The document summarizes Ganesh Shanker's summer training project report from June 20th to July 15th, 2016 at the Bridgeworkshop of North Eastern Railway in Gorakhpur. The project involved the design of a 12.2m span composite girder (welded type) and aggregate testing. The report details the fabrication process of the girder including layout, marking, welding inspections, assembly, drilling, riveting and painting. It also describes the aggregate testing process and includes sieve analysis, water absorption, impact and shape tests.

1. SUMMER TRAINING
PROJECT REPORT
UNDER THE GUIDANCE
OF
Mr. Vikrama Prasad
(Sr. Section engineer)

2. SUMMER TRAINING
REPORT
From 20-06-2016 to 15-07-2016
On
DESIGN OF 12.2m SPAN
COPMOSITE GIRDER (WELDED TYPE)
&
AGGREGATE TESTING
At
BRIDGEWORKSHOP
N.E. RAILWAY GORAKHPUR
Submitted for Partial fulfilment of award of degree of
Bachelor of Technology In CIVIL ENGINEERING
SUBMITTED TO- SUBMITTED
BY-
DEPARTMENT OF CIVIL ENGINEERING GANESH
SHANKER

3. R.E.C. AZAMGARH B.TECH FINAL
YEAR
PREFACE
This report has been prepared after getting different theoretical and
practical training in Indian Railway Bridge Corporation from 20-06-2016
to 15-07-2016 in reference to my collage letter for summer training. The
process of training from my point of view was excellent for each section
was very useful for Civil Engineering Student with a lot of resources and
limited time schedule. There are many things in the Directorate on each
subject which can be learnt from regular training and proper guidance.
A little knowledge which I could get from this training, I am trying
to re-produce some of them in following pages. Any error in making
deliberations may please be ignored.
DATE-15-07-2016 GANESH
SHANKER

4. DECLARATION
I hereby declare that the project report on “12.2m span Composite
Girder” and “Aggregate Testing” is a record of my original work done
under the guidance of Mr. Vikrama Prasad. This project report is
submitted to Indian Railway Bridge Corporation Gorakhpur, in the
partial fulfilment of the requirements for the award of the degree of
Bachelor of Technology in Civil Engineering.
The result embodied in this report has not been submitted to any other
University or Institute for the award of any degree.
Place: Gorakhpur
Date:15-07-2016
GANESH
SHANKER
B.TECHFINAL
YEAR
CIVIL
ENGINEERING
ROLL NO.:1373600019

5. CERTIFICATE
This is to certify that Ganesh Shanker(1373600019) has carried out the
project work Entitled “12.2 m span Composite girder (Welded type)”
&“Aggregate Testing”forthe award of Bachelorof Technology in Civil
Engineering from Rajkiya Engineering College, Azamgarh (736)undermy
supervision. The Project embodies results of original work, and studies are
carried out by the student himself and the contents of the project do not
form the basis for the award of any other degree to the candidate or to
anybody else from this or any other University/Institution.
MR. VIKRAMA PRASAD
(Sr. Section Engineer N.E.Railway)
ProjectCoordinator

6. SUBJECT INDEX
S.No. Description
1. Introduction
2. Fabrication
3. Consisting of fabrication process
Flow diagram of fabrication process
Layout of drawing
Marking and Templating
Jig and Fixture making
Cutting of plates
Tack assembly of job
Tack welding and Fillet welding
Inspection of weld
 Etching test
 Visual inspection
 Dye penetration test
Initial assembly of the job
 Drilling
 Riveting
Final assembly of job
 Riveting section
 Final assembly section
 Inspection
 Painting
 Metalizing
 Dispatch section
4. Aggregate testing

7. 5. Introduction
6.  Sieve analysis
 Water absorption
 Aggregate impact value
 Shape test
 Flakiness index
 Elongation index
7. Material suppliers
8. Acknowledgement

8. DESIGN OF COMPOSITE GIRDER
(WELDED TYPE)
COMPOSITE GIRDER
The RCC deck is castin situ after launching steel girders on
substructure. Shear connectors are provided on top flange plates of
steel beams with channel sections welded all round with side fillet
welds. Shear connectors are required to make cast in situ RCC slab
and steel girder act together under load.
In a composite girder system the concrete acts together with the
steel to createa stiffer, lighter, less expensive structure.

9. COMPONENTSOF COMPOSITE
GIRDER
 RCC deck (Cast in situ at the site of bridge) with shear
connectors embedded in the slab.
 Steel beams with shear connectors welded on top flange
(Fabricated in workshop).
 Cross frames
 Bearings
ADVANTAGES OF USING STEEL FOR
GIRDERS
 Reduced dead loads.
 More economic foundations.
 Simpler erection procedures.
 Shorter execution time.
 Faster and easier rehabilitation.
 Durability.

10. FABRICATION
THE PROCESS OF BUILDING UP/PUTTING TOGETHER,
PROPERLY SHAPED INDIVIDUAL COMPONENTS (ROLLED
SECTION & PLATES) TO FORM THE DESIRED STRUCTURE.
 Tested steel of required quality
 Appropriate design and drawings
 Well eqquiped workshop
 Experienced and skilled staff
 Inspection at every stage
TESTED STEEL OF REQUIRED QUALITY
 IS:2062, Quality “A” Grade DesignationE250(Fe 410 W) as
rolled semi-killed or killed shall be used for foot-over bridges and
other structures subjected to non-critical loading.
 Is:2062-2011 gr.-b0 fully killed and normalized – for welded
girders subjected to railway loading
 (If service temp. Does not fall below 0 degree centigrade).
 Plates less than 12mm thick need not be normalized.
 Plates more than 12mm thick should be normalized and
ultrasonically tested.
 Is:2062 gr.-c fully killed and normalized – for welded/ girders
subjected to railway loading
 (If service temp. Fall below 0 degree c).
 Plates less than 12mm thick need not be normalized.
 Plates more than 12mm thick should be normalized and
ultrasonically tested.
APPROPRIATEDESIGN AND DRAWINGS
 Work should be executed as per approved drawings.
 All the drawings should be checked thoroughly before starting
execution.

11.  If any particular section is not available, the possibility of using
alternative section may be explored.

12. MAINLY CONSISTINGOF
FABRICATION PROCESS
 Layout of drawings
 Marking and templating
 Jig and fixture making
 Cutting of plates
 TACK ASSEMBLY OF I-section
 Saw welding of I-section
 Inspection of weld
 Initial assembly of job
 Cutting of stiffener
 Drilling of job
 Riveting of job
 Stud welding
 FINAL ASSEMBLY OF JOB
 Inspection of job
 Metalizing of job
 Painting
FLOW DIAGRAM OF FABRICATION
PROCESS

13. LAYOUT OF DRAWINGS
 Layout is drawing of complete structure on full scale. Normally
half span is drawn on a levelled smooth concrete/steel floor. (Other
half will be the mirror image)
 NOMINAL AS WELL AS CAMBER LAYOUT WILL BE
DRAWN ON THE FLOOR.
 Length of the members will be kept as per camber layout. However
the jigs/masters jigs for main gussets will be fabricated using
nominal layout.
MARKING & TEMPLATING
 The template shall be used for marking of cutting material and as
well as profile machining for girders of railway loading.
 Templates shall be used for marking of drilling holes in steel
structures other than girder of Railway loadings.

14. JIG AND FIXTUREMAKING

15.  Jigs are the device used in the mass productionof standard jobs for
drilling holes without marking. Jig is the member with drilled holes
of one component, so that by placing this jig over the component,
holes can be drilled in the component
 For guiding the drilling toll and to prevent oversizing holes of jig,
bushes are provided over the jigs. The internal dia. Of bushes
should be within tolerance –0.0mm TO +0.1mm. When the bores
exceed a tolerance of -0.0mm TO +0.4mm, the bushes shall be
rejected.
 For every working jig, one master plate should be fabricated. This
master plates is used only for checking the working jigs. Tolerance
for checking jigs from master plates shall be +0.0mm TO -0.13mm.
CUTTING OF PLATES
 This is a operation done at the site to get the desired shape of steel
plates being use in the construction of deferent components of the
structure. Oxy-fuel gas cutting is use for this purposeat site.
 Oxy-fuel cutting are processes that use fuel gases and oxygen to
cut metals.
 LPG is used as fuel gas at site for the cutting purpose.

16.  Plates are cut into desired length using …
 ordinary oxy-acetylene cutting torch
 pug cutting machine
 profile cutting machine
 galloting shear machine (faster but for plates up to 10mm
thickness)
 Angles are cut into desired length using …………
 shaper machine
 shearing and punching machine
 circular saw profile cutting machine
 Cutting allowance …………
 3mm up to 12mm thick plates
 6mm for than 12mm thick plates
After cutting it should be ensured that all the edges are clean, reasonably
square and true.
PUG CUTTING MACHINE
Pug cutting machine is automated flame cutting machine
which is used for cutting of ferrous metal sheets and plates. An
aluminium track is designed over which the machine moves and
the speed of this machine can be adjusted according to the
thickness of the cutting metals by electronic control switch.

17. TACK ASSEMBLY OF JOB
 Job in fixture

18. -
 Steel sections after cutting to a required size and strengthening will
be brought to this process fortemporary assembly with tack
welding to form a member so that it will be placed in fixture will
be placed over tack assembly member and prepared for saw
welding.
TACK WELDING – MMAW

19.  TACK welding is to be done by AC welding transformer set as on
following-
 Electrode:- 4 mm dia: type- a2, 4212x
 Class- irs-m-28/2002

20.  Current :- AC
 Current IN (amp.) :- 180 (approximate)
 Arc voltage (v) :- 80 (approximate)
FILLET WELDINGby SAW M/C
 Fillet welding 6mm to 10 mm welding is to be done by automatic
submerged arc welding machine as on following approximate)-
 4 mm coppercoated wire class-IRS- M-39 / 2001 is used.
 Flux class- IRS- m-39 / 2001is used.
 Current in :- dc
 Current IN (amp.) :- 500 to 600
 Arc voltage (v) :- 32 to 34
 Wire feed speed (m/min) :- 2.550 to 3.200
 Travel speed of SAW (m/min) :- 0.375 to 0.475

21. INSPECTION OF WELD
 Macro etching test - yes
 Visual test – yes
 Weld gauge - yes
 Dye penetration-yes
ETCHING TESTS
• Etching tests on run-off coupons and at the edges of girders for
checking the root fusion and throatlength.
• Etching tests are conducted on smooth, clean surfaceby:
 Applying 2 % nitric acid.
 Cleaning it with water.
 Cleaning it with alcohol
• Then check the leg length, throat and penetration and recording the
details in Etching Test Register

22. VISUAL INSPECTION
 The finished welds shall be visually inspected and shall conform to the
size and contour specified in the drawing.
 The following types of defects can bedetected during visual inspection.
 Weld defects at the surface such as blow holes, pipes,
exposed porosity, exposed inclusions, etc.
 Surface cracks in the weld metal or in the parent metal
adjacent to it.

23.  Damage to the parent metal such as undercut, burning,
overheating, etc.
 Profile defects such as excessive convexity, concavity or
unequal leg lengths etc.
 Incorrect finish, uneven welds, spatter, etc
DYE PENETRANT TEST
 In the dye or liquid penetrant testing, a suitable liquid penetrant is
applied to the surface of the portion under examination and remains
there for a sufficient time to allow the liquid in to any defectopen at the
surface.
 After the penetration time, the excess penetrant which remains on the
surface is removed.
 Then, alight colourabsorbentcalled developer is applied onthe surface.
 This developer acting as a blotter draws out a portionof penetrant which
had earlier seeped in to the surface opening.
 As the penetrant is drawn out, it diffuses in to the coating of the
developer forming the indication of the surface discontinuities as a
flaws

24.  Figure:
(a) DPT KIT (b) DPT PROCESS
(a)Defects noticed in D.P. Test (b) Blow hole (Enlarged view)
(c)After rectification of defects

25. Dye Penetrant Inspection (DPI), also called Liquid Penetrant Inspection
(LPI) or Liquid Penetrant Testing (PT), is a widely applied and low-cost
inspection method used to locate surface-breaking defects in all non-
porous materials (metals, plastics, or ceramics).The Penetrant may be
applied to all non-ferrous materials and ferrous materials, but for
inspection of ferrous components magnetic-particle inspection may
be preferred for its subsurface detection capability.
Commonly, DPI is used to detect cracks, surface porosity, lack of
penetration in welds and defects resulting from in-service conditions (e.g.
Fatigue cracks of components or welds) in castings, forgings, and
welding surface defects.
.
. .The basic steps are:
 Clean the part
 Apply the Penetrant and allow dwelling
 Remove excess Penetrant.
 Apply a developer and allow developing
 Read the part for indications. 6) Clean the part.
INITIAL ASSEMBLY OF JOB
 All the surfaces which will be in permanent contactshall be
throughly cleaned by grinding to remove paint, mill scale, dust etc.

26. Zinc chrome red oxide priming to is:2074 should be applied
immediately after cleaning
DRILLING OF JOB
• Drilling through jigs and supporting by fixture. This method is
used for open web girders
• Jigs should be removed from the component after all holes are
drilled otherwise it will be very difficult to drill left over holes at
later stage
• All burrs left by the drill and sharp edge of all the rivet holes
completely removed.

27. • The rivet holes shall be 1.5 mm greater than the diameter of the
rivet bars used.
RIVETING OF JOB
 The rivet holes shall be 1.5 mm greater than the diameter of the
rivet bars used. The rivets shall be made to IS:1929.

28.  The clearance i.e. the difference in diameter between the rivets
measured under head before being heated and the rivet hole shall
not be less than 0.75mm.
 All rivets shall be properly heated to straw heat for the full length
of the shank, firmly backed and closed. The head of the rivet,
particularly in long rivets, shall be heated more than the point and
in no caseshall the point be heated, more than the head. Sparking
or burnt rivets shall not be used.
 All loose and burnt rivets and rivets with cracks badly formed,
eccentric or deficient heads shall be cut out and replaced.
 Steel for rivets should conform to is:1148 and rivet should be made
conforming to is:1929.
 The rivets hole should be 1.5mm bigger than the rivet dia.
 Length of rivets = grip+1.5d+1mm extra to every 4mm grip.
 Compressed air pressure required at the hammer end is approx. 6 to
7 kg/sq.cm.
 Heating time of rivets is 20 to 25 minutes.
 All the rivets should be tested 100% by a responsible supervisor by
using testing hammer weight 110 gram.
 All the defective rivets shall be distinctly marked on their heads
with paint and promptly replaced.
 When all the rivets of joints have been finally passed they should
be painted with one coat of ready mixed zinc chrome primer to
is:104 followed by one coat of ready mixed paint red oxide zinc
chrome primer to is:2074.
FINAL ASSEMBLY OF JOB
RIVETTING SECTION
 Details of rivet checking to be maintained as per rivet checking
register (item no.-2 of appendix-i of b1-2008.

29. FINAL ASSEMBLY SECTION
 Final finishing of length, profile, notches etc.
 Fixing of fitting for site connections.
 All the defects should be rectified
 Final check & inspection
 Final assembly includes accurate machining of end profile of
component.
 All the members should be correctly marked before dispatch to
facilitate easier erection.
ISNPECTION
 After final finishing, identification of marking of component
(shipping mark) is done. After final inspection by
RDSO/inspecting agency, the girder parts are cleared for
metalizing/painting.
PAINTING
 No part shall be painted unless inspected & passed by
RDSO/inspecting officials.
 Dry film thickness shall be measured by ELCOMETER.
 Before painting the surface to be painted should be prepared
carefully.
 Surface preparation ………………
 Manual hand cleaning
 Cleaning with power driven tools
 Blast cleaning
 Flame cleaning (for plates>10mm thick)
Painting in areas where there is no service corrosion……………..
PRIMER COAT :
 One Coat of Ready Mixed Paint Zinc Chromate to IS:104
followed by one coat of Ready Mixed Paint Red Oxide Zinc
Chrome to IS:2074.

30. FINISHING COAT :
 Two Coats of Red Oxide paint to IS:123 (One Coat in
Workshop before dispatch, 2nd Coat at site after errection)
METALIZING
As per appendix –vii of b1-2008
 Surface shall be cleaned and roughened by compressed air
blasting with a suitable abrasive material as per is:6586
 After cleaning the surface, metal spraying should be done by
wire method using 2 to 5mm aluminium wire. The purity of
aluminium should be 99.5% conforming to IS: 2590.

31.  The min. Thickness of al coating should be 110 micron and
average thickness should be 150 micron. The specified
thickness should be applied in min.2 layers.
 atleast 01 layer of the coating must be applied within 4 hrs. Of
blasting. The surface must be finished to specified thickness
within 8 hours of blasting. Spray coating shall be uniform
texture and free from lumps, coarseareas etc.
WELL EQUIPPED WORKSHOP
PAINTING SECTION
 Metalizing
After metal spraying ………..
 one coat of etch primer to is:5666
 one coat of zinc chrome primer to is:104
 Two coats of aluminium paint to is:2339 (one coat in workshop
before dispatch, 2nd coatat site after errection)
DESPATCHSECTION
After metalizing and painting the members of the girders may be sent to
errection on site.

32. TESTING OF AGGREGATE USED IN
RAILWAY BRIDGES
INTRODUCTION
The properties of the aggregates affect both the fresh and hardened
properties of concrete. It is crucial to know the properties of the aggregates
to be used in the making of concrete in order to obtain the desired quality
in a concrete. Therefore, the tests performed on aggregates are very
important. Concrete is a composite material in which a binding material
mixed in water on solidification binds the inert particles of well graded
fine and coarse aggregates. Cement and lime are generally used as binding
materials, whereas sand cinder is used as fine aggregates and crushed
stones, gravel, broken bricks, clinkers are used as coarseaggregates.

33. Definitions
Aggregate -granular material used in construction. Aggregate may be
natural, manufactured or recycled.
Natural aggregate -aggregate from mineral sources which has been
subjected to nothing more than
Mechanical processing.
Manufactured aggregate -aggregate of mineral origin resulting from an
industrial process involving
Thermal or other modification.
Recycledaggregate -aggregate resulting from the processingof
inorganic material previously used in
Construction.
Aggregate size - designation of aggregate in terms of lower (d) and upper
(D) sieve sizes expressed
As d/D
Fine aggregate -designation given to the smaller aggregate sizes with D
less than or equal to 4 mm
Coarse aggregate - designation given to the larger aggregate sizes with
D greater than or equal to 4 mm and d greater than or equal to 2 mm.
All-in aggregate- aggregate consisting of a mixture of fine and coarse
aggregates.
Fines - particle size fraction of an aggregate which passes the 0,063 mm
sieve.
Grading - particle size distribution expressed as the percentages by mass
passing a specified set of sieves.
The aggregate should have the following properties
 STRENGTH: Theconcrete should be able to withstand the stresses
that it is subjected to. It is quite strong in compressionbut weak in
tension.
 DURABILITY: It should be durable enough to resist the effect of
weathering agents.
 RESISTANCETO WEAR AND TEAR: when used in floors and
in the construction of roads the concreteshould be able to
withstand abrasive forces.
 WORKABILITY: Itshould be easily workable.

34. SIEVE ANALYSIS
AIM
To determine the particle size distribution of fine and coarseaggregates
by sieving as per IS: 2386 (Part I) - 1963.
PRINCIPLE
By passing the sample downward through a series of standard sieves,
each of decreasing size openings, the aggregates are separated into
several groups, each of which contains aggregates in a particular size
range.
APPARATUS
A SET OF IS SIEVES
i) A set of IS Sieves of sizes - 80mm, 63mm, 50mm, 40mm,31.5mm,
25mm, 20mm, 16mm, 12.5mm, 10mm, 6.3mm,4.75mm, 3.35mm,
ii) Balance or scale with an accuracy to measure 0.1 percent of the weight
of the test sample
The weight of sample available should not be less than the weight given
below:-

35. Maximum size present
in substantial
proportions
(mm)
Minimum weight of
sample despatched
for testing
(kg)
63
50
40
25
20
16
12.5
10.0
6.3
100
100
50
50
25
25
12
6
3
The sample for sieving should be prepared from the larger sample either
by quartering or by means of a sample divider.
PROCEDURE
 The test sample is dried to a constant weight at a temperature
of 110 + 5oC and weighed.
 The sample is sieved by using a set of IS Sieves.
 On completion of sieving, the material on each sieve is
weighed.
 Cumulative weight passing through each sieve is calculated
as a percentage of the total sample weight.
 Fineness modulus is obtained by adding cumulative
percentage of aggregates retained on each sieve and dividing
the sum by 100.
REPORTINGOF RESULTS
The results should be calculated and reported as:
 The cumulative percentage by weight of the
total sample

36.  The percentage by weight of the total sample
passing through one sieve and retained on the
next smaller sieve, to the nearest 0.1 percent.
The results of the sieve analysis may be recorded graphically on a semi-
log graph with particle size as abscissa(log scale) and the percentage
smaller than the specified diameter as ordinate.
A sample chart is provided
WATER ABSORPTION
AIM
To determine the water absorption of coarseaggregates.
APPARATUS
 Wire basket - perforated, electroplated or plastic coated with
wire hangers for suspending it from the balance

37.  Water-tight container for suspending the basket
 Dry softabsorbent cloth - 75cm x 45cm (2 nos.)
 Shallow tray of minimum 650 sq.cmarea
 Air-tight container of a capacity similar to the basket
 Oven
SAMPLE
A sample not less than 2000g should be used.
PROCEDURE
 The sample should be thoroughly washed to remove finer
particles and dust, drained and then placed in the wire basket
and immersed in distilled water at a temperature between 22
and 32oC.
 After immersion, the entrapped air should be removed by
lifting the basket and allowing it to drop 25 times in
25seconds. The basket and sample should remain immersed
for a period of 24 + ½ hrs. afterwards.
 The basket and aggregates should then be removed from the
water, allowed to drain for a few minutes, after which the
aggregates should be gently emptied from the basket on to
one of the dry clothes and gently surface-dried with the
cloth, transferring it to a second dry cloth when the first
would remove no further moisture. The aggregates should be
spread on the second cloth and exposed to the atmosphere
away from direct sunlight till it appears to be completely
surface-dry. The aggregates should be weighed (Weight 'A').
 The aggregates should then be placed in an oven at a
temperature of 100 to 110oC for 24hrs. It should then be
removed from the oven, cooled and weighed (Weight 'B').
REPORTINGOF RESULTS
Water absorption = [A/B] x 100%
Two such tests should be done and the individual and mean results should
be reported.
A sample farm for the record of the test results is given

38. AGGREGATE ABRASION VALUE

39. AIM
To determine the abrasion value of coarseaggregates.
APPARATUS
LOS ANGLES MACHINE
 Los Angles abrasion testing machine
 IS Sieve of size - 1.7mm
 Abrasive charge - 12 nos. cast iron or steel spheres
approximately 48mm dia. and each weighing between 390
and 445g ensuring that the total weight of charge is 5000 +
25g
 Oven
PREPARATION OF SAMPLE
The test sample should consist of clean aggregates which has been dried
in an oven at 105 to 110oC to a substantially constant weight and should
conform to one of the grading shown in the table below:

40. PROCEDURE
The test sample and the abrasive charge should be placed in the Angles
abrasion testing machine and the machine rotated at a speed of 20 to 33
revolution/minute for 1000 revolutions. At the completion of the test, the
material should be discharged and sieved through 1.70mm IS Sieve.
Tolerance of +2 percent permitted.

41. REPORTINGOF RESULTS
 The material coarserthan 1.70mm IS Sieve should be
washed, dried in an oven at a temperature of 100 to 110oC to
a constant weight and weighed (Weight 'B').
 The proportionof loss between weight 'A' and weight 'B' of
the test sample should be expressed as a percentage of the
original weight of the test sample. This value should be
reported as,
Aggregate abrasion value = [(A – B)/A]x 100%
A sample farm for the record of the test results is

42. AGGREGATE IMPACT VALUE
AIM
To determine the aggregate impact value of coarse aggregates.
APPARATUS
AGGREGATE IMPACT TEST MACHINE
 Impact testing machine conforming to IS: 2386 (Part IV) -
1963
 IS Sieves of sizes - 12.5mm, 10mm and 2.36mm.
 A cylindrical metal measure of 75mm dia. and 50mm depth.
 A tamping rod of 10mm circular cross section and 230mm
length, rounded at one end
 Oven
PREPARATION OF SAMPLE
 The test sample should conform to the following grading:
 Passing through 12.5mm IS Sieve 100%
 Retention on 10mm IS Sieve 100%
 The sample should be oven-dried for 4hrs. at a temperature of 100
to 110oC and cooled.
 The measure should be about one-third full with the prepared
aggregates and tamped with 25 strokes of the tamping rod.
A further similar quantity of aggregates should be added and a further
tamping of 25 strokes given. The measure should finally be filled to
overflow, tamped 25 times and the surplus aggregates struck off, using a
tamping rod as a straightedge. The net weight of the aggregates in the
measure should be determined to the nearest gram (Weight 'A').

43. PROCEDURE
 The cup of the impact testing machine should be fixed firmly
in position on the base of the machine and the whole of the
test sample placed in it and compacted by 25 strokes of the
tempering rod.
 The hammer should be raised to 380mm above the upper
surface of the aggregates in the cup and allowed to fall freely
onto the aggregates. The test sample should be subjected to a
total of 15 such blows, each being delivered at an interval of
not less than one second.
REPORTINGOF RESULTS
 The sample should be removed and sieved through a 2.36mm IS
Sieve. The fraction passing through should be weighed (Weight
'B'). The fraction retained on the sieve should also be weighed
(Weight 'C')and if the total weight (B+C) is less than the initial
weight (A) by more than one gram, the result should be discarded
and a fresh test done.
 The ratio of the weight of the fines formed to the total sample
weight should be expressed as a percentage.
Aggregate impact value = [A/B] x100%
 Two such tests should be carried out and the mean of the results
should be reported.
A sample proforma for the record of the test results is

44. AGGREGATE CRUSHING VALUE
AIM
To determine the aggregate crushing value of coarseaggregates.
APPARATUS

45. CYLINDRICAL MEASURE AND PLUNGER
 Cylindrical measure and plunger
 Compressiontesting machine
 IS Sieves of sizes - 12.5mm, 10mm and 2.36mm
PROCEDURE
 The aggregates passing through 12.5mm and retained
on10mm IS Sieve are oven-dried at a temperature of 100
to110oC for 3 to 4hrs.
 The cylinder of the apparatus is filled in 3 layers, each layer
tamped with 25 strokes of a tamping rod.
 The weight of aggregates is measured (Weight 'A').
 The surface of the aggregates is then levelled and the
plunger inserted. The apparatus is then placed in the
compressiontesting machine and loaded at a uniform rate so
as to achieve 40t load in 10 minutes. After this, the load is
released.
 The sample is then sieved through a 2.36mm IS Sieve and
the fraction passing through the sieve is weighed (Weight
'B').
 Two tests should be conducted.

46. REPORTING OF RESULTS
Aggregate crushing value = [B/A]x 100%
The result should be recorded to the first decimal place and the mean of
the two results reported.
SHAPE TEST
AGGREGATE FLAKINESS INDEX VALUE
AIM
Determination of flakiness index of coarse aggregate, where the size of
the coarse aggregate are larger than 6.3mm.
EQUIPMENT& APPARATUS
 Thickness gauge
 Sieves [63, 50, 40, 31.5, 25, 20, 16, 12.5, 10 & 6.3mm]
 Balance [0-10 kg]

47. Thickness gauge
PREPARATION SAMPLE
Surface dry samples is used for the test. A minimum number of 200
pieces of any specified fraction is required to do the test.
PROCEDURE
The sample is sieved through IS sieve specified in Table shown
below.

48. Dimension of Thickness andLength Gauge
 A minimum of 200 pieces of each fraction is taken and weighed.
 In order to separate flaky materials, each fraction is then gauged
individually for thickness on a thickness gauge.
 The total amount of flaky material retained by the thickness gauge
is weighed to an accuracy of 0.1% of the weight of sample.
CALCULATION
In order to calculate the flakiness index of the entire sample of
aggregates, first the weight of each fraction of aggregate passing and
retained on the specified sets of sieves is noted (Y1, Y2, Y3, Y4…..etc.).
Each piece of these are tried to be passed through the slot of the specified
thickness of the thickness gauge are found and weighed (y1, y2, y3,
y4…etc.). Then the flakiness index is the total weight of the material
retained on the various thickness gauges, expressed as a percentage of the
total weight of the sample gauged.
REPORT
Flakiness index is reported in percentage to the nearest whole number

49. AGGREGATE ELONGATION INDEX
AIM
For determination of elongation index of coarse aggregate, where the size
of the coarseaggregate are larger than 6.3 mm.
EQUIPMENT& APPARATUS
 Length gauge
 Sieves(63mm,50mm,40mm,31.5mm,25mm,20mm,16mm,12.5mm
,10mm)
 Balance (0-10kg)
 Oven (3000c)
Length Gauge
TEST SAMPLE PREPARATION
Surface dry samples is used for the test. A minimum number of 200
pieces of any specified fraction is required to do the test.
PROCEDURE
 A minimum of 200 pieces of each fraction is taken and weighed.
 In order to separate elongated materials, each fraction is then
gauged individually for length in the length gauge.
 The pieces of aggregate from each fraction tested which could not
pass through the specified gauge length with its long sides
elongated are collected separately to find the total weight of
aggregate retained on the length gauge from each fraction.
 The total amount of elongated material retained by the length
gauge is weighed to an accuracy of 0.1% of the weight of sample.

50. The sample is sieved through IS sieve specified in Table shown below.
CALCULATION
In order to calculate the elongation index of the entire sample of
aggregates, first the weight of each fraction of aggregate passing and
retained on the specified set of sieves is noted (Y1, Y2, Y3, Y4…..etc.).
Each piece of these are tried to be passed through specified length of the
gauge length with its longest side and those elongated pieces which do
not pass the gauge are separated and weighed (y1, y2, y3, y4…etc.). Then
the elongated index is the total weight of the material retained on the
various length gauges, expressed as a percentage of the total weight of the
sample gauged.
REPORTS
Elongation index is reported in percentage to the nearest whole number.
SAFETY & PRECAUTIONS
 Use hand gloves while removing containers from oven after
switching off the oven.
 Use safety shoes, mask & aprons at the time of test.

51. LIST OF SUPPLIERS OF MATERIAL
TESTING EQUIPMENTS ALONGWITH
THEIR ADDRESSES
1. AIMIL Ltd.
Malhotra House, Walchand Hirachand Marg,
Opp. to G.P.O. Fort, Mumbai - 400 001.
2. Testwell Scientific Instrument Pvt. Ltd.
5, Nand Dham, Ground Floor,
Plot No. 270, Sion Cementary Road, Sion (W) - 400 022.
3. Utile Equipments
13, Jal Tarang, Prabhat Road,
Lane No.1, Pune - 411 004
4. Lawerence & Mayo (India) Pvt. Ltd.
3, Dr. Ambedkar Road, Pune - 411 001.
5. Laxmi Sales & Agencies
84, Pannalal Nagar, Amaravati - 444 605.
6. Commander Agencies
1466, Sadashiv Peth, Pune - 411 030.
7. M/s Rout Scientific & General Traders
17/B, Ashiwini Society, Behind Hotel Monali,
Wakadewadi, Pune - 411 005.
8. DYEGLO
820/7, Shee-Krishna Kunj,
Bhandarkar Institute Road,
Pune - 411 004.

52. ACKNOWLEDGE
MENT
I express my sincere gratitude to Executive Director/ Bridge
Corporation, all Directors of the Directorate along with Assistant Engineers
associated with this summer training for his proper guidance, useful
suggestions and timely treatment where ever required during the entire
training. My best wishes to Director Bridge Corporation for giving a chance
for this summer training and know about bridge structures in Indian
Railways. My special thanks goes to Mr. Vikrama Prasad (Sr. Section
Engineer) forguiding us in courseofthis project and suggesting us the ways
and means to enhance it. He has been very helpful and a great source of
inspiration during the entire project. I wish to extend my sincere thanks for
his excellent guidance and suggestions for the successfulcompletion of my
project work.