Building and construction materials : testing and quality control : lab manual

576 Pages·2014·27.048 MB·English

by  Murari Lal Gambhir, Neha Jamwal

Lab Manual
BUILDING AND CONSTRUCTION MATERIALS
Testing and Quality Control
ABOUT THE AUTHORS
Dr M L Gambhir was Professor and Head of Civil Engineering Department, and
Dean Planning & Resource Generation at the Thapar University, Patiala ( previously
Thapar Institute of Engineering & Technology, Patiala). He obtained his Bachelor’s
and Master’s degree from University of Roorkee (presently Indian Institute of
Technology, Roorkee) and PhD from Queen’s University, Kingston, Canada.
His major research interests were in the areas of structural engineering particu-
larly in structural failures and rehabilitation of structures; vibration-based health
monitoring of structures; structural reliability; structural stability and dynamics;
high performance concrete; steel and reinforced concrete design. He had wide ex-
perience in structural design of diverse types of structures in structural steel and reinforced concrete.
Dr Gambhir had over 65 technical papers in archival refereed journals and international conferences to his
credit and had authored with reputed publishers.
Dr Gambhir had authored the following books with McGraw-Hill Education (India) Private Limited:
• Concrete Technology, 5e
• Building Materials
Mrs Neha Jamwal is currently working with Santos Ltd, Australia as Contracts Engineer (Contracts &
Procurement); formerly Contracts Engineer with QGC Pty Ltd- a BG Group Company, Australia. Prior to
QGC she has worked as Project Engineer (Engineering- Projects) with John Holland Pty Ltd, Australia, fol-
lowing on from Deputy Manager (Engineering & Coordination- Projects) with Punj Lloyd Ltd (Middle East
Operations, Abu Dhabi, Dubai, UAE) & Senior Engineer (Engineering- Projects) with Punj Lloyd Ltd (New
Delhi, India).
She obtained her Master’s Degree in Structural Engineering from National Institute of Technology,
Kurukshetra, India in 2006, and Bachelor’s Degree in Civil Engineering from Punjab Technical University,
Jalandhar, India in 2002. Her major research interests are theoretical and experimental structural engineering.
She evolved a unified design approach for reinforced concrete members.
Throughout her professional career she has been involved in Engineering Design & Coordination, Front
End Engineering Design, Contracts & Procurement, and Project Engineering & Execution. In recent years,
she has been involved in a number of prestigious projects in India, Middle East and now Australia. She has
worked on prestigious projects like GLNG & QCLNG which involves extraction of coal seam gas, conver-
sion to LNG & transporting it to global market. She has extensively worked on project management systems,
and state-of-art engineering systems.
She is member of CIPSA (Chartered Institute of Purchasing & Supply, Australia) and Engineers Australia.
She has also been a recipient of several awards in Safety, Engineering, and safe industrial and workplace
practices in the construction & resources industry. She has also co-authored a book on Building Materials.
Lab Manual
BUILDING AND CONSTRUCTION MATERIALS
Testing and Quality Control
M L Gambhir
Formerly Professor and Head
Department of Civil Engineering
Dean, Planning and Resource Generation
Thapar University, Patiala
Punjab
Neha Jamwal
Engineer (Contracts & Procurement)
SANTOS Ltd, Australia
McGraw Hill Education (India) Private Limited
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Lab Manual-Building and Construction Materials (Testing and Quality Control)
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CONTENTS
Preface ix
1.. Concept of Quality Control ................................................................................................................................................................................1
1.1 Concept of Quality Control 1
1.2 Quality Control Through Testing 1
1.3 Quality of Concrete 2
1.4 Distribution of Results 3
1.5 Standard Deviation 3
1.6 Applications 4
1.7 Advantages of Quality Control 7
National Standards 7
References 7
2.. Cement ....................................................................................................................................................................................................................................................8
2.1 Introduction 8
2.2 General-Purpose Portland Cements 8
2.3 Special-Purpose Cements 9
2.4 Storage of Cement 10
2.5 Tests For Physical Properties of Portland Cement 11
2.6 Preparation of Cement Sample 13
National Standards 42
References 42
3.. Building Limes ......................................................................................................................................................................................................................43
3.1 Introduction 43
3.2 Properties of Lime 44
3.3 Classification of Lime 45
3.4 Tests for Building Limes 45
3.5 Precautions While Handling Lime 51
3.6 Preparation of Lime Mortars 51
3.7 Grades of Mortars 52
National Standards 77
References 77
4.. Aggregates ....................................................................................................................................................................................................................................78
4.1 Introduction 78
4.2 Fine Aggregate 78
4.3 Coarse Aggregate 82
4.4 All-In-Aggregates 84
4.5 Gap-Graded Aggregate 84
4.6 General Characteristics 84
vi Contents
4.7 Preparation of Aggregate Sample for Testing 87
National Standards 121
References 121
5.. Water For Construction ..................................................................................................................................................................................122
5.1 Introduction 122
5.2 Quality of Mixing Water 122
5.3 Gravimetric Testing of Water 123
National Standards 138
References 138
6.. Fresh Concrete ..................................................................................................................................................................................................................139
6.1 Introduction 139
6.2 Workability 139
6.3 Preparation of Sample 142
6.4 Principles of Measurement of Workability 143
National Standards 165
References 165
7.. Self-Consolidating Concrete ......................................................................................................................................................................166
7.1 Introduction 166
7.2 Advantages 166
7.3 Rheology 167
7.4 Production and Quality Control 168
7.5 Specification Classification of SCC 169
7.6 Test Procedures for SCC 171
National Standards 202
References 202
8.. Hardened Concrete ..................................................................................................................................................................................................203
8.1 Introduction 203
8.2 Properties of Hardened Concrete 203
8.3 Impermeability of Concrete 206
8.4 Durability of Concrete 206
8.5 Shrinkage 207
8.6 Creep 207
8.7 Modulus of Elasticity 208
8.8 Poisson’s Ratio 208
8.9 Thermal Properties 208
8.10 Resistance to Fire 208
8.11 Testing of Hardened Concrete 208
8.12 Testing of Hardened Concrete 212
8.13 Recording of Observations and Calculations 214
Contents vii
Test Report 219
National Standards 242
References 242
9.. Non-Destructive Testing ................................................................................................................................................................................243
9.1 Introduction 243
9.2 Test Methods 243
National Standards 264
References 264
10.. Concrete Mix Design ..........................................................................................................................................................................................265
10.1 Introduction 265
10.2 Basic Considerations of Concrete Mix Design 265
10.3 Types of Mixes 266
10.4 Factors Affecting the Choice of Mix Proportions 266
10.5 Expressing Mix Proportions 268
10.6 Mix Design Procedure 268
10.7 Methods of Concrete Mix Design 270
10.8 Testing 270
National Standards 296
References 296
11.. Pavement Materials-I ........................................................................................................................................................................................297
11.1 Introduction 297
11.2 Desirable Characteristics 297
11.3 Aggregate Tests 298
National Standards 330
References 330
12.. Pavement Materials-II ....................................................................................................................................................................................331
12.1 Introduction 331
12.2 Different Forms of Bitumen 331
12.3 Properties of Bitumen 332
12.4 Tests on Bitumen 332
12.5 Collection of Material Sample 333
12.6 Safety Precautions While Testing Bitumenous Binders 333
National Standards 385
References 385
13.. Bricks And Tiles..........................................................................................................................................................................................................386
13.1 Bricks 386
13.2 Tiles 389
13.3 Acceptance Criteria 392
National Standards 419
References 419
viii Contents
14.. Infrastructural Materials ............................................................................................................................................................................421
Metals
14.1 Introduction 421
14.2 Mechanical Properties of Steel 422
14.3 Test Procedures 426
14.4 Torsion Test of Materials 429
14.5 Compression Test of Materials 430
14.6 Bending Test 432
14.7 Fatigue Test 433
14.8 Codes for Test Procedures 436
National Standards 487
References 488
15.. Construction Materials ..................................................................................................................................................................................489
Structural Timber
15.1 Introduction 489
15.2 Measurements of Strengths 490
15.3 Test Procedures 495
National Standards 528
References 528
16.. Investigative Tests ....................................................................................................................................................................................................530
16.1 Introduction 530
16.2 Purpose of Admixture 530
16.3 Classification of Admixtures 531
National Standards 566
References 566
PREfACE
Introduction
Materials play an important role in the construction all types of structures. Right selection of quality materials
adds to the economy and service life of a structure. The design of structures is usually based on the presump-
tion that each of the materials to be used in construction of a typical structure has certain characteristics; this
presumption makes it mandatory to verify that the materials used in construction have the assumed character-
istics. This can only be ensured by regular testing of materials according to certain National and International
standard procedures which will provide a clear picture of material characteristics.
The past practice of exercising quality control only during construction is irrelevant in modern quality
control concept; quality control is exercised at all the three stages of construction activity, i.e., at preconstruc-
tion stage specifying and controlling the quality of materials, during the construction phase and acceptance
quality checks after completion of each stage of construction, which is termed as “stage passing”.
As in the manual, references has been made to numerous codes and specifications which are frequently
amended and updated, users should use the latest edition of the referenced specifications/code. Moreover, the
codes are the source of more complete and error-free information. Readers are cautioned to exercise inde-
pendent professional judgment while using the information set forth in this manual; it is not aimed to render
engineering or other consultancy services.
It is earnestly hoped that the manual will also provide enough guidance to the concrete/material testing/
construction materials/building material laboratories to provide testing services to builders and the construc-
tion industry. It will prove to be a helpful guide to the field engineers for day-to-day reference and the con-
tractors engaged in construction work.
Salient Features of the Book
• Tests relevant to various construction activity described in a systematic and logical style, enabling read-
ers to first get acquainted with the basics of the material and then move on to the test procedures
• Test procedures to be followed for conducting various tests, along with the equipment required for each
test are in accordance with the National and International Standards
• List of relevant National Standards (IS codes) and references given at the end of each section
• Pedagogical features include
98 Experiments
973 Viva-voce questions
155 Figures
225 Tables
Book Organisation
The manual covers the curriculum requirements of civil engineering and architecture students at both degree
and diploma level programs of most of the institutions, and is intended to develop in the reader the ability to
conduct material test systematically. The test procedures have been divided into 16 sections, namely concept
of quality control, cement, building limes, aggregates, water, conventional fresh concrete, self-compacting
concrete, hardened concrete, non-destructive tests, concrete mix design, pavement aggregates, bitumen,
bricks, steel and investigative tests.
The test procedures to be followed for conducting various tests, along with the equipment required for
each test are in accordance with the methods given in the relevant National and International Standards. The
objective and scope of the test with its significance has also been given for each test. List of relevant National
x Preface
Standards (IS codes) and references are given at the end of each section, and a set of searching questions
based on the test procedure are given at the end of each test.
The test procedures relevant to three stages of construction activity are described in a systematic and logi-
cal style that will enable the readers to first get acquainted with the basics of the material before moving on to
the test procedures. The manual also provides detailed information on current thinking on the subject matter
in the discussion part of the procedure.
Besides presenting adequate relevant information, the manual has been made users friendly by including a
large number of coloured images (photographs) of equipment in each section to enhance comprehension.
Acknowledgements
We are indebted to numerous sources for the information presented in the manual some of them are listed in
the references at the end of each section. Dr Gambhir is grateful to the Bureau of Indian Standards for their
published material to which references are made at numerous places in the manual.
We wish to acknowledge the contributions made by many individuals and organizations that provided
valuable assistance in bringing out the manual. It gives us immense pleasure in acknowledging the assis-
tance rendered by Dr Puneet Gambhir, Er Mohit Gambhir and Er Atul Jamwal CE MBA. The task could be
completed because of their wholehearted inputs. We would also like to express our deepest gratitude to Mrs
Saroj Gambhir, wife of Dr Gambhir for her personal sacrifices, unwavering cooperation and encouragement
in bringing out this text.
We would like to thank the following reviewers for suggesting constructive inputs in improving the script:
Shamsher Bahadur Singh BITS Pilani, Rajasthan
Ashok Kumar Khan NIT Jamshedpur, Jharkhand
Tuhin Subhra Konar Heritage Institute of Technology, Kolkata, West Bengal
Tanuja Pradeep Bandivadekar Sardar Patel College of Engineering, Andheri, Maharashtra
K Madan Mohan Reddy SriKalahasteeswara Institute of Technology, Chittoor, Karnataka
Manmohan Sharma Projects Services and Assurance Advisor, BHP Billiton, Australia.
Special thanks to the editorial team at McGraw Hill Education (India) for their support and cooperation in
bringing out this manual.
M L Gambhir
Neha Jamwal
Feedback
The manual of this nature cannot remain static; it has to be dynamic with continuous upgradation of technol-
ogy; in process, the users play very important role in pointing out the deficiencies. Feedback/suggestions will
greatly help in improving and making the manual more useful in future reprints and editions.
The publisher regrets to inform the sad and untimely demise of Dr M.L. Gambhir on 4th January 2013. This
work is dedicated to the untiring spirit of an academician par excellence who always dreamt of a seamless
dissemination of knowledge and strove incessantly towards the same.
Publisher’s Note
We look forward to receiving valuable views, comments and suggestions for improvements from teachers
and students, all of which can be sent to [email protected], mentioning the title and author’s
name on the subject line.
Piracy related issues can also be reported..