Lab Testing Procedures

Laboratory Testing Procedures
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APPROVED BY;
Ahluwalia Contracts (India) Ltd.

WORK INSTRUCTIONS
Inspection & Testing- SILT CONTENT (Fine
agg)
DOCUMENT NO WI/01
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METHOD-1 (By Volume- As per CPWD Specification)

OBJECT:
This method of test deals with the procedure for determining the Silt Content of Sand by
Sedimentation Method.
APPARATUS:
The apparatus required for the test is as follows:
A 250 ml capacity-measuring cylinder.
TEST SAMPLE:
Material sampled for the test should be thoroughly mixed before sampling and it should
contain sufficient moisture to prevent segregation.
PROCEDURE:
Fill the cylinder to 50 ml mark with salt water. (Salt to be 1 teaspoonful to half litre of
water).
Pour in the sample of sand to be tested until the level of sand is 100 ml mark.
Add more water until 150 ml mark is reached.
Shake the cylinder well, talking a particular care to spill any of the contents.
Keep the cylinder filled with sand for 3 hours.
Note the Silt height (above sand layer) and sand height (below silt layer).
REPORTING OF RESULTS:
The Calculation & Reports shall be maintained in the Format F-01/WI/IT/01.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
agg)
DOCUMENT NO WI/01
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METHOD-2 (By Weight- As per IS 2386 part-1)

OBJECT:
This method of test deals with the procedure for determining the total quantity of material
finer than 75-micron IS sieve in aggregates by washing.
APPARATUS:
The balance or scale shall be of sufficient capacity and sensitivity and shall have an
accuracy of 0.1 percent of the weight of test sample.
Sieves-A nest of two sieves, the lower being 75-micron IS Sieve and the upper
approximately 1.18 mm IS Sieve.
Container-A pan or vessel of a size sufficient to contain the sample covered with
water and to permit of vigorous agitation without loss of any part of the sample of
water.
Oven-An oven of sufficient size capable of maintaining a uniform temperature of
110oC 5oC.
TEST SAMPLE:
The weight of sample available shall not be less than the weight
Maximum Nominal Size of Aggregates
(mm)
4.75
10.0
20.0
40 or over
Approximate minimum weight of sample

(gm)
500
2000
2500
5000
PROCEDURE:
The test sample shall be dried to constant weight at a temperature of 110oC5oC and
weighed to the nearest 0.1 percent.
The dried and weighed sample shall be placed in the container and sufficient water is
added to cover it. Then the contents of the container are agitated vigorously.
The agitation shall be sufficiently vigorous such that the coarse particles are separated
and the fine particles are brought into the suspension.
The water (mixed with fine particles) shall be poured over the nested sieves arranged
with the coarser sieve at the top.
SIGNATURE:
DESIGNATION:
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WORK INSTRUCTIONS
agg)
DOCUMENT NO WI/01
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All materials retained on the both the sieves shall be container containing coarser
particles.
Steps 3, 4 & 5 are repeated till the wash water looks clear. Care should be taken such
that no materials retained on the sieve get lost.
The retained materials should be dried to a constant weight at a temperature not
exceeding 110oC and weighed to the nearest 0.1 percent.
The Calculation & Reports shall be maintained in the Format F-02/WI/IT/01.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- PARTICLE SIZE
DISTRIBUTION (Coarse & Fine agg)
DOCUMENT NO WI/02
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OBJECT:
This method of test covers the procedure for the determination of Particle size distribution of
Fine & Coarse aggregates by sieving or screening (As per IS: 2386 part-1)
APPARATUS:
Sieves- Sieves (Conforming to IS:460-1962) of size 40mm ,20mm ,12.5mm ,10mm,
4.75mm ,2.36mm ,1.18mm ,600 micron ,300 micron & 150 micron.
The balance or scale shall be such that it is readable and accurate to 0.1 percent of
weight of the test sample.
Sieve shaker.
TEST SAMPLE:
The weight of the sample available shall not be less than the weight given in the table below.
The sample for sieving shall be prepared from the larger sample either by quartering or by
means of sample divider.
Maximum Size present in Substantial
proportions (mm)
20
10
6.3
Minimum weight of sample required for

quartering (Kg)
25
6
3
Minimum weight of sample required for Sieve analysis after Quartering shall be as follows.
Maximum Size present in Substantial
proportions (mm)
20
10
4.75
Minimum weight of sample required for

Sieve analysis (Kg)
2.0
0.5
0.2
PROCEDURE:
Bring the sample to an air-dry condition before weighing and sieving.
Weigh the air-dry sample and sieve successfully on the appropriate sieves starting with
the largest.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- PARTICLE SIZE
DISTRIBUTION (Coarse & Fine agg)
DOCUMENT NO WI/02
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Each sieve shall be shaken separately over a clean tray until not more than a trace
passes, but in any case for a period of not less than 2 minutes.
Shake with a varied motion so that the material is kept moving over sieve surface in
frequently changing directions.
Light brushing of the underside of sieve with a soft brush may be used to clear the
sieve openings.
On completion of sieving the material retained on each sieve together with any
material cleaned from the mesh, shall be weighed.
The Calculation & Reports shall be maintained in the Format F-01/WI/IT/02,

F-02/WI/IT/02, F-03/WI/IT/02 & F-04/WI/IT/02.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- SP.GRAVITY &
WATER ABSORPTION (Coarse & fine agg)
DOCUMENT NO WI/03
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OBJECT:
This method of test covers the procedures for determining the Specific gravity & Water
Absorption of aggregates. (As per IS: 2386 part-III)
APPARATUS:
A balance of capacity 3 kg or more, readable & accurate to 0.5g.

An Oven to maintain a temperature of 100oC to 110oC.
A Pycnometer of about one liter capacity
A tray of area not less than 325 cm2.
Filter papers & funnel.
TEST SAMPLE:
The sample taken for test shall be approximately 500 g for fine aggregates & 1000 g for coarse
aggregates.
PROCEDURE:
Making the sample at SSD condition: A sample of about 1000 g for coarse
aggregates & 500 g for fine aggregates shall be placed in separate trays and water is
poured in the tray such that the sample gets completely immersed in water. The
temperature of water shall be maintained between 22oC to 32oC.The immersed
aggregates shall be agitated with rod so the entrapped bubbles gets completely
removed from the aggregates. Then the sample is left immersed in water for 241/2
hours. The water shall then be carefully drained from the sample such that no
particles get lost. The sample is kept in exposed air or below fan so that the surface
moisture gets evaporated (i.e. the sample shall be stirred at frequent interval to ensure
uniform drying until no free surface moisture is seen and the material just attains a
free running condition. The weight (W1) of the sample is taken which is SSD
weight.
The SSD aggregate shall then be placed in the Pycnometer, which shall then be filled
with distilled water. The hole at the top of brass cone of pycnometer shall be closed
with finger and the trapped air shall be removed by rotating the pycnometer on its
side. The Pycnometer shall be filled completely with water, wiped/dried from outside
and weighed. (W2)
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- SP.GRAVITY &
WATER ABSORPTION (Coarse & fine
agg)
DOCUMENT NO WI/03
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The aggregates along with water are taken out carefully on a tray. The Pycnometer
shall be completely filled with water, wiped/dried from outside & weighed. (W3).
The water present in the tray along with aggregates shall be completely drained such
that no aggregate particles get lost. The sample with tray shall then be kept in the
oven at a temperature 100oC to 110oC for 241/2 hours. It shall be cooled and
weighed (W4).
W1 = Weight in g of SSD sample.
W2 = Weight in g of pycnometer containing sample and filled with water
W3 = Weight in g of pycnometer filled with water only.
W4 = Weight in g of oven dried sample.
The Calculation & Reports shall be maintained in the Format F-01/WI/IT/03 &
F-02/WI/IT/03.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing-MOISTURE
CONTENT(Coarse & Fine agg)
DOCUMENT NO WI/04
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OBJECT:
This method of test covers the procedures for determining the Moisture Content of
aggregates. (As per IS: 2386 part-III)
APPARATUS:
A balance of capacity 3 kg or more, readable & accurate to 0.5g.
An Oven to maintain a temperature of 100oC to 110oC.
A Container.
TEST SAMPLE:
The sample taken for test shall be approximately 500 g for fine aggregates & 1000 g for
coarse aggregates.
PROCEDURE:
1. Take the sample in container and weigh it accurately.(W1)
2. Dry the sample in oven and weigh it. (W2)
3. Now weigh the empty container. (W3)
4. Weight of water can be calculated as follows:
Weight of water (W4) = W1 W2
5. Weight of dry sample can be calculated as follows:
Weight of dry sample (W5) = W2 W3
6. Moisture content can be calculated as follows:
Moisture Content % = W4 x 100
W5
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing-MOISTURE
CONTENT(Coarse & Fine agg)
DOCUMENT NO WI/04
ISSUE NO
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RESULTS:
The calculations and results can be reported as per Format F-01/WI/IT/04.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- BULKING OF SAND
DOCUMENT NO WI/05
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OBJECT:
This method of test covers the procedures for determining the necessary adjustment for
bulking of Fine aggregate. (As per IS: 2386 part-III)
APPARATUS:
A container of capacity 3 liter.

A Steel Ruler.
A Steel Rod 6 mm in diameter.
A 250 ml capacity measuring cylinder.
TEST SAMPLE:
The sample taken for test shall be approximately 5kg.
PROCEDURE:
METHOD 1
1. Put sufficient quantity of sand loosely into a container until it is about two-third full.
Level off the top of the sand.
2. Push a steel rule vertically down through the sand at the middle to bottom. Measure the
height. Suppose this is h cm.
3. Empty the sand out of the container into another container where none of it is lost.
4. Half fill the first container with water. Put back about half the sand and rod it with a
steel rod so that its volume is reduced to a minimum.
5. Then add the remainder, rod it and level the top surface of inundated sand.
6. Measure its depth at the middle with steel rule. Suppose this is h1 cm.
7. Percentage bulking of sand due to moisture content shall be calculated as:
Percentage Bulking = (h/h1 1) x 100
DOCUMENT NO WI/05
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WORK INSTRUCTIONS
Inspection & Testing- BULKING OF SAND
ISSUE NO
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REV. NO
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METHOD 2
1. In a 250ml-measuring cylinder, pour the damp sand and consolidate it by staking until it
reaches the 200 ml mark.
2. Fill the cylinder with water and stir the sand well (the water shall be sufficient to submerge
the sand completely).
3. It will be seen that the sand surface is now below its original level.
4. Suppose the surface is at the mark of h Level, therefore the % of bulking of sand due to
moisture shall be calculated as:
Percentage Bulking = (200/h-1) x 100.
The Calculation & Reports shall be maintained in the Format: F-01/WI/IT/05

WORK INSTRUCTIONS
DOCUMENT NO WI/06
ISSUE NO
DATE
REV. NO
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DATE
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
Inspection & Testing-AGGREGATE

CRUSHING VALUE
PAGE
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OBJECT:
This method of test covers the procedure for determining the aggregate crushing value of
coarse aggregate. (As per IS: 2386)
APPARATUS:
A 15-cm diameter open-ended steel cylinder, with plunger and base-plate. The
surfaces in contact with the aggregate shall be machined and case-hardened or
otherwise treated so as to have a diamond (VH) pyramid hardness number of not less
than 650VH.
A straight metal tamping rod of circular cross-section 16mm in diameter and 45 to
60cm long, rounded at one end.
A balance of capacity 3 kg, readable and accurate to one gram.
IS Sieves of sizes 12.5mm, 10mm and 2.36mm.
A compression testing machine capable of applying a load of 40 tonnes and which
can be operated to give a uniform rate of loading so that the maximum load is
reached in 10 minutes. The machine may be used with or without spherical seating.
For measuring the sample, cylindrical metal measure of sufficient rigidity its form
under rough usage and of the following internal dimensions:
Diameter
11.5cm
Height
18.0cm
TEST SAMPLE: 1. The material for the standard test shall consist of aggregate passing a 12.5 mm IS Sieve
and retained on a 10 m IS Sieve, and shall be thoroughly separated on the sieves before
testing. For other sizes, the material shall be separated on the appropriate sieves given in
Table 1.
2. The aggregate shall be tested in a surface-dry condition. If dried by heating, the period of
drying shall not exceed four hours, the temperature shall be 100 C to 110 C and the
aggregate shall be cooled down to room temperature before testing.
3. The quantity of aggregate shall be such that the depth of material in the cylinder, after
tamping as described next shall be 10 cm.
4. The appropriate quantity may be found conventionally by filling the cylindrical measure in
three layers of approximately equal depth, each layer being tamped 25 times with the
rounded end of the tamping rod as a straightedge.

WORK INSTRUCTIONS
DOCUMENT NO WI/06
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DATE
REV. NO
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SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

CRUSHING VALUE
PAGE
2 OF 3
5. The weight of material comprising the test sample shall be determined (Weight A) and the
same weight of sample shall be taken for the repeat test.
TABLE I. DETAILS OF AGGREGATE CRUSHING TEST FOR NON-STANDARD
SIZES OF AGGREGATE
NOMINAL Sizes (IS SIEVE)
Passing through
(mm)
Retained on
(mm)
25
20
10
6.3
4.75
3.35
20
12.5
6.3
4.75
3.35
2.36
DIAMETER OF
CYLINDER TO BE USED
SIZE OF IS SIEVE
FOR SEPRATING FINES
(cm)
15.0
15.0
15.0 to 7.5
15.0 to7.5
15.0 to7.5
15.0 to 7.5
4.75mm
3.35mm
1.70 mm
1.18 mm
850 microns
600 microns
PROCEDURE:
1.
The cylinder of the test apparatus shall be put in position on the base-plate and the
test sample added in thirds, each third being subjected to 25 strokes from the tamping rod . The
surface of the aggregate shall be carefully levelled and the plunger inserted so that it rests
horizontally on the surface, care being taken to ensure that the plunger does not jam in the
cylinder.
2.
The apparatus, with the test sample and plunger in position, shall then be placed
between the platens of the testing machine and loaded at a uniform rate as possible so that the
total load is reached in 10 minutes. The total load shall be 40 tonnes.
3.
The load shall be released and the whole of the material removed from the cylinder
and sieved on a 2.36-mm IS Sieve for the standard test, or the appropriate sieve given in Table
I. The fraction passing the sieve shall be weighed (Weight B).

WORK INSTRUCTIONS
DOCUMENT NO WI/06
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SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

CRUSHING VALUE
PAGE
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In all of these operations, care shall be taken to avoid loss of the fines, two tests shall be
made.
The ratio of weight of fines formed to the total sample weight in each test shall be expressed
as a percentage, the result being recorded to the first decimal place:
Aggregate Crushing Value = B /A * 100
RESULTS:
The Calculation & Reports shall be maintained in the Format: F-01/WI/IT/06.
DOCUMENT NO WI/07
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingIMPACT VALUE
ISSUE NO
DATE
REV. NO
: 01
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1 OF 2
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
OBJECT:
This method of test covers the procedure for determining the aggregate impact value of coarse
aggregate. (AS per IS: 2386)
APPARATUS:
An impact testing machine of the general form and in compliance as per I.S.2386 (part
IV)-1963.
I.S Sieves of sizes 12.5mm, 10mm & 2.36mm.
A cylindrical metal measure, tarred to he nearest gram , of sufficient rigidity to retain its
form under rough usage, and of the following internal dimensions:
Diameter
75mm
Depth
50mm.
A straight metal tamping rod of circular cross-section 10mm in diameter and 230mm long,
rounded at one end.
A balance of capacity not less than 500g, readable and accurate to 0.1gram.
A well ventilated oven thermostatically controlled to maintain a temperature of 100-110 oC.
TEST SAMPLE: 1. The material for the standard test shall consist of aggregate passing a 12.5 mm IS Sieve and
retained on a 10 m IS Sieve, and shall be dried in an oven for a period of 4 hours at a
temperature of 100 oC to 110 oC and cooled.
2. The measure shall be filled about one-third full with the aggregate and tamped with 25
strokes of the rounded end of the tamping rod. A further similar quantity of aggregate shall be
added and a further tamping of 25 strokes given. The measure shall be finally being filled till
overflowing, tamped 25 times and the surplus aggregate struck off, using the tamping rod as a
straight edge. The net weight of aggregate in the measure shall be determined to the nearest
gram (wt. A) & this wt. of aggregate shall be used for the duplicate test on the same material.
DOCUMENT NO WI/07
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingIMPACT VALUE
ISSUE NO
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PROCEDURE:
1. The impact machine shall rest without wedging or packing upon the level plate, block or
floor, so that it is rigid and the hammer guide columns are vertical.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
2. The cup shall be fixed firmly in position on the base of the machine and the whole of the
test sample placed in it and compacted by a single tamping of 25 strokes of the tamping
rod.
3. The hammer shall be raised until its lower face is 380mm above the upper surface of the
aggregate in the cup, and allowed to fall freely on to the aggregate. The test sample shall
be subjected to a total of 15 such blows each being delivered at an interval of not less than
one second.
4. The crushed aggregate shall then be removed from the cup, and the whole of it is sieved on
the 2.36mm I.S. Sieve until no further significant amount passes in one minute. The
fraction passing the sieve shall be weighed to an accuracy of 0.1g (wt. B). The fraction
retained on the sieve shall also be weighed (wt. C), and if the total weight (wt. B+C) is less
than the initial weight (wt. A) by more than on gram, the result shall be discarded and a
fresh test be made. Two tests shall be made.
The ratio of weight of fines formed to the total sample weight in each test shall be expressed
as a percentage, the result being recorded to the first decimal place:
Aggregate Impact Value = B /A * 100
RESULTS:
The Calculation & Reports shall be maintained in the Format F-01/WI/IT/07
DOCUMENT NO WI/08
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingFLAKINESS INDEX
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OBJECT:
This method of test lays down the procedures for determining the Flakiness Index of coarse
Aggregate. (As per IS: 2386 part-I)
APPARATUS:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
A balance of sufficient capacity, sensitivity & accuracy of 0.1 % of the weight of the
test sample.
A Metal gauge of the pattern specified in I.S.2386 (part I)-1963.
I.S.Sieves of sizes 50mm, 40mm, 20mm, 16mm, 12.5mm, 10mm & 6.3mm.
TEST SAMPLE:
A quantity of aggregate shall be taken sufficient to provide the minimum number of 200
pieces of any fraction to be tested.
PROCEDURE:
Sieving-The sample shall be sieved in accordance with the method described as per
IS: 2386 part-I with the sieves specified in table I.
Separation of Flaky Material- Each fraction shall be gauged in turn for thickness on a
metal gauge of the pattern as specified in I.S.2386 (part I)-1963 or in bulk on sieves
having elongated slots. The width of the slot used in the gauge or sieve shall be of the
dimensions specified in col. 3 of table I for the appropriate size of material.
Weighing of Flaky Material- The total amount passing the gauge shall be weighed to
an accuracy of at least 0.1 % of the weight of the test sample.
DOCUMENT NO WI/08
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingFLAKINESS INDEX
ISSUE NO
DATE
REV. NO
: 01
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TABLE I DIMENSIONS OF THICKNESS AND LENGTH GAUGES

SIZE OF AGGREGATE
Passing through
IS Sieve
mm
50
40
20
16
THICKNESS GAUGE
Retained on
IS Sieve
mm
40
25
16
12.5
LENGTH GAUGE
mm
mm
27
19.5
10.8
8.55
81
58.5
32.4
25.6
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
12.5
10
10
6.3
6.75
4.89
20.2
14.7
REPORTING OF RESULTS: The calculations & reports shall be maintained in the format
F-01/WI/IT/08
DOCUMENT NO WI/09
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingELONGATION INDEX
ISSUE NO
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OBJECT:
This method of test lays down the procedures for determining the Elongation Index of coarse
Aggregate (As per IS: 2386 part-I)
APPARATUS:
A balance of sufficient capacity, sensitivity & accuracy of 0.1 % of the weight of the
test sample.
A Metal gauge of the pattern specified in I.S.2386 (part I)-1963.
I.S.Sieves of sizes 50mm, 40mm, 20mm, 16mm, 12.5mm, 10mm & 6.3mm.
TEST SAMPLE:
A quantity of aggregate shall be taken sufficient to provide the minimum number of 200
pieces of any fraction to be tested.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
PROCEDURE:
Sieving-The sample shall be sieved in accordance with the method described as per
IS: 2386 part-I with the sieves specified in table I.
Separation of Elongated Material- Each fraction shall be gauged in turn for thickness
on a metal gauge of the pattern as specified in I.S.2386 (part I)-1963. The gauge
length used shall be that specified in col. 4 of table I for the appropriate size of
material.
Weighing of Flaky Material- The total amount passing the gauge shall be weighed to
an accuracy of at least 0.1 % of the weight of the test sample.
DOCUMENT NO WI/09
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingELONGATION INDEX
ISSUE NO
DATE
REV. NO
: 01
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TABLE I DIMENSIONS OF THICKNESS AND LENGTH GAUGES

SIZE OF AGGREGATE
Passing through
IS Sieve
mm
50
40
20
16
12.5
10
THICKNESS GAUGE
Retained on
IS Sieve
mm
40
25
16
12.5
10
6.3
LENGTH GAUGE
mm
mm
27
19.5
10.8
8.55
6.75
4.89
81
58.5
32.4
25.6
20.2
14.7
REPORTING OF RESULTS: The calculations & reports shall be maintained in the format
F-01/WI/IT/09
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
DOCUMENT NO WI/10
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingCONCRETE SLUMP
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OBJECT: To determine the workability of Concrete by taking the slump with the help of
the required apparatus. (As per IS: 1199)
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
APPARATUS:
Slump Cone.
Tamping Rod.
Scoop.
Tray.
Wheel Burrow.
PROCEDURE:
Mould shall consist of a metal frustum of cone having the following internal dimensions:
Bottom diameter:.20 cm
Top diameter...10 cm
Height..30 cm
1. The mould shall be of a metal other than brass and aluminium of at least 1.6 mm
thickness. The top and bottom shall be open and at right angles to the axis of the cone.
2. The mould shall have a smooth internal surface and shall be provided with suitable foot
pieces and hand pieces to facilitate lifting it from the moulded concrete test specimen in
a vertical direction as required by the test.
3. Tamping Rod shall be of steel or other suitable material 16 mm in diameter 60 cm long
and rounded at one end.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
4. Clean the internal surface of the mould and place it on a smooth, horizontal, rigid and
non-absorbent surface.
5. Hold the mould firmly in place while it is being filled with test specimen of concrete.
6. Fill the mould in 4 layers, each approximately one-quarter of height of mould.
7. Tamp each layer with 25 strokes of the rounded end of the tamping rod.
8. Clean any mortar leaked pout between the mould and base plate.
9. Remove the mould from the concrete immediately after filling by raising it slowly.
10. Allow the molded concrete to subside and immediately measure the slump by
determining the difference between the height of the mould and that of the highest point
of specimen.
RESULT
Record the slump in terms of millimeters of subsidence of the specimen during the test. Any
slump specimen which collapses or shears off laterally gives incorrect results; hence, test
shall be repeated with another sample.
DOCUMENT NO WI/10
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingCONCRETE SLUMP
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
2 OF 2
TABLE-1/WI/ IT/10
ACCEPTABILITY LIMITS:
Frequency: At the time of commencement of concreting on everyday of concreting
S.No
Placing Conditions
Blinding concrete;
Degree of
Workability
Very Low
Slump (mm)
Determination of
Remarks
IS:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
1199
Shallow Sections;
Pavements using Pavers
1.
2.
3.
4.
Compacting Factor
more appropriate
Mass concrete;
Lightly reinforced sections in slabs,
beams, walls, columns;
Floors;
Hand placed pavements;
Canal lining;
Strip Footing
Heavily Reinforced sections in slabs,
beams, walls, columns
Slip form Work;
Pumped Concrete
Trench Fill;
In-situ piling
Tremie Concrete
Low
25-75
Medium
50-100
Medium
75-100
High
100-150
Very High
Determination of flow
Compacting
factor of 0.75
to
0.80
suggested
IS: 9103 for

determination
of flow
If water cement ratio changes, moisture in aggregate increases or decreases and at the time of
commencement of concrete, slump test shall be done.
DOCUMENT NO WI/11
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingCONCRETE COMP.
STRENGTH (CUBE
TESTING)
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 5
OBJECT: To determine the Compressive Strength of Concrete by testing the Cube Samples in
Compression Testing Machine. (As per IS: 516)
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
PROCEDURE:
1. One sample consisting of 6 cubes 15x15x15 cm shall be taken for every 20 cum or part
thereof concrete work with aggregate size not more than 40mm.
2. For concrete with aggregate size more than 40 mm size of mould shall be specified by
the Engineer-in-charge.
3. Take samples of concrete for test specimen at the mixer or in the case of ready mixed
concrete from the transportation vehicle discharge.
4. Lightly oil the interior surfaces of the mould before placing concrete.
5. Place fresh concrete in the mould in three layers, each approximately one-third of the
volume of the mould.
6. Rod each layer 35 times with 16 mm rod, 60 cm in length, bullet-pointed at the lower
end.
7. In case of vibration, care is to be taken that there is no mortar loss.
8. After the top layer has been rodded, the surface of the concrete shall be struck of with a
trowel and covered with a glass plate.
9. If needed, the concrete can also be compacted by vibration.
10. Cover the moulds with wet straw or gunny bags to ensure uniform temperature and
moisture conditions during the first 24 hours.
11. Place them in storage box such that the temperature is always between 22C to 33C.
12. The tests shall be made generally at the end of 7 days and at the end of 28 days and
immediately after the removal of test specimen from the curing room.
13. Place the test specimen in the machine in such a manner that the load is applied to the
side of the specimens as cast.
14. The load shall be applied axially without shock at the rate of approximately 140 kg. sq
cm per minute.
15. Record the total load indicated by the testing machine at failure of test specimen.
16. Calculate the unit compressive strength in kg per cm sq using the area computed from the
measured dimensions of the test specimen.
17. The type of failure and the appearance of the concrete shall be noted.
DOCUMENT NO WI/11
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
STRENGTH (CUBE
TESTING)
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 5
TABLE-1/WI/IT/11
GRADES OF CONCRETE WITH COMP. STRENGTH
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
GROUP
GRADE
DESIGNATION
Ordinary Concrete
Standard Concrete
High Strength Concrete
M 10
M 15
M 20
M 25
M 30
M 35
M 40
M 45
M 50
M 55
M 60
M 65
M 70
M 75
M 80
SPECIFIED CHARACTERISTIC
COMP. STRENGTH AT 28 DAYS IN
N/mm2
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
DOCUMENT NO WI/11
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
STRENGTH (CUBE
TESTING)
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 5
ACCEPTANCE CRITERIA: (As per IS: 456)

The concrete shall be deemed to comply with the strength requirements when both the
following condition is met:
a) The mean strength determined from any group of four consecutive test results compiles with
the appropriate limits in col. 2 of Table 11.
b) Any individual test result complies with the appropriate limits in col. 3 of Table 11.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
REPORTING OF RESULT:

WORK INSTRUCTIONS
Inspection & Testing- SETTING TIME
TEST (CEMENT)
DOCUMENT NO WI/12
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This method of test covers the procedures for determining the Initial & Final Setting Time of
cement (As per IS: 4031-1968)
APPARATUS:
1. The Vicat Apparatus conforming to IS: 5513-1969.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
PROCEDURE:
1. The temperature of water and that of the test room at the time of gauging shall be
within 27 2 oC.
2. Take 500 gram of cement sample & gauge it with 0.85 times the water required to
produce cement paste of standard consistency (0.85P)
3. Fill the paste into the Vicat mould in specified manner within 3-5 minutes.
4. Start the stopwatch the moment water is added to the cement.
Determination of Initial Setting Time1. Place the test block confined in the mould & resting on the non-porous plate, under the
rod bearing the needle.
2. Lower the needle gently in contact with the surface of the test block & quickly release,
allowing it to penetrate into the test block.
3. In the beginning, the needle will completely pierce the test block. Repeat this procedure
until the needle, when brought in contact with the test block & released as described
above, fails to pierce the block for 5 0.5mm measured from the bottom of the mould.
4. The period elapsing between the time when water is added to the cement & the time at
which the needle fails to pierce the test block by 0.5mm shall be the initial setting
time.

WORK INSTRUCTIONS
Inspection & Testing- SETTING TIME
TEST (CEMENT)
DOCUMENT NO WI/12
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
Determination of Final Setting Time1. Replace the needle of the Vicat apparatus by a circular attachment.
2. The cement shall be considered as finally set when, upon, lowering the attachment
gently cover the surface of the test block, the center needle makes an impression, while
the circular cutting edge of the attachment fails to do so.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
3. The period elapsing between the time when water is added to the cement and the time
at which the needle makes an impression on the surface of test block while the
attachment fails to do so shall be the Final setting time
RESULTS:
The requirements of the setting time shall be as per Table I.
The reports and results for the test should be maintained in the Format F-01/WI/IT/12

WORK INSTRUCTIONS
Inspection & Testing- COMPRESSIVE
STRENGTH TEST (CEMENT)
DOCUMENT NO WI/13
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This method of test covers the procedures for determining the Strength of cement as
represented by compressive strength tests on mortar cubes compacted by means of a standard
vibration machine. (As per IS: 4031-1968)
APPARATUS:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

1. Enamel tray.
2. Trowel.
PROCEDURE:
1. The standard sand to be used in the test shall conform to I.S.650-1991.
2. Take 555 grams of standard sand, 185 grams of cement (i.e. ratio of cement to sand is
1:3) in a non-porous enamel tray & mix them with a trowel for 1minute.
3. Add water of quantity (P/4) + 3 % of combined weight of cement & sand and mix the
three ingredients thoroughly until the mixture is of uniform colour. The time of mixing
should not be less than 3minutes nor more than 4minutes.
4. Immediately after mixing, the mortar is filled into a cube mould of size 7.06cm.
5. The area of the face of the cube will be equal to 50sq.cm.
6. Compact the mortar either by hand compaction in a standard specified manner or on the
vibrating equipment (12000RPM) for 2minutes.
7. Keep the compacted cube in the mould at a temperature of 27 oC 2 oC & at least 90%
relative humidity for 24hours.
8. Where the facility of standard temperature & humidity room is not available, the cube
may be kept under wet gunny bag to stimulate 90% relative humidity.
9. After 24hours, remove the cubes from the mould & immerse in clean fresh water until
taken out for testing.
10. Three cubes are tested for compressive strength at the interval of 3, 7 & 28 days.
The compressive strength shall be the average of the strengths of the 3 cubes for each period
respectively.
The strength required for the various types of cement is shown in Table I.

WORK INSTRUCTIONS
Inspection & Testing- COMPRESSIVE
STRENGTH TEST (CEMENT)
DOCUMENT NO WI/13
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
RESULTS:
The requirements for the compressive strength of various types of cement should be as per
Table I.
The calculations and results should be maintained as per Format F-01/WI/IT/13
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- FINENESS TEST BY
DRY SIEVING (CEMENT)
DOCUMENT NO WI/14
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This method of test covers the procedures for determining the Fineness of cement by dry
sieving as represented by the weight of the residue left on a standard 90-micron I.S. Sieve
conforming to IS: 460-1962. (As per IS: 4031-1968)
APPARATUS:
1. I.S. Sieve no.9
2. Sieve Shaker
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
PROCEDURE:
1. Break down any air-set lumps in the cement sample if any with fingers.
2. Place 100gram of the cement accurately weighed on a standard I.S. Sieve no. 9/ 90
microns. (Wt. A)
3. Continuously sieve the sample giving circular and vertical motion for a period of 15
minutes. Mechanical sieving devices may also be used.
4. Weigh the residue left on the sieve (Wt. B).
5. This weight shall not exceed 10% for ordinary cement.
Percentage of fineness of sample shall be calculated as follows & the average of 3 tests shall be
reported.
% Of fineness (C) = B X 100
A
RESULTS:
The requirements of fineness should be as per Table I.
The reports and results for fineness test should be maintained in the Format F-01/WI/IT/14

WORK INSTRUCTIONS
Inspection & Testing- FINENESS TEST BY
DRY SIEVING (CEMENT)
DOCUMENT NO WI/14
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
TABLE.I
PHYSICAL CHARACTERISTICS OF VARIOUS TYPES OF O.P.CEMENT
GRADE OF
CEMENT
SETTING TIME
Initial
(minutes)
Min.
Final
(minutes)
Max.
FINENESS
Max.
COMPRESSIVE STRENGTH
3 days
Mpa
7 days
MPa
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
28 days
MPa
33 OPC
(I.S.269-1989)
43 OPC
(I.S.8112-1989)
53 OPC
(I.S.12269-1987)
30
600
10%
16
22
33
30
600
10%
23
33
43
30
600
10%
27
37
53
DOCUMENT NO WI/15
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingCHEMICAL & PHY.
PROP. OF WATER
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 1
PROCEDURE: (As per IS: 3025)
1. Water used for mixing and curing shall be free from injurious quantities of alkalis, acids,
oils, sugar, organic materials, vegetable growth or other substances that may be
deleterious.
2. Ph Value of water shall generally not be less than 6.
3. Limits of Acidity: To neutralize 100 ml sample of water, using phenolphthalein as an
indicator, it should not require more than 5 ml of 0.02 normal NaOH.
4. Limits of Alkalinity: To neutralize, 100 ml sample of water, using mixed indicator as an
indicator, it should not require more than 25 ml of 0.02 normal H2SO4.
5. Percentage of Solids: Maximum permissible limits of solid:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
Organic
Inorganic
Sulphates (as SO3)
Chlorides (as Cl)
Tested as Per
IS 3025 (Part 18)
IS 3025 (Part 18)
IS 3025 (Part 24)
IS 3025 (Part 32)
2000mg/litre
Permissible Limit, Max

200mg/litre
3000 mg/litre
400 mg/litre
500 mg/litre for RCC
and
for other works

Suspended Matter
IS 3025 (Part 17)
2000mg/litre
6. Water from each source shall be tested before the commencement of work and thereafter
once every three months.
RESULTS:
The reports and results for the test should be maintained in the Format
F-01/WI/IT/15
DOCUMENT NO WI/16
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingRELATIVE DENSITY &
PH VALUE of Concrete
Admixture
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This method of test covers the procedures for determining the Relative Density & PH Value of
admixture. (As per IS: 9103-1999)
APPARATUS:
The apparatus required for the tests is as follows:
Relative Density:
1. Constant temperature bath.
2. Hydrometer.
3. Measuring Cylinder.
P
H Value:
1. PH meter.
PROCEDURE:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
RELATIVE DENSITY1. Take a 500 ml graduated cylinder and place 400 ml of admixture in it avoiding the
formation of air bubbles in the liquid.
2. Maintain the temperature of the liquid at 20 5 oC.
3. Insert the hydrometer into the cylinder ensuring that it floats free and does not touch the
side of the cylinder.
4. Release the hydrometer when approximately it has attained equilibrium position.
5. When in equilibrium read the scale at the bottom of the meniscus for transparent liquids
or where the meniscus merges with the stem of the hydrometer for opaque liquids to
report the Relative Density.
PH VALUE:
The Hydrogen ion concentration of the liquid superplasticiser shall be determined with the help
of a suitable PH meter.
DOCUMENT NO WI/16
Ahluwalia Contracts
(India) Ltd.
WORK INSTRUCTIONS
Inspection & TestingWATER RELATIVE
DENSITY & PH VALUE
(Admixture)
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
RESULTS:
The reports and results for relative density test should be maintained in the Format
F-01/WI/IT/16 & for PH test should be maintained in the Format F-01/WI/IT/16
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- TEST FOR
DIMENSIONAL TOLERANCE (Bricks)
DOCUMENT NO WI/17
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This method of test covers the procedure for determining whether the bricks used for
construction are of specified dimensional tolerance. (As per IS: 1077)
APARATUS:
A measuring steel tape.
PROCEDURE:
1. Select 20 or more bricks at random from the stack.
2. Remove all the blisters, loose particles of clay and small projections from the surface of
bricks.
3. Arrange a specimen of 20 bricks upon a level surface successively in contact with each
other and in straight line as per 2A, 2B & 2C below for measurement of Length, width &
height respectively.
4. The overall length of the assembled bricks shall be measured with a steel tape sufficiently
long to measure the whole row at one stretch.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
DIMENSIONAL TOLERANCE (Bricks)
DOCUMENT NO WI/17
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
2 OF 2
ACCEPTABILITY:
The actual dimensions of bricks when tested should be within the following limits per 20
bricks:
Modular Bricks:
Length 3800 80 mm
Width 1800 40 mm
Height 1800 40 mm (For 90 mm high bricks)
800 40 mm (For 40 mm high bricks)

Non modular Bricks:
Length
4600 80 mm
Width
2200 40 mm
Height 1400 40 mm (For 70 mm high bricks)
600 40 mm (For 30 mm high bricks)
RESULTS:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
COMPRESSIVE STRENGTH (Bricks)
DOCUMENT NO WI/18
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This method of test covers the procedures for determining the Compressive strength of bricks.
(As per IS: 1077-1992/3495)
APPARATUS:
The apparatus required for the test is as follows;
A trowel.
3 plywood sheets of thickness 3mm.
A Compression Testing machine.
PROCEDURE:
1. Five whole bricks shall be taken from the samples as specimen. Length and
width of each specimen shall be measured correct to 1 mm.
2. The specimen shall be immersed in water for 24 hours at 25 to 29 C. Any
surplus moisture shall be allowed to drain at room temperature.
3. Fill the frog of the bricks with mortar 1:3 and keep them under damp jute bags
for 24 hours.
4. Then immerse them in water for 3 days.
5. After removal from water, place the specimen with flat faces horizontal and
mortar filled face upward between 3 plywood sheets each of thickness 3 mm.
6. Apply the load carefully axially at uniform rate of 14 N/mm2 per minute till the
failure of the specimen occurs.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
7. The compressive strength of each specimen shall be calculated as:

Compressive Strength =
Maximum load at failure (in N)

Area of Specimen (in sq mm)
8. Compressive strength of all the individual bricks comprising the sample shall be
averaged and reported.

WORK INSTRUCTIONS
COMPRESSIVE STRENGTH (Bricks)
DOCUMENT NO WI/18
ISSUE NO
: DATE
REV. NO
: 01 DATE
PAGE
: 2 OF 2
ACCEPTABILITY:
A lot shall be considered having satisfied the requirements of average compressive
strength if it is not below the minimum average compressive strength specified for the
corresponding class of bricks by more than 20%.
Average Compressive Strength is given in Table-1/WI/IT/18
Table-1/WI/IT/
Class
Designation
10 (100)
7.5 (75)
5.0 (50)
3.5 (35)
5.0
3.5
Average Compressive Strength

Not Less than
Less than
N/mm2
Kgf/cm2
N/mm2
Kgf/cm2
10
100
12.5
1225
7.5
75
10
100
50
7.5
75
35
5.0
50
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
DOCUMENT NO WI/19
WORK INSTRUCTIONS
ISSUE NO
DATE
Inspection & Testing- TEST FOR WATER

ABSORPTION (Bricks)
REV. NO
: 01
DATE
PAGE
1 OF 1
OBJECT:
This method of test covers the procedures for determining the Water Absorption of bricks.
(As per IS: 1077-1992)
APPARATUS:
The apparatus required for the test is as follows;
A Balance sensitive to weigh 0.1 % of the weight of the specimen.
PROCEDURE:
1. Five whole bricks shall be taken from the sample as specimen.
2. Allow the specimen to dry in a ventilated oven at 110oC to115oC till it attains a
substantial constant weight.
3. It shall be then allowed to cool at room temperature and then weighed (wt.1)
4. Specimen should be completely dried before immersion in water.
5. Keep it in clean water at a temperature of 27oC +/- 2oC for 24 hours.
6. Wipe out the specimen after taking out from water and then weigh it within 3 mins. of
removal from water.(wt.2)
7. The water absorption of each specimen shall be calculated as follows and the average of
5 tests shall be reported.
Water Absorption = W2 W1 x 100
W1
ACCEPTIBILITY:
A lot is considered to have satisfied the requirements of water absorption if the average water
absorption is not more than 20% by weight.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
RESULTS:

WORK INSTRUCTIONS
Inspection & Testing- COMPACTION
TEST OF SOIL (PROCTOR TEST)
DOCUMENT NO WI/20
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This test deals with the procedure to determine the compaction characteristics of a soil
specimen by Proctor test. (As per IS: 2720)
APPARATUS:
1. Compaction mould, capacity 1000ml.
2. Rammer, mass 2.6 kg.
3. Detachable base plate.
4. Collar, 60mm high.
5. IS Sieve 4.75mm.
6. Oven.
7. Desiccator.
8. Weighing balance, accuracy 1gram.
9. Large mixing pan.
10. Straight edge.
11. Spatula.
12. Graduated jar.
13. Mixing tools, spoons, trowels, etc.
PROCEDURE:
1. Take about 20 kg of air-dried soil. Sieve it through 20 mm & 4.75mm I S Sieves.
2. Calculate the percentage retained on 20mm sieve, and 4.75mm sieve, and the
percentage passing 4.75mm sieve. Do not use the soil retained on 20mm sieve.
Determine the ratio of fraction retained & that passing 4.75mm sieve.
3. If percentage retained on 4.75 mm sieve is greater than 20, use the larger mould of
150mm diameter. If it is less than 20%, the steel mould of 100mm diameter can be
used.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
4. Mix the soil retained on 4.75mm sieve & that passing 4.75 sieve in the proportions
determined in step (2) to obtain about 16-18 kg of soil specimen.
5. Clean & dry the mould & the base plate. Grease them lightly.
6. Weigh the mould with the base plate to the nearest 1-gram.
7. Take about 16-18 kg of soil specimen. Add water to it to bring the water content to
about 4 % if the soil is sandy and to about 8 % if the soil is clayey.
8. Keep the soil in air tight container for about 18-20hours for maturing .Mix the matured
soil thoroughly. Divide the processed soil into 6-8 parts.
9. Attach the collar to the mould. Place the mould on a solid box.

WORK INSTRUCTIONS
Inspection & Testing- COMPACTION
TEST OF SOIL (PROCTOR TEST)
DOCUMENT NO WI/20
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
10. Take about 2 1/2kg of the processed soil, and place it in the mould in 3 equal layers.
Take about 1/3rd the quantity first, & compact it by giving 25 blows of the rammer. The
blows should be uniformly distributed over the surface of each layer. The top surface of
the 1st layer should be scratched with a spatula before placing the second layer. The
second layer should also be compacted by 25 blows of rammer. The amount of the soil
used should be just sufficient to fill the mould & leaving about 5mm above the top of
the mould to be struck off when the collar is removed.
11. Remove the collar, and trim off the excess soil projecting above the mould using a
straight edge.
12. Clean the base plate & the mould from outside. Weigh it to the nearest gram.
13. Remove the soil from the mould.
14. Take the soil sample for the water content determination from the top, middle & bottom
portions.
15. Add about 3% of the water to a fresh portion of the processed soil, & repeat the
steps(10-14)
RESULTS: Calculations & reports shall be maintained as per Format F-01/WI/IT/20
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- DRY DENSITY
TEST OF SOIL (Core Cutter

method)
DOCUMENT NO WI/21
ISSUE NO
DATE
REV. NO
PAGE
:
: 01
DATE
1 OF 2
OBJECT:
This test deals with the field method of determination of dry density of soil. (As per IS: 2720)
APPARATUS:
1. A cylindrical cutter, 100mm internal dia & 130mm long.
2. Steel rammer, mass 9 kg overall length, with the foot and staff about 900mm.
3. Steel dolley, 25mm high & 100mm internal dia.
4. Weighing balance, accuracy 1gram.
5. Palette knife.
6. Straight edge, steel rule.
PROCEDURE:
1. Determine the internal diameter & height of the core cutter to the nearest 0.25 mm.
2. Determine the weight (W1) of the cutter to the nearest gram.
3. Expose a small area of the soil mass to be tested. Level the surface, @300mm square in
area.
4. Place the dolley over the top of the core- cutter and press the core-cutter into the soil
mass using the rammer. Stop the process of pressing when @ 15mm of the dolley
protrudes above the soil surface.
5. Remove the soil surrounding the core-cutter and take out the core-cutter. Some soil
would project from the lower end of the cutter.
6. Remove the dolley. Trim the top and bottom surface of the core-cutter filled with the
soil to the nearest gram (W2)
7. Remove the core of the soil from the cutter. Take a representative sample for the water
content determination.
RESULTS:
The Dry density is obtained as:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
d = / (1 + w % ) = W3/V
(1 + w %)
The calculations & reports can be maintained as per Format F-01/WI/IT/21
DOCUMENT NO WI/22
WORK INSTRUCTIONS
ISSUE NO
DATE
Inspection & Testing- REINFORCEMENT
REV. NO
: 01
DATE
PAGE
1 OF 2
OBJECT:
This method of test lays down the procedures for calculating Nominal Mass of steel for
reinforcement. (As per IS: 1786-1985)
PROCEDURE:
The nominal mass per meter of individual sample, batch and coils shall be determined as
given below:
1. The tolerance on mass/weight for round and square bars shall be the percentage given in
Table-01/WI/IT/22 of the mass/weight calculated on the basis that the masses of the
bar/wire of nominal diameter and of density 0.785 kg/cm3.
2. Physical properties of all sizes of steel bars shall be as mentioned in Table-02/WI/IT/22
3. Select all the test pieces wither by cutting the bars. The test pieces shall be of length not
less than 1 meter and of full sections of the bars as rolled and subsequently cold worked
and subjected to physical test without any further modifications.
4. The nominal mass of an individual sample be calculated by determining the mass of any
individual sample at random as specified in Table-03/WI/IT/22 and dividing the same by
the actual length of the sample.
5. The nominal mass of a batch shall be calculated by determining the mass of the test
specimens taken as specified in Table-03/WI/IT/22 and dividing the same by the actual
length of the specimens. Each specimen shall be of length not less than 0.5metre.
6. The nominal mass of a coil shall be calculated by determining the mass of two samples
of minimum1metre length taken from each end of coil and dividing the same by the
actual length of the samples
7. No test piece shall be enacted or subjected to heat treatment
8. Store steel for reinforcement in such a way to prevent any distortion and corrosion.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
DOCUMENT NO WI/22
WORK INSTRUCTIONS
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
S.No.
1
2
3
S.No.
1.
2.
3.
1 OF 2
Table 1/WI/IT/22
TOLERANCE ON NOMINAL MASS
Nominal Size in mm
Tolerance on the Nominal Mass Percent
Batch
Individual
Individual Sample
Sample
of Coil (-x-)
Up to and including 10
7
-8
8
Over 10, up to and
5
-6
+6
including 16
Over 16
3
-4
4
Table 2/WI/IT/22
PHYSICAL PROPERTIES OF STEEL BARS
Property
Grade
Fe 415
Fe 500
Fe 550
0.2% proof stress/yield stress,
415
500
550
2
min. N/mm
Elongation, percent min. on
14.5
12
8
gauge length 5.65A, where A
is the X-sectional Area
Tensile Strength
10% more than
8% more than
6% more than
actual proof stress
actual proof
actual proof
but not less than
stress but not
stress but not
465 N/mm2
less than 545
less than 585
2
N/mm
N/mm2
Table 3/WI/IT/22
FREQUENCY FOR NOMINAL MASS, TENSILE,BEND AND REBEND TESTS

QUANTITY
For casts /heats below 100tonnes
For casts /heats over 100tonnes
NOMINAL SIZE
Under 10 mm
10 mm to 16 mm
inclusive
1 sample from each 25 tonnes or part

thereof
thereof

thereof
thereof
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
Over 16 mm

thereof

thereof
DOCUMENT NO WI/22
WORK INSTRUCTIONS
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
RESULTS:
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

WORK INSTRUCTIONS
Inspection & Testing- MARBLES
DOCUMENT NO WI/23
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
PROCEDURE: (As per IS: 1122, IS: 1124)
1. The size of marble blocks, slabs and tiles shall be as mentioned in Table IT/23-01.
2. Tolerance that shall be allowed in the dimensions of blocks, slabs and tiles is given in
Table IT/23-02.
3. The physical properties of marble for blocks, slabs and tiles and method of tests are
mentioned in Table IT/23-03.
4. In any consignment of blocks/slabs/tiles of the same group, size and finish shall be
grouped together to constitute a lot.
5. Samples shall be selected and tested separately for each lot and for determining its
conformity or otherwise to the requirements of the specification. Sample size and
criteria shall be in accordance with Table IT/24-04.
Table-01/WI/IT/23
S.No.
Length (mm)
Width (mm)
Thickness (mm)
1.
Blocks
300 to 2500
300 to 1000
300 to 900
2.
Slabs
700 to 2500
300 to 1000
20 to 150
3.
Tiles
100 to 600
100 to 600
8 to 24
Table-02/WI/IT/23
Tolerance
Blocks
(a) Length
+2%
(b) Width
+2%
(c) Thickness
+2%
Slabs
(a) Length
+2%
(b) Width
+2%
(c) Thickness
+3%
Tiles
(a) Linear dimension
+3%
+1%
(c) Thickness

WORK INSTRUCTIONS
Inspection & Testing- MARBLES
DOCUMENT NO WI/23
ISSUE NO
DATE
REV. NO
: 01
DATE
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
Table IT/23-03
S.No.
1.
Characteristic
Moisture absorption
Requirements
Max. 0.4% by weight
Method of Test
IS: 1124
Minimum 3
Minimum 2.5
Mhos Scale
IS: 1122
after 24 hours
2.
3.
immersion in cold water

Hardness
Specific Gravity
Table IT/23-04
Number of blocks/
slabs /tiles in the lot
Up to 25
26 to 100
101 to 200
201 to 500
501 to 1000
Number of blocks/
slabs /tiles to be
selected in sample
3
5
8
13
20
Permissible
number of
defectives
0
0
0
0
1
Method of
Test
2
2
3
4
5
RESULTS:

WORK INSTRUCTIONS
Inspection & Testing- TIMBER
DOCUMENT NO WI/24
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
PROCEDURE: (As per IS:1141, IS: 401)

SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
METHOD 1
1) Moisture content of timber shall be checked for every 1 cum or part thereof by
electrical moisture meters as per IS: 287.
2) Electrical moisture meters are of resistance type and shall be used when the moisture
content is within the range of 8 to 25 %.
3) When checking moisture content with electrical moisture meter it shall be ensured that:
a) Timber is hot or the surface wet and the moisture gradient is not large due to
wet cores.
b) Electrode probes are of adequate depth (not less than 1/5 th the thickness of the
timber).
4) Sufficient number of readings at different positions is taken on each piece of timber to
eliminate localized variations in surface moisture and species corrections are applied
for the make of electrical resistance, type moisture meter.
METHOD 2
1. For checking the moisture content by oven drying method, a complete test cross section,
12 to 19 mm long in the direction of timber grain, free from all defects shall be cut from
each piece of timber selected for test as follows:
a) If weighing can be done immediately, the test section can be cut from a point at
least 450 mm from one end of the piece or from its center.
b) In case cutting is not allowed then a boring shall be collected by augur upto half
of the thickness of the piece.
2. The test sections obtained shall be immediately weighed on a balance with sensitivity not
less than 10 mg.
3. They shall be dried in a ventilated, and preferably thermostatically controlled, oven at a
temperature of 100C to 105C until the weight is constant.
4. The weight of the test section will deemed to have become constant if successive
weighing at intervals of 2 to 4 hours do not differ from one another by more than 50 mg.
5. The percentage moisture content in the test section shall be calculated as:
Moisture Content (%)
= W1 W0 x 100
W0

WORK INSTRUCTIONS
Inspection & Testing- TIMBER
DOCUMENT NO WI/24
ISSUE NO
DATE
REV. NO
: 01
DATE
PAGE
1 OF 2
Where: W1 = initial weight of test section

SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
W0 = Oven dry weight of test section

TOLERANCE ON MOISTURE CONTENT
Average Moisture content of all the samples shall be within + 3% and moisture content of
individual samples within + 5% of maximum permissible moisture content.
RESULTS:
DOCUMENT NO WI/25
WORK INSTRUCTIONS
ISSUE NO
DATE
Inspection & Testing- FLUSH SHUTTERS
REV. NO
01DATE
PAGE
1 OF 2
PROCEDURE: (As per IS: 2202)

Shutters of decorative or non-decorative type shall be grouped separately and each group
shall constitute a lot. Sampling shall be as per Table-1/WI/IT/25
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
Table-1/WI/IT/25
LOT SIZE
SAMPLE SIZE
1
2
3
4
5
Up to 50
50-150
151-300
301-500
501 and above
I. END IMMERSION TEST

1. Door shutters shall be tested for resistance of their base to immersion in water as follows:
a)
The door shutter shall be immersed vertically to a height of 300 mm in water at
room temperature for 24 hours and then allowed to dry for 24 hours at 27 2C
and relative humidity of 65 5%.
b)
The cycle shall be repeated eight times.
c)
There shall be no delamination at the end of the test.
II. KNIFE TEST
1. The type of knife required to be used may be made from a 250 x 25 mm file. The cutting
edge shall be kept chisel sharp.
2. The knife is inserted with its cutting edge parallel to the grain of the outer veneer and
worked into, or if possible along glue line and the veneers are prised upwards. In soft
timber the knife tends to follow an easy course through the wood and in this case it is
essential that the knife be firmly guided along the glue line.
3. The bond should just pass the requirement, which is judged, by the relative amount of
wood fibre left on the core veneer, and the area prised off. The grading is assessed chiefly
on the appearance of the break.
DOCUMENT NO WI/25
WORK INSTRUCTIONS
ISSUE NO
DATE
Inspection & Testing- FLUSH SHUTTERS
REV. NO
01DATE
PAGE
1 OF 2
4. The bond is excellent when it is difficult to find the glue line and impossible to keep the
tool within it for more than 6 mm without cutting adjacent wood.
5. The bond is poor when knife meets little opposition in the glue line and the prise results
in the easy removal of almost all the veneers.
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
III. GLUE ADHESION TEST

1. Four square sections, 150 x 150 mm shall be cut from the corners of the door and
immersed in boiling water for four hours and then dried at 27 2C and relative
humidity of 65 5% for 24 hours.
2. At the end of the drying period, the samples shall be examined for delamination.
3. A specimen shall be considered to have passed the test if no delamination has occurred in
the glue lines in the plywood and if no single delamination more than 50 mm in length
and 3 mm in depth has occurred in the assembly glue lines between the plywood faces
and the stile and rail.
4. Delamination at the corner shall be measured continuously around the corner. A door
shall be deemed to have passed this test if three of the four specimens pass the test.
RESULTS:
DOCUMENT NO WI/26
WORK INSTRUCTIONS
ISSUE NO
DATE
Inspection & Testing- PRECAST CEMENT
REV. NO
01DATE
PAGE
CONCRETE/TERRAZZO TILES
1 OF 2
PROCEDURE: (As per IS: 1443, IS: 1237)

Sampling of tiles for each mandatory tests shall be as follows:
a.
For conformity to requirements on shape and dimensions, wearing layer, and
general quality 12 tiles
b.
For wet transverse strength test 6 tiles
c.
For resistance to wear tests 6 tiles
d.
For water absorption test 6 tiles
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
I. WET TRANSVERSE STRENGTH TEST

1. Six full size tiles shall be test for the determination of wet transverse strength.
2. When tested according the procedure laid down in IS:1237, the average wet transverse
strength shall not be less than 3 N/mm2
II. RESISTANCE TO WEAR TEST
1. The 12 test specimens shall be square in shape and of size 7.06 cm x 7.06 cm. The
abrasion test of specimens shall be carried out in a machine conforming to IS: 1237. A
suitable instrument capable of measurement to accuracy of 0.01 mm shall be used for
determining the change in the thickness of the specimen after abrasion.
2. The specimen shall be dried at 110C for 24 hours and then weighed to the nearest 0.1
gm. The specimen after initial drying and weighing shall be placed in the thickness
measuring apparatus with its wearing surface uppermost and the reading of the
measuring instrument taken.
3. The grinding path of the disc abrasion machine shall be evenly strewn with 20 gm. of
abrasive powder. The specimen shall then be fixed in the holding device with the
surface to be ground facing the disc and loaded at the center with 30 kg.
4. The grinding disc shall then be put in motion at a speed of 30 rpm. After every 22
revolutions, the disc shall be stopped, the powder removed and fresh abrasive powder
in quantities of 20m gm applied each time.
5. After 110 revolutions, the specimen shall be turned about the vertical axis through an
angle of 90 and test continued until 220 revolutions have been completed.
6. After abrasion is over, the specimen shall be reweighed to the nearest 0.1 gm. It shall
then be placed in the thickness measuring apparatus once again in the identical manner
and the reading taken with the same position and setting of the dial gauge.
7. The wear shall be determined from the difference in readings obtained by the
measuring instrument before and after the abrasion of the specimen.
DOCUMENT NO WI/26
WORK INSTRUCTIONS
ISSUE NO
DATE
REV. NO
01DATE
PAGE
t = 10 x (W1 W2) V1
W1 x A
Where t = Average loss in thickness in mm
W1 = Initial weight, in gm. of the specimen
W2 = Final weight, in gm of the abraded specimen
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
1 OF 2
V1 = Initial volume, in CC, of the specimen, and

A = Surface area, in sq.cm. of the specimen
Acceptable Tolerance
When tested their average wear shall not exceed 3.5 mm and the wear on any individual
specimen shall not exceed 4 mm
III. WATER ABSORPTION
1. Full six size tiles shall be used for this test. They shall be immersed in water for 24
hours, then taken out, wiped dry and tested for waster absorption.
2. Each tile shall be weighed immediately after saturation and wiping. The tile shall be
oven dried at a temperature of 65 1C for a period of 24 hours, cooled to room
temperature and reweighed.
3. The water absorption per cent by weight for each tile shall be determined as follows:
On oven dry basis water absorption per cent by weight = (W1 W2) x 100
W2
Where W1 = weight in grams of the saturated specimen; and
W2 = Weight in gram of the oven dried specimen
RESULTS:
DOCUMENT NO WI/26
WORK INSTRUCTIONS
ISSUE NO
DATE
REV. NO
01DATE
PAGE
BIBLIOGRAPHY
1. CPWD Specifications 1996 Revised 2000
2. Compilation of Quality Assurance Circulars of CPWD, 2001
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;
1 OF 2
3. IS 2386 (Part-1): 1963; Methods of Test for Aggregate for Concrete Part 1: Particle Size
and Shape
4. IS 2386 (Part-2): 1963; Methods of Test for Aggregate for Concrete Part 2: Estimation of
deleterious materials and organic impurities
5. IS 2386 (Part-3): 1963; Methods of Test for Aggregate for Concrete Part 3: Specific
gravity, density, voids, absorption and bulking
6. IS 516: 1959; Method of Test for Strength of Concrete
7. IS 1599: 1985; Method for Bend Test
8. IS 1608: 1972; Method for tensile testing of steel products
9. IS 1786: 1985; High strength deformed steel bars and wires for concrete reinforcement
10. IS 3495: 1992; Method of Test for Clay Building Bricks
11. IS 456: 2000; Plain and Reinforced Concrete Code of Practice
SIGNATURE:
DESIGNATION:
PREPARED BY:
REVIEWED BY:
APPROVED BY;

Lab Testing Procedures

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Lab Testing Procedures

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Laboratory Testing Procedures

Ahluwalia Contracts (India) Ltd.

METHOD-1 (By Volume- As per CPWD Specification)

Ahluwalia Contracts (India) Ltd.

METHOD-2 (By Weight- As per IS 2386 part-1)

Approximate minimum weight of sample

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

Minimum weight of sample required for

Minimum weight of sample required for

Ahluwalia Contracts (India) Ltd.

The Calculation & Reports shall be maintained in the Format F-01/WI/IT/02,

Ahluwalia Contracts (India) Ltd.

A balance of capacity 3 kg or more, readable & accurate to 0.5g.

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

A container of capacity 3 liter.

Percentage Bulking = (h/h1 1) x 100

Ahluwalia Contracts (India) Ltd.

The Calculation & Reports shall be maintained in the Format: F-01/WI/IT/05

Ahluwalia Contracts (India) Ltd.

Inspection & Testing-AGGREGATE

Ahluwalia Contracts (India) Ltd.

Inspection & Testing-AGGREGATE

Ahluwalia Contracts (India) Ltd.

Inspection & Testing-AGGREGATE

TABLE I DIMENSIONS OF THICKNESS AND LENGTH GAUGES

TABLE I DIMENSIONS OF THICKNESS AND LENGTH GAUGES

IS: 9103 for

High Strength Concrete

ACCEPTANCE CRITERIA: (As per IS: 456)

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

The apparatus required for the test is as follows:

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

PROCEDURE: (As per IS: 3025)

Permissible Limit, Max

for other works

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

800 40 mm (For 40 mm high bricks)

Height 1400 40 mm (For 70 mm high bricks)

600 40 mm (For 30 mm high bricks)

Ahluwalia Contracts (India) Ltd.

7. The compressive strength of each specimen shall be calculated as:

Maximum load at failure (in N)

Ahluwalia Contracts (India) Ltd.

Average Compressive Strength

Ahluwalia Contracts (India) Ltd.

Inspection & Testing- TEST FOR WATER

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

Ahluwalia Contracts (India) Ltd.

TEST OF SOIL (Core Cutter

Ahluwalia Contracts (India) Ltd.

Inspection & Testing- REINFORCEMENT

Ahluwalia Contracts (India) Ltd.

Inspection & Testing- REINFORCEMENT

FREQUENCY FOR NOMINAL MASS, TENSILE,BEND AND REBEND TESTS