ratios

Thickness of specimen, in mm Correlation Ratio

58.70 1.14
60.30 1.09
61.90 1.04
63.50 1.00
64.00 0.96
65.10 0.93
66.70 0.89
68.30 0.86

Note*
The measured stability of a specimen multiplied by the correlation ratio for the specimen thickness
equals the corrected stability for a 63.50 mm specimen.

REPORT
 Report all the test results density, voids, stability and flow in a typical format.
Acceptance Criteria: For DBM (With Bitumen grade 60/70) - 917.43 Kg min.
For BC (With CRMB-60) - 1200Kg min.

52
 SWELL TEST ON ASPHALT MIX

STANDARD

 MS-4 1989

OBJECTIVE

 To determine the swelling of the compacted specimen under specified conditions of the test.

APPARTUS

 Mould of height 127mm and inside diameter 101.6mm tripod of height 170mm suitable to fix for
the mould of 101.6mm diameter.
 Dial gauge sensitivity to 0.025mm.
 Deep aluminum pan of size 194mm x 64mm
 Perforated bronze plate with adjustable stem.
 Graduated scale capable of reading up to 1mm.

PROCEDURE

 Compact the asphalt mix in to the mould as specified in MS-4 1989

 Allow the mould to cool at room temperature for at least one hour (This is done to permit rebound
after compaction).
 Place the mould and the specimen in the aluminum pan.
 Place a perforated bronze disc on the top of the specimen.
 Position tripod on the mould with dial gauge reading 2.54mm.
 Introduce 500ml of water in to the mould and measure distance (H) from top of the mould to the top
of the water with a graduated scale and keep the set up undisturbed for 24 hours.
 After 24 hours again read dial gauge (R1) and record the change.
 Also measure the distance (H1) from top of the mould to the top of the water with graduated scale
and record the change as permeability or the amount of water in millimeters that percolates in to and
/ or through the test specimen.
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CALCULATIONS
R1 – R
 Swelling, (%) = -------------
R
R = Initial dial gauge reading
R1 = Final dial gauge reading
 Permeability = H - H1
H = Initial height of water from the top of the mould
H1 = Final height of water from the top of the mould

REPORT

 Report the amount of swelling to the nearest second decimal and permeability to the nearest 1mm.

PRECAUTION

 Do not disturb the specimen during the period of swelling.

Acceptance Criteria: For BC (With CRMB-60) - 1.5% maximum

54