THE SABA ENGINEERING PLC CENTRAL MATERIAL TESTING LABORATORY Addis Ababa Manual of Soil Testing Part IT Ayehutsega Awgchew 25 November 2002 ESQ, : P 8 7B 6D nat crams erm trie = Oho. SABA ENGINEERING pawate umirep company 080 62688; Tel. 89 08 68 301086 | 301409 901750 999004; Fox 991200 91617 nui sibeeag@etionetat Website: www so engioaing.com ‘Ads Abb, EilePreface This manual intended primarily describes the procedures and as working manual for field and laboratory technicians engineers and other engaged on the testing of material such as. Rock, Aggregates, Cement and Asphalt in laboratory for civil engineering such as high was (Roads) dam, air port, bridge, rail ways and seaport etc Purposes. ‘The test procedures are based on BS, ASTM and AASHTO standard for laboratory and field testing of aggregate, cement Asphalt and concrete. It is based of may own experience over many years both in managing large Aggregate, Asphalt, Cement and Concrete (most of through Ethiopia) material testing laboratory and in the instruction of technicians and graduated engineers and others in test procedures. The step ~ by — step presentation of procedures and test result examples, the use of test data examples flow diagram and calculations are provided for this purpose, especially for the trainees and new comers to material testing Manual part II presents details of the methods in Los Angeles Abrasion, Aggregate crushing value, Impact value, specific gravity, unit weight sieve analysis, cement quality test, asphalt quality test and concrete test. Most of these procedures are covered by Bs, ASTM and AASHTO standards. May Ihope that the manual giving back ground information, basic theory and general applications will enable engineers and technicians to obtain a better appreciation of the purpose and significance of the tests they perform. T hope that this part II manual will be well used in the laboratory and field and I should we come any comments and criticism from those who use it. Ayehutsega Awgchew Head SABA Eng. C.Lab] | Ea | TABLE OF CONTENT LAdsLivereo~r"] Page Introduction. ROCK onsen 143, Aggregates .. 153 Cement... 156 Bitumen... 163 TESTS Rock (Stone) «.. 165 Agerevatel Flakiness Index 167 Elongation... . 168 Aggregate Crushing Value..... 169 Aggregate Impact Value 170 Ten Percent fine Value . in Sodium and Magnesium Sulphate Soundness Definition .... 74 174 Specific Gravity Unit Weight. Fineness Modules. Organic Impurities ... Cement Quality Test Water Consistency of Cement 178 Time of Setting by Vicat Necdle . 180 Time of Setting GillMore Needle 181 Compressive Strength of Cement (Morter} L183 Sand Mortar 1185 Conerete... a 185 Sieve Analysis of Fine and Coarse Ageregates 197 Coarse Abgeregate by Abrasion 209 Soundness of Aggregate 23 221 Gradation Example With Grading ChartWor Example (Lab 223 224 225 Loss Angeles Abrasion Test. Ageregate Crushing Value... Aggregate Impact Value... Sodium or Magnesium Sulphate Soundness...... Solubility of Asphalt.......... . 230 Loss on Heating of Oil and Asphaltic Compound ... 233 Test for Flash and Fire Points... 236 Penetration of Bituminous........ 240 Ductility of Bitumious.... 246 SAYBOLT - Viscosity .. . 249 Kinematic Viscosity Asphalts 0 253 Distillation of Cut — Back Asphalt..... -. 253 265 Extraction of Bitumen... 270 Stripping of Bitumen.....| ] AGGREGATES : ; “ INTRODUCTION 7 Rock i J A rock forms portion of earth's crust having no definite shape or chemical composition. It is usually a mixture of two or more minerals and is not homogencous. Geological classification of rock:- Rocks classified into three main categories. 1, Metamorphic Rooks 2. Sedimentary Rocks 3. Igneous Rocks q 1. Metamorphic Rock:- Due to structure changes in carth igneous or sedimentary rocks find the airway deep in earth where they are subject to high temperature and heavy pressure which cause changes in texture or in mineral composition or in both resulting in the formation of new types of rocks known as metamorphic rocks - Granite or Igneous ~ changes to ~Gneiss q ~ Sandston or Sedimentary — changes to- Quartzite, u - Lime stone or Sedimentary — changes to - marble. = Shale or Sedimentary ~ change to - slate 2. Sedimentary Rocks:- Surface of earth is subjected to the destructive action of rain frost, | winds and chemical actions. These destructive agents break up the surface of earth, which gets further broken up when carried ] down by rains and rivers. In the journey of river from mountains to sea the velocity goes on decreasing ad the river moves further. l ] ‘As the velocity of river decreases so it goes on depositing the debris carried by it. The heavier ones being the first to be } deposited followed by the deposit of smaller and finer ones, Sand and silt get deposited in the voids of deposited debris - the latter having the binding properties, Due to seasonal variations the material are deposited in layers. The deposit in layers continues fur millions of years in which period the deposited layers subjected to enormous pressure of over lying layers and of uy 143aT 3. Igneous Rocks: flowing water get consolidated forming stratified sedimentary or aqueous rocks. Sand stones and limestones belong to this class Sedimentary rocks are often well stratified and show well defined bedding planes. These rocks can be split and cleared easily both in the bedding direction and normal to the bedding planes giving building blocks of fairly regular shape. Properties of sedimentary rocks vary considerably depending upon the nature of sediment and the type of bonding that exists between the adjacent sediment grains, Sand stone formed by consolidation of sand deposits consist primarily of small rounded grains of silica, The sand stone will be relatively soft or hard depending upon the nature of binding material Inner layers of earth are at such high temperatures thet masses of silicates melt. This molten mass, known as magma is forced up. Magma solidifies into rocks when it reaches the surface of earth and forms Basalts and Traps. If however, the magma solidifies before reaching the surface of earth it forms solid crystalline rock known Granite. Rock is obtained from quarries Stone, Gravel, cobbles and sand produced from Rock. Uses of Stone: preparing conerete required for For road, building, railways construction for s and reinforced foundations flooring, hollow and solid blocks, artificial stone: conerete. For blocks and slabs, face work of buildings requiring architectural treatment arious other ‘As limestone, it is used in the manufacture of lime. cement and in v chemical processes. Characteristics of stones (Rock, Lt. Ha Iis the resistance of stone to abrasive forces caused by mach wear and friction as in floors. pavements and aprons of bridges and w ess:- weirs in rivers. 144Ceo mM 13. 16. Ease of working:- The ease with which the stone can be worked upon ie. Cut, dressed, carved and moulded etc... is on important consideration from economy point of view. But this property is opposed to strength durability and hardness Porosity and absorption:- More porous stones are unsuitable for use in construction especially for exposed surfaces of structures. Rainwater while coming down carries some acidic gases forming light acids, which lodge on the surface of stones and soak in them. Acids react with the constituents of stones causing them to crumble. In cold regions water freezes in the sores of stones This water causes the disintegration of stone because of its increase in volume on freezing, Weathering:- Is the extent to which the face of a sione resists the action of weather, The best way of knowing the use the rings made with the same quality of stone possibly’ in the near by place or at a place having similar atmospheric conditions. Inspection of an old face of some quarry could also be informative, Heaviness:- Heavier varieties of stones are more compact, less porous and have greaten specific gravity. Constructions in water, like weirs, dams and retained walls. Strength: In usual constructions the stones used are generally quite stones t© with stand the forces likely to be encountered yet in case of construction where unusually bigger forces are likely to come the stone to be used should be tested for its strength. Stones of igneous class are generally stronger them those of the sedimentary class. Stones with compact fine crystalline texture are stronger. ‘Appearance:- For the face wok of curve stone, building and others this property is of extreme importance from architectural point of view color of the stone should be such as to go well with surroundings. Lighter shades should be preferred to the darker ones, as the latter are less durable. Red and the brown shades of sedimentary rocks are due to the presence of oxide of iron ~ which, it present in excess is liable to disfigure the stone with rust stains and to disintegrate it. Stones should be of uniform colour and free from clay holes, bands or spots of colour what so ever. 145| aa co co c 2, Quarry: Quarry is open my 22 1, Excavating: 3. Heating:- is obtained part (Area) of the natural rock form which useful material Quarrying:- Is the art of taking stones of various sites from natural rocks. Purpose of quarrying: - is to obtain different stones for mas concrete, Asphalt, base course surfacing etc... of Road. construction and any other purpose. Four methods in common quarrying is done. 23.1, Excavating 2.3.2. Wedging 23.3. Blasting 23.4. Heating The method is employed when stones to be quarri earth or under losses over burden. Chisles etc: stone blocks are quarried by this method. is started near a vertical face in the absence of w! ‘This method is suitable for quarrying soft stratified rocks. sonry. Aggregate for for part and other ied are lying buried in Shovels: Pickaxes. Hammers and are made use of for the purpose. On wesi coast lateritice The operation hich one is created by cutting a channel init, Then 10 cm to 1Sem deep holes about 10cm apart are bores pluge are then struck with heavy steel hammers call This method is suitable where only smaller blocks shape are required and suitable rocks bedded in h much thickness are to be quarried, It consists in pilin small area of the hours, ‘The loosened portion is then broken into si aid removed with pickaxes and crowbars. 146 exposed face of rock and burning 4 or drilled along the boundary of the slab to be quattied. Stee! led sledge hammers. of more or less regular horizontal layers of not heap of fuel on a ua steady fore for some smaller pieces as desired4 Blasting:- It is quarrying stones with explosives. Blasting may sometimes have to be done to excavate foundations for roads, buildings and dams structures in rockwork. The purpose of blasting for quarrying is to loosen large masses of rocks and not to violently blow up the whole mass causing the breakage of stones into small pieces of on use. The operation of blasting constitutes the boring or drilling of holes changing them with same suitable explosive and then firing the change. Precautions to be taken while blasting 4.1.1 Responsible person should satisfy himself that all the changes have riploded by comparing the number of changes fined with the number of explosions heard. Incase ofa misfire necessary precautions should be taken 4.1.2 All fuses should be cut to proper lengths before inserting them into holes. 4.13 Blasting operations should not be carried out in evenings or in early mornings it should be done at fixed hours made known to the public. 4.14 Before actual firing, siren should give timely working to workman and others to retire to safety. 4.1.5. Red danger flags should be prominently displayed at a safe distance of about 200 meters all round the area of explosion. 4.1.6 Cartridges should preferably be handled with rubber or polythene gloves on. 5. Explosives used in Quarrying 5.1 Gun cotton. 5.2 Dynamite 5.3 Gun powder 3. Cause of Deterioration of Rock or stone, 3. By the chemical and physical changes brought about by various agencies weather, 3.1.1. Frequent drying and wetting of stone by rains and sun causes internal stresses there by resulting in the disintegration of stones. 3.1.2 {t materials having different physical characteristics are used together then they may cause mutual decay. 1473.1.3. Temperature variations. At places where temperature variations are too much : or too frequent, stones if used. Would crumble because of the setting up of 4 internal stresses. Stones should not be used at such places. 3.1.4 Frost at very cold place causing its deterioration. I 3.1.5 Wind Dusty winds cause deterioration of stones because of the abrasive effect of dust particles. Also winds force rainwater and frost to enter the pores of stones deeper resulting in deterioration of stone. 3.1.6 Vegetable growth: Roots of tress that penetrate the joints of stone masonry keep stones damp and seotete organic and acidic matters which cause deterioration of stones. n 4 ‘Types of Rock (stone Itis igneous rock (stone) In 4.1 Basalt Rock Characteristies Ithas black, red, yellow, gray, darkgrey, green, and blue colures. 1 ul 2. It weather well 3. Itis hard, compacted and durable, good surface on dressing. { 4. It is heavier than granite ~ 5. Its compressive strength is 150 to 300Ke/mm* 7 6. Its specific gravity 2.6 to 3.00 by 7. Bulk density about 2.8 ~ 3.00 g/ee : 8. Resistant to abrasion and low absorption of water: L 9. Suitable for masonry work and rain for cement concrete work. 4 10. Very good for Concrete, Bitumen and gravel road and building construction. 4.2. Granite It isa useful structural and ornamental rock(stone) because of its high ] compressive strength, durability and resistance to wear and abrasion n and characteristics | Origin, composi ILis an igneous rock composed it quartz and mica Ivis durable, strong and hard unstratified Rock (stone) ¢ grained i 2 3. Itis crystalline and fine to c« 4. Iteracks badly under fire U 148=) — oa 3 ao mo co J eo =] 5. 6 1 8 9 Its colour depends upon the colour of felspar that it contains. Fine grained granite takes high polish It is difficult to work upon hence costly and unsuitable for ordinary Road. building and down wor Its compressive strength is 100 to 250 Kg/mm’. Bulk density about below 2.80 gee 10. Suitable for masonry work and concrete work, 11. Very good for bitumen's and concrete pavement. Sedimentary Rock 43,2 Lime Stone = 4.3.1 Quartzite 1. Reasonably hard and durable 2, Fine to medium grain site colour 3. Light brown or pinkish 4. Low absorption of water 5. Resistance to abrasion 6. High Bulk density (Reasonably) 2.5 ~2.8e/ce 7. Good for base course, bitumen and concrete pavement work 8. Suitable for masonry work 9° Suitable for R.C.C. work Origin and composition. It is sedimentary, stratified calcareous respectively. small portions of silica, magnesium carb containing calcium carbonate ad magnesium carb: quantities are known as dolomites Characteristics 1. It is good hard and for use in industrial areas Liable to polish to a smooth surface under traffic Good quality of it is fairly durable 4. Its usual colours are white gra and black. 5. Its texture is bedded, granular and fine grained 6. ts compressive strength is 30 to 250Ke/mm?, Good for base courses Unsuitable for wearing surfaces because of polishing characteristics. es 149 and It consists chiefly of calcium carbonate with yonate, iron and clay. Stones jonate in equal durable for road building and others But unsuitable | pink, red, blue, brown, green, yellowI Cc 3 a 9. Fine grained 10. High water absorption I. Bulk density low in the range. 1.90 ~ 2.2glec Uses:- It is used in the manufacture of lime, cement, blast furnaces, bleaching, tanning and other industries. It is used as road construction of not very important building, 4.3.3. Sand Stone:- Origin and composition - It is sedimentary . stratified rock which according to chemical classification is silicious. It contains grains of sand cemented together by calcium carbonate. Besides almost all sand stones contain oxide of iron upon which depend their colour. Carbonate of magnesia and aluminum are the other usual constituents. Characteristics 1. Itis porous 2. Itweathers well 3. Good quality sand stones are suitable for all types of road dam and building work 4, Itis easy to work upon and is particularly suited for carved work 5, Itisasoft and moderately stratified stone and fine'to coarse grained 6. The more # sand stone is free from lime and iron the more durable it is 7. Itisavailable in red, gray, yellow and blue colours. 8. Moderately hard and durable 9. Fine to medium grained 10, Bulk density in the range 2.3 to 2.7e/ce Uses:- Fine grained sand stones are good for curved work. Good weathering sand stones are used for all types of road, building work. ‘Though not very suitable yet at times it is used as road. 44. Later cous according to chemical classification. It is a sandy clay stone agri high percentage of oxide o| colour. Decomposition of basalt and other rocks. 150 Origin and_composition :- It is a metamorphic rock which is n because of which it gets deep brown or red3 co am Oo co c oo 7 Cc oom =) Ps Characteristics thas a porous and cellular structure It is not fit for use at places subjected to action of water or heavy loads Itis soft and easy to work upon. Ithas black, red, deep brown and yellow colour. It can be easily quarried in blocks suitable for use as road dam and building work Spongy porous open texture Water absorption very high 5-25% Bulk density varies from 2.2 to 2.8 g/cc Soft to medium hard, losing strength when it absorbs moisture 5S PS wane Chalk: [tis pure white lime stone. easily powdered and hence unsuitable for building purposes. Used in the manufacture of Portland cement and making of gluteus putty. It is also used for marking and as colouring matter. 4.6. Marble Origin and composition: - It is a metamorphic rock. Physical and chemical classifications being sedimentary and calcareous respectively. It contains calcium carbonate. Characteristics 1. Itis tine to course grained, massive, crystalline and granular in texture. 2. Itis quite hard and takes a fine polish 3. Itcan be easily carved 4. Good marble is extremely durable Its compressive strength is 100 to 250 Kg/mm* 4.7 Serpentine origin and composition: - It is derived from igneous rocks Characterii 1. [tig compact but soft and can be easily worked upon It does not weather well and is affected by smoke. Uses:- [tis used in the construction of superior buildings and for interior decoration works 1514.8 Moorum:- It is decomposed laterite and is available in the vicinity of late rite quarries where it is collected as red earth. It is of orange to pinkish colour. ‘These are water worn pebbles of and kind of stone and are up to 7.5 4.9 Gravel om in diameter, Usually found in riverbeds or in alluvial tracts. These are used for road blind age, surfacing and in concrete. 4.10 Shingle:- These are water worn pebbles of any kind of stone and bigger in site than gravel. It too is found in riverbeds and alluvial tracts. It is used as road metal and in concrete. 4.11 Kankar origin and_composition:~ It is an impure form of lime stone containing about 30 % of clay and sand. Soft to medium hard. good for sub base and base. 4.12 Slate origin and composition: It is a metamorphic stone and is agrilace according to chemical and sedimentary according to physical classification. It is ous usually composed of alumina mixed with sand or carbonate of lime and sometimes with carbonaceous matter. Characteristics 1. It is hard and touph. It gives metallic ringing sound when struck with a hammer 2. Iti fine grained and less absorbent Good slate is uniform in colour and free form patches, purple, blue, black, green and gray are the usual colours of slate 4, These are hard and touph to touch 5, These can be easily split in to this laminate 6. _ Its compressive strength is 100 to 200 Kg/mar a lis specific gravity about 2.6 to 2.8 Uses:- Roof covering, flooring, damp proofing, shelves. and for making electrical switch boards. Its non-absorbent nature, it is used in baths ete: 4.13 Gypsum:- White in colour and soft and highly abraded absorbs water (0 a high degree. It has a low density (2.2 to 2.5Kg) 152co Aggregates Ageregate materials uncrushed or crushed derived from the natural sources such as gravel, boulders, sand and rocks. Aggregate are inext materials. These shall consist of naturally occurring stones, gravel and sand and shall be hard, strong, dense, free from veins, adherent coating and integrated pieces and deleterious substances. durable, clear and injurious amounts of dis Aggregates shall not rials such as laminated, pyrites materia, alkali, seashells, contain in excess harmful mate Aggregates are classified organic impurities and those which may attach the reinforcement, as coarse fine and cyclopean aggregated. the size of whose particles is bigger than N® 4 (4.75mm) 1. Coarse Aggregate sieve smaller than 3 inch (75mm) es. are knowin as coarse ags Following are the coarse aggregates commonly used Ll. Stone ballast 1.1.2. Gravel or Shingle 1.1.3. Breeze and Clinker 1.1.4. Brick ballast LiL, Stones ballast It is and excellent aggregate, stone ballast to be used for preparin 2 conorete should be free form organic matter Granite, sand ed lime stones are well suited for the purpose. It is stone and close grain used for making asphalt and concrete in the construction of roads and building and others. 1.12. Gravel or Shingle- Th Being hard and durabl ese are obtained from river beds, quarries and sea shores. le these are extensively used as an aggregate in the preparation of concretes. 1.13. Brick ballast:- Broken brick is used a5 @ course aggregate in lime concrete at places where aggregate from natural resources 'S either not available or is expensive. It is a good substitute for stone aggregate nt good bricks are available in sufficient 16-24 hours sttould not ‘When well bu quantity. The aggregate after immérsion in cold water For s weight of water, The ballast should be absorb more than 25% of it ¢ using it in preparing the concrete thoroughly saturated with water befort 153Aggregates should not contain any harmful material like clay. organic importing, alkali, iron pyrites, shale, coal, mica, soft fragments and seashells etc. In such quantities as to impair the strength and durability of the asphalt and concrete work. Also the aggregates should not be chemically reactive with cement. 2. Fine aggregate :- Particles of fine aggregates pass through N° 4 (4.75mm) ] sieve and retained on N° 100 (0.15mm) sieve. Most commonly used fine aggregates are sand, crushed aggregate (stone) ash and cinder. Sand:- It consists of small grains of silica and is formed by the disintegration of rocks caused by weather. u 4 2.2. Type of sand :- The source from which sand is obtained itis classified as u 2.2.1. Quarry sand:- It is found as deposits in soil and has to be 4 excavated out angular and sharp in grains U 22.2. River Sand: It is obtained from the rivers beds and banks. It may 9 be fine or coarse. Coarse sand is clean and is excellent for all purposes. - It consists of fine rounded grains of brown colour and 2.2.3. Sea sand: is collected from sea beach. It contains salt, which attracts moisture from the atmosphere, and couses disintegration of he work in which it is used. It could be tised locally after it has been thoroughly washed to remove the salts. 2.2.4. Crushed rock (stone):- It is obtained from crushil quarries to the particle site of sand waste rock of I 2.2.5. Quality of good sand:- 1. It should be well graded that is should contain in suitable proportions particles of various sizes It should be free from silt, clay or any such salts. The grains of sand should be hard strony and durable, Good sand should have coarse and angular grain of pure silica It should not contain any organic and clay etc. 154| 22.6. Standard sand:- Standard sand (calibrated sand) used in testing cement quality and others are = It shall be well grated, : It shall be angular, shape of grains approximating to { spherical form, sharp, elongated and flattened grains being ud present in negligible. In 3. Itshall be free from clay, silt and dust | U 4. Itshall be of quartz, light gray or whitish variety colours lay 5. Shall be washed and treated U 6. It shall be passed 0.850mm and retained 0.60mm sieves or passed 0.60mm and refined 0.30mm sieves n 7. It shall be free from organic impurities loss of weight on extraction with hot hydrochloric acid shall to exceed 22.7. Grading requirement for fine aggregate u eve size (mm percent passing - 95 100 fi 4.75 95 - 100 - 2.36 90 - 100 fi 118 70 - 100 u (0.6mm(600Micron) 40-100 nl 0.3mm (300Micron) 5-70 J 0.15mm(150Micron) 0-15 22.8. Bulkage:- Volume of sand fluctuates with the variations in its moisture content . When the sand or fine aggregate is wet than particle gets & ‘ch due to surface tension keeps them apart there by coating of water whi .¢ volume of sand. This increase in volume due J causing an increase in th to the sand being wet is known as Bulkage of sand. Bulk age increase with the increase in moisture contents. At 4% U moisture content, the increase in volume is about 25%. It decreases in moisture till it becomes zero (0) when the water with the increase in the coarser fine is more than 20%. Finer sand is more bulk age than i aggregates. In measuring sand by volume its bulking due to moisture content should be taken,[ u co ae 3, 3.1, Cement is the main bondi CEMENT ing material used in Bridge, Building, dam Airport, Road ete construction. Manufacture of Portland cement ~ chemical composition of port land cement ~ natural, port land and aluminous cements are the three main natural groups. Compounds of lime are the main elements having the basic property of cementing Portland cement is obtained by mixing of calcareous (limestone or chalk) and argillaceous (clay or shale containing silica and alumina) materials, burning the mixture at clinkering temperatures and psum in to a fine powder. grinding the clinker along with some The name Portland cement, given originally due to the resemblance of the colour in Dorset has remained throughout the world to this day to describe a cement obtained by intimately mixing together calcareous and argillaceous or other silica, alumina , and iron oxide, bearing materials, burning them at aclinkering temperature, and grinding the resulting clinker. However for use under specific Ordinary port land cement: Its quick conditions a variety of cements are available these days. th which it can be used under pt of construction It was first of all setting property, strength and ease wit variety of conditions has revolutionized the conce and male it the most popular cementing material. introduced in 1824 by Joseph Aspdin, a brick layer of leads, England on setting, the colour of cement resembles the colour of rocks near Portland in England and hence the name of this cement ome type of cement: Ordinary Portland cement (OPC) White port land cement (WPC) Sulphate resisting port land cement (SRPC) Low heat port land cement (LPC) Rapid hardening Portland cement (RRHPC) Portland ~ pozzolana cement (PPC) 156ae ooo aoono 3 c mo 1 3 Cc am msc om) Extra rapid hardening Portland cement (ERHPC) Pozzolana cement 3.2 Composition of Cement:- Approximate composition of row materials used for manufacturing ordinary Portland cement is 2 Calcium oxide (Ca 0) = 601065 % Silica (Si Os) 0 10.25 % Aluminum Oxide (Al; 02) =4 to 8% Ferrous Oxide (Fe2 03) =2t04% Magnesium Oxide (Mg 0) 103% L. Ordinary Portland cement :- This is by far the most common cement in use: about 90% of all cement used in the world, Ordinary Portland cement (Type 1) is suitable for use in general concrete construction work when there is no exposure to sulphates in the soil or in ground water. Portland cement is obtained by mixing of calcareous (lime stone or chalk) and clay or shale containing silica and alumina materials, burning the mixture at clinkering. temperatures and grinding the clinker along with some gypsum into a fine powder. Process of cement: Wet process:- Broken raw materials are mixed with water In separate wash mills to from fine mixtures. “The mixtures are screened, mfxed in appropriate proportions and the resulting slurry is pumped into storage tanks. ‘The slurry is kept under constant stirring against any sedimentation, The slurry having proper proportions is fed in to a rotary kiln, Pulverized coal, which gets burned in kiln, is blown in from the other end of the 1573m C kiln, The slurry as it moves down in the kiln dries and finally forms into clinker. The clinker is than lat through cooling chambers and after wards pulverized in ball — mills along with gypsum. The powder ground to a satisfactory level is separated as cement. The crushed raw materials in appropriate The + Dry_process:~ proportions are ground into fine powder in a grinding mill dry powder is blended into a fine mixture in @ blending silo with The granules also called pellets are the help of compressed ai baked by hot air and fed into a rotating kiln where the material undergoes some chemical reactions when exposed to high temperature (1300" to 1500%). ‘The clinker formed in the kiln is cooled and ground with gypsum in ball mills. The powder ground to satisfactory level. Diagram Rapid high ~ early strength cement :- The strength developed by rapid hardening cements in about 3 days is almost equal to that of the ordinary cement developed in 29 days. Its initial and final setting times are the same as those of ordinary cement. It contains more of tri - calcium silicate and is more finally ground. ts used early loads e.g. repair of bridge and roads ete, It is move costly than the ordinary cement. Its compressive strength is 24 hours age not less than 15.7 Mpa (157Kg/em*) 72- hours not less than 27 Mpa (270Kg/em’) it is quick setting cement. It sets faster than the ordinary Portland cement, Its initial setting time ig Sminutes and final setting time is 30 minutes. It is always the danger of concrete having under gone initial setting during mixing and placing. White Portland cement:- It is a white colour , chalk or lime stone which is used as a raw e from impurities and very little of oxides of iron and manganese material needs to be fre ies as those of Portland cement. should be permitted to make white cement. It's some properti Grayish colour of ordinary cement is due to iron oxide. It is much more costly than ordinary erally used for architectural and decorative purposes and Is cement. White cement is g generally meant for non-structural use. 158U co f u co FLOW DIAGRAM OF CEMENT MANUFACTURE Lime Stone Wet Process Clay Clinker Elevator (Storage Bunker Clinker grinding Cube Eleveators (Cementsilos) —— ‘Weighing and [packing | > ‘Supply 159 ‘Washing (Wash ‘Water Preliminary Crushing mils) Elevators (Storage Elevators (Storage ere Bankers) Water Ball wi (Wet ee Gliding) Raw Slurry, 1 Lime slurry Elevations Clay sun tee {storage Tanks) a Correction Crashed (all Tanks mils) Rotory kiln Pulverised | | |ca co Hydraulic Portland cement = It is 2 finely ground material which on addition of appropriate quantity of water 1s capable of harding both under water and in air by chemical interaction of its constituents. This cement is used in the construction of structures under water, The cement floats on water for a period of not less than 24hours. Compressive strength is the same as of ordinary Portland cements, High strength ordinary Portland cement = ‘This cement is used for prestressed concrete and certain items of precast concrete, where cement having compressive Sting mach higher than of ordinary Portland cement. [ts initial setting time is not more than 30 minutes and 0 hours compressive strength of this cement is 72 hours .nd 168hours (7days) not less than 33Mpa final setting time is not more than 1 (days) age not less than 23Mpa (230Kg/em’) ai (33 ‘Air entraining Portland cement: It is ordinary Portland. cement mixed with small quantities of air entraining materials at the time of grinding Usual air entraining materials used are resin, vinsol resin, oils, fats and fatty acids, yinsol resin and darex, are most ave the property of entraining air in the form of fine alr commonly used. These materials hi jrkable and bubbles in concrete. These bubbles render the concrete more plastic more more resistant to freezing, However, because of ait entraining the strength of concrete reduces and as such the quantity of air so entrained should not exceed five percent Heat generated by cement while setting may cause the sructire to crack Low heat cement: percentage of Tri-calcium im case of concrete. Heat generation is controlled by keeping the silicate low. Its inital setting time shall not be less than 60 The rate of its developing aluminate and of Tri-calcium minutes and final setting time shall not be more than 10 hours strength is very slow. {tis not very suitable for use in ordinary structures, when not only the use of structure shall be delayed but also the shuttering shall have 19 be kept for long and curing shall be prolonged. High alumna cement: - It is of black colour and resists well the attack of chemicals especially of sulphates and of sea water. Its ultimate strength ig much higher than that of ordinary Portland cement, ts initial setting time is not less than 30 minutes and final setting st 10 hours as & time not more than 10 hours. Most of the heat is given out by it in the firs 160oo c | u oa 0 result of which it can be conveniently used in freezing temperatures but is used in thin layers in normal temperatures. Compressive strength of this cement is 24 hours not less than 30 Mpa (300Kg/em*) 72 hours (Sdays) not less than 35 Mpa (350Kg/em’) It should not be used in locations where temperature exceeds 18%. It should not mixed with other types of cements. Portland slag coment:- It is obtained by mixing Portland cement clinker, gypsum and granulated slag in proper proportions a Portland cement with the following improvements, ind grinding it finally. This cement has properties very much similar to those of ordinary Ithas better resistance to acid water Ithas lesser heat of hydration It has better resistance to soils, sulphates of alkali metals, alumna and iron. Compressive strength = 72 hours (3days) not less than 16 Mpa (160Kg/em*) 168 hours (7days) 22 Mpa (220Kg/em*) Is produced either by grinding together Portland 3.2.2 Portland pozzulana cement: blending Portland cement clinker and pozzolona , or by intimately and uniformly cement and fine pozzolana. Pozzolona is a siliceous material, which reacts with lime Cement producing by in the presence of moisture producing calcium silicate. addition of grinding Portland cement clinker and pozzotona together _ with be obtained by uniform blending of the Portland cement gypsum. It can also with fine pozzolana, The percentage of poz: 30 percent and it is usually around 20 percent pumi zolana in such cements varies form 10 to icite and shales. volcanic Portland- pozzolana d diatomaceous earth have pozzolanic properties. to the attack of ashes ani cement produces less heat of hydration and offers greater resistance It develops the strength at a lower rate in the same tune of for aggressive waters. ordinary cement with extended period of moist curing. Its particularly useful mass concrete construction hydraulic and marine structures 161true as of cement cht era eats nando iewet pred tema Make ane thermos canna bbl aft the weg sale STORING CEMENT Everyboos ows that cement must be kept dey. but itis not albsays realized tho: damp aie c1n do as much harm as direct moisture The lengtls of time at cement can be stored-and-then used sotiw fuctorily depends mainly on the storage container and climatic ditions, Cesnent stored in airtight tins will Keep indefinitely: stored in bull ins silo Kept in good condition, it sill sill be satisfactory up te about three months. However, cement ia the normal 3:ply paper stored under good conditions can lose signiticant strerigth (about 26) after 4 to 6 weeks. ‘Comes delivered in bays should be inspected as itis placed in the store, Torn bags of bags showing signs of damp should not be 162‘ae Fineness not to exceed 3000 em2/g_ Le chatelter Soundness not to exceed 10mm by Le chaterier method. Setting time initial not less than 30min final not more than 10 hours [ee Compressive strength at 7 days (Mpa) = 22 l 3.2.3 Pozzolana :- is a siliceous material which when finely divided reacts with lime in moist condition producing calcium silicate, Cements are produced using pozzolana material such as pumicite diatomaceous clay certain shale's and clays fly ash, etc n u 4. BITUMEN MATERIAL fn Bitumen is defined as a non ~ crystalline solid or viscous material, having adhesive | os properties derived from petroleum either by natural or refinery process and substantially | i 1 soluble in colour and may occur naturally. but are usually made as end products from distillation of or as extracts from selected petroleum oils i u 4.1 Some properties of bitumen:- | n «Bitumen is insoluble in water a * Itis highly impermeable + Itis chemically inert \ U «It is contain predominantly hydrocarbons, with small quantities of | Sulphur, Oxygen, Nitrogen and metal l + It is predominantly soluble in carbon disulphide the portion insoluble in carbon disulphide the portion insoluble in Csp_ being generally less than | f 01% Ago 0 ‘Asphalt (Bitumen) divided in to tow parts. | f 1. Asphalt (Bitumen) cement :- Its solid asphalt natural no added solvent and unbread U by using solvent agent asphalt cement grading by using penetration 5 penetration grades asphalt cement for use in road, Air port and other construction = | 40 to 50 601070 | A) 85 10 100 | = : 120 to 150 180 to 200 | i U 200 to 300 ‘Asphalt cement shall be prepared by the refining of erude petroleum by suitable methods Lests carried out for these asphalt cement grades. J 163 |am i] anw ww 1.1. Penetration 1.2. Solubility 1.3. Ductility 1.4. Flash point 1.5. Loss on heating 1.6. Water content 1.7, Spot test Cut Back Asphalt :- In certain cases. a portion or fraction of the distillate is mixed with the residue at the close of distillation which is termed “cutting back" the object of which is to modify the properties of residual product or to dispose economically of a fraction which other wise has little value commercially. They have the advantage as compared to straight —run asphalts. that they can be used with cold aggregates and with a minimum of heat. When a low building solvent such as naphta or gasoline ot kerosene is used to temporarily soften or cut-back the residual asphalt the liquid asphalt produced like called. 1. Rapid - curing (RC) 2. Medium curing (MC) 3. Slow curing (SC) RC (Rapid-Curing Asphalt) ;- In this case the solvent will rapidly evaporate after its use leaving only the asphalt cement. solvent used gas oil (benzene) MC(Medium Curing Asphalt) :- A cut-back asphalt when this type of liquid asphalt is used the solvent will to evaporate as rapidly as the gasoil range solvent used in the manufacture of RC ~ cut back type of solvent is kerosene SC(Slow Curing Asphalt) ;- A cut - back asphalt when this type of liquid asphalt is used the solvent is oil. This is slow curing (SC) cut ~ back asphalt. Since the solvent in this case is a semi volatile material it requires much longer time for curing, There are 5 types of liquid asphalt in different grades 1645 TESTS Grade Uses MC ~ 30 Prime coat MC - 250 Tack coat MC ~ 800 Road mix MC ~ 3000 Surface treatment RC- 70 Tack coat RC ~ 250 Tack coat Rock (Stone) A 5.12 Compressive Strength :- Stones or Rocks are dressed to give them a definite and regular shape with smooth faces. The required test specimens are dressed and shape with the site of 100,150 and 200mm cubes. Inthe compression test, the cube is placed with the dressed faces or casts in content with the platens of the testing machine ie. The position of the cubes when tested is at right angles to that Lg'~ dress or cast. The load on the cubes should be applied at a constant rate of stress equal to 15Mpafmin, Because of the non-linearity of the stress ~ strain relation of rock at high stresses, The rate of increase in strain must be increased progressively as failure is approached ie. the speed of the movement of the head of the testing machine has to be increased. This can be done only with a hydraulically operated machine. ‘Apparatus :~ - Chisle Hammer = Angle tron, . Scale - Compression machine = Balance block shall conform to the following The spherically seated beat face of the requirements. ‘The maximum diameter of the bearing f 165= {| eee) ea) | a suspended spherically seated block shall not exceed the values given below Diameter of Test | Maximum Diameter Specimens mm | of Beering face mm St 102 76 127 102, 165 152 254 203 279 rock (stone) = Prepare the test - Dress by using Chisle Measure the cube an equal four equal size either 100,150 or 200mm - Make smooth and an even surface = Put the finished cube on the machine platen ~ Start and operate the machine Placing the cube (Specimen) = Place the plain (lower) bearing block, with its hardened face up on the table or platen of the testing machine directly under the spherically seated (upper) bearing block. Wip and clean the bearing faces of the upper and lower bearing blocks and of he test specimen and place the test specimen on the lower bearing block carefully align the axis of the specimen with the center of thrust of the spherically seated block. Rotate its movable portion gently: by hand so that uniform seating is obtained. Apply the load continuously and without shock. If the machine type is serew the moving head shall travel at a rate of approximately 1.3 mm/min when the machine is running idle, For hydraulically operated machines the load shall be applied at a rate of movement corresponding to a loading rate on the specimen within the range of 0.14 to 0.34 Mpa Apply the load until the specimen during the test 166y C 3 ml Cc ae i eo) ea) (cee eel — a 5.1.4: - Calculation Compressive strength = Load Area Area of cubes = Lx Bx H But for cylindrical area = Id? 4 If the specimen length to diameter ratio is less than 1.8 correct the result by multiplying by the appropriate correction factor shown in the following table. 117s 098 | 5.2. Aggregates ‘An aggregate containing both fine and coarse aggregates is called all in aggregates. Aggregates divided in two parts ‘A. Coars= Ageregate:- Natural gravel river gravel crushed gravel crushed rock and crushed stone. It's size above 4.75 mm. = Natural sand, river sand, Desert sand, wind and natural deposit sand and Artificial sand produced from crushed rock, stone, gravel. It's size bellow 4.75 mm. i B. Fine — Ageregat 5.2.1. Flakiness Index :- The shape of the aggregate for use in the conerete asphalt and oihers should not be flakiness that is, thin and oblong. The flakiness of an aggregate is indicated by sieving the aggregate through a set of sieves having oblong openings Flakiness index is the total wight of the sample: st portion. If 5.2.1. Sample preparation :- Reduce the sample to produce te n dried at the test sample un clean shall be washed and over 167105 to 100 °C and allow the sample to cool and weigh ; : the sample Nominal size | Minimum of ofsample | test portion (am) sample (kg) 50 35 ao co co ae co co 52.1.2. Procedure :- Discard all aggregates retained on the 63mm sieve oo and all aggregate passing 6.3 mm sieve weigh cach of the individual size retained on the sieves. and store them in co trays. From the masses of the fractions in the trays (wl) calculate the individual percentage retained on each of the n Ju various sieves. Discard any fraction whose mass is 5% or f) Jess of mass (wl). Record the mass remaining (w2). | ° Select the gauge appropriate to the size-fraction under test ip] and gauge each particle of that size fraction separately by ie hand. Combine and weight all the particles passing each of the gauges (w3) Calculation Flakiness Index F = W3 x 100 w2 3 ined on various length 5.2.2. Elongation: - It is the total weight of the material reta gauges, expressed as'a percentage co * Elongation index = wi/w2 co 168, — i)} —7= Sone ooe Cc ca co co co aon oe = 5.2.3. Aggregate crushing value > Samplin Apparatus :- sieves, compression machine. Straight edg, tamping rod Where W2: the sum of the masses of fractions that have a mass greater than. 5% of the total mass WI: the mass of all the elongation particles. (Passed) through the elongation apparatus. The strength of an aggregate depends on the te. Aggregate crushing nature of the base rock, size and shape of the aggregat ecify the strength value and impact value are the usual indices used to sp quality of an aggregate General += The aggregate crushing value gives a relative measure of the resistance of an aggregate to crushing under a gradually applied compressive Joad with aggregate of an aggregate crushing value higher than 30 the result may be anomalous and in such cases the 10% fine value. If the sample size greater or less then 14 to 10 mm sieve or size is not available test may be performed on the optional.size aggregate passing @ 14 or-12.5 mm sieve and retained on 10mm or 9.5 mm sieve or passing 28 mm retained 20 mm sieve or passing 20mm retain 14 mm, ~ | Sieve Fraction mm (Passing After test) 28-20 mm 5mm 7 For the sample smaller than ee eee 10mm cylinder mold may be 14-10 mm 2.36 used 75 mm diam and 57 x 90 3 mm 8 mm diam rod and with Noree ED applied force 100KN 63-5 1.18 5-335 0.850 3,35 -2.36 0.40 1g.:- Shall be free of clay or the lumps and any contamination ‘oven, mold and oven. 169Q cj Put the test apparatus on the box plate and add the test sample in thirds each third being subjected to 25 strokes from the tamping road over the surface of the layer and dropping form a height about 50mm above the surface of the aggregate. Label the surface of the layer and dropping from a height about 50 mm above the surface of the aggregate, Label the surface of the aggregate and insert the piston so that is rests horizontally on this surface taking care to ensure that the platen dose not jams in the cylinder. Put the cylindrical mold, with the test sample and piston in position between the platens of the testing machine and road it is as unilorm a rate as possible so that the required force is reached in 10 min. The required force shale be 400) kw. Release the load and remove the crushed aggregate by holding the mold oven a eléan tray and hammering on the outside with a suitable rubber mallet until the sample is sufficiently disturbed to enable the mass of the sample to fall freely on to the in side of the plunger to the troy by means of a brush. Sieve the whole of the sample on the tray on the No 8 sieve until no further significant amount passes in weigh the fraction: passing the sieve (mass A) Calculation: ACV or % fine = A/B x 100 Where : B= the mass of surface dry sample ‘A= the mass of the fraction passing the N® 8 sieve 5.2.4. Impact value test: - A relative measure of the resistance of an aggregate to sudden shock or impact. Impact value higher than 30 the result may be anomalous. Aggregate sizes larger than 14mm are not appropriate to the aggregate impact test ‘Apparatus Aggregate impact machine balance oven sieve Rod, mold and hammer. Sample preparation : Aggregate passing 14mm and retained on 10mm sieve ‘The aggregate shall be tested in a surface-dry condition. Oven drying shall not exceed 4 hours with their 170(eee sep ere) fe] co U a u temperature 105 to 110 °c and cool room temperature before testing. Grade of the Minimum aggregate mess of the sample 0 — 40 mm Max. 20 size 0 - 20 mm Max 15 size 40-5 mm 12 2010 5 mm Procedure: - Fill the measure to over flowing with the aggregate. Tap the aggregate with 25 blows fiom about 50mm above the surface of the aggregate. Remove surplus sample by rolling the tamping rod and remove by hand any sample, which impedes its progress, and fill any obvious depression with added aggregate. Record the net mass of aggregate in the measure and use the same mass for the second test specimen. Fall freely on to the aggregate to achieve a total of 15 blows at intervals of not less than 15, Remove the crushed aggregate by holding the cup over a clean tray and hemmering on the out side with the rubber malet until the particles are sufficiently loose to enable the specimen to fall freely on to the tray use a brush to remove the fine particles adhering to the inside of the cup and the underside of the hammer, Weigh the aggregate and tray (MI) Sieve the whole specimen in the tray on the 2.36 mm sieve. Weigh the mass to the fraction passing and retained on the sieve (M2 + M3). If the total mass (M2 +M3) differs from the initial mass MI by more than 19 discard the result and test a further specimen. Calculation: - Aggregate Impact Value (AIV) = M2/MI x 100 Where MI is the mass of the test specimen M2 is the mass of the material passing the 2/36 (N° 8) sieve 711 co 3 1 co co Soaked Condition Aggregate Crushing Value: Follow the dried bases procedure described above except that the number of blows of the hammer is the number of blows that yield between 5% and 20 % fines. However 15 blows may also be used for the soaked condition. Remove the crushed specimen from the cup and dry it in the oven at a temperature of 105 to 110 % for at least 12 hours. Allow the material to cool and weigh to the nearest 0.19m (M1). Sieve the whole specimen in the tray on the 2.36 (N28) sieve until no further significant amount passes. Weigh and record the masses of the fraction passing and retained on the sieve to the nearest 0.19m (M2 +M3). If the total mass (M2 + M3) differs from the initial mass M1 by more than 19m discard the result and test a further specimen. jon = M= MMI x 100 Catew Where = MI is the mass of the oven ~ dried sample M2 is the mass of the oven ~ dried material passing the 2.36mm sieve. M is mass of fine. Calculate the Aggregate Impact Value (AIV) AIV = 15m/n Where:- nis the number of hammer blows to which the specimen is subjected for both the dry condition and the soaked condition the mean of the two values shall be determined to the nearest whole number. The mean is reported as the Aggregate Impact Value, unless the individual results differ by more than 15% of shall be repeated for two the mean value. In this case the te more specimens. The median value shall be reported as the AV 5.2.5. Ten Percent Fines Value TFV (10%) The aggregate strength is also indicated by a load required for 10% fine oven dry sample similar to that used in the impact test is subjected to a specific penetration and the load for 10% is determined. ‘The test sumple shall be oven dried for not more than 4 hours. Allow to cool before testing. Sieve the oven 172,a] (= =) dried sample passing 14mm and retained 10mm sieve tamp each 3 equal layers by 25 times froma height of 50mm above the surface of the aggregate. Carefully level the surface of the aggregate and insert the plunger on the surface of the aggregate and insert the plunger on the surface of the aggregate. Place the mold on the compression machine. Apply force a total penetration of the plunger in 10min 15 mm depth for rounded or uncrushed aggregate 20 mm depth for crushed (normal) aggregate - 24mm depth for honey combed aggregate Transfer the tested aggregate from mold to clean tray and hammering on the outside with the rubber mallet until the aggregate sufficiently loose ta enable the specimen to fall freely on to the tray. Use a brush to remove the fine particles adhering to the inside of the cylinder. the base plate and the underside of the plunger. Record the max force (f) applied on the aggregate. Weigh the tray and the aggregate (WI) sieve the whole aggregate on the 236mm (N? 8) sieve weigh the passing and retained on the 2.36mmsieve (W2 + W3). If the total: mass (W2 + W3) differs from the initial weight (WL) by more than 10 gm discard the result and test again. Calculation = M= W1/W2 Where M = % of fine with in the range of 7.5 to 12.5% W2 = weight of sample afier test and passed on sieve 2.36mm WI = weight of sample before test and retained on.10 mm sieve and passed on 14mm sieve. If dose not fall within the range 7.5 to 12.5% test shall be adjusted maximum test loading t© bring the percentage of the required fines (Repeat complete test procedure) 173rom Follow the test procedure as above except that after the aggregate has dried at 105 - 110°c for at least 12 hours and Soaking Condition been removed from the mold it shall be oven ~ allow cool and weigh (W1) complete the procedure as above % fines calculation. Force (F) calculation :- Required to produce 10% fines, with percentage of material passing in the range 7.5 to 12.5% Lafiwed Where F = the max load (force) applied on the sample, K.14 W =the percentage of passing the 2.36mm sieve at max. Force Ee. % fine F=160 Ki Fe 160s 14 O44 5.2.6. Sodium and magnesium sulphate soundness test Coarse and fine aggregates when exposed to changes in temperature and weather tend to disintegrate into smaller particles. More disintegration implies less-sound in the aggregate, The soundness of an aggregate is measured by subjecting it to alternate wetting in saturated solution of sodium or magnesium sulphate and drying i in an oven through a set of cycles. The reduction in the particle size of this ageregate, which is obtained through a sieve analysis, indicates the soundness or un soundness of the aggregate unsoundness proportional to the absorption. The ratio of the mass of a unit volume of @ aggregate at stated 5.2.1. Specific gravity temperature 10 the mass of the same volume of gass-free distilled water at a stated temperature ¢ weight in air of a unit volume ofa 5.2.7.1 := Bulk specific gravity :- ‘The ratio of th permeable material 5.2.72:- Apparent specific gravity :- The ratio of the weight in air of @ unit volume of material at a stated temperature to the weight in air of equal density of an equal volume of gass-free distilled water at stated temperature. The apparent specific gravity is then the im,es) c ae — d in on oven at 105 to 110 °c to the ratio of the aggregate weight of water occupying a volume equal to that of the solid including the impermeable pores. Thus. in order to eliminate the effect of totally enclosed impermeable pores. Laboratory Test A. Coarse Aggregate. = Sample preparation :- The fine part of aggregate shall be passing through 4.75 and retained on sieve 4.75 mm. = Apparatus: - Soaking dish (Large) = Balance - Oven = Towel - Procedure: About 5000 g coarse aggregate shall be immersed in water for 16 ~ 24 hours al room temperature of 20 to 30%. Placed the saturated aggregate on a dry cloth or towel and surface dried with the h till the cloth’ removes no further moisture. - The test agaregate is then spread clot deep on another cloth and left exposed to atmosphere in a shall for.about one ston ten minutes by when they appear completely surface dry. - Calculation WI. Weight of saturated surfaced dried in air W2. Weight of saturated surfaced in water Bulk specific gravity = WL. e.g, Weight of saturated surface dried aggregate in air =5000z Weight of saturated surface dried aggregate in water = 3000g 5000 = 250 100-3000 Bulk specific gravity % Absorption 175,aoa oe «put the saturated surface dried Agg in the oven (5000 8) = Weight of oven dried Age = 4900 © Calculation = % Absorption 5000-4900 = 2% 4900 ts the mass of a unit weight of material a specified temperature. 5.2.8, Unit weigh “The units shal be stated such as grams per em’ (g/€e) oF pounds per cubic foot (Ubfeuft) or other. Laboratory Test :~ Apparatus Mold Balance Tamping rod ~ Sample tray Procedure a) Loose unit weight = Quarter the test sample. - Calculation A- Weight of the mold _ Put the Air dried sample in mold B- Weigh sample + mold (3 typs) Vv ~ Volume of mold Loose unit weight: B (Ave) =A = gee Vv Eg, Weight of mold = 3600 8 Weight of sample + mold = (Ave) ~ 90008 Jnt = 9000 ~ 36000 ~ 1.46 glee 3700 cc Unit by Rodded unit weight :- Aggregate shall be dried 176oy se Cee) ee eee eee =) Cc ato} ee eee “— co om A ~ Weight of the old _ Put the dried aggregate in mold and tamped 25 times in 1 2" and 3 layers B - Weight of the compacted Agg + mold. V - Volume of mold Rodded unit weight = B(Ave) =A v Volume of mold = 3700 ce Weight of rodded Aggregate + mold = 9600 Weight of mold = 3600 gm Fg. 9600 - 3600 = 1.62 glce 3700 Rodded unit weigl 2.9. Fineness = modules:- The sum of the cumulative percentage retained on each of sieves divided by 100 Fineness modules eg, Sieve size (mm) % Passing 9.5 100 = 45 96 (100-96) = 4 - 236 82 (100-82) = 18 118 4B (100-43) =57 0.60 18 (100 - 18) = 82 0.150 4 (100-4) = 96 Sum 257 Fineness modules = 257 = 2.57 100 52.10. Organic Impurities: Affect or organic Impurities in fine agercgsts O° strength of mortar, Test for color of transparent liquids, Apparatuts ~ Ovales - glass bottles 12 ounce, 350 ml graduated clear glass prescripti stoppers. ‘on bottles with rubber, Kork or Solution “ Sodium Hydroxide Solution (3%) Ge by 97 ce part of water. Sample preparation :- About 300gms ~ Air dried sample, 7C co co a C3 CO cc cj Oo Om ee co co co Procedure :- Filla glass bottle to the 4'/3 OZ (about 30ml) level with the sample of the sand. _ Add a 3% NaoH solution in water until the volume of the sand and liquid, indicated after shaking, 157 liquid, indicated after shaking, 157 liquid ounce. = Stopper the bottle, shake vigorously, and then allow to stand in air for 24 hours ~ Compared with a glass color plate having clors equal to the organic color No 1.2.3.4 and 5 11. Cement Quality Test S2U11 Water consistency of cement Apparatus - Scale (balance) = Graduates glass 200 to 250 ml capacity ~ Vicat needl (Apporatos) ~ Rod, 300g weighing ~ Conical ring diameter of ring Top side 60 mm , bottom 70 mm. height 40 mm ~ Glass plate about 100 mm? ~ Mixing bow! . - Weigh 600 g of cement ~ Place the dry paddle and the dry bowl in the mixing position in the mixer. B ~ Place all initial mixing water in the bowl ~ Add the weighed cement to the water and allow 3 seconds for he absorption to the water = Start to the mixer and mix at glow speed about 140 pm for 30 seconds. = Stop the mixer for 15 seconds and during Procedure = Weigh 500 g cement ~ Place the weighed cement on the glass plate shall be = Prepared a shape of hip and spot shape on the top of the biped position 178ft _ Add the initially measured water on the cement - ~ Allow 30 second to absorption of water I ] ~ Mix quickly with gloved hands for 90 seconds (1% min) - _ Toss six times through a free path of about 150 mm from on hand to mn L another s0 as to produce a nearly spherical mass that may be easily inserted in to the vicat ring. press the ball resting in the palm of one hand in to the larger and of the u , conical ring (G port ) Fig — | held in the other hand, completely filling fi the ring with paste. _ Remove the excess at larger end by a single movement of the palm of { the hand. 0 = Place the ring an its larger end on a plane none absorptive plate (4- Position) Fig — 1 and slice off the excess paste at the smaller end at the q top of the ring by a single oblique stroke of a Sharpe edged trowel held o at 4 plight angle with the top of the ring, and smooth the top part, with a few light touches of the pointed end of the trowel. During these operations of cutting and smoothing take care not to compress Or disturb the paste. = Center the paste confined in the rng, resting on the plate under the rod Fig ~ 1.B, the plunger end C - Fig of the paste, and tighten the screw E—Fig—1. Then set the movable indicator F- Fig -1, to the g upper zero mark of the scale, or take an inital reading and release the 4 rod immediately. This must not exceed 30 second after completion of u mixing. The apparatus shall be free of all vibrations during the test. 4 ‘The paste shall be of normal consistency when the rod settles {0 @ point C 10 mm below the original surface in 30-second after being released. Make trial pastes with varying percentages of water until the normal 1 with fresh cement. Deter consistency is obtained. Make each tril ine the required for hormal consistency of the nearest 0.1 % and a report it o the nearest 0.5 % of the weight to the cement 179me =) ca 5.2.11.2. Time of Setting. a) By v vicat needle. ‘Apparatus Balance Measuring graduated cylinder 200 to 250 ml Vicat Apparatus Procedure Place the dry paddle and the dry bow! in the mixing position - Weight 500 g cement Place the determined normal consistency of distilled mixing water in to the bowl introduce the weighed cement in to the bow! Allow 30 second be for mixing Start the mixer and mix at slow speed about 140 mm for 30 seconds Stop the mixer for 15 second and during this time serape down into the batch any paste that may have collected on the side of the bowl Start the mixer at medium speed 285 rpm and mix for | min. Quickly form the cement paste prepared as in toa ball with the gloved hands and toss six times from one hand to the other maintaing the hands and toss six times from on ¢ hand to the other maintaing the hands about 6.182 mm apart. Press the ball, resting in the pal -1, held in the im of the hand, into the larger end of the conical ring, G, Fig other hand, completely filling the ring with paste. Remove the excess at the larger and by a single movement of the palm of the hand, place the ring on its larger and on a glass plate, H ~Fig-1, and slice off the by a single excess paste at the smaller and at the top of the rir oblique stroke of a sharp ~ edged trowel held at a slight angle with the vop to the ring smooth the top of the specimen. with one or (wo Tight touches of the pointed end of the towel. During the operation of cutting and smoothing take care not to compress the paste Immediately after molding place the test specimen in the moist closet for moist room and allow it to ‘remain there exeept when determinations of time of setting and being made. The specimen shall 180b) remain in the conical mold. supported by the glass plot H- Figl, throughout the test period. A time of setting specimen and an autoclave bar may be made from the same batch. ‘Allow the time of setting specimen to remain in the moist cabinet for 30 min after molding with def heing disturbed. Determined the penetration of the | - mm needle at this time and every 15 min there after (every 10 min for type 3 cement) until a penetration of 25 mm or less is obtained for the penetration test, lower the needle D- Figl, of the road B ~ Fig! until it rests on the surface of the cement paste Tighten the set screw, eg. Figl, and set the indicator, F - Fig, at the upper end of the scale, or take an initial reading. Release the rod quickly by releasing the setserew, E ~ Figl and allow the needle to settle for 30 second, then take the reading to determine the penetration. If the paste is obviously quite soft on the early reading, the fall of the rod may be retarded to avoid bending the 1-mm needle, but the rod shall be released only by the set screw when. Actual determinations for the setting form are made. No penetration test shall be made closed than 9.5 mm from the inside of the mold Record the result of all penetration tests and by interpolation of 25 mmis obtained, This is the initial setting time. The final setting time is when the needle does not sink visibly into the paste. Time of setting by Gillmore needles Apparatus = Balance ~ Glass measuring (graduate) cylinder 200 to 250 ml - Gilmore needles Procedure . - Weigh 500 g of cement. Put the required percentage of missing water for normal consistency (determined) in sec Make a pat about 76 mm in diameter and 13 mm thickness at the center with a flat top and tapering to atin edge. On a flat. clean glass plate 18)70 —— about 102 mm square. In molding the pat, flatten the cement paste first oon the glass and then from the pat by drawing the trowel from the outer edge toward the center, then fattening the top. After making, place the J main there es pat in the moist closet or moist room and allow it tore except of time of setting are being made. In determining the time of setting hold the needles in a vertical position and apply lightly to the surface ofthe pate. Consider the hen the pat wills beav, with i ca co cement to have acquired its initial setting w! eciable in dentations, the initial Gill ore needle. Consider the with out out appr ave acquired its final set when the pat will bear, ! C2 cement to hi appreciable in dentition, the final gillimor needle. co 5.2.1.3. Compressive Strength Apparatus ~ Balance ~ Graduates measuring cylinder (suitable) = Specimen molds (mortar) = Tamper wooden and metal made - Trowel = Mixer bow! - Testing machine co co co com Sample Preparation _- Graded sand (standard) passing 0.850 and retained 0.600 mm sieve or | aia pring 0.600 retained 0.300 mm sieve. = Cement a Procedure co prepare mold and thinly cover the interior faces of the specimen molds co with mineral oil, ‘Alter assembling the molds, remove excess oil or grease from the vurfaces of each mold co interior faces and the top and bottom st = Weigh 500gm of cement Weigh standard sand 1375 gm (a ratio 71.2 75) col CC 182 co{ ona a) Cc co U moo nt ratio about 0.49 for non Air-entraining port land 1g water for other than port land and air - produce a flow of 110 + Use a water cemet cement, The amount of mi enter airing port land cements hall be such as 5 or (105 to 115) The quantities of materials to be mixed at one time in the batch of scimens shall be 500gm cement 1375 sand ing port land cement or other mortar for making six spe and for port land about 242 Air-entraini 230 ml by using flow table 105 to 115 Fill the mold with mortar and tamp first and. 2" Jayer 25 times each layer _ Cutoff mortar to plane surface or trime by using trowel. Wipe the flow tabletop side clean and dry. ng Lift the mold away from the mortar | min afier completing the mixin operation _ Immediately drop the flow table through a hei in 15 seconds. The flows is the resulting increase in average bs measured on at Jeast four diameters and ght of 12.7 mm 25 times ase diameter of the mortar mass, add the four diameter result the sum of four shall be in 105 to 115 range. Make trial mortars with varying percentage of water until the specified flow is obtained. Make each trial with fresh mortar, Allow the mortar to stand in the mixing bow! 90 seconds with out covering. During the last 15 second of this i have collected on the side of interval, quickly scrape down in to the batch any mortar that may the bowl. Then remix for 15 seconds at edium speed ~ Upon completion of mixing paddle shall be shaken to remove excess mortar into the mixing bow! Place the mortar in the mortar cubes mold a larger of mortar about 25 Tamp the mortar in each cube mm one half of the depth of the mold out 10 seconds in 4 rounds, each round (0 compartment 32 times in ab be at right angles to the other and consisting of 8 adjoining strokes over the surface of the specimen, During tamping of the second layer bring in the mortar forced out on to the tops of the mold s oved fingers and the tamper upon suffer cach round of tamping by means of the gl 183aa] (esa) J completion of each round and before starting the next round of tamping. Smooth off the cubes by drawing the flat side of the trowel ortar to a plane surface flash with the top of the mold by he trowel with a sawing motion over the Cut off the m drawing the straight edge of U length of the mold. Place the test specimens in the moist closet or moist room. Keep all test specimens, immediately after molding, in the molds on the base plates in the moist closet or moist room from 20 10 24 hours with their upper surfaces exposed to the moist air but protected from dripping water, Ifthe specimens are removed from the molds before 24 hours. keep them on the shelves of the moist claset oF moist room until the are 24 hours old. and then immerse he specimens, except those for 24 hours test. _ Keep the lime-saturated water in storage tanks constructed of nonecorroding materials. The storage water clean by changing 4S required. Compressive Strength Immediately after their removal from the moi: and from storage water in the case of all other - st closet in the case of 24 hours specimens, specimens. All test specimens fora given test age shall be broken, Mostly Age of mortar is 3, 7 and 28 days. Carefully place the specimen in the testing machine, An initial 4 up to one half of the expected maximum loads for specimens ximum loads of more than 3000 Ibf (135 leg) loadin having expected mai Joad up to failure. appl Calculation Record the total 3 Specimens for one test of maximum load indicated nd calculate the compressive strength in Mpa by the testing machine or kg/cm’, If the cross-sectional area of a specimen varies more than 184c aa Cc Seeeeee om mn oa a {] 2 percent from the normal, use the actual area for the calculation of the compressive strength. The compressive strength of all 3 or more acceptable test specimen shall be averaged and reported to the nearest 0.7kg/em? or 10PSI Compressive strength = Load Area 5.2.12. Sand mortar Refer all procedure from cement mortar procedure Except mm sieve and saturated surface dried, 1. River sand shall be passed through 9 Cement 600g and water cement ratio 0.6 or 360cc water, ‘Amount of saturated sand to be used the mix by trial controlling by trial of flow table using 4. Tamping in conical mold 10 times and flow table 20 times. 5. In cubes mold tamping 25 times in 2 layers. 52.13. Conorete te, coarse aggregate and Concrete is an artificial stone consisting of cement, fine aggregat aste to harden water, The water reacts chemically with the cement causing the water cement pi and thus to bind the aggregates particles together. “The strength of concrete depends entirely on the water cement ratio provided that 1. Suitable cement and aggregates are used. 2. The amounts of aggregates are such as to pr 3. Proper curing conditions are maintained during 1 joduce a workable mix the hardening period, In the design of concrete there are however some problems involved and these are |A) The selection of the proper water cement ratio B) ‘The selection of the suitable materials C) The determinations of the proper quant tities of fine and concrete aggregate test. ‘The better the gradation of aggregates ie. The smaller the volume of voids. the less cement paste is needed to fill these voids. Water is needed for 185mona a aoa OoO oO fe occ co for wetting the surface of the aggregates. As water is added. hydration and ry of the mix increases (ie its workability improves) the plasticity and fluidity but the strength decreases because of the larger volumes of voids created by the free water, To reduce the free water while retaining the workability cement must be added. There fore water cement ratio is the chief factor, which controls the strength of concrete. or coarse is inert filler material added to cement paste to increase its Aggregate either fine cel and crushed rock are the bulk. Because of wide spread distribution natural sand and grav’ most commonly used aggregates. a - and that it be s coated structurally sound, strong and drabble. Aggregates should be clean since partic! se mater or crusher dust will not bond with the surrounding cement paste with clay, silt, organi at concrete is a extremely versatile material of construction which is used for a variety Cemet massive dams, bridges and others, small cottages to scraper building, of works ranging from is quite strong in compression but not so in tension. heavy duet construction. Concret rr lLrLrLrLtlLrl-FEl embedded in concrete, The concrete then i reinforcement is known as plain concrete. 5 known as reinforced “concrete. Concrete without Selection of materials Conerete forming materials shall be carefully selected so as to get quality concrete I. Cement shall be checked quality or not 2. Fine and coarse hall be checked quality test A) Gradation B) Strength - LAA. ACV. AIV and Flakiness index organic impuri and for fine- aggregate nd chloride ities mortar strength clay content and siphate ar content €)_ Water quality: sulphat and chloride and dissolved matters. 186,a) cy ae (se ee ee) ieee) a oa aoa es 32IoOo woo Batching of ingredients ‘There are two methods of batching the ingredients of concrete 1. By weight 2. By volume Volume of one bag of cement weighing SOkgs is 35 liters. When itis taken out of bags it becomes loose showing a considerable increase in volume. Mixing conerete Mixing should preferably be done by machines called concrete mixers If these machines are not readily available or are too expensive for the job on hand then perfectly good results ‘could be obtained by hand mixing it the following procedure is adopted. Hard mixing f cement concrete a closely joined plat form of timber or bricks large | pilling should be prepared. One bag of cement and the | over this plat form. Cement and sand For hand mixing o enough to turn over the mix without s corresponding quantity of sand required is spread be tured over thoroughly with shovels at least three times so as t0 produce a mix. should then of uniform colour. Spread this mixture evenly over the correctly measured quantity of coarse ageregate in a layer. Now turn this mixture thoroughly with shovels so that the stone pieces are evenly distributed throughout the mixture of cement and sand. Then water is slowly poured on to the heap from a water can fitted with a hose and the turning of mixture continued till e workable, smooth and uniform mixture is obtained. Only the right amount of water should be used in mixing concrete. Placing of concrete te with water it should be used up within 30 minutes ie, before the Afier mixing the conere! that initial setting of cement starts. Only so much of concrete should be mixed with water can’be easily used up in 30 min, In no case shoul) cement concrete be remixed with water | and used after 30 minutes. Water cement rat | It is the ratio of water and cement (by weight or by volume) used in the preparatio? of concrete. The quantity of water used in mixing conerete is very important. IF the percentage 187fy J fl Uu co 0 nt quantity of water to hydrate cement, It of water used is less then there shall not be sufficie 1 tendency is to use too much shall result in porous and weak conerete, However, the usual water, which gives a more workable mix but it does not give sound concrete, To make the concrete sufficiently workable to be placed in position some more water is needed. So long as the concrete is sufficiently workable, for the method of placing used, its strength depends upon the proportion of water to the cement in the mix. Water cement ratio should not be ceed the specified limits for various types of conerete and should generally be 5 of placing will allow. The ratio of quantity of mixin: allowed to © kept as low as the method: 1g water to the long as the mix is of a quantity of cement alone determines the strength of concrete workable plasticity. This is known as water cement ratio For a given cement and accepiable aggregates, the strength that may be developed by @ workable, properly placed mixture of cement, aggregate and water is influenced by the = a) Ratio of cement to mixing water b) | Ratio of cement to aggregate c) Maximum size of the aggregate 210 ce 50 ke If_ mixing water Cement content Water cement Ratio shall be 210 = 0.6 35 Slump test cone in 3 layers, each layer being rammed 25 times with metallic Concrete is filled in the in diameter. Just after the slump cone has thus been tamping rod 600mm long and 16 mm filled then it is little. The extent by which the conc from the top of cone to the top of concrete after the cone ete drops is called the slump. It is measured has been removed. The slump test — How to do it You must'alway's make the slump test in accordance with the following. procedure: A) Move sure the cone is clean, free from hardened concrete and dry inside stand it on the base plate which also must be clean. 8) Stand.with your feet on the foot rests ©) Using the seoop fill the cone to about one fourth ofits height and rod thi concrete exactly 25 times using the tamping rod. 188 s layer of3 3 nh fi C a 7 ae out 75 mm deep) ridding each one D) Add three further layers of equal height (each ab: rate through into the layer below. in turn exactly 25 times, allowing the rod to penet [After ridding the top layer make sure that there isa slight surcharge of concrete, ie, that some concrete sticks out of the top. E) Strike off the surplus concrete using the steel float F) Wipe the cone and base plate clean Keeping your feet stil on the Footrests G) Take hold of the hands and pushing down words remove your feet from the foot rests. H) Very: carefully lift the cone straight up turn it over and pat it down on the ba ‘As soon as the cone is lifted the concrete will se plat next to the mound of concrete. slump to some extent. 1) Rest the tamping fod across the top of the empty inverted cone so (rat reaches over the slumped conerete. 1) Using the ruler measure from the underside of the rod to the highest point of the concrete, to the nearest Smm, this represents @ 50 mm slump. There are three types of slump keeping its shape approximately 1. A true slump ~ where the concrete just subsides, shears off and slips side ways down 2. A shear slump - where the top half of the cone and inclined plane. ollapses completely. Both true and shear 3. A collapse slump ~ where the concrete must not be composed with the other. slump can happen with the same mix, but one ‘The only on e that is of any use is the true slump. If you get # shear slump, you should make a second test in order to obtain a shape more nearly the " true” slump. If this also shears, it is probably due to the design of the mix and you should record this fact on the report. similarly, collapsed slumps should be recorded as collapsed slumps. ‘Slump depending on the type of concrete mix Eg Slump 0 - 25-Very low 25 - 50-Low 50 - 75-Medium 75 - 100 - High 100 - 175 Very high 189)I is cq co r U Concrete casting (moldin: Before concrete mixing prepare cubical or cylindrical concrete mols. apply little oil or other ointment the inner and outer part of the mold body. ‘After completed slump test immediately poured the fresh concrete i the ready 3 or more ndard tamping rod penetration int" 2" and 3 layer tamping molds tamped each with sta p surface of the 1" layer and the 3 tamping shall be penetration should be reached on the to} reached on the top surface of the 2" layer, ‘After completed of tamping, allow in air for 2 hours and at end of 2 hours time and lavel the ce of the mold by using trowel. keep the mold and the concrete in shaded room for top surfac 20 to 24 hours. Demolding concrete fan soaking tanker for 3, 7, 14, 21. Demold the concrete and keep the 24 edged concrete in cle and 28 days. Compressive strength After the specified edge of concrete remove from soaking t@rk oF moist room, allow in air for 2 hours before break. If the concrete is cylindrical it shall be made smooth surface by casting using cement or sulpher. Put the concrete on the bottom platen of concrete machine in smother part of concrete face. ‘Adjust concrete machine to zer before starting or on position the concrete machine. Start on position and record the final load of the conerete Calculation sive strength of concrete = Load Calculate the compres ‘Area If the concrete is cylindrical Area = ad 4 Cubical= W x Zx TH 190{ ee al ri 3Figure? The stamp othe detanve beoseen : Pique 6: The cane must he hed carta the hehe pam on the concrete and the no. ‘and que stv ed ecu the oad lis { r i | LI | in i u n | u thoroughly mived together so that se sample ws uniform. IF your S supe isin a barrows the remixing cam be done inthe burrow using | { «shovel or the sampling seo0p. Akermtively. and especially if the sample is in a bucket, you should first tip it on to « non-absorbent | have and thoroughly mix it together 1 Co 193 iZ7 om ac cs) oa J] Cc } EE eve Stu: Fig. 43, Stamp: ue. 194 25- 5omm (1-2) ip to 125mm (5) [ogee » sivear, are ealiapse ur CouenseThe higher the «4 los ! Fig. 2 q row of yon ot essuaee { n {| TRUE AVERAGE CUGE STRENGIN OF BATCH OF CONCRETE (100%) — a Sampling ecror i ul Failure to remix sample Giserted cabematd - Lack of mould oil; Improper or 1 incomplete compactin of crete i Curing below 20°C nm U Lack of centinous mest ing 0 Faully test procedure | Faulty test machine : 7 —— u . oko “0 a 10 . a “0 Strength of cube relative fo true average cube strenath U ‘of baich of concrete i - i [1 i q - u eoak fl . 3E i Ui TC i n LM EE F ”Co co co ooo Co 34 SIEVE ANALYSIS OF FINE AND COARSE AGGREGATE L. Scope This method of test covers a procedure for the determination of the particle size distribution of fine and coarse aggregates by means of sieves with This test procedure is not intended for use in the sieve square openings. ‘ed from bituminous mixtures or for the sieve analysis of aggregates recover analysis of mineral fillers. 2. Apparatus 1.1 Balance ~ A balance with a capacity of 2000gm and sensitive to O.1gm 12 Scale _.a heavy duty scale with a capacity of at least S0lb and sensitive to 0.1 Ib. 1.3 Sieves - Woven wire cloth sieves with square openings confirming to the requirements of AASHTO DESIGNATION M ~ 92 1.4 Sieve Shaker ~ Any mechanical device which produces @ thoroughness of sieving L5 Drying Oven ~ an oven capable of maintaining @ uniform temperature of 230°F + 9°F. 1.6 Riffle Box — sample splitter for quartering 1.7 Sieve Brush 1.8 Metal try 1.9 Scope or shovel 1.10 Bench 2. Samples ‘ed [rom the material to be tested by g.. The test sample the lysis shall be obtain itter or by the method of quarterin ly of the weight desired, as shown below; however, Samples for sieve anal the use of sample spl shall be approximatel 107equie en, TECHNIQUES AN 198, 1D SAFETY3 g 199n u selection of samples of an exact predetermined weight shall not be attempted. Samples of fine aggregate for sieve analysis shall weigh, after drying, not less than the amount indicated in the following table. Maximum Particle Size Minimum Sample Weight 3/8 inch 1000gm % “ 2500 gm eo 5000 gm 1 “ 10000gm an 15000 gm 2“ 20000gm a 25000gm 3 30000gm 3% “ 35000gm 3. Sample Preparation ‘Two methods may be used for subdividing a large sample of gravel to obtain a representative test sample. These are: - 3.1 Riffle box method 3.2 Cone and Quartering method 4.1 Riffle Box material ‘The material to be divided must first be thoroughly mixed then poured evenly into the riffle box from a scoup or shove. It should be distributed slong most of the slots, not confined to two or three stots near the middle, ive an identical sample, one of Each receiving container should then recei ffle box which is rejected and the other remixed and poured back into the ri eiver has been inserted. This process is repeated as many been achieved. after an empty rec times as necessary until the required reduction has 201n 4.2 Cone and Quartering Method ‘The initial material is mixed on a large metal tray and formed into a circular conical heap. Ny coarse particles around the base of the cone shall be evenly distributed with cruciform sample splitter or a straight edge. The heap is divided into four equal portions and the two diagonally opposite portions are separated out and mixed thoroughly together and formed into a smaller heap for quartering as before. ‘The portions remaining are rejected ‘and returned to the original sample container. The above process is repeated le is obtained. as may times as necessary until enough representative samp If there is not riffle box, then cone quartering method shall be used. The appropriate minimum quantity of sample is placed on @ tray and is allowed to dry in an oven maintained at 105 - 110°c. 4, Selection and Assembly of Sieves The sieves to be used are selected to suit the size of sample and type of, material. inspect every sieve for, defects, such as tears, splits, large. ‘oe Before each use, holes, etc. one inside to other to prevent escape d together with the largest aperture the smallest aperture sieve at the Ensure that the sieve frames are fitted of particles and dust. Sieves are neste sieve at the top and the receiving pan under bottom. . 4, Sieving Procedure . using such sieves are necessary 4.1 Separate the sample into a series of sizes fications for the material under to determine compliance with the speci test. 4.2 Determine the weight of aggregate retained on each sieve, these weights. 4.3 Determine the total amount and record of material finer than the No. 200 sieve by adding the weight of the material passing the No. 200 sieve by dry sieving to that last by washing, as determined in the test for amount of material finer than No. 200 sieve in aggregate. 202[ U t ca 5. Calculations tages shall be calculated from the weights recorded. The The grading percent on any sieve shall be compacted as follows: percentage retained A=W1X 100 Ww Where A =the percent retained WI= the weight retained W = the total weight of sample “The percentage passing any sieve shall be completed as follows: B=100-c Where B = the percent passing C =the cumulative percent retained to the nearest whole number, except the percentage Report the percentag' passing the No. 200 sieve, which shall be reported to the nearest 0.1 percent. Seer sith Precautions 7 1. For samples weighing 5000gm or more, use 16in. diameter sieves, larger. ; 2. Check sieves frequent! defective sieves, 3, Fine sieves, such as No. 80 and be handled accordingly, and in no event should wire ly for broken or distorted wires. Repair or replace?” 200, are extremely delicate. They shold brushes be used on these sieve. 4. Never sieve hot samples. Hot aggregate will distort the fine mesh of the No. 80 and 200 sieves. Toke care to avoid loss of rhaterial during washing and during transfer of the sample from the swashing vessel to the sieves. 203ETT flunitocmity cootticient Roveco-some fll 1 oso] A F F us -O1SeAInE a a aT eam [eoaces[oonccrs | | ig. AA Porte sve distrib 204PARTICLE SIZE “SUMMARY OF RESULTS FROM fos PARTICLE SIZE TEST : sige: +T oeseriotion: Light brown fine to medium SANO ei { eit ea i - Ee _ | i Fieve aperture Percent u E size passing i Teme 100 f a 600 pm 26 u BI 300um 62 | ° Er sum 18 r Seer ne Fay oa | eee a gpl [lee | : Se n Eels fom parle sie est and erating cree Uu f] | 205Frew Lach elven Aid be ceckes W580 cond reding. ree Stare | eo 0 a6é (es the stockpile, Although it should ain at keeping the moist way af doing this is by keepi 3 q so Meas time vo Jno u sre usvally damp or wet when delivered 10 ste reese water can drain away fails sai. the mois= r rane rmptent does not wary teo emuch and so does Hou Wave & SEBS U aoe com he conerete mix. Sitar rushed ach wire AEETERAED- cree tae exwally Jolivered dry. do aot hase mach effect om the 206f u a |Aer LO LR ey epeei) co) oc -co ca oo ao q amo mm wa 6.1 Standard Method of Test for Resistance to Degradation of Small size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine 1. Scope 1.1 This method covers a procedure for testing sizes of coarse aggregate smaller than 37.5mm (1% in.) for resistance to abrasion using the Los Angeles testing Machine. 1.2 The Los Angeles test has been widely used as an indicator of the relative quantity or competence of various sources of aggregate having similar mineral compositions. The results do nol automatically permit valid comparisons to be made between sources distinctly different in origin, composition, or structure. Specification limits based on this test should be assigned with extreme care in consideration of available aggregate types and their performance history in specific end uses. 2, Summary of Method ‘The Los Angeles test is a measure of degradation of mineral aggregates of standard gradings resulting from a combination of action including abrasion or attrition, impact and grinding in a rotating steel drum containing @ specified number of steel spheres, the number depending upon the grading of test sample, As the drum rotates, a shelf plate picks up the sample and the steel spheres, carrying them around until they are dropped to the opposite Side of the drum, creating an impact ~ crushing effect. The contents then roll within the drum with an abrading and grinding action until the shelf plate impacts and the cycle is repeated. After the prescribed number of evolutions, the contents are removed from the drum and the aggregate portion is sieved to measure the degradation as percent loss. 3. Apparatus 3.1 Los Angeles Machine - The Los Angeles abrasion testing machine @ counter and conforming in all its essential characteristics shall be used. ‘The machine shall consist ofa hollow steel cylinder, closed at both ends, having an inside diameter of 711 + smm (28 + 0.2in.) and an inside length of 508 + Smm (20 * 0.2in.) The cylinder shall be mounted on stub shafts attached to the ends of the cylinder bit not entering if, and shall be mounted in such a manner-that it equipped with 209may be rotated with the axis in a horizontal position within a tolerance in a slope of | in 100. An opening in the cylinder shall be provided for the introduction of the test sample. A suitable, dust tight cover shall be : provided for the opening with means for bolting the cover in place. The fq cover shall be so designed as to maintain the cylindrical contour of the interior surface unless the shelf is so located that the charge will not fall n ‘on the cover, or come in contact with it during the test. A removable ul steel shelf extending the full length of the cylinder and projecting in wards 89 + 2mm (3.5 + 0.1in.) shall be mounted on the interior cylinder surface of the cylinder, or on the inside surface of the cover, in such away that a plane centered between the large faces coincides with an axial plane. The shelf shall be of such thickness and so mounted, by bolts or other suitable means, as to be firm and rigid. The position of the shelf to the opening, measured along the outside circumference of the cylinder in the direction of rotation, shall not be Tess than 1.27m (50in.). A 3.1.1 The machine shall be do driven and so counterbalanced as to maintain a substantially uniform peripheral speed. If an angle is used as the shelf, the direction of rotation shall be such that the charge is caught in the outside surface of the angle. a 3.2 Sieves - Conforming to the specification of Wire — Cloth sieves for testing purposes (AASHTO M 92). 3.3 Balance - The balance shall conform to AASHTO M 231, class G5. 3.4 Oven — The oven shall be capable of maintaining at uniform temperature» of 110 + 5°c (230 + 9°F). . 3.5Charge - The charge shall consist of steel spheres averaping approximately 1 27/32 in. (46.8mm) in diameter and each weighing between 390 and 445g. 3.5.1 The charge, depending upon the grading of the test sample 2s described in section 5, shall be as follows: r Grading Number of Spheres Weight of Charge u of A 12 5,000 + 25 B ir 4,584 + 25 c 8 3,330 + 20 D 6 2,500 + 15 fl 210J 4, Sampling The field sample shall be obtained in accordance with TZ and reduced to test portion size in accordance with T248. 5. Test Sample The test sample shall be washed and oven — dried to a constant mass, separated into individual size fractions, and recombined to the grading of Table | most nearly corresponding to the ranges of sizes in the aggregate furnished for the work. The weight of the sample prior to test shall be recorded to the nearest 1.0g. 6. Procedure 6.1 Place the test sample and the change in the Los Angeles testing Tmachine and rotate the machine at a speed of 30 to 33 rpm for 500 ‘After the prescribed number of revolutions, the discharge ke a preliminary separation of the small Sieve the finer portion on a revolutions. material from the machine and mal on a sieve coarser than 1.70mm (No. 12) 27. Wash the material coarser 1.70mm sieve in a manner conforming to T: than 1.70mm, oven dry to a constant mass, and weigh to the nearest 1.0g. TABLE |. Grading of Test Samples Sieve Size Mass of Indicated sizes. Passing/mm Retained on A B c [37.5(1 4 in) 25(lin.) 1250425 - ; (25.00 in.) 1903/4 in.) 1,250+25 - : 19 @/8 in.) _12.5(1/2 in.) 1,250410 2,500H10_- 12.5(12 in) 9.5 G/8 in.) 1,250 +10 _2,500+10_- 95 Gi8in) 630/4in) = : 2,500#10 6.3 (1/4in.) 4.75(No. 4) : z 2,500+10 24.75 (No. 4) 2.36 (No. 8) . 5,000+10 Total 5,000+10 5,000 +10 5,000 + 10 5,000410 7. Calculation Express loss (difference between the original weight and final weight of the test sample) as a percentage of the original weight of the test sample. Report this value as the percent loss. 8. Precision and Bias 8.1 Precision - For nominal 19.0mm (3/4in.) maximum size coarse aggregate with percent losses in the range of 10 to 45 percent, the multi laboratory co-efficient of variation has been found to be 4.5 percent. Therefore, results of two properly conducted tests from two different laboratories on samples of the same coarse aggregates shouldn’t differ from each other by more than 12.7 percent of their average. The single operator co — efficient of variation has been found to be 2.0 percent. Therefore, results of two properly conducted tests by the same operator on the same coarse aggregate should not differ from each other by more than 5-7 percent of their average. 8.2Bias — Since there is no accepted referencs determining the bias for this procedure, no statemen made. material suitable for on bias is being 2120 co co co =) ) co 6.2 Standard Method of Test for Soundness of Aggregate by use of Sodium Sulfate or Magnesium Sulfate? ~""*= 1. Scope This method covers the procedure to be followed in testing aggregates to determine their resistance to disintegration by saturated solution of sodium sulfate or magnesium sulfate. This is accomplished by repeated immersion in saturated solutions of sodium or magnesium sulfate followed by over drying to partially or completely dehydrate the salt precipitated in permeable pore space. This method furnishes information helpful in judging the soundness of aggregates subjected to weathering action, particularly when adequate information is not available from service records of the material exposed to actual weathering conditions. Attention Is called to the fact that test results by the use of the two salts differ considerably and care must be exercised in fixing proper limits in any specifications which may include requirements for these tests. 2. Apparatus 2.1 Sieves - With square openings of the following sizes conforming to 1492. - 2.2 Containers for Samples — Eight (8) inch diameter sieves for each separate size fractions of aggregate during test. Used — of — tolerance sieves according to M92, in acceptable condition may be used as container. 23 Apparatus for Immersing Samples in Solution (optional) - When necessary, apparatus for holding the sieves containing the sample for immersing into the solution shall be constructed in such a manner to permit free access of the solution to the sample and drainage of the solution from the sample. 2.4 Temperature Regulation — Suitable means for regulating the temperature of the sample during immersion in sodium sulfate or magnesium sulfate solution shall be provided. 2.5 Balance - The balance shall conform to the requirements of AASHTO M231 for the class of general purpose balance required for the principal sample weight of the sample being tested 2.6 Drying Oven - The over shall be capable of being heated continuously at 230° + 9°F (110° + 5°C) and at the rate of evaporation, at this range of 23