QUICK REFERRENCE

TO

CIVIL ENGINEERING

LAB TESTINGSBY

VINAY KUMAR GUPTA(DY.CHIEF ENGINEER/G

NORTHERN RAILWAY)

IMPACT TEST FOR COARSE AGGREGATE (10MM, 20MM)(IS: 2386 Pt-IV, Para 4/ IS: 383 Para 3.4)

PASSING THROUGH 12.5MM & RETAINED AT 10MM

IN CUP IN 3 LAYERS, EACH LAYER COMPACTED 25 TIMES

WEIGHT OF SAMPLE IN CUP (A)15 BLOWS IN IMPACT TEST APPARATUSPASSING THROUGH 2.36 SIEVE (B)IMPACT VALUE IN %= (B)/(Ax100)

LIMITS:IS < 45% FOR OTHER THAN WEARING COAT, 30% FOR WEARING COATS

ABRASION TEST FOR COARSE AGGREGATE (10MM, 20MM)(IS: 2386 Pt-IV, Para 5/ IS: 383 Para 3.5)

DEVAL TESTING MACHINEGRADING.SAMPLE & ABRASION CHARGE (6 SPHERES, 48mm dia.) IN TESTING MACHINE10,000 REVOLUTIONS @ 30-33 rpm.RETAINED ON 1.7mm SIEVE. WASHED & DRIED.W= (AL+(100-A)L')/100 WHERE 'W' IS PERMISSIBLE % OF WEAR, 'A' IS % OF UNCRUSHED FRAGMENTS, 'L' IS MAXIMUM % OF WEAR PERMITTED FOR GRAVEL OF UNCRUSHED FRAGMENTS & 'L'' IS MAXIMUM % OF WEAR PERMITTED FOR GRAVEL OF CRUSHED FRAGMENTS

LOS-ANGELES TESTING MACHINE (PREFFERED TO ABOVE)

GRADING.SAMPLE & ABRASION CHARGE (6 SPHERES, 48mm dia.) IN TESTING MACHINE500-1,000 REVOLUTIONS @ 20-33 rpm.RETAINED ON 1.7mm SIEVE. WASHED & DRIED.W= (AL+(100-A)L')/100 WHERE 'W' IS PERMISSIBLE % OF WEAR, 'A' IS % OF UNCRUSHED FRAGMENTS, 'L' IS MAXIMUM % OF WEAR PERMITTED FOR GRAVEL OF UNCRUSHED FRAGMENTS & 'L'' IS MAXIMUM % OF WEAR PERMITTED FOR GRAVEL OF CRUSHED FRAGMENTS

LIMITS 30% FOR OTHER THAN WEARING COAT & 30% FOR WEARING COATS

POLISHED STONE VALUEFOR ROADS ONLY (IS:2386 Pt-IV, Para 6/ IS: 383)

AGGREGATE CRUSHING VALUESURFACE DRY (IS:2386 Pt-IV, Para 2/ IS: 383 Para 3.3)CYLINDER ON BASE PLATE, SAMPLE IN 3 LAYERS, EACH LAYER COMPACTED 25 TIMES. PLUNGER INSERTED AFTER LEVELLING THE SAMPLE IN CYLINDER. APPARATUS KEPT BETWEEN PLATENS OF TESTING MACHINE. 40 TONNES LOAD IN 10 MINUTES. TOTAL LOAD OF SAMPLE IN CYLINDER (A).RELEASE PRESSURE. SIEVE ON 2.36mm SIEVE & WEIGH(B) FOR STANDARD TEST

FOR OTHER THAN STANDARD TEST:PASSING THROUGH RETAINED ON SIZE OF SIEVE FOR

SEPARATING FINES

25 20 4.75

20 12.5 3.35

10 6.3 1.70

6.3 4.75 1.18

4.75 3.35 850 microne

3.35 2.36 600 microne

CRUSHING VALUE = (B/A)*100…………………not >45%

TEN PERCENT FINES VALUESURFACE DRY (IS:2386 Pt-IV, Para 3)

PASSING 12mm RETAINED ON 10mm. CYLINDER ON BASE PLATE, SAMPLE IN 3 LAYERS, EACH LAYER COMPACTED 25 TIMES. PLUNGER INSERTED AFTER LEVELLING THE SAMPLE IN CYLINDER. APPARATUS KEPT BETWEEN PLATENS OF TESTING MACHINE. IN 10 MINUTES FOR 20mm DISPLACEMENT OF PLUNGER. NET LOAD 'X' TONNES.RELEASE PRESSURE. SIEVE ON 2.36mm SIEVE (PASSED SHOULD BE BETWEEN 7.5 TO 12.5%).REPEAT AGAIN. TAKE AVERAGE OF % PASSING 'Y' AND AVERAGE OF LOAD 'X'. LOAD REQUIRED FOR 10% VALUE = (14*X)/(Y+4)

FINE AGG.ZONE-II

COARSE AGG 20mm

COARSE AGG 10mm

COMBINED COARSE AGG. (ALL - IN - AGG.)

40 - 100 - 100

20 - 85-100 - 95-100

12.5 - - 100 -

10 - 0-20 85-100 25-35

4.75 90-100 0-5 0-20 0-10

2.36 75-100 - 0-5 -

1.18 55-90 - - -

600 MICRONE 35-59 - - -

300 MICRONE 8-30 - - -

150 MICRONE 0-10 - - -

75 MICRONE - - - -

SIEVE ANALYSIS FOR FINE & COARSE AGGREGATEDRY (IS:2386 Pt-I, Para 2/ IS: 383 Table 2,5,4 & PARA 3.2)WEIGH 1000 gm FOR FINE AGGREGATE & 2000gm FOR COARSE AGGREGATEIN SIEVE SHAKER FOR 2 MINUTESWEIGH & TAKE %.

SILT CONTENT (SAND & STONE DUST) (CPWD SPECS PAGE 42, IS:2386 Pt-II PARA 3 FOR SILT CONTENT BY SEDIMENTATION USING SODIUM OXALATE)

TAKE ABOUT 110 ml OF SAMPLE IN A GRADUATED CYLINDER OF 200 mlADD WATER UPTO 150ml MARK. ADD SALT @ 5ml/500ml OF WATERSHAKE WELL & LET IT SETTLE FOR ABOUT 3 HOURSTAKE READING OF TOP(A) & BOTTOM(B) OF SILT LEVELSILT % = (A-B)/(Bx100) <=8% as per CPWD annex-D page 42, vol-2, 15% for stone dust as per IS:383 TABLE-1

MOISTURE CONTENT (SAND & STONE DUST)

TAKE SAMPLE OF FINE AGGREGATE IN MOITURE APPARATUS BALANCEPUT IT IN APPARATUS CUP. TAKE CALCIUM CARBONATE SPOONFUL. PUT IT IN 2ND CUP. PUT 2ND CUP OVER 1ST CUP IN APPARATUS. TIGHTEN THE SCREW. SHAKE WELL THE APPARATUS. READING IN THE METER IS %AGE OF MOISTURE IN SAMPLE.

SIEVE ANALYSIS FOR MATERIAL FINER THAN 75mm IS:2386 PARA 3, IS:383 TABLE 1

SURFACE MOISTURE FOR FINE AGGREGATE (IS:2386 Pt-III, Para 5)P1 = (Vs-Vd)*100/(Ms-Vs)P2 = (Vs-Vd)*100/(Ms-VD)WHERE P1=% SURFACE MOISTURE OF SATURATED SURFACE DRY FINE AGGREGATEP2=% SURFACE MOISTURE IN TERMS OF WEIGHT OF WET FINE AGGREGATEVs=WEIGHT IN gm OF WATER DISPLACEDVd=WEIGHT OF SAMPLE/SP. GRAVITYMs=WEIGHT OF SAMPLE IN gm

WATER ABSORPTION TEST (COARSE AGGREGATE): IS:2386 PARA 2SAMPLE OF 2000gm. WASH THOROUGHLY. PUT IN A JAR. FILL WITH DISTILLED WATER IMMERSED AT LEAST 5cm(IN WIRE BASKET IMMERSED IN A TANK). 25 TIMES UP & DOWN TO REMOVE ENTRAPPED AIR. LEAVE FOR 24 plus/minus ½ HOURS at 22-320c.DRAIN WATER. SURFACE DRY ON CLOTHS & IN OPEN AIR(NOT IN SUNLIGHT). MAY BE UNDER FAN AFTER 10 MINUTES OF DRYING.WEIGH (A)PUT IN OVEN AT 100-1100C FOR 24 plus/minus ½ HOUR. COOL IN AIR TIGHT CONTAINERWEIGH (B)WATER ABSORPTION= (A-B)*100/(B)

WATER ABSORPTION TEST (AGGREGATE FINER THAN 10mm):SAMPLE OF 500gm. PUT IN A TRAY. FILL WITH DISTILLED WATER IMMERSED. SHAKE TO REMOVE ENTRAPPED AIR. LEAVE FOR 24 plus/minus ½ HOURS at 22-320c.DRAIN WATER THROGH FILTER PAPER SO THAT MATERIAL RETAINED CAN BE PUT BACK. UNIFORM SURFACE DRYING BY STIRRING TILL ‘FREE RUNNING’.WEIGH (A)PUT IN OVEN AT 100-1100C FOR 24 plus/minus ½ HOUR. STIR INBETWEEN. COOL IN AIR TIGHT CONTAINERWEIGH (B)WATER ABSORPTION= (A-B)*100/(B)

SOUNDNESS OF COARSE AGGREGATE (IS 386 PARA 3.6, IS2386 Pt 5) TO DETERMINE RESISTANCE TO DISINTEGRATION OF COARSE AGGREGATE BY SATURATED SOLUTION OF Na2SO4 OR MgSO4.

TESTING WITH Na2SO4 TESTING WITH MgSO4

FINE AGGREGATE 10% 15%

COARSE AGGREGATE 12% 18%

SPECIFIC GRAVITY (COARSE AGGREGATE & FINE AGGREGATE) :(IS:2386 Pt-III, Para 2)TAKE SAMPLE OF ABOUT 500 gm PUT IN A WIRE BASKET. DIP IN WATERS JOLTED AND WEIGHED IN WATER ALONGWITH BASKET. BASKET EMPTIED OUT AND AGAIN WEIGHED IN WATER. DIFFERENCE OF BOTH THE WEIGHTS IS WEIGHT OF AGGREGATE IN WATER (A). DRY THE SAMPLE IN AIR & WEIGH. (B).DRY THE AGGREGATE IN OVEN AT 100-110OC FOR 24 HOURS & WEIGH ( C)SP. GRAVITY= C/B-AAPPARENT SP. GRAVITY=C/C-AUSING PYCNOMETER: SAMPLE WETTING AS ABOVE FOR 24 HOURS. SURFACE DRY. WEIGH (A)AGGREGATE IN PYCNOMETER & FILLED WITH DISTILLED WATER UPTO TOP. WEIGH (B)EMPTY PYCNOMETER. FILL UPTO TOP WITH DISTILLED WATER. WEIGH (C )SAMPLE IN OVEN FOR 24 HOURS. SAMPLE WEIGHED (D)SP GR.=D/A-(B-C)APPARENT SP GRAVITY= D/D-(B-C)

BULK DENSITY: Kg/Liter. OF NO USE PRACTICALLY. SIZES OF CONTAINERS GIVEN IN IS: 2386 Pt III, PARA 3

VOID RATIO: = (SP. GRAVITY-BULK DENSITY)*100/SP. GRAVITY

(IS:2386 Pt-III, Para 3)

FLAKINESS & ELONGATION: (IS:2386 Pt-I, Para 4 IS:383 PARA 3.1 LAST LINE)TAKE SAMPLE IN SUFFICIENT QUANTITY SUCH THAT 200 NOS OF PIECES ARE RETAINED ON EACH SIEVE i,e 20,16,12.5,10 & 6.3 SIEVES AS APPLICABLEWEIGH RETENTION ON 10 & 6.3mm FOR 10mm & 20,16,12.5,10 & 6.3mm FOR 20mm(A).PASS THROUGH FLAKINESS (THICKNESS) GAUGE FOR DIFFERENT RETENTIONS (B).FLAKINESS=(B*100)/A (NOT MORE THAN 35% AVARAGE OF ALL GAUGES IN DIFFERENT GAUGES.PASS THROUGH ELONGATION GAUGES FOR DIFFERENT RETENTIONS (B).ELONGATION=(B*100)/A (TAKE AVARAGE OF ALL GAUGES IN DIFFERENT GAUGES.

CUBE TESTING IS:516 PARA 2,3,5 & IS:1199 PARA 4 (IS:9013 FOR ACT)3 DAYS – 50%, 7 DAYS – 70%, 28 DAYS – 100% STRENGTHCUBE STRENGTH IN N/mm2 IS LOAD IN 'N' AT WHICH THE CUBE FAILS DIVIDED BY AREA OF CUBE IN mm2.DEVIATION OF ANY CUBE BY >15% OF AVERAGE VALUE – DON’T CONSIDER THE CUBEIN CASE OF ACT R28=(Ra*1.64)+8.09 WHERE R28 IS EXPECTED STRENGTH AFTER 28 DAYS, Ra IS STRENGTH RECEIVED AFTER 24 HOURS WITH ACT.LOADING RATE = 14 N\mm2 \Minute.FOR ACT: BY BOILING WATER:: SAMPLE AT 27 +/- 2OC AT 90% HUMIDITY FOR 23 HOURS +/- 15 MINUTES FROM TIME OF ADDING WATER. THEN IN BOILING WATER FOR 3.5 HOURS +/- 5 MINUTES. REMOVE FROM MOULD. IN COOLING TANK AT 27 +/- 2OC. AGE 28 HOURS +/- 20 MINUTES.1Mpa=10Kg/cm2

AIR CONTENT TEST IS:1199 PARA 8FILL CONCRETE IN 3 LAYERS EACH COMPACTED 25 TIMES OR BY VIBRATING. ALSO TAP THE SIDES WITH MALLET. REMOVE EXCESS CONC. IF ANYASSEMBLE THE APPARATUS TIGHTLY & ADD WATER TILL HALF WAY IN THE STAND PIPE. TILT WHOLE ASSEMBLY AT 300 & ROTATE TO REMOVE ENTRAPPED AIR IF ANY.FILL WATER TO BRING LEVEL TO ZERO AT TOP OF PIPE.APPLY PRESSURE 'P'(.8Kg/cm2). TAP. TAKE READING OF WATER COLUMN IN STAND PIPE i.e. h1. RELEASE AIR PRESSURE THROUGH VENT AT TOP OF WATER COLUMN & TAKE READING h2.APPARENT AIR CONTENT IS h1-h2. REPEAT FOR 2nd TIME & TAKE AVERAGE OF TWO APPARENT AIR CONTENT VALUES, A1AIR CONTENT =A= A1-G, WHERE G IS AGGREGATE CORRECTION FACTOR (& G IS h1-h2 WHEN THERE IS COARSE AGGREGATE INSTEAD OF CONCRETE IN THE BOWL.)

WORKABILITY IS:1199 PARA 5SLUMP TESTIN 4 EQUAL HEIGHT LAYERS IN SLUMP CONE EACH LAYER COMPACTED WITH ROD FOR 25 TIMES.IN 1st LAYER ROD TO GO UPTO FULL DEPTH & IN 2nd, 3rd & 4th LAYERS ROD TO GO AT LEAST UPTO NEXT LAYER.SLUMP TAKEN AFTER REMOVING CONE.

COMPACTING FACTOR TEST: More accurate but in lab only.

VEE-BEE TEST: Preferred for stiff concrete with low & very low workability, not so accurate.

TRIAL MIXCLEAN THE MIXER WITH WATER & CEMENT SLURRY(BUTTERING)

PUT COARSE AGGREGATE 20MM, THEN 10MM50% OF FINE AGGREGATE (SAND & STONE DUST ETC)ADD 50% WATER. MIX.ADD 100% CEMENT, BALANCE SAND & STONE DUSTADD 40% MORE WATER. MIX. ADD SOME WATER TO ADMIXTURE & ADD TO CONCRETEADD BALANCE WATER TO ADMIXTURE EMPTIED CYLINDER & ADD TO CONCRETE

ORPUT COARSE AGGREGATE 20mm, 10mm, SAND, STONE DUST IN THE MIXER. ROTATE FOR SOME TIME. ADD 99% WATER. MIX.TAKE CONTROLLED SLUMP. ADD ADMIXTURE. ADD BALANCE WATER TO EMPTIED JAR OF ADMIXTURE & PUT IN MIXTURE.

MIX FOR 3 MINUTESTAKE SLUMP AFTER 10 MINUTES, 30 MINUTES, 1hr., 1.5 hr., 2hrs.SLUMP SHOULD BE AS PER REQUIREMENTSFILL UP CUBES

PILE TESTING: IS:2911 Pt. 4VERT. LOAD TEST (PARA 6)LATERAL LOAD TEST (PARA 7)PULL OUT TEST (PARA 8)INITIAL: ONE (TWO WHEN SOIL STRATA NOT KNOWN)ROUTINE: ½% (MAY BE INCREASED TO 2%MAY BE ON A SINGLE OR A GROUP OF PILES

GENERALLY TESTED AT C.O.L.

VERT. LOAD TEST(COMPRESSION):PILE HEAD CHIPPED TO SOUND CONC. REINF BENT OR CUT. SMOOTH FINISH BY P.O.P. BEARING PLATE AT TOP OF PILELOAD APPLICATION: EACH INCREMENT ABOUT 20% OF SAFE DESIGNED LOADFOR RAKER PILE LOAD ALONG AXISLOAD APPLICATION: (LOAD SHOULD BE 25% EXCESS OF LOAD TO BE APPLIED):

(A) KENTLEDGE, (B) ANCHOR PILE © ROCK ANCHORSETTLEMENT:

MINIMUM TWO DIAL GAUGES, 4 FOR GROUP OF PILESDATUM BAR SUPPORT AT 3D(SUBJECT TO A MINIMUM OF 1.5m) FROM PILE EDGE, WHERE D IS DIA OF CIRCULAR PILE OR DIA OF CIRCUMSCRIBIBG CIRCLE FOR A RECT OR SQUARE PILE

SAFE LOAD: FOR INITIAL TEST PILE: LEAST OF 2/3 OF FINAL LOAD AT WHICH DISPLACEMENT IS 12mm(UNLESS OTHERWISE MENTIONED IN DESIGN DEPENDING ON NATURE OF SOIL & STRUCTURE) OR 50% OF FINAL LOAD AT WHICH DISPLACEMENT IS 10% OF DIA OF PILE(7.5% OF BULB DIA FOR UNDER REAMED PILES.FOR ROUTINE TEST PILE: TESTED FOR 1.5 TIMES OF WORKING LOAD, THE SETTLEMENT NOT MORE THAN 12mm

FOR GROUP OF PILES FINAL LOAD AT WHICH DISPLACEMENT IS NOT MORE THAN 25mm(UNLESS OTHERWISE MENTIONED IN DESIGN) OR 2/3 OF FINAL LOAD AT WHICH DISPLACEMENT IS NOT MORE THAN 40mmIN ROUTINE LOAD TEST SETTLEMENT SHOULD NOT EXCEED 25mm.

LATERAL LOAD TEST:INCREMENT OF ABOUT 20%DISPLACEMENT AT C.O.L.

SAFE LATERAL LOAD: 50% OF FINAL LOAD AT WHICH DEFLECTION IS 12mm OR FINAL LOAD AT WHICH DISPLACEMENT IS 5mm OR AS PER DESIGN.PULL OUT TEST:

LOAD APPLIED BY REINF. OR SPECIALLY DESIGNED BOLT(S) EMBEDDED IN PILE AT TIME OF CASTINGLOAD INCREMENT ABOUT 20%SAFE LOAD: 2/3 OF FINAL LOAD AT WHICH DEFLECTION IS 12mm OR FINAL LOAD AT WHICH DISPLACEMENT CURVE SHOWS A BREAK

INITIAL LOAD AT 2.5 TIMES OF WORKING LOAD & ROUTINE TEST AT 1.5 TIMES WORKING LOAD(OR 12mm DEFLECTION WHICHEVER IS EARLIER)

BENTONITE SOLUTION: IS:2911(Pt. 1/Sec 2 APPENDIX - A, PARA A.3)

LIQUID LIMIT 300-450%SAND CONTENT<= 7%DENSITY: 1.12SWELLING INDEX : TWO TIMES AFTER 12 HOURS WETTINGpH VALUE < 11.5

CEMENT TESTSCONSISTENCY OF CEMENT (VICAT APPARATUS) IS:4031 Pt.4

CEMENT 500gm + 24% WATER. MIX – PASTE.IN MOULD. SHAKE MOULD.USE PLUNGER. FREE FALLING FROM TOP OF MOULD.READING SHOULD BE 5-7mm i.e. 33-35mm PENETRATION.IF NOT TRY 25%, 26%……TILL READING IS 5-7mm i.e. 33-35mm PENETRATION. THIS IS ‘P’ THE CONSISTENCY OF CEMENT i.e. 0.24, 0.25……….etc.

INITIAL & FINAL SETTING TIME: IS:4031 Pt.5CEMENT 500gm + WATER(‘P’x0.85x500). MIX – PASTE. THIS IS STARTING TIME.IN MOULD. SHAKE. USE 1mm NEEDLE. FREE FALLING OF NEEDLE FROM TOP OF MOULD.TAKE READING. READING SHOULD BE 5-7mm i.e. 33-35mm PENETRATION.IF NOT WAIT FOR 10 MINUTES. FREE FALLING OF NEEDLE FROM TOP OF MOULD. REPEAT TILL READING IS 33-35mm. THIS WILL BE THE INITIAL SETTING TIME(>30 MINUTES)REPLACE NEEDLE WITH ATTACHMENT FOR F.S.T. WITH A PIN AT END & A CIRCULAR CUTTING EDGETAKE READING AT INTERVALS TILL THE NEEDLE LEAVES A MARK ON CEMENT TOP BUT CUTTING EDGE DOES NOT LEAVE A MARK. THIS TIME IS FINAL SETTING TIME.(< 600 MINUTES)

FINENESS OF CEMENT:90 MICRONE SIEVE. 15 MINUTES SHAKING HORRIZONTAL & VERTICAL BY HAND OR SHAKER.RETENTION NOT MORE THAN 10%

DRYING & SHRINKAGE OF CEMENT IS 4031 Pt10

CONCRETE PERMEABILITY TEST IS:3085 & MOST PARA 1716.5ONE BAR 48 HOURSTHREE BARS 24 HOURSSEVEN BARS 24 HOURS. (TOTAL 96 HOURS)BREAKING CUBE DIAGONALLY. DEPTH OF MOISTURE AT COENERS & MIDDLE.AVERAGE OF THREE READINGS NOT MORE THAN 25mm.

COMPRESSIVE STRENGTH OF CEMENT: IS:4031 Pt.6

SAND(IS:650-1960) – 555gm. CEMENT – 185gmWATER – (‘P’/4)+3% OF COMBINED WEIGHT OF CEMENT & SAND. MIX FOR 3-4 MINUTES.CURE FOR 24 HOURS IN 90% HUMIDITY AT 27 plus/minus 20C. IMMERSE IN WATER.3 DAYS – 160Kg/cm2 . 7 DAYS – 220Kg/ cm2

SOUNDNESS TEST: IS:4031 Pt.??????

UNSOUND DUE TO EXCESSIVE LIME, MAGNESIA, CALCIUM SULPHATE, GYPSUM(2-3% DEPENDING UPON C3A).CALCIUM SULPHATE IS USED TO PREVENT FLASH SET.LE-CHATELIER TEST (TESTS FREE LIME ONLY):

ADD 0.78x’P’ WATER. FILL MOULD AND KEEP IT ON GLASS. COVER WITH ANOTHER GLASS PLATE.IMMERSE ASSEMBLY IN WATER AT 27-32 OC FOR 24 HOURS. MEASURE DISTANCE BETWEEN INDICATOR POINTS.SUBMERGE MOULD IN BOILING WATER. WATER FOR 3 HOURS. ALLOW TO COOL.MEASURE AGAIN. EXPANSION SHOULD NOT BE MORE THAN 10mm.

MAGNESIA SHOULD NOT BE MORE THAN 3%. IF MORE, TESTED FOR SOUNDNESS BY ‘ AUTOCLAVE TEST’NO STANDARD TEST AVAILABLE FOR UNSOUNDNESS DUE TO CALCIUM SULPHATE

HEAT OF HYDRATION: IS:4031 Pt.9REACTION OF CEMENT IS EXOTHERMIC WITH WATER.120 Cal./gmTEMP. RISE MAY BE UPTO 50% OCCOOLING CREATES SHRINKAGE & CRACKSTEST BY VACUUM FLASK METHOD OR BY ADIABATIC CALORIMETER (FOR ONLY LOW HEAT PORTLAND CEMENT)

CHEMICAL COMPOSITION OF CEMENT:

OPC & RAPID HARDENING

LOW HEAT PORTLAND

PORTLAND BLST FURNACE SLAG

HIGH ALUMINA

SUPER SULPHATED

INSOLUBLE RESIDUE

2% 2% 2.5% - 4%

MAGNESIA (MgO)

6% 5% 8% - 10%

SULPHUR AS SO3

2.75% 2.75% 3% - 6%

AS SULPHIDE (S)

- - 2% - 1.5%

MANGANESE OXIDE MnO2

- - - - -

LOSS ON IGNITION

5% 4% 4% - 5%

INHIBITOR SOLUTION:CLEANING OF STEEL BY WIRE BRUSH FOR DUST & RUSTAPPLY ONE COAT OF CEMENT SLURRY (1 KG CEMENT: 600cc OF INHIBITOR SOLUTION (PATENT NO. 109784/67)). ALLOW TO DRY FOR 24 HOURS IN SHADE. WATER IS NOT TO BE USED AS INHIBITOR SOLUTION IS PREPARED IN IONISED WATER.

STORAGE OF CEMENT: IS:4082 Pt.4.2BAGSCEMENT OLDER THAN 3 MONTHS NOT TO BE USED.CEMENT HAVING LUMPS TO BE REJECTED.MINIMUM NO. OF WINDOWS IN THE STORE. CLOSE FITTING DOORS. KEPT CLOSED. BUILDING SHOULD BE DRY, LEAKPROOF, MOISTURE PROOF, DAMP PROOF.600mm FROM WALL.PLANKS OVER WOODEN BATTENS. BATTENS OVER 15mm CC OR BRICKS IN 2 LAYERS. CC/BRICKS OVER 150mm CONSOLIDATED EARTH.STACK WIDTH NOT MORE THAN 4 BAGS LENGTH.STACKS HEIGHT NOT MORE THAN 10 BAGS(TO PREVENT LUMPING). IF HEIGHT MORE THAN 8 BAGS, BAGS SHOULD BE INTERLOCKED.DRUMS:DRUMS ON LEVEL GROUND. NEAR BATCHING PLANTLID SECURILY TIED AFTER USE TO PREVENT MOISTURESILOS:NEAR BATCHING PLANTS. PROPER ACCESS TO REPLACE SILOS.

DIFFERENT TYPES (GRADES, WEEK, BATCH) OF CEMENT SEPARATLY.

CALIBRATION OF BATCHING PLANTDONE MONTHLYADMIXTURE:QUANTITIES OF 1.0 LTRS, 1.5 LTRS, 2.0 LTRS, 2.5 LTRS, 3.0 LTRS OF ADMIXTURE ARE DRAWN ONE BY ONE FROM THE BATCHING PLANT & MEASURED ACCURATLY BY USING GRADUATED BOROSIL GLASS CYLINDERS.WATER:QUANTITY OF 125 LTRS OR 100 LTRS OF WATER IS DRAWN FROM THE BATCHING PLANT & MEASURED ACCURATLY BY USING CORRECTLY GRADUATED JARS AND CYLINDERS.CEMENT:IN SOME OF THE BATCHING PLANTS CEMET & WATER ARE FED JOINTLY. IN SUCH CASES CALIBRATION OF WATER CAN NOT BE CHECKED SEPARATLY & IS DONE ALONGWITH CEMENT ONLY.WEIGHTS ARE PUT ONE BY ONE ON THE CEMENT CONTAINER & THE CORRESPONDING READING AFTER EACH INCREMENT NOTED FROM THE METER. 1ST OF ALL A 50 Kg WEIGHT IS PLACED & ITS CORRESPONDING READING TAKEN. INCREMENT OF 50 Kg IS REPEATED TILL 250 Kg. AFTER THAT 20 Kg, 20 Kg & 10 Kg. AFTER REACHING AT 300 Kg UNLOADING IS DONE IN THE SAME SEQUENCE & CORRESPONDING READINGS AT 290, 270, 250, 200, 150…… & 0 Kg WEIGHT ARE TAKEN.

AGGREGATE:WEIGHTS ARE PUT ONE BY ONE ON THE AGGREGATE CONTAINER & THE CORRESPONDING READING AFTER EACH INCREMENT NOTED FROM THE METER. 1ST OF ALL A 50 Kg WEIGHT IS PLACED & ITS CORRESPONDING READING TAKEN. INCREMENT OF 50 Kg IS REPEATED TILL 1000 Kg. AFTER REACHING AT 1000 Kg UNLOADING IS DONE IN THE SAME SEQUENCE & CORRESPONDING READINGS AT 950, 900, 850,……., 250, 200, 150…… & 0 Kg WEIGHT ARE TAKEN.IN CASE WHERE 1000 Kg WEIGHT IS NOT AVAILABLE, ABOVE EXERCISE IS DONE FOR 500 Kg. THEREAFTER 500 Kg AGGREGATE IS LOADED & EXERCISE FROM 500 Kg TO 1000 Kg & UNLOADING BACK TO 500 Kg IS DONE.AVERAGE ERROR FOR EACH OF ABOVE IS CALCULATED

SHEATHING TESTS: MOST CHAPTER - 1800AT LEAST THREE SAMPLES FOR EACH LOT NOT MORE THAN 7000MWORKABILITY:1100mm LONG SAMPLE SOLDERED TO A FIXED PLATE AT ONE END WITH A SOFT SOLDER. BENT TO A RADIUS OF 1800mm ALTERNATLY ON EITHER SIDE TO COMPLETE THREE CYCLES AS SHOWN BELOW.SEALING JOINTS INSPECTED TO VERIFY THAT THERE IS NO FAILURE. 8

1800mm dia

TRANSVERSE LOAD RATING TEST:TO ENSURE STIFFNESS OF SHEATHING IS ENOUGH TO PREVENT PERMANENT DISTORTION.SAMPLE PLACED ON A HORRIZONTAL SUPPORT OF 500mm LENGTH SUCH AS SAMPLE IS SUPPORTED AT ALL POINTS OF OUTWARD CORRUGATION.A LOAD APPLIED AS BELOW AT CENTRE OF THE SUPPORTED PORTION THROUGH A CONTACT SURFACE OF 12mm LENGTH(LOAD AT CENTRE OF CORRUGATION.

Dia.in mm 25-35 35-45 45-55 55-65 65-75 75-85 85-90

Load in N 250 400 500 600 700 800 1000

LOAD

500mm

12mm

TENSION LOAD TEST:1100mm LONG SAMPLE SOLDERED TO A FIXED PLATE AT ONE END WITH A SOFT SOLDER. FILLED WITH A WOODEN PIECE HAVING A DIA OF 95% OF INNER DIA OF SAMPLE. ON THE OTHER END A COUPLER IS SCREWED. LOAD INCREMENT IN WEIGHT PAN.NO DEFORMATION OF JOINTS. NO SLIPPING OF COUPLER.

Dia.in mm 25-35 35-45 45-55 55-65 65-75 75-85 85-90

Load in N 300 500 800 1100 1400 1600 1800

COUPLER

WEIGHT PAN

WATER LOSS TEST:SEALED AT ONE END. FILLED WITH WATER. OUTLET SEALED. PRESSURE OF 0.05 MPa MAINTAINED FOR 5 MINUTES. LOSS OF HEAD NOT MORE THAN 1.5%

TO MAINTAIN A PRESSURE OF 0.05MPa

OUT LET

POST TENSIONING:POST TENSIONING SYSTEM IS GENERALLY APPLIED IN CAST IN SITU COMPONENTS & IN PARABOLIC PROFILING IN BOTH DIRECTIONS.HT STRANDS ARE CUT BY CUTTING WHEELS TO THE REQUIRED LENGTHSHEATHING DUCTS OF APPROPRIATE SIZE ARE INSERTED IN REINFORCEMENT CAGE AND PROFILED AFTER PROVIDING TUBE UNITS AT ENDSHDPE PIPE OF SMALLER SIZE IS INSERTED IN SHEATHING DUCT TO PROTECT FROM SLURRY LEAKAGE AND MOVEMENT TO AND FRO IS DONE AND IS TAKEN OUT AFTER INITIAL SETTING OF CONCRETE.HT STRANDS ARE THREADED BOTH ENDS ARE CLEANED BY PETROL BEARING PLATES AND WEDGES ARE FIXED AFTER SERIAL NUMBERING AND WELL CLEANED. WEDGES ARE WASHED ON OUTER SURFACE.SINGLE PULL/ MULTIPLE JACKS ARE USED AT ACTIVE END. MARKING ON PASSIVE END TENDONS ARE RECORDED AFTER ATTAINING 80% STRENGTH OF CONCRETE CUBES FIRST STAGE /FINAL STAGE STRESSING IS DONE.STRESSING CAN BE DON AT ONE END / BOTH ENDS AS SPECIFIED.INITIALLY SLACKNESS SHALL BE REMOVED AT ZERO LOAD.

ELONGATION OF STRANDS/ CABLES SHALL BE RECORDED AT EVERY INCREMENT LOAD AT THE RATE OF 20% UP TO 75% OF DESIGNED UTS LOAD.LOCK THE WEDGES BY SELF-LOCKING DEVICE AVAILABLE IN PRESTRESSING JACK. RELEASE THE PRESSURE GRADUALLY AND NOTE THE SLIP AT BOTH ENDS.FILL UP THE STRESSING RECORD AND CHECK AS PER DESIGN ELONGATION AND UTSTHE MODIFIED ELONGATION SHALL BE CALCULATED AS PER ACTUAL LENGTH OF TENDON, AREA OF STRAND AND VALUE OF MODULUS OF ELASTICITY.PROVISION FOR JACK EFFICIENCY SHALL BE ALSO BE RECORDED.THE ACTUAL FORCE SHALL NOT BE GIVEN LESS THAN DESIGNED FORCE, 5%-INCREASED LOAD IS PERMISSIBLE LIMIT FOR ACHIEVING REQUIRED ELONGATION.IF THE ELONGATION HAS NOT BEEN ACHIEVED AFTER GIVING 1.05% OF DESIGN LOAD THE MATTER SHALL BE FORWARDED TO ENGINEER IN CHARGE.TRANSFER SLIP SHALL BE CHECKED FOR 24 HRS AND THE STRANDS SHALL BE CUT BEYOND 40MM OF WEDGESEPOXY COATING SHALL BE APPLIED ON STRANDS, WEDGES AND BEARING PLATES.

GROUTING THE PURPOSE OF GROUTING IS TO KEEP THE TENDONS FREE FROM RUST AND MAKING HOMOGENEOUS TO CONCRETE COMPONENTS FOR BEARING LOAD.ALL THE CABLES ARE FIXED WITH GROUT CAP AND WATER IS FILLED MIXED WITH 1% LIME FOR ABOUT 24HRS BEFORE GROUTING.THE WATER IS CLEANED BY AIR JETTING AND VALVE NIPPLE RUBBER PRESSURE PIPE. IT IS CONNECTED THROUGH GROUT HOLE IN BEARING PLATE.RECIPROCATING POSITIVE DISPLACEMENT GROUT PUMP WITH AGITATOR IS USED FOR MAKING GROUT BY CEMENT AND WATER CEMENT RATION .4 WITH ADMIXTURE COMBEX-100 FOR SHRINKAGE FOR 5 MINUTES AND SCREENED BY 1.18 MM IS SIEVE AND THEN OPERATE THE PUMPING. AS SOON AS THIS GROUT MORTAR IS SEEN ON THE OTHER END THE VALVE SHALL BE CLOSED AND THE GROUT SHALL BE CONTINUED TILL PRESSURE IS ACHIEVED FOR 0.7MPA AND MAINTAINED FOR ONE MINUTE. CLOSE THE ACTIVE END VALVE. RELEASE THE PRESSURE AND PROCEED FOR NEXT CABLE.GROUT CUBE OF L OR XL SHALL BE FILLED AT LEAST 12 NOS FOR ONE DAY WORKING.THE GROUT CAP, NOZZLE ETC SHALL BE TAKEN OUT AFTER INITIAL SET AND TOP PORTION OF GROUT CAP AND GROUT HOLE SHALL BE FILLED PROPERLY NEXT DAY.

PRE TENSIONINGPRE TENSIONING SYSTEM IS APPLIED FOR THE CABLE ELEMENTS WHERE NOS OF COMPONENTS ARE SUFFICIENT AND SPACE IS AVAILABLE FOR MAKING BONDS AND THERE IS LITTLE BIT DEVIATION IN CABLE PROFILING TO HORIZONTAL PLANE.ANCHOR HEAD AT BOTH STRESSING AND DEAD END ARE MADE FOR RESISTING THE FORCE OF STRANDS DESIGNED FOR ELEMENTS.SUITABLE NOS OF CASTING BED ARE MADE AND ROLLING SHUTTERS ARE MADE FOR EASY WORKING. STEAM CURING CAN ALSO BE DONE FOR FASTENING THE CYCLE.TENDONS ARE THREADED THROUGH REINFORCEMENT CAGE AND REQUIRED HOPE DEBONDING TUBES ARE PROVIDED WHEREVER NECESSARY.QUICK RELEASE BARRELS AND WEDGES (MASTER WAGES) ARE FIXED AFTER CLEANING STRANDS AND WEDGES.INITIAL PULL IS GIVEN FOR REMOVING SLACKNESS OF STRAND.

STRESSING CAN BE DONE BY SIMPLE PULL JACK/HYDRAULICALLY OPERATED MULTIPULL JACKS UP TO REQUIRED ELONGATION AND FORCE.THE LOAD AND ELONGATION AND MODIFIED ELONGATION SHALL BE CALCULATED AND APPLIED AS PER POST-TENSIONED PARA 9 AND 16.THE CONCRETING SHALL BE DONE AS EARLY AS POSSIBLE AFTER STRESSING.AFTER ACHIEVING 80% STRENGTH OF DESIGNED MIX, DISTRESSING SHALL BE DONE.DISTRESSING CAN BE DONE FOR INDIVIDUAL TENDONS FROM BOTH ENDS AND CUTTING WIRE BETWEEN ELEMENT BEDS, PROVIDING U CLAMPS FOR HOLDING WIRE OR BY MULTI PULL JACK ARRANGEMENT AT A SINGLE OPERATION SLOWLY.AFTER CHECKING TRANSFER SLIPS AND DEBONDING TUBE SLACKNESS, CUT DOWN THE STRANDS FROM FACE OF CONCRETE SURFACE.SEAL THE STRANDS AND DEBONDING TUBE GAP WITH EPOXY

COATING AND MORTAR.

SP-24

Cement 4.1Rapid Hardening cement More Finely Ground (Strength same at 28 days)Portland Slag Cement Resistant to Sulphates attacks & marine environmentPortland Pozzolana cement Less heat of hydration, Greater resistance to aggressive water. Useful for marine works & mass construction. May be used as OPC. Some time fly ash included in manufacture.High strength OPC For PSC etc. (Increased Tricalcium Silicate)Hydrophobic Cement: - OPC with certain hydrophobic contents i.e. some acids which make the cement water repellant & cement can be stored for more longer periods. Needs longer Mixing.

Fly Ash : IS 3812 Physical Chemical Properties for use as PozzolanaWater

Oils 2% by weight of cement may reduce strength by 20% (4.3).Sugar content upto 500 ppm is Ok.Organic material dangerous, Sea water not good, May cause efflorescence & rusting. But may be used under water experiment in salt water.Solids upto 2000 ppm of solids ok.Setting time affected by sugar, carbonates & bicarbonates of sodium & potassium, salts of Na, Zn, Cu & Pb. Sodium hydroxide may quick set.For PCC sea Water upto 35000 PPM of Salt is ok.

Admixture Accelerating - Adding Calcium, Flrosilicates & triatholomineRetarding : Useful in hot weather, Common Type are starches & cellulose, sugar, hydroxic - Carboxylic acid & their salts.Water Reducing or Plasticizing : Contain Lignosulphate salts or Polyhydroxy compounds.Air Entraining admixtures: To intentionally entrain a controlled quantity of air into the concrete in form of discrete minutes bubbles. Are generally organic compounds like animal & Veg Oils, resins, alkali, Salts of sulphates.

POZZOLANAS : Used in four Ways.As Ingredient of Pozzolana cement.As a Part replacement OPC (While Manufacturing)As a fine aggregate (While mixing for concrete)As an admixture. (While mixing for concrete)Generally 20% to 30% for replacement of cement. This may reduce strength of concrete at early age.Fly ash as Pozzolana increase workability if used as FINE AGGREGATE As admixture. it also may decrease bleeding in mix.Pozzolana IS : 3812Burnt clay Pozzolana IS ; 1344

Reinforcement: - IS : 432 Plain BarsIS : 1786 High strength Deformed bars.

High strength deformed bar have strength > 40% of Plain bars.IS: 1786 Strength of 250N/mm2 (M.S.), 415 N/mm2 & 500N/mm2 (Cold worked deformed high strength)IS : 1139 Deformed bars, hot rolled.Hard drawn steel wires IS: 1566.IS: 226 Rolled steel section.Rust in normal amount increase bond with concrete.IS : 4082 for storage of Materials.

Durability of Concrete (7.1) (Page 3)Absence of Durability may be due to Internal agencies like harmful alkali aggregates, sulphates & chlorides in the ingredients, change in Volume charge in cement & aggregates paste due to their properties.External agencies like weathering, industrial gases & liquids, bacterial growth etc.Requirement for Durability: -Choice of Materials QualityDense & impermeable concreteCover Design Cracks > 0.3mm1N = 9.81 Kg. M1 = 1N/mm2

= 1 x 9.81 Kg/mm2= 1 x 9.81 x 100kg/cm2= 981 x 15 x 15 Kg for

cube of 15x15cm= 220725 kg =

220.725 t M30 = 6621 tCube

AGGREGATES (4.2) Fine < 4.75 mm

Aggregate

Coarse >= 4.75mmZone II is Good, Zone IV only in design mixes. Zone - I not in lean concrete.Testing Aggregates IS : 2386Should be free from deleterious materials such as iron, Pyrites, coal, mica, shale, clay, alkali, soft fragments, sea shells & organic matters (IS: 383).Inadequate washing may leave clay film over fine & coarse aggregates.For high compressive strength, adopt lower maximum size.Using Plums? (P-14)Spacing of bars to be based upon nominal maximum size of aggregate.Batching of FA & CA is essential for mix.

PRESTRESSED CONCRETE (MOST - Chapter-1800)

Cement: C3S (Tricalcium Silicate) & C2S (Bicalcium Silicate)Minimum cement content 400 Kg/cumMax W/C ratio 0.40Min. strength: M35Max nominal size of COARSE AGGREGATE 20mm (10mm less than cover or clear distance between reinforcements)Prestressing Steel: IS: 1785(Pt.1 &2), IS: 6003, IS: 6006, IS: 2090Water: free from oils, acids, alkalis, salts, sugar, organic matters etc.Prestressing materials: prestressing steel, sheathing, anchorages, sleeves /couplings (all these to be protected from rain/ dampness)Tendons:

Stored 300 mm above ground in covered and closed space. Away from high temperature, dampness and humidity. No heat treatment like welding, galvanizing etc will be done. Stored in large diameter coils & no kinks, no notches. (5-mm dia wires 2 m dia). Protective wrapping should be chemically neutral.

Anchorage components:No mechanically damage, no corrosion, use correct oil/greases (guaranteed by manufacturer). No C3S (Tricalcium Silicate ) windows, only one door in room. No humidity (instrument installed for meaning humidity). Steel used within 3 months of manufacture.

Sheathing:Spiral corrugated type. Cold rolled. Cold ammeaded (CRCA). MS Steel to IS: 513. No quench hardening or tempering. Bright finish for normal environment. Thickness not less than 0.3 mm, 0.4 mm, 0.5 mm for ducts internal diameter 50 mm, 75 mm & 90 mm respectively. 3 samples per lot ( not exceeding 7000m)

Workability test:1100 mm long sample soldered to a fixed plate bent to a radius of 1800 mm alternately or either side to complete 3 cycles. Sheathing joints should be o.k.

Transverse load rating test:To insure stiffness deformation should be less than 5 %

Tension load test:No deformation of joint.

Water loss test:Water at 5-mpa pressure for 5 minutes. Loss of head is not more than

1.5 % of volume. Sheathing should perfectly be manufactured at site for big projects. Joints if unavoidable, corrugated threaded with coupler should be used to make it slurry tight. Length of sleeve coupler should at least be 150 mm. Joints provided with adhesive sealing tape.

Anchorage:(BS: 4447) To be procured for approved manufacturers only. Test

certificates of approved labs not more than 12 months. No damage. Protect from corrosion. Threads greased. Holes if any, protected. Free from mortar at all times. Swages bottom heads where provided shall develop strength of 95% of safe bearing load.

Tendons: Shall be free from Rust, Oil, Grease, Tar, Paint, Mud, etc. Shall be straight on unwinding coils. (If kinks, bends it has to be rejected). Patching of strands should be removed just before use. On stands for uncoiling. High capacity tendons to be used to reduce No of cables thereby eliminating necessity of grouping.Any two cables horizontal or vertical should not be less than 100 mm. In case of pre-cast segments it shall be 150 mm.Profile of sheathing by providing suitable ladders & spacers at about 1.0 m. Sheathing should be tied to ladders or spacers.Profile of sheathing should not be disturbed during concreting.Tendons if possible shall be placed just before sheathing. Till than may be some temporary tendons inserted.Anchorage Devices:Cleaned.To be set square in the line of action of the Prestressing Tendons

Cutting of wire or Strands:Mechanical or flame cutting.In case of flame cutting other tendons do not come in touch of flame.Flame must be at least 75 mm from where tendon is gripped by anchorage / jacks.In Post-tensioning ends of tendons cut after grout has set.Protection of steel:Done until grouted. The corrosion protection shall not effect, concrete or bond strength of the two.Sheathing:Joints should be tight especially at ends where sheathing must fit on protruding trumpet end of anchorage & made waterproof by using heat shrink tapes (tape is supplied in form of bandages rolls that can be used for all diameters. With a soft flame this bandage material shrinks on sheathing ducts & makes it waterproof. Sheathing weighing machine can be positioned at site for large works. Sheathing shall be water tight to prevent mortar, dust, water etc.

Grout Vents:20 mm diameter, at both ends of Sheathing and valleys & crest along length and not more than 20 mm apart. Plugged to withstand a pressure of 20 mm.Anchorage's:Cleaned before concreting and tensioning.Anchor cones, blocks & plates positioned & maintained such that center line of duct passes axially through anchorage assembly.Recessed from concrete surface at least by 100 mm.After Prestressing wires cut, surface painted with two coats of epoxy of 80 micron finer and entire area filled with concrete or non Shrink mortar or epoxy concrete.Supervision:In the presence of representative of supplier of pretensioning system who shall certify their correctness.

Tensioning Equipment:Hydraulic jacks power driven, unless otherwise approved by the Engineer.Safe.Where more than one wires constitute a tendon, a single multiple stressing jack shall be used. Facility for attaching & handling the multiple jack to the tendons shall be provided.Can apply controlled total force gradually.Means to directly measure force by dynamometer or gauges. Also for linear measurement of extension of steel to nearest mm & any slip of gripping devices at transfer. All meters & gauges calibrated after every 3 months from approved Laboratory.Minimum nominal size of gauges 100 mm. Gauges such that at 75% of breaking load, Gauge reading is between 50-80% of its full capacity.Pressure gauges can withstand sudden release of pressure.Master gauge can be attached to be used as a check wherever desired.

Post Tensioning:Done only after concrete attain required strength or as per stipulated by the prestressing system supplier, which ever is late.Release of pressure shall be graduated to avoid shocks to steel or anchorage.Calculated elongation shall be adjudged w.r.t. modulus of elasticity of steel for particular lot as given by the manufacturer

Important:If calculated elongation is reached before final pressure, continue till 1.05 times of the calculated elongation. If still calculated pressure is not reached inform Engineer.If calculated pressure is reached before calculated elongation, continue till 1.05 times of the calculated pressure If still calculated elongation not reached thenCheck correct functioning of the jack.Determine the cable, slide it in the duct to check for any blockage in the sheathing. Retention if cable is free.Re-establish modulus of elasticity from lot.If still the elongation is not obtained, inform Engineer.Appropriate allowances for any slip at not jacking end.No. of stages prestressing & grouting shall be reduced to a minimum, preferably to two in case of simply supported girders

PRE-TENSIONING:Stressing Bed:Notice showing maximum tensioning from permitted.In long line method, sufficient location plates should be distributed throughout the bed to ensure proper positioning of wires. Moulds shall be free to slide in the direction of their length to permit the transfer of prestressing force to all the concrete elements along the whole line.Deflections, which are in contact with tendons, shall have a diameter not less than tendon subject to a maximum of 15 mm.Desired force should be available in tendon after anchorage slips etc.Trail stressing to establish the frictional resistance & slip during anchoring.Contractor shall submit the calculation showing that the holding downs have been designed to withstand concentrated loads resulting from application of prestressing force.

Tensioning Procedure:Tensioning of wires/strands not too much in advance of concreting.Tensioning applied gradually and uniformly.An initial force to lift wires off the bed floor. This taken into account while calculating elongation.Tendons marked for elongation after initial force applied. Marked at both the jacking end & dead end, also at couplers if used to measure slip and draw in. Where defected Tendons specified elongation or strain gauges at various positions along the tendons to determine force in tendons at those points.

Transfer of Prestress:Hydraulic jacks can accomplish process of Prestress, some mechanical means shall be provided to maintain the tension during the entire period between tensioning and transfer of prestressing force to the concrete.Tendons should be released gradually and perfectly simultaneously.Tendons shall in no case to be cut while in tension.No eccentricity of prestressing force in vertical or horizontal directly during releasing the tension.Cubes should be cured in same environment as the concrete element.Maximum slip of any tendon during transfer shall not exceed 3 mm.Protection of ends:Two coats of epoxy tar paint to give a dry film of 80-micron (second layer before drying of first) on tendons (& concrete within 50 mm of tendons).

Safety:Jacks should be secured tightly.No person behind the jack or close to line of tendons.Safety barrier at both ends to prevent any tendon that might become loose from recoiling.Warning signs displayed.No chipping, drilling or cutting of any concrete after prestressing without approval of the Engineer.No heating or welding near tendon is permitted, if so the affected tendons to be rejected.

Transfer & storage of PSC units:In upright position points of support & direction of reaction w. r. t girder approximately same during transportation & storage.During stacking lateral movements & instability be avoided by using inclined side supports all around.Tolerances:Variation from horizontal profile, vertical profile & specified position of member shall be limited to 5 mm.Payments:ONLY CONCRETE & STEEL BY WEIGHT, TENDONS BY WEIGHT SHALL BE PAID.

DEFORMED STEEL BARS & WIRES FOR CONCRETE REIFORCEMENTHYSD : HIGH YIELD STRENGTH DEFORMED BARSTMT : THERMO MECH. TREATED BARS.IS : 1786Deformed Bars Hot Rolled

Hot Rolling followed by cold TwistingFe 415m Fe 500, Fe 550 Min. 0.2% Proof Stress or yield stress in N/mm2Chemical Composition

Fe 415 Fe 500 Fe 550

C 0.300 0.300 0.300

S 0.060 0.055 0.055

P 0.060 0.055 0.050

S & P 0.110 0.105 0.100

FOR WELDING IS : 9417RIB AREA ABOVE THE CORE -: 0.12 dia for dia ≤ 10mm

0.15 dia for dia 10mm < ø ≤ 16mm0.17 ø for ø > 16mm

Size (mm) 6 8 10 12 16 18 20

Area mm2 28.3 50.3 78.6 113.1 201.2 254.6 314.3

Wt. 0.222 0.395 0.617 0.888 1.58 2.00 2.47

Size (mm) 25 28 32 36 40 45

Area mm2 491.1 616.0 804.6 1018.3 1257.2

1591.1

Wt. 3.85 4.83 6.31 7.99 9.85 12.50

Gross x-Sectional are in mm2 = W/0.00785 LWhere W = Mass in Kg L = Length in metersTOLERANCESLength + 75 - 25mm (+50 -0 if minimum length specified)Mass Upto 10mm ø - (-) 8% +7

Over 10 upto 16 (-)6% +5>16 (-)4%+3

Fe415 Fe500 Fe 500

Elongation % min. on gauge length 5.65 A1/2 where A=X-Sec Area

14.5 12.0 8.0

Tensile Strength (Minimum)

10% more than actual 0.2% Proof Stress & not < 485 M/mm2

8% more than actual 0.2% Proof Stress & not < 545 N/mm2

6% more than actual 0.2% Proof Stress & not < 585 N/mm2

2% Proof stress /Yield stress min, N/mm2

415 500 550

BOND TEST : If surface area is ok it is ok.TEST PIECES : IS :226TENSILE TEST : IS : 1608 - 1972, IS : 226BEND TEST : No transverse cracks in bent position

Fe 415 Fe 500 Fe 550

Mandrel dia. Upto 22 dia. 3 d 4 dia 5 dia

Mandrel dia. Over 22 dia. 4 dia 5 dia. 6 dia

REBEND TEST Keep in 1000C Water for 30 Minutes & then cool.

Fe 415 & 500 Fe 550

Mandrel Dia Upto 10 dia 5 dia. 7 dia

Over 10 dia. 7 dia. 8 dia.

CUBE MARKING & NO. OF CUBES TO BE TAKEN:

Name of the structure/Identification

Date of casting

Cube No /Total cubes taken from transit mixer

Sequential Transit mixer number

D - 1/5 RW Pile 30-12-04

T4 1/6

FOR R.C.C WORKS (IS: 456-2000 Para 15.2 & 15.3) No of Cubes: - (Generally 6 cubes from each transit mixer)

1

2

3

4

5

6

7

8

9

7 days

Extra

28 days

For 1m3 to 5m3 9 cubes

1

2

3

4

5

6

7

8

9

10

11

12

6 m3 to 15 m3 12 cubes

7 days

28days

Extra

SIMILARLY FOR: -

16 m3 to 30m3 – 18 cubes including 3 extra 31 m3 to 50 m3 – 24 cubes including 3 extra 51 m3 to 100 m3 – 30 cubes including 3 extra101 m3 to 150 m3 – 36 cubes including 3 extra151 m3 to 200 m3 – 42 cubes including 3 extra

FOR PSC WORK: -

12 cubes 1

2

3

4

5

6

7

8

9

10

11

12

For 35 MPa for U girder & 40 MPa for L girder

28days

Extra

28 days

AGGREGATES:-IS : 383 - 1970/1993SPECIFICATIONS FOR COARSE AGGREGATE & FINE AGGREGATE FOR CONCRETE ZONE I,II,III,IV. COARSER FINERSAMPLING: IS : 2430 - 69 IS : 2- 1960(Rounding off values)FINE AGGREGATE : Passing through 4.75 mm sieve.COARSE AGGREGATE: Retaining on 4.75 mm sieve.AGGREGATES:Uncrushed from natural disintegration of Rock.Crushed from Rocks/Gravels/ Stones.Combination of above two.

COARESE AGGREGATEShall be hard, strong, dense, durable, clear, free from veins &

adherent coating, free from disintegrated pieces like Alkali, Organic matter and other deleterious matter. If possible, flakiness & elongation should be avoided.Deleterious Materials:Pyrites, Coal, Ignite, Mica, Shale, Clay, Alkali, Soft fragments, Seashells & Organic impurities.AGGREGATE CRUSHING VALUE:Not more than 30% for wearing surfaces i.e. Roads, Runways, Pavements etc.Not more than 45% for others.

IMPACT VALUE:Not more than 30% for wearing surfaces i.e. Roads, Runways, Pavements etc.Not more than 45% for others.ABRASION VALUE:Not more than 30% for wearing surfaces i.e. Roads, Runways, Pavements etc.Not more than 50% for others.SOUNDNESS:When exposed to action of FROST.

Tested with Na2SO4 Tested with MgSo4

FINE AGGREGATE 10% 15%

COARSE AGGREGATE 12% 18%

TABLE-1 :LIMITS OF DELE TERIOUS MATERIALS

DELETA-RIOUS SUBSTA-NCE

TEST METHOD

F.A. % BY WEIGHT MAX. C.A. % BY WEIGHT MAX.

UNCRUSHED CRUSHED UNCRUSHED CRUSHED

i)coal & ignite

Is:2386 Pt-II

1 1 1 1

Clay lumps Is:2386 Pt-I

1 1 1 1

Material finer than 75 micron

Is:2386 Pt-II

3 15 3 3

Soft fragments

Is:2386 Pt-II

- - 3 -

shale - 1 - - -

Total 5 2(except for finer materials)

5 5

TABLE-2,3,4,5(GIST) :COARSE AGGREGATESFINE AGG.ZONE-II

COARSE AGG 20mm

COARSE AGG 10mm COMBINED COARSE AGG. (ALL - IN - AGG.

40 - 100 - 100

20 - 85-100 - 95-100

12.5 - - 100 -

10 - 0-20 85-100 25-35

4.75 90-100 0-5 0-20 0-10

2.36 75-100 - 0-5 -

1.18 55-90 - - -

600MICRONE

35-59 - - -

300MICRONE

8-30 - - -

150MICRONE

0-10 - - -

75MICRONE

- - - -

COMPLETE INFORMATION ABOUT THE PHYSICAL & CHEMICAL PROPERTIES OF AGGREGATES CAN BE HAD FROM THE SUPPLIER IN PROPER FORMATS