Division 03 Concrete Final

AL FATEH UNIVERSITY ODAC Division (03) Concrete

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Al LABINA / AL MANAR in partnership with Hamza/ ECH/ LCE JV

GENERAL SPECIFICATIONS FOR

BUILDING CONSTRUCTION

DIVISION 03: CONCRETE


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Foreword

The internationally recognized framework known as “Masterformat” released by the Construction

Specifications Institute (CSI) has been adopted in order to organize the sorting and numbering in the new

edition of the specifications in a manner that insures the easy flow and exchange of information among

specialists and the community of the building industry at large. The new edition involves 12 main

divisions. These divisions are:

Division 01: General Requirements

Division 02: Site work

Division 03: Concrete

Division 04: Masonry

Division 05: Metals

Division 06: Wood and Plastics

Division 07: Thermal and Moisture Protection

Division 08: Doors and Windows

Division 09: Finishes

Division 14: Conveying Systems

Division 15: Mechanical

Division 16: Electrical

Each Division comprises a number of related Sections. For example: Division 08 includes eight sections.

They are:

08100 Doors and Frames

08200 Wooden and Plastic Doors

08300 Special Doors

08400 Entrances and Storefronts

08500 Metal Windows

08600 Wooden and Plastic Windows

08700 Hardware

08800 Glazing

Further, each Section incorporates seven Parts as follows:

Part 1: General: This is mainly concerned with the references, quality control, submittals, programs,

and maintenance.


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Part 2: Products: This gives a breakdown of material used in addition to their properties and place of

installation.

Part 3: Execution: The most significant items in this Part are the execution and installation of the

works, field quality control, as well as cleaning and protection methods.

Part 4: Methods of Measurement: This indicates the measurement units and the measuring methods

that shall be used for the Bill of Quantity.

Part 5: Basis of Payment: This indicates the work that shall be completed for each item of the Bill of

Quantity. It also indicates the ancillary works to be included in the unit price rate.

Part 6: Annex: Tables and Figures: Those relevant to the individual Section.


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DIVISION 03 CONCRETE


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INDEX

Division 01: General Requirements Division 02: Sitework Division 03: Concrete

03100 Concrete Formwork

03200 Concrete Reinforcement

03300 Cast-in-Place Concrete

03400 Precast Concrete

Division 04: Masonry Division 05: Metals Division 06: Wood & Plastics Division 07: Thermal & Moisture Protection Division 08: Doors & Windows Division 09: Finishes Division 14: Conveying Systems Division 15: Mechanical Division 16: Electrical


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AL FATEH UNIVERSITY ODAC H42 PRECAST CONCRETE PANEL CLADDING/ FEATURES

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H42 PRECAST CONCRETE PANEL CLADDING/ FEATURES To be read in conjunction with General Requirements. TYPES OF CLADDING/ FEATURES 110 PRECAST CONCRETE PANELS – Type EW2 - Support structure: insitu concrete frame with dense blockwork infill panels. - Panel type: Homogeneous concrete. - Panel finish: Machine polished finish. - Matching sample: Agreed with panel manufacturer. - Profile: Smooth. - Thermal insulation: none. - Fixing: via stainless steel support system to manufacturers design.

- Panel joints: Square edged with double sealant beads - Accessories/ Features/ Incorporated components: Provide drips to cills and

copings. GENERAL REQUIREMENTS/ PREPARATORY WORK 210 DESIGN - Cladding: Complete detailed design. - Standard: To BS 8297. - Related works: Coordinate in detail design. 212 DESIGN PROPOSALS

- Submission of alternative proposals: Preliminary design drawings indicate intent. Other reasonable proposals will be considered.

215 INFORMATION TO BE PROVIDED - Submit the following cladding particulars: - Typical plan, section and elevation drawings at suitable scales. - Typical detailed drawings at large scales, including flashings at head cills and

openings, movement joints and support system. - Technical information and certification demonstrating compliance with

specification of proposed incorporated products and finishes. - Certification, reports and calculations demonstrating compliance with

specification of proposed cladding. - Proposals for connections to and support from the support structure/

background. - Proposals for additional support structure/ background to that shown on

preliminary design drawings. - Schedule of builder’s work, special provisions and special attendance by

others. - Examples of standard documentation from which project quality plan will be

prepared. - Preliminary fabrication and installation method statements and programme. - Proposals for replacing damaged or failed products. - Areas of non-compliance with specification.


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216 INFORMATION TO BE PROVIDED DURING DETAILED DESIGN - Submit the following cladding particulars: - A schedule of detailed drawings and dates for submission for comment. - A schedule of loads that will be transmitted from cladding to the support

structure. - Proposed fixing details and systems relevant to structural design and

construction with methods of adjustment and tolerances. - Labelled samples, that represent the range of variation in panel finish, for

approval of appearance. - A schedule of fabrication tolerances/ size tolerances. - A detailed testing, fabrication and installation programme in compliance with

construction programme. 218 INFORMATION TO BE PROVIDED BEFORE COMMENCEMENT OF

MANUFACTURE OF CLADDING PANELS - Submit the following cladding particulars: - Detailed drawings to fully describe fabrication and installation. - Detailed calculations to prove compliance with all design/ performance

requirements. - Project specific fabrication, handling and installation method statements. - Recommendations for spare parts for future repairs or replacements. - Recommendations for safe dismantling and recycling or disposal of all

products. 222 FABRICATION SAMPLES - General: During detailed design work, submit samples of panel finish. - Obtain approval of appearance before proceeding. 224 MOCK-UP - General: Construct during detailed design work. Satisfy purpose and obtain

approval of appearance before proceeding. Retain undisturbed until completion of cladding installation.

DESIGN/ PERFORMANCE REQUIREMENTS 232 INTEGRITY OF CLADDING - Requirement: Determine sizes and thickness of panels, sizes, number and

location of fixings and handling fixings, incorporation of accessories and components to ensure cladding installation and panels will resist factored dead, imposed and design live loads and accommodate deflections, shrinkage, creep, handling and thermal movements without damage.

- Wind loads: Calculate to BS 8297 Annex A appropriate to location and exposure and taking account of existing and known future adjacent structures.

- Impact loads: Visible surfaces of cladding to meet the requirements of BS 8297 clause 12.2.5.

234 WEATHER AND IMPACT RESISTANCE - Requirement: - Cavity environment: Cavity to be free draining and ventilated.


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- Ingress of moisture: No water to reach inner leaf face. 244 INITIAL SURFACE ABSORPTION - Testing: To BS 1881-208. - Maximum values for each sample: 10 minute test: 0.50 ml/m².s. 1 hour test: 0.20 ml/m².s. 270 DIMENSIONAL COORDINATION - Detailing cladding: Comply with the requirements for accuracy in manufacture

and erection, and accommodate deviations in support structure. - Fixings/ Fasteners: Select to give sufficient three dimensional adjustment. - Proposals to achieve required tolerances: Submit. MAKING CONCRETE 310 CONCRETE MIXES GENERALLY - Production of concrete: To BS 8500 and BS EN 206-1. - Chloride ion content of mix constituents: Not to exceed 0.4% of weight of cement. - Admixtures containing calcium chloride: Not allowed. - Sampling rate for compressive strength testing: Not less than one sample for

each day of use. 330 MIXES FOR VISIBLE FACES - Constituent materials and mix design: To remain constant for each finish type. - Panel colour and appearance: To be consistent for each finish type. - Aggregates: To be of consistent colour, free of deleterious materials that cause

popping and staining. - Origin: Single source for each finish type having sufficient quantity for whole

contract. 340 RECORDS FOR EACH MIX TYPE - Requirements: Correlate and maintain records for: - Mix designs: Composition including admixtures. - Batching: Relate batch identification numbers to precast unit identification

numbers and test samples. - Slump and other tests at casting yard. - Testing authority test reports including cube identification numbers. 350 CONCRETE COMPRESSIVE STRENGTH TESTING AUTHORITY - Testing: Carried out by the precast concrete panel manufacturer. MANUFACTURE 420 MANUFACTURING ACCURACY - Standard: To BS 8297, table 11 and to allow compliance with clause 630. 430 FIXINGS - Materials generally: Nonferrous metal. - Stainless steel: Austenitic in accordance with BS 8297, clause 4.3.3.1.


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- Allowable alternative: Galvanized steel when located away from external faces or edges.

- Lifting devices: Mild steel permitted when mortar cover will provide the same protection required for reinforcement in the panel.

- Bimetallic corrosion and staining: Prevent by appropriate selection and use of materials.

435 LIFTING POINTS - Device types: In accordance with BS 8297, clause 10.2. 440 REINFORCEMENT - Carbon steel reinforcement: To BS 4449, BS 4482 and BS 4483 as appropriate. - Cutting and bending: To BS 8666. - Stainless steel reinforcement: To BS 6744. - Designation (grade): 1,4301 (304). - Cutting and bending: To BS 8666. - Galvanized reinforcement: Galvanized to BS EN ISO 1461 after cutting, chromate

treated. - Condition at time of placement: Clean, free of corrosive pitting, loose materials

and substances that adversely affect reinforcement, concrete, or bond between the two.

- Fixing: Accurate and secure. - Method: Wire tying, approved steel clips or tack welding if permitted. - Concrete cover: Maintain free of all tying wire or clips. 450 PLACING REINFORCEMENT - Method statement: Submit. - Cover spacers: Not permitted on visible surfaces. 460 CONSISTENCY OF PRODUCTION - Production methods: To remain consistent for each matching type of finish. - Finish appearance: To remain within the range of variation indicated by

samples submitted. - Changes to production methods: If variations are proposed for panels of same

finish, submit evidence that there will be no difference in appearance. Obtain approval.

470 PANELS WITH NATURAL STONE FACINGS - Casting method: Face down. - Method of attaching facings: To BS 8297, clause 8.2. - Joints between stone slabs: Weathertight. 480 CASTING AND CURING - Placement of concrete: Thoroughly compact. - Immature panels: Avoid movement, vibration, overloading, physical shock, rapid

cooling and thermal shock. - Protection from weather: Do not expose panels to direct sunlight and drying

winds until at least 5 days after casting. - Delivery to site: Not until at least 14 days after casting.


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490 QUALITY OF FINISHES - Appearance standard: As established by samples/ control panels. 500 PRODUCTION CONTROL PANELS - First production panel: Submit for inspection. - Approved panels: Retain for use as appearance control standard. - Identification and storage: Clearly label and retain safely at factory. - Delivery to site: Last of type. 510 INSPECTION - Give notice: When completed units are ready to be inspected at factory. 520 RECORDS - Records for each type of unit: Maintain details including: - Unique identification number. - Correlation with records of mixes, including batch numbers. - Date of each stage of manufacture. - Dates and results of all tests, checks and inspections. - Dimensions related to specified levels of accuracy. - Specific location in finished work. - Damage and making good. - Any other pertinent data, e.g. if unit is a production control unit. - Availability of records for inspection: On request. ERECTION/ FIXING/ JOINTING 610 INSTALLATION INSTRUCTIONS PROVIDED BY MANUFACTURER - Information: Provide clear and comprehensive instructions and ensure that they

are understood by the site operatives. 630 ACCURACY OF ERECTION - Supporting structure: Before commencing installation of precast panels, carry out

survey sufficient to verify that required accuracy of erection can be achieved. - Give notice: If the structure will not allow the required accuracy or security of

erection. - Joint centres: Set out to ensure consistent joint widths. - Joint width: Within the length of any joint, including those interrupted by tranverse

joints, to vary by not more than 5mm (max 25% of designed joint width). - Variations: Evenly distributed with no sudden changes. - General: Within recommendations of joint sealant of baffle manufacturer. - In-line edges in elevation: Deviation across transverse joint to vary by not more

than 3mm (max 15% of designed joint width). - Flat faces of adjacent panels: Offset in plan or section across any joint to vary by

not more than 5mm (max 25% of designed joint width). - Finished appearance: Notwithstanding tolerances stated above and in clause

420, panels must be square, regular, true to line, level and plane with a satisfactory fit at junctions.

640 FINAL FIXING


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- Approval of appearance: Obtain for each elevation prior to tightening fasteners, filling bed joints and dowel sockets or sealing joints.

- Threaded fasteners: Tighten to torque figures recommended by manufacturer. - Restraint fixings permitting lateral movement: Do not overtighten. - Filling for dowel bars and recessed lifting devices: Well tamped fairly dry 1:4

cement:sand or suitable epoxy or polyester mix. 650 MORTAR BEDDING TO PANELS ON SUPPORT STRUCTURE - Condition of surfaces: Clean. - Cavity adjoining bedding: Free of mortar. - Bed joint: Fully filled with dry 1:3 cement:sand mix. Well compacted. 652 CEMENT:LIME:SAND MORTAR JOINTING TO NATURAL STONE FACINGS - General: As section Z21. - Mix: Cement:lime:sand 1:1:5-6. - Preparation: Wet stones thoroughly. - Laying: Fully fill joints. 660 SEALANT JOINTS - Sealant Silicone. - Location: All panel joints. - Class to BS EN ISO 11600: F 25LM . - Colour: Black. - Application: As section Z22. 670 OPEN DRAINED JOINTS - Rear seals: Airtight and watertight. - Baffles and flashings: Securely installed.

AL FATEH UNIVERSITY ODAC Division (03) Concrete Section 03100 Concrete Formwork

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03 - Concrete

Section 03100 - Concrete Formwork

Part 1: General 1 01 Summary This chapter covers the design and construction of formwork and shores in accordance with the present specifications and the indications given on the drawings.

The Contractor will provide all labor, materials, equipment, testing, quality control, quality assurance, services and transportation required to complete all formwork.

Formwork shall be deemed to cover all surfaces required for containing concrete including stiffening, bracing and tying and all props, shores and other supports to prevent over-stress of completed parts of the structure.

Formwork with its necessary supports and braces shall be designed to safely support all vertical and lateral forces that might be evident including the pressure of placing and vibrating of the concrete. The design of formwork should also encompass their facile erection, unconstrained removal without damaging the in-placed concrete, and efficient reuse.

Vertical and lateral forces must be carried to the ground or by in-place structure that has attained adequate strength by the formwork system.

Formwork shall be constructed and maintained so to ensure that after removal of formwork, the finished concrete members shall have true surfaces, free of offset waviness and will conform accurately to shapes, dimensions, lines elevation and position with the tolerances for reinforced concrete buildings specifications.

1 01 01 Section includes 01.0 Structural Concrete Formwork

02.0 Architectural Concrete Formwork

03.0 Permanent Formwork

1 01 04 Related Sections 02500 Paving and Surfacing


03300 Cast-In-Place Concrete


04200 Unit Masonry

1 02 References The latest revision of the publications listed below or a part of the specifications, unless otherwise specified. The publications are referred to in the text by basic designation only


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1 02 01 Applicable Standards 1 02 01 03 International Standards 1 02 01 04 USA Standards 1 02 01 04 02 American Concrete Institute (ACI) ACI 318 Building Code Requirements for Reinforced Concrete

ACI 303 Guide to Cast-in place Architectural Concrete Practice.

ACI 301: 96 Standard Specification for Structural Concrete.

ACI 347R: 94 Guide to Formwork for Concrete.

1 02 01 05 European Standards ENV 206: 92 Concrete - Performance, Production, Placing and Compliance Criteria

1 02 01 06 British Standards BSI DD ENV 206: 92 see: EN

1 02 01 07 German Standards DIN 1045: 88 Structural Use of Concrete - Design and Construction

DIN 4420 Service and working scaffolding

DIN 4420-1: 90 General rules, safety requirements, tests

DIN 4420-2: 90 Ladder scaffolds; safety requirements

DIN 4420-3: 90 Types of scaffolding

DIN 4420-4: 88 Made of prefabricated elements; materials, design, loads and safety requirements

DIN 18203 Tolerances for building construction

DIN 18203-1: 97 Prefabricated components made of concrete, reinforced and prestressed concrete

DIN 18203-2: 86 Prefabricated steel components

DIN 18203-3: 84 Building components of timber and wood based panel products

AMERICAN HARDBOARD ASSOCIATION (AHA)

AHA A 135.4 Basic Hardboard

DEPARTEMENT OF COMMERCE (DOC) DOC PS-1 Construction and Industrial Plywood

1 02 02 Codes ACI 318 Building Code Requirements for Structural Concrete

ACI 318R Building Code Requirements for Structural Concrete Commentary

ACI 318M: 89 Building Code Requirements for Reinforced Concrete (318M-89/Revised 92)

ACI 318RM: 89 Building Code Requirements for Reinforced Concrete Commentary (318RM-89/Revised 92)


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1 03 Definitions 1 03 01 Technical Terms

Formwork - total system of support for freshly placed concrete including the mould or sheathing which contacts the concrete as well as all supporting members, hardware, and necessary bracing.

Shuttering - see: formwork.

False work - the temporary structure erected to support work in the process of construction; composed of shoring or vertical posting, formwork for beams and slabs, and lateral bracing.

Shoring - props or posts of timber or other material in compression used for the temporary support of formwork.

Striking - the releasing or lowering of centering or other temporary support

Centering - false work used in the construction of arches, shells, space structures, or any continuous structure where the entire false work is lowered (struck or decentered) as a unit.

Propping - see: shoring.

Prop - vertical formwork member used as a brace.

Post - see: prop

1 03 02 Abbreviations B.O.Q. Bills of Quantities

Q.C. Quality Control

1 04 System Description 1 04 01 Design Requirements 1 04 01 01 General The design and engineering of the formwork, as well as its construction, shall be the responsibility of the Contractor.

The design shall be in accordance with ACI 318, ACI 347R and ACI 347

Formwork and its supporting structure comprising floor centers, timber, anchors, etc. shall be designed to resist all vertical and horizontal forces, the design also taking into account the effect that the rate of discharge and the method of compaction will have.

Adjustable floor centers and props shall be provided with a test mark in order to control the deflection.

Formwork shall be designed, constructed, and maintained so as to ensure that after removal of formwork the finished concrete members will have true surfaces, free of offset, waviness and bulges and will conform accurately to the indicated shapes, dimensions, lines, elevations, and positions within the tolerances.

Formwork and scaffoldings shall be designed so they can be easily and safely removed without impact or shock.

1 05 Submittals In compliance with the Conditions of Contract and the provisions of Section 01300 the following shall be submitted within thirty (30) days after the award of the Contract and written acceptance to be obtained from the Engineer, before construction of formwork commences unless otherwise approved.

1 05 01 Product Data The product data for each different type of formwork, accessory and other material indicated.


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Certificates of compliance - not more than 12 months old - with referenced standards for formwork and accessories.

1 05 02 Shop Drawings The shop drawings for formwork include the location of shoring, re-shoring and with location of all ties.

The plans for re-shoring, where permitted or required, with details of loads on structural members.

1 05 03 Samples Samples of formwork coating materials to be used.

Unless otherwise required, samples shall be not part of the finished construction but shall be retained at the job site until all work has been accepted.

1 05 04 Quality Control Submittals Documented experience of Contractor’s site engineer(s), supervisor(s) and carpenter(s) (see: ref. 1 06 01 Part 1: General)

Reports and records of Contractor’s Source Q.C. (see: ref. 1 06 05 Part 1: General)

Reports and records of Contractor’s Field Q.C. (see: ref. 3 04 Part 3: Execution)

Reports and records of Contractor’s Internal Q.C. (see: ref. 1 06 04 01 Part 1: General)

Reports and records of Contractor's External Q.C. (see: ref. 1 06 04 02 Part 1: General)

Manufacturer's instructions concerning handling, installation and maintenance of formwork and accessories.

1 05 06 Other Submittals Records and reports of Contractor’s major equipment.

1 06 Quality Assurance Sampling, testing and checking shall be recorded on a daily basis (i.e. indicating day, month, year) including corrective actions taken by the Contractor if necessary.

Reports and records shall be available for assessment to the Engineer not later than three (3) days after testing and checking.

Failure to detect any defective work or material shall not in any way prevent later rejection when the defect is discovered nor shall it obligate the Engineer for final acceptance.

Arrangements shall be made in Contractor’s work schedule and time allowed for testing and checking as indicated.

1 06 01 Qualifications Site supervisor shall have knowledge of referenced standards and at least five (5) years of documented experience in reinforced concrete and concrete formwork. He shall have had successfully completed reinforced concrete and concrete formwork similar in material, design, and extent to that work indicated for the Project.

Formwork foremen shall have knowledge of concrete and related works at least three (3) years.

Carpenters shall be familiar with all materials and installation procedures and shall be skilled and trained.

1 06 04 Quality Control 1 06 04 01 Internal Quality Control Contractors Internal Q.C. shall include but not be limited to:

Checking of suppliers test certificates and certificates of compliance for formwork and accessories to be delivered to the job site prior to first delivery and each shipment that comes from another source than the previous one to conform compliance with specifications.


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Checking of suppliers delivery tickets of each delivery for completeness and compliance with supply order and specifications.

For additional requirements see: Section 03300 - Clause 1 06 04 02.

1 06 04 02 External Quality Control See 1 06 03 “Certifications”

1 06 04 03 Source Quality Control The source quality control is the responsibility of the Contractor.

1 07 Delivery, Storage and Handling 1 07 01 Packing and Shipping The delivery of formwork materials shall be done in such a manner that damage can be prevented.

Formwork shall be clearly indicated and marked on the delivery note, invoice or supplier's certificate supplied with a consignment, in particular the identification of the manufacturer, the country of origin, and the standard which they comply with.

All materials shall not be contaminated.

Damaged formwork, damaged packaged materials,, and damaged accessories will not be accepted.

1 07 02 Storage and Protection 1 07 02 01 General All formwork and accessories shall be stored in order to prevent damage, corrosion and impurities.

Formwork shall be stored, after cleaning and preparing for re-use if used before, in such a manner that access to all different materials and kinds of formwork is available.

Materials which can be affected by weathering shall be stored in appropriate shelters.

1 07 02 02 Care and Storage of Used Formwork Formwork shall be thoroughly cleaned and oiled as soon as possible after stripping.

Any open seams in panels shall be filled warped boards planed, metal facings straightened and joints re-matched. Steel formwork shall be oiled on the back as well as on the face.

Following any necessary drying period of the coating material, the formwork shall be stacked off the ground on 50 mm or heavier lumber protected against harmful weather conditions.

1 08 Project and Site Conditions 1 08 02 01 Dust Control Dust caused by Contractor’s operations on and near work shall be controlled by use of all means necessary.

1 08 02 02 Pollution Prevention Necessary precautions shall be taken to prevent pollution of ground with fuel, oil, chemicals or other harmful materials.

1 09 Schedules and Programs Construction procedure must be planned in advance to ensure the necessary safety of personnel engaged in formwork and concrete placement and the integrity of the finished structure.


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Part 2: Products 2 01 Formwork Materials 2 01 01 General Materials for formwork are at the discretion of the Contractor and may be of wood, plastic, metal, or a combination thereof for different purposes, unless otherwise indicated.

The formwork of exposed surfaces shall allow as indicated

01.0 fairfaced finish.

02.0 rough finish.

2 01 02 Architectural Concrete 01.0 Formwork

Formwork for architectural concrete shall be designed to produce the required finish or finishes. Deflection of facing materials between studs as well as deflection of studs and walers shall be limited to 0.025 times the span unless otherwise specified.

02.0 Dressing Where natural plywood formwork finish, grout cleaned finish, smooth rubbed finish, scrubbed finish, or sand floated finish is required, formwork shall be smooth (faced with plywood, liner sheets, or prefabricated panels) and true to line, in order that the surfaces produced will require little dressing to arrive at true surfaces. Where any as-cast finish is required, no dressing shall be permitted in the finishing operation.

03.0 Joints Where as-cast surfaces, including natural plywood formwork finish, are specified, the panels of materials against which concrete is cast shall be orderly in arrangement, with joints between panels planned in approved relation to openings, building corners, and other architectural features.

04.0 Formwork Ties Where panels for as-cast surfaces are separated by recessed or otherwise emphasized joints, the structural design of the formwork shall provide for locating formwork ties, where possible, within the joints so that patches of tie holes will not fall within the panel areas.

05.0 Fabricating Drawings In addition to shop drawings normally required, fabricating drawings of formwork for architectural concrete shall be submitted for approval showing the joining of facing panels, the locations of formwork ties, and any necessary alignment bracing.

06.0 Formwork Re-use Formwork shall not be re-used if there is any evidence of surface wear and tear or defect which would impair the quality of the surface. Formwork shall be thoroughly cleaned and properly coated before re-use.

07.0 Formwork Accuracy Formwork for architectural concrete shall be observed continuously while concrete is being placed to see that there are no deviations from desired elevation, alignment, plumbness, or camber.

If, during construction, any weakness develops and the formwork shows any undue settlement or distortion, the work shall be stopped, the affected construction removed, if permanently damaged, and the formwork strengthened.


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2 01 03 Materials Formwork shall be metal, plastic, fiberglass or other material, which will produce the specified finish. Materials used as formwork for profiled formwork, chamfers, splays, rebates and other features shall be such that they produce the same finish as the main formwork.

Plywood for formwork shall have a close, uniform grain and edges shall be sealed with barrier paint, polyurethane varnish or other impermeable material.

2 01 03 01 Formwork for Class A Finish Formwork for all concrete works except for foundations and concrete surfaces in contact with soil shall be Class A finished surface and shall be of modular prefabricated formwork system with skin of marine plywood not less than 16mm thick, or specially designed and fabricated steel formwork system. In either case the finished concrete surfaces shall be uniform, dense and smooth surface, free from staining, discoloration, blemishes, grout runs or blowholes. Permitted abrupt irregularities shall be less than 1mm. Gradual irregularities permitted shall not be more than 5mm in 2 meters Circular and curved formwork shall be prefabricated with seamless material.

2 01 03 02 Formwork for Class B Finish Formwork for foundations and concrete surfaces in contact with soil shall be Class B finished surface and shall be steel or other approved material. The finished concrete surface shall be uniform and dense, free of grout run, grain pattern, major blemishes or blowholes more than 5mm.

2 01 03 03 Steel joists and steel frame shoring Formwork support shall be steel joints and steel frame shoring.

2 01 03 04 Formwork Ties Formwork ties shall be factory-fabricated metal ties, shall be of the removable or internal disconnecting or snap-off type, and shall be of a design that will not permit form deflection and will not spell concrete upon removal. Solid backing shall be provided for each tie.

Except where removable tie rods are used, ties shall not leave holes in the concrete surface less than 6 mm nor more than 25 mm deep and not more than 25 mm in diameter.

Removable tie rods shall be not more than 38 mm in diameter.

Formwork ties for water tanks shall be of a type such that any removable part can be removed without damaging the concrete. Any part left in the concrete shall be at least 40 mm or the specified nominal cover to reinforcement which ever is greater from the concrete surface. Cement mortar for filling holes left by form work ties and components shall consist of 1 part cement and 3 parts of aggregate with the minimum amount of water necessary to achieve a consistency suitable for compacting the mortar into ties, the mix shall contain a non- shrink admixture.

2 01 03 05 Chamfer Strips Chamfer strips shall be 12 mm 45 degree strips for beams and columns edges. With appropriate material installed by the fabricator of the formwork for beam, columns, and opening in walls ... etc.

2 01 03 06 Formwork Releasing Agents Formwork releasing agents shall be commercial formulations that will not bond with, stain or adversely affect concrete surfaces. Agent shall not impair subsequent treatment of concrete surfaces depending upon bond or adhesion nor impede the wetting of surfaces to be cured with water or curing compounds.

Release agents shall be of a type which will not stain or color the concrete and which will not affect the bond between the concrete and subsequent coverings. Release agents shall be of a type, which will not affect the hardening of the concrete.

Release agents used on formwork for water retaining structure for potable and fresh water shall be non-toxic and shall not impart a taste to the water.

Release agents used on steel formwork shall contain a rust-inhibiting agent.


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Release agents used on formwork shall be chemical release agents.

In areas, which in the opinion of the Engineer are likely to be affected by pedestrian traffic, rain or dust, release agents used on formwork shall be of a type, which evaporates to leave a dry film on the formwork unless protection from such effects provided.

2 01 03 07 Cement Mortar For Concrete Surfaces Cement mortar for filling blowholes where allowed shall consist of cement and fine aggregate together with the minimum amount of water necessary to achieve a consistency suitable for completely filling the blowholes.

Cement mortar for filling holes left by formwork ties and components shall consist of 1 part of cement to 3 parts of fine aggregate together with the minimum amount of water necessary to achieve a consistency suitable for compacting the mortar into the holes; the mix shall contain a non-shrink admixture.

Cement mortar for filling blowholes and holes left by formwork ties and components in concrete surfaces shall be of the same color as the hardened concrete; light-colored sand or white cement may be used for this purpose.

2 02 Formwork Accessories 2 02 01 Formwork Coatings Provide formwork coating compounds that will not bond with, stain, or adversely affect concrete surfaces and will not impair subsequent treatments of concrete surfaces.


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Part 3: Execution 3 02 General Preparation 3 02 01 Loading Loading of new slabs or beams shall be avoided in the first few days after placement.

Loads such as aggregate, timber, boards, reinforcing steel or support devices shall not be thrown on new construction nor be allowed to pile up in quantity.

When materials and components are distributed to the work position ensure that all design requirements and project related information are considered.

3 03 Formwork Installation Formwork shall be deemed to cover all surfaces required for containing concrete including stiffening, bracing and tying and all props, shores and other supports to prevent over-stress of completed parts of the structure.

Formwork with its necessary supports and braces shall be designed to safely support all vertical and lateral forces that might be evident including the pressure of placing and vibrating of the concrete. The design of formwork should also encompass their facile erection, unconstrained removal without damaging the in-placed concrete, and efficient rotation.

Formwork shall be constructed and maintained so to ensure that after removal of formwork the finished concrete members shall have true surfaces, free of undulations and will conform accurately to shapes, dimensions, lines elevation and position with the tolerances for reinforced concrete buildings specifications. Blowholes up to 5mm are accepted for finishes type A & B.

Formwork shall be designed and constructed by the Contractor in accordance with the requirements of ACI 347R for anticipated loads, lateral pressures, and stresses. Formwork shall be capable of producing a surface, which meets the requirements of finish specified hereinafter. Formwork shall be capable of withstanding the pressures resulting from placement and vibration of concrete. The Contractor shall submit the design and details of formwork for the Engineer’s acceptance. Formwork shall be designed so that concrete slabs, walls, and other members will be of correct dimensions, shape, alignment, elevation, and position and within established tolerances. The formwork shall result in a final structure that conforms to shapes, lines, and dimensions of the members as required by the design drawings and shall be in accordance with the requirements of ACI 347 R

Formwork for all concrete works shall be of modular prefabricated formwork system with skin of marine plywood not less than 16mm thick specially designed and fabricated steel formwork system or other approved material. In either case the finished concrete surfaces shall be uniform, dense and smooth surface, free from staining, discoloration, blemishes, grout runs or blowholes. Circular and curved formwork shall be prefabricated with seamless material.

Formwork ties shall be factory-fabricated metal ties, of the removable or internal disconnecting or snap-off type and shall be of a design that will not permit form deflection and will not spell concrete upon removal. Solid backing shall be provided for each tie.

Except where removable tie rods are used, ties shall not leave holes in the concrete surface less than 6 mm nor more than 25 mm deep and not more than 25 mm in diameter.

Removable tie rods shall be not more than 38 mm in diameter.

Formwork ties shall be of a type such that any removable part can be removed without damaging the concrete. Any part left in the concrete shall be at least 40 mm or the specified nominal cover to reinforcement which ever is greater from the concrete surface. Cement mortar for filling holes left by formwork ties and components shall consist of 1 part cement and 3 parts of aggregate with the minimum amount of water necessary to achieve a consistency suitable for compacting the mortar into ties, the mix shall contain a non- shrink admixture.

Formwork shall be mortar tight, properly aligned and adequately supported to produce concrete surfaces meeting the surface requirements and conforming to construction tolerance given in TABLE 1 herein. Where concrete surfaces are to have a Class A finish, joints in formwork panels shall be arranged as approved.


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Where formwork for continuous surfaces are placed in successive units, care shall be taken to fit the formwork over the completed surface so as to obtain accurate alignment of the surface and to prevent leakage of mortar. Formwork shall not be reused if there is any evidence of surface wear and tear or defects, which would impair the quality of the surface. Surfaces of formwork to be reused shall be cleaned of mortar from previous concerting and of all other foreign material before reuse. Formwork ties that are to be completely withdrawn shall be coated with a non-staining bond breaker.

3 03 01 Examination and Preparation 3 03 01 01 General Important formwork have to be inspected and checked by the Engineer before the reinforcing steel is placed to ensure that the concrete will have the dimensions and be in the location shown in the drawings and that the formwork is safe.

Formwork shall be accurately set, clean, tight, adequately braced, and constructed of or lined with materials that will impart the desired formed-surface finish to the hardened concrete.

Wood formwork shall be moistened before placing concrete. Formwork shall be made for removal with minimum damage to the concrete. With wood formwork, use of too large or too many nails shall be avoided to facilitate removal and reduce damage.

3 03 01 02 Formwork Joints Formwork joints shall be sufficiently tight to prevent loss of mortar from the concrete.

3 03 01 03 Coating Formwork for Class A finished surfaces shall be coated with a formwork-releasing agent before the formwork or reinforcement is placed in final position. The coating shall be used as recommended in the manufacturer’s printed or written instructions. Formwork for Class B finished surfaces may be wet with water in lieu of coating immediately before placing concrete. Surplus coating on form surfaces and coating on reinforcing steel and construction joints shall be removed before placing concrete. 3 03 01 04 Re-use The number of re-uses is dependent on the resulting finish quality and is subject to approval by the Engineer.

Formwork shall not be re-used after damage from previous uses or when they have reached the stage of possible impairment to concrete surfaces.

3 03 02 Techniques and Workmanship 3 03 02 01 General Formwork shall be constructed smooth, plumb, true, water and mortar-tight; sufficiently rigid and strong to prevent sagging between supports and to maintain true position and shape during and after placing of concrete, without waves or bulges.

Exceptional care shall be taken at dome frames and plywood formwork at finish surfaces to minimize fins, ridges, offsets, leaking of fins and other defects as it is intended that the forming of these surfaces shall be such as to require only a nominal amount of finishing to achieve a true, even surface.

3 03 02 02 Erection 3 03 02 02 01 Camber The bottom of each beam shall have a camber according to the dimensions of the beam.

Where specific camber is noted, the formwork have to be positioned properly to maintain hardened concrete lines within specified tolerances measured from camber lines.

For tolerances see Clause 3 03 04

The supporting struts shall be adjusted and fixed in position by suitable means and placed on timber bearers where required.


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3 03 02 02 02 Slopes Sloped surfaces in excess of 35 deg from the horizontal (1.5 horizontal to 1 vertical) shall be provided with a top formwork to hold the shape of the concrete during placement unless there is a continuous mat of bars or mesh sufficient to keep the concrete in place.

3 03 02 02 03 Chamfering External corners of columns, girders, beams, foundation walls projecting beyond overlying masonry, and other external corners that will be exposed shall be chamfered, bevelled, or rounded by mouldings placed in the formwork unless otherwise indicated.

3 03 02 02 04 Studs and Wales Studs and walers shall be spaced to prevent deflection of formwork material.

3 03 02 02 05 Shores Shores shall be adjustable by screw jacks or wedges.

3 03 02 02 06 Props Shall not be adjusted after concrete has set.

3 03 02 02 07 Juncture Formwork and joints shall be sufficiently tight to prevent leakage of grout and cement paste during placing of concrete. Waterproof tape, caulking, compressible seals and the like shall be used.

Joints in formwork shall be arranged vertically and horizontally to conform to the pattern of the design. Junctions of formwork panels shall occur at architectural lines, vertical control joints, including alignment with the masonry control joints, and construction joints.

01.0 Round Columns Formwork for round columns that will be exposed to view or painted shall be prefabricated and of nearly seamless type.

02.0 Beam Formwork All formwork for beams and similar members shall be designed and constructed so that the sides may be removed without disturbing the bottom boards supports thereto.

03.0 Bulkheads Bulkheads for control joints or construction joints shall preferably be made by splitting along the lines of reinforcement passing through the bulkheads so that each portion may be positioned and removed separately without applying undue pressure on the reinforcing rods which could cause spalling or cracking of the concrete.

04.0 Bevelled inserts Bevelled inserts at control joints shall be left undisturbed when formwork are stripped, and removed only after the concrete has been sufficiently cured and dried out. Wood strips inserted for architectural treatment shall be kerfed to permit swelling without pressure on the concrete.

3 03 02 03 Stripping and Re-shoring 3 03 02 03 01 General The concrete is to be regarded as sufficiently hardened when the component has attained such strength that it can, with a degree of safety, resist all loads acting at the time of removal of formwork and shores.

Formwork shall be removed in such a manner as to ensure the complete safety of the structure. Where the structure as a whole is adequately supported on shores, the removable floor formwork, beam and girder sides, columns and similar vertical structural members shall be carefully lowered or loosened respectively by using the devices for striking.


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It is not permissible to knock those supports away abruptly or wrench them away forcibly. Shock or vibration shall be avoided.

Particular care is necessary with components which have to carry virtually the full design load directly upon removal of formwork; e.g. in the case of roofs or floor slabs which have to support loading from floors above them which have not yet hardened .

Supporting formwork and shores may not be removed from beams, floors, and walls until these structural units are strong enough to carry their own weight and any approved superimposed load, which at no time shall exceed the live load for which the floor was designed unless provision has been made with the approval of the Engineer to allow for anticipated temporary construction loads such as in multi-storey work.

3 03 02 03 02 Stripping Times When field operations are not controlled by control tests as per Clause .3 04 02, under ordinary conditions formwork and supports shall remain in place for not less than the periods of time shown in Table 1.

These periods represent cumulative number of days or fractions thereof, not necessarily consecutive, during which the temperature of the air surrounding the concrete is above 10 deg C.

If high early-strength concrete is used, or in the case of very high temperatures, these periods may be reduced as approved by the Engineer.

Conversely, in the case of temperatures less than 10 deg C or if retarding agents are used, these periods may be increased at the discretion of the Engineer.

3 03 02 03 03 Re-shoring Removal times are contingent on re-shores, where required, being as soon as practicable after stripping operations are complete but not later than the end of the working day in which stripping occurs.

Where re-shores are required to implement early stripping while minimizing sag or creep, capacity, placing and spacing of such re-shores have to be approved by the Engineer.

3 03 02 03 04 Removing of Re-shores Final removal of re-shores shall be based on the same limits as removal of shores. Re-shoring shall not be removed until the slab or members supported have attained sufficient strength to support all loads.

Removal of re-shores must be carried out so that the structure supported is not subject to impact or loading eccentricities. In no case shall re-shores be removed within two days after placing a slab above or within two floors below such a freshly placed slab.

Formwork shall be removed in a manner that will prevent injury to the concrete and ensure the complete safety of the structure. Formwork for columns, walls, side of beams and other parts not supporting the weight of concrete may be removed when the concrete has retained sufficient strength to resist damage from the removal operation but not before 24 hours after the complication of the placement of concrete. Formwork props and shoring of bottoms of beams and suspended slabs should not be removed before the concrete has attained 70% of its ultimate design strength. In case the removal of formwork prior to this constraint is allowed by the Engineer, the formwork should be removed in sections and propped as approved by the Engineer. In no case the bottom of beams and suspended slabs should be stripped before the elapse of 72 hours after the completion of the placement of the concrete. Depending on site circumstances, the Engineer may require propping of the bottoms of beams and suspended slabs for the full duration of 28 days.

3 03 03 Interface with other Products 3 03 04 Tolerances This Clause provides tolerances for reinforced concrete structures.

The Contractor shall set and maintain concrete formwork so as to ensure completed work within the tolerance limits.

Formwork shall be erected - unless otherwise directed - within the tolerances specified below.


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3 03 04 01 Camber 01.0 Spans over 5.0 m shall have camber of 1.0 mm per meter of span measured at

the center, except where specific camber is noted.

02.0 Camber is to be maintained as noted +/- 3 mm until re-shoring is removed.

3 03 04 02 Variation from plumb 3 03 04 02 01 In the lines and surfaces of columns, piers, walls and in arises:

In any 3 m length: 6 mm

Maximum for the entire length: 13 mm

3 03 04 02 02 For exposed corner columns, control joint grooves and other conspicuous lines: In any 6 m length 6 mm

Maximum for the entire length 8 mm

3 03 04 03 Variation from the level or slope indicated in drawings 3 03 04 03 01 In slab soffits, ceilings, beam soffits, and in arises, measured before

removal of supporting shores: In any 3 m length 6 mm


3 03 04 03 02 For exposed lintels, sills, parapets, horizontal grooves and other conspicuous Iines In any bay or 6 m length 6 mm


3 03 04 04 Variation of the linear building lines from established positions in planning related positions of columns, walls and partitions

In any bay or 6 m maximum 12 mm


3 03 04 05 Variation in the sizes and locations of : Sleeves floor openings and wall openings +/- 6 mm

3 03 04 06 Variation in cross-sectional dimensions of columns and beams and in the thickness of slabs and walls

Minus 3 mm

Plus 6 mm

3 03 04 07 Variation in Footings 3 03 04 07 01 Variation in dimensions in plan

Minus 12 mm

Plus 50 mm

3 03 04 07 02 Misplacement or eccentricity 2 % of the footing in the direction of the misplacement but not more than 50 mm

3 03 04 07 03 Thickness Decrease in specified thickness 5 %


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Increase in specified thickness no limit

3 03 04 08 Variation in steps 3 03 04 08 01 In a flight of stairs

Rise +/- 3 mm

Tread +/- 6 mm

3 03 04 08 02 In consecutive steps Rise +/- 2 mm

Tread +/- 3 mm

3 03 05 Formwork Accessories Anchor bolts, plates, sleeves, frames, reglets, pipes, electrical boxes, duct openings, chases, conduits, and inserts or fixtures for attachment of other work have to be installed or placed at locations and with spacing indicated in the Drawings and in coordination with the relevant Sections.

Ample notification to all responsible for such items prior to installation time is required.

All items to be cast in the concrete and in the formwork for holes, chases and the like shall be accurately set out and firmly fixed in position prior to the concrete being placed. No cutting away of concrete for any of these items shall be permitted.

The items to be cast in shall be securely fixed to the formwork in such a way that they are not displaced during the concreting operation and that there is no loss of material from the wet concrete through holes in the formwork.

For further details see: Section 03300

3 03 05 01 Ties The use of bolts or ties or any part of them, which remain cast into the concrete, if not directed otherwise, will not be permitted. Ties shall be of an approved design whereby the whole of the tie shall be capable of being removed so that no part remains embedded in the concrete.

No tie shall be nearer to any reinforcement in the concrete than the amount of cover to reinforcement specified for the particular location.

3 04 Field Quality Control 3 04 01 General See: Section 03300 Cast-In-Place Concrete (3 04).

3 04 02 Concrete Strength Control Tests Stripping times can be determined varying to the times shown in Table 1 provided the concrete strength is confirmed by tests on cubes stored under the same conditions as the structure to be stripped (see: Section 03300). Removal of formwork and supports for suspended structures can be accomplished when 75 % at least is reached of the designed compressive strength being required (nominal compressive strength) and when the ratio of cube test compressive strength to design strength is equal to or greater than the ratio of total dead load and construction load to the total design load.

3 05 Adjusting and Cleaning 3 05 01 Adjusting Remove and replace damaged formwork.


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3 05 02 Cleaning 3 05 02 01 General Formwork shall be thoroughly cleaned from all dirt, mortar and foreign matter and coated before each use. All steel formwork shall be free of rust and scale.

3 05 02 02 Cleanouts Where necessary or required by the Engineer, temporary opening panels in the formwork to facilitate cleaning, placing, and inspection shall be provided.


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Part 4: Method of Measurement 4 02 Units Of Measurement

Rate for formwork is included in the rates of concrete work and is not separately measured or taken into consideration unless it is clearly mentioned in the Bills of Quantities.

Where formwork is stated to be measured separately in the Bills of Quantities, the followings rules are to apply.

4 02 01 Formwork measured by area Formwork shall be measured by area (m2), taken as the net area in contact with the finished face of concrete, classified as follows:

Soffits; formwork to soffits over 0.2 m wide.

Sloping upper surfaces, which shall include surfaces more than 15 deg from horizontal

Sides of foundations, which shall include bases, pile caps and ground beams

Sides of walls, which shall include attached columns.

Returns to walls, which shall include ends, projections and reveals of openings or recesses

Sides and soffits of beams, which shall include lintels and breaks in soffits; isolated beams shall be so described

Sides of columns

Staircases, which shall include treads, risers and strings but exclude soffits

Other classifications (e.g. tunnel linings, bridges, bridge abutments) as may be appropriate

4 02 02 Formwork measured by length Formwork to edges, which shall include face of kerb or upstand or break in upper surface of floor, shall be measured by length (m).

Soffits; formwork to soffits up to 0.2 m wide.


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Part 5: Basis of Payment 5 02 Ancillary Works to be Included in the Unit Rate 5 02 01 General Rate for formwork is deemed to be included in the unit rate of concrete work and is not separately measured or taken into consideration unless it is clearly mentioned in the Bills of Quantities.

The unit rate of concrete work should allow for formwork to include work to any height, all cutting, notching, splayed edges, chamfers, allowance for overlaps and passing at angles, filleting to form chamfered edges, splayed internal angles, grooves, throats, rebates, battens, strutting, bolting, wedging, easing and striking and removal. No deductions shall be made for intersections of main beams with walls, columns or secondary beams.

The unit rate for blinding shall include formwork at edge or extra width of concrete.

5 02 02 Concrete Strength Control Tests The Contractor shall allow the cost involved for concrete cubes to be tested by an approved testing laboratory or by the Contractor in the presence of the Engineer or his Representative.


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Annex: Tables and Figures Tables

Table 1: Stripping Times (see 3 03 02 03 02) DL = Dead load

Stripping tim ewhere design live load isStructural m em ber

less than DL higher thanDL

Arch centers 14 days 7 days

Joist, beam , or girder soffitsUnder 3.0 m clear span between supports3.0m to 6.0 m clear span between supportsOver 6.0 m clear span between supports

7 days14 days21 days

4 days7 days

14 days

SlabsUnder 3.0 m clear span between supports3.0 m to 6.0 m clear span between supportsOver 6.0 m clear span between supports

4 days7 days

10 days

3 days4 days7 days

Post-tensioned slab system As soon as full post-tensioninghas been applied

W allsColum nsSides of beam s and girders

12 — 24 hr12 — 24 hr12 — 24 hr

Pan joist form s750 m m wide or lessov er 750 m m wide

3 days4 days


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Annex: Specific Information 7 01 Design Requirements (see Clause 1 04 01)

Formwork shall be designed, erected, supported, braced, and maintained so that it will safely support all vertical and lateral loads that might be applied until such loads can be supported by the concrete structure. Vertical and lateral loads must be carried to the ground by the formwork system and by the in-place construction that has attained adequate strength for that purpose.

7 02 Formwork Materials 7 02 01 General

Formwork for Exposed Finish Concrete

Plywood, metal, metal-framed plywood faced, or other acceptable panel-type materials, to provide continuous, straight, smooth, exposed surfaces. Furnish in largest practicable sizes to minimize number of joints.

Formwork for Unexposed Finish Concrete

Plywood, lumber, metal, or other acceptable material. Provide lumber dressed on at least two edges and one side for tight fit.

Metal and Fiberglass Formwork Systems

These systems shall be shop-fabricated by fully qualified manufacturers specialized in such work.

7 02 02 Wood Timber and Lumber

Principle Use: Formwork framing, sheathing, and shoring.

Plywood

Principle Use: Formwork sheathing and panels.

Hardboard

The surface reaction with wet concrete shall be checked before using hardboard.

Principle Use: Formwork liner and sheathing; pan formwork for joint construction.

7 02 03 Metal Steel

Principle Use: Heavy formwork and falsework

Column and joint formwork

Permanent formwork

Welding of permanent formwork

Aluminum

Aluminum shall be readily weldable, non-reactive to concrete containing calcium chloride, and protected against galvanic action at points of contact with steel.

Principle Use: Lightweight panels and framing; bracing and horizontal shoring.

7 02 04 Plastics Polystyrene, Polyethylene, Polyvinyl chloride

Principle Use: Formwork liners for decorative concrete.


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Fiberglass Reinforced Plastic

Principle Use: Ready-made column and dome pan formwork, custom-made formwork for special architectural effects.

7 02 05 Combined and Other Materials Fibre or Laminated Paper Pressed Tubes or Formwork

Principle Use: Column and beam formwork; void formwork for slabs, beams, girders, and precast piles.

Corrugated Cardboard

Principle Use: Internal and under-slab voids; voids in beams and girders (normally used with internal "egg crate" stiffeners).

Concrete

Foundations.

Permanent formwork.

Precast floor and roof units.

Moulds for precast units.

Plaster

Principle Use: Waste moulds for architectural concrete

Rubber

Principle Use: Formwork lining and void formwork.

7 02 06 Accessories Formwork Coatings

Principle Use: Facilitating formwork removal

Insulating Board

Principle Use: Formwork insulation for cold weather protection of concrete (permanent formwork).

Fibre wood

Fibre glass

Foamed plastic

Steel Joists and Steel Frame Shoring

Principle Use: Formwork support.

Form Ties, Anchors, and Hangers

Principle Use: For securing formwork against placing loads and pressures

AL FATEH UNIVERSITY ODAC Division (03) Concrete Section 03200 Concrete Reinforcement

1


Division 03 - Concrete

Section 03200 - Concrete Reinforcement

Part 1: General 1 01 Summary The work covered by this section consists of providing all plant, labor and materials and performing all operations in connection with and necessary for the incorporation of steel reinforcement into the concrete structure

1 01 01 Section includes 01.0 Steel Reinforcement for Structural Concrete

02.0 Steel Reinforcement for Prestressed Concrete

03.0 Steel Reinforcement for Precast Concrete

04.0 Steel Reinforcement for Unit Masonry

1 01 04 Related Sections 02500 Paving and Surfacing

03100 Concrete Formwork 03300 Cast-In-Place Concrete

03400 Precast Concrete 04200 Unit Masonry

1 02 References The latest version of the publications listed below form a part of the Specifications, unless otherwise specified. The publications are referred to in the text with the basic designation only.

1 02 01 Applicable Standards 1 02 01 03 International Standards 1 02 01 03 01 International Standard Organization (ISO)

ISO 6934 Steel for prestressing of concrete ISO 6934-1: 91 General requirements ISO 6934-2: 91 Cold drawn wire ISO 6934-3: 91 Quenched and tempered wire ISO 6934-4: 91 Strand ISO 6934-5: 91 Hot-rolled steel bars with or without subsequent processing.

ISO 6935 Steel for the reinforcement of concrete ISO 6935-1: 91 Plain bars ISO 6935-2: 91 Ribbed bars ISO 6935-3: 92 Welded fabric ISO 10544: 92 Cold reduced steel wire for the reinforcement of concrete and the manufacture of welded fabric

1 02 01 04 USA Standards 1 02 01 04 01 American Society for Testing and Material (ASTM)

ASTM A 184M: 96 Standard Specification for Fabricated Deformed Steel Bar Mats for Concrete Reinforcement.


2


ASTM A 416: 88b Standard Specification for Steel Strand, Uncoated Seven-Wire Stress-Relieved for Prestressed Concrete.

ASTM A 496: 97a Standard Specification for Steel Wire, Deformed, for Concrete Reinforcement.

ASTM A 497: 97 Standard Specification for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement.

ASTM A 615M: 96a Standard Specification for Deformed and Plain Billet-Steel Bars for Concrete Reinforcement.

ASTM A 82 Specification for steel wire, plain, for concrete reinforcement

ASTM A704/A704M Specification for welded steel plain Bar or rod Mats for concrete reinforcement.

ASTM 706/A706M Specification for low-alloy steel deformed bars for concrete reinforcement.

ASTM A185 Steel welded wire fabric, plain, for concrete reinforcement

1 02 01 04 02 American Concrete Institute (ACI) ACI 116R : 90 Cement and Concrete Terminology

ACI 301 : 96 Specifications for Structural Concrete for Buildings

ACI 315 : 92 Details and Detailing of Concrete Reinforcement

ACI 315R : 94 Manual of Engineering and Placing Drawings for Reinforced Concrete

ACI 117 Tolerances for concrete construction and materials

ACI 318 Building code requirements for structural concrete

1 02 01 05 European Standards ENV 10 080: 96 Steel for the Reinforcement of Concrete - Weldable Ribbed

Reinforcing Steel B500 - Technical Delivery Conditions for Bars, Coils and Welded Fabric.

1 02 01 06 British Standards BS 4482: 85 Specification for cold reduced steel wire for the reinforcement of

concrete.

BS 4483: 98 Steel fabric for the reinforcement of concrete.

BS 4486: 80 Specification for hot rolled and processed high tensile alloy steel bars for the prestressing of concrete.

BS 5896: 80 Specification for high tensile steel wire and strand for the prestressing of concrete.

BS 8110 Structural use of concrete.

BS 8110-3: 85 Design charts for single reinforced beams, doubly reinforced beams and rectangular columns.

BS 4449 2005 Steel for the reinforcement of concrete.

1 02 01 07 German Standards DIN 488 Reinforcing steel

DIN 488-1: 84 Grades, properties, marking

DIN 488-2: 86 Reinforcing steel bars - Dimensions and masses

DIN 488-3: 86 Reinforcing steel bars – Testing


3


DIN 488-4: 86 Reinforcing steel fabric and wire - Design, dimensions and masses

DIN 488-5: 86 Reinforcing steel fabric and wire – Testing

DIN 488-6: 86 Inspection

DIN 488-7: 86 Verification of weldability of reinforcing steel bars – Test procedure and evaluation

DIN 1045: 88 Structural use of concrete - Design and construction

DIN 4099 : 85 Welding of reinforcing steel - Execution of welding work and testing

DIN 4227-1 : 88 Prestressed concrete - Partly or fully prestressed normal-weight concrete structural members.

1 02 02 Codes ACI 318M/RM: 95 Building Code Requirements for Reinforced Concrete and

Commentary

ACI 318: 95/R: 95 Building Code Requirements for Reinforced Concrete and Commentary

BS 8110-1: 97 Code of practice for design and construction.

BS 8110-2: 85 Code of practice for special circumstances.

EC 2: 89 Eurocode No. 2: Design of Concrete Structures

1 03 Definitions For further definitions see ACI 116 and Section 03300.

1 03 01 Technical Terms Characteristic value - value having a prescribed probability of not being attained in a hypothetical unlimited test series.

Connection rebars - reinforcement partially and temporarily not embedded in concrete due to the sequence of concrete placements or for assembling of precast reinforced concrete members.

Construction joints - are formed by the interruption of concrete placements: the bonded surface between the individual job sections to be concreted and to be established prior to beginning concreting operations, designed to resist all loads and stresses occurring.

Contraction joints - formed, sawed or tooled groove in a concrete structure to create a weakened plane and to regulate the location of cracking.

Core - the part of a cross-section of the bar that contains neither longitudinal nor transverse ribs.

Expansion joint - a separation provided between adjoining parts of a structure to allow movement and extending through the entire structure.

Fabric - a geometrical arrangement of longitudinal and transverse wires that are arranged substantially at right angles to each other and welded together at all points of intersection.

Helical reinforcement - continuously wound steel reinforcement in the form of a cylindrical helix (more commonly known as spiral reinforcement).

Hoop - a one-piece closed tie.


4


Lateral reinforcement - applied to ties, hoops, and spirals in columns and columns-like members.

Nominal cross-sectional area - the cross-sectional area equivalent to the area of a circular plain bar of nominal diameter.

Reinforcing steel - steel (bar, fabric or wire) with a practically circular cross section used for reinforcing concrete.

Reinforcing steel bars - reinforcing steel supplied in technically straight bars for single reinforcement.

Reinforcing steel fabric - reinforcement prefabricated in a workshop from bars assembled in a cross-wise fashion, joint together at the crossover points by means of resistance spot welding to give resistance to shear.

Reinforcing steel wire - smooth or profiled reinforcing steel produced in the form of a coil and fabricated into reinforcements in a workshop.

Spiral reinforcement - see helical reinforcement.

Splice - connection of one reinforcing bar to another by lapping, welding, mechanical couplers, or other means.

Strand - steel wires twisted together into a reinforcement cable for prestressed concrete.

Tie - loop of reinforcing bars encircling the longitudinal steel in columns.

1 03 02 Abbreviations B.o.Q Bills of Quantities

Q.C Quality Control

1 04 System Description 1 04 01 Design Requirements The design shall be in accordance with ACI 318

1 05 Submittals In compliance with the Conditions of Contract and the provisions of Section 01300 the following shall be submitted for approval after the award of the Contract within forty five (45) days

1 05 01 Product Data The product data for each different type of steel reinforcement, accessory and other material indicated.

1 05 02 Working Drawings Detail drawings shall be submitted and shall be in accordance with ACI 318 and ACI 315, unless otherwise specified. Drawings shall show support details including types, sizes and spacing. Dimensions shall not be scaled from structural drawings to determine lengths of reinforcing bars.

The working and placing drawings for steel reinforcement shall be submitted for review with full details as indicated:

01.0 position of all reinforcement.

02.0 detailed bar bending schedules.

03.0 welding locations and procedures.

04.0 any re-location of bars to an extent that causes placement tolerances to be violated.

05.0 splices and mechanical connectors.


5


06.0 bending of reinforcement partially embedded in hardened concrete.

1 05 03 Samples Samples of steel reinforcement and accessories (e. g. non-ferrous bar chairs, spacers and hangers).


1 05 04 Quality Control Submittals Documented experience of Contractor’s site engineer’s, supervisor(s) and steel fixer(s) (see: ref. 1 06 01 Part 1: General)

Reports and records of Contractor’s Source Q.C.(see: ref. 1 06 04 03 Part 1: General)

Reports and records of Contractor’s Field Q.C.(see: ref. 3 04 Part 3: Execution)

Reports and records of Contractor’s Internal Q.C.(see: ref. 1 06 04 01 Part 1: General)

Reports and records of Contractor's External Q.C.(see: ref. 1 06 04 02 Part 1: General)

Certificates of compliance - not more than 12 months old - with referenced standards for reinforcement and accessories.

Manufacturer's instructions concerning handling, installation and maintenance of reinforcement and accessories.

Contractor’s Quality Control Programs and Methods.

1 05 06 Other Submittals 01.0 Records and reports of Contractor’s major equipment (e. g. bending and cutting

machines).

1 06 Quality Assurance Sampling, testing and checking shall be recorded on a daily basis (i.e. indicating day, month, year) including corrective actions taken by the Contractor if necessary.

Reports and records shall be available for assessment to the Engineer not later than three (3) days after testing and checking.

Reports and records shall be established in a manner to ensure correlation between records, test results and locations of reinforcing steel.

Arrangements shall be made in Contractor’s work schedule and time allowed for testing and checking as indicated.

1 06 01 Qualifications Site supervisor shall have knowledge of referenced standards and at least five (5) years of documented experience in reinforced concrete works. He shall have successfully completed reinforced concrete works similar in material, design, and extent to that work indicated for the Project.

Steel reinforcing foremen shall have knowledge of reinforced concrete and related works.

Steel fixer shall be familiar with all materials and installation procedures and shall be skilled and trained.

1 06 04 Quality Control 1 06 04 01 Internal Quality Control Contractors Internal Q.C. shall include but not be limited to:

Checking of suppliers test certificates and certificates of compliance for steel reinforcement and accessories to be delivered to the job site prior to first delivery and each shipment that comes from another source than the previous one to conform compliance with specifications.


6


Checking of suppliers delivery tickets of each delivery for completeness and compliance with supply order and specifications.

See: Section 03300 Cast-in-Place Concrete.

1 06 04 03 Source Quality Control Each consignment of steel shall be accompanied by a manufacturer's delivery certificate or shall refer to a previous certificate, if the consignment is from the same batch, showing that the steel complies with the requirements.

If such certificate is not made available, or if the Engineer considers that the manufacturer's tests are inadequate, samples shall be taken for acceptance tests from different consignments as directed and shall be tested in accordance with the specified standards at Contractor's expense. Should the result of such tests show that any sample does not comply with the specifications, the whole consignment will be rejected and removed from the Site at the Contractor's expense.

Acceptance tests will be directed if the fabrication of the reinforcing steel is not inspected by an independent third party and certified in accordance with DIN 488-6 or equivalent.

The following tests shall be performed:

01.0 Steel Bars - Tensile test. - Bending test. - Determination of diameter and cross-sectional area.

02.0 Steel Fabric - Shear strength test for weld joints. - Determination of dimensions. - Tensile test. - Appearance test . - Bending test.

1 07 Delivery, Storage and Handling 1 07 01 Packing and Shipping Steel bars shall be delivered in bundles firmly secured and tagged. Strands shall be supplied wounds on reels or coils.

Each bar or bundle of bars shall be identified by marks stamped onto the surface of each bar and the identifying mark shall contain the following information in accordance with the standard indicated:

- Name of the manufacturer and/or his trademark. - Standard to which the bars have been manufactured. - The class, type and strength respectively. - The diameter. - The number of the test certificate.

Each coil or reel of strands shall carry a label giving the following details:

- The number and appropriate section of the standard to which the strands have been produced. - Nominal diameter of strand. - Specified characteristic load. - Coil or reel number. - Number of the test certificate to which the coil or reel number refers. - Net mass in kg. - Manufacturer’s name.

The delivery of steel reinforcement shall be done in such a manner in order to prevent any damage.


Damaged steel reinforcement and damaged accessories will not be accepted.


7


1 07 02 Storage and Protection The method of storage shall be approved by the Engineer.

All reinforcement and accessories shall be stored in order to prevent damage, corrosion and impurities.

Steel reinforcement delivered to the Site and not immediately placed in forms shall be stored in racks, or other supports, at least 150 mm above ground.

Steel reinforcement stored at the Site or any other storage area shall be protected from rusting, damage, contamination or the effects of local environment.

Bars of differing diameters and grades of steel shall be kept separate.

Any reinforcement exposed to chloride contamination shall be thoroughly washed with clean fresh water prior to fixing, and if necessary before concreting.

Reinforcement shall not be dropped from a height greater than 50cm at any time.

1 08 Project and Site Conditions 1 08 02 01 Dust Control Dust caused by contractor’s operations on and near work shall be controlled by used of all means necessary.



8


Part 2: Products 2 01 General Reinforcing steel shall be fabricated to shapes and dimensions in compliance with the applicable provisions of standards and as indicated on the drawings.

Reinforcement shall be free of loose or flaky rust and mill scale, or coating, and any other substance that would reduce or destroy the bond.

Reinforcing steel reduced in section shall not be used.

2 02 Reinforcing Steel 2 02 01 Reinforcing Steel Bars Dimensions, classification and properties shall be as indicated in the. Bills of Quantitiesor elsewhere.

Reinforcing steel shall comply with:

* 01.1 ISO 6935-2

* 01.2 BS 4461

* 01.3 DIN 488

* 01.4 ASTM A 615M.

02.0 The steel bars shall comply with the structural design and shall be: Hot rolled ordinary tensile and / or Hot rolled high tensile and / or Cold worked high tensile twisted, as shown in drawings of grade 400 and shall have a yield stress or proof stress not less than 400 Mpa and an ultimate tensile strength not less than 600 Mpa..

Stirrups shall be made from normal grade steel grade 24/36 there yield stress shall not less than 240 MPa and ultimate stress shall not less than 360MPn.

Steel reinforcement shall be as specified in the Drawings. Reinforcement shall be clean and free from loose mill scale, loose rust, oil, grease, tar, paint, mud, retarders, concrete, earth, and contamination by salts or other deleterious matter and shall be maintained in such condition up to the time of concreting. Pitted bars shall not be used. Torch cutting of steel bars shall not be permitted.

All steel reinforcement shall be obtained from the same source and shall have uniform properties all through the duration of the works.

Samples of the different diameters and types of steel reinforcement shall be taken at intervals, as specified by the Engineer, and sent to an accepted authorized laboratory for testing

2 02 02 Reinforcing Steel Fabric Dimensions, classification and properties shall be as indicated in the Project B.o.Q. or otherwise noted

Reinforcing steel fabric shall comply with:

* 01.1 ISO 6935-3

* 01.2 BS 4483

* 01.3 DIN 488

* 01.4 ASTM A 184.

02.0 Welded steel fabric shall be factory made from cold reduced high tensile steel bars or wires unless otherwise indicated and shall comply with the structural design (Clause 1 04 01).

2 02 03 Reinforcing Steel Wire Dimensions, classification and properties shall be as indicated in the Project B.O.Q. or otherwise.


9


Wire ties shall be 1.6 mm diameter or heavier black annealed steel wire or otherwise.Reinforcing steel wire shall conform to 2 and shall be tested according to 107 and 690.

Reinforcing steel wire shall be produced cold reduced.

The steel grade shall be not less than 500 N/mm2.

Reinforcing steel wire shall comply

* 01.1 ISO 10544

* 01.2 BS 4482

* 01.3 DIN 488

* 01.4 ASTM A 496.

02.0 Steel wire shall comply with the structural design

2 02 04 Reinforcing Steel for Prestressed Concrete All bars and strands shall be sound and free from harmful surface defects. Until the bars and strands are built-in the Contractor shall give adequate protection to prevent corrosion and damage to threaded ends.

Production lengths shall contain no welds.

All bars and strands shall not be subject to any subsequent welding operations.

Unless otherwise indicated, strands shall not be coated with any lubricant, oil or other matter to a degree likely to impair adhesion to concrete.

High tensile reinforcing bar and wire for pre-stressed reinforcing shall be in accordance with one of the following standards:

* 01.0 ISO 3934

* 02.0 DIN 4227-1

* 03.0 BS 5896

* 04.0 ASTM A 416.

2.02.05 Welded Wire Fabric Welded wire fabric shall conform to ASTM A185 or ASTM A497.

2 03 Reinforcing Steel Accessories 2 03 01 Supports for Reinforcement Space chairs spacers and hangers shall be in accordance with ACI 301, ACI 315, ACI 318, DIN 1045 or an equivalent standard.

All chairs shall be plastic, galvanized steel, plastic protected or stainless steel within 13 mm of concrete surface if indicated and approved.

For further details concerning accessories see the related Section 03300 - Cast-In Place Concrete.

2 04 Tolerances 2 04 01 Steel Bars Reinforcement steel bars used for concrete reinforcement shall meet the following requirements for fabricating and bending tolerances:

01.0 Sheared length: +/- 25 mm

02.0 Overall dimensions of stirrups, ties and spirals: +/-10 mm

03.0 All other bends: +/- 25 mm.


10


Part 3: Execution 3 01.01 Bar Bending Schedules Reinforcement bending schedules listing the cut lengths, diameter or size, bending dimensions and locations of each bar in the work shall be provided by the Contractor. The cutting and bending of bars shall not commence until the bar bending schedules have been checked by the Engineer against the reinforcement Drawings and the corresponding general arrangement Drawings. The Contractor shall also check that the correct grade of reinforcement on the schedule corresponds to the Drawings. The Contractor shall be responsible for all delays and changes arising directly from failure to comply with these requirements.

Unless otherwise shown in the Drawings, the minimum lap lengths and effective anchorage lengths for parts under stress shall be full tension lengths in accordance with ASTM A 704.

3 01.02 Bending Steel reinforcement shall be cold bent to the forms and dimensions shown in the Drawings and in accordance with ACI 318 and ACI 315. No heating will be allowed to facilitate bending. Bending of bars shall be carried out slowly at a steady even pressure without jerks or impact.

Bent bars shall not be re-bent unless permitted by the Engineer. Any reinforcement showing signs of fracture shall be rejected and removed from the Site.

Diameter of bend measured on the inside of the bar, other than for stirrups and ties in sizes #3 through #5, shall not be less than the values given in Table 7.2 of ACI 318.

Inside diameter of bend for stirrups and ties shall not be less than 4 times the nominal diameter of bar, for #5 bar and smaller. For bars larger than #5, diameter of bend shall be in accordance with Table 7.2 of ACI 318.

Inside diameter of bend in welded wire fabric (smooth or deformed) for stirrups and ties shall not be less than 4 times the nominal diameter of bar for deformed wire larger than D6 and twice the nominal diameter of bar for all other wires.

After bending, the bars shall be marked for identification and shall be stored, as described in Clause 1.5, until required for use.

3 02 General Preparation 3 02 01 General When materials and components are distributed to the work position ensure that all design requirements and project related information are considered.

After any substantial delay in the work previously placed, reinforcing steel left for future bonding shall be inspected and cleaned.

3 03 Steel Reinforcement Installation Bending, placement and fixing of reinforcement shall be in accordance with ACI 301, ACI 315, ACI 318, DIN 1045 or an equivalent standard.

3 03 01 Reinforcing Steel Bars and Steel Fabric 3 03 01 01 Bending and Re-bending Bars shall be bent cold.

Reinforcing steel shall not be bent or straightened in a manner injurious to the steel or concrete. Bars with kinks or bends not shown on drawings shall not be placed. The use of heat to bend or straighten reinforcing steel will not be permitted unless approved by the Engineer.

Re-bending or straightening of reinforcement shall be subject to approval by the Engineer.

Connection rebars shall not be field bent, except as shown in the drawings or approved by the Engineer.


11


If warm bending is approved, bars shall not be cooled by quenching.

Reinforcing steel shall not be pickled or galvanized unless approved. Precautions have to be taken to control embrittlement of a bent bar and the production of hydrogen in the concrete.

3 03 01 02 Welding Welding of reinforcing steel shall conform to DIN 4099 or an equivalent standard. The welding processes given in Table 1 shall be used as appropriate.

No welding of reinforcing steel shall be carried out unless shown in the drawings or otherwise approved by the Engineer.

Such welding shall be made by a welder carrying a certificate of an approved institution, showing that he passed a welding course for this particular type of work.

No welding shall be done at the bend of a bar and not within 75 mm of a bend having an internal diameter less than 12 bar diameters, or any part of a bar that has been bent and subsequently bent in the reverse direction or straightened.

Welding of crossing bars (tack welding) will not be permitted unless approved by the Engineer.

Reinforcement which is specified to be welded shall be welded by any process which demonstrates by bending and tensile tests that the strength of the parent metal is not reduced and that the weld possesses a strength not less than that of the parent metal. The welding procedure established by successful test welds shall be maintained and no departure from this procedure shall be permitted. 3 03 01 02.01 Mechanical Couplings Mechanical couplings for splicing steel bars shall be accepted by the Engineer and shall be installed with equipment supplied by the coupling manufacturer and operated in accordance with the manufacturer's instructions. The specified minimum cover to reinforcement shall be maintained at the couplers.

Where sockets of connectors are left for connection of future works, they shall be protected by packing with grease and closed with a screw fitting durable plug

3 03 01 03 Splicing Splices and development of reinforcements shall be according to ACI 318-95 and in conformance with the UBC 97 Section 1912. Splicing shall be by lapping, by mechanical connection or welded splices (lap or butt) unless otherwise indicated on the Drawings and/or by the Engineer. Lap splices shall not be used for bars larger than 32 mm diameter, and welded splices or mechanical connections shall be used for larger bars. Welded butt splices shall be full penetration butt welds. Lapped bars shall be placed in contact and securely tied or spaced transversely apart to permit the embedment of the entire surface of each bar in concrete. Lapped bars shall not be spaced apart further than one-fifth the required length of lap or 150mm. Mechanical splices shall be in accordance with the recommendations of the manufacturer of the mechanical splicing device. Butt-welded and mechanical splices shall develop 125 percent of the specified minimum yield tensile strength of the spliced bars or of the smaller bar in transition splices. Bars shall be flame dried before butt-welding splicing. Adequate jigs and clamps or other devices shall be welding spliced in a straight line.

Not more than 25% of the reinforcing steel shall be spliced at the same location. For lap splices, Tension Lap Length or compress lap length shall be used depending on the state of stress in the considered bar or the location of there bars within the structural elements. Shop drawing showing the exact location of splices as well as length of lap splice shall be submitted to the Engineer for approval before construction.

Clear distance between parallel bars in a layer shall be not less than nominal diameter of bar nor 25mm.

Where parallel reinforcement is placed in two or more layers, bars in the upper layers shall be placed directly above bars in the bottom layer with a clear distance between layers of not less than 25mm.

In spirally reinforced or tied reinforced compression members, clear distance between longitudinal bars shall not be less than 1.5 times the nominal diameter of bar, nor 40mm.

Clear distance limitation between bars shall apply also to the clear distance between a contact lap splice and adjacent splices or bars.


12


3 03 01 04 Lateral Reinforcement Lateral reinforcement shall be executed in accordance with the working drawings.

All changes are subject to the approval of the Engineer.

3 03 01 04 01 Spiral and Tie Reinforcement for Compressive Members Spiral reinforcement shall consist of evenly spaced continuous helix held firmly in place and true to line by vertical spacers.

All bars shall be enclosed by lateral ties.

3 03 01 05 Concrete Protection for Reinforcement The concrete cover shall be sufficiently thick and dense to ensure an effective bond and to provide protection against fire and corrosion.

The concrete cover of reinforcement shall be as shown in the working drawings unless otherwise approved by the Engineer and shall be measured as the minimum distance between the outside of any reinforcement embedded in the concrete (including fittings) and the nearest permanent surface of the concrete member, excluding plaster, render or other surface finishes.

Fire-protective covering shall be as shown in the working drawings or as directed by the Engineer.

If any measure of concrete cover is missing in the drawings, the limits as per Clauses 3 03 01 05 01 to 3 03 01 05 03 below shall apply.

3 03 01 05 01 Cast-In-Place-Concrete (non prestressed) The minimum concrete cover shown in the working drawings shall comply with the structural design and ACI 301, ACI 315 and ACI 318 as shown in Table 2.1.1 and Table 2.1.

3 03 01 05 02 Precast Concrete (manufactured under plant control conditions) The minimum concrete cover shown in the working drawings shall comply with the structural design and ACI 318 as shown in Table 3 .

3 03 01 05 03 Prestressed Concrete The minimum concrete cover shown in the working drawings shall comply with the structural design and ACI 318 as shown in Table 4.

3 03 01 06 Exposed Reinforcement Exposed reinforcement inserts, and plates intended for bonding with future extensions shall be protected from corrosion.

3 03 01 07 Placement Reinforcing steel shall be placed and fixed in accordance with ACI 301, ACI 318, DIN 1045 or an equivalent code or standard.

Reinforcement shall be placed in accordance with the Drawings and shall be supported and maintained in position by using a sufficient number of spacers, chairs or supporting frames. Spacers shall be securely fixed to the reinforcement at the time of placing concrete.

Reinforcement shall not be continuous through expansion joints and shall be as indicated through construction or contraction joints.

Bars, wire fabric, wire tie, support, and other devices necessary to install and secure reinforcement shall be as specified in ACI 318. Reinforcement shall not contain rust, scale, oil, grease, clay, or foreign substances that would reduce the bond with concrete. Rusting of reinforcement is a basis of rejection if the effective cross-sectional area or the nominal weight per unit length of the reinforcement has been reduced to less than that specified in ASTM A618 and ACI 318. Loose rust shall be removed prior to placing steel.

Special care shall be exercised to assure that the bars are not coated with salts or other chemicals, which may cause corrosion of the reinforcing, steel after placing in the concrete.


13


All reinforcement shall be supported and fastened together to prevent displacement by construction loads or the placing of concrete beyond the tolerances indicated.

Supports of reinforcing steel shall be bent as shown in the drawings, and shall be accurately placed and adequately supported by concrete or other chairs, spacers or ties as approved and be maintained in position within the permissible tolerance until the concrete has hardened.

Bars may be moved as necessary to avoid interference with other reinforcing steel, conduits, or embedded items. If bars are moved by more than one bar diameter or enough to exceed the tolerances indicated in the drawings and Specifications, the resulting arrangement of bars shall be subject to the approval of the Engineer.

Install reinforcing steel wire in top of concrete slabs where shown in drawings or otherwise indicated. Lap all construction and contraction joints 150 mm and wire securely. Extent steel wire or fabric within 50 mm of sides and ends of slabs.

Vertical bars in columns shall be offset at least one bar diameter at lapped splices. To ensure proper placement, templates shall be furnished for all column dowels.

Except where otherwise shown in the Drawings or specified, the nominal concrete cover to the reinforcement exclusive of plaster or other decorative finish and concrete bindings shall be as follows:

For foundations: 70 mm

For Shell: 50 mm

For Slabs: 20 mm

For Columns, and beams: 25 mm

For Walls: 40 mm

No part of the reinforcement shall be used to support formwork, access ways, working platforms, or the placing equipment or for conducting an electric current.

No concreting shall be commenced until the Engineer has inspected and accepted the placed reinforcement.

3 03 02 Placing and Protection of Tendons and Prestressing Accessories 3 03 02 01 Tendons and Sheathing Tendons and sheathing for use in bonded construction shall be checked before placing to be free of grease, oil, paint and other foreign matter. A light coat of rust is permissible, provided loose rust has been removed and the surface of the steel is not pitted.

Grout fittings and sheathing for bonded construction shall be adequately protected from collapse and other damage. Prior to placing concrete, the sheathing and grout fittings shall be examined for holes. All such holes shall be repaired. If the tendon is to remain ungrouted for more than 28 days from the time of tendon placement, temporary corrosion protection shall be provided.

Tendons for use in unbonded construction shall be clean and undamaged and shall be permanently protected as indicated.

3 03 02 02 Anchorage End anchorages, which will be permanently protected with concrete, shall be free of loose rust, grease, oil and other foreign matter except paint.

3 03 02 03 Projecting Reinforcement No item of projecting reinforcement shall be bent, or otherwise disturbed, after any part of it is embedded in concrete, unless the Engineer's prior acceptance is obtained.

The Contractor shall be responsible for ensuring that projecting reinforcement is protected to prevent undue rusting and/or subsequent staining of finished surfaces by water running off rusted bars.


14


3 03 03 Interface with other Products Conduits and pipes of aluminum shall not be embedded in structural concrete unless effectively coated or covered to prevent aluminum-concrete reaction or electrolytic action between aluminum and steel.

3 03 04 Tolerances 3 03 04 01 Steel Bars Unless otherwise indicated or approved by the Engineer, reinforcement shall meet the fabricating tolerances and be placed in its specified position within the tolerances given as follows, such that the nominal concrete cover indicated shall not be encroached upon.

Reinforcement shall be placed and secured with non-corrodible chairs, spacers, or metal hangers. Concrete or other non-corrodible material shall be used for supporting reinforcement on the ground. Tolerances for reinforcement placement shall be as specified in clause 2.2 of ACI 117-90.

Placing Tolerances:

Clear distance to formed surfaces + 5 mm; - 3 mm

Spacing between bars +/- 5 mm

Top bars in slabs and beams:

nominal cover

Members 200 mm deep or less + 5 mm; - 3 mm

Members more than 200 mm but not over 600 mm deep + 10 mm; -3 mm

Members more than 600 mm deep + 25 mm; -3 mm

Crosswise of members, spaced evenly: within 50.0 mm

Lengthwise of members: within 50.0 mm

Minimum cover to reinforcement below ground 50 mm in minimum.

3 03 04 02 Tendons and Prestressing Accessories Tendons, sheathing and anchorages shall be firmly supported to prevent displacement during concrete placement.

They shall be placed within the following tolerances:

Concrete dimensions of: 200 mm or less +/- 6.0 mm over 200 mm but not over 600 mm +/- 9.5 mm over 600 mm +/-12.5 mm

The tolerances apply separately to both vertical and horizontal dimensions and may be different for each direction except that in slabs the horizontal tolerance shall not exceed 25 mm in 4.50 m of tendon length.

The bearing surface between anchorages and concrete shall be concentric with and perpendicular to the tendons within +/-1 degree.

3 03 05 Steel Reinforcement Accessories 3 03 05 01 Construction and Contraction Joints All reinforcement shall be continued across construction and contraction joints.

3 03 05 02 Expansion Joints Reinforcement or other embedded material items bonded to the concrete (except dowel in floors bonded on only one side of joints) shall not be permitted to extent continuously through any expansion joint.


15


3 04 Field Quality Control 3 04 01 General See: Section 03300 Cast-In-Place Concrete and Section 03100 Concrete Formwork.

3 04 02 Inspection The Contractor shall give the Engineer 24 (twenty four) hours notice and opportunity to inspect all placement of reinforcing steel before concrete is poured. Reinforcement shall be in place and placement approved far enough ahead of concreting operation to prevent these operations from interfering with each other.


16


Part 4: Method of Measurement 4 01 General Rate for reinforcement steel is deemed included in the unit rate of concrete work and is not separately measured or taken into consideration unless it is clearly mentioned in the Bills of Quantities.

Where reinforcement is stated to be measured separately in the Bills of Quantities, the followings rules are to apply.

4 02 Units of Measurement 4 02 01 Reinforcing Steel Bars, Steel Fabric and Steel Wire Steel bars, steel fabric and steel wire will be measured by weight (kg), taken from the steel bending lists in accordance with the As-Built Drawings.

Steel fabric will be measured with no allowance for laps and splices.

4 02 02 Reinforcing Steel for Prestressed Concrete Prestressed tendons will be measured by length.

The lengths of post-tensioned tendons will be measured to outer faces of anchorage.

The lengths of pre-tensioned tendons will be measured to the surfaces of the concrete members.

Anchorages will be enumerated (no).


17


Part 5: Basis Of Payment 5 01 General Rate for reinforcement steel is deemed included in the unit rate of concrete work and is not separately measured or taken into consideration unless it is clearly mentioned in the Bills of Quantities.

5 02 Ancillary Works to be Included in the Unit Rate 5 02 01 General The unit rate of concrete work should allow for reinforcing steel to include cutting, rolling and bending margins, distance blocks, chairs, spacers, tying wire and the like.

5 02 02 Control and Other Tests The Contractor shall allow the cost involved for testing of all reinforcements.

.


18


Annex: Tables and Figures 6 01 Tables 6 01 01 Welding of Reinforcement

Table 1: Permitted welding processes and applications in accordance with DIN 1045 (18.6.6).

1

2

3

4

Type of loading

Welding process

Tension bars

Compression

bars 1

Flash welding

Butt joints

2

Gas pressure welding

Butts joints where ds ≥14mm

3

Metal arc welding with covered electrode31) Metal active gas welding 32)

Strap joints, tap joints, cross joints 33), and connection to other steel parts Butt joints where ds ≥20mm

4

Predominantly static

Resistance spot welding

Lap joints where ds ?12mm, And cross joints 33)

5

Flash welding

Butt joints

6

Gas pressure welding

Butt joints where Ds ≥14mm

Metal arc welding with covered electrode

7

Repeated

Metal active gas welding

Butt joints where ds ≥20mm

31) The nominal diameter of bars shall be not less than 8 mm. 32) The nominal diameter of bars shall be not less than 6 mm. 33) with ds not exceeding 16 mm for load bearing connections.


19


6 01 02 Minimum Concrete Cover 6 01 02 01 Cast-In-Place-Concrete (non pre-stressed) Table 2.1: Minimum concrete cover for reinforcement

a) According to ACI 318 (7.7.1) b) according to ACI 301 (3.3.2.3)

Minimum cover, mm

(a) Concrete cast against and permanently exposed to earth

70

(b) Concrete exposed to earth or weather:[Note: See code interpretation page ii.]

50

No. 20 through No. 55 bars…. No. 15 bar, W31 or D31 wire, and smaller ………………….

40

Concrete not exposed to weather or in contact with ground: Slabs, walls , joists: No. 45 and No. 55 bars ….. 40 No. 35 bar and smaller 20 Beams, columns: Primary reinforcement, ties, stirrups spirals ………….

40

Shells, folded plate members:

No. 20 bar and larger ………. 20 No. 15 bar, W31 or D31 wire,

and smaller ……………. 15


20


Table 2. 2: Concrete cover, type of structural element and bar spacing in accordance with ACI 315 (2.7.1).

Reinforcing bars in structural

element

Concrete cover

Category, according to center-to-

center bar spacing ≤

3db

> 3db < 4db

≥ 4db < 6db

≥ 6db

Longitudinal bars in beams and columns, and inner layers of walls or slabs

≤ db

> db

1 1

1 3

1 5

2 6

All other reinforcing bars ≤ db

> db < 2db

≥ 2db

1 1 1

1 3 3

1 3 5

2 4 6

Where db = nominal diameter of a bar


21


Table 2.3: Minimum concrete cover for corrosion protection an bonding in accordance with DIN 1045 (13.2).

1 2 3 4

Environmental conditions to which members

are subjected

Bar

diameter, ds, in mm

Minimum

cover for B 25 and over, min

c, in cm

Nominal

cover for B 25 and over, nom c, in cm

1 Members in enclosed rooms, e.g. in dwellings (including kitchen, bathroom and laundry), offices, schools, hospitals and shops, unless the criteria given in lines 2 to 4 apply. Members which are kept permanently free of moisture.

Up to 12 14, 16

20 25 28

1.0 1.5 2.0 2.5 3.0

2.0 2.5 3.0 3.5 4.0

2 Members to which outside air has constant or frequent access, e.g. in open sheds and garages. Members which remain permanently under water or in the soil, unless the criteria given in lines 3 and 4 or other criteria apply. Roofs with a watertight roof covering (for the side on which the covering is situated).

Up to 20

25 28

2.0 2.5 3.0

3.0 3.5 4.0

3 Members in the open. Members in enclosed rooms with a high frequency of very high humidity at normal room temperature, e.g. in canteen kitchens, bathrooms, laundries, cattle sheds and rooms situated in indoor swimming pools, which are exposed to high humidity. Members that are exposed to repeated humidification, e.g. as a result of the frequent formation of condensation, or members designed for use in the tidal zone. Members exposed to ‘slightly aggressive’ chemical attack as defined in DIN 4030.

Up to 25

28

2.5

3.0

3.5

4.0

4 Members in which concrete or steel is exposed to particularly corrosive action, e.g. due to constant action of aggressive vapours or de-icing salts or to ‘aggressive’ chemical attack as defined in DIN 4030 (see also subclause 13.3)

Up to 28

4.0

5.0


22


6 01 02 02 Precast Concrete (manufactured under plant control conditions) Table 3: Minimum concrete cover for reinforcement in accordance with ACI 318 (7.7.2).

(a) Concrete exposed to earth or weather : Minimum Cover , mm Wall panels : No. 45 and No. 55 bars ……… 40 No. 35 bar and smaller ……………. 20 Other members: No. 45 and No. 55 bars ………… 50 No. 20 through No. 35 bars . 40 No. 15 bar, W31 or D31 wire. and smaller ……. 30 (b) Concrete not exposed to weather or in contact with ground:

Slabs, walls, joists: No. 45 and No. 55 bars ……….. 30 No. 35 bar and smaller …. 15 Beams, columns: Primary reinforcement …………. ………….. db but not less than 15

and need not exceed 40 Ties, stirrups, spirals ….. 10 Shells, folded plate members: No. 20 bar and larger ………. 15 No. 15 bar, W31 or D31 wire and smaller ……………

10


23


6 01 02 03 Pre-stressed Concrete The minimum concrete cover as shown in Table 4 shall be provided for prestressed an non-prestressed reinforcement, ducts, and end fittings, except as provided in 6 01 02 01 and 6 01 02 02.

For prestressed concrete members manufactured under plant control conditions, minimum concrete cover for non-prestressed reinforcement shall be as required in 6 01 02 02.

Table 4: Minimum concrete cover for reinforcement in accordance with ACI 318 (7.7.3).

Minimum cover, mm(a) Concrete cast against and permanently exposed toearth

70

(b) Concrete exposed to earth or weather:Wall panels, slabs, joists …… 30Other members ……. 40

(c) Concrete not exposed to weather or in contact withground: Slabs, walls, joists ……….. 20

Beams, columns: Primary reinforcement …… 40Ties, stirrups, spirals ………. 20

Shells, folded plate members: No. 15 bar, W31 or D31 wire, and smaller …….. 10Other reinforcement ……. db but not less than 20


24


Annex: Specific Information 7 01 General

The design of steel reinforcement for structural concrete depends on the selection of the various standards and specifications for design, structural analysis and materials.

While DIN 1045 and DIN 488 consider only high tensile reinforcing steel with a yield strength not less than 420 N/mm2, 2, 224, ISO 6935-1, 6935-2 and EC 2, ACI 318 and ASTM A 615M allow ordinary tensile steel classes of 220, 240, 250 and 300 N/mm2 yield strength.

224 allows ‘interwoven or clipped’ steel fabric, whereas international standards accept only ‘welded’ connections.

Other differences concern diameter, masses, chemical composition, tolerances, bend mandrel diameter etc..

In order to demonstrate the importance of specifying the most favourable standards, this Annex shows excerpts and examples of various standards and specifications for essential design criteria which should be considered by the Project specifier for the structural design, preparation of shop-drawings and steel bending lists (Clause 1 04 01) and for the specification of the material (Clause 2 02).

For further references and advise to specify how, what and where, see ACI 301.

7 02 Products 7 02 01 Reinforcing Steel Bars 7 02 01 01 Classification and Mechanical Properties

The minimum mechanical properties of reinforcing steel shall conform to one of the following tables:

Table 1.1 Classification and mechanical properties according to 2

Table 1.2 Classification and mechanical properties according to ISO 6935-2.

Hot rolled steel bars Property Ordinary tensile High tensile

Cold worked twisted steel bar

Yield stress, min. N/mm2 250 460 460 Tensile strength, min. N/mm2 275 506 506 Elongation percentage calculated on gauge length 5D* min.

22

12

12

D = diameter of the bar.

Note: In case of no significant yield point, the yield stress can be considered the stress at total elongation equal to 0.5% of the gauge length, or the proof stress for elongation 0.2%.

Steel grade Upper yield stress Reff N/mm2

Tensile strength Rm N/mm2

Elongation A5.65 %

RB 300 300 330 16 RB 400 RB 400W

400 440 14

RB 500 RB 500W

500 550 14


25


Table 1.3 Classification and mechanical properties according to DIN 488-1.

The mandrel diameter to be used for the bend and rebend test varies as shown in the following tables:

7 02 01 02 Mandrel Diameter and Angle of Bending Table 2.1 Mandrel diameter and angle of bending according to 2 (*D=dia bar)

1 2 3 4 5 Abbreviation BSt 420 S BSt 500 S BSt 500 M2) Symbol 1) III S IV S IV N Material number 1.0428 1.0438 1.0466

Rei

nfor

cing

st

eel g

rade

Product form Reinforcing steel bar

Reinforcing steel bar

Reinforcing steel fabric2)

Value P3) %

1 Nominal diameter ds mm 6 to 28 6 to 28 4 to 124) - 2 Yield strenggth Re (βs)5) or 0.2 % proof

stress R p0.2 (β0.2) 5) N/mm2

420 500 500 5.0

3 Tensile strength Rm (βz ) 5) N/mm2

5006) 5506) 5506) 5.0

4 Elongation after fracture A10 (δ10) 5) %

10 10 8 5.0

5 Fatigue strength N/mm2

straight bars7) amplitude 2δA(2x106)

215 215 - 10.0

6 Bent bars 2δA(2x106) 170 170 - 10.0 7 - - 100 10.0 8

Straight bars taken from 2δA(2.106) a fabric, with weld point 2δA(2.105) - - 200 10.0

9 6 to 12 5 ds 5ds - 1.0 10 14 and 16 6ds 6ds - 1.0 11

Bend mandrel diameter, In mm, in rebend test for Nominal diameter ds, in mm

20 to 28 8ds 8ds - 1.0

12 Bend mandrel diameter, in mm, in rebend test at the weld point

- - 6ds 5.0

13 Shear force of the joint S N - - 0.3 x As x Rs 5.0 14 Permissible minus

deviation from the % nominal cross section As

8 )

4

4

4

5.0

15 Relative rib area fR See DIN 488 Part 2

See DIN 488 Part 2

See DIN 488 Part 4

0

16 C 0,22 (0,24) 0,22 (0,24) 0,15 (0,17) - 17 P 0,050 (0,055) 0,050

(0,055) 0,050 (0,055) -

18 S 0,050 (0,055) 0,050 (0,055)

0,050 (0,055) -

19

Chemical composition in the cast analysis and product analysis 9), % by mass, maximum

N10) 0,012 (0,013) 0,012 (0,013)

0,012 (0,013) -

20 Suitability for welding by processes11) E, MAG, GP RA, RP

E, MAG, GP RA, RP

E12), MAG12), RP

-

Diameter of mandrel of bend Property

Angle of bending Ordinary

tensile steel High tensile

steel Cold worked twisted steel

Cold bending 180o 2D* 3D* 3D*

Rebending 45o 2D 5D 5D


26


Table 2.2 Mandrel diameter (mm) for bend test according to ISO 6935-2.

Table 2.3 Mandrel diameter (mm) for rebend test according to ISO 6935-2.

Angle of bending between 160 and 180 degree for the bend test, for the rebend test 90 degree before heating and 20 degree for rebend.

For the mandrel diameter according to DIN 488 see Table 1.3.

7 02 01 03 Dimensions and Masses Table 3.2 Dimensions, masses and tolerances acc. to ISO 6935-1 - Plain Bars

Nominal diameter 1) of bar 6 8 10 12 16 20 25 32 40 Steel grade RB 300

12,5 16 20 32 50 63 100 125 160

RB 400 RB 400W

16 20 25 40 63 80 125 160 200

RB 500 RB 500W

20 25 32 50 80 100 160 200 250

1) for nominal diameters larger than 40 mm, the mandrel diameter in bend tests shall be agreed between manufacturer and purchaser

Nominal diameter 1 ) of bar 6 8 10 12 16 20 25 32 40

Steel grade RB 400 RB 400W RB 500 RB 500W

32 40 50 63 100 160 200 320 400

Mass per length Nominal bar

diameter

mm

Nominal cross- sectional area

mm2

Requirement

kg/m

Permissible deviation2)

%

6 8 10 12 16 20

28.3 50.3 78.5 113 201 314

0.222 0.395 0.617 0.888 1.58 2.47

±8 ±8 ±5 ±5 ±5 ±5

1) Permissible deviation refers to a single bar.


27


.

Table 3.3 Dimensions, masses and tolerances acc. to ISO 6935-2 - Ribbed Bars.

Mass per length Nominal bar

diameter1) mm

Nominal cross- sectional area

mm2

Requirement

kg/m


% 6 8 10 12 16 20 25 32 40

28.3 50.3 78.5 113 201 314 491 804 1256

0.222 0.395 0.617 0.888 1.58 2.47 3,85 6,31 9,86

±8 ±8 ±5 ±5 ±5 ±5 ±4 ±4 ±4

1) if diameters larger than 40 mm are required, the size increase should be in increments of 5 mm. Permissible deviation on such bars is ±4 %. 2) Permissible deviation refers to a single bar.


28


7 02 01 04 Chemical Composition Table 4.1 Chemical composition according to 2

Table 4.2 Chemical composition according to ISO 6935-2.

For the chemical composition according to DIN 488 see Table 1.3.

ASTM A 615M limits the content of phosphorus only: 0.06 %

7 02 02 Steel Fabric 7 02 02 01 Classification, Mechanical Properties and Chemical Composition

The minimum mechanical properties of reinforcing steel fabric in accordance with 224 shall be as follows:

high strength steel wires proof stress not less than 420 N/mm2

ultimate tensile strength not less than 500 N/mm2

mild steel yield stress not less than 240 N/mm2

ultimate tensile strength not less than 370 N/mm2

Maximum Permitted PercentageTypes of Bars Carbon

%Sulphur

%Phosphorus

%

Hot rolled, ordinary tensile steel bars

Hot rolled, high tensile steel bars

Cold worked, high tensile steel bars

0.30

0.33

0.25

0.05

0.05

0.05

0.05

0.05

0.05

Steel grade C1) Si Mn P S N2) Ceq1)

RB 300 RB 400 RB 500

- - - 0,060 (0,070)

0,060 (0,070)

- -

RB 400w RB 500w

0,22 (0,24) 3)

0,60 (0,65)

1,60 (1,70)

0,050 (0,055)

0,050 (0,055)

0,012 (0,013)

0,50 (0,52)

for RB 400W and RB 500W with diameters larger than 32 mm, the maximum carbon content (c) is 0,25 % (0,27) %) and the maximum carbon equivalent (Ceq) is 0,55 % (0,57 %).

A higher nitrogen content may be used if sufficient quantities of nitrogen binding elements are present. 3) The value in bracket apply for the product analysis.


29


The percentage of phosphorus and sulphur shall not exceed 0.06 %. The percentage of nitrogen shall not exceed 0.01 %, or 0.012% if phosphorus does not exceed 0.05%.

The minimum mechanical properties and the chemical composition of reinforcing steel fabric in accordance with ISO 6935-3 shall comply with the product analysis requirements of

- ISO 10544 for cold reduced wires

- ISO 6935-1 for plain bars

- ISO 6935-2 for ribbed bars.

The minimum mechanical properties and the chemical composition of reinforcing steel fabric in accordance with DIN 488-4 are shown in Table 1.3.

7 02 02 02 Dimensions and Masses Dimensions, masses and tolerances shall conform to the following tables:

Table 5.1.1 Dimensions and masses according to 224.

Nominal bardiameter

mm

Nominal cross-sectional area

mm2

Nominal massof metre length

Kg.

4.04.55.05.56.06.57.07.58.08.59.09.510.010.511.011.512.0

12.615.919.623.828.333.238.544.250.356.763.670.978.586.695.0

103.9113.1

0.0990.1250.1540.1870.2220.2600.3020.3470.3950.4450.4990.5560.6170.6800.7460.8150.888


30


Table 5.1.2 Cross sectional area of fabric in meter length according to 224.

Table 5.1.3 Nominal masses of square meter of fabric according to 224.

Cross sectional area of wires per metre length of fabric, cm2/m

Distance between wire centres – f – (single fabric) mm.

50 75 100 150 200 250 300 350 400

Distance between wire centres (double wire fabric), mm

Nom

inal

dia

met

er o

f w

ire,

mm

Cro

ss s

ectio

nal a

rea

of w

ire,

cm2

100 150 4.0 0.126 2.52 1.68 1.26 0.84 0.63 0.50 0.42 0.36 0.32 4.5 0.159 3.18 2.12 1.59 1.06 0.80 0.64 0.53 0.45 0.40 5.0 0.196 3.93 2.62 1.96 1.31 0.98 0.78 0.65 0.56 0.49 5.5 0.238 4.75 3.17 2.38 1.58 1.19 0.95 0.79 0.68 0.59 6.0 0.283 5.65 3.77 2.82 1.88 1.41 1.13 0.94 0.81 0.71 6.5 0.332 6.64 4.43 3.32 2.21 1.66 1.33 1.11 0.95 0.83 7.0 0.385 7.70 5.13 3.85 2.57 1.92 1.54 1.28 1.10 0.96 7.5 0.442 8.84 5.89 4.42 2.95 2.20 1.77 1.47 1.26 1.10 8.0 0.503 10.05 6.70 5.03 3.35 2.51 2.01 1.67 1.44 1.26 8.5 0.567 11.35 7.57 5.67 3.78 2.84 2.27 1.89 1.62 1.42 9.0 0.636 12.72 8.48 6.36 4.24 3.18 2.54 2.11 1.82 1.59 9.5 0.709 14.18 9.45 7.09 4.73 3.54 2.83 2.36 2.03 1.77 10.0 0.785 15.71 10.47 7.85 5.24 3.92 3.14 2.61 2.24 1.96 10.5 0.866 17.32 11.55 8.66 5.77 4.33 3.46 2.88 2.47 2.17 11.0 0.950 19.01 12.67 9.50 6.34 4.74 3.80 3.15 2.72 2.38 11.5 1.039 20.77 13.85 10.39 6.92 5.19 4.15 3.45 2.97 2.60 12.0 1.131 22.62 15.08 11.31 7.54 5.66 4.52 3.76 3.23 2.83

Nominal mass of wires in the same direction per square metre of fabric, kg/m2

Distance between wire centres (single fabric), mm.

50 75 100 150 200 250 300 350 400

Distance between wire centres (double wire fabric), mm

Nom

inal

dia

met

er o

f w

ire,

mm

Nom

inal

mas

s of

m

etre

leng

th o

f wire

, k g

/m

100 150 4.0 0.099 1.97 1.32 0.99 0.66 0.49 0.39 0.33 0.28 0.25 4.5 0.125 2.50 1.66 1.25 0.83 0.62 0.50 0.42 0.36 0.31 5.0 0.154 3.08 2.06 1.54 1.03 0.77 0.62 0.51 0.44 0.39 5.5 0.187 3.73 2.49 1.87 1.24 0.93 0.75 0.62 0.53 0.47 6.0 0.222 4.44 2.96 2.22 1.48 1.11 0.89 0.74 0.63 0.56 6.5 0.260 5.21 3.47 2.60 1.74 1.30 1.04 0.87 0.74 0.65 7.0 0.302 6.04 4.03 3.02 2.01 1.51 1.21 1.01 0.86 0.76 7.5 0.347 6.94 4.62 3.47 2.31 1.73 1.39 1.16 0.99 0.87 8.0 0.395 7.89 5.26 3.95 2.63 1.97 1.58 1.37 1.13 0.99 8.5 0.445 8.91 5.94 4.45 2.97 2.23 1.78 1.48 1.27 1.11 9.0 0.499 9.99 6.66 4.99 3.33 2.50 2.00 1.66 1.43 1.25 9.5 0.556 11.13 7.42 5.59 3.71 2.78 2.23 1.85 1.59 1.39 10.0 0.617 12.23 8.22 6.17 4.11 3.08 2.47 2.06 1.76 1.54 10.5 0.680 13.59 9.06 6.80 4.53 3.40 2.72 2.27 1.94 1.70 11.0 0.746 14.92 9.95 7.46 4.97 3.73 2.98 2.49 2.13 1.87 11.5 0.815 16.31 10.87 8.15 5.44 4.08 3.26 2.72 2.33 2.04 12.0 0.888 17.76 11.84 8.88 5.92 4.44 3.55 2.96 2.54 2.22


31


Table 5.1.4 Tolerances according to 224.

The joints at the intersections of longitudinal and transverse wires shall be firm welded or interwoven or clipped by sound and uniform process.

According to ISO 6935-3 the steel fabric shall be made of either

-cold reduced wires with nominal diameters in the range from 4 mm to 16 mm and with mass and geometry complying with ISO 10544;

or

-plain bars with nominal diameters of 6, 8, 10, 12 or 16 mm and with mass complying with ISO 6935-1;

or

-ribbed bars with nominal diameters of 6, 8, 10, 12 or 16 mm and with mass and geometry complying with ISO 6935-2.

Resistance welding of the joints at all intersections of longitudinal and transverse wires is stipulated to provide shear resistant connections.

The size, cross-sectional area and mass of wires for reinforcing steel fabric and reinforcing steel wire together with dimensions of oblique ribs and relative rib area for fabric according to DIN 488-4 are shown in Table 5.2.

Length of fabric Tolerance on width Tolerance on length

Up to 6 m Over 6 m

± 25 mm ± 25 mm

± 25 mm ±1%


32


Table 5.2 Dimensions and masses for steel fabric (ribbed bars) acc. to DIN 488-2.

Resistance welding of the joints at the intersections of longitudinal and transverse wires is stipulated to provide shear resistant connections.

7 02 03 Steel Wire 7 02 03 01 Classification, Mechanical Properties and Chemical Composition

For the specification of steel wire in accordance with 224 see item 7.2.2 Steel Fabric.

ISO 10544 specifies technical requirements for cold reduced steel wire designed for the reinforcement of concrete or for use in welded fabric, and defines one steel grade: 500 N/mm2.

The minimum mechanical properties and the chemical composition of reinforcing steel wire in accordance with ISO 10544 are shown in the Tables 6.1 and 6.2.

1 2 3 4 5 6 7 8 Oblique ribs (guideline values)

Height Nominal size ds

Nominal cross

sectional area1)

As Cm2

Nominal mass2)

G Kg/m

Height In the middle

h

At the quarter points

h1/4 h3/4

Crest width

b3)

Rib spacing c4)

Relative rib area fR*)

4.0 0.126 0.099 4.5 0.159 0.125

0.30

0.24

0.036

5.0 0.196 0.154 0.32 0.26

4.0

5.5 0.238 0.187 6.0 0.283 0.222

0.40

0.32

0.039

6.5 0.332 0.260 7.0 0.385 0.302

0.46

0.37

5.0

7.5 0.442 0.347 8.0 0.503 0.395 8.5 0.567 0.445

0.55

0.44

6.0

0.045

9.0 0.636 0.499 9.5 0.709 0.556 10.0 0.785 0.617 10.5 0.866 0.680

0.75

0.60

7.0

0.052

11.0 0.950 0.746 11.5 1.039 0.815 12.0 1.131 0.888

0.97

0.77

~0.1xds

8.4

0.056

Dimensionless quantity, see DIN 488 part 1, September 1984 edition, table 1 (line 14 and footnote 8). Calculated taking the density as 7,85 kg/m3. Crest widths at mid-rib up to 0,2.ds shall not give grounds for complaint. Permissible deviation: ±15 %.


33


Table 6.1 Mechanical properties according to ISO 10544.

Table 6.2 Chemical composition according to ISO 10544.

Table 6.3

STANDARD BS 4449/97

GRADE GR.250 GR. 460 B

SHAPE Plain Bars

Plain Coils Deformed Bars

MECHANICAL PROPERTIES TS KG/mm2

YS KG/mm2

EL %

> = 1.15 YS MIN. 25.3 (250 N /MM2 )

Min . 22 (220 N /MM2 )

> = 1.08 YS MIN. 46.9 (460 N /MM2 )

Min . 14(140 N /MM2 )

CHEMICAL ANALYSIS C %

Proof stress Rp0,2N/mm2

Tensile strength RmN/mm2

Elongation1)

A5,65%

500 550 12

1) By agreement between purchaser and supplier, a total elongation atmaximum force (Agt) of 2,0 % shall be used instead of A5.65

C Si Mn P S N1) Ceq

0,22(0,24) 2)

0,60(0,65)

1,60(1,70)

0,050(0,055)

0,050(0,055)

0,012(0,013)

0,50(0,52)

1) A higher nitrogen content may be used if sufficient quantities of nitrogen binding elements are present.2) The value in bracket apply for the product analysis.


34


S %

P %

Mn %

N %

Ceq %

Max , 250

Max , 060

Max , 060

< = 120 PPM

< = 0.42 %

Max , 250

Max , 050

Max , 050

< = 120 PPM

< = 0.51 %

# Ceq = % C+ % Mn / 6 + % ( Cr + Mo + V ) / 5 + % ( Ni + Cu ) / 15

7 02 03 02 Dimensions and Masses For the specification of steel wire in accordance with 224 see item 7.2.2 Steel Fabric.

Dimensions, masses and tolerances according to ISO 10544 shall conform to table 6.3:

Table 6.3 Dimensions and masses according to ISO 10544.

BS 4482 and DIN 488 specify technical requirements for cold reduced steel wire equal or at least similar to ISO 10544.

ASTM A 496 specifies deformed steel wire, which has been cold worked. Dimensions and masses differ from those of , ISO, BSI and DIN due to the conversion from Inch-Pound Units into SI Units.

Mass divided by length Nominal wire

diameter

mm

Nominal cross-

sectional area mm2

Requirement

kg/m


% 5 6 7 8 9

10 12

19.6 28.3 38.5 50.3 63.6 78.5

113,1

0.154 0.222 0.302 0.395 0.499 0.617 0.888

±9 ±8 ±8 ±8 ±5 ±5 ±5

1) Refers to a single wire.

Nominal size

Batch

Individual bar

All sizes

+4 to –2 %

+6 to –2 %


35


7 02 04 Reinforcing Steel for Prestressed Concrete This item does not particularize prestressing steel. It only gives some general information. For details see ISO 6934, ASTM A 416, ASTM A 722, BS 4486, BS 5896, DIN 4227, DIN 1045 and ACI 318.

The hereafter given basic information applies to the following standard bars and strands used for prestressed concrete:

- Cold-worked high-tensile alloy steel bars - Steel wire for prestressed concrete - Seven-wire steel strands

All other prestressing steel members used in prestressed concrete, but being subject to special techniques, are not prescribed under this item.

7 02 04 01 Cold-worked High-tensile Alloy Steel Bars for Prestressed Concrete The hereafter specified requirements apply to plain round alloy steel bar tendons, which are prepared from hot-rolled steel bars by cold working.

Threads

The steel shall be hot-rolled into bars and subsequently processed to give the required mechanical properties. Where the bars are threaded, the threads shall be cold-rolled to the required tolerances.

Surface Condition

All bars shall be well and cleanly rolled and shall be sound and free from harmful surface defects. Until the bars are built-in the contractor shall give adequate protection to:

(1) prevent corrosion and damage to threaded ends; (2) prevent corrosion to all bars

Welding

Production lengths shall contain no welds. All bars shall be protected at all stages of handling from the effects of local heat, whether by weld-splash or other accidental means.

This material shall not be subjected to any subsequent welding operations.

Tolerances

Where bars are ordered and supplied by mass, the mass of finished bar tendons shall vary from the mass calculated on the nominal diameter by not more than the tolerances.

7 02 04 02 Seven-wire Steel Strand for Prestressed Concrete The hereunder specified requirements apply to strands, which are made by cold-drawn wires, manufactured from patented plain carbon steel.

Stranding Process

The strand shall comprise seven wires with a center wire at least 2 % greater in nominal diameter than the surrounding wires. The latter shall be tightly laid around the center wire.

Joints


36


No length of strand shall be joined to another length of strand by welding, brazing, splicing, or any other method.

Straightness

The treated strand shall be reformed into coils or wound on to reels, having a core diameter of sufficient size, and in any case, not less than 600 mm diameter, to ensure that the strand shall pay off reasonably straight.

The wires shall be suitably formed during the stranding operation so that they will not unravel when the strand is cut.

Surface Condition

Unless otherwise indicated, the finished strand shall not be coated with any lubricant, oil or other matter to a degree likely to impair adhesion to concrete.

A colour code identification of low relaxation strand is permissible provided the surface area affected by the marking is an insignificant proportion of the total surface of the strand in the coil.

Specification

Prestressed tendons shall be enumerated stating their length, number of wires, ultimate strength and size of wires, type of core and sheathing.

Descriptions shall state whether tendons are for pre-tensioned or post-tensioned members.

Descriptions shall state whether tendons are for pre-tensioned or post-tensioned members.

Anchorages shall be enumerated stating their components.

7 03 Execution The following design requirements are excerpts of or at least similar to ACI 318 (Tables and sketches ACI 315 (part C)) and have to be observed in the course of preparation of the working drawings.

For equivalent design requirements see DIN 1045.

7 03 01 Standard Hook A standard hook shall mean either:

- a 180-degree bend plus an extension of at least four bar diameters but not less than 70 mm at the free end of the bar; or

- a 90-degree bend plus an extension of at least 12 bar diameters at the free end of the bar; or

- for stirrups and tie anchorage’s only either a 90-degree or a 135-degree turn plus an extension of at least six bar diameters but not less than 70 mm at the free end of the bar.

Minimum Bend Diameter

The internal bend diameter of standard hooks shall not be less than the values of the following table:


37


A standard hook having an internal bend diameter greater than 10 times bar diameter shall be regarded as a straight extension of the bar for the purpose of development of tensile stress.

7 03 02 Stirrups and Tie Hooks and Bends other than Standard Hooks:

Inside diameter of bends for stirrups and ties shall not be less than

Bends for all other bars shall have diameters on the inside of the bar not less than

allowed in item 7.3.1. 7 03 03 Spacing of Reinforcement Minimum Clear Spacing of Parallel Bars

The clear distance between two parallel reinforcing bars or bundles of bars shall not be less than the greatest of the dimensions given in columns 3, 4, and 5 of the following table:

M.N.S. = the maximum nominal size of the aggregates

The clear distance specified above shall apply also between a splice and an adjacent parallel bar or other splice.

Bar diameter in mm Minimum bend diameter

10 through 2528 through 3436 and more

6 bar diameters8 bar diameters10 bar diameters

Bar diameter in mm Minimum bend diameter

101216

Not less than 38Not less than 50Not less than 65

Minimum clear spacing in parallel bars1 2 3 4 5

Bars between whichclear spacing ismeasured

Direction in whichspacing is measured

Minimum clear spacing or pitchshall be the greatest value of

a) Horizontal bars inbeams

HorizontallyVertically

25 mm25 mm

1.0 d1.0 d

1.5 M.N.S

b) ) Horizontal barsin slabs, walls

HorizontallyVertically

50 mm25 mm

3.0 d1.0 d

1.5 M.N.S

c) Vertical bars Horizontally 40 mm 1.5 d 1.5 M.N.Sd) Bars in ribs ofhollow-block orconcrete-joist slabconstr.

Horizontally 15 mm 1.0 d 1.5 M.N.S


38


Minimum Clear Spacing of Horizontal Bars in Layers

If horizontal bars are arranged in two or more layers close together, the above-men-tioned spacing shall apply to the horizontal clear distance between any two bars, irrespective of whether the bars are in the same layer or not.

Maximum Center-to-centre Spacing of Parallel Bars

The center-to-centre spacing of parallel bars shall be not greater than 300 mm or 2 h (h = thickness of member), whichever is lower.

Bundled Bars

Bundling of bars needs the approval in writing by the Engineer. If bundling is allowed, bundled bars shall comply with ACI 318 (7.6.6) and as detailed in ACI 315.

7 03 04 Splices of Reinforcement 7 03 04 01 General

For the use and application of

- Lap Splices

- Mechanical Connections

- Welded Splices

see ACI 318 (12.14).

7 03 04 02 Splices of Deformed Bars and Deformed Wire in Tension For the use and application see ACI 318 (12.15).

7 03 04 03 Splices of Deformed Bars in Compression For the use and application see ACI 318 (12.16).

7 03 04 04 Special Splice Requirements for Columns For the use and application see ACI 318 (12.17).

7 03 04 0 5 Splices of Welded Deformed Wire Fabric in Tension For the use and application see ACI 318 (12.18).

7 03 04 06 Splices of Welded Plain Wire Fabric in Tension For the use and application see ACI 318 (12.19).

7 03 05 Shrinkage and Temperature Reinforcement Reinforcement for shrinkage and temperature stresses normal to flexural reinforcement shall be provided in accordance with ACI 318 (7.12).

AL FATEH UNIVERSITY ODAC Division (03) Concrete Section 03250 Expansion Control

1



Section 03250 - EXPANSION CONTROL

Part 1: General 1.01 Scope These specifications cover the requirements for expansion control and providing extruded aluminum expansion joints where indicated on the Drawings and as specified herein. The Contractor shall be responsible for provision of a complete expansion control system to meet the movement requirement stated on the drawings, details of which are to be submitted for approval by the Supervising Engineer.

1.02 System Description Expansion control shall be a system that can provide for floor-to-floor, floor to wall, and wall and ceiling; including cross connections, closures, transitions and accessories to be a complete system.

System shall be of extruded aluminum and an elastomeric joint sealer to permit free movement of joint.

1.03 References At least version of the publications listed below from apart of the specifications, unless otherwise specified. The publications are, referred to in the text with the basic designations only:

American Society for testing and Materials (ASTM)

ASTM B 209 Aluminum-Alloy Sheet and Plate

ASTM B 221 Aluminum-Alloy Extruded Bars, Rods, Wire Shapes and Tubes

ASTM D 412 Test for Rubber Properties in Tension Federal

Specifications (FS)

FS QQ-A-200/9C(1) Aluminum Alloy Bar, Rod, Shapes, Tube and Wire,

Extruded, 6063

FS QQ-A-250/11E Aluminum Alloy 6061, Plate and Sheet

FS TT-S-00227E Sealing compound, Elastomeric Type, Multi-

Component (for Caulking, Sealing and Glazing in

Buildings and other Structures).


2


Part 2: PRODUCTS 2.01 Materials

2.01.01 Material 0.1 Metal extruded aluminum conforming to ASTM B221.

0.2 Elastomer: Polyurethane conforming ASTM TT-S00227E.

2.01.02 Finish Aluminum concealed surfaces: Zinc chromate prime coat or the approved coating.

Aluminum exposed surfaces: Clear anodized, satin brush aluminum, or hard coat anodized aluminum, as selected by the Architect.

Elastomers: Color as selected by the Architect.

Exposed surfaces shall have a strippable protective coat when delivered, and shall not be removed until directed.

2.01.03 Fire Barrier system Provide prefabricated fire barrier assemblies tested in accordance with ANSI/UL 263 procedures for one and two hour classification, unless otherwise detailed and in compliance with ASTM E119 and NFPA # 251 procedures.

Material shall carry UL label and be subject to underwriters Laboratories follow-UP system for quality assurance.

2.02 Fabrication 2.02.01 Housing Formed as to provide positive interlocking of the Elastomer into the extrusion.

2.02.02 Elastomeric strips Of adequate width to completely fill the assigned space.


3


Part 3: EXECUTION 3.01 Installation/Application/Erection

0.1 Install expansion joint covers in accordance with the manufacture’s approved shop

drawings and printed instructions.

0.2 Set anchored components into bedding material so that when cover is installed, it

is flush with floor finish. Clean out joint prior to installation.

0.3 Intersection of vertical and horizontal sections of cover: Only sufficient clearance to

allow for movement without rubbing.

3.01 Adjusting and Cleaning When directed, remove strippable protective coat.

AL FATEH UNIVERSITY ODAC Division 03 Concrete Section 03300 Cast-In-Place Concrete

1 Al LABINA / AL MANAR

in partnership with Hamza/ ECH/ LCE JV


Section 03300 - Cast-In-Place Concrete

Part 1: General 1 01 Summary

The work covered by this section consists of providing all plant, labor and materials and performing all operations in connection with plain and reinforced Cast-In-Place Concrete. These requirements shall apply but not be limited to furnishing concrete for the following: - Foundations - Isolated footings - Retaining walls - Slabs on grade - Suspended floor and roof slabs - Walls - Columns and beams

1 01 01 Section includes 01.0 Structural Concrete

02.0 Architectural Concrete

03.0 Prestressed Concrete

04.0 Mass concrete

05.0 Concrete Accessories

06.0 Concrete Restoration and Cleaning

1 01 04 Related Sections 02200 Earthworks

02500 Paving and Surfacing

03100 Concrete Formwork



04200 Unit Masonry

07100 Waterproofing

07900 Joint Sealers

1 02 References 1 02 01 Applicable Standards 1 02 01 03 International Standards 1 02 01 03 01 International Standard Organization (ISO) ISO 565: 90 Test sieves - Metal wire cloth, perforated metal plate and

electroformed sheet - Nominal sizes of openings.

ISO 679: 89 Methods of testing cements - Determination of strength.




ISO 680: 90 Cement - Test methods - Chemical analysis.

ISO 1920: 76 Concrete tests - Dimensions, tolerances, applicability of test specimens.

ISO 2194: 91 Industrial screens - Woven wire cloth, perforated plate and electroformed sheet - Designation and nominal sizes of openings.

ISO 2736 Test specimens

ISO 2736-1: 86 Part 1: Sampling of fresh concrete.

ISO 2736-2: 86 Part 2: Making and curing of test specimens for strength tests.

ISO 4012: 78 Concrete - Determination of compressive strength of test specimens.

1 02 01 04 USA Standards 1 02 01 04 01 American Society for Testing and Material (ASTM) ASTM A 167: 96 Standard Specification for Stainless and

Heat-Resisting Chromium-Nickel Steel Plate, Sheet and Strip.

ASTM B 370: 98 Standard Specification for Copper Sheet and Strip for Building Construction.

ASTM C 33: 99 Standard Specification for Concrete Aggregates.

ASTM C 40: 98 Standard Test Method for Organic Impurities in Fine Aggregates for Concrete.

ASTM C 87: 83(95) Standard Test Method for Effect of Organic Impurities in Fine Aggregate on Strength of Mortar.

ASTM C 88: 99 Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate.

ASTM C 94: 98 Standard Specification for Ready-Mixed Concrete.

ASTM C 109/M: 99 Standard Test Method for Compressive Strength of Hydraulic Cement Mortars (Using 2-in. or 50-mm Cube Specimens).

ASTM C 117: 95 Standard Test Method for Materials Finer than 0.075 mm (No. 200) Sieve in Mineral Aggregates by Washing.

ASTM C 123: 98 Standard Test Method for Lightweight Particles in Aggregate.

ASTM C 127: 88 Standard Test Method for Specific Gravity and Absorption of Coarse Aggregate.

ASTM C 128: 97 Standard Test Method for Specific Gravity and Absorption of Fine Aggregate.

ASTM C 131: 96 Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine.

ASTM C 136: 96a Standard Method for Sieve Analysis of Fine and Coarse Aggregates.

ASTM C 142: 97 Standard Test Method for Clay Lumps and Friable Particles in Aggregates.

ASTM C 143: 98 Standard Test Method for Slump of Hydraulic Cement Concrete.

ASTM C 144 Standard Specifications for Aggregate for Masonry mortar

ASTM C 150: 98 Standard Specification for Portland Cement.




ASTM C 156: 98 Standard Test Method for Water Retention by Concrete Curing Materials.

ASTM C 171: 97a Standard Specification for Sheet Materials for Curing Concrete.

ASTM C172 Standard Practice for Sampling Freshly Mixed Concrete

ASTM C173 Standard test method for air content of freshly mixed concrete by the volumetric method

ASTM C 185: 99 Standard Test Method for Air Content of Hydraulic Cement Mortar.

ASTM C 188: 95 Standard Test Method for Density of Hydraulic Cement.

ASTM C 191: 99 Standard Test Method for Time of Setting of Hydraulic Cement by Vicat Needle.

ASTM C231 Standard test method for air content of freshly mixed concrete by t he pressure method

ASTM C232 Standard test method for bleeding of concrete

ASTM C 260: 98 Standard Specification for Air-Entraining Admixtures for Concrete.

ASTM C 289: 94 Standard Test Method for Potential Alkali-Silica Reactivity of Aggregates (Chemical Method).

ASTM C 309: 98a Standard Specification for Liquid Membrane - Forming Compound for Curing Concrete.

ASTM C 330: 99 Standard Specification for Lightweight Aggregates for Structural Concrete.

ASTM C 332: 87 Standard Specification for Lightweight Aggregates for Insulating Concrete.

ASTM C 494: 98a Standard Specification for Chemical Admixtures for Concrete.

ASTM C 535: 96 Standard Test Method for Resistance to Degradation of Large-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine.

ASTM C 567: 99a Standard Test Method for Unit Weight of Structural Lightweight Concrete.

ASTM D 75: 97 Standard Practice for Sampling Aggregates.

ASTM D 226: 97a Standard Specification for Asphalt-Saturated Organic Felt Used in Roofing and Waterproofing.

ASTM D 994: 98 Standard Specification for Preformed Expansion Joint Filler for Concrete (Bituminous Type).

ASTM D 1056: 98 Standard Specification for Flexible Cellular Materials - Sponge or Expanded Rubber.

ASTM D 1190: 97 Standard Specification for Concrete Joint Sealer (Hot-Poured Elastic Type).

ASTM D 1667: 97 Standard Specification for Flexible Cellular Materials - Vinyl Chloride Polymers and Copolymers (Closed Cell Form).

ASTM D 1751: 97 Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Types).




ASTM D 1752: 84 Standard Specification for Preformed Sponge Rubber and Cork Expansion Joint Filler for Concrete Paving and Structural Construction.

ASTM D 4397: 96 Standard Specification for Polyethylene Sheeting for Construction, Industrial, and Agricultural Applications.

ASTM E 11: 95 Standard Specification for Wire-Cloth Sieves for Testing Purposes.

ASTM E 96: 95 Standard Test Methods for Water Vapor Transmission of Materials in Sheet Form.

ASTM E 154: 99 Standard Test Methods for Water Vapor Retarders Used in Contact with Earth under Concrete Slabs, on Walls, or as Ground Cover.

ASTM E 337: 84 Standard Test Methods for Measuring Humidity with a Psychro meter (the Measurement of Wet-Bulb and Dry-Bulb Temperatures).

ASTMC403 Standard test method for time of setting of concrete mixtures by penetration resistance

ASTM C595 Standard Specifications for Blended Hydraulic Cement

ASTM C685 Standard Specifications for Concrete Made By Volumetric Batching and Continuous Mixing

ASTM C684 Standard test method for making, accelerated curing, and testing concrete compression test specimens

ACI 318 Building code requirements for reinforced concrete

1 02 01 04 02 American Concrete Institute (ACI) ACI 116R: 90 Cement and Concrete Terminology.

ACI 121R: 85 Quality Assurance Systems for Concrete Construction.

ACI 211.1: 91 Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete.

ACI 211.2: 98 Standard Practice for Selecting Proportions for Structural Lightweight Concrete.

ACI 211.4R: 93 Guide for Selecting Proportions for High-Strength Concrete with Portland Cement and Fly Ash.

ACI 212.3R: 91 Chemical Admixtures for Concrete.

ACI 212.4R: 93 Guide for the Use of High-Range Water-Reducing Admixtures (Superplasticizers) in Concrete.

ACI 214: 77 Recommended Practice for Evaluation of Strength Test Results of Concrete (1989).

ACI 214.1R: 81 Use of Accelerated Strength Testing (1986).

ACI 214.3R: 88 Simplified Version of the Recommended Practice for Evaluation of Strength Test Results.

ACI 224.1R: 93 Causes, Evaluations and Repair of Cracks in Concrete Structures

ACI 224.2R: 92 Cracking of Concrete Members in Direct Tension

ACI 301: 96 Standard Specifications for Structural Concrete.

ACI 302.1R: 96 Guide for Concrete Floor and Slab Construction.




ACI 303R: 91 Guide to Cast-In-Place Architectural Concrete Practice.

ACI 303.1: 97 Standard Specification for Cast-In-Place Architectural Concrete.

ACI 304R: 89 Guide for Measuring, Mixing, Transporting, and Placing Concrete.

ACI 304.2R: 96 Placing Concrete by Pumping Methods.

ACI 304.3R: 96 Heavyweight Concrete: Measuring, Mixing, Transporting, and Placing.

ACI 304.4R: 95 Placing Concrete by Belt Conveyors.

ACI 304.5R: 91 Batching, Mixing, and Job Control of Lightweight Concrete.

ACI 304.6R: 91 Guide for the Use of Volumetric-Measuring and Continuous- Mixing Concrete Equipment.

ACI 305R: 91 Hot weather Concreting.

ACI 308: 92 Standard Practice for Curing Concrete.

ACI 309R: 96 Guide for Consolidation of Concrete.

ACI 309.1R: 93 Behavior of Fresh Concrete During Vibration.

ACI 309.2R: 90 Identification and Control of Consolidation-Related Surface Defects in Formed Concrete.

ACI 309.3R: 92 Guide to Consolidation of Concrete in Congested Areas.

ACI 358.1R: 92 Analysis and Design of Reinforced and Prestressed Concrete Guideway Structures.

ACI 372R: 97 Design and Construction of Circular Wire and Strand Wrapped Prestressed Concrete Structures.

ACI 373R: 97 Design and Construction of Circular Prestressed Concrete Structures with Circumferential Tendons.

ACI 423.3R: 96 Recommendations for Concrete Members Prestressed with Unbonded Tendons.

ACI 517.2R: 87 Accelerated Curing of Concrete at Atmospheric Pressure- State of the Art.

1 02 01 04 04 American Association of Highway and Transportation Officials (AASHTO)

AASHTO T 26: 79 Standard Method of Test for Quality of Water to be used in Concrete.

1 02 01 05 European Standards ENV 206-1: 00 Concrete – Part 1: Specification, Performance, Production,and

Conformity.

EN 480: 97 Admixtures for concrete, mortar and grout - Test methods Part 1 to 12 (series)

1 02 01 06 British Standards BSI 812 Testing aggregates Part 2, .100 . 124 (24 Parts - 1984 . 1998).

BSI 882: 92 Specification for aggregates from natural sources for concrete.

BSI 1881 Testing concrete Part 5, 101 . 209 (39 Parts - 1970 . 1998).

BSI 3148: 80 Methods of test for water for making concrete (incl. notes on the suitability of the water).




BSI 3837 Expanded polystyrene boards.

BSI 3837-1: 86 Specification for boards manufactured from expandable beads.

BSI 3837-2: 90 Specification for extruded boards.

BSI 3927: 86 Specification for rigid phenolic foam (PF) for thermal insulation in the form of slabs and profiled sections.

BSI 8110 Structural use of concrete.

BSI 8110-3: 85 Design charts for singly reinforced beams, doubly reinforced beams, and rectangular columns.

1 02 01 07 German Standards DIN 1045: 88 Structural Use of Concrete - Design and Construction.

DIN 1045/A1: 96 Concrete and Reinforced Concrete – Design and Construction; Alterations

DIN 1045-1: 97 Concrete, Reinforced and Prestressed Concrete Structures – Part 1: Design

DIN 1048 Testing Concrete.

DIN 1048-1: 91 Testing of fresh Concrete DIN 1048-2: 91 Testing of hardened Concrete (Specimen taken in situ).

DIN 1048-4: 91 Test Methods for Concrete, Determination of the CompressiveStrength in hardened Concrete in Structures and Components; Application of Reference lines and Evaluation with special Methods.

DIN 1084 Control (Quality Control) of Concrete Structures and Reinforced Concrete Structures.

DIN 1084-1: 78 Concrete B II on Building Sites.

DIN 1164-1: 94 Cement – Part 1: Composition, Specifications.

DIN 1164-2: 96 Cement – Part 2: Attestation of Conformity .

DIN 4030 Assessment of Water, Soil and Gases for their Aggressiveness to Concrete.

DIN 4030-1: 91 Principles and Limiting Values.

DIN 4030-2: 91 Collection and Examination of Water and Soil Samples.

DIN 4226 Aggregates for concrete.

DIN 4226-1: 83 Aggregates of dense structure (heavy aggregates)Terminology, designation and requirements.

DIN 4226-2: 83 Aggregates of porous structure (lightweight aggregates)- Terminology, designation and requirements.

DIN 4226-3: 83 Testing of heavy and lightweight aggregates.

DIN 4226-4: 83 Inspection.

DIN 18161-1: 76 Cork products as insulation materials for construction. – Thermal insulating material.

DIN 18164 Rigid cellular plastics insulating building materials.

DIN 18164-1: 92 Thermal insulating materials.

DIN 18164-2: 91 Polystyrene foam impact sound insulating materials.




DIN 52114: 88 Determination of flakiness index of mineral aggregates using a granulometric gauge.

1 02 02 Codes ACI 318M/RM : 92 Building Code Requirements for Reinforced Concrete and

Commentary.

ACI 318R : 95 Building Code Requirements for Structural Concrete and Commentary.

BSI 8110-1 : 97 Code of practice for design and construction.

BSI 8110-2 : 85 Code of practice for special circumstances.

ENV 1992-1-1: 92 Eurocode 2: Design of Concrete Structures - Common unified rules

ENV 1994-1-1: 94 Eurocode 4: Design of Composite Steel and Concrete Structures - Common unified rules.

ECC203-2003 Egyptian code of practice for concrete design and construction.

CODE No. (205) Egyptian code of practice for steel construction and bridges.

CODE No. (202) Egyptian code of practice for soil mechanics and foundation.

1 02 03 Other References Portland Cement Association: EB 075 D Concrete floors on ground. Design and control of concrete mixtures.

European Committee for Concrete/lnternational Federation of Prestressed Concrete: International recommendations for the design and construction of concrete structures. FIP 6th Congress, Prague, June 1970. London, Cement and Concrete Association, 1970.

1 03 Definitions For technical terms and definitions not listed below see: ACI 116.

1 03 01 Technical Terms Admixtures - substances added to the concrete and which, by chemical or physical action or by both, modify such properties of the concrete as its workability, hardening, setting, etc.

Additions - finely ground substances added to modify certain properties of the concrete, the volumes of which are to be taken into account when designing the mix. Examples are pozzolana or pigments for producing colored concrete. The term additives are sometimes used for additions.

Additives - see additions

Architectural concrete - concrete which is exposed to view as an interior or exterior surface in the completed structure.

Average compressive strength - the strength of a given class of concrete, required to statistically meeting a designated specific strength.

Batching - proportioning a quantity of either concrete or mortar to be mixed at one time.

Cast-in-place-concrete - concrete that is deposited and allowed to harden in the place where it is required to be in the complete structure, as opposed to precast concrete.

Characteristic strength - the value of strength below which 5 % of the population of all possible strength measurements of the specified concrete are expected to fall.




Compaction - see consolidation

Compressive strength - the compressive strength of concrete is expressed in terms of the characteristic strength. The strength shall be determined on moulded cube or cylinder specimens.

Concrete - material formed by mixing cement, coarse and fine aggregate and water, produced by the hardening of cement paste (cement and water); besides these basic components, it may also contain admixtures and/or additions (If the maximum particle size of the aggregate is 4 mm or less, the resulting material is termed mortar, not concrete).

Consolidation - a process of inducing a closer arrangement of the solid particles in freshly mixed concrete or mortar, during placement by reduction of voids; usually by vibration, centrifugation, rodding, tamping, or some combination of these actions.

Construction joint - the surface where two successive placements of concrete meet, across which it may be desired to achieve bond and through which reinforcement may be continuous.

Contraction joint - formed, sawed or tooled groove in a concrete structure to create a weakened plane and to regulate the location of cracking resulting from the dimensional change of different parts of the structure (see also isolation joint).

Control joints - see contraction joint.

Design strength - nominal strength of a member multiplied by a strength reduction factor.

Designed mix - mix for which the user is responsible for specifying the required performance and additional characteristics and the producer is responsible for providing a mix which complies with the required performance and additional characteristics.

Effective water content - mixing water plus water already present on the surface of the aggregates and in the admixtures and additions (and possibly water from added ice or steam heating).

Expansion joint - (1) a separation provided between adjoining parts of a structure to allow movement where expansion is likely to exceed contraction; (2) a separation between pavement slabs on grade, filled with a compressible filler material; (3) an isolation joint intended to allow independent movement between adjoining parts.

Finishing - leveling, smoothing, consolidating, and otherwise treating the surface of fresh and recently placed concrete or mortar to produce desired appearance and service.

In-situ concrete - see cast-in-place-concrete.

Isolation joints - a separation between adjoining parts of a concrete structure, usually a vertical plane, at a designed location such as to interfere least with performance of the structure, yet such as to allow relative movement in three directions and avoid formation of cracks elsewhere in the concrete and through which all or part of the bonded reinforcement is interrupted (see also contraction joint and expansion joint).

Mix designs - see proportioning.

Nominal strength - strength of a member or cross-section calculated in accordance with provisions and assumptions of the strength design method before application of any strength reduction (phi) factor.

Placement - the process of placing and consolidating concrete; a quantity of concrete placed and finished during a continuous operation; inappropriately referred to as pouring.

Placing - the deposition, distribution and consolidation of freshly mixed concrete in a place where it is to harden; inappropriately referred to as pouring.




Precast concrete - concrete cast elsewhere than its final position.

Prescribed mix - mix which the user specifies the composition of the mix and materials to be used. The producer is responsible for providing the specified mix but is not responsible for the performance of the concrete.

Proportioning - selection of proportions of ingredients to make the most economical use of available materials to produce concrete or mortar of the required properties (see: mix design).

Ready-mixed concrete - concrete manufactured for delivery to a purchaser in a plastic and unhardened state.

Site mixed concretes - concrete batched and mixed on or near the construction site by the user.

Water/cement ratio - ratio of effective water content in the concrete.

1 03 02 Abbreviations B.o.Q. Bills of Quantities

f’c specified compressive strength of concrete

Q.C. Quality control

w/c ratio water/cement ratio

1 04 System Description 1 04 01 Design Requirements

The design and structural analysis - when being part of the Contract - shall be in accordance with UBC and ACI 318

1 05 Submittals In compliance with the Conditions of Contract and the provisions of Section 01300 the following shall be submitted for approval after award of Contract within thirty one (31) days

1 05 01 Product Data The product data for each different type or grade of cement, aggregate, mix, accessory and other product indicated.

After the Engineer’s review of the design mixes for each class of concrete, the Contractor shall prepare and test each class of concrete. The Contractor shall prepare and submit a laboratory mix report to the Engineer on the results of tests ensuring that the design mixes meet the specifications herein and with the appropriate recommendations.

The Contractor shall obtain from the Concrete Supplier copies of the results of all tests, which shall become part of the Contractor's Weekly Quality Control report to the Engineer.

1 05 01.01 Concrete Mix Design Data Forty days minimum prior to concrete placement, a mix design for each class of concrete shall be submitted with a complete list of materials including type, brand, source and amount of cement, and admixtures; and applicable reference specifications. Data regarding concrete aggregates shall also be submitted. Submittal shall clearly indicate where each mix design will be used. Acknowledgment of receipt shall be obtained prior to concrete placement.




1 05 02 Shop and Working Drawings For shop, working and placing drawings see: Section 03100 Concrete Formwork Section 03200 Concrete Reinforcement Section 03400 Precast Concrete

The Contractor shall submit for review all working and/or shop drawings, which indicate the location of concrete placement and the related concrete strength class.

Detailed working drawings showing positions of construction joints not shown on the Contract Drawings for approval.

1 05 03 Samples The Contractor shall submit samples for - all basic materials and ingredients for concrete mixtures; - all accessories and built-in items under this section.


1 05 04 Quality Control Submittals Documented experience of site supervisor(s).(see: ref. 1 06 01 Part 1: General).

Reports and records of Contractor’s Source Q.C.(see: ref. 1 06 04 03 Part 1: General)

Reports and records of Contractor’s Field Q.C.(see: ref. 3 04 Part 3: Execution)

Reports and records of Contractor’s Internal Q.C.(see: ref. 1 06 04 01 Part 1: General)

Reports and records of Contractor's External Q.C.(see: ref. 1 06 04 02 Part 1: General)

Certificates of compliance - not more than 12 months old - with referenced standards for all materials and products related to cast-in-situ concrete and accessories referred to under this Section.

Mix design(s) of concrete including test results as specified in ref. 2 02 01, Part 2: Products.

Table 1 in Part 6: Annex shows the material reports to be submitted by the Contractor and the frequency of those reports as indicated.

1 05 05 Handing-Over Submittals 1 05 05 01 Project Records

Upon completion of the construction, the results of all compressive strength tests, of the w/c - ratio determinations and all other tests shall be handed over to the Engineer.

All records shall be available on Site during the construction period and be submitted to the Engineer on request. Along with all other notes these records shall be kept by the Contractor for at least five years after the termination of job.

1 05 05 02 Operation & Maintenance Data

1 05 06 Other Submittals Recommended suppliers and/or sources of all ingredients for making concrete, including cement, water, fine and coarse aggregates, admixtures and additions (item 1 in Table 1, see Part 6: Annex).

The name and location of the test laboratory to be used by the Contractor or Contractor's concrete supplier, as well as the proposed program, methods and




details of plant, equipment and personnel to be used in testing ingredients, mix design and concrete samples (item 4 in Table 1, see Part 6: Annex).

Contractor’s program, methods and details of plant and equipment to be used for batching and mixing of concrete (item 5 in Table 1, see Part 6: Annex).

Contractor’s proposed methods for compliance with hot weather concreting (item 6 in Table 1, see Part 6: Annex).

Written reports of all tests and inspections of fresh and hardened concrete performed in accordance with the requirements as indicated shall be submitted to the Engineer within 24 hours after completion of tests and inspections unless otherwise directed. Form of the reports is subject to the approval of the Engineer.

Procedure for developing bond at joints shall be submitted for review by the Engineer.

1 05 06.01 Statements 0.1.Curing Concrete Elements: Proposed materials and methods for curing concrete elements shall be submitted.

0.2 Concrete Pumping: Proposed materials and methods for concrete pumping shall be submitted. Submittal shall include mix designs, pumping equipment including type of pump, size and material for pipe, and maximum length and height at which concrete will be pumped.

0.3 Method statement of concreting of mass concrete for foundations. Including supporting calculations for Supervising Engineers approval.

0.4.Method statement of concreting of mass concrete for the transfer slabs (exceeding 1.00m thick) in that the Contractor shall take into consideration the requirements of the method of casting to ensure compliance with the design criteria and deflection limitations. Including supporting calculations for Supervising Engineers approval

1 06 Quality Assurance The Contractor shall nominate a responsible and qualified engineer as Q. C. Supervisor. Sampling, testing and checking shall be recorded on a daily basis (i.e. indicating day, month, year) including corrective actions taken by the Contractor if necessary.

Reports and records shall be available for assessment to the Engineer not later than three (3) days after testing and checking unless otherwise indicated.

Reports and records shall be established in a manner to ensure traceability between records, test results and locations of placed concrete.

Contractors own laboratory shall be located at Site unless otherwise approved by the Engineer.

Failure by the Engineer or his Representative to detect any defective work or material shall not in any way prevent later rejection when the defect is discovered nor shall it obligate the Engineer for final acceptance.

1 06 01 Qualifications Site engineer(s) shall have knowledge of referenced standards and at least seven (7) years of documented experience in reinforced concrete works. He shall have successfully completed reinforced concrete works similar in material, design, and extent to that work indicated for the Project.

Site supervisor(s) shall have knowledge of referenced standards and at least five (5) years of documented experience in reinforced concrete works. He shall have successfully completed reinforced concrete works similar in material, design, and extent to that work indicated for this project .




Concrete Foremen shall have knowledge of reinforced concrete and related works at least three (3) years.

Concrete worker shall be familiar with all materials and installation procedures and shall be skilled and trained.

1 06 03 Certifications Prior to use, all concrete ingredients shall be sampled and tested in accordance with DIN 1048 Part 1 to 3 or an equivalent standard by an approved laboratory to determine compliance with specification and referenced standards.

The mix design for each class of concrete shall be as determined by the Contractor through an approved laboratory and accepted by the Engineer.

With each mix design, independent laboratory tests reports or manufacturer's external Q. C. certificates attesting the conformance of ingredients with the specifications.

In case the source, brand or characteristic properties of the ingredients need to be varied during the term of the Contract, a revised mix design prepared by an independent laboratory shall be submitted (items 1, 2, and 3 in Table 1, see Part 6: Annex).

A certificate of an independent laboratory shall be submitted stating that each admixture used is identical in composition to the sample used for acceptance testing, and is compatible with all other material in the mix design (item 8 in Table 1, see Part 6: Annex).

1 06 04 Quality Control 1 06 04 01 Internal Quality Control 1 06 04 01 01 General

Contractors internal Q.C. shall include but not be limited to:

Checking suppliers test certificates and certificates of compliance for basic materials, mixes and accessories to be delivered to the job site prior to first delivery and each shipment that comes from another source than the previous one to conform compliance with specifications.

Checking supplier’s delivery tickets of each delivery for completeness and compliance with supply order and specifications.

Quality inspection of supplier to ensure continuous quality control of ingredients by periodic sampling, testing and reporting to the Engineer on the quality of materials being supplied (item 2 in Table 1, see Part 6: Annex).

All design mixes, for each class of concrete, indicating that the concrete ingredients and proportions will result in a concrete mix complying with the requirements specified (item 3 in Table 1, see Part 6: Annex).

Checking proper storage of materials at least every one (1) week.

If cement, aggregates, concrete or accessories do not comply with the specified requirements, the whole consignment will be rejected and removed from the Site.

Field Q. C see: Clause 3 04.

Reports of tests on materials and concrete samples shall include clear identification of the source or batch number, specimen identification, physical characteristics of the materials including temperature at time of sampling and testing, ambient temperature, date and time of procurement and testing, curing techniques for concrete if applicable, results of tests, point of incorporation of concrete in the construction, design of concrete mix and concrete yield strength.




1 06 04 02 External Quality Control The Contractor shall have at his disposal an approved independent laboratory, which is equipped with all necessary apparatus for carrying out all tests required according to the Contract specifications or directed by the Engineer.

1 06 04 03 Source Quality Control Concrete shall be sampled and tested at the source prior to delivery.

1 06 04 04 Test Reports 0.1 Concrete Mix Design: Copies shall be submitted of test reports showing that the mix has been successfully tested to produce concrete with the properties specified and that the mix will be suitable for the project conditions. Test reports shall be submitted along with the concrete mix design. The Engineer’s acceptance shall be obtained before concrete placement.

0.2 Ordinary Portland cement: The Contractor shall submit results of tests for Ordinary Portland Cement performed in accordance with ASTM C150, within three weeks of submittals date.

0.3 Aggregates: The aggregate shall comply with ASTM C33 and the submitted test results shall include the results of ASTM C 289, C227 and/or ASTM C586 for potential alkali-silica reactions, and ASTM C295 for petrographic analysis.

1 07 Delivery, Storage and Handling 1 07 01 Packing and Shipping 1 07 01 01 General

Concrete shall not be delivered until corresponding forms, reinforcement, and all embedded items are in place and ready for concrete placement.

Materials shall be protected from contaminants such as grease, oil, and dirt. Extra care shall be taken to ensure that materials can be accurately identified after bundles are broken and tags removed.

Cement shall be delivered in bulk or in sealed and marked bags, and shall be protected from the weather by enclosed transfer systems or other accepted coverings. The Contractor shall provide accepted silos to store sufficient bulk cement for continuity of work and the cement shall be placed therein upon delivery. Accepted precautions shall be taken to prevent cement dust causing a nuisance. If cement is delivered in bags, the Contractor shall provide suitable storage to store sufficient bagged cement for continuity of work, and the cement shall be placed therein upon delivery. The storage shall have adequate air circulation needed to maintain the cement dry. Damp or open bags shall be rejected.

Aggregate shall be stored in concrete-based bins or stages to prevent intermixing and the inclusion of dirt and foreign materials. Aggregate shall also be shaded from direct sunlight and shall be drained. Each size of aggregate shall be stored separately with the various types and sizes necessary to meet the grading requirements of the accepted mix. Storage bins or stages shall be sufficient for continuity of work and shall be emptied and cleaned regularly. All necessary measures shall be taken to prevent segregation of aggregates occurring during storage and between mixes. The Contractor shall take all necessary measures to prevent nuisance of dust and shall provide an up-to-date aggregate washing system.





Accessories shall be clearly indicated and marked on the delivery note, invoice or supplier's certificate supplied with a consignment, in particular the identification of the manufacturer, the country of origin and the standard which they comply with.

All concrete accessories shall be delivered in adequate containers, drums or bags.

Damaged packaged materials and damaged accessories will not be accepted. Adequate precautions shall be taken to guard against any possibility of damage.

1 07 01 02 Basic Materials Cement shall be delivered either in bulk by purpose-built vehicles or in sealed bags.

Packaged cement shall be delivered to the mixing site in original moisture-proof, sealed containers, which shall be labeled with the weight, name of manufacturer, brand and type specified.

Containers of cement, which vary in weight by more than 3 %, will not be accepted.

Mixing water supply shall be either through pipelines or with special tankers, which are used for this purpose only.

Admixtures and additions shall be delivered in adequate containers or packages and shall be clearly marked with the proprietary name, type, standard and the net weight or volume.

1 07 01 03 Concrete A delivery ticket from the ready mix plant for each batch delivered to the job-site shall be submitted setting forth the following Information:

Date Name of purchaser Registration number of delivery truck Name of driver Class of concrete Slump ordered Air content Amount of concrete in truckload in m3 Cement per m3 concrete in truckload Total water in batch in liters Type of admixtures used, if any Type of cement used Time of mixing of concrete (if dry, time cement added to aggregates) Temperature specified (maximum) * Temperature of concrete (when discharged at location of placement) * Time of arrival at job-site * Time of discharge at job-site * Amount of extra water added in liters (at request of Contractor’s Q. C. Super-visor only, and his signature) * Final location in concrete structure. Remark: * to be completed by the Contractor on job-site.

1 07 02 Storage and Protection 1 07 02 01 General

Accessories and embedded items shall be stored in order to prevent corrosion and accumulation of dirt and oil.




1 07 02 02 Cement 1 07 02 02 01 Packaged Cement

Cement containers shall be stored in dry, weather-tight and proper ventilated enclosures.

Sacked cement shall be stacked on pallets or similar platforms to permit proper circulation of air.

1 07 02 02 02 Bulk Cement Bulk cement shall be stored separately from packaged cement. Bulk cement shall be stored in dry, weather-tight, well-ventilated bins or silos with provisions for prevention of moisture absorption or the intrusion of foreign matter.

Storage facilities for bulk cement shall have separate compartments for each type of cement used.

Storage silos shall be emptied frequently, preferably once per month, to prevent cement caking.

Facilities for sampling of cement shall be provided at the weighing hopper, or at the feed line immediately before entering the hopper.

1 07 02 03 Aggregates Aggregates shall be transported and stockpiled separately according to their sources and gradations. Aggregates shall be handled in a manner, which will prevent contamination with earth or other matters.

If aggregates show segregation, or if the different gradations become mixed, the aggregates shall be re-screened before placing in the proportioning bins.

Aggregates shall not be transferred directly from trucks, railroad cars or barges to the proportioning bins when moisture content or/and water absorption is such that it will affect the accuracy of the proportioning of the concrete mixture. In such cases, the aggregates shall be stockpiled until the excess moisture drains off.

Muddy or oil-leaking equipment shall not be allowed to operate on the stockpiles.

1 07 02 04 Mixing Water Water shall be stored in closed water tanks and kept at an appropriate temperature.

1 07 02 05 Admixtures and Additions Admixtures shall be stored in such a manner as to permit an easy access for proper inspection and identification of each consignment, and in a suitable welterweight location protected from dampness, sun radiation, heat and frost.

Admixtures manufactured in liquid form shall be protected from freezing.

Admixtures manufactured in powder form may be converted to liquid for dispensing. Mixing drums or storage tanks from which the admixture will be dispensed shall be equipped with agitation or mixing equipment to keep solids in suspension.

The requirements for storage of powdered admixtures shall be the same as those for storage of cementitious materials.

Storage and handling of admixtures shall comply with ACI 212.1 through ACI 212.3 or an equivalent standard.

1 07 02 06 Temperature Control The Contractor shall provide procedures and facilities to control or reduce the temperature of all materials used in the concrete mix during hot weather at air




temperature over 32 deg C. The following methods may be used to assist in lowering the temperature of fresh concrete to meet the limit values at the point of placement (see Clause 2 02 05):

(a) Exposed water tanks and piping, the roofs and vertical walls of cement storage silos or buildings, the tops and vertical walls of mixer discharge hoppers, weighing hoppers, mixer drums and tops of mixer discharge hoppers may be shaded from the rays of the sun when it is 30 degC or more above the horizon, and may also be protected from drying winds by screens.

(b) Mixing water for concrete may be chilled by the use of heat exchanger coils, or by the addition of flaked ice.

(c) Coarse aggregates may be cooled by misting, provided that any moisture retained is taken into account when determining the water-cement ratio for the mix.

(d) Aggregates reclaimed from stockpiles by the ‘tunnel method’ may be cooler than those from the surface layer of the stockpile.

(e) Shade and wind protection may be used to protect the elevating conveyor to the batching plant.

1 08 Project and Site Conditions 1 08 02 01 Dust Control

Dust caused by Contractor’s operations on and near work shall be controlled by use of all means necessary.





Part 2: Products 2 01 Basic Materials 2 01 01 Cement

Portland cement and sulphate resisting cement shall comply with SASO 143, SASO 570, SASO 855 and SASO 1250.

Cement not covered by SASO 143, SASO 570, SASO 855 and SASO 1250 shall conform to ASTM C 150, DIN 1164 or an equivalent standard.

Cement shall be of an approved brand and shall be obtained directly from an approved manufacturer or an approved supplier.

Different brands of cement, or the same brand from a different source, shall not be used without approval by the Engineer.

High alumina cement shall not be used unless otherwise indicated.

Rapid-hardening Portland cement and cement with a low heat of hydration shall only be used as indicated and approved by the Engineer.

Cement type and strength class for work above or below ground level shall be as indicated and approved.

Methods of sampling and testing shall comply with SASO 142 and SASO 1251.

Sampling and testing not covered by SASO 142 and SASO 1251, shall conform to ASTM C 150, DIN 1164 or an equivalent standard.

Cement which has been stored for more than 3 months shall be tested in accordance with the above mentioned standards before use with regard to: - Fineness (Blaine) - Setting time (Vicat) - Compressive strength.

The following mandatory tests shall be carried out for any cement consignment on a representative sample if no certification according to Clause 1 06 03 can be provided by the Contractor: - Fineness (Blaine) - Setting time (Vicat) - Soundness. - Compressive strength. - Lime saturation factor. - Chemical analysis.

If the representative sample fails any of the mandatory tests, two new samples shall be taken from the same group and all the mandatory tests shall be repeated.

The group shall be considered conforming to the standard if the two new samples pass all the repeated mandatory tests.

2 01 02 Aggregates 2 01 02 01 General

Aggregates shall conform to ASTM C33. Coarse aggregate to withstand the specific environmental conditions shall be used. The Contractor shall obtain acceptance of the proposed aggregate sources, and shall select suitable samples of fine and coarse aggregate for specified testing before obtaining the aggregate. Laboratory tests shall be made at regular intervals to confirm the suitability of the aggregate. The acid-soluble Sulphate (SO3) level in the combined aggregate as a percentage by weight shall not exceed 0.4%. The acid-




soluble chloride ion (Cl) in the combined aggregate as a percentage by weight shall not exceed 0.05%.

Water to be used for cooling and/or washing aggregates shall have the quality of mixing water.

2 01 02 02 Normal Weight Aggregates Aggregates shall comply with BS 882, ASTM C 33, DIN 4226 or an equivalent standard.

Sizes and grading of aggregates shall comply with ACI 318, DIN 1045, DIN 52114 or an equivalent standard.

Sampling and testing shall conform to DIN 4226 or an equivalent standard.

For test frequencies see item 10 in Table 1 (see Part 6: Annex).

2 01 02 02 01 Fine Aggregates Fine aggregate shall consist of natural sand, manufactured sand or a combination of both, and shall be composed of clean, hard, durable spherical or cubical particles.

The salt content of fine aggregate shall not exceed the limitations as set out in Table 2 (see Part 6: Annex) unless otherwise indicated or approved.

Deleterious substances shall be limited in fine aggregates to the amounts shown in Table 3 (see Part 6: Annex) unless otherwise indicated or approved.

The amount of material passing a 75-micron (sieve No. 200) when tested in accordance with ASTM C117 shall not exceed 3% by weight. When subjected to five cycles of the soundness test specified in ASTM C88, fine aggregate shall show a weight loss not exceeding 10% when magnesium sulphate solution is used.

2 01 02 02 02 Coarse Aggregates Coarse aggregate shall consist of gravel, crushed gravel, or crushed stone confirming the requirements of ASTM C33. The coarse aggregate shall comply with the grading of size No. 67 (19.0 to 4.75 mm) and shall be of a nominal maximum size not exceeding 19 mm. The amount of material passing a 75- micron (sieve No. 200) when tested in accordance with ASTM C117 shall not exceed 1% by weight.

When subjected to five cycles of the soundness test specified in ASTM C88, coarse aggregate shall not show a weight loss exceeding 10% when Magnesium sulphate solution is used. Flaky and elongated aggregate shall not be permitted.

The salt content of coarse aggregate shall not exceed the limitations as set out in Table 2 (see Part 6: Annex)unless otherwise indicated or approved.

Deleterious substances shall be limited in fine aggregates to the amounts shown in Table 4 (see Part 6: Annex) unless otherwise indicated or approved.

2 01 02 02 03 Grading of Combined Aggregates The grading of fine and coarse aggregates shall be within the limits as shown in Table 5 (see Part 6: Annex) unless otherwise indicated or approved.

The grain size distribution (grading curves) is subject to approval of the Engineer. The maximum nominal grain size related to spacing of rebars shall be as shown in Fig. 1 (see Part 6: Annex) unless otherwise indicated or approved.

2 01 02 03 Lightweight Aggregates Lightweight aggregates shall be composed predominately of lightweight cellular and granular inorganic material.




The unit weight of successive shipments of lightweight aggregates shall not differ from the submitted sample by more than 10 %.

Lightweight aggregates for structural concrete shall comply in all respects with ASTM C 330, DIN 4226-2 or an equivalent standard.

Lightweight aggregates for insulating concrete shall comply in all respects with ASTM C 332 or an equivalent standard.

2 01 02 04. Quality and Testing of Aggregates Aggregate shall be free from dust, clay, loam and soft, clayey, shaley or decomposed stone, organic matter and other impurities and shall be hard and dense, to satisfy the properties and limits specified herein. Aggregate shall not contain any matter, which, in the opinion of the Engineer, is likely to undergo disruptive expansive reactions with alkalis in the mix or likely to otherwise affect the long-term durability of the concrete.

As precautionary measures against deleterious alkali-silica reactions, the Contractor shall send samples of the aggregates proposed to be used to an accepted specialized laboratory for petrographic analysis and alkali-aggregate reactivity tests, including testing by chemical methods described in ASTM C289, or rock cylinder test ASTM C586, and mortar bar tests in accordance with ASTM C227.

No. Test Coarse or fine aggregate 1 Grading 1/ day or 1/200 m3

Whichever is more frequent

2 Magnesium sulphate soundness Initial only or When When changing the source

3 Specific gravity and Absorption 1/ week or 1/1000 m3 Whichever is more frequent

4 Materials finer than 75-micronsμ 1/ day or 1/200 m3 Whichever is more frequent

5 Clay lumps and friable Particles 1 / week or 1/1000 m3Whichever is more frequent

6 Organic impurities 1/ week or 1/1000 m3 Whichever is more frequent

7 Sulphate and chloride content 1/ week or 1/1000 m3 Whichever is more frequent

8 Resistance to Degradation by Abrasion and Impact in the Los Angeles Machine

1/ week or 1/1000 m3 Whichever is more frequent

9 Elongation and flakiness 1 / day or 1/200 m3

10 Potential alkali reactivity Initial only or When changing the source




The tests shown in Table (1) shall be conducted to assess the suitability of aggregates. The frequency of these tests shall be in accordance with Table (1), or as otherwise specified more frequently by the Engineer. The tests shall be carried out in accordance with ASTM Standards, as appropriate, and the results shall comply with the limits given therein, or as otherwise stated herein.

Table (1) - Frequency of Tests for Aggregates

Grading test shall be carried out daily or per 200 m3 of concrete whichever is more frequent, when concrete is being produced on a regular basis, or beforehand when production is irregular. The combined grading of aggregate shall be constant. The percentage passing any sieve size, as determined by accepted trial mixes, shall be the target grading for all concrete of that type. The combined grading of the works concrete shall not vary on any sieve from that target by more than 4.0% of the total quantity of fine and coarse aggregate. If the estimated or measured combined grading of the permanent works concrete does not meet this requirement, a new trial mix shall be prepared for acceptance.

2 01 03 Mixing Water Water for concrete mixing shall be potable unless otherwise indicated and approved.

Mixing water shall be suitable to ensure that the salts content of the total concrete mix does not exceed the limitations set out in Table 2 (see Part 6: Annex). All water shall be tested and testing has to be approved by the Engineer.

The Contractor shall make his own arrangements and obtain acceptance for the provision of fresh water for the manufacture and curing of concrete. Water to be used for mixing and curing concrete and mortar shall be fresh and free from sediment and dissolved or suspended matter which may be harmful.

Water samples from the intended source of supply shall be taken for analysis before any concrete work is commenced, and at intervals throughout the duration of the Works as specified by the Engineer. If the samples are unacceptable, the Contractor shall either change to a new supply or take steps to improve the existing source as accepted.

The Sulphates (SO3) content shall not exceed 300 mg/L and the chloride ion content shall not exceed 500 mg/L. Tests to establish the contents shall be carried out at weekly intervals. These limits shall be subjected to the overall limit given for the concrete as mixed.

11 Moisture content 2 / day

12 Petrographic analysis Initial only or When changing the source




2 01 04 Admixtures and Additions Admixtures and additions used as indicated shall be proprietary products added in the proportions and manner recommended by the manufacturer unless otherwise indicated.

2 01 04 01 Admixtures The tests for quality control of admixtures shall be carried out according to ASTM C 260, ASTM C 494 respectively or equivalent standards.

Agitation of admixtures manufactured in liquid form shall be as recommended by the manufacturer.

Any concrete to include admixtures shall first undergo a suitability test and have to be approved by the Engineer. The trial mixes will be compared with concrete of the same class but containing no admixture to determine the effects of the admixture especially regarding workability, strength, setting time, and density.

0.1 Achieving workability with the lowest appropriate water-cement ratio in order to achieve durability.

0.2 Controlling and retarding setting.

0.3 Reducing bleeding and associated plastic settlement and cracking.

Admixtures shall comply with the following standards unless otherwise indicated:

(a) Water reducing agent shall comply with ASTM C 494 or DIN 51043.

(b) Retarding agent shall comply with ASTM C 494 or DIN 51043.

(c) Accelerating agent shall comply with ASTM C 494.

(d) Water reducing and retarding agent shall comply with ASTM C 494 or DIN 51043.

(e) Water reducing and accelerating agent shall comply with ASTM C 494.

(f) Air-entraining admixture shall comply with ASTM C 260 or DIN 4164. The total volumetric air content of air-entrained concrete after pouring shall be within 4 to 6% for maximum aggregate size of 20 mm and 3 to 5% for maximum aggregate size of 40 mm unless otherwise approved.

Corrosion inhibiting admixtures and all other admixtures shall be tested according to the directions of the Engineer.

Admixtures containing chlorides or other corrosive agents shall not be used.

In the event of admixtures being used, the concrete tests described in the Specifications shall be incorporated to ensure the specified strengths are achieved and comparison shall be made with concrete manufactured without the admixture to prove that the density has not been reduced and the other characteristics have not been adversely affected. If air-entraining agents are used, the density shall not be reduced by more than 5%.

When admixtures are used in the Works, very strict control shall be maintained to ensure that the correct quantity of admixture is used at all times. The equipment to be used for dispensing and the method of incorporating the admixture in the concrete shall be to the acceptance of the Engineer. The dispensing unit shall be translucent such that the operator can see the discharge of the admixture.

2 01 04 02 Additions The additions shall in no way adversely affect the concrete strength or contain chemicals, which may be harmful to other building materials.

It is strictly forbidden to add gypsum to the cement or concrete.




Cement coloring addition shall be dry powder dust or mineral oxide dye. Total coloring addition shall not exceed 6 % of the weight of cement.

2 02 Concrete 2 02 01 Design Criteria and Mix Design 2 02 01 01 General

Design concrete mixes are to have a minimum cement content per cubic meter of concrete consistent with the required slump, a water content corresponding to the appropriate water/cement (w/c) - ratio, a specified maximum size of coarse aggregate, and a grain size distribution of aggregates, in accordance with limits set forth in this Section, and in compliance with the structural design (see Clause 1 04 01). A design mix shall be proportioned in accordance with ACI 318, DIN 1045, ENV 206 or an equivalent standard, as determined by the type of structure and exposure conditions, and adjusted to meet specified design mix requirements. Mix designs shall be tested in accordance with the referenced standards and reported on as specified herein unless otherwise indicated.

Concrete for use in the Works shall be classified as shown below. The class of concrete is denoted by the 28-day characteristic strength and the nominal maximum aggregate size. Characteristic strength shall be defined as the value of the cube strength below which not more than 5% of the results of all possible cube strength measurements of the specified concrete are expected to fall. Except where otherwise specified, all concrete mixes shall be designed according to the grades listed in Table (2). The criteria given in this table are designed to achieve the desired concrete strength and durability.

The maximum cement content for any mix shall be 450 kg/m3 unless a higher content is accepted by the Engineer giving due consideration to the increased risk of shrinkage cracking or thermal stresses.

Table (2-a) - Description and Main Characteristics of Designed Concrete Mixes

Concrete Works Foundation Slabs, beans and Columns Screed Plain

Concrete

Mix Designation 35/19 35/19 25/25 20/25

Type of Cement according to ASTM C150

Sulfate Resisting (Type

V) OPC(Type I) OPC (Type I) OPC(Type I)

Aggregate Size No. According to ASTM C33 67 67 57 57

Nominal maximum size of coarse aggregates (mm) 19 19 25 25

28-day Characteristic Strength for cubes (N/mm2 ) 40 45 25 20

Minimum Cement Content (kg/m3) 400 375 250 250

Maximum Cement Content (kg/m3 ) 450 450 350 300




Maximum Free W/C Ratio 0.40 0.40 0.60 0.70

Slump at concreting location (mm) 120-150 120-150 120-150 120-150

Temperature of Fresh Concrete

Maximum oC

Minimum oC

30

7

30

7

30

7

30

7

Sampling rate for testing

each 50 m3 or every casting day, which is more frequent




Initial setting time of concrete from 3 to 6 hours

from 3 to 6 hours

from 3 to 6 hours

from 3 to 6 hours

2 02 01 02 Mix Design

According to ACI 318, any mix design shall be determined by one of two methods: Proportioning on the basis of field experience, or proportioning by laboratory trial batches and shall be submitted according to the form shown in Table 6 (see Part 6: Annex).

Once a design mix for any class of concrete has been accepted by the Engineer, it shall not be changed as to source, quality, quantity, and grading of materials, or in any other way that reduces durability.

All proposed changes shall be accomplished by preparing a new mix design as specified herein.

Mixes for the classes of concrete shown in Clause 3.1 herein shall be designed by the Contractor. The design of concrete mixes shall be carried out in accordance with ACI 211.The target mean strength shall exceed the specified characteristic strength 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 accepted by the Engineer, a standard deviation of 7 N/mm2 shall be used.

The workability of each class of concrete shall be such that satisfactory compaction is obtained when the concrete is placed and vibrated in the Works with no tendency to segregate when it is handled, transported and compacted by the methods, which the Contractor proposes to use in the Works.

The total content of chlorides in concrete (as chloride ion) shall not exceed 0.20% by weight of cement and the total acid-soluble sulphates (as sulphate ions) shall not exceed 4.0% by weight of cement in the mix.

Preliminary Mix Tests The proportions of cement, aggregate, water and admixtures determined by the Contractor in his mix designs shall be used in preliminary mixes of concrete made and tested under laboratory conditions to determine for each class of concrete, given in Clause 3.1 herein, the minimum practical water/cement ratio, the optimum dosage of used admixtures, the optimum mix proportions of cement with fine and coarse aggregate, and the resulting strength and workability.

Preliminary mixes shall be repeated until adjusted relevant requirements of Clauses 3.1 and 3.2 have been achieved




2 02 01 02 01 Proportioning on the Basis of Field Experience: Where a concrete production facility has a record, based on at least 30 consecutive strength test results that represent similar materials and conditions to those expected, required average compressive strength used as the basis for selecting concrete proportions shall exceed required strength margin at designated test age by the standard deviation.

Strength test data for determining standard deviation shall be considered to comply if data represents either a group of at least 30 consecutive results or a statistical average for two groups totaling 30 or more results.

Strength test results used to establish standard deviation shall represent concrete produced to meet a specified strength within 5.0 MPa of that specified for the proposed class.

2 02 01 02 02 Proportioning on the Basis of Laboratory Trial Batches: When laboratory trial batches are used as the basis for selecting concrete proportions, strength tests shall be in accordance with ACI 318, DIN 1045 and DIN 1048 or an equivalent standard.

A curve shall be established showing the relationship between the cement content and the compressive strength. The curve shall be based on at least three points, each point being the average of at least three cylinders tested at 28 days, and representing batches, which produce strengths above and below the required average compressive strength. The required average compressive strength shall be 9.0 MPa greater than the design strength.

The minimum cement content for any concrete shall be that as shown by the curve to produce the average compressive strength required for that class, unless a higher cement content is required by a limit value.

Preliminary laboratory tests shall be carried out to determine the mixes characteristics satisfying the Specifications with the available materials. Trial mixes shall be tested to determine the following properties of mixes proposed for field trial tests:

1. Bleeding in accordance with ASTM C232

2. Air content in accordance with ASTM C173 or ASTM C231

Consistency by the slump test in accordance with ASTM C143-90a

3. Initial setting time of concrete in accordance with ASTM C403

4. Flexural strength of concrete in accordance of ASTM C293-79 or C78-84

5. Compressive strength in accordance with ASTM C39-86

6. Splitting tensile strength in accordance with ASTM C490-90

7. Time of setting of concrete mixtures by penetration resistance in accordance with ASTM C403-92

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

2 02 01 02 03 Reduction of Margin Based on Field Data. In case sufficient test data have been determined from the job, the margin (the amount by which the average strength must exceed the design strength) can be reduced provided that:

- the probable frequency of strength tests falling more than 3.5 MPa below the design strength will not exceed 1 in 100; and




- the probable frequency of the average of three consecutive strength tests falling below the design strength will not exceed 1 in 100; and

- the approval of the Engineer has been obtained for such reduction on the basis of Contractor’s tests reports.

2 02 01 02 04 Field Trial Mixes At least 35 days before the commencement of concreting, field trial mixes shall be prepared under full-scale site conditions and tested in accordance with ASTM.

These trial mixes of concrete shall preferably be mixed for the same time and handled by means of the same plant as the Contractor proposes to use in the Works. If the trial mixes have been accepted prior to setting up the batching plant, these trial mixes shall be repeated before concreting commences.

Acceptable values for the limits of these properties shall be established during the trials. These values shall henceforth be used to monitor the quality control of the mixes and set the standards of compliance.

All reinforced concrete classes shall have minimum flexural beam strength of 4.0 N/mm2 at 28 days.

2 02 01 02 05 Practical Tests on Trial Moulds Unless otherwise accepted by the Engineer, the Contractor shall carry out practical tests on Site by filling trial moulds with trial concrete mix to confirm the suitability of each class of concrete for the Works. Trial moulds shall be made for reinforced and plain concrete with typical dimensions of the Works. The formwork face of the trial mould, for each class of concrete, shall be designed to display all the relevant surface finishes intended for use in the Works. In making, transporting, placing, compacting and curing the trial mix concrete in the trial moulds, the Contractor shall observe all the relevant requirements of the Specifications.

When curing is completed, the trial moulds shall be stripped and the concrete thus revealed shall be submitted for acceptance by the Engineer.

Where re-design of any concrete mix becomes necessary, the making and testing of the Trial mix shall be repeated until the Trial Mix satisfies the above requirements. The final acceptance of any Trial Mix of any class of concrete will not be given if the Trial Mix does not comply fully with the specified requirements appropriate to that class of concrete or if it does not satisfy the specified requirements relating to salt content.

Further tests shall be carried out if any feature of materials or mixes is changed during the course of the work.

2 02 02 Concrete Strength Classes Concrete strength classes shall comply with ENV 206, DIN 1045 or an equivalent standard.

Concrete shall be graded as indicated according to the strength classes shown in Table 8 (see Part 6, Annex) on the basis of its compressive strength as determined by testing of cubes of 200 mm nominal size at an age of 28 days unless otherwise indicated or approved by the Engineer.

Concrete shall comply with

- C I concrete construction sites (see Clause 5.2.1 of DIN 1045) or/and

- C II concrete construction sites (see Clause 5.2.2 of DIN 1045)

unless otherwise indicated.

The relation in percent between 7-days strength and 28-days strength shall be determined by using the results of test specimen prepared for suitability tests.




Water resistant concrete shall have a nominal compressive strength of at least 35 N/mm2 unless otherwise indicated.

2 02 03 Consistence of Fresh Concrete Consistence ranges of fresh concrete are shown in Table 9 (see Part 6: Annex).

2 02 03 01 Cement Content The minimum cement content per cubic meter fresh concrete shall be as specified in Table 8 (see Part 6: Annex) for each class of concrete unless otherwise indicated.

The required cement content shall be determined on the basis of a suitability test and subject to the approval of the Engineer.

2 02 03 02 Ultrafine and Ultrafine/Fines Content Concrete shall contain a certain quantity of ultrafine particles to be properly workable and to achieve a closed texture.

Maximum ultrafine or ultrafine/fines content shall be as specified in Table 10 (see Part 6, Annex) unless otherwise indicated.

2 02 03 03 Workability 2 02 03 03 01 Slump

The slump as specified in Table 8 (see Part 6: Annex) shall be maintained for concrete at the point of delivery unless otherwise indicated.

The slump shall be within the following limits: - Concrete designed for a 50 mm slump + 25 mm - Concrete designed for a 100 mm slump + 35 mm

Concrete of an individual batch with a slump lower than the average slump of the recent 10 batches tested, is subject to the approval of the Engineer.

Contractor is to assess slump at job-site for acceptable workability.

Where the slump is deemed inappropriate for acceptable workability the Contractor's Quality Control Supervisor may authorize adding additional water to the mix to obtain acceptable workability, but within the limitations of the concrete durability as required by this specification.

2 02 03 03 02 Flow-table The use of a flow-table and the flow-table spread (e. g. in accordance with DIN 1048, Part 1) shall be as indicated for concrete with special properties and subject to the approval of the Engineer.

2 02 03 04 Water/Cement Ratio 2 02 03 04 01 General

The w/c-ratio established by suitability tests and approved with the mix design shall not be exceeded.

To add any additional water during mixing , transportation and placing is not allowed, unless under the supervision of Contractor’s Q. C. Supervisor and in quantities which will not exceed the allowable w/c-ratio and which will not effect the design strength of the concrete.

2 02 03 04 02 Maximum W/C-Ratio For reinforced concrete the w/c ratio should not exceed 0.65.




2 02 03 04 03 Water Resistant Concrete Water resistant concrete shall have a w/c ratio not exceeding 0.55 if exposure will be to fresh water or 0.50 for exposure to seawater unless otherwise indicated.

2 02 03 04 04 Architectural Concrete Architectural concrete for exterior exposure shall be air-entrained with a w/c - ratio not exceeding 0.55 by weight unless otherwise indicated.

2 02 04 Type of Concrete 2 02 04 01 Structural Concrete

Normal weight plain, reinforced or prestressed concrete shall comply with ACI 318, ENV 206, DIN 1045 or an equivalent standard.

Structural lightweight or insulating concrete shall comply with ACI 211.2 or an equivalent standard.

High density, heavyweight or mass concrete shall comply with ACI 211.1, ACI 304.3 or an equivalent standard.

Concrete may be site-mixed or ready-mixed.

Ready-mixed concrete shall comply with ASTM C 94, ACI 318, ACI 304, DIN 1084 or an equivalent standard and all other requirements set forth in this specification.

2 02 04 02 Architectural Concrete Designated colors and uniformity of colour shall be maintained.

For concrete of a desired colour, the same mixture proportions shall be used throughout. Changes in the quantity of Portland cement per cubic meter shall be particularly avoided .

Only one type and one brand of cement from the same mill, only one source and one maximum size of coarse aggregate, only one source of fine aggregate, and only one placing consistency shall be used.

2 02 05 Sampling and Testing Sampling and testing shall comply with DIN 1045, DIN 1084, BS 1881 or an equivalent standard.

Concrete strength quality control charts shall be maintained in accordance with the requirements of ACI 214 for standard deviation and coefficient of variation unless otherwise indicated.

The test frequency of compressive strength of concrete production shall be for

- Grade C I construction sites: per maximum of 500 m3 for every type of concrete, per storey, but at least every week.

- Grade C II construction sites: per maximum of 500 m3 for every type of concrete, per storey, but at least every week, every day for concrete grades higher than C25.

2 02 06 Plant and Site Mixture Trial Runs Prior to the delivery of any concrete for permanent works to the job-site, the Contractor shall demonstrate the suitability of the supplier and of the mix designs by plant trial mixes. The Contractor shall obtain appropriate notice from the supplier so that he may be present to witness the trial runs.

Trial batches of concrete shall be produced for all the classes of concrete proposed, and shall be designed in accordance with Clause 2 02 01 above. Trial




mixtures shall be designed for maximum permitted slump, air content and ambient temperature range of use.

A minimum of six (6) test cylinders shall be made and cured as indicated for each w/c-ratio, using mix materials all of which shall be in the same temperature range of the materials which will be used in the concrete to be delivered to the job-site. Ambient temperatures and the temperatures of each trial batch shall be recorded and made part of the test report.

Design mix shall be reworked and new test cylinders shall be prepared as described in preceding Clause when average ambient temperatures differ in excess of 15 deg C.

The report shall be submitted to the Engineer for approval based on the Contractor's recommendation (see item 9 in Table 1, Part 6: Annex).

2 02 07 Weather Conditions 2 02 07 01 Cold Weather

No concrete shall be mixed or placed in position when the ambient temperature is below 4 deg C unless otherwise indicated.

2 02 07 02 Hot Weather The Contractor shall comply with ACI 305 unless otherwise indicated.

The fresh concrete temperature shall not exceed 38 deg C at time of pouring.

If the temperature of the concrete exceeds 38 deg C, precautionary measures concerning mixing, transport, placing, consolidation and finishing of concrete shall be put into effect approved by the Engineer.

Concrete shall not be placed when environmental conditions indicate a rate of evaporation of surface moisture from concrete in excess of 1.0 kg per m2 per hour unless otherwise indicated.

For testing evaporation see 3 04 Field Q. C.

2 02 07 03 Wet Weather Unless adequate protection is provided and approval is obtained, concrete shall not be placed during rain. Rainwater shall not be allowed to increase the mixing water nor to damage the surface finish.

2 02 08 Batching and Mixing Concrete shall be batched and mixed at a central batching and mixing plant and/or batched at a central batching plant and mixed in a truck mixer subject to approval of the Engineer.

2 02 08 01 Batching: Batching of cement in any plant shall be by weight

Batching of aggregates shall be by weight in any plant whose noted capacity is less than 100 m3 / hr, but may be by volume in any plant of rated capacity greater than 100 m3 / hr.

Batching of water and of admixtures may be by weight or volume.

Scales for weighing concrete ingredients shall be accurate within plus/minus 0.5 % of their total capacities. Standard test weights shall be available to permit checking scale accuracy.

Operation of equipment shall be such that the concrete ingredients are consistently batched within the following tolerances:




- Cement +/- 3% - Water +/- 3% - Aggregates +/- 3% - Admixtures +/- 5%

Batching accuracy test records shall be obtained from the batching plant by the Contractor monthly, comprising an account of weekly calibration tests and a record of adjustments made and also accompanied by a statement as to the accuracy of all measuring devices. This record shall be maintained at all times by the Contractor, and shall be available for inspection by the Engineer at any time.

2 02 08 02 Mixing 2 02 08 02 01 Central Mixing Plant

Measuring tolerances shall comply with DIN 1045, Part 9.2 and mixing capability and time shall be in accordance with DIN 1084, Parts 1 to 3, or equivalent standards.

The fine and coarse aggregates and the cement shall be mixed for not less than four turns of the drum or paddle before the water is added. Water is to be added gradually while the drum or paddle remains in motion, and the concrete shall be mixed until a uniform consistency and colors have been obtained.

The quantity of water added to each batch shall be the net water, excluding moisture content of aggregate and free water if any, but including water that will be absorbed by the aggregate, dependent on absorption and moisture content values determined daily and before any mixing takes place.

The water shall be added to the batch of concrete by means of a measuring device with an automatic cut off of entry water whilst emptying into the mixer. All valves, etc. shall be regularly maintained to ensure there is no leakage of water into the mixing drum. The gauging receptacle shall be kept clean and must be completely emptied after each batch.

The retempering of concrete which has partially hardened, by addition of cement aggregate or water will not be allowed. Concrete which has been overmixed to the extent that addition of water is necessary to preserve the required consistency during discharge shall not be used.

The maximum size of the batch or mix shall not exceed the maximum rated capacity of the mixer as stated by the manufacturer and stamped on the drum.

2 03 Accessories All concrete accessories shall not impair the strength of the structure and shall be located as indicated in the drawings or elsewhere.

2 03 01 Expansion Joint Filler Pre-moulded expansion joint fillers shall be as indicated on the drawings or elsewhere and shall conform to one of the following types.

2 03 01 01 Bituminous Type ASTM D 994: "Preformed expansion joint filler for concrete" or equivalent.

2 03 01 02 Non-extruding and Resilient Bituminous Types ASTM D 1751: "Preformed expansion joint filler for concrete paving and structural construction " or equivalent.

2 03 01 03 Sponge Rubber and Cork ASTM D 1752: "Preformed sponge rubber and cork expansion joint fillers for concrete paving and structural construction" or equivalent.




2 03 01 04 Premoulded Cell Material See: 04200 Masonry

2 03 01 05 Extruded Polystyrene Boards ASTM D 1056, ASTM D1667 or equivalent

2 03 02 Sealant All sealing materials shall be as indicated and approved by the Engineer before use.

Sealant shall comply with one of the following or equivalent standards:

ASTM D 1190: Concrete joint sealer (hot-poured elastic type) or equivalent, see Section 07900 Joint Sealers.

2 03 03 Waterstops Material for waterstops shall extend each side into the concrete a minimum of 100 mm and shall be as indicated:

2 03 03 01 Copper Corrugated copper jointing strips shall comply with ASTM B 370 or equivalent.

2 03 03 02 Stainless Steel Stainless steel waterstops shall conform to ASTM A 167 or equivalent.

Unless otherwise indicated, they shall be of type 304, finish 2 D, annealed and with a nominal thickness of 1.0 mm.

2 03 03 03 Non-metallic Waterstops Non-metallic waterstops shall be flexible extruded polyvinyl chloride multi-rib proprietary type. Minimum thickness 6 mm.

2 03 04 Thermal Insulation Materials Thermal insulation shall be as indicated in Section 07200.

2 03 05 Anchorage Items Slots and inserts for anchoring masonry and mechanical items to concrete shall be as indicated and approved by the Engineer.

See Section 03200 Concrete Reinforcement.

2 03 05 01 Slots Slots shall be dovetail-type, of not lighter than 0.65 mm zinc-coated steel, with filler that prevents concrete or water from entering and that can be easily removed or punctured for installing anchors unless otherwise indicated.

2 03 06 Vapour Barriers See Sections 07100 and 07150.

Part 3: Execution 3 01 General Examination

The Contractor shall consider the weather conditions before starting concrete production for permanent works and shall make sure that any precautions have been taken to comply with the specified concrete quality.

When materials and components are distributed to the work position ensure the:




- Correct design dimensions of the components.

- Safe construction and three-dimensional bracing of formwork, falsework and scaffolding, ensuring that they are not overloaded, e.g. during transport of concrete, or as a result of materials stacked on them.

3 02 General Preparation 3 02 01 Equipment for Placing and Working Concrete

For transporting, placing and curing site-mixed concrete and ready-mixed concrete, the plant and equipment for proper placing and for obtaining uniform concrete strength shall be available on site and regularly serviced.

3 03 Installation 3 03 01 Cast-In-Place Concrete

Before casting formwork shall be completed and all water shall be removed. Reinforcement shall be secured in place; expansion joint material, anchors and other embedded items shall be positioned and the entire preparation shall be accepted by the engineer.

Hardened concrete and foreign materials shall be removed from the inner surfaces of the conveying equipment.

Semi-porous subgrade shall be sprinkled sufficiently to eliminate suction and porous subgrades shall be sealed in an approved manner.

Where concrete is to be deposited on rock, all loose material must be removed, and cut faces shall be nearly vertical or horizontal.

3 03 01 01 Batching and Mixing see Part 2: Products.

3 03 01 02 Transportation Truck mixers shall be of the revolving drum type, watertight and generally in accordance with ASTM C 94, DIN 1045, Part 9 or an equivalent standard.

Truck mixing shall be continued for not less than 50 revolutions, after all ingredients including water are in the drum. The speed shall be not less than 4 revolutions per minute and not more than a speed resulting in a peripheral velocity of 70 meters per minute.

Temperature of concrete leaving the mixing plant shall be such that at the time of placement the maximum temperature does not exceed that specified for its placement.

Concrete shall be so transported, discharged and placed that contamination, segregation or loss of the consistent materials does not occur.

Concrete shall be transported with agitators operating continuously in truck mixers.

Concrete shall be compacted in its final position within ninety (90) minutes from the time of adding of the cement into the aggregates, unless otherwise indicated.

Upon arrival at the place of deposition the concrete truck driver must present to the Contractor a delivery ticket from the concrete supplier subject to the acceptance of the Contractor of that concrete, stating the information as described in Part 1. The Contractor shall collect and file all Batch Tickets for inspection by the Engineer at any time.




3 03 01 03 Placement Deposition, distribution and consolidation shall comply with ACI 309, ACI 318, BS 8110, DIN 1045 or an equivalent standard.

3 03 01 03 01 Deposition and Distribution Concrete shall be deposited continuously as near as possible to its final position. In slab construction, placing shall be started along the perimeter at one end of the work with each batch discharged against previously placed concrete.

In walls, beams, and girders, the first batches in each lift shall be placed at each end of the section, with subsequent placement progressing toward the center. In all cases, water shall be prevented from collecting at the ends, in corners, and along faces of forms.

Placing of concrete in supported elements shall not be started until the concrete previously placed in columns and walls is no longer plastic and has been in place at least two hours.

It shall be ensured that there is an effective bond between concrete layers placed at the individual job sections. The surface of construction joints shall be prepared in accordance with Clause 3 03 02: Joints.

When concrete deposited in layers, thickness of layers shall be such that no concrete will be deposited on concrete which was hardened sufficiently to prevent the formation of seams or planes of weakness within the section.

Concrete shall not be dumped in separate piles and then leveled and worked together; nor shall the concrete be deposited in large piles and then moved horizontally into final position.

If a section cannot be placed continuously, construction joints shall be located as shown in the drawings or as approved.

Placing shall be carried on at such a rate that the concrete, which is being integrated, with fresh concrete is still plastic. Concrete, which has partially hardened or has been contaminated by foreign materials shall not be deposited.

Temporary spreaders in forms shall be removed when concrete placing has reached an elevation rendering their service unnecessary.

They may remain embedded in the concrete only if made of plastic or concrete and if prior approval has been obtained.

The equipment shall be cleaned at the end of each operation or workday.

3 03 01 03 02 Consolidation All concrete shall be consolidated by vibration so that the concrete is thoroughly worked around the reinforcement, around embedded items, and into corners of forms; eliminating all air or stone pockets which may cause honeycombing, pitting, or planes of weakness. Internal vibrators shall have a minimum frequency of 8000 vibrations per minute and sufficient amplitude to consolidate the concrete effectively. They shall be operated by competent workmen. Use of vibrators to transport concrete within forms shall not be allowed. Vibrators shall be inserted and withdrawn at points approximately 450 mm apart. At each insertion, the duration shall be sufficient to consolidate the concrete but not sufficient to cause segregation, generally from 5 to 15 seconds. One spare vibrator for each three vibrators in use shall be kept on Site during all concrete placing operations unless otherwise approved.

Due regard shall be made of the size of any one pour of concrete to avoid the generation of heat in any one mass of concrete.




3 03 01 04 Curing 3 03 01 04 01 General

Curing shall comply with ACI 308 or an equivalent standard.

Beginning immediately after placement, concrete shall be protected from premature drying, excessively hot temperatures, and mechanical injury and shall be maintained with minimal moisture loss at a relatively constant temperature for the period necessary for hydration of the cement and hardening of the concrete. The materials and methods of curing shall be subject to the approval of the Engineer.

Moisture loss from surfaces placed against wooden forms or forms exposed to heating by the sun shall be minimized by keeping the forms wet until they can be safely removed. After form removal, the concrete shall be cured until the end of the time and methods indicated.

During the curing period, the concrete shall be protected from damage and mechanical disturbances, such as load stresses, heavy shock, and excessive vibration.

3 03 01 04 02 Curing Water Water used for curing shall meet the requirements of the mixing water.

3 03 01 04 03 Preservation of Moisture For concrete surfaces not in contact with forms, one of the following procedures shall be applied immediately after completion of placement and finishing:

(a) Ponding or continuous sprinkling

(b) Application of absorptive mats or fabric kept continuously wet.

(c) Continuous application of mist spray.

(d) Application of waterproof sheet materials.

(e) Application of a curing compound: The compound shall be applied in accordance with the recommendations of the manufacturer immediately after any water sheen which may develop after finishing has disappeared from the concrete surface. It shall not be used on any surface against which additional concrete or other material is to be bonded unless it is proven that the curing compound will not prevent bond, or unless positive measures are taken to remove it completely from the areas to receive bond applications.

3 03 01 04 04 Curing Time Curing shall be continued for at least 14 days unless otherwise approved.

Alternatively, if tests are made of specimen kept adjacent to the structure and cured by the same methods, moisture retention measures may be terminated when the average compressive strength has reached 70 % of the specified compressive strength of concrete (f ’c).

3 03 01 04 05 Materials for Curing Concrete a) Impervious Sheeting: ASTM C 171; waterproof paper, clear or white polyethylene sheeting, or polyethylene-coated burlap.

b) Liquid Membrane-Forming Compound. ASTM C 309, white-pigmented, Type 2, Class B.

c) Others acceptable by the Engineer.

compressive strength of concrete (f ’c).




3 03 01 04 06 Waterstops Waterstops shall conform to COE CRD-C 513 or COE CRD-C 572. PVC center bulb water-stops of minimum 250-mm width and 10 mm thickness shall be used.

3 03 01 05 Finishing of Formed Surfaces 3 03 01 05 01 As-Cast Finishes

As-cast finishes shall be as indicated:

01.0 Type 1 Finish: Rough form finish for concrete surfaces not exposed to public view, or requiring a waterproof coating. Tie holes and defects shall be patched. Fins exceeding 5 mm in height shall be chipped off or rubbed off. Surfaces shall be left with the texture imparted by the forms.

02.0 Type 2 Finish: The form facing material for concrete surfaces exposed to public view shall produce a smooth hard, uniform texture on the concrete. It may be plywood, tempered concrete-formgrade hardboard, sheet metal, or other approved material capable of producing the desired finish. The arrangement of the facing material shall be orderly and symmetrical with the number of seams kept to the practical minimum. It shall be supported by studs or other backing capable of preventing excessive deflection. Material with raised grain, torn surfaces, worn edges, patches, dents, or other defects, which will impair the texture of the concrete surface, shall not be used. Tie holes and defects shall be patched. All fins shall be completely removed.

3 03 01 05 02 Related Unformed Surfaces Tops of walls or buttresses, horizontal offsets and similar unformed surfaces occurring adjacent to formed surfaces shall be smoothened after concrete is placed and shall be floated to a texture reasonably consistent with that of the formed surfaces unless otherwise indicated. Final treatment on formed surfaces shall continue uniformly across the unformed surfaces.

3 03 01 05 03 Architectural Finishes Architectural Finishes shall be as indicated:

01.0 Applied Finish Finishes of plaster, stucco or similar trowelled materials shall be prepared to insure permanent adhesion of the finish. If the concrete is less than about 24 h old, it can be roughened with a heavy wire brush or scoring tool. If the concrete is older the surface may be roughened mechanically. After roughening, the surface shall be washed free of all dust, chemical retarder, and other foreign material before the final finish is applied.

02.0 Paint Finish: Finishes of paint or similar materials shall be Type 2 Finish unless otherwise indicated.

03.0 Textured Finishes: Textured form liners may be of formed plastic sheet, wood, sheet metal, or other material.

04.0 Aggregate Transfer Finishes

05.0 Exposed Aggregate Finishes: Aggregate shall be exposed by a method approved by the Engineer such as sandblasting, bush hammering or the use of a surface retarder.




06.0 Scrubbed Finish: Scrubbed finish shall be produced on partially hardened concrete. The surface shall be thoroughly wetted and scrubbed with stiff fibre or wire brushes, using water freely, until the surface mortar is removed and the aggregate is uniformly exposed. The surface shall then be rinsed with clean water.

07.0 Sand Blast Finish: The concrete surface shall be blasted with an abrasive (sand or grits) until the aggregate is in uniform relief.

08.0 Tooled Finish: The thoroughly cured concrete surface shall be dressed with electric, air, or hand tools to a uniform texture, and shall be given a hand tooled, rough or fin pointed, or bush hammered surface texture.

3 03 01 06 Finishing to Surfaces of Concrete Slabs 3 03 01 06 01 Scratched Finish

After the concrete has been placed, consolidated, struck off, and leveled to a Class C tolerance the surface shall be roughened with stiff brushes or rakes before the final set.

3 03 01 06 02 Floated Finish After the concrete has been placed, consolidated, struck off and leveled, the concrete shall not be worked further until ready for floating,

Floating shall begin when the water sheen has disappeared and when the surface has stiffened sufficiently to permit the operation. During or after the first floating, plainness of surface shall be checked with a 3 meter straightedge applied at not less than two different angles. All high spots shall cut down and all low spots filled during this procedure to produce a surface within Class B tolerance throughout. The slab shall then be re-floated immediately to a uniform sandy texture.

3 03 01 06 03 Trowelled Finish The surface shall receive a float finish. It shall next be power trowel led, and finally hand trowel led. The first trowel ling after power floating shall produce a smooth surface which is relatively free of defects but which may still show some trowel marks. Additional toweling shall be done by hand after the surface has hardened sufficiently. The final toweling shall be done when a ‘ringing sound’ is produced as the trowel is moved over the surface. The surface shall be thoroughly consolidated by the hand toweling operations. The finished surface shall be essentially free of trowel marks, uniform in texture and appearance and shall be plane to a Class A Tolerance.

3 03 01 06 04 Broom or Belt Finish Immediately after the concrete has received a floated finish as indicated, it shall be given a coarse transverse scored texture by drawing a broom or a burlap belt across the surface.

3 03 01 08 Tolerances 3 03 01 08 01 General

Pouring layers shall be 150 to 500 mm thick for reinforced members, 400 to 500 mm thick for mass work, the thickness depending on the width between forms and the amount of reinforcement.

The height of free fall of concrete shall be limited to 1.0 m maximum to prevent separation.




3 03 01 08 02 Concrete Cover see: Section 03200 Concrete Reinforcement.

3 03 01 08 03 Finishes: Finishes with Class A tolerances shall be true planes within 4 mm in 3 m, as determined by a 3 m straightedge placed anywhere on the slab in any direction.

Finishes with Class B tolerances shall be true planes within 6 mm in 3 m, as determined by a 3 m straightedge placed anywhere on the slab in any direction.

Finishes with Class C tolerances shall be true planes within 6 mm in 500 mm, as determined by a 500 mm straightedge placed anywhere on the slab in any direction.

3 03 01 08 02 Patching The total patched area shall not exceed 0.2 m2 in each 100 m2 of as-cast surface. This is in addition to form tie patches unless otherwise indicated.

3 03 01 09 Architectural Concrete 3 03 01 09 01 General

In addition to the requirements as specified for structural concrete the following conditions shall apply for Architectural Concrete:

3 03 01 09 02 Placing, Consolidation and Finishing Smooth rubbed or similar finish shall have a full surface of mortar, avoiding the production of surface voids.

Vibrators shall not be allowed to contact the formwork for exposed concrete surfaces.

Architectural Finishes: see Clause 3 03 01 05 03.

3 03 01 09 03 Patching Patching shall comply with Clause 3 05: Adjusting and Cleaning.

In addition, any patches in as-cast architectural concrete shall closely match the colour and texture of the surrounding surface. The mix formula for patching mortar shall be determined by trial to obtain a colour match with the concrete when both patch and concrete are cured and dry. After initial set, surfaces of patches shall be dressed manually to obtain the same texture as surrounding surfaces.

In any finishing process, which is intended to expose aggregate in the surface, patched areas shall show aggregate faces. The outer 25 mm of patch shall contain the same aggregates as the surrounding concrete. In the case of aggregate transfer finish, the patching mixture shall contain the same selected colored aggregates. After patches have been allowed to cure thoroughly, the aggregates shall be exposed together with the aggregates of adjoining surfaces by the same process of mortar removal.

Patches shall be protected from premature drying to the same extent as the body of the concrete.

3 03 01 10 Water Resistant Concrete Water resistant concrete for members 10 to 40 cm thick shall be graded so dense that, when tested in accordance with DIN 1048 Part 1, water does not penetrate to a depth of more than 50 mm (average value from three specimens).

Water resistant concrete shall be of strength class not below C35 unless otherwise indicated.




For w/c-ratio see Clause 2 02 03 04.

3 03 02 Concrete Joints 3 03 02 01 Construction Joints 3 03 02 01 01 General

Construction joints not shown in the drawings shall be made and located as least not to impair the strength of the structure and shall be approved by the Engineer.

In general, they shall be located near the middle of the spans of slabs, beams and girders unless a beam intersects a girder at this point, in which case the joint in the girder shall be offset a distance equal to twice the width of the beam. Construction joints in walls and columns shall be at the underside of floors, slabs, beams, or girders and at the tops of footings or floor slabs.

Beams, girders, brackets, column capitals, haunches, and drop panels shall be placed at the same time as slabs.

Construction joints shall be at right-angles to the general direction of the member and perpendicular to the main reinforcement.

Concrete shall not be allowed to run to a feather edge and vertical joints shall be formed against a stop board. The top surface of a layer of concrete shall be level and reasonably flat unless otherwise indicated.

Concreting shall be carried out continuously up to construction joints.

All reinforcement shall be continued across construction joints unless otherwise indicated. Keys and dowels shall be provided as directed by the Engineer.

The surface of the concrete at all joints shall be thoroughly cleaned and all latencies removed prior to placing adjoining concrete.

3 03 02 01 02 Bonding Bonding shall be obtained by the following methods unless otherwise indicated or approved:

The hardened concrete of construction joints and of joints between footings and walls or columns, between walls or columns and beams or floors they support, joints in unexposed walls and all others not mentioned below shall be dampened (but not saturated) immediately prior to placing of fresh concrete.

Joints receiving an approved adhesive shall have been prepared and adhesive applied in accordance with the manufacturer's recommendations prior to placing of fresh concrete.

Surfaces of joints, which have been treated with an approved chemical retarder, shall have been prepared in accordance with the manufacturer’s recommendations prior to placing of fresh concrete. Retarded mortar shall be removed within 12 hours after placing to produce a clean exposed aggregate bonding surface.

Roughening the surface of the concrete shall be undertaken in an approved manner, which will expose the aggregate uniformly and will not leave latencies, loosened particles of aggregate or damaged concrete at the surface.

see Section 07900.

3 03 02 02 Expansion Joints Expansion joints shall be placed and filled or sealed as indicated and approved.

Expansion joints shall extend through the entire structure, including the cladding and the roof.




Reinforcement or other embedded metal items bonded to the concrete (except dowels in floors bonded on only one side of joints) shall not be permitted to extend continuously through any expansion joint.

Edges of exposed expansion joints shall be neatly finished with a slightly rounded edging tool.

The surface of the concrete shall be thoroughly cleaned and all latencies removed , grooves left for sealant shall be thoroughly cleaned out prior to injection of sealant.

see Section 07900 Joint Sealers.

3 03 02 03 Contraction Joints Contraction joints shall be made at locations as indicated on the drawings and approved.

Contraction joints in slabs on grade shall be located and detailed as indicated. Where saw-cut joints are required, cutting shall be timed properly with the set of the concrete: cutting shall be started as soon as the concrete has hardened sufficiently to prevent aggregates being dislodged by the saw, and shall be completed before shrinkage stresses became sufficient to produce cracking.

3 03 03 Concrete Accessories Expansion joint material, waterstops, and all other embedded items shall be positioned accurately and supported against displacement. Voids in sleeves, inserts, anchor slots and the like, shall be filled temporarily with readily removable material to prevent the entry of concrete into the voids.

3 03 03 01 Waterstops Location of waterstops in expansion joints shall be as indicated on the drawings.

Each piece of premoulded waterstop shall be of maximum practicable length in order to held the number of end joints to a minimum.

Spliced joints at intersections and at ends of pieces shall be made in the manner most appropriate to the material being used.

Spliced joints shall develop effective watertightness fully equal to that of the continuous waterstop material, shall permanently develop not less than 50 % of the mechanical strength of the parent section, and shall permanently retain their flexibility.

Waterstops shall be installed so as to form a continuous watertight diaphragm. Adequate provision shall be made to support and completely protect the waterstops during the progress of the work. Spliced joints shall be made as follows:

Metal: Copper shall be soldered or brazed. When stainless steel is used, splices shall be lapped and welding and brazing shall be in compliance with the manufacturer's recommendations.

Rubber or Neoprene: Rubber or neoprene waterstops shall be vulcanized.

Polyvinyl Chloride: With the adjacent surfaces heat-sealed in accordance with the manufacturer's recommendations. The temperature shall be sufficient to fuse but not char the plastic.




3 03 03 02 Vapour Barrier 3 03 03 02 01 Slabs on Grade

Immediately prior to placing concrete, subgrade under slabs shall be covered with a vapour barrier unless otherwise indicated.

Punctures and tears shall be patched. Edges shall be lapped not less than 100 mm and end joints shall be lapped not less than 150 mm.

Edges and lapped joints shall be sealed with a pressure-sensitive tape, not less than 40 mm wide, compatible with the membrane.

3 03 03 03 Embedded Items Set and build into the work anchorage devices and other embedded items as indicated and required for other work that is attached to or supported by cast-in-place concrete in accordance with setting drawings, diagrams, instructions and directions.

3 03 03 03 01 Conduits and Pipes: Follow conditions indicated to control placing of conduits and pipes, unless otherwise approved by the Engineer.

Locate conduits and pipes so as not to reduce strength of structure.

(a) Pipes: Do not embed pipes in structural concrete, unless so detailed on drawings. Provide sleeves in concrete for passage of pipes and locate so as to maintain maximum strength of structure.

(b) Conduit: Electrical conduits may be embedded in concrete provided the following conditions are met:

- Outside diameter of conduit shall not exceed 1/3 of concrete thickness.

- Do not place conduits closer than three diameters on center.

- Do not embed conduits in structural concrete slabs less than 100 mm thick.

- Provide 40 mm minimum concrete cover for conduits in structural concrete slabs. Run conduit at the neutral axis in slabs.

- Do not place conduits between bottom of reinforcing steel and bottom of structural concrete slab.

- Conduits are not permitted in beams and girders unless shown on drawings.

a) The Contractor shall establish locations and dimensions of all holes and chases required for services and submit details to the Engineer for checking before proceeding with the Work.

b) Holes and chases in in-situ concrete shall be cast in. The Contractor shall not cut hardened concrete or drill holes larger than 10mm diameter without permission.

c) Holes, recesses and chases are in locations which least affect the strength, stability and sound resistance of the construction, and are of the smallest practicable size.

d) Holes must not exceed 300mm square otherwise the structural element must be redesigned.

e) No chases are cut in walls of hollow cellular blocks without approval.

f) In walls of other materials:




• Vertical chases must not be deeper than one third of the single leaf thickness.

• Horizontal or raking chases must not be longer than 1m and not deeper than one sixth of the single leaf thickness.

g) No chases or recesses are set back; offset by a clear distance not less than the wall thickness. Where sockets, etc. are shown on drawings as nominally back-to-back, obtain instructions.

h) No cutting is done until the mortar is fully set. Cut carefully and nearly, avoiding spilling, cracking or other damage to surrounding structure. Do not chases with mechanical or hand impact tools.

Bridging

The Contractor shall submit proposals for bridging over holes for ducts, pipes, etc. which exceed 300mm in width.

Installing Pipe Sleeves

Sleeves shall extend through the full thickness of wall/floor and shall be accurately positioned to give a minimum clearance around service of 20mm or diameter of service, whichever is the least.

Sleeves, whether built in or installed in preformed holes shall be bedded solid.

Seal annular space between service and sleeve.

Where exposed to view, finish bedding and sealing neatly to approval.

Sealing Around Services

Seal around services pipes where they pass through walls with an approved material. Completely fill the space, leaving no gaps and finish neatly.

3 03 03 03 02 Displacement of Reinforcement No reinforcement for slabs or beams shall be bent or displaced to permit passage of conduit pipes, or the like without the written approval of the Engineer.

3 03 03 03 03 Securing Embedded Items Provide necessary ties, nailing blocks, bolts inserts, and other items required to properly position and secure embedded items. Keep voids in embedded items, which are not intended to be filled with concrete, free of concrete by means of easily removable material.

3 03 04 Concrete Restoration and Cleaning The recommendations of ACI 224.1R-93 and ACI 224.2R-92 shall be complied with.

For adjusting, repair and cleaning of fresh cast concrete see: Clause 3 05!

3 04 Field Quality Control 3 04 01 Inspection

Contractor shall notify the Engineer in writing of any defects or conditions that will prevent satisfactory concrete works.

3 04 02 Notice of Commencement of Construction Work Unless otherwise instructed, the Contractor shall give notice of the following to the Engineer 24 hours before:

- start of concrete works.




- in the event of interruption (e.g. due to hot weather) the resumption of concreting work;

- commencement of important welding operations on Site.

3 04 03 Concreting Permission The Contractor is not allowed to cast any concrete works, normal or reinforced, without written permission prepared and signed by the Engineer in accordance with his instructions.

3 04 04 Field Laboratory 3 04 04 01 General

Contractor’s field laboratory shall be equipped with all necessary machines, apparatus and staff unless otherwise indicated.

All field testing shall be done in the presence of the Engineer or his Representative in accordance with his instructions.

3 04 04 02 Temperature Control Contractor shall check temperatures and provide precautionary measures for hot or cold weather construction as required in Part 2: Products and Part 3: Execution.

Evaporation shall be determined from the chart "Rate of Evaporation" (see Fig 2; Part 6: Annex).

When the rate of evaporation is above the specified maximum limit, and/or any value exceeds the limitations of the chart, concrete operations shall stop at the nearest possible construction joint location and curing of the placed concrete shall be intensified.

3 04 04 02 01 Ambient Air Temperature and Relative Humidity Test The ambient air temperature and relative humidity shall be determined as specified in ASTM E 337. Tests shall be taken as close to the concrete work as practical and no further than 6 meters from the point of the latest concrete placing.

If the rate of evaporation is near to the above-mentioned limit, at least one ambient air temperature and relative humidity test shall be taken for each 50 cubic meters of concrete cast, or portion thereof, and the results of these tests shall be recorded.

Increased frequency of testing may be specified by the Engineer if required .

Decreased frequency of testing may be authorized if it is judged by the Engineer that the conditions have not changed significantly enough to alter results from previous tests.

3 04 04 02 02 Wind Velocity Tests The wind velocity shall be determined using a standard anemometer approved by the Engineer.

The wind velocity shall be determined as close to the concrete work as practical at a location representative of the average conditions at the site of the most recent concrete pour.

At least one wind velocity shall be determined and the results of this test shall be recorded.

Increased or decreased frequency of testing may be required by the Engineer in conjunction with changes in frequency of the ambient air temperature and relative humidity tests.




3 05 Adjusting And Cleaning 3 05 01 Repair of Concrete 3 05 01 01 General

After forms are removed, all bulges, fins, and small projections shall be removed by chipping or tooling. The surfaces shall then be rubbed or ground. Any cavities such as tie rod holes shall be filled unless they are to remain for decorative purposes. Honeycomb areas shall be repaired and stains removed to present a concrete surface that is uniform in colour.

3 05 01 02 Patching 3 05 01 02 01 General

Samples shall be applied and cured in an inconspicuous location, to determine the most suitable proportions of cement. Steel trowelling shall be avoided since this darkens the patch.

For patching of Architectural Concrete see Clause 3 03 01 11 03.

3 05 01 02 02 Holes and Other Cavities If directed by the Engineer, holes and other cavities that are small in area but relatively deep shall be filled with a dry-pack mortar. The mortar shall be mixed as stiff as practical using 1 part Portland cement, 2 1/2 parts sand passing 2 mm sieve, and just enough water to form a ball when the mortar is squeezed gently in the hand. After the cavity has been cleaned of oil and loose material and kept damp with water for several hours, the mortar shall be tamped into place in layers about 10 mm thick. Vigorous tamping and adequate curing will ensure good bond and minimum shrinkage of the patch.

3 05 01 02 03 Honeycombs Honeycombs and other defective concrete shall be cut out to expose sound material. No defective concrete shall be left adjacent to a patch to prevent moisture getting into the voids. The edges shall be cut or chipped straight and at right angles to the surface, or slightly undercut to provide a key at the edge of the patch. No feather edges shall be permitted.

3 05 01 02 04 Patching Procedure Before the patching concrete is applied, the surrounding concrete shall be kept wet for several hours. A grout (1 part Portland cement, 1 part fine sand passing a 0.60 mm sieve, and sufficient mixing water for a creamy consistency) shall be scrubbed with a brush into all surfaces to which the new material is to be bonded. The area shall be damp when the grout is applied but not wet with free moisture.

Shallow patches can be filled with stiff mortar similar to that used in the concrete. This shall be placed in layers not more than 10 mm thick, with each layer given a scratch finish to improve bond with the subsequent layer. The final layer can be finished to match the surrounding concrete by floating, rubbing, tooling, or on formed surfaces by pressing the form material against the patch while still plastic. Deep patches can be filled with concrete held in place by forms. Such patches shall be reinforced and doweled to the hardened concrete.

3 05 01 02 05 Curing Patches Curing shall be started as soon as possible to avoid early drying and shall be continued for 7 days.

3 05 02 Cleaning Concrete surfaces shall be uniform in colour when forms are removed.




All surfaces shall be cleaned from blotchy appearance and/or slight film of release agent, mortar stains or rust stains after construction has progressed to the stage where no discoloration will occur unless otherwise approved.

Concrete surfaces may be cleaned with water, chemical, and/or mechanical cleaners. as approved by the Engineer.

Before finally selecting a cleaning method, the one chosen shall be tried on a test area subject to the approval of the Engineer.

3 07 Protection Protect the top of newly built concrete work from wet, hot or cold weather, in particular from rain and from frost if imminent, and at all times when work is not proceeding.

Care shall be taken especially with architectural finishes.

Provide final protection and maintain conditions, in a manner acceptable to the Engineer, that ensures concrete works are without damage and deterioration at time of Substantial Completion.




Part 4: Method of Measurement 4 01 General Walls measured by area with a bevelled cross section at the top will be measured to the highest edge.

Suspended floors and ceilings will be measured to the outside edge of the floor. Inclined and arched ceilings will be measured as the development of the surface of the slab.

When measuring by volume, members which cross each other are calculated once only; main beams are always calculated straight through. In the case of crossing with columns, and connection to columns the latter are not included.

Where work is measured by volume, no deductions will be made for voids less than 0.25 m3.

Where work is measured by area, no deductions will be made for voids not exceeding 1 m2.

No deductions will be made from concrete for reinforcement or sections built in.

4 02 Units Of Measurement 4 02 01 Works Measured by Volume Cast-In-place concrete of the following categories will be measured by volume geometrically (m3):

- Foundations in trenches

- Isolated foundation bases

- Pile caps and ground beams

- Beds over 300 mm thick

- Suspended slabs which shall include floors, roofs, landings and the like over 300 mm thick.

- Upstands and kerbs

- Walls over 300 mm thick

- Columns

- Beams (measured below the slab)

- Steps and stair cases

Piles are measured by number or linear metre, rate includes concrete, reinforcement, and demolishing piles up to the required level

Columns height are measured from surface of reinforced foundation or slab up to bottom of beam or slab.

Beams are measured C.L. To C.L. and its depth from bottom of beam to bottom of slab.

Cantilevers are measured C.L. to end and its depth from bottom of beam to bottom of slab

4 02 02 Works Measured by Area Cast-in-place concrete of the following categories will be measured by area (m2) stating the thickness:

Blinding beds, suspended slabs which shall include floors, roofs and the like and landings not exceeding 300 mm thickness

Special surfaces finishes.

4 02 03 Sundries Sundries prices are included in the rates of concrete work and shall not be measured or taken into consideration unless it is clearly mentioned in the bill of quantities.

Expansion joint material or the like shall be measured by length (m) or area (m2).




Designated joints, waterstops or the like shall be measured by length (m).




Part 5: Basis Of Payment 5 01 General Payment will be in full compensation for the delivery, transport, placement and finishing of Cast-In-Place Concrete, including all labour, plant, equipment, tools, traffic control, certifying and testing, quality assurance, and all other operations to perform the work, including but not limited to the following ancillary works (ref. 5 02).

Material, which is unnecessarily wasted, disposed off site, or otherwise misused, shall be replaced at Contractor’s expense.

No payment will be made for quantities resulting from oversized or unauthorized work or any other unauthorized operation.

Material or work, which does not conform to specification requirements, shall be removed and replaced at Contractor’s expense.

5 02 Ancillary Works to be included in the Unit Rate The unit rate for concrete include for working at different levels, hoisting and covering, laying in bays, construction joints, cast in place and vibration, finishing surface of concrete, unless otherwise noted, protecting and curing by any material working concrete in and around reinforcement.

The unit rate for concrete include for all materials (fine and coarse aggregates, cement, steel reinforcement steel chairs, additives, water, formwork, all kinds of shuttering and scaffolding …etc.).

The unit rate for concrete include for mechanical mixing or ready-mix concrete.

The unit rate for concrete include for shuttering dismantling, and dismantling agents.

Concrete accessories (including waterstops and vapour barriers unless it is clearly mentioned in the Bills of Quantities), embedded items, mortises, plugs, grouting for general fixing of joinery and metal work shall be deemed to be included in the unit price rates.

Costs of all tests shall be included in the unit price rates.

External Q. C. by Third Party.

Certifications.




Annex: Tables and Figures 6 01 Tables 6 01 01 Summary of Contractor’s Reports and Submittals

Table 1: Summary of Contractor’s Reports and Submittals

(Continued)

No. TI TLE

REPORT SUBMITTED FREQUENCY OF REPORT

1 Sources of materials 31 days prior to delivery of concrete

On apparent chanqe

a) One time b) As required

2 Supplier Quality Inspection Plan

31 days prior to delivery of concrete

a) One time

3 Mix Design for all Classes of Concrete R e f e r e n c e (Table 6)


when mix is re-designed for any purpose


4 Name, Location, Equipment & Personnel of Test Laboratory to be used by Supplier (including own laboratory)


If changed


5 Program, Methods and Details of Batching plant & Equipment


a) One time

6 Proposed Methods of Complying with Hot Weather Mixing and Delivery


Each summer (March to October)

7 Certificate for Cement from Manufacturer


For each new delivery from manufacturer





Continued Table 1: Summary of Contractor’s Submittals

No. TI TLE

REPORT SUBMITTED FREQUENCY OF REPORT

8 Certificates for Admixtures from Manufacturer


If any change occurs

One time b) As required

9 Report on Plant Trial Mixes with 7 day & 28 day Test of Results for all Classes of concrete Required for the work

31 days prior to delivery of Concrete b) If changed

One time b) As required

10 Report of the following tests on Fine and Coarse Aggregate:

Los Angeles Abrasion at 100 & 500 Revolutions

Sieve Analysis 3) Clay, Silt F, Dust (passing 75 micron)

C I a y lumps & Friable Particles

Water Absorption. Percentage of sulphates

(SO3) Chlorides (NaCI)

31 days prior to delivery of concrete b) During production

of concrete

one time

Weekly (with independent check report monthly

11

Reports of the following tests on water for mixing concrete, washing and/or cooling aggregates and curing: 1) Sulphates (as SO3) 2) Chlorides (as Nac1)


During production of concrete

One time

Weekly (with independent check report monthly

12

Delivery ticket with delivery of each load of concrete

Each delivery

13

Reports and records on tests of accuracy and calibration for concrete plant equipment and measuring devices

as applicable

Monthly




6 01 02 Total allowable salts contents Table 2: Total allowable salts contents

6 01 03 Fine Aggregates - Allowance of deleterious substances Table 3: Fine Aggregates – Allowance of deleterious substances

6 01 04 Coarse Aggregates - Allowance of deleterious substances Table 4: Coarse Aggregates – Allowance of deleterious substances

6 01 05 Grading Limits of Combined Fine and Coarse Aggregate Mix for Concrete Table 5: Grading limits of combined fine and coarse aggregate mix for concrete

MAXIMUM ALLOWANCE PERCENT BY WEIGHT SALT In Fine

Aggregate by weight of fine

aggregate

In Coarse Aggregate by

weight of coarse aggregate

Total by weight of cement

Chlorides (NaCI)**

0.06

0.10

0.50*

Sulphates (SO3)

0.40

0.50

4.00*

* Includes salts in cement and water ** equivalent determined by chloride ion x 1.6

Item Maximum Allowable Percentage by weight

Clay lumps and friable particles 1.0 Material finer than 75 micron 2.0

Item Maximum Allowable Percentage by weight

Clay lumps and friable particles 1.0 Material finer than 75 micron 1.0




6 01 06 Form of Standard Mix Presentation Table 6: Form of standard mix presentation

Percentage Passing (by weight) S I E V E (mm) 40 mm nominal size

of maximum aggregate

20 mm nominal size of maximum aggregate

75 38.1 19 9.5 4.75 2.36 1.18 0.60 0.30 0.15

75 micron

100 90 – 100 65 – 85 35 – 60 25 – 45 22 – 40 18 – 38 15 – 33 6 - 17 0 – 6 0 - 2

- 100

90 – 100 55 – 70 35 – 55 30 – 45 25 – 42 22 – 38 10 – 20

0 – 8 0 - 2

S T A N D A R D M IX D E S IG N P R E S E N T A T IO N

S u p p lie r a n d C la s s o f C o n c re te : C e m e n t C o n te n t a n d T yp e : (k g /m 3) W a te r – C e m e n t R a tio : F re e W a te r : ( litre s /m 3) o r (k g /m 3) S p e c if ie d S tre n g th 2 8 d a ys : (M P a ) C u rre n t M e a n S tre n g th : (M P a ) C u rre n t S ta n d a rd D e v ia tio n : (M P a )A d d itive T yp e :A d d itive T yp e : ( litre s /m 3 ) o r (k g /m 3 )S lu m p 3 0 m in u te s /s lu m p6 0 m in u te s ( in la b o ra to ry) : (m m )/(m m )A ir c o n te n t : (% )C h lo r id e s (a s N a C l)* : (% )S u lp h a te s (a s S O 3)* : (% )M e th o d o f P la c e m e n t** : P u m p /O th e rC o m b in e d A g g re g a te G ra d in g :

S ie veS ize

7 5 m m

3 8 .1m m

1 9m m

9 .5m m

4 .7 5m m

2 .3 6m m

1 .1 8m m

0 .6 0m m

0 .3 0m m

0 .1 5m m

7 5m ic ro n

%p a s s in g

b yw a s h in g

L o s A n g e le s A b ra s io n 5 0 0 re vs /1 0 0 re vs : (% )/(% )

C la y a n d F ria b le P a rtic le s : (% )

V a lid H o t W e a th e r T r ia l M ixR e p o rt a tta c h e d :Y e s /N o

* T o ta l in m ix , e x p re s s e d a s a p e rc e n ta g e b y w e ig h t o f c e m e n t** E n c irc le a s a p p ro p r ia te




6 01 07 Proportioning Strength and Standard Deviation Table 7: Proportioning strength and standard deviation

6 01 08 Concrete Mix Design and Standard Parameters Table 8: Concrete mix design and standard parameters

28 Day Compressive

Strength

Nominal Size of

Maximum Aggregate

Mpa mm 50 mm slump 100 mm slump

C 10 10 20 220 250 ** 1.20C 20 20 20 340 375 ** 0.52C 25 25 20 360 400 ** 0.48C 35 35 20 360 400 0.44

Concrete ClassDesignation

Maximum freewater cement

ratio (by weight)

** All cement for concrete subject to exposure to sulphate attack shall be sulphate resisting cem

Minimum Cement Content

kg/m3

6 01 09 Workability of Fresh Concrete Table 9.1: Consistence ranges of fresh according to DIN 1045

Required strength Margin MPa

Standard Deviation MPa

4.1 5.7 7.4 9.0 11.5

2 to 3 3.1 to 4 4.1 to 5 5.1 to 6 6.1 to 8

1 2 3 4 Consistence range

Designation Symbol Spreading index,

a, in cm Compaction index

υ 1 Stiff KS - > 1.20 2 Plastic KP 35 to 41 1.19 to 1.0813)

3 Soft KR 42 to 48 1.07 to 1.0213) 4 With flowing

properties KF 49 to 60 -

13) Use of the compaction index is especially recommended for concrete types listed in subclause 6.5.3, paragraph (3).




Tables 9.2: Consistence classes of fresh according to ENV 206




Slump classes Class Slump in mm

S1 S2 S3 S4

10 to 40 50 to 90 100 to 150

>160

The measured slump is to be rounded off to the nearest 10 mm.

Vebe classes Class Vebe in seconds

V0 > 31 V1 V2 V3 V4

30 to 21 20 to 11 10 to 5

<4

Compaction classes Class Degrees of compactibility

C0 C1 C2 C3

>1.46 1.45 to 1.26 1.25 to 1.11 1.10 to 1.04

Flow classes Class Flow Diagram in mm

F1 F2 F3 F4

< 340 350 to 410 420 to 480 490 to 600




6 01 10 Ultrafines and Ultrafines/Fines Content Table 10: Maximum Permitted Ultrafines and Ultrafines/Fines Content for Concrete

with Aggregate of 16 mm to 63 mm maximum particle Size (DIN 1045, Table 3)

Content for Concrete with Aggregate of 16 mm to 63 mm maximum particle Size (DIN 1045, Table 3)

1 2 3 Maximum permitted content, in kg/m3, of

Ultrafines Ultrafines/fines For test sieve aperture size of

Cement content

in kg/m3

0.125 mm 0.250 mm 1 < 300 350 450 2 350 400 500




6 02 Figures

Fig. 1: Maximum Nominal Size (NS) of Aggregate Related to Spacing of Rebars

Maximum NS: ¼ of smallest dimension (h, b, d) and 80 % or 90 % of the aggregate respectively smaller than the smallest spacing (S) or smallest concrete cover (C) according to grading area.




Fig. 2: Effect of concrete temperature and air temperature, relative humidity and wind velocity on the rate of evaporation of surface moisture.

This chart provides a graphic method of estimating the loss of surface moisture for various weather conditions. To use the chart, follow the four steps outlined above .




Annex: Specific Information 7 01 Notes: 7 01 01 General

The following items may be used as explanatory information only or as well as alternatives or additions to modify the specifications under Part 1 through Part 6. furthermore following items shall draw the attention of the Specifier to the importance of the structural design and the structural analysis as basis for specifying Cast-In-Situ Concrete.

In addition, there are slight or essential differences between the standards or codes referred to. Tables and Figures shown in this Part 7: Annex: Specifier Information contain values and limits excerpted from various standards (ASTM, ACI, BSI, DIN, etc.), sometimes mixed-up.

7 01 02 Project Documents The Project Documents shall include, but shall not be limited to the following Project related information:

(1) Whether ordinary Portland or moderate sulphate-resisting cement shall be used below ground level or not.

(2) Where cement with low heat of hydration is required.

(3) Where ‘Low alkali cement’ is required.

(4) Where ‘Rapid-hardening cement’ is required.

(5) Use of cements other than ‘Ordinary Portland’ cement.

(6) Maximum particle size of aggregate.

(7) Requirements concerning mechanical properties of aggregates (if relevant).

(8) Kind and source of aggregate (if relevant).

(9) Types of admixtures to be used and location of use.

(10) Location of use of other than normal weight concrete.

(11) Specified compressive strength (class of concrete) and location.

(12) Use of additions and location of concrete containing them.

(13) Location of watertight concrete.

(14) Use of test specimens other than 150 mm cubes.

(15) Location and type of expansion joints.

(16) Location and type of contraction joints.

(17) Type and locations of all imbedded items.

(18) Requirements with regard to thermal insulation.

(19) Requirements with regard to waterstop and vapour barriers.

(20) Kind and location of finishing.

For additional detailed information what, where and how to specify in the Project Documents see: ACI 301, ACI 302.1, ACI 303 and ACI 303.1.




7 02 Quality Assurance and Quality Control Contractor’s permanent concrete testing laboratory (including field laboratory, if any) must undertake the following duties:

1. Checking the site equipment before commencement of concreting operations, routine checking and advisory services during concrete making, placing and curing.

2. Tests for all concrete ingredients and concrete mixes within a frequency to be indicated by the Specifier: Internal Q. C. Routine Tests.

All concrete ingredients and concrete mixes delivered without a certificate of an independent approved laboratory must be tested and verified on behalf of the Employer by an independent Agency at the expenses of the Contractor: External Q. C. Acceptance Tests.

The same procedure as for Routine Tests (but not the frequency) shall apply to the Acceptance Tests.

7 03 Materials 7 03 01 Cement 7 03 01 01 General

Work above Ground Level All cement for work above ground level shall be ‘Ordinary Portland Cement’ of an approved brand.

Work below Ground Level All cement used below ground level shall be ‘Sulphate-resisting Portland Cement’ and shall be of a brand approved by the Engineer.

If the soil investigation allows use of ASTM C 150 Type ll or ‘Ordinary Portland Cement’, it shall be approved by the Engineer.

Limits for compressive strength of some types of cement are shown in Table 1, further requirements for other properties are shown in Table 2.

Table 1: Minimum average compressive strength of cement.

Type 3 days 7 days 28 days Ordinary PC Rapid-hardening PC Moderate sulphate-resisting PC type II Sulphate-resisting PC type V

15 N/mm2 21 N/mm2 10 N/mm2 8 N/mm2

23 N/mm2 28 N/mm2 17 N/mm2 15 N/mm2

35 N/mm2 35 N/mm2 22 N/mm2 20 N/mm2




Table 2: Limits of cement properties.

7 03 01 02 Sampling and Testing If the source does not change, routine tests should be carried out for each 100th, 500th or 1000th ton delivered.

If the representative sample fails any of the mandatory tests, two new samples shall be taken from the same group and all the mandatory tests shall be carried out on them.

The group should be considered conforming to the standard if the two new samples pass all the repeated mandatory tests.

7 03 02 Aggregates 7 03 02 01 Properties 7 03 02 01 01 General

The chemical and physical properties as shown in Table 3 differ from those as shown in Part 6 01 02 to 6 01 04 and the Project Specifier may select alternative properties.

In addition to chemical and physical properties as shown in Table 3, following limits may be applicable:

Alkali aggregate reaction: Aggregate for use in concrete being subject to wetting, extended exposure to humid atmosphere, or contact with moist ground shall not contain any materials that are deleteriously reactive with the alkalis in the cement in an amount sufficient to cause excessive expansion of mortar of concrete, except that if such materials are present in injurious amounts, the aggregate may be used with a cement containing less than 0.6 % alkalis calculated as sodium oxide or with the addition of a material that has been shown to prevent harmful expansion due to the alkali-aggregate reaction.

Specific Surface (Blaine) 2250 cm2/gram

initial not less than 45 min. Setting time

(Vicat needle) final not more than

10 hours Content of alkalies (if low alkali content is required)

0,60 % by weight

Heat of hydration (if low heat of hydration is required)

250 kJ/kg at 7 days

Tricalcium ASTM Type II 8 % Aluminate ASTM Type III 15 % C3A = 2,65 (Al 2O3) - ASTM Type IV 7 % 1,69 (Fe2O3) ASTM Type V 5 % Tetracalcium Aluminaferrite ASTM Type V 20 %

Sulphate expansion limit after 14 days

not more than 0,045 %




Table 3: Alternative Limits for selected properties of aggregates. (see: Clause 6 01 02 through 6 01 04)

Notes to Table 3:

Note 1: If the colour is darker than the standard (dark yellow, brown or reddish) the aggregates can be rejected, unless it is proved by control mix, that the content producing that colour has no negative effect on the quality of the concrete.

Note 2: The aggregate may be acceptable, if it meets the indicated limit for either sodium sulphate or magnesium sulphate soundness.

Note 3: These limits apply for reinforced concrete or prestressed concrete where the tendons are protected by ducts.

Note 4: If a proposed aggregate has an absorption of 3 % or more, the Contractor should demonstrate by trial mixes and tests that the strength and durability of the concrete are not adversely affected and that adequate workability can be maintained during the placing and compacting processes.

Note 5: Including sulphate already present in cement.

Max/min permissible limit Kind of requirement Fines Coarse

See Note No.

Organic impurities Not darker than standard

1

Natural aggregate

max. 5 % by weight max. I % by weight

Material Finer than 0,075 mm

Crushed aggregate

max. 7 % by weight max. 1.5 % by weight

Clay lumps and friable particles

max. 3 % by weight max. 2 % by weight

If surface appearance or abrasion is of importance: max. 0.5 % by weight

Coal and lignite

All other concrete: I % by weight

Sodium sulphate soundness

max. 10 % max. 12 % 2

Magnesium sulphate soundness max. 15 % max. 18 % 2 Soluble chlorides (NaC 1) max 0.10 % by weight max 0.4 % by weight of cement

3 Soluble chlorides

Prestressed concrete, tendons not in ducts: max. 0.02 % by weight

Specific gravity min. 2300 kg/m3

min. 2300 kg/m3

Water absorption max. 3 % 4 Acid soluble sulphates, calculated as S03

max. 0.4 %

Total sulphate content

max 4 % by weight of cement 5




Particle shape of coarse aggregate: The content of elongated particles (length to thickness greater than 3 : 1) should not exceed 50 % by weight.

Mechanical properties should be as follows:

Abrasion loss of gravel, crushed gravel, or crushed stone using the Los Angeles test should not be higher than 50 %.

The ‘10 % fines’ value in accordance with BS 812, should not be less than 50 kN. Where aggregates are to be used for concrete wearing surfaces, the ‘10 % fines’ value shall not be less than 100 kN.

The aggregate impact value according to BS 812 should not exceed 45 %. Where aggregates are to be used for concrete wearing surfaces, the aggregate impact value should not exceed 30 %.

7 03 02 01 02 Sizes and Grading The grain size distribution of the aggregate is prescribed by the grading curves, shown in Figs. 1 to 7.

Fig. 1: Grading curves for maximum particle size 8 mm similar to SASO 378




Fig. 2: Grading curves for maximum particle size 16 mm similar to SASO 378.

Fig. 3: Grading curves for maximum particle size 32 mm similar to SASO 378




Fig. 4: Grading curves for maximum particle size 63 mm similar to SASO 378.




Fig. 5: Grading curves for maximum particle size 9.5 mm similar to ASTM C 33




Fig. 6: Grading curves for maximum particle size 19.0 mm similar to ASTM C 33.

Fig. 7: Grading curves for maximum particle size 38.1 mm similar to ASTM C 33.




Each figure must be used separately and cannot be mixed with another one.

Choosing the relevant figure depends on the maximum particle size of the mix to be prepared.

Combined aggregates should be as coarse-grained and dense-graded as possible and the grading curve should be located between the limits shown as the curves A and C in Figs. 1 to 7. If the grading does not fit into the area between the curves A and C, trial mixes have to be made to prove the suitability of the grain size distribution which needs the approval of the Engineer.

Grading Limits:

Each figure contains three curves, which represent the grading limits of the favourable or serviceable area respectively in percent passing by weight. The area between curves A and B comprises the favourable grain size distribution while the area between curves B and C is to be regarded as serviceable.

Concrete with aggregate fitting into the favourable area (grading zone (3) requires less cement than concrete of the same strength class fitting in serviceable area (grading zone (4)) only, the as shown for one example in Table 4.

Table 4: Minimum cement content for B I concrete with aggregate of 32 mm maximum particle size and cement strength Z 35 complying with DIN 1164-1(acc. to DIN 1045, Table 4)

1 2 3 4 5

Concrete strength class

Grading zone of

aggregate 14)

Minimum cement content, in kg per m3,

of compacted concrete for consistence range

KS KP KR

1 3 140 160 -

2 B 5 15)

4 160 180 -

3 190 210 230

4 B 10 15)

4 210 230 260

5 3 240 270 300

6 B 15

4 270 300 330

7 3 280 310 340

8 B 25, general

4 310 340 380

9 3 300 320 350

10

B 25, for external applications 4 320 350 380

14) See figure 3 15) For plain concrete only




Deviation: Deviations in the grading curves, shown in Figs. 2 to 7, concerning grain sizes above 8 mm have little effect on the properties of the concrete.

Differing Specific Gravity: For aggregates composed of particle size fractions which differ significantly in specific gravity, the grading curves should be referred to, not to parts by weight of the aggregate, but to parts by absolute volume.

The absolute volume is obtained by dividing the weight of the material by the specific gravity. The ordinates of the grading curve diagram should then be ‘percentage passing in ‘% by absolute volume’ instead of ‘% by weight’.

Figs. 1 to 4 show the grain size distribution areas for aggregates with maximum particle sizes of 8 mm, 16 mm, 31.5 mm and 63 mm for grading curves for metric test sieves . The mesh sieve openings shall be according to ISO 565 (R 20/3).

Figs. 5 to 7 show the grain size distribution areas for aggregates with maximum particle sizes of 9.5 mm, 19 mm and 38.1 mm for grading curves for inch test sieves (US). The mesh sieve openings shall be according to ASTM E 11.

7 03 02 02 Sampling and Testing 7 03 02 02 01 Routine tests by the Contractor:

Sampling of aggregates may be done in accordance with ASTM D 75 or an equivalent standard. The required tests shall be made on test samples that comply with requirements of the designated test methods and are representative of the grading that will be used in the concrete.

E. g., following routine tests could be carried out on representative samples within the periods stated below complying with the standards indicated or equivalent standards:

1.0 Test Frequency Each Week - Grading - ASTM C 136 or DIN 4226. - Determination of chloride content - BS 812, Part 4. - Determination of sulphur trioxide content - DIN 4226. - Determination of clay lumps and friable particles - ASTM C 142.

2.0 Test Frequency Each Two Weeks - Amount of material finer than 0.075 mm - ASTM C 117.

3.0 Test Frequency Each Month -.Organic impurities- ASTM C 40. - Effect of organic impurities - ASTM C 87, if colour is darker than light yellow. -.Determination of chloride content - BS 812 Part 4, if result is between 20 % and 60 % of the limit. - Determination of sulphur trioxide content - DIN 4226, Sheet 3, if result is between 20 % and 60 % of the limit. - Particle shape - DIN 52114. - Soundness - ASTM C 88. - Coal and lignite - ASTM C 123. - Water absorption - ASTM C 127. - Specific gravity - ASTM C 127. - Alkali reactivity - ASTM C 289.

4.0 Test Frequency each 4 Months - 10 % fines value- BS 812.

5.0 Test Frequency each 6 Months - Determination of chloride content - BS 812, Part 4. - Determination of sulphur trioxide content - DIN 4226.




7 03 03 Mixing Water When not specified as ‘potable’, some of the following requirements could be applied:

7 03 03 01 General Water to be used for cooling and/or washing aggregates, and for mixing and curing concrete shall be clean and free from injurious amounts of oil , acid, salt, alkali, organic matter or other substances deleterious to concrete or reinforcement. All water shall be tested and testing has to be approved by the Engineer.

Mixing water shall comply with DIN 4030 or an equivalent standard.

The Contractor shall at all times maintain on the site such quantities of mixing water as are considered by the Engineer to be sufficient to ensure continuity of work. The water should be stored in closed water tanks and kept as cool as possible.

7 03 03 02 Sampling and Testing Samples shall be taken in clean bottles or containers which can be tightly closed.

The samples container shall be labeled with the following information: - Name of supplier and source - Name of sampler - Date of sampling.

Requirements

(1) General Appearance

(1.1) Smell, sediments, unusual colour, foaming water, oil and grease

Control mixes have to be carried out, if - any strange smell is perceivable, - sediments or swimming particles can be seen, - water has unusual colour, - water shows foam on top or is able to produce foam, - water has any signs of oil or grease content.

(1.2) Algae

Water containing algae is unsuited for making concrete because the algae can cause excessive reduction in strength either by influencing cement hydration or by causing a large amount of air to be entrained in the concrete. Algae may also be present on aggregates, in which case the bond between the aggregate and cement paste is reduced. Water containing algae shall not be used.

(2) Acceptance Tests

(2.1) Chemical Analysis The water shall be chemically analyzed to determine the amount of the following chemicals: - Dissolved solids - Alkalis - Chloride - Sulphate - pH-value

Possible limits of chemical contents are shown in Table 5.




(2.2) Trial Mixes All waters containing suspicious impurities or defects shall be checked by trial mixes.

(3) Control Mix Water of questionable suitability can be used for making concrete, if mortar cubes made have 7 and 28 day strengths equal to at least 90 % of comparable specimens made with potable water. Mortar cubes shall be made and tested according to ASTM C 109. In addition, the Vicat needle tests as detailed in ASTM C 191, should be made to ensure that impurities in the mixing water do not adversely shorten or extend the setting time of the cement.

Table 5: Limits of chemical contents in Mixing water.

* The maximum concentration of chloride (Cl) in prestressed concrete should not be higher than 500 ppm. In general, for reinforced concrete in moist environments or concrete containing embedded aluminum structures with dissimilar metals, a maximum concentration of 1000 ppm is acceptable.

Industrial Waste Water Waters carrying sanitary sewage and seawater are only allowed to be used as mixing water, if it is permitted in the Project Documents. It is permissible to re-use waste water as mixing water in concrete, if the waste water complies with the requirements as per item (1) through (3) above.

7 03 04 Admixtures 7 03 04 01 General

Other admixtures not mentioned in Part 2:

- Pozzuolana - Gas former - Damp-proofing agents

Kind of Ingredients Permissible Limit Dissolved solids 2000 ppm Alkali Carbonate and Bicarbonate. 1000 ppm Chloride* 500 ppm

1000 ppm Sulphate (SO4) 3000 ppm Alkalies (Na2O + 0,658 K2O) 600 ppm ph-Value 4 (min)




- Waterproofing agents - Pumping aids - Superplasticisers - Bonding agents - Grouting agents

7 03 04 02 Sampling and testing 7 03 04 02 01 Acceptance Tests (External Q. C.)

If manufacturer's certificate is not available, acceptance tests by control mixes must be made to show the influence of the admixture on the following concrete properties: - Water content - Slump - Air content - Time of setting - Compressive strength - Flexural strength (if required) - Length change - Durability factor (if relevant) - Bleeding (only for air-entraining agent) - Effect of under and overdosage.

7 03 05 Concrete 7 03 05 01 Mix Design and Selection of Proportions

For each class of concrete there must be as many mix designs as there are different combinations of ingredients, anticipated to cover the requirements of the work. Mix design may vary to meet field conditions particularly for hot weather concreting, but after acceptance by the Engineer no changes shall be made without notice and to the approval of the Engineer based on the Contractor’s report and recommendation.

The proportions of ingredients for a design mix should be such as to produce a mixture which will work readily into the corners and angles of the forms and around reinforcement by the methods of placing and consolidation employed in the work, but without permitting the materials to segregate or to collect excessive free water on the surface.

ACI 318, ACI 211 give methods for different properties of concrete mixes necessary to meet the requirements of a specification (see Part 2: Products). The properties of ingredients can be selected in accordance with one of the methods to produce the proper workability, durability, strength, and other required properties.

ENV 206 is using the method of ‘designed’ or ‘prescribed’ mixes.

DIN 1045 distinguishes between the composition of class C I and C II concrete, C II concrete including concrete with special properties based on w/c-ratio. The mix design must proof by suitability tests a certain consistence considering the site relevant conditions.

Other generally accepted design methods may be used, if the results of the trial mixes meet the specified requirements.

7 03 05 02 Types Normal Weight Concrete

Normal weight concrete is a concrete for which density is not a controlling attribute, usually having a unit weight in the range of 2100 kg per m3 to 2600 kg per m3.




Lightweight Concrete

Lightweight concrete is intentionally made to have a low density by use of lightweight aggregates or a mixture of lightweight and normal weight aggregates, and usually required to have an air-dry unit weight of less than 2000 kg per m3.

High Density Concrete

High density or heavyweight concrete which is generally for shielding structures differs from normal weight concrete by having a higher density and special compositions to improve its attenuation properties.

The use of high density concrete in construction is a specialized field; the work must be undertaken by qualified personnel according to a special specification.

Insulating Concrete

Insulating concrete is a low density concrete, which is intentionally made to decrease the thermal conductivity of a structure.

7 03 05 03 Concrete Quality 7 03 05 03 01 Concrete Classes

Materials for concrete are to be proportioned to ensure a plastic and workable mixture which will result in durable concrete with the classes as shown in Tables 5 and 6.

Table 6: Concrete strength classes according to DIN 1045 (Table 1).

Strength requirements are based on 28-day compressive strength for 200 mm cubes.

The strength requirements are to be regarded as fulfilled if the minimum average compressive strength of each series, each comprising three consecutive cubes, attains at least the values shown in Table 5, column 4, and the compressive strength of each individual cube attains at least the values stated in column 3.

Further information about the 5 percent defective level (5 % fractile) are given in CEB/FIP recommendations for the design and construction of concrete structures.

1 2 3 4 5 6 Grade Strength

class Characteristic

strength10),βwlN (minimum

compressive strength, βw28 , of each cube as in

subclause 7.4.3.5.2), in

N/mm2

Series strength, βws (minimum average

compressive strength, βwm , of

each series of cubes),

in N/mm2

Made in compliance

with (subclause)

Application

1 B 5 5 8 2 B 10 10 15

Plain concrete only

3 B 15 15 20 4

B I

B 25 25 30

6.5.5

5 B 35 35 40 6 B 45 45 50 7

B II

B 55 55 60

6.5.6

Plain and reinforced concrete

10) The characteristic strength is based on the 5 % fractile of the population.




Table 7: Concrete strength classes according to Eurocode 2 and ENV 206.

Seven-days Strength:

The relation in percent between 7-days strength and 28-days strength has to be determined by using the results of test specimen prepared for acceptance or suitability tests.

Strength for Slabs on Grade:

The required compressive strengths for slabs on grade are subject to intensity of abrasion and may be specified similar to the values given in Table 7.

Strength of Watertight Lightweight Concrete:

Lightweight concrete for such application has to be proportioned to produce a specified compressive strength of at least 25 N/mm2 for exposure to fresh water and of 35 N/mm2 for exposure to seawater.

Table 8: Concrete strength classes in slabs on grade.

Strength classes of concrete strength classes

C12/15 C16/20 C20/25 C25/30 C30/37 C35/45 C40/50 C45/55 C50/60

ƒckcyt1)

N/mm2 12 16 20 25 30 35 40 45 50

ƒckcube N/mm2

15 20 25 30 37 45 50 55 60

1)ƒckcyt is identical with ƒckck used in the Eurocodes.

Strength classes of concrete related to w/c ratio Water/cement ratio

Strength class of cement 0,65 0,60 0,55 0,50 0,45 CE 32,5 C20/25 C25/30 C30/37 C35/45 C40/50

CE 42,5 C25/30 C30/37 C35/45 C40/50 C45/55

Class Usual Traffic Typical Uses Concrete class

Maximum slump for normal weight

concrete mm* Light foot Residential or tile

covered, mosques Foot Offices, schools

hospitals, residences

1

Light foot and pneumatic wheels

Drives, garage floor and sidewalks for residences

C 25 100

Foot and pneumatic wheels

Light industrial commercial

2

Foot and wheels abrasive wear

Single-course industrial integral topping

C35 75

3 Foot and steel Tire vehicles Severe abrasion

Two-course heavy industrial, bonded topping

Base C 25 Topping**

C 35-55 ***

100

25




*Slump not to exceed 75 mm if structural lightweight aggregates are used. All values of slump shown are working maxima and may be exceeded by up to 25 mm for individual field batches.

**Maximum aggregate size not more than one-third the thickness of topping.

***The strength required will depend on the severity of abrasive exposure. The range shown will cover most situations.

7 03 05 03 02 Cement and Ultrafines Content For reinforced concrete, the minimum cement content should be 240 kg per m3 of compacted concrete if the cement has a strength of 35 N/mm2 and above, and 280 kg per m3 of compacted concrete if the cement has a strength of at least 25 N/mm2.

Concrete for external applications should have a cement content of equal to at least 300 kg of compacted concrete.

For plain concrete, the minimum cement content should be 100 kg per m3 of compacted concrete.

Table 9 shows the minimum cement content for B I concrete with aggregate of 63 mm maximum particle size and cement of strength class Z 35 complying with DIN 1164, Part 1.

The ultrafines content comprises the cement, the aggregate particles of 0 - 0.25 mm size, and such additional material of this particle size range as it may be necessary to introduce. Such additional material, if any, should consist of natural or artificial mineral substances, comprising as far as possible a mixture of different-sized particles, which do not soften and do not impair the durability of the concrete.

An adequate content of ultrafine material is especially important in concrete which has to be conveyed long distances or through pipelines, in concrete for thin-walled densely reinforced components, and in waterproof concrete.

In general, an ultrafines content as indicated in the Table 9 is advantageous, but it is not obligatory.

Table 9: Ultrafine content related to maximum grain size.

If air-entraining agents are used, a lower ultrafines content is adequate.

The ultrafines content should, as far as possible, be limited to the amount necessary for working the concrete, particularly if concrete properties are required which are likely to be adversely affected by an excessive content of

Maximum particle Size of the Aggregate

mm

Content of Ultrafine particles in 1 m3 of compacted

concrete kg

8 16 32 63

525 450 400 325




ultrafine particles, such as - Concrete with high resistance to chemical attack. - Concrete with high wearing resistance. - Concrete with high frost resistance.

For concrete with special properties see: DIN 1045, ref. 6.5.7.

7 03 05 04 Sampling and Testing For each different concrete type cast per day, the following procedures and tests should be performed:

7 03 05 04 01 Fresh Concrete (1) Preparation of Compression Specimens

(1.1) Frequency A minimum of - 6 cubes per pouring day or: - 4 cubes per 100 m3 for each class and age of concrete, to be prepared, whichever gives a higher number or: - sufficient number, at least 3 cubes for each member and proposed control test for stripping time determination.

(1.2) Assembly of Moulds In assembling the cleaned mould ready for use the joint between the sections of the mould and between the bottom of the mould and the base plate should be thinly coated with mould oil to prevent escape of water. The internal faces of the assembled mould should also be thinly coated with mould oil to prevent adhesion of the concrete.

(1.3) Filling The test specimens should be made as soon as practicable after sampling, in such a way as to produce full compaction of the concrete with neither segregation nor excessive laitance.

The mould should be filled in layers approximately 50 mm deep and each layer shall be compacted either by hand or by vibration. After the top layer has been compacted the surface of the concrete should be finished level with the top of the mould by means of a trowel.

(1.4) Compacting by Hand When compacting by hand, the standard compacting bar should be used and the strokes of the bar should be distributed in a uniform manner over the cross-section of the mould.

The number of strokes per layer required to produce the specified condition will vary according to the type of concrete, but in no case shall the concrete be subjected to less than 35 strokes per layer for 150 mm cubes or 50 strokes per layer for 200 mm cubes.

The compacting bar should be a steel bar weighing 1.8 kg, 380 mm long, and having a ramming face 25 mm square.

(1.5) Compacting by Vibration When compacting by vibration, each layer should be vibrated by means of the hammer or vibrating table until the specified condition is attained.

The vibrator may be in the form of either an electric or pneumatic hammer, or a suitable vibrating table.

(2) Curing Test Cubes

(2.1) Specimens made in the Laboratory Immediately after they are made, the test specimens should be stored in a place free from vibration in moist air of at least 90 % relative humidity and at a




temperature of 23 plus/minus 2 deg C for 16-24 hours from the time of adding the water to the mix. This can be achieved by storing the specimens in their moulds, either in a moist air curing room or cabinet maintained at the relative humidity and temperature conditions stated, or under damp matting or other suitable damp material covered completely with polyethylene or other similar impervious sheeting in a room maintained at the temperature stated.

If the concrete has not achieved sufficient strength to enable demoulding to be carried out within the stated period the demoulding should be delayed for a further 24 hours, but this fact has to be stated in the test report. During this further period, the specimens shall be stored in the moist air conditions stated.

The specimens should be marked for later identification, removed from the moulds and, unless required for test within 24 hours, immediately submerged in the tank and kept there until taken out just before testing.

One or more tanks must contain clean water, renewed at least once a month and maintained at a temperature of 23 +/- 1 deg C in the laboratory.

Note: The tolerances are intended to allow for variations in temperature from point to point within the tank.

The specimens shall not be allowed to become dry at any time until they are tested.

Specimens to be tested at 24 hours should be stored for this period in the moist air conditions stated and demoulded just before testing.

(2.2) Specimens made on Site After preparation, the specimens should be stored, cured and demoulded and handled according to item (2.1) above.

While the specimens remain on site, records of the daily maximum and minimum air and water storage temperatures shall be kept with maximum and minimum thermometers or with continuous recording instruments.

The specimens, well-packed in damp sand or wet sacks and enclosed when necessary in a polythene bag or sealed container, should be sent to the testing laboratory when they are not less than 3 days nor more than 7 days old, to arrive there in a damp condition not less than 24 hours before the time of testing. On arrival at the testing laboratory, the specimens have to be stored in water maintained at a temperature of 23 +/- 1 deg C until the time of test. The specimens shall not be allowed to become dry at any time until they are tested.

Specimens to be tested at 24 hours have to be stored for this period in the moist air conditions stated and demoulded just before testing.

(2.3) Specimens for Stripping Time Determination The test specimens have to be removed from moulds after 24 hours and have to be stored in the structure as near as possible to the points of sampling, and shall receive insofar as practicable the same protection during curing as given to those portions of the structure which they represent, and shall not be removed from the structure for transmittal to the laboratory prior to expiration of three-quarters of the proposed period before removal of forms.

(3) Report

The following information should be included in the report on each cube: - identification of test cube, - particulars of the concrete from which the test cube was made, recorded in accordance with the requirements of the appropriate clause in Part 1 of BS 1881, - method of compaction (by hand or by vibration), and - maximum and minimum storage temperatures.

(4) Workability Test




A minimum of - 3 workability tests per pouring day or - 2 tests for each 100 m3 concrete, shall be performed, whichever gives the higher number.

(5) Fresh Concrete Temperature

(5.1) Frequency of Test If the ambient temperature exceeds 40 deg C - 4 temperature measurements per pouring day or - 2 measurements per 100 m3 concrete should be taken.

(5.2) Accuracy of Thermometer A thermometer with +/- 0.5 % accuracy should be used and immersed into concrete batches selected at random at the time of placement.

The stabilized temperature should be read and recorded with the time of measurement.

(6) Unit Weight (fresh concrete density)

A minimum of - 1 unit weight determination per pouring day or - 1 determination per 100 m3 concrete shall be made.

(7) Criteria of Technical Conformity

The test results should be within the specified limits.

7 03 05 04 02 Hardened Concrete (1) Frequency of Testing

The frequency of testing depends on the specified test age.

(2) Age at Test

(2.1) General Preferred ages for test are 3, 7 and 28 days, 13 weeks and 1 year.

(2.2) Tolerances Tests should be carried out within the following tolerances: to specify

up to and including 30 hours: within +/- 1/2 hour; above 30 hours up to and including 100 hours: within +/- 2 hours; above 100 hours up to and including 60 days: within +/- 8 hours; above 60 days: within +/- 1 day.

The ages should be calculated from the time of the addition of the water to the other materials.

(3) Required Tests

- Compressive strength (half of sample number) after 7 days.

- Compressive strength (half of sample number) after 28 days.

- Determination of compressive strength for removing time for forms - if relevant.

(4) Criteria of Technical Conformity

The test results shall be equal or higher than required.

Identification

Reports of tests on materials and samples of concrete should include clear identification of the source or batch number, specimen identification, physical characteristics of the materials including temperature at time of sampling and testing, ambient temperature, date and time of procurement and testing, curing




techniques for concrete if applicable, results of tests, point of incorporation of concrete in the construction, design of concrete mix and concrete yield.

7 03 06 Batching (1) During measurement operations, aggregates should be handled in a manner to maintain their desired grading, and all materials should be weighed to the tolerances required for the desired reproducibility of the concrete mix selected. In addition to accurate weighing, also necessary for successful batching is the proper sequencing and blending of the ingredients during charging of the mixers to obtain uniformity and homogeneity in the concrete produced as indicated by such physical properties as unit weight, slump, air content, strength, and air-free mortar content in successive batches of the same mix proportions.

(2) The mix recipe for the mixes to be produced should hang within view of the mixer operator.

7 03 06 01 Plant Factors affecting the choice of the proper batching system are

- size of the job - required production rate - required standards of batching performance

The productive capacity of a plant is determined by a combination of such items as the materials handling system, bin size, batcher size, and plant mixer size and number.

Available equipment falls into three general categories - manual, semi-automatic, and fully automatic.

(1) Manual batching

Manual plants are acceptable for small jobs having low batching rate requirements, generally for jobs up to a total concrete quantity of 4000 m3 and 20 m3/h, but as the job size increases, automation of batching operations is rapidly justified.

(2) Semi-automatic batching

In this system, aggregate bin gates for charging batchers are opened by manually operated push buttons or switches. Gates are closed automatically when the designated weight of material has been delivered. With satisfactory plant maintenance the batching accuracy will meet the required tolerances.

(3) Automatic batching

Automatic batching of all materials is electrically activated by a single starter switch. However, interlocks shall interrupt the batching cycle when the scale has not returned to +/- 0.3 %t of zero balance or when weighing tolerances as specified are exceeded.

(4) Bins and Weigh Batchers

Batch plant bins should be of adequate size to effectively accommodate the productive capacity of the plant. Compartments in bins should adequately separate the various concrete materials, and the shape and arrangement of aggregate bins should prevent aggregate segregation and leakage. Weigh batchers should be charged with easy-operating clam shell or undercut radial-type bin gates. Gates used to charge semi-automatic and fully automatic batchers must be power operated and equipped with a suitable "dribble" control to obtain the desired weighing accuracy. Weigh batchers must be accessible for obtaining representative samples, and they shall be arranged to obtain the proper sequencing and blending of aggregates during charging of the mixer.




7 03 07 Mixing Thorough mixing is essential for production of uniform concrete. Therefore, equipment and methods used should be capable of effectively mixing concrete materials containing the largest specified aggregate to produce uniform mixes of the lowest slump practical for the work. Sufficient mixing as well as transporting and placing capacity should be provided so that unfinished concrete lifts can be maintained plastic and free from cold joints.

7 03 07 01 Charging Concrete Materials Each batch should be so charged into the mixer that some water will enter before cement and aggregates. Controls shall be provided to prevent batched ingredients from entering the mixer before the previous batch has been completely discharged.

It is preferable that cement being charged with other materials, but it should enter the stream after approximately 10 percent of the aggregate is in the mixer. When it is necessary to charge cement into truck mixers separately, additional mixing time may be required to obtain desired mix uniformity. Water should enter the mixer first with continuous flow while other ingredients are entering the mixer. Water charging pipes must be of proper design and of sufficient size so that water enters at a point well inside the mixer and charging complete within the first 25 % of the mixing time.

7 03 07 02 Charging Admixtures Admixtures shall be charged to the mixer at the same point in the mixing sequence batch after batch. Liquid admixtures shall be charged with the water, and powdered admixtures shall be spread into the mixer with other dry ingredients. When more than one admixture is used, each shall be batched separately and they shall not be premixed before entering the mixer.

If the manufacturer's instructions indicate different procedures, they shall be applied.

7 03 07 03 Mixing Time for Stationary Mixers The mixing time required should be based upon the ability of the mixer to produce uniform concrete throughout the batch and from batch to batch. Manufacturer's recommendations and usual specifications, such as 1 min for 0.75 m3 plus 15 s for each additional 0.75 m3 of capacity in case of compulsory type mixer can be used as satisfactory guides for establishing initial mixing time. If gravity batch mixers are used, each batch should be mixed for at least 2 minutes.

However, final mixing times used should be based on the results of mixer performance tests made at frequent intervals throughout the life of the job.

The mixing time shall be measured from the time all ingredients are in the mixer. Batch timers with audible indicators used in combination with interlocks which prevent mixer discharge prior to completion of a preset mixing time shall be provided on automatic plants and are also desirable on manual plants. The mixer must be designed for starting and stopping under full load.

7 03 07 04 Mixer Performance The performance of mixers is usually determined by a series of uniformity tests made on samples taken from two to three locations within the concrete batch being mixed for a given time period. Mixer performance requirements are based on allowable differences in test results between any two locations or in differences between individual locations and the average of all locations.

Among the many tests used to check mixer performance, the following are the most common and necessary:




- air content - slump - unit weight of air-free mortar - compressive strength - water content of mortar - cement content of dried mortar - coarse aggregate content

Another important aspect of mixer performance is batch-to-batch uniformity of the concrete which is also largely affected by the uniformity of materials and their measurement as well as by the efficiency of the mixer. Visual observation of the concrete during mixing and discharge from the mixer is an important aid in main-taining a uniform mix, particularly uniform consistency.

7 03 07 05 Uniformity The concrete should be discharged at the normal operating rate for the mixer, with care being exercised not to obstruct or retard the discharge by an incompletely opened gate or seal.

The following requirements have to be fulfilled, expressed as maximum permissible difference in results of tests of samples taken from two locations (one after 15 % discharge and the second after 85 % of discharge of the load) in the concrete batch.

(1) Unit Weight

The weight per cubic metre calculated to an air-free basis should not differ by more than 25 kg/m3.

(2) Slump

If the average slump is 100 mm or less the difference should not be greater than 25 mm. If the average slump is between 100 and 150 mm, the difference shall not be greater than 35 mm.

(3) Coarse Aggregate Content

The percentage of coarse aggregate difference as a proportion by weight of each sample retained on a 4.75 mm sieve should not exceed 8.0 %.

(4) Unit Weight of Air-free Mortar

The percentage of the difference of unit weight of air-free mortar based on average for all comparative samples tested, should not exceed 2.5 %.

(5) Compressive Strength

The compressive strength at 7 days for each sample, based on the average strength of all comparative test specimen should have no greater difference than 7.5 %.

7 03 07 06 Mix Temperature Batch-to-batch uniformity of concrete from a mixer, particularly with regard to slump, water requirement, and air content also depends on the uniformity of the concrete temperature. It is, therefore, important that maximum and minimum con-crete temperatures be controlled throughout all seasons of the year.

7 03 07 07 Discharge of Mixer Mixers must be capable of discharging concrete of the lowest slump suitable for the structure being worked without segregation (separation of coarse aggregate from the mortar). Segregation shall also be avoided in handling and discharging operations in batch plant holding hoppers and transfer conveyances.




7 03 07 08 Truck-mixed Concrete 7 03 07 08 01 Uniformity

For concrete to be completely mixed in a truck mixer, 70 or 100 revolutions at the mixing speed designated by the manufacturer to produce the uniformity of concrete indicated are necessary.

Concrete uniformity tests have to be made in accordance with ASTM C 94 and if the requirements for uniformity of concrete are not met with by 100 revolutions of mixing after all ingredients, including water, are in the drum, that mixer shall not be used until the condition is corrected.

When satisfactory performance is found in one mixer, the performance of mixers of substantially the same design and condition of blades may be regarded as satisfactory.

Additional revolutions of the mixer beyond the number found to produce the required uniformity of concrete shall be at a designated agitating speed.

7 03 07 08 02 Truck Mixer Used for Transport When a truck mixer or truck agitator is used for transporting concrete that has been completely mixed in a stationary mixer, any turning during transportation shall be at the speed designated by the manufacturer of the equipment.

When a truck mixer or agitator is approved for mixing or delivery of concrete, no water from the truck water system or elsewhere shall be added after the initial introduction of mixing water for the batch except when on arrival at the job site the slump of the concrete is less than specified. Such additional water to bring the slump within required limits shall be injected into the mixer under such pressure and direction of flow that the requirements for uniformity specified are met with.

The drum or blades should be turned an additional 30 revolutions or more, if necessary, at mixing speed, until the uniformity of the concrete is within the limits.

Water should not be added to the batch at any later time.

7 03 07 08 03 Time of Discharge Discharge of the concrete should be completed within 1 hour or before the drum has revolved 300 revolutions, whichever comes first, after the introduction of the mixing water to the cement and aggregates or the introduction of the cement to the aggregates. These limitations may be waived by the Engineer if the concrete is of such slump after 1 hour time or the 300 revolution limit has been reached that it can be placed without the addition of water to the batch.

In hot weather, or under conditions contributing to quick stiffening of the concrete, a time less than 1 hour may be accepted by the Engineer.

When the concrete temperature exceeds 30 deg C, the time should be reduced to 30 minutes.

Every effort must be made to maintain the temperature of concrete produced during hot weather as low as possible.

7 04 Depositing of Concrete 7 04 01 Equipment 7 04 01 01 General

Concrete should be handled from the mixer to the place of final deposit as rapidly as practicable by methods which will prevent segregation or loss of ingredients




and in a manner which will ensure that the specified quality of concrete is maintained .

Placing equipment should be of a size and design such that detectable setting of concrete could not occur before adjacent concrete is placed.

7 04 01 02 Belt Conveyors Belt conveyors should be horizontal or at a slope which will not cause excessive segregation or loss of ingredients.

Mortar is not be allowed to adhere to the return length of the belt. Long runs shall be discharged into a hopper or through a baffle.

7 04 01 03 Pumps Pumping or pneumatic conveying equipment should be of suitable kind with adequate pumping capacity.

The loss of slump in pumping or pneumatic conveying equipment should not exceed 50 mm. Concrete should not be conveyed through pipes made of aluminum or aluminum alloy.

7 04 01 04 Bucket Sand Hoppers Discharge gates should have a clear opening equal to not less than one-third the maximum interior horizontal area or five times the maximum aggregate size being used.

Side slopes should be steep, being not less than 60 deg to the horizontal. Controls on the gates must permit personnel on the placement to open and close them during any portion of the discharge cycle.

Principles of filling and discharging, using vertical falls free from obstructions, should be followed when using buckets and hoppers.

Contamination must be prevented by landing buckets on platforms, and not swinging them over freshly finished uncovered concrete.

Spilled concrete should not be shoveled back into buckets and hoppers for subsequent use.

7 04 01 05 Manual or Motor Propelled Buggies Provide smooth rigid runways in order to prevent segregation of concrete materials in transit.

7 04 01 06 Chutes and Drop Pipes They shall be made of metal or have a metal lining.

The bottom shall be round and they shall have sufficient capacity to avoid overflow.

The slope should be constant and steep enough to permit concrete of the slump required in place to flow continuously down the chute without segregation.

The flow of the concrete at the end of the chute should be controlled to prevent segregation and long open chutes shall be covered to prevent drying and slump loss.

Drop pipes should be of circular shape.

The pipe should have a diameter of at least eight times the maximum aggregate size at the top but may be tapered to approximately six times the maximum aggregate size below.

It should be plumb, secure, and positioned so that the concrete will drop vertically.




The placement should start by coating the pipe with a batch of mortar grout prior to depositing the first concrete.

7 04 02 Weather Considerations 7 04 02 01 Hot Weather Concreting 7 04 02 01 01 Preparation Before Concreting

If concrete temperatures are expected to exceed 35 deg C, preparation must be made to mix, transport, place, and consolidate and finish the concrete as quickly as possible.

(1) Concrete Delivery ScheduIe

(2) Equipment Capacity

Equipment for placing the concrete must have adequate capacity to service and cover the job so there will be no delays at distant portions of the work.

There must be ample vibration equipment and manpower to consolidate the concrete quickly after placement and to maintain the rate of placement in difficult areas. All equipment should be in first-class operating condition.

(3) Stand-by Equipment

Due to more rapid slump loss in hot weather, the strain on vibrating equipment will be greater. Accordingly, provision should be made for an ample number of stand-by vibrators, one stand-by for each three vibrators in use. A concrete placing operation is in serious trouble, especially in hot weather, when vibration equipment fails and the stand-by equipment is inadequate.

(4) Windbreaks, Fogging

In any event, the job should be equipped with ample water supply, hose, and fog nozzles. The subgrade should be moist, but free of standing water and soft spots at the time of concreting.

Fogging can be used to cool the forms and steel prior to placing concrete; and to cool and moisten surrounding air to prevent excessive evaporation during finishing.

Fog nozzles for this use should produce a fog blanket.

(5) Cooling and Shading of Equipment

Mixers, belts, pump lines, and chutes shall be shaded.

Where they cannot be shaded, they will absorb appreciably less heat from the sun if painted white and kept clean. Pump lines and other surfaces can be kept appreciably cooler by covering them with damp burlap.

(6) Temperature of Formwork and Reinforcement

The formwork and reinforcing bars should be shaded from the direct rays of the sun prior to concrete placement so that the concrete, formwork and reinforcing bars are not warmer than the ambient air temperature. If the temperature of formwork and reinforcing bars is less than 38 deg C at the time of concrete placement, shading prior to placement is not required.

(7) Cooling Concrete Materials

Water should be kept in a cool place, preferably in underground tanks. If this is not possible, water should be chilled with ice or cooled down by any cooling device.

(8) Protection




To avoid serious damage and cracking, any proper method for protecting exposed surfaces from drying in hot weather shall be provided.

For most concrete works water curing should preferably be applied. White membrane coating may be more practical than others in treating vast areas on subgrade in the form of road pavements and canal lining, in accordance with ASTM C 309 Specifications for liquid membrane.

Water curing must be continuous and all exposed surfaces should be covered.

7 04 02 01 02 Fresh Concrete Temperature Measurement Three random temperature readings should be made for every 50 cubic metres of concrete placed or fraction thereof. These readings are to be recorded.

Increased frequency of testing concrete temperature during exceptionally hot weather conditions may be directed by the Engineer.

Decreased frequency of testing may be authorized by the Engineer if the ambient air temperature and the previously tested concrete temperature do not exceed 35 deg C.

7 04 02 01 03 Rate of Temperature Change Changes in temperature of the air immediately adjacent to the concrete during and immediately following the curing period should be kept as uniform as possible and should not exceed 3 deg C in any 1 hour or 30 deg in any 24 hour period.

7 04 02 01 04 Concrete Casting and Finishing Casted concrete surfaces should be finished as soon as possible, and the casting and finishing should be executed quickly during hot weather. Arrangements must be taken to cast concrete in the forms at a speed conforming to the available and necessary supplies, incorporating labour and equipment to finalize compacting and finishing works.

The rate of casting should be in accordance with the numbers of available labour on site. Any inconsistency in this regard will lead to cold joints, poor consolidation and irregular finished surfaces.

7 04 02 01 05 Construction Joints, Carbonate Coatings Preparation for placing includes proper location and preparation of construction joints. In hot weather, due to faster setting and hardening of the concrete, the timing of clean-up by various methods is essential.

It must also be noted that hot weather increases the formation of carbonate coatings on joint surfaces. For this reason, sandblasting or high pressure water cleaning immediately prior to placement of concrete, are most likely to provide the clean, fresh joint surface that is conducive to a full bond with the new concrete.

7 04 02 02 Cold Weather Concreting When the mean daily outdoor temperature is less than 4 degrees C, the temperature of the concrete should be maintained between 10 and 21 deg C for the required curing time of Clause 3 03 01 20 54.

When necessary, arrangements for heating, covering, insulating, or housing the concrete work may be made in advance of placement and should be adequate to maintain the required temperature without injury due to concentration of heat.

Combustion heaters should not be used which expose the concrete to exhaust gases which contain carbon dioxide.




7 04 03 Placing The rate of placement has to be rapid enough by providing enough staff and equipment so that the layer of concrete is plastic when a new layer is placed upon it in order to avoid flow lines, seams, and planes of weakness.

7 04 03 01 Avoidance of Bleeding of Water When concrete is placed in tall forms at a fairly rapid rate, there is likely to be some bleeding of water to the top surface, especially with non-air-entrained con-crete. Bleeding can be reduced by placing more slowly and by using concrete of a stiffer consistency.

When practical, concrete should be placed to a level about 300 mm below the top of tall forms and should then be allowed to settle. Placing must be resumed before the surface hardens to avoid formation of cold joints.

It is good practice to overfill the form by 25 mm and cut off the excess concrete after it has partly stiffened.

Another means of controlling the accumulation of bleed water is to increase the amount of coarse aggregate in the mixture as the placement approaches the top of the lift.

7 04 03 02 Avoidance of Cracking due to Settlement To avoid cracking due to settlement, concrete in columns and walls shall be allowed to stand for at least two hours, and preferably overnight, before concrete is placed in any slabs, beams, or girders framing into them. Haunches and column capitals are considered part of the floor or roof and shall be placed integrally with them.

7 04 04 Consolidation The method chosen depends on the consistency of the mix and the placing conditions, such as complexity of the formwork and amount of reinforcement.

7 04 04 01 Use of Internal Vibrators It should penetrate quickly to the bottom of the layer being placed and at least 150 mm into any preceding layer. (In thin slabs, the vibrator should be inserted at an angle or horizontally, if need be, so that the head is fully embedded.)

The vibrator should be held stationary for 5 to 15 seconds until adequate consolidation is attained, and then slowly withdrawn.

The concrete should move to fill the hole left by the vibrator. If the hole does not refill, reinsertion of the vibrator at a nearby point should solve the problem.

Allowing a vibrator to remain immersed in concrete after the paste accumulates over the head is bad practice and results in non-uniformity.

7 04 04 02 External Vibration External vibrators can be form vibrators, vibrating tables, or surface vibrators such as vibrating screeds, plate vibrators, vibrator roller screeds, or vibrator hand floats or trowels.

Form vibrators, designed to be securely attached to the outside of the forms, are especially useful

- for consolidating concrete in members that are very thin or congested with reinforcement; - to supplement internal vibration and - where internal vibrators cannot be used.




Rather, the vibrator should be attached to a steel plate that in turn is attached to steel-beams or channels, passing through the form stiffeners themselves in a continuous run.

Form vibrators should be spaced to distribute the intensity of vibration uniformly over the form. It is recommended that form vibrators be equipped with controls to regulate their frequency and amplitude.

Form vibrators should not be applied within the top area of vertical forms.

In heavily reinforced sections where an internal vibrator cannot be inserted, it is sometimes helpful to vibrate the reinforcing bars by attaching a form vibrator to their exposed portions.

Surface vibrators such as vibrating screeds are used to consolidate concrete in floors and other slab work, this equipment should not be used on concrete with slumps in excess of 75 mm.

Surface vibrators should not be operated after the concrete has been adequately consolidated.

7 04 05 Bonding 7 04 05 01 General

When fresh concrete is placed on hardened concrete, certain precautions must be taken to secure a well bonded, watertight joint. The hardened concrete must be clean, moist, fairly level, and reasonably rough with some coarse aggregate particles exposed. Any laitance, soft mortar, dirt, wood chips, form oil, or other foreign materials should be removed from the top surface of the hardened concrete since they would interfere with proper bonding of the subsequent placement.

At horizontal construction joints, the surface of the lower layer can be prepared either before or after the concrete hardens. When the concrete against which new concrete will be placed is less than about 4 hours old, all that is needed is to remove any laitance, loose particles, and dirt.

7 04 05 02 Roughening When the existing concrete is older, the surface should be thoroughly cleaned to remove all surface films and deposits. This may require roughening with a chipping hammer, water jet, or sandblasting. Fresher concrete may only require stiff-wire brushing.

7 04 05 03 Grouting This method has been removed from ACI 318 (ref. Commentary R.6.4.2) and should not be recommended:

For two-course floors, the top surface of the base slab can be roughened, just before it sets, with a steel or stiff-fibre broom. The surface should be level, heavily scored, and free of laitance. It must then be protected until it is thoroughly cleaned just before the grout coat and top course are placed. The grout, which is a mixture of Portland cement, sand and water, should have a consistency of thick paint and should be scrubbed into the surface of the slab close ahead of the top course.

The grout should be as thick as possible on vertical surfaces and 10 mm thick on horizontal surfaces. The fresh concrete should be placed before the grout has attained its initial set.

7 04 05 04 Overfill and Removing of Excess Concrete In wall construction and other reinforced concrete work, good results have been obtained by constructing the forms to the level of the joint, overfilling the forms 25




to 50 mm, and then removing the excess concrete just before setting occurs. The top surface then can be roughened with stiff brushes.

7 04 06 Finishing 7 04 06 01 Concrete Slabs 7 04 06 01 01 General

Detailed recommendations are given in 'Concrete Floors on Ground', Portland Cement Association publication EB 075 D, 1978.

Various colours and textures, such as an impressed pattern or exposed-aggregate surface, may be called for. Some surfaces may require only strike-off and screeding to proper contour and elevation, while for other surfaces a broomed, floated, or trowelled finish shall be specified in the Project Documents.

(1.1) Preparation

see: 02200 Earthwork

(1.2) Execution

The mixing, transporting, and handling of concrete for slabs must be carefully coordinated with the finishing operations. Concrete shall not to be placed on the subgrade or forms more rapidly than it can be spread, struck off, consolidated, and bullfloated or darby floated. In fact, concrete shall not be spread over too large an area before strike-off, nor shall a large area be struck off and bleed water allowed to accumulate before bull floating or darby floating.

Finishing crews must be large enough to correctly place, finish, and cure concrete slabs with due regard to the effects of concrete temperature and atmospheric conditions on the setting time of the concrete and the size of the placement to be completed .

7 04 06 01 02 Strike-Off (Screed) (2.1) General

Strike-off or screeding is the process of striking off excess concrete to bring the top surface to proper grade. The template used in the manual method is called a straightedge although the lower edge may be straight or curved, depending on the surface specified.

(2.2) Execution

It shall be moved across the concrete with a sawing motion and advanced forward a short distance with each movement. There shall not be a surplus of concrete against the front face of the straightedge as it passes over the slab; allowing too great a surplus, however, may tend to leave hollows. Beam straightedges are sometimes equipped with vibrators that consolidate the concrete and assist in reducing the strike-off work.

7 04 06 01 03 Bull floating or Darby floating To eliminate high and low spots and to embed large aggregate particles, a bull float or darby shall be used immediately after strike-off. The long-handle bull float can be used on areas too large to reach with a short-handle darby. For normal concrete these tools shall preferably be made of wood; for air-entrained concrete they can be of aluminum or magnesium alloy.

One of the principal causes of surface defects in concrete slabs is finishing while bleed water is on the surface.

The use of low-slump, air-entrained concrete with an adequate cement content and properly graded fine aggregate will minimize bleeding and help ensure maintenance-free slabs.




On most slabs bull floating or darby floating is followed by one or more of the following operations: edging, jointing, floating, trowelling and brooming. A slight hardening of the concrete is necessary before any of these operations can begin. When the bleed-water sheen has evaporated and the concrete will sustain foot pressure with only a slight indentation, the surface is ready for final finishing.

7 04 06 01 04 Edging and Jointing Edging is required along all isolation and construction joints in floors and outdoor slabs such as walks, drives, and patios. Edging densifyes and compacts the concrete slab next to the form where floating and trowelling are less effective, making it more durable and less vulnerable to spalling and chipping.

In the edging operation, the concrete shall be cut away from the form to a depth of 25 mm with a pointed mason trowel or a margin trowel. Then an edger has to be held flat on the surface and run with the front slightly raised to prevent digging into the surface. Caution is necessary to prevent the edger from leaving too deep an impression. Edging may be required after each subsequent finishing operation.

Right after or during the edging operation, the slab should be jointed. Proper jointing practice can eliminate unsightly random cracks. Control joints are made with a hand groover, power saw, or by inserting strips of plastic, wood, metal, or preformed joint material into the plastic concrete.

7 04 06 01 05 Floating After the concrete has been edged and jointed, it should be floated with wood or metal hand floats or with a finishing machine using floating blades.

Floating produces a relatively even (but not smooth) texture that has good slip resistance and is often used as a final finish, especially for exterior slabs. Where such a finish is desired, it may be necessary to float the surface a second time after it has partially hardened.

Marks left by edgers and hand groovers are normally removed during floating unless they are desired for decorative purposes, in which case those tools shall be re-run after final floating.

7 04 06 01 06 Trowelling Where a smooth, hard, dense surface is desired, floating should be followed by steel trowelling. Trowelling shall never be done on a surface that has not been floated; trowelling after only bull floating or darby floating is not an adequate procedure.

It is customary when hand-finishing large slabs to float and immediately trowel an area before moving the kneeboards. These operations may be delayed until after the concrete has hardened enough so that water and fine material are not brought to the surface. Too long a delay, of course, will result in a surface that is too hard to float and trowel. The tendency, however, is to float and trowel the surface too soon while the concrete is too soft and plastic. Premature floating and toweling can cause scaling, crazing, or dusting and will result in a surface with reduced wear resistance.

Spreading dry cement on a wet surface to take up excess water is bad practice and can cause crazing. Such wet spots shall be avoided, if possible, by adjustments in aggregate gradation, mix proportions, and consistency. When wet spots do occur, finishing operations shall be delayed until the water either evaporates or is removed when a rubber floor squeegee is used, care must be taken so that no cement is removed with the water.

The first trowelling may produce the desired surface free of defects. However, surface smoothness, density and wear resistance can all be improved by additional trowellings. There should be a lapse of time between successive




trowellings to permit the concrete to become harder. As the surface stiffens, each successive trowelling shall be made with smaller trowels, using progressively more tilt on the trowel blade. The final pass should make a ringing sound as the trowel moves over the hardening surface.

When the first trowelling is done by machine, at least one additional trowelling by hand should be done to remove small irregularities. If necessary, tooled edges at joints shall be re-run after trowelling to maintain uniformity and true lines.

7 04 06 01 07 Brooming A slip-resistant surface can be produced by brooming before the concrete has thoroughly hardened, but it shall be sufficiently hard to retain the scoring. Rough scoring can be achieved with a rake, a steel-wire broom or a stiff, coarse, fiber broom; such scratching usually follows floating. If a finer texture is desired, the concrete shall be floated, trowelled to a smooth surface, and then brushed with a soft-bristled broom. Best results are obtained with a broom that is specially made for texturing concrete. Slabs are usually broomed transversely to the main direction of traffic.

7 04 06 01 08 Patterns and Textures A variety of patterns and textures can be used to produce decorative finishes. Patterns can be formed with dividing strips or by scoring or stamping the surface just before the concrete hardens. Textures can be produced by little effort and expense with floats, trowels, and brooms while more elaborate textures can be achieved with special techniques using a mortar dash bond coat.

An exposed-aggregate finish provides a rugged, attractive surface. Selected aggregates shall be evenly distributed on the surface immediately after the slab has been bull floated or darby floated. Flat or elongated aggregate particles shall not be used since they could be dislodged while being exposed.

Aggregates to be exposed shall be washed thoroughly before use to assure satisfactory bond. The aggregate particles must be completely embedded in the concrete. This can be done be lightly tapping them with a wooden hand float (a darby), or the broad side of a piece of 50 x 100 mm lumber; then, when the concrete can support a finisher on kneeboards, the surface shall be hand-floated with a magnesium float or darby until the mortar completely surrounds and slightly covers all the aggregate particles. When the concrete has hardened sufficiently, the aggregate shall be exposed by simultaneously brushing and flushing with water.

Since timing is important, test panels shall be made to determine the correct time for exposing the aggregate without dislodging the particles. On large jobs, a reli-able retarder can be sprayed or brushed on the surface immediately after floating, but on small jobs this may not be necessary.

7 04 06 02 Formed Surfaces 7 04 06 02 01 General

Formed surfaces exposed to view or painted should be true and well defined, smooth, free of form marks, and should have surface blemishes and imperfections finished to match adjoining concrete in colour and texture. Many formed concrete surfaces require little or no additional treatment when they are carefully made with the proper forming materials or form liners. These surfaces are divided into two general classes: smooth and textured or patterned. The smooth surfaces are produced with plastic-coated forms, steel forms, fibreglass reinforced plastic forms, or tempered hardboard forms. Textured or patterned surfaces are achieved with rough-sawn timber, special grades and textures of plywood, form liners, or by fracturing the projections of a striated surface.




7 04 06 02 02 As-cast Finishes As-cast finishes require patching of tie holes and defects, but the surfaces otherwise need no further work since texture and finish are imparted by the forms.

7 04 06 02 03 Smooth Form Finish For a smooth form finish, it is important to arrange the smooth-faced forming material and tie rods in a symmetrical pattern. Smooth-finish forms must be supported so that they are capable of preventing excessive deflections.

7 04 06 02 04 Smooth Rubbed Finish A smooth rubbed finish is produced on a newly hardened concrete surface no later than the day following form removal. The forms are removed and necessary patching completed as soon as possible after concrete placement without jeopardizing the structure. The surface is wetted and rubbed with a carborundum brick or other abrasive until a satisfactory uniform colour and texture are produced.

7 04 06 02 05 Sandblast Finish All exposed surfaces of precast concrete specified to receive a sandblast finish shall have uniform appearance similar in all respects to that finish produced on the approved sample panel. The degree of blast is one which will on a sparse basis reveal the edges of some of the coarse particles. Surfaces shall receive what is generally termed a "light sandblast" finish.

7 04 06 02 06 Defects Defects in surfaces which will be exposed to view such as migrated entrained air, entrapped air bubbles over 5 mm diameter, sand streaks, staining, lack of uniformity of color, blotches, form leakage, ridges, honeycomb, and physical damage may be cause for rejection.

7 04 06 03 Special Architectural Finishes 7 04 06 03 01 Textured Finishes

Linear panels may be secured in forms by cementing or stapling, but not by methods which will permit impressions of nail heads, screw heads, washers, or the like to be imparted to the surface of the concrete.

Edges of textured panels should be sealed to each other or to divider strips (if specified or shown) to prevent bleeding of grout. The sealant used should be non-staining to the surface.

7 04 06 03 02 Aggregate Transfer Finishes Aggregate transfer and other special finishes should be produced using methods and materials designated in the Project Documents in such a way as to duplicate sample panels prepared in advance.

7 04 06 03 03 Exposed Aggregate Finishes The surface should be produced in such a way as to duplicate a sample panel prepared in advance. The Contractor shall submit to the Engineer for approval prior to placement the intended procedure, such as use of gap-graded mixtures or pre-placed aggregates or others, by means of which uniform distribution of the exposed aggregate will be achieved.

7 04 06 03 04 Scrubbed Finish If portions of the surface have become too hard to permit uniform aggregate exposure, dilute hydrochloric acid (commercial muriatic acid diluted with 4 to 10




parts water) may be used to remove the excess after the concrete is at least 2 weeks old. The acids shall be removed from the finished surface with clean water within 15 minutes after application.

(CAUTION: Muriatic acid is hazardous. Workmen performing this operation should wear protective goggles and rubber gloves, and should take necessary precautions to prevent contact of the acid with the skin. If the acid comes in contact with the skin, the affected area shall be immediately flushed with large quantities of fresh water.)

7 04 06 03 05 Sand Blast Finish and Tooled Finish The depth of penetration of the finish should be specified by one of the following criteria:

a) Remove only the surface mortar. b) Remove sufficient mortar to expose the coarse aggregate to the specified depth (for sand blast) or to fracture the coarse aggregate (for tooled finish).

7 04 06 04 Grout Clean-up A grout clean-up may be used to give a uniform colour and appearance to a smooth surface. After defects have been repaired, the surface shall be saturated thoroughly with water and kept wet during grout operations.

A grout of 1 part Portland cement and 1 1/2 to 2 parts of fine sand may all be applied uniformly by brush, plasterer's trowel, or rubber float to completely fill air bubbles and holes.

White Portland cement can be used for part or all of the cement in the grout to match the colour of the existing concrete. The surface shall be vigorously floated with a wood, sponge, rubber, or cork float immediately after applying the grout to fill any small air holes (bug holes) that are left and to remove some excess grout. The excess grout shall be scraped off with a sponge rubber float.

If possible, work should be done in the shade and preferably during cool, damp weather. During hot or dry weather, the concrete can be kept moist with a fine fog spray during the grout clean-up.

The completed surface should be moist-cured by keeping the area wet the entire day following the clean-up. When completely dry, the surface shall have a uniform colour and texture.

7 05 Concrete Curing 7 05 01 Curing Methods and Materials 7 05 01 01 Water Curing

The economics of the method selected for water curing should be considered for each job since the availability of water, labour, curing materials, and such items for the job in question will influence the selection. The method selected must provide a complete cover of water meeting the requirements of mixing water and, where appearance is to be a factor, the water must be free of substances that will stain or discolour the concrete. Common methods of water curing are described in the following Clauses.

(1) Ponding or Immersion

The most thorough but seldom used method of water curing consists of total immersion of the finished concrete unit in water. "Ponding" is sometimes used for slabs such as culvert or bridge floors, pavements, flat roofs, or wherever a pond of water can be easily created by a ridge or dyke of impervious earth or other material at the edge of the slab, or where there is a stream of water as through a culvert.




Damage from untimely or sudden release of ponded water shall be avoided. For example, if the ponded water leaks out, the slab would not get proper curing and the water might soften the supporting soil, or damage other construction or objects.

Curing water should not be more than about 10 deg C cooler than the concrete, because of temperature-change stresses which would be introduced with resultant cracking.

(2) Fog Spraying or Sprinkling

Fog spraying or sprinkling with nozzles provides excellent curing when temperature is well above freezing. When higher temperatures than normal atmospheric are permissible as in products plant curing, steam at atmospheric pressure is used and if properly controlled will maintain a film of moisture on the concrete surfaces during curing.

Lawn sprinklers are effective where water run-off is of no concern. The disadvantage of sprinkling is the cost of the water unless there is an ample supply available . Intermittent sprinkling is not acceptable if there is drying of the concrete surface.

Soaking hoses are useful, especially on surfaces that are vertical or nearly so. Care must be taken that erosion of the surface does not occur.

(3) Burlap, Cotton Mats and Rugs

Burlap, cotton mats, rugs and other coverings of absorbent materials will hold water on the surface, whether horizontal or vertical. Burlap must be free of sizing or any substances that are injurious to Portland cement or cause discolouration. New burlap shall be thoroughly rinsed in water to remove soluble substances and make the burlap more absorbent.

Burlap is available that has been treated to resist rot and fire (properties of interest when damp or dry burlap is to be stored between jobs). The heavier the weight of burlap, the more water it will hold and the less frequently it will need to be wetted.

Double thickness may be used advantageously. Lapping the strips by half widths when placing will give greater moisture retention and aid in preventing displacement of the burlap during high wind or heavy rain.

Cotton mats and rugs hold water longer than burlap with less risk of inadequate curing. They are handled much the same as burlap except that due to their greater weight, application to a freshly finished surface must wait until the concrete has stiffened to a greater degree than for burlap. Usually initial curing with a light burlap, or impermeable sheet, is applied for a few hours before placing the heavier wet cotton mats.

(4) Earth Curing

Wet earth curing has been used effectively, both on comparatively small jobs of slab or floor work, and on highway pavements. The earth shall be free of particles larger than 25 mm, and shall not have organic matter or other substances that will damage the cement by retarding or destroying its setting properties.

(5) Sand and Sawdust

Wet clean sand and sawdust are used in the same manner as earth curing. Sawdust from woods containing too much tannic acid, such as oak, shall not be used for curing, but other types of wood are acceptable. These clean, granular materials are especially useful where carpenters and form setters must work on the surface since such coverings help to protect the surface against scars and stains.




(6) Straw or Hay

Wet straw can be used but there is always the danger that wind may remove it unless it is held down with screen wire, burlap or other means. There is also the danger of fire if the straw is allowed to become dry. Such vegetable fibres may cause discolouration of the surface for several months after removal. The layer shall be at least 150 mm thick.

7 05 01 02 Sealing Materials Sealing materials are sheets or membranes placed on concrete to reduce the loss of mixing water from the concrete. Although not necessarily as effective as the application of water throughout the curing period, there are advantages in the use of sealing materials for curing that make their use preferable under many conditions. For example, if the moisture is sealed in, there is less likelihood of deficient curing due to negligence in keeping the covering wet. Also sealing materials are often less costly and are easier to handle and can be applied earlier, often without any other initial curing.

Common sealing materials are described in the following Clauses. Forms left in place serve to inhibit loss of moisture from surfaces in contact with the forms.

(1) Plastic Film

Plastic film is light in weight and can be applied as soon as free water has disappeared from the surface. It is available in different thickness and weights, and in clear, white, or black sheets. However, for curing concrete the film should meet the requirements of ASTM C 171, which specifies a 50 microns thickness.

Care must be taken not to tear or otherwise interrupt the continuity of the film curing. Plastic film reinforced with glass fibres is more durable and is less Iikely to be torn than the non-reinforced type.

Architectural or coloured concrete that is subject to critical scrutiny should be cured by other means because moisture condensing on the underside of the smooth plastic film creates an uneven distribution of water in the concrete and the migration of soluble substances that will usually result in a mottled appearance. This may not be serious in pavements, roof slabs, and kerbs and gutters, and may be prevented by occasional flooding under the film.

Combinations of plastic film bonded to absorbent fabric help to retain and distribute the moisture released from the concrete and condensed on the curing cover.

In its application, the plastic film shall be placed over the wet surface of the fresh concrete as soon as possible without marring the surface, and shall cover all exposed surfaces of the concrete. It shall be placed and weighted so that it remains in contact with the concrete during the specified length of curing.

On flat surfaces such as pavements, the film should be extended beyond the edges of the slab at least twice the thickness of the slab. Windrows of sand or earth, or strips of wood can be placed along all edges and joints in the film to retain moisture in the concrete and prevent wind from getting under the film and removing it.

(2) Waterproof Paper

Waterproof paper should comply with ASTM C 171. It is composed of two sheets of Kraft paper cemented together with a bituminous adhesive and reinforced with fibre. Most paper sheets for curing have been treated to reduce the amount of expansion and shrinkage when wetted and dried. The sheets can be cemented together with bituminous cement as desired to meet width requirements.




Paper sheets with one surface white to give reflectance and reduce absorption of heat are available. A reflectance requirement is included in ASTM C 171 to assure a useful degree of temperature control.

Waterproof paper is applied in the same manner as plastic film as above.

It is permissible to re-use waterproof paper as long as it retains moisture efficiently. Tears are readily discernible and can be repaired with a patch of paper cemented on with a waterproof glue or bituminous cement. Pin holes resulting from walking on the paper, or from deterioration of the paper through repeated use, are evident if the paper is held up to the light. When the condition of the paper is questionable, additional use can be made of it by using it in double thickness.

(3) Liquid Membrane-Forming Curing Compounds

Liquid membrane-forming compounds for curing concrete should comply with the requirements of ASTM C 309.

Compounds consisting essentially of waxes, resins, chlorinated rubber and solvents which are highly volatile at atmospheric temperatures are used extensively for curing concrete. The formulation must be such as to provide a seal shortly after being applied and must not be injurious to Portland cement paste.

White or grey pigments are sometimes added to the compound to provide reflectance of the sunrays, and to make the compound visible on the structure for inspection purposes.

Curing compounds should not be used on surfaces that are to receive additional concrete, paint or tile that requires a positive bond, unless it has been demonstrated that the membrane can be satisfactorily removed before the subsequent application is made, or that the membrane can serve satisfactorily as a base for the application.

The compound should be applied at a uniform rate sufficient to comply with the requirement of the test for water retention (ASTM C 156). The usual values for coverage range from 3.5 to 5.0 I/m2.

It can be applied by hand spray or a mechanical application distributor, usually at a pressure of 5 to 7 bar.

If the job size warrants, mechanical application is preferred because of speed and uniformity of distribution. For very small areas such as patches it can be brushed on with a wide, soft-bristled brush.

Liquid membrane-forming compounds generally must be applied at the time that the free water on the surface has disappeared and no water sheen is seen, but not so late that the liquid curing compound will be absorbed into the surface pores of the concrete.

However, under certain adverse weather conditions which could result in the formation of plastic shrinkage cracking in the fresh concrete, application of the liquid curing compound immediately after the final finishing operation and before the free water on the surface has completely disappeared may be necessary to prevent the formation of cracks.

On formed concrete surfaces the curing compound is applied immediately upon removal of the forms. If there is any drying or appreciable loss of moisture the surface shall be sprayed with water and allowed to reach a uniformly damp appearance with no free water on the surface when the compound is applied.

Pigmented compounds should be stirred to assure even distribution of the pigment during application, unless the formulation contains a thixotropic agent to prevent settlement .




7 05 01 03 Moisture Loss Moisture loss from surfaces placed against wooden forms or metal forms exposed to heating by the sun should be minimized by keeping the forms wet until they can be safely removed.

7 05 01 04 Curing Time If one of the curing procedures under item 7 05 7 02 is used initially, it may be replaced by one of the other procedures of this Clause any time after the concrete is one day old provided the concrete is not permitted to become surface dry during the transition.

7 06 Protection 7 06 01 Mechanical Damage

Self-supporting structures should not be loaded in such a way as to overstress the concrete.

7 07 Joints 7 07 01 Expansion Joints 7 07 01 01 Joints with Joint Sealant

At expansion joints in concrete slabs to be exposed, expansion joints where filler is completely covered by base and shoe mould, and at other joints indicated to receive joint sealant, premoulded expansion joint filler strips should be installed at the proper level below the finished floor with a slightly tapered, dressed-and-oiled wood strip temporarily secured to the top thereof to form a groove not less than 20 mm deep.

The wood strip should be removed after the concrete has set. The groove, when surface dry, should be cleaned of foreign matter, loose particles, and concrete protrusions, then filled approximately flush with joint sealant so as to be slightly concave after drying.

7 07 01 02 Joints with Compound When slabs on grade are to receive resilient flooring and premoulded expansion joint, filler is required between the slabs or between the slabs and vertical surfaces, the filler strips should be installed at the proper level below the finished floor with a slightly tapered, dressed-and-oiled wood strip temporarily secured to the top thereof, to form a groove not less than 6.5 mm deep. The wood strip should be removed after the concrete has set.

7 07 02 Contraction Joints 7 07 02 01 Control Joints in Walls

Control joints in cast in-situ walls are planes of weakness that permit differential movements in the plane of the wall. In lightly reinforced walls, half of the horizontal steel bars shall be cut at the joint. Care must be taken to cut alternate bars precisely at the joint. Control joints in walls should be spaced not more than about 6 m apart. In addition, control joints should be placed where abrupt changes in thickness or height occur, and near corners, if possible, as close as 1.5 m.

7 07 02 02 Control Joints in Slabs on Grade Concrete must be placed continuously so that each unit of operation will be monolithic in construction.

Concrete could be placed in alternate checkerboard pattern terminating at crack-control joints or may be placed in alternate paving lanes as limited by




expansion and construction joints and with contraction joints to provide panels of size specified.

Joints not shown should be located at column centrelines and at intermediate intervals so that each panel shall be not more than 60 square metres in area. Panels should be approximately square with dimension of any one side not more than 7.5 metres.

Forms should remain in place for at least 12 hours after concrete placement.

Where columns bear on thickened slabs or thickened edges, floor slab construction, contraction or expansion joints should be offset from thickened slabs or thickened edges.

One of the most economical methods is to saw a continuous straight slot in the top of the slab (Fig. 8).

Fig. 8: Crack control joints

The spacing of control joints in slabs on grade depends on - slab thickness - shrinkage potential of the concrete and - curing environment

Suggested joint spacing is given in the following table. Unless reliable data indicate that more widely spaced joints are feasible, the intervals given in the table should be used. The resulting panels should be approximately square. Panels with excessive length-to-width ratio (more than 1.5 to 1) are likely to crack.




Table 10: Spacing of control joints in slab on grades.

* Given spacing also apply to the distance from control joints to parallel isolation joints or to parallel construction joints. Other factors may call for different spacing.

7 08 Embedded Items 7 08 01 Installation of Anchorage Items

(1) Slots

Dovetail slots may be installed vertically in the concrete spaced not more than 600 mm apart for anchoring stone or brick facing and may be installed horizontally approximately 600 mm apart to anchor furring. Adequate slots or inserts shall be provided for anchoring members at openings.

Slots and dowels should be provided for anchoring ends and tops of masonry partitions abutting concrete. Where concrete columns to be faced with brick are less than 400 mm wide, slots may be omitted; where such columns are formed 400 to 750 mm wide, one row of slots shall be installed; where columns are more than 750 mm wide, slots shall be installed not more than 600 mm apart on centres.

Dovetail anchor slots for anchoring brick facing may be omitted in spandrel beams less than 400 mm in depth.

(2) Wire Inserts for Plaster Accessories

Where ribbed lath and metal furring are to be secured to the underside of concrete joists, fastenings should be provided for each rib or furring strip at all bearings.

If joists are more than 200 mm wide, two rows of fastenings should be used so that the unsupported span will not exceed 700 mm.

(3) Inserts for Hangers

Inserts for hangers for piping and mechanical fixtures and their installation should be as specified in the relevant Section.

Maximum spacing* of joints

Slump more than 100 mm Slump less than 100 mm

Maximum aggregate size

Slab Thickness

mm less than 16 mm more than 16 mm all sizes

125 150 175 200 225 250

3.00 m 3.60 m 4.20 m 4.80 m 5.40 m 6.00 m

3.30 m 4.00 m 5.50 m 6.00 m 7.00 m 7.50 m

4.00 m 5.50 m 6.50 m 7.20 m 8.20 m 9.00 m




7 09 Cleaning 7 09 01 Water Cleaning

Water cleaning methods include low-pressure washes, moderate to high-pressure water blasting, and steam.

Low-pressure washing is the simplest, requiring only that water run gently down the concrete surface for a day or two. The softened dirt then is flushed off with a slightly higher pressure rinse. Stubborn areas can be scrubbed with a non-metallic bristle brush and rinsed again. High-pressure water blasting is used effectively by experienced operators. Steam cleaning must be performed by skilled operators using special equipment. Water methods are the least harmful to concrete, but are not without potential problems.

7 09 02 Chemical Cleaning Chemical cleaning is usually done with water-based mixtures formulated for specific materials such as brick, stone, and concrete. A small amount of acid or alkali is included to separate the dirt from the surface. There can be problems related to the use of chemical cleaners. Their acid or alkaline properties can lead to reaction between cleaner and concrete. Since chemical cleaners are used in the form of water-diluted solutions they too can liberate soluble salts within the concrete. Chemical cleaners shall be used by skilled operators taking suitable safety precautions.

7 09 03 Mechanical Cleaning Mechanical cleaning includes abrasive blasting (sandblasting) and power chipping and grinding. These methods wear the dirt off the surface rather than separate it from the surface. They, in fact, wear away both the dirt and some of the concrete surface, and it is inevitable that there will be loss of decorative detail, increased surface roughness, and rounding of sharp corners. Abrasive methods may also reveal defects hidden beneath the formed surface.