Project R881/2C: Comprehensive Improvements of the Parallel Roads – (Contract – 2C)

General Specifications

SECTION 4 - CONCRETE WORKS

SUB-SECTION DESCRIPTION PAGE

4/1 CEMENT 4/3

4/2 AGGREGATES, GENERAL REQUIREMENTS 4/4

4/3 FINE AGGREGATES 4/9

4/4 COARSE AGGREGATE FOR CONCRETE 4/10

4/5 COMBINED AGGREGATE 4/10

4/6 WATER FOR CONCRETE 4/10

4/7 APPLICABLE TESTS AND CODES 4/11

4/8 REINFORCEMENT BARS 4/13

4/9 BAR SCHEDULE AND SHOP DRAWINGS 4/14

4/10 BAR CUTTING AND BENDING 4/14

4/11 PLACING AND FIXING REINFORCEMENT 4/15

4/12 WELDED WIRE FABRIC 4/15

4/13 SPACER BLOCKS 4/15

4/14 ADMIXTURES 4/16

4/15 CONCRETE MIX SPECIFICATION 4/16

4/16 CONCRETE MIX DESIGN 4/19

4/17 QUALITY CONTROL 4/20

4/18 CONCRETE DESIGN LIMITS 4/23

4/19 CONSISTENCY OF CONCRETE 4/23

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General Specifications

SUB-SECTION DESCRIPTION PAGE

4/20 TOLERANCES IN PROPORTIONING THE 4/23

MATERIALS

4/21 ASSEMBLY AND HANDLING MATERIAL 4/24

4/22 MIXING CONCRETE 4/25

4/23 READY MIXED CONCRETE 4/26

4/24 TRANSPORT AND PLACING 4/27

4/25 COMPACTION OF CONCRETE 4/28

4/26 CONSTRUCTION JOINTS 4/29

4/27 CURING OF CONCRETE 4/30

4/28 EARLY LOADING 4/30

4/29 CONCRETING AT NIGHT 4/31

4/30 CONCRETING IN HOT WEATHER 4/31

4/31 MINIMUM TEST REQUIREMENTS FOR 4/33

CONCRETE

4/32 FORMWORK 4/33

4/33 CLASSES OF FINISH 4/37

4/34 MORTAR 4/39

4/35 EXTENT OF POURS 4/39

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Project R881/2C: Comprehensive Improvements of the Parallel Roads – (Contract – 2C)
General Specifications

SECTION 4 - CONCRETE WORKS

Concrete work shall consist of furnishing all materials and constructing structures of the
forms, shapes and dimensions shown on the Drawings or as directed in accordance with
the details shown on the Drawings and these Specifications.

4/1 CEMENT

SULPHATE RESISTING CEMENT

4/1.1 Sulphate Resisting Cement shall comply with BS 4027 – 1996, Class 42.5N or
ASTM C150 Type V. In addition the cement shall comply with the following:-

 The acid soluble alkali level measured as (Na 2 0+0.658 K2 0) shall not
exceed 0.6% by weight determined in accordance with BS EN-196
Part 2 1995.

 The heat of hydration shall not exceed 290 KJ/Kg at 7 days when
tested in accordance with BS 4550 : Part 3 Section 3.8.

 The specific surface shall be not greater than 375 m²/Kg and not less
than 280 .m²/Kg when tested as described in BS EN 196 : Part 6 : 1992.

 The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196: Part 21.

 The tricalcium aluminate content shall be 3.5% max when tested

according to the method BS EN 196: Part 2: 1995.

ORDINARY PORTLAND CEMENT

4/1.2 Ordinary Portland Cement shall conform to the requirements of BS 12 - 1996,

Class 42.5N or ASTM C150 Type I and with the following amendments:-

 The acid soluble alkali level measured as Na 2 0+0.658 K20 shall not
exceed 0.6% by weight determined by the test method described in BS EN
196 Part 2.

 The heat of hydration shall not exceed 290 KJ/Kg at 7 days when
tested in accordance with BS 4550: Part 3 Section 3.8.

 The tricalcium aluminate content shall lie within the range of 4% to

13% when tested according to the method BS EN 196: Part 2: 1995.

 The specific surface (fineness) shall be not greater than 375 .m²/Kg
and not less than 280.m²/Kg when tested as described in BS EN 196 : Part
6 : 1992.

 The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196: Part 2.

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General Specifications

MODERATE SULPHATE RESISTING PORTLAND CEMENT

4/1.3 Moderate sulphate resisting Portland Cement shall comply with ASTM C150
Type II. It shall also comply with Clause 4/1.2. In addition the cement shall
comply with the following:-

 The acid soluble alkali level measured as (Na 2 0+0.658 K2 0) shall not
exceed 0.6% by weight determined in accordance with BS EN-196
Part 2 1995.

 The specific surface (fineness) shall not be greater than 375 sq.m/Kg and
not less than 280 sq.m/Kg when tested as described in BS EN 196: Part 6:
1992.

 The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196: Part 21.

 Contain not less than 4% and not more than 8% proportion of tricalcium
aluminate by weight when tested according to the method BS EN 196: Part
2: 1995.

 Contain less than 2.7% proportion of Sulphur trioxide by weight

GENERAL

4/1.4 Each cement batch shall bear manufacturer's name and batch number. Type
of cement shall be the same as mentioned in the approved analysis report.
Each separate consignment of cement shall be tested by the manufacturer
before delivery and certified copies of such tests shall be supplied to the
Engineer before any part of the consignment is used in the works. The
Engineer reserves the right to order a re-test of cement at any time. Approval
of cement does not relieve the Contractor of the responsibility to produce
concrete of the specified strength.

4/1.5 Cement shall be delivered to site in bulk, or with the Engineer's approval, may
be supplied in sealed bags which shall bear the manufacturer's name and the
date of manufacture. Each consignment shall be accompanied by a copy of
the manufacturer's batch test certificate and certificate of guarantee.

4/1.6 Each consignment of cement shall be kept separate, identified and used in
order of delivery.

4/1.7 Any consignment not used within 2 months from the date of manufacture will
not be allowed to be used in the works.

4/1.8 One brand only of cement as approved by the Engineer shall be used
throughout the works unless otherwise authorised by the Engineer in writing.

4/2 AGGREGATES GENERAL REQUIREMENTS

4/2.1 Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS 882 "Concrete
aggregates from natural sources" and the fine aggregate shall also comply
with Dubai Municipality Administrative Order No. 143/91.

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General Specifications

4/2.2 The aggregates used in the permanent works shall be naturally occurring or
crushed materials obtained only from approved sources.

4/2.3 Before any material from a particular source is used, the Contractor shall
obtain representative samples of fine and coarse aggregates and carry out the
necessary tests and analyses to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.

4/2.4 The results of these tests, etc. shall be submitted to the Engineer and his
approval shall be obtained before any of the material is used in the works.
Part of each sample will be required for concrete trial mixes and part shall be
retained for comparison with subsequent deliveries.
4/2.5 Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS 812: 1989 Part 102.
4/2.6 The maximum size of the aggregate shall not be larger than 1/5 of the
narrowest dimension between sides of the member for which the concrete is to
be used and not larger than 3/4 of the maximum clear distance between
reinforcing bars.
4/2.7 Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.
4/2.8 Coarse aggregate shall be crushed aggregate obtained from a quarry
approved by the Engineer.
4/2.9 Unless otherwise authorized by the Engineer coarse aggregate shall be
delivered to site in separate sizes according to the maximum specified
aggregate size for each grade of concrete.
4/2.10 Aggregates shall meet the requirements of Table 4.1.
4/2.11 The frequency of testing of aggregates shall be in accordance with Table 4.2
or as directed by the Engineer.

TABLE 4.1: LIMITS FOR PHYSICAL, CHEMICAL AND MECHANICAL

PROPERTIES OF AGGREGATES FOR CONCRETE

TEST METHODS PERMISSIBLE LIMITS

SR. KIND OF REQUIREMENT ---------------------- -----------------------------------
NO. BS 812 / ASTM FINES COARSE

1. Grading BS EN 933-1 Standard Standard

(Dry)

2. Material finer
Than 0.075 mm BS EN 933-1 or
ASTM
C117:2004
(Wet)
Natural, uncrushed/
crushed max.3% max.1%
Crushed rock max.7% max.1%

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General Specifications

TABLE 4.1: LIMITS FOR PHYSICAL, CHEMICAL AND MECHANICAL

PROPERTIES OF AGGREGATES FOR CONCRETE

TEST METHODS PERMISSIBLE LIMITS

SR. KIND OF REQUIREMENT ---------------------- -----------------------------------
NO. BS 812 / ASTM FINES COARSE
3. Clay lumps and
friable particles C142 : 1997 max.1% max.1%

4. Light weight pieces C123 max.0.5% max.0.5%

5. Organic impurities for C40 : 1999 The color of

fine aggregate the Super-
natant liquid
is lighter than
standard
color solution
6. Water absorption C128 : 2001 max.2.3% max.2.0%
C127 : 2001

7. Specific Gravity C128 : 2001 min.2.60 min.2.60

C127 : 2001
(apparent)

8. Shell content in BS EN 933-

aggregates 7:1998
Coarser than 10mm max.5%
Between 5mm & 10mm max.15%

9. Particle shape
Flakiness index Part 105.1 max.25
Elongation index Part 105.2 max.25

The index shall be max.

25 for combined
aggregates but should
not exceed more than
30 for individual sizes.

 Partially crushed faces DMS 8 : 2001

of coarse aggregate
shall be 100% with at
least one crushed face.

10. Acid soluble Part 117,

Chlorides, CL Appendix C
For reinforced
concrete made with
SRPC cements max.0.03% max.0.01
%
OPC & MSRPC max.0.03% max.0.02
cements %

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Project R881/2C: Comprehensive Improvements of the Parallel Roads – (Contract – 2C)
General Specifications

TABLE 4.1: LIMITS FOR PHYSICAL, CHEMICAL AND MECHANICAL

PROPERTIES OF AGGREGATES FOR CONCRETE

TEST METHODS PERMISSIBLE LIMITS

SR. KIND OF REQUIREMENT ---------------------- -----------------------------------
NO. BS 812 / ASTM FINES COARSE
For mass concrete
made with
SRPC cements max.0.03% max.0.02
%
OPC & MSRPC max.0.03% max.0.04
cements %

For prestressed
concrete & steam
cured structural
concrete max.0.03% max.0.01
%

11. Acid soluble

sulphates, S03 BS EN 1744- max.0.3% max.0.3%
1:1998

12. Soundness, MgS04

(5 cycles) C88 : 1999A max.12% max.12%

13. Mechanical strength

10% fines value Part 111 min100KN
or Impact value Part 112 max.30%

Los Angeles
Abrasion C131 : 2001 max.30%
C535 : 2001

14. Drying Shrinkage Part 120 max.0.05%

15. Potential reactivity,

Note 2
Of Aggregates,
Chemical Method C289 Innocuous Innocuous
Of Cement-Aggregate
Combination C227 6 month
expansion
0.10% max.

Note 1 : There is no requirement of shell content in sands passing 5 mm

sieve size.

Note 2 : Aggregates may initially be assessed for its reactivity in

accordance with ASTM C289 and if potential reactivity is indicated,

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General Specifications

then mortar bar tests in accordance with ASTM C227 shall be

carried out.

TABLE 4.2: FREQUENCY OF ROUTINE TESTS ON AGGREGATES

SR. KIND OF REQUIREMENT - TEST FREQUENCY RATE

NO. TEST METHOD

1. Grading - BS EN 933-1:1997 Per 1,000m3

2. Material finer than 0.075 mm - - do -

BS EN 933-1 or ASTM C117:2004

3. Clay lumps and Friable Particles Per 4,000m3

- ASTM C 142

4. Organic impurities ASTM C 40 Per 2,000m3

5. Water absorption - ASTM C128 : - do -

2001/C127 : 2001

6. Specific Gravity - ASTM C128 : - do -

2001/C127 : 2001

7. Shell content - BS EN 933-7:1998 - do -

8. Particle shape BS 812 : 1990 P 105.1 - do -

P 105.2

9. Acid soluble chlorides, CL

Qualitative-BS 812 : 1988 Part 117 Per 1,000m3

Appendices A/B

Quantitative-BS 812 : 1988 Part 117 Each 12 concrete

Appendix C days if result is
more than 75% of
the limit and each
month if result is
less than 75% of
the limit.

10. Acid soluble sulphates, Per 1000 M3 or Each 24

S03 - BS EN 1744-1:1988 concrete days if
result is more than 75%
of the limit & each 2
months if result is less
than 75% of the limit

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General Specifications

TABLE 4.2: FREQUENCY OF ROUTINE TESTS ON AGGREGATES

SR. KIND OF REQUIREMENT - TEST FREQUENCY RATE

NO. TEST METHOD
which ever is less

11. Soundness, Mg S04 (5 cycles) Each 48 concrete

ASTM C88 : 1999A Days or 4,000 m3

12. Mechanical Strength

10% Fines or impact value Each 72 concrete

- BS 812 Parts 111, 112 Days or 6,000 m3

Los Angeles abrasion - - do -

ASTM C 131/C 535

13. Moisture variation in sand - by Twice daily

Moisture Meters

14. Drying Shrinkage At the start of the project

BS812 Part 120 and whenever there is a
change in the source of
supply.

15. Potential Reactivity: At the start of the project

of aggregates and wherever there is a
(ASTM C295, C289) change in the source of
Supply
of Carbonate (ASTM C586)

of Cement aggregate
combination
(ASTM P214 and C227)

16 Light weight pieces test (ASTM C 123) Per 2,000 m3

Note : Drying Shrinkage and potential reactivity of aggregates shall be

determined initially at the start of the project or whenever there is a
change in the source of supply.

4/3 FINE AGGREGATES

4/3.1 The gradation of fine aggregate shall be in accordance with BS 882 latest
edition.

4/3.2 Each batch of aggregate delivered to site shall be kept separate from previous
batches and shall be stored for at least 3 (three) working days before use to
allow inspection and tests to be carried out.

4/3.3 Fine Aggregate shall be clean sharp natural and/or crushed sand.

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4/3.4 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.

4/4 COARSE AGGREGATE FOR CONCRETE

4/4.1 Coarse aggregate shall be prepared as single sized aggregate and blended to
produce normal size grading. The combined grading shall be within the
appropriate grading limits given in BS 882.

4/4.2 Aggregates that are deleteriously reactive with the alkalis in the cement in an
amount sufficient to cause excessive expansion of concrete shall not be used.

4/4.3 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.

4/5 COMBINED AGGREGATE

4/5.1 Approved coarse aggregate and fine aggregate in each batch shall be
combined in proportions as specified in BS 882 and as approved by the
Engineer. However, in no case shall materials passing the 0.075mm, sieve
exceed three (3) percent by weight of the combined aggregate.

4/5.2 The combined aggregate gradation used in the work shall be as specified,
except when otherwise approved or directed by the Engineer. Changes from
gradation to another shall not be made during progress of the work unless
approved by the Engineer.

4/6 WATER FOR CONCRETE

4/6.1 The Contractor shall make his own arrangement and obtain approval for the
supply of water.

4/6.2 The mixing water should be clear, apparently clean and free from matter
harmful to concrete in its fresh or hardened state. Potable water can be used.
Water of questionable quality should comply with the physical tests of Table
4.3 and chemical limitation listed in Table 4.4. Water shall also meet the
requirement of BS 3148 of latest addition.

4/6.3 The temperature of water for concrete should not be less than 5 degree
Celsius nor more 25 degree Celsius. Water may be cooled to not less than 5
degree Celsius by the gradual addition of chilled water or ice but on mixing, no
ice particles should be present in the mix. Alternatively, flaked ice may be
used. The ice to be used should be crushed and should be the product of
frozen water which complies with acceptance criteria of Tables 4.3 and 4.4.

4/6.4 Water for curing concrete shall not contain impurities in sufficient amounts to
cause discoloration of the concrete. Sources of Water shall be maintained at
such depth and the water shall be withdrawn in such a manner as to exclude
silt, mud, grass and other foreign matter.

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General Specifications

TABLE 4.3

ACCEPTANCE CRITERIA AND PHYSICAL

TESTS FOR MIXING WATER

Limits ASTM Test

Compressive strength,min.% 90 C109 : 2002

control at 7 days

Setting time, deviation from 1:00 early

from control,h:min. to 1:30 later C 191

TABLE 4.4: CHEMICAL LIMITATIONS FOR MIXING WATER

Max. Concentration, Limit, ppm Test Method

1. Chloride as C1 250 ASTM D512: 1989

MB (R1999)

2. Sulphates as SO4 350 ASTM D516: 2002

3. Alkali carbonates 500 ASTM D 513

and bicarbonates

4. Total dissolved
solids, including
1, 2 & 3 above 2000 BS 1377 : Part 3 :
1990:
Test 8

5. PH min.7/max. 9 ASTM D1293 :

1999

4/7 APPLICABLE TESTS AND CODES

4/7.1 All concrete, aggregate, cement, steel and water shall be tested during the
construction as per frequency in Tables 4.2 and 4.6 or as directed by the
Engineer. All test samples shall be supplied by the Contractor at his expense.
Samples shall be obtained in accordance with BS 812, BS 3148, BS 1881 and
BS EN 196. Testing shall be at the frequencies stated above or relevant
standards. All sampling shall be carried out by the Engineer.

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General Specifications

Table 4.6 Frequency of Routine Testing:

Sampling Test
ITEM Test Frequency Rate
Method Method
a. Cement - as per BS EN BSEN BSEN-196 Each 500m3 of concrete
196 196-7 poured.
b. Steel
1. Deformed S. Bar as BS 4449 BS 4449 Each size 100 ton
per BS 4449:1997
2. Strand as per BS 5896 BS 5896 - As per Clause 23.3 of
BS 5896:1980 if APPENDIX BS 5896
needed A
c. Concrete
1. Air content, as per BS BSEN BSEN Once at the time of mix
EN 123501-7:2000 12350-1 12350-7 design of concrete or as
directed by the Engineer.
2. Flexural strength of BSEN BSEN Once at the time of mix
Prism as per BS EN 12350-1 12390-5 design of concrete or as
12390-5 directed by the Engineer.
3. Bleeding as per BS 1881 - C 232 One at the time of mix
ASTM C232 101 design of concrete or as
directed by the Engineer.
4. Splitting Tensile of BS 1881 - C-496 One at the time of mix
Conc. Cylinder as per 101 design of concrete or as
ASTM C-496:1996 & directed by the Engineer.
others
5. Depth of Water BSEN BSEN Each 2000m3 of a
Penetration (BS EN 12350-1 12390-8 particular grade of
12390 P-8:2000) structural concrete or as
directed by the Engineer.
6. ISAT as per BS 1881- BS 1881- BS 1881 - Each 2000m3 of a
p-208 101 Part 208 particular grade of
structural concrete or as
directed by the Engineer.
7. Water absorption of BS 1881- 1881-122 Each 2000m3 of a
Hardened Conc. As 101 particular grade of
per BS 1881 P122 structural concrete or as
directed by the Engineer.
8. Rapid chloride BS 1881 - ASTM C Each 2000m3 of a
permeability 101 1202 particular grade of
structural concrete or as
directed by the Engineer.

9. Slump test - as per BS 1881- BS-1881- From each transit mixture

BS 1881 P102 101 102 load arrived at site

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General Specifications

Sampling Test
ITEM Test Frequency Rate
Method Method
10. Concrete Mix Design All mixes are to be
(Mixing and Sampling designed once for
in the lab) as per BS verification and approval.
1881 P125 & In Site
(Sampling) as per BS
1881 P 101
11. Kerbs-as per BS 7263 BS 7263-1 BS 7263-1 Sample to be taken from
each batch of upto 1000
kerb in whole consignment
d. Water 3148 BS 3148 For DEWA WD no test is
required or other than
DEWA twice a week or as
directed by the Engineer.

4/7.2 WORKABILITY

Workability shall be assessed by the following tests the requirements for which
shall be as specified elsewhere in the documents.

Slump test shall be performed according to BS 1881 Part 102 : 1983

Compaction factor shall be performed according to BS 1881 Part 103.

Vebe time shall be performed according to BS 1881 Part 104

Flow test shall be performed according to BS 1881 Part 105.

4/7.3 COMPRESSION TEST

The Compression tests shall be performed on cubes 150 x 150 x 150 mm as

described in BS 1881 Part 116. Sampling, making test cubes and curing of
cubes shall be in accordance with BS 1881: 1983 Parts 101, 108 and 111
respectively.

4/8 REINFORCEMENT BARS

4/8.1 All reinforcement bars shall be of a deformed type in accordance with

BS 4449, 1997, except that plain bars may be used where specifically
indicated on the Drawings. Plain bars shall be in accordance with
BS 4449:1997.

4/8.2 All steel reinforcement shall conform to the requirements of the Specifications
for Deformed High Yield Steel Bars grade 460 Type 2, unless otherwise
shown on the Drawings or specified by the Engineer.

4/8.3 Certification. Three (3) copies of a mill test report shall be furnished to the
Engineer for each lot of steel reinforcement bars proposed for use on the
project.

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4/8.4 Identification. The bars in each lot shall be legibly tagged by the manufacturer
and/or fabricator before being offered for inspection. The tag shall show the
manufacturer's test number and lot number and other applicable data that will
identify the material with the certificate issued for that lot of steel.

4/8.5 The fabricator shall furnish three (3) copies of a certification which shows the
heat number or numbers from which each size of bar in the shipment was
fabricated.

4/8.6 The Engineer reserves the right to sample and inspect all reinforcement steel
upon its arrival at the work site. The Contractor shall provide a certificate
confirming that samples taken from the bars delivered to the works pass all the
required tests. The frequency of sampling and the method of quality control
shall be in accordance with BS 4449 - 1997 Clause C.3.2.

4/8.7 All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust,
paint, grease, oil or other foreign substance, fins, or tears. There shall be no
evidence of visual flaws in the bars, test specimens or on the sheared ends of
the bars.

4/8.8 Uncoated reinforcement shall be grit-blasted before use to remove rust, oil,
grease, salt and other deleterious materials and where pitting has occurred the
causes and products thereof. Repeated blasting may be required when the
reinforcement is in position, or partially cast in. Partially set concrete adhering
to exposed bars during concreting operations shall be removed.

4/8.9 The minimum thickness of concrete cover to reinforcement shall be as shown

on the drawings. Only approved concrete spacers shall be used. The
concrete shall be of similar grade to the main concrete and shall have non
metallic ties.

4/9 BAR SCHEDULES AND SHOP DRAWINGS

4/9.1 Before ordering reinforcing steel, the Contractor shall check the bar schedules
and adjust them if necessary to the approval of the Engineer. Bar schedules
shall show the weight of each bar, the total weight of each bar size and the
total weight of bars, and bending diagrams for bars in accordance with BS
4466.

4/9.2 The Contractor shall provide and submit to the Engineer for approval any
working drawings additional to the Contract Drawings which may be found
necessary for the production of revised bar schedules or for the completion of
the works.

4/9.3 The approval of working drawings, or revised bar schedules by the Engineer
shall in no way relieve the Contractor of responsibility for the correctness of
such drawings or schedules.

4/10 BAR CUTTING AND BENDING

4/10.1 Reinforcement shall be cut and bent in accordance with B.S. 4466. Cutting or
bending by the application of heat is not permitted. Welding of reinforcement
shall only be permitted when approved in writing by the Engineer. If such
approval is given then the workmanship shall be in accordance with BS 5135.

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General Specifications

The Contractor shall submit full technical details of his proposed procedures
prior to seeking approval.

4/10.2 Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than
four times the nominal size of the bar.

4/11 PLACING AND FIXING REINFORCEMENT

4/11.1 Reinforcement shall be placed and maintained in the position shown in the
Contract Drawings. Unless otherwise permitted by the Engineer, all bar
intersections shall be tied together using 1.2mm diameter steel wire or No. 18
gauge stainless steel wire as indicated on the drawings and the ends of the
tying wire shall be turned into the main body of the concrete.

4/11.2 Metal supports, approved by the Engineer, shall be provided and used to
retain the reinforcement at proper distances from the forms. Supports under
horizontal bars at the bottom of base slabs shall be spaced at not more than
eighty (80) diameters of the bar. All reinforcement shall be so rigidly
supported and fastened that displacement will not occur during construction.
Reinforcing steel shall be inspected in place and must be approved by the
Engineer before any concrete is deposited.

4/11.3 No splices shall be made in the reinforcement except where described in the
Contract Drawings or where approved by the Engineer.

4/11.4 Reinforcement temporarily left projecting from the concrete at construction or

other joints shall not be bent out of position during the periods in which
concreting is suspended, except with the approval of the Engineer.

4/12 WELDED WIRE FABRIC

4/12.1 Welded wire fabric to be used for the reinforcement of concrete shall conform
to the following requirements:

- Dimensions. Welded steel wire fabric shall conform to the size and
dimensions shown on the Drawings.

- Properties. Wire fabric furnished under this specification shall conform to

the requirements for "Welded Steel Wire Fabric for Concrete
Reinforcement" BS 4483 or equivalent.

4/13 SPACER BLOCKS

4/13.1 Spacers as approved by the Engineer shall be of such material and design as
will be durable, not lead to corrosion of the reinforcement and not cause
spalling of the concrete cover.

4/13.2 Spacer blocks made from cement, sand and small aggregate shall match the
mix proportions of the surrounding concrete so far as is practicable with a view
to being comparable in strength, durability and appearance.

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4/14 ADMIXTURES

4/14.1 Unless agreed by the Engineer neither admixtures nor cements containing
additives shall be used.
4/14.2 Where the use of admixture had been agreed by the Engineer, they shall
conform to the requirements of Type A, Type D, Type F or Type G as specified
in ASTM C494 and shall be used in strict accordance with the manufacturer's
instructions.
Preliminary tests of cube strength and other tests shall be carried out using the
combination of aggregates cements and admixtures proposed for use.
4/14.3 The Contractor shall be entirely responsible for the use of any approved
admixtures.
4/14.4 Approved methods and equipment shall be used for dispensing and
incorporating the admixture into the concrete. The dispensing unit shall be
designed so that the discharge of the admixture is visible.

4/15 CONCRETE MIX SPECIFICATION

4/15.1 Concrete shall be as shown in the Table of 4.5. The number of mixes may
require to be increased.
The criteria given in the Table are designed to produce concrete of the
required strength and durability.
If the maximum aggregate size is 10 mm then the cement content stipulated
for the class of concrete given in table 4.5 shall be increased by 40 Kg per m3.
All concrete mixes shall be verified by DM - DCL

TABLE 4.5

TABLE OF MIXES

Concrete Max. Min. Max. Characteristic Cube

Class Size Qty of Free Strength
Agg Cement Water/ CCS
Cement
Ratio
7-day 28-day
mm. [Link] m3 N/mm2 N/mm2

45/20 20 400 0.425 33 45

40/20 20 370 0.475 30 40
37/20 20 350 0.50 26 37
35/20 20 330 0.525 25 35
30/20 20 310 0.55 20 30
25/20 20 275 0.60 16 25
15/20 20 250 0.65 10 15

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The CCSs are for concrete which has been cured at a temperature of 23
degrees C + 2 degree C, and are the values below which no more than 5% of
the test results fall. The 7-day strengths shall be used only as a guide.

4/15.2 Concrete shall comply with BS 8110 except where BS 8007 or this
specification differs. Sampling for test purposes shall comply with BS 1881
Part 101 : 1983 (on site) & Part 125 : 1986 (in laboratory).

If air-entertainment is specified the average air content at the time of placing

measured in accordance with BS 1881 PART 106 shall be:

Concrete containing 20mm

Maximum size aggregate 5% + 1%

Concrete for water-retaining shall be watertight and shall comply with the
recommendations of BS 8007.

Concrete for paving or precast units shall be tested to BS EN 12390: Part 5:

2000 and shall have a minimum flexural beam strength of 3.5N/mm2 at 28
days. If the concrete has a specified CCS of 40N/mm2 or greater, then the
minimum flexural strength shall be 4N/mm2.

If concrete specimens are cured at higher temperatures or for longer periods

than BS 1881 Part 111 : 1983 requires, the adjusted CCS shall be calculated
as follows:

100f'/f = A + B log {24D (T+12)/1000}

f’ = adjusted CCS
f = specified CCS
T = curing temperature
D = age at testing in days
A&B = are coefficients given in the
following table.

The above equation applies only to OPC, MSRPC and SRPC.

Recorded Cube Strength N/mm2 A B

Less than 15 10.0 67.5

15 to 35 20.0 60.0
Greater than 35 30.0 52.5

This calculation may be applied for curing at temperatures up to 27 degrees C.

Before placing concrete the Contractor shall obtain approval of the mixes
proposed for each class of concrete and the average target strengths. The
mixes shall be designed to achieve the minimum workability for the Contractor
to place and compact the concrete with the equipment proposed for use.

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The mean strength shall exceed the CCS by a margin of 1.64 times the
standard deviation expected from the concreting plant, except that no standard
deviation less than 3.5 N/mm2 shall be used as a basis for designing a mix.
Unless otherwise approved a standard deviation of 7 N/mm2 shall be used for
initial mixes.

4/15.3 The ultimate compressive strength of the concrete shall be determined on test
specimens obtained and prepared in accordance with B.S. 1881. Part 108.

4/15.4 Mixes for structural concrete shall be designed by the Contractor. The class of
concrete (shown on the drawings) is denoted by the 28 day characteristic cube
strength and the maximum size of aggregate.

4/15.5 The chloride and sulphate levels in the concrete mix shall comply with the
following requirements:-

Maximum Limits of acid soluble Chloride and Sulphate content as a

percentage by Weight of Cement in the Mix.

TYPE OF CONCRETE CHLORIDES SULPHATES

AS Cl AS SO3
ACCORDING TO BS-1881 : 1988
PART 124

Amd 01:1998 Amd 06:2002

a. For reinforced concrete

if made with OPC/MSRPC 0.30 3.70
if made with SRPC 0.06 3.70

b. Prestressed concrete & 0.10 3.70

Heat-cured reinforced
concrete

c. For mass concrete

if made with OPC/MSRPC 0.60 3.70
if made with SRPC 0.12 3.70

Note: BSEN 196-21: 1992 Clause 8, Method of Testing Cement Part 21 will be
used to determine the percentage chloride by weight of cement. The
OPC and MSRPC cements can also contain chlorides, the relevant
standard BS 12 allows up to 0.1% Cl. Therefore any chloride content
present in the cement has to be taken into account while computing
total Cl in the mix. In case the cement contains the maximum limit of
0.1% Cl, then the aggregates, water and admixtures used for
prestressed concrete or heat cured reinforced concrete should be
absolutely free of chlorides.

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4/16 CONCRETE MIX DESIGN

TRIAL MIXES

4/16.1 Preliminary laboratory tests shall be carried out to determine the mixes to
satisfy the specification with the approved materials.

Trial mixes shall be tested to determine the following properties of mixes

proposed for initial field tests:

a) Bleeding in accordance with ASTM C232: 1999 (non-vibrating) shall not

exceed 0.5%.
b) Drying shrinkage in accordance with BS 1881 Part 5.
c) Air content if applicable BS EN 12350: P7: 2000.
d) Free water/cement ratio.
e) Workability BS 1881 Part 102: 1983.
f) Chloride permeability shall be less than 2,000 coulombs, when tested in
accordance with ASTM C-1202 : 1997.
g) Fresh and hardened concrete densities BS 1881 Parts 107 and 114 :
1983 respectively.
h) Compressive strength BS 1881 Part 116 : 1983.
i) Depth of Water Penetration Test BS EN 12390 Part 8 : 2000
(maximum 10 mm at 28 days)
(maximum 15 mm at 7 days).
j) The Initial Surface Water Absorption Test as per BS 1881: P-208: 1996.

If the values obtained are unacceptable, the mixes shall be re-designed.

4/16.2 At least 35 days before commencement of concreting trial mixes shall be

prepared under full-scale site conditions and tested in accordance with BS
1881 : 1983.

Samples of concrete incorporating the reinforcing details to be used shall be

cast and examined, before hardening using hand tools, and after hardening by
coring to assess the mixes. Cores shall be taken in accordance with BS 1881
Part 120 : 1983.

Trial mixes shall be made on each of three days; the workability shall equate
to the designed target value. Six cubes from each mix shall be taken, three for
test at 28 days.

Further trial mixes shall be made if the range (the maximum minus the
minimum of the three cube results in any batch) exceeds 15% of the average
of that batch, or if the range of the three batch averages exceeds 20% of the
overall average of the batches.

The mixes shall be tested to determine the following properties:

a) Bleeding in accordance with ASTM C232 : 1999

b) Air content if applicable BS 12350: P7: 2000.

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c) Free water/cement ratio

d) Tensile strength in accordance with BS 1881 Parts 117 and 118.
Splitting tensile strength of concrete cylinder shall be in accordance with
ASTM C496: 1996. Flexural strength of concrete prism in accordance
with BS EN 12390: P5.

The average 28-day CCS of the three trial mixes shall not be less than the
designed mean strength, and the results of the above tests shall be
acceptable before the mix is approved. Otherwise the mix shall be
re-designed.

4/16.3 The Engineer will review the Contractor's trial-mixes and crush the test cubes
at seven (7) and twenty-eight (28) days. The Engineer will then determine
which of the trial mixes shall be used. If none of the trial mixes for a class of
concrete meets the Specifications, the Engineer will direct the Contractor to
prepare additional trial-mixes. No class of concrete shall be prepared or
placed until its job-mix proportions have been approved by the Engineer.

4/16.4 The approval of the job-mix proportions by the Engineer or his assistance to
the Contractor in establishing those proportions, in no way relieves the
Contractor of the responsibility of producing concrete which meets the
requirements of these Specifications.

4/16.5 The Engineer may also require practical tests to be made on the Site by filling
trial moulds to confirm the suitability of the mix for the works, the type of plant
used for mixing, the method of compaction used and the formwork face
intended for use in the works.

4/16.6 All costs connected with the preparations of trial-mixes and the design of the
job-mixes shall be borne by the Contractor.

4/16.7 In the event, any Concrete mix that is currently being used in another running
DM project, is proposed by the contractor for approval of using that mix in this
contract, then

1. Prior to according the approval or otherwise, the Engineer must ensure

that all copies of test results pertaining to another running DM project
submitted by that contractor comply with all specifications as stated in this
contract and

2. shall also ensure that the proposed mix complies with clause 4/16 by
verifying that proposed mix at DCL

NOTE: Any mix that is obsolete & currently not in use shall not be
accepted at all for re-approval.

4/17 QUALITY CONTROL

4/17.1 TEST CUBES

Cubes shall be manufactured in an on-site laboratory, specially equipped for

the purpose, in controlled conditions. They shall be made, cured, stored,
transported and tested to BS 1881: 1983 Parts 108,111 and 116. The method

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of compacting cubes shall be as approved and shall be means of vibrating

table in the laboratory or 25mm vibrating poker on site.

4/17.2 SAMPLING CUBES

A sample of concrete shall be taken at random on eight separate occasions

during the first five days of using a mix at least one sample being taken each
day. The standard deviation shall be calculated from at least 40 individual
cube results each representing separate batches of similar concrete produced
by the same plant under the same supervision. The current margin for the
plant shall be thus established as 1.64 times the standard deviation.

Thereafter one sample shall be taken at random for each class of concrete in
accordance with Clause 4/31 of the Specification.

In addition to the above requirements, at least one sample shall be taken from
each individual structural unit, or part of a unit, when the latter is the product of
a single pour.

From each sample three cubes shall be made for testing at 28 days and three
for testing at 7 days for control purposes.

Six cylinder samples shall also be taken to determine the split tensile strength
of the concrete 3 at 7 days and 3 at 28 days, as specified in ASTM C496:
1996. These samples shall be taken from every 100 batches, but at least
once a week during concreting operations, and shall coincide with samples
taken for test cubes.

The frequency of sampling may be required to be varied if directed by the

Engineer.

The procedures shall be repeated when materials or design mixes are

changed.

4/17.3 CUBE STRENGTH RESULTS

The results will be acceptable if:

i) The average strength determined at the age of 28 days from a sample of

three or more cube test results exceed the Governing Strength which is
the 28 days cube strength obtained in the approved trial mix by 0.5 times
the current margin,
ii) No individual result of the sample is less than that (Governing Strength
which is the 28 days cube strength obtained in the approved trial mix
minus 3 N/mm2),
iii) Number of individual results in the sample below Governing Strength
which is the 28 days cube strength obtained in the approved trial mix is
not more than one.

If the above criteria is not satisfied, the unit represented by the sample is
questionable and the following actions may be instructed as appropriate :

i) Cutting and testing cores from placed concrete.

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ii) Non-destructive testing of placed concrete.

iii) Load-testing relevant structural units.
iv) Cutting out and replacing defective concrete.

If the range of individual cube strengths made from the same sample
exceeds 15% of the mean, then the method of making, curing and
testing cubes shall be checked. In the event of a sample having a range
exceeding 20%, then the result shall be unacceptable and the Engineer
may order any of the following actions:

a) Changing the mix.

b) Improving quality control.
c) Cutting and testing cores from placed concrete.
d) Non-destructive testing of placed concrete.

In the event of cutting and testing of cores are required, the Contractor
shall cut cores from approved locations and test them to BS 1881 as
modified by BS 6089.

4/17.4 DURABILITY TESTS

Concrete shall be tested for durability properties by undertaking absorption

and permeability tests where appropriate, or directed by the Engineer, as
directed below:

Water absorption tests shall be carried out in the laboratory on 75mm diameter
cores cut at an age of 24 to 28 days to enable the tests to be carried out
between 28 and 32 days in accordance with BS 1881 Part 122 : 1983. The
upper acceptable limit for absorption after 30 minutes shall be 2%.

Effective permeability tests in accordance with the method described in BS EN

12390 Part 8 : 2000 shall be carried out. The maximum acceptable
penetration at seven days shall be 15 mm and the maximum acceptable
penetration at 28 days shall be 10mm.

Initial surface absorption test as per BS 1881: P-208: 1996 shall be carried
out.

4/17.5 OTHER TESTS

When instructed by the Engineer concrete shall be tested for drying shrinkage
and wetting expansion, for which 75x75mm prisms shall be prepared and
tested in accordance with Test 5 of BS 1881 (1970) Part 5 or BS6073 : 1981
Part 1 Appendix D. The maximum acceptable limits shall be:

Drying Shrinkage : 0.05%

Wetting Expansion : 0.03%

Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.

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The air content of air-entrained concrete shall be determined (ASTM C231) for
each batch produced until consistency has been achieved, when batches may
be tested. The maximum value shall not exceed 2%.

Compaction factor, slump, vebe or other workability tests shall be carried out
as required during concreting of permanent works to control workability at the
batching plant at the site of the pour. The degree of workability shall be as for
the trial mixes; permitted tolerances shall be in accordance with BS 5328.

4/18 CONCRETE DESIGN LIMITS

4/18.1 The following will be designated by the Engineer within the limits of the
Specifications.

a) The minimum Cement content in kg. per cubic metre of concrete.

b) The maximum allowable water/cement ratio including surface moisture,

but excluding water absorbed by the aggregates.

c) Slump or Slumps designated at the point of delivery.

d) Changes requested by the Contractor in mix proportioning previously
approved shall be made only with the agreement of the Engineer.

e) When, in the opinion of the Engineer, cement is being lost due to windy
conditions, the Contractor shall add additional amounts of cement as
directed by the Engineer. No additional payment shall be made for the
added cement.

f) Failure of the mixed concrete to meet specifications as determined by

the Engineer will be grounds for the Engineer to reject the concrete.

g) Bleeding limitations when tested in accordance with ASTM C232 : 1999.

4/19 CONSISTENCY OF CONCRETE

4/19.1 The consistency of concrete shall be determined in the field by the Slump
Test. The consistency of concrete at the time of delivery will be designated by
the Engineer and shall not vary by more than 25mm from the designated
consistency.

4/20 TOLERANCES IN PROPORTIONING THE MATERIALS

4/20.1 CEMENT

In the case of bagged cement it shall be measured as packed by the

manufacturer: a sack of cement shall weigh fifty (50) kilograms. Measurement
for proportioning all cement shall be accurate to within two (2) percent
throughout the range of use. Only full bags, undamaged or unbroken will be
permitted.

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4/20.2 WATER

The mixing water shall be measured by weight or by volume. In either case

the measurement shall be accurate to within one (1) percent throughout the
range of use.

4/20.3 AGGREGATE

The aggregates shall be measured by weight to an accuracy within two (2)

percent through-out the range of use.

4/21 ASSEMBLY AND HANDLING MATERIALS

ASSEMBLY

4/21.1 Aggregates shall be assembled in such quantities that sufficient material

approved by the Engineer is available to complete any continuous pour
necessary for any element. The batching site shall be of adequate size to
permit the stockpiling of sufficient, unsegregated materials, having proper and
uniform moisture content, to ensure continuous and uniform operation.
Aggregates shall enter the mixer in a manner approved by the Engineer and in
such a manner to ensure that no matter foreign to the concrete or matter
capable of changing the desired proportions is included. In the event two (2)
or more sizes or types of coarse or fine aggregates are used on the same
project, only one (1) size or type of each aggregate may be used on one
continuous concrete pour.

STOCKPILING Of AGGREGATES

4/21.2 All aggregates shall be stockpiled before use in order to prevent segregation
of material, to ensure a uniform moisture content and to provide uniform
conditions for proportioning plant control.

4/21.3 The use of equipment or methods of handling aggregates which result in the
degradation and contamination of the aggregates is strictly prohibited.
Bulldozers with metal tracks shall not be used on coarse aggregate stockpiles.
All equipment used for handling aggregates shall be approved by the
Engineer.

4/21.4 Stockpiling of aggregates shall be in the manner approved by the Engineer,

and in addition, every precaution shall be taken to prevent segregation.
Segregation shall be prevented by making no layer higher than one and
one-half (1.5) metres and if two (2) or more layers are required, each
successive layer shall not be allowed to "cone" down over the next lower layer.

4/21.5 Aggregates shall not be stockpiled against the supports of proportioning

hoppers and weighing devices.

SEGREGATION

4/21.6 Segregated aggregates shall not be used until they have been thoroughly
remixed and the resultant pile is of uniform and acceptable gradation at any

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point from which a representative sample is taken. The Contractor shall

re-mix aggregate piles when ordered by the Engineer.

TRANSPORTING Of AGGREGATES

4/21.7 If aggregates are to be transported from a central proportioning plant to the

mixer in batch-boxes or dump trucks, such equipment shall be of sufficient
capacity to carry the full volume of materials for each batch of concrete.
Partitions separating batches shall be approved by the Engineer and shall be
adequate and effective to prevent spilling from one compartment to another
whilst in transit or being dumped.

CEMENT

4/21.8 Cement shall be stored in a dry weather-proof shed with a raised wooden floor
or in a silo and shall be delivered in quantities sufficient to ensure that there is
no suspension or interruption of the work of concreting at any time. If stored in
sheds, each consignment shall be kept separate and distinct.

4/22 MIXING CONCRETE

4/22.1 The weighing and water-dispensing mechanisms shall be maintained in good

order. Their accuracy shall be maintained within the tolerances described in
BS 1305 and checked against accurate weights and volumes when required
by the Engineer.

4/22.2 The mass of cement and of aggregate indicated by the mechanism employed
shall be within a tolerance of 2% of the respective mass per batch agreed by
the Engineer. The mass of the fine and coarse aggregates shall be adjusted
to allow for the free water contained in them. The water to be added to the
mix shall be reduced by the quantity of free water contained in the fine and
coarse aggregates, which shall be determined by the Contractor by a method
approved by the Engineer immediately before mixing begins and further as the
Engineer requires.

4/22.3 Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch
type mixer manufactured in accordance with BS 1305. Where appropriate the
batch capacity, method of loading, mixing time and drum speed shall conform
to the details furnished in accordance with the requirements of BS 3963 for the
mix which corresponds most closely to the mix proportions being used. The
mixing blades of pan mixers shall be maintained within the tolerances
specified by the manufacturer of the mixer and the blades shall be replaced
when it is no longer possible to maintain the tolerance by adjustment. The
period of mixing, judged from the time that all the ingredients including water
are in the mixing drum shall be as ordered by the Engineer's representative
but shall not be less than 2 minutes or 20 revolutions of the drum whichever is
the longer.

All plants shall be equipped with an approved automatic cycling and

monitoring system installed as part of the batching equipment. The system
shall include equipment for accurately proportioning the various components
of the mixture by mass. Admixtures may be measured volumetrically. The
automatic proportioning system shall be capable of consistently delivering
each constituent within the tolerances specified. All records of batches shall
show the batch weights, the batch number, the day, the month, the year and

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the time of day to the nearest minute for each batch. This information shall be
imprinted on the record so that each batch may be permanently identified.
The Engineer will be provided with a clear and legible copy of all batch records
for concrete supplied for the project.

4/22.4 Mixers which have been out of use for more than 30 minutes shall be
thoroughly cleaned before any fresh concrete is mixed.

4/22.5 The method of discharge from the mixer shall be such as to cause no
segregation whether partial or otherwise of the concrete materials.

4/22.6 The Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between
its discharge from the mixer and compaction in its final position. Precautions
shall include the shading of aggregate stockpiles and the use of chilled water.

4/23 READY MIXED CONCRETE

4/23.1 Ready mixed concrete as defined in BS 5328, batched off the site, may be
used only with the agreement of the engineer and shall comply with all
requirements of the Contract.

4/23.2 The Concrete shall be carried in purpose-made agitators, operating

continuously, or truck mixers. The concrete shall be compacted and in its final
position within 1 hour of the introduction of cement to the aggregates, unless a
longer time is agreed by the Engineer. The time of such introduction shall be
recorded on the delivery note together with the weight of the constituents of
each mix.

4/23.3 When truck mixed concrete is used, water shall be added under the
supervision, either at the Site or at the central batching plant as agreed by the
Engineer but in no circumstances shall water be added in transit.

4/23.4 Unless otherwise agreed by the Engineer, truck mixer units and their mixing
and discharge performance shall comply with the requirements of BS 4251.
Mixing shall continue for the number and rate of revolutions recommended in
accordance with Item 9 in Appendix B of BS 4251 or, in the absence of the
manufacturer's instructions, mixing shall continue for not less than 100
revolutions at a rate of not less than 7 revolutions per minute.

4/23.5 Pumping concrete through delivery pipes may be permitted but only with the
prior approval of the Engineer.

4/23.6 Re-mixing of concrete which has commenced to set shall not be allowed and
in no case shall such concrete be used in the Works.

4/23.7 Coarse aggregate shall be kept in identified stockpiles from which samples
can be collected and tested as specified.

4/23.8 The concrete supplier is required to certify that the Cl content in the mix being
delivered is within the limits specified in Clause 4/15.5. The Cl and SO3
content shall be checked at frequent intervals.

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4/24 TRANSPORT AND PLACING

4/24.1 The method of transport and placing concrete shall be to the approval of the
Engineer. Concrete shall be so transported and placed that contamination,
segregation or loss of the constituent materials does not occur.

4/24.2 All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.

No concrete work shall be stopped or temporarily discontinued within forty-five

(45) centimeters of the top of any finished surface, unless such work is
finished with a coping having a thickness less than forty-five (45) centimeters
in which case the joint shall be made at the under edge of the coping.

Concrete in simple slab spans shall be placed in one (1) continuous operation
for each span, unless otherwise indicated on the drawings or approved by the
Engineer.

4/24.3 Prior to placing any concrete on natural surfaces a blinding layer of Class 15
concrete shall be laid to a minimum of 75 mm thickness unless otherwise
specified on the drawings. This blinding shall be suitably cured prior to
subsequent concrete placement. The blinding shall be clean and free from
any dust or impurities prior to subsequent concrete placement.

4/24.4 No concrete shall be placed in a foundation until the extent of excavation and
the character of bearing material have been approved and no concrete shall
be placed in any structure until the placement of reinforcing steel and the
adequacy of the forms and falsework have been approved.

4/24.5 Concrete shall not be placed in any part of the Works until the Engineer's
approval has been given. If concrete has not started within 24 hours of such
approval being given, approval shall again be requested. Concreting shall
then proceed continuously over the area between construction joints. Fresh
concrete shall not be placed against in-situ concrete which has been in
position for more than 30 minutes unless a construction joint is formed in
accordance with the Specification. When the concrete has been in place for 4
hours, or less as directed by the Engineer, further concrete shall not be placed
against it for a further 20 hours.

4/24.6 Concrete when deposited shall have a temperature of not more than 32 deg. C
unless otherwise specified. Concrete shall be compacted in its final position
within 30 minutes of discharge from the mixer unless carried in purpose made
agitators operating continuously, when the time shall be within 1 hour of the
introduction of cement to the mix and within 30 minutes of discharge from the
agitator.

4/24.7 Except where otherwise agreed by the Engineer, concrete shall be deposited
in horizontal layers to a compacted depth not exceeding 400mm where
internal vibrators are used or 300mm in all other cases.

4/24.8 Unless otherwise agreed by the Engineer, concrete shall not be dropped into
place from a height exceeding 2m. When trunking or chutes are used they
shall be kept clean and used in such a way as to avoid segregation. Where
steep slopes are required for placing concrete with chutes, the chutes shall be
equipped with baffle boards or be in short lengths that reverse the direction of

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the movement. Chutes and the use of chutes must be approved by the
Engineer. All chutes shall be kept clean and free from coating of hardened
concrete by thoroughly flushing with water after each run. The water used for
flushing shall be discharged clear of the concrete already in place.

4/24.9 No concrete shall be placed in flowing water. Underwater concrete shall be

placed in position by tremies, or by pipeline from the mixer.

4/24.10 Full details of the method proposed shall be submitted in advance to the
Engineer and his approval obtained before placing begins. Where the
concrete is placed by the tremie, its size and method of operation shall be in
accordance with BS 8004. During and after concreting under water, pumping
or dewatering operations in the immediate vicinity shall be suspended until the
Engineer permits them to be continued.

4/24.11 Approved measures shall be taken to avoid premature stiffening of concrete

placed in contact with hot, dry surfaces. Surfaces including reinforcement
against which concrete is to be placed shall be shielded against the direct rays
of the sun and shall be sprayed with water to prevent excessive absorption by
the surfaces of water from the fresh concrete.

4/24.12 A complete record shall be kept of the date, time, temperature and conditions
of placing the concrete in each portion of the work and shall be available for
inspection by the Engineer at any time.

4/24.13 Unless otherwise shown on the drawings all concrete placed below ground
level shall have a minimum protection to its outside faces as follows:

Underside - Protected by the laying of a grade 1000 approved polyethylene

sheeting on the blinding concrete. The sheeting shall be returned up the
outside faces of the concrete and suitably sealed.

Sides - Coated with 3 coats of an approved bitumen rubber latex emulsion

flexible damp and vapour-proof liquid membrane conforming to BRE Digest
No. 54.

4/25 COMPACTION OF CONCRETE

4/25.1 All concrete shall be compacted to produce a dense homogeneous mass.

Unless otherwise agreed by the Engineer, it shall be compacted with the
assistance of vibrators. Sufficient vibrators in serviceable condition shall be on
site so that spare equipment is available in the event of breakdown. A 50mm
diameter internal vibrator shall be deemed capable of compacting 20 Cu.
m./hr. Internal vibrators shall be capable of producing not less than 10,000
cycles per minute.

4/25.2 Vibration shall not be applied by way of the reinforcement. Where immersion
vibrators are used, contact with reinforcement and all inserts shall be avoided.

4/25.3 Concrete shall not be subject to vibration between 4 and 24 hours after
placing.

4/25.4 Vibrators shall be so manipulated as to work the concrete thoroughly around

the reinforcement and embedded fixtures and into corners and angles of the

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General Specifications

forms. Vibrators shall not be used as a means to cause concrete to flow or its
position in lieu of placing. The vibration at any point shall be of sufficient
duration to accomplish compaction. After initial set of the concrete, the forms
shall not be jarred and no strain shall be placed on the ends of projecting
reinforcement.

4/26 CONSTRUCTION JOINTS

4/26.1 The position and detail of any construction joints not described in the Contract
shall be subject to the approval of the Engineer and shall be so arranged to
minimise the formation of shrinkage cracks.

4/26.2 The timetable for the depositing of concrete between construction joints should
be so arranged that no face of concrete shall be left for more than 20 minutes
before fresh concrete is deposited against it. Pauses for meals, servicing of
machines, changes of shift, etc. and the distribution of concrete among the
positions where work may be proceeding simultaneously must be carefully
organised to ensure that the above mentioned interval shall not be exceeded.

4/26.3 When the continuous placement of concrete in any structural member is

interrupted or delayed, for any reason, for a period long enough for the
previously partially placed concrete to take its initial set, the Engineer shall
declare such joint a cold joint and the Contractor shall immediately remove the
previously partially placed concrete from the forms. No extra payment will be
made for the initial placement or the removal of concrete which is wasted
because of a cold joint. The Engineer may suspend all or any part of
subsequent concrete work until he deems the Contractor has corrected the
cause for the cold joint occurrence.

4/26.4 Where dowels, reinforcing bars or other adequate ties are not required by the
drawings, keys shall be as made by embedding water soaked beveled timbers
in soft concrete. The key shall be sized as shown on the details, or as
directed by the Engineer, which shall be removed when the concrete has set.
In resuming work the surface of the concrete previously placed shall be
thoroughly cleaned of dirt, scum, laitance or other soft material with stiff wire
brushes, and if deemed necessary by the Engineer, shall be roughened with a
steel tool. The surface shall then be thoroughly washed with clean water and
painted with a thick coat of neat cement mortar, after which the concreting
may proceed.

4/26.5 Expansion joints shall be constructed at the locations, of the materials and to
the dimensions shown on the drawings.

4/26.6 The upper surface of lifts of concrete walls and columns shall be horizontal
and if the formwork extends above the joint on the exposed face, it shall be
cleaned of adhering concrete before the next lift is placed. The concrete
placed immediately above a horizontal construction joint shall not be the first
batch through the mixer and shall be thoroughly compacted and worked
against the existing concrete.

4/26.7 In the case of vertical surfaces, a 1:1 slurry of cement and concreting sand
shall, wherever possible, be well worked into them immediately before the
fresh concrete is placed.

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4/26.8 Where sections of the work are carried out in lifts the reinforcement projecting
above the lift being cast shall be adequately supported to prevent movement
of the bars during the casting and setting of the concrete.

4/26.9 Wherever possible laitance and all loose material shall be removed while the
concrete is still green and no further roughening shall then be required.
Where this is not possible, it shall be removed by mechanical means provided
the concrete has been in position for more than 24 hours. The roughened
surface shall then be washed with clean water.

4/27 CURING OF CONCRETE

4/27.1 Immediately after compaction and for 14 days thereafter, concrete shall be
protected from the harmful effects of weather, including rain and rapid
temperature changes, and from drying out. The methods of protection shall be
subject to the Engineer's approval. The Engineer's approval will be conditional
upon the proposed curing method proving to be satisfactory on site. Only
water curing shall be allowed for bridges and retaining walls which shall be
continuously cured for a minimum of 14 days.

4/27.2 The method of curing used shall minimise the loss of moisture from the
concrete. On concrete surfaces which are to be water-proofed, and for bridge
superstructures including piers, abutments, retaining walls and culverts curing
membranes shall not be used. Details of all curing methods to be used shall
be subject to the approval of the Engineer.

4/27.3 For the bridges retaining walls and culverts exposed and stripped concrete
surfaces shall be kept damp using soaked hessian sheeting. Polythene sheet
covering shall be used where directed by the Engineer to minimise
evaporation. The hessian sheeting shall be maintained continuously damp for
a minimum period of 14 days after casting. The water used for this purpose
shall be of the same quality as that allowed in mixing the concrete.

4/27.4 Whenever approved by the Engineer, membrane curing of concrete with an

approved liquid may be used as an alternative to curing with water except that
membrane curing liquid shall not be applied to surfaces of concrete from which
the shuttering has been stuck, until the concrete has been inspected and
approved by the Engineer's representative.

4/27.5 Concrete curing compound shall be of an approved type which shall be readily
distinguishable upon the concrete surface for at least four hours after
application. The colour, if any, shall become inconspicuous within seven days
after application.

4/28 EARLY LOADING

4/28.1 Concrete shall at no time be subject to loading, including its own weight, which
will induce a compressive stress in it exceeding 0.25 of its compressive
strength at the time of loading or of the specified 28 day strength whichever is
lower.

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4/28.2 For the purpose of this Clause, the assessment, of the strength of the concrete
and the stresses produced by the loads shall be subject to the agreement of
the Engineer.

4/28.3 No superstructure load shall be placed upon finished piers or abutments until
the Engineer so permits, but in no case shall any load of any kind be placed
until the curing has been completed. The Contractor shall not place any
temporary loads on deck slabs. Bridge deck slabs shall be opened to traffic or
construction equipment only when so permitted by the Engineer.

4/29 CONCRETING AT NIGHT

4/29.1 No concrete shall be mixed or placed when the light is insufficient, unless an
adequate and approved artificial lighting system is operated and such night
work is approved by the Engineer.

4/30 CONCRETING IN HOT WEATHER

4/30.1 When the rate of evaporation of surface moisture from concrete is expected to
approach 1 Kg/m2 per hour (estimated from following chart) or when the
shade air temperature is 35 deg. C and rising, precautions shall be taken,
including the following:-

a. Dampening the forms.

b. Reducing the concrete temperature to the lowest practical level by

procedures such as:-

i. Shading the aggregate.

ii. Cooling the mixing water before use.

iii. Screening the mixing plant and transporting vehicles from wind,
rain and sun.

c. Erecting wind breaks and sunshades at the concrete placing location.

d. Reducing the time between the placing of the concrete and the start of
curing to the minimum possible.

e. Minimising evaporation (particularly during the first few hours subsequent

to placing the concrete) by suitable means such as applying moisture by
fog spraying.

4/30.2 All precautions to be taken shall be subject to the Engineer's approval and the
Contractor shall demonstrate that all approved precautions are available for
use prior to the Engineer granting approval to any concreting operation.

4/30.3 The temperature of the concrete when placed shall not exceed 32 deg.C nor
shall concrete be mixed or placed when the shade air temperature is 40 deg.C
or above, or is expected to reach such a level during concreting, without
special permission from the Engineer.

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General Specifications

To use this chart:-

1. Enter the air temperature

(c) move upto relative
humidity (b).

2. Move right to concrete

temperature (c).

3. Move down to wind

velocity (d).

4. Move left read approx.

rate of evaporation (e).
- EFFECT OF CONCRETE AND AIR TEMPERATURE RELATIVE HUMIDITY
AND WIND VELOCITY ON THE RATE OF EVAPORATION OF SURFACE
MOISTURE FROM CONCRETE

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4/31 MINIMUM TEST REQUIREMENTS FOR CONCRETE

4/31.1 Any one set of 6 cubes for each class of concrete and for each particular
application represent a maximum quantity of concrete as shown in Table 4.6.
The point of sampling of fresh concrete shall be at delivery into the
construction unless otherwise directed by the Engineer. Each set of cubes
shall be made from a separate batch.

4/31.2 Portland Cement: One 2 Kg sample for quality test shall be taken from each
1,700 bags or equivalent weight in accordance with BS EN 196 - 7.

4/31.3 Water: One 1 - gallon sample shall be obtained prior to use from each source
and at least once every week for quality testing.

TABLE 4.6

SAMPLING RATES

SAMPLING TO
TYPE OF STRUCTURE REPRESENT A
VOLUME OF M3

1. Critical structures
e.g. masts, cantilevers, columns 10

2. Intermediate structures
e.g. beams, slabs, bridge decks 50

3. Heavy concrete construction

e.g. breakwaters, solid rafts 100

4/32 FORMWORK

CONSTRUCTION

4/32.1 Formwork shall include all temporary or permanent forms required for forming
the concrete, together with all temporary constructions required for their
support.

4/32.2 All formwork shall be of such quality and strength as will ensure rigidity
throughout the placing, ramming, vibration and setting of the concrete without
visible deflection.

4/32.3 All formwork shall be so constructed that there shall be no loss of material
from the concrete. After setting, the concrete shall be in the position and of
the shape and dimensions prescribed. The finished surface of exposed
concrete shall be of a quality specified on the drawings and approved by the
Engineer.

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4/32.4 Unless otherwise provided on the drawings or directed by the Engineer, all
exposed edges shall be bevelled by using dressed, mill-cut, triangular
molding, having twenty (20) millimetres sides.

All curved surfaces shall be formed with approved plywood or steel.

The Contractor shall in all cases request the approval of the formwork by the
Engineer's representative in sufficient time to allow an inspection to be made
and shall not commence concreting until such approval is obtained. The
period between the Contractor's request for approval and his intention to
commence concreting shall be not less than one clear normal working day and
the Engineer's representative may require a longer period if, in his opinion, the
formwork is of such complexity as to require it.

Such approval shall not absolve the Contractor of his responsibilities under the
Contract.

4/32.5 Where internal metal ties are permitted, they or their removable parts shall be
extracted without damage to the concrete and the remaining holes filled with
mortar. No permanently embedded metal part shall have less than 40 mm
cover to the finished concrete surface or the specified cover to the
reinforcement whichever is the greater.

4/32.6 The Contractor shall submit to the Engineer for his approval strength and
deflection calculations and drawings of the formwork he proposes to use. The
Contractor shall ensure that adequate time is given to enable the Engineer to
examine the calculations and drawings and also to inspect the formwork
before concrete is placed within it.

FALSEWORK

4/32.7 Detailed drawings for falsework and centering shall be prepared by the
Contractor and submitted to the Engineer for approval. The drawings must be
approved by the Engineer before the work is started.

4/32.8 The Contractor shall submit to the Engineer for approval at least one (1)
month before commencing work, details of his proposed system of falsework,
including detailed drawings and calculations. Falsework shall be capable of
accommodating temperature changes without causing damage to the
concrete.

4/32.9 Falsework and centering shall be designed and constructed to provide the
necessary rigidity to support all loads placed upon it without appreciable
settlement or deformation. Falsework columns shall be supported on wood or
metal bases to support all falsework that cannot be founded on rock, shale or
thick deposits of other compact material in their natural beds. Falsework shall
not be supported on any part of the structure, except the footings, without the
written permission of the Engineer. The number and spacing of falsework
columns, the adequacy of sills, caps and stringers and the amount of bracing
in the falsework framing shall be subject to approval of the Engineer.

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4/32.10 All timber shall be of sound wood, in good condition and free from defects that
might impair its strength. If the vertical members are of insufficient length to
cap at the desired elevation for the horizontal members, they shall preferably
be capped and frames constructed to the proper elevation. Ends of the
vertical members shall be cut square for full bearing to preclude the use of
wedges. If vertical splices are necessary, the abutting members shall be of
the same approximate size, the ends shall be cut square for full bearing, and
the splices shall be scabbled in a manner approved by the Engineer.

4/32.11 All steel members shall be in good condition, free from damage, kinks,
corrosion or any other defect which might impair their strength.

4/32.12 The Contractor shall compute the form settlement and deflection required for
bridges so that when the final settlement is complete, the structure will
conform to the required camber, section and grade as shown on the drawings.

4/32.13 The Engineer will check and approve the Contractor's computations. Long,
tapered hardwood wedges or screw jacks shall be used in all falsework
construction and shall be so placed that they can be adjusted to give proper
form alignment. The Contractor shall, if required by the Engineer, provide
means for adjusting forms to offset any excessive settlement, if screw jacks
are used, they shall be adequately braced and secured in such a manner that
will prevent tipping of the jacks in any direction.

4/32.14 The Contractor shall provide means for accurately measuring settlement in
falsework during placement of concrete, and shall provide a competent
observer to observe and correct the settlement.

4/32.15 In designing forms and centering, concrete shall be regarded as a liquid. In

computing vertical loads, a weight of twenty four hundred (2,400) kilograms
per cubic metre shall be assumed, and not less than thirteen hundred and
sixty (1,360) kilograms per cubic metre shall be assumed in computing
horizontal pressure.

4/32.16 The Engineer may refuse permission to proceed with other phases of the work
if he deems the falsework unsafe or inadequate to support properly the loads
to which it will be subjected.

4/32.17 The review or approval of falsework drawings by the Engineer or permission to

proceed with the work shall not relieve the Contractor of the responsibility for
successful erection or satisfactory results.

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TOLERANCE

4/32.18 The formwork shall be set to such lines and levels as to ensure that the
following tolerances are not exceeded in the structures as cast.

- For all buried concrete. + 25mm - 12mm

In addition, for concrete surfaces

that are to be waterproofed,
abrupt irregularities in the surface
finish shall not exceed 3mm.

- For soffit edge beams and +/- 3mm but not more
sides of parapet plinths than 3mm in 3.5m.

- For all other concrete +/- 6mm but not more than 3mm in
3.5 m.

PREPARATION OF FORMWORK BEFORE CONCRETING

4/32.19 The inside surfaces of forms shall, except for permanent formwork, or unless
otherwise agreed by the Engineer, be coated with a release agent approved
by the Engineer. Release agents shall be applied strictly in accordance with
the manufacturer's instructions and shall not come into contact with the
reinforcement. Different release agents shall not be used in formwork to
concrete which will be visible in the finished works. A panel shall be
constructed utilising the proposed release agent for the Engineer's approval.
The surface of the panel shall not exhibit discolouration or any significant
retard of the surface mortar strength.

4/32.20 Immediately before concreting all forms shall be thoroughly cleaned out. All
formwork shall be inspected and approved by the Engineer before any
concrete is placed in it but such approval shall not relieve the Contractor of his
responsibilities for the safety, accuracy or efficiency of the work.

REMOVAL OF FORMWORK

4/32.21 The Engineer shall be informed in advance when the Contractor intends to
strike any formwork.

4/32.22 At the time of striking any formwork, the concrete shall be of sufficient age and
strength for it to withstand the effects of striking, including the effect of thermal
shock or the loss of surface durability upon premature exposure, and to be
able to withstand the resulting stresses without adverse effects.

4/32.23 The time at which the formwork is struck shall be the Contractor's
responsibility but the minimum periods between completion of placing
concrete in a section of the works and the removal of forms shall be as
follows:-

Sides of beams, walls and columns 2 days

Soffits of beams and slabs (props left in) 7 days

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Removal of props (beams and slabs) 14 days

Soffits of precast beams 7 days

4/32.24 Formwork shall be constructed so that the side forms of members can be
removed without disturbing the soffit forms and, if props are to be left in place
when the soffits forms are removed, these props shall not be disturbed during
the striking.

4/32.25 Formwork shall be removed without damage to the concrete.

4/32.26 Where it is intended to re-use formwork it shall be thoroughly cleaned and

made good to the satisfaction of the Engineer.

4/33 CLASSES OF FINISH

FORMED SURFACES

4/33.1 The class of finish of formed surfaces shall be as shown on the drawings.

4/33.2 Class F1: As struck.

4/33.3 Class F2: The irregularities in the finish shall be no greater than those
obtained from the use of wrought thicknessed square edged boards arranged
in a uniform pattern. The finish is intended to be left as struck but
imperfections such as fins and surface discolouration shall, if required, be
made good by methods approved by the Engineer.

4/33.4 Class F3 : The formwork shall be lined with a material approved by the
Engineer to provide a smooth finish of uniform texture and appearance. This
material shall leave no stain on the concrete and shall be so joined and fixed
to its backing that it imparts no blemishes. It shall be of the same style and
obtained from only one source throughout.

4/33.5 The Contractor shall make good any imperfections in the finish as required by
the Engineer. Internal ties and embedded metal parts will not be allowed.

4/33.6 Class F4 : The requirements for Class F4 are as for class F3 except that
internal ties and embedded metal parts will be permitted. The ties shall be
positions as described in the Contract or as agreed by the Engineer.

4/33.7 Permanently exposed concrete surfaces to Classes F4, F3 and F2 finish shall
be protected from rust and stains of all kinds.

4/33.8 Unless otherwise described in the Contract, all formwork joints for exposed
surfaces of concrete to Class F2, F3 and F4 finish shall form a regular pattern
with horizontal and vertical lines continuous throughout each structure and all
construction and movement joints shall coincide with these horizontal or
vertical lines.

4/33.9 REMEDIAL TREATMENT OF SURFACES

An inspection of the concrete surface shall be carried out immediately after

removing the formwork, and any remedial treatment to surfaces proposed by
the Contractor shall be submitted to the Engineer for approval and shall be

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carried out without delay. Portions of the structure which can not be finished
or properly repaired to the satisfaction of the Engineer shall be removed.

4/33.10 Any concrete, the surface of which has been treated before being inspected by
the Engineer, shall be rejected.

UNFORMED SURFACES

4/33.11 Class U1 Finish. The concrete shall be uniformly levelled and screeded to
produce a plain surface as described in the Contract. No further work shall be
applied to the surface unless it is used as a first stage for a Class U3 finish.

4/33.12 Class U2 Finish. After the concrete has hardened sufficiently to prevent
laitance from being worked to the surface, a Class U1 finish shall be floated by
hand or machine sufficiently to produce a uniform surface free from screed
marks.

4/33.13 Class U3 Finish. When the moisture has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, a
Class U1 finish shall be steel-trowelled under firm pressure to produce a
dense, smooth uniform surface free from trowel marks.

4/33.14 Class U4 Finish. This finish is for bridge decks that are to receive approved
waterproofing systems. The concrete shall be uniformly levelled and screeded
to produce a plain surface. When the concrete has sufficiently hardened to
prevent laitance being worked to the surface it shall be floated to produce a
uniform surface free from screed marks and exposed aggregate. Finally the
surface shall be textured by brushing or otherwise to the waterproofing
manufacturer's requirements as agreed by the Engineer. The accuracy of the
finished surface shall be such that it does not deviate from the required profile
by more than + 5 mm over a 3 m gauge length or have any abrupt
irregularities more than 3 mm.

SPECIAL FINISHES

4/33.15 Where special finishes are specified in the drawings or in a particular

specification the Contractor shall make trial panels for the formed finishes
specified for inspection and approval by the Engineer.

4/34 MORTAR

4/34.1 Mortar shall be mixed by approved mechanical mixers. Mortars containing

plasticisers shall not be overmixed. Mixers shall be kept clean at all times.

4/34.2 Mortar shall be used within thirty minutes after mixing. Hardened mortar shall
not be used in the work and shall be removed immediately from the site.
Mortar shall be prepared in the following proportions with the addition of a
minimum quantity of water for workability.

4/34.3 MORTAR (3:1)

Sand/Cement mortar (3:1) shall be composed of one part of cement to three

parts of sand by volume. This type of mortar shall be used in blockwork where
high strength is required.

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4/34.4 MORTAR (4:1)

Sand/Cement with plasticiser mortar (4:1) shall be composed of one part of

cement to four parts of sand with a mixture of an approved plasticising agent,
added in accordance with the manufacturer's instructions.

4/34.5 The sand used in mortar must be dry when proportioning. Allowance for
bulking shall be made when gauging by volume. The mean compressive
strength at 28 days for each mortar shall conform to BS 5628 : Part I.

4/34.6 Sand shall be natural sand or crushed natural stone or a combination of both
as specified in BS 1200.

4/35 EXTENT OF POURS

4/35.1 The limit of individual pours and the height of lifts shall be as approved. The
sequence of pours shall be arranged to minimise thermal and shrinkage
strains.

4/35.2 For walls, the length of panel placed at one time shall not exceed 6 m,
adjacent panels shall not be placed within 2 days, but shall be placed as soon
as practicable thereafter. Subsequent vertical lifts shall not be poured within 2
days.

4/35.3 Bridge decks, floors, roofs and ground slabs shall be placed in an approved
sequence of panels. 'Chequerboard' placing shall be avoided. Adjacent
panels shall not be placed within 3 days, and then only provided that the
concrete in the first pour has cooled down to below 38 degrees centigrade or
ambient temperature. Placing of adjacent panels shall take place as soon as
practicable after the above criteria have been satisfied. Panels shall be 5 m x
5 m and any pour exceeding 25 m2 will only be considered for approval if
substantiated by calculations.

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