Академический Документы
Профессиональный Документы
Культура Документы
The objective for the development was to design, fabricate and demonstrate, a simple,
easy to use, effective and economic water permeability test equipment conforming the
guidelines provided by the Railways.
It is based on simple principal of keeping water under air pressure in a confined
pressure chamber. Due to different densities of water and air the water will always be under
air as it is heavier, ( this is best explained by filling a transparent balloon partially with
water and air). The water pressure is applied on the concrete specimen in most effective
way to find the water penetration in the concrete specimen. The highlight of the equipment
is that the concrete specimen is always available for visual inspection during all the 96 hrs
of pressure application. The concept may look somewhat odd at first glance, but it path
breaking and it works and works well!
When the author was posted as Executive Engineer (Const), for Guntakal-Hospet
doubling (115Km), it is found that in all the approved major & important bridge drawings
(GAD) the permeability test made mandatory and no institute available nearby to conduct
-2-
the test as per DIN-1048 standards including the JNTU, Hydrabad, local Vijay Nagar
Engineering College(ISO-9000) and IISc, Banglore. While the CRS/ Southe Central Circle,
Secundrabad insisting on the permeability test during his inspection of Gudur-Renugunta
doubling inspection. Then the author searched for the literature from every available source
including the internet, but not even a single reference found for portable, handy equipment
for water permeability test of concrete as per DIN-1048 requirements. They are mainly
related to air permeability, chloride ion permeability, and some reference for water
permeability based on the amount of water penetration during a given time interval i.e. rate
of water penetration. However this kind of test does not give the correct picture as
explained later in the paper. In fact it is better to say that everybody talks of permeability/
durability of concrete and its importance but no body tells how to do the test and where to
get the test done regularly? Mostly methods/equipments were designed for the air and
chloride penetration and none as per the guidelines of DIN 1048 Part I. So the author
started with one page literature available in the Report no. BS-14(Revised) Jan-2001 (a
RDSO publication) and appendix ‘C’ of Clause 5.4.1.1 of IRS Concrete Bridge Code.
Currently the permeability test as per ASTM standards (not as per DIN 1048 standards),
is being done by a very few technical institutes, which charges a very high amount for
conducting this test which does not confirm to Railways requirement. Because of this very
few tests for permeability are being done in practice. Also most of the field construction
units, which are executing huge quantities of the concrete, are not able to perform this test.
Even the Zonal Railways material testing labs are not conducting this test due to non-
availability of the simplified equipment and procedure. This is resulting in majority
RCC/PSC concrete components are not being tested for permeability, despite being
mandatory? What a paradox?
The author then design a simplified equipment, and after about seven months work, the
equipment was conceptualized, designed and developed, which has been greatly
appreciated by the CAO/C, S.C. Railway and other CE’s/Construction, and other Dy CE’s
of other units. The same was published in the Hindi magazine “Nirman Darpan” of South
Central Railway in 2004.
The frequency of test/tests to be done for various RCC/PSC components is not exactly
defined neither in IRS concrete bridge code/ Durability of Concrete Structure-Report no.
BS-14(Revised) Jan-2001 nor in IS -456, 2000. It is given for concrete cube strength which
is based on the quantity of concrete work done. However the author is of the opinion that
the water permeability test should be conducted for all major concrete components like PSC
girder, deck slab, RCC bed block, RCC slab of concrete bridges and other important
structure like water tank etc. Also the Engineer-in-charge of the project can decide the
frequency of test under his juriddiction.
1.5 Equipment as per IRS concrete Bridge code Appendix-C, as per clause 5.4.1.1:
This equipment described in the IRS concrete bridge code is mainly consist of a very
complex arrangements and with this set of arrangements it very-very difficult to
conduct the test by any field staff as shown below in fig 1. The application of pressure
by using hand pump of 7-bar pressure is very difficult to achieve unless some
reciprocating pump is provided. This may be the reason of not doing this test frequently.
Also the equipment does not have the portability.
Fig-1
2.0. Details of the Permeability Test Equipment:
TOP PART
Fig-4 Fig-5
3.0 PREPARATION OF CONCRETE TEST SPECIMEN FOR TEST:
2. Seal all the joints of the mould with neat cement paste or with any other sealing
material and apply the lubricant all round the mould surface inside, similar to
cube casting.
3. Pour the concrete in the mould and make the test specimen similar to the cube
making and vibrate the mould with concrete so that uniform compaction is
achieved. This is very important as this will give uniformly compacted concrete.
4. Remove the test specimen from the mould next day
after 24 hours of casting and immerse in water for
curing for 28 days as shown in figure-7 below.
( As per IRS bridge code appendix ’C’ , the central
100mm diameter circular area on the side on which
water pressure is to be applied is to be roughened
with wire brush and to be sealed with two coats of
cement water past, preferably with same W/C ration
as that of mix), However this is not required as this
will not give actual concrete surface for
permeability test, as has been done and observed by
the tests done by the author. Fig-7
PROCEDURE
3. Put the middle arrangement fixed with the top arrangements, over this and fully
tighten all the nuts and bolts uniformly so that the rubber gasket and the test.
Specimen will be subjected to uniform pressure and will seal the around except
central 100mm dia opening, as shown in the Fig-9.
4. From the top hole fill the clean water (app.200ml) and tighten with the water sealing
nut fully, as shown in the figure-10.
5. Apply the 1 bar of air pressure through foot pump or any other arrangements and
check for any leakage of pressure (this can be done by observing the pressure gauge
reading or even by putting the complete set under water. If all the nuts & bolts are
tightened fully & properly, no leakage of either water or air will be observed, as
shown in the figure below. ( View videos taken during trial stage).
Fig-10
7. After expiry of 48 hours of one bar pressure, apply 3 bar pressure and again check
for any leakage and leave for next 24 hours.
Fig-11 Fig-12
8. After expiry of 72 hours, apply 7 bar pressure. This pressure is very high and may
be difficult to apply through foot pump or hand pump. The test equipment can be
taken to any auto puncture air filling shop and by using air compressor, a pressure
of 7-bar can be applied, as shown in fig 5, ( the equipment developed has been
subjected to even up to 8 bar (>125 psi) and tested in by submerging in water for
any leakage of pressure and no leakage was observed as shown in figure 11 and 12
above.
9. After expiry of 96 hours, release the pressure though the valve provided at top and
release the water by loosening the water inlet/outlet bolt.
1. While applying the first one bar pressure, observe for any leakage of water, as this
may result in the loss of pressure. If any drop in pressure observed retighten all the
nuts and bolts. It is better to tight all the nuts and bolts fully before applying
pressure.
6.0 Testing of the Concrete Test specimen for water penetration for Permeability:
Fig-16 Fig-16A
1. The equipment with minor modification can be directly used at site, both for vertical
and horizontal components. This can be done in two ways:,
1. By providing dowels at least four equidistant (either by drilling and fixing the
dowels with epoxy or by fixing the dowels at pre-determined position at the time
of concrete casting) from the center and the fixing the equipment (top & middle
part) with screws, similar to doing the lab test. As the specimen can not be
broken, to determine the water penetration, rate of water penetration by
measuring a definite quantity of water penetration over a time period and
correlating the quantity of water and the time relationship, for these further tests
can be done. The author is currently doing the same. However this is not found
more convincing as the water penetration may differ from one location to
another as explained in 8.0.(1) & (2).
3. The test duration of 96 hrs is very long. There should be accelerated test
reduced to 24 hrs (1/4th) at the most. With this equipment we have applied more
than 10 bar (150 psi), if a co-relation permeability with pressure is fully well
defined, reducing the time is possible. This will help in monitoring the concrete
work for durability in a better way.
4. As the equipment is very handy and robust, easy to use. The equipment should
be used at the concrete mix design stage. The designer/consultant should provide
the water permeability value along with the strength of the concrete mix with
cement consumption for a minimum of three mix designs. This will help the
Engineer-in-charge to decide the appropriate mix based on the site condition and
not only on the strength. The permeability will vary with the proportioning of
different aggregates (CA&FA) keeping the cement content same.
5. The equipment can be very useful for comparing the water permeability of
different type of concrete e.g. concrete with admixture, self compacting concrete
(SCC), FRC etc.
1. As more than 80 tests has been done by the author. In two cases of trial mix the
water penetration was found between 25-45 mm. Than the specimen was further
broken in smaller parts and it is observed that some soft stones (from the top surface
of stone quarry) found near the top surface and these were responsible for ingress of
water with less compaction/vibration which resulted in cavities, helped the water to
penetrate deeper. So even few bad/soft stones at exposed surface may deteriorate the
3. The above two cases the average compressive strength of the concrete cube was
found to be within the acceptable limits, but failed in permeability test. So the field
staff educated regarding the role of water, mixing time, gradation of aggregates.
This has resulted in controlled quantity of water. So the combination of strength and
water penetration is best requirement for specifying acceptable concrete.
1. Each of the members in the team (all AXEN’s, IOW’s and even khalasi’s)
understood the importance of use of adequate quantity of water and the weigh
batched concrete. It will definitely help in concrete quality control in future projects.
Awareness and ease with the equipment.
2. All the contractors got the firm message to produce quality concrete all the time at
the rate quoted by them in tender. This has helped in enforcing discipline, work
culture and quality product.
3. At each major bridge site one equipment was kept and for all important reinforced
concrete members the test was done at site itself. This led to constant monitoring of
concrete work with least available manpower.
4. The equipment has been fabricated and supplied to other Dy CE/Const for their use
and a dedicated effort has been made for executing durable concrete. The other Dy
CE’s sent their supervisory staff for demonstration and learning to Bellary and they
have been trained.
5. The equipment in use/being used at following important bridge sites and Projects.
1. Bridge in river Pennar under Dy CE/C/Kuddapa
2. Bridge in river Cheyar under Dy CE/C/Kuddapa
3. Bridge in river Krishna under Dy CE/C/Raichur
4. Bridge in river Pennar under Dy CE/C/Kuddapa
5. Bridge in river Hagari under Dy CE/C/Guntakal
6. Gudur-TPTY Doubling under Dy CE/C/RU & under Dy CE/C/
7. Gadwal-Raichur Doubling under Dy CE/C/Raichur
8. Mudked-Adilabad Gauge Conversion under Dy CE/C/Secundrabad
4. After breaking the concrete specimen in two parts, the water penetrated will dry very
fast and to be measured as early as possible. Even a small delay may cause water to
dry.
10.0 CONCLUSION:
With this equipment the permeability test can be conducted as and when required and
the field construction units can be sure of the durability of the concrete structure. The
equipment is low cost, easy to use, user friendly; having transportability can be handled
by one person and even can be kept at any major construction site laboratory. Fabricated
with the readily available material and can be fabricated easily by any mechanical
workshop. Once the equipment made, any nos. of tests can be done at no additional cost.
The performance of the equipment is satisfactory and the results are excellent. Nearly 80
tests have been done by the author and all have given desired results.
However the open line is not very keen and none of the division of SC Railway yet
started using the equipment, while these divisions are also doing important works
involving concrete.
For feed back, any suggestions for improvements or for any query please contact: