CONCRETE AND CONCRETING 1 Reference to British Standard This Specification for concrete used in the Works is based upon

the following British Standards with the latest amendments:B.S. 12: 19 1 B.S. )1*: 19+9 B.S. -12: 19+ B.S. --2: 19+2 B.S. 1--1: 19 * B.S. 41)-: 1929 B.S 242-: 199* !ortland "ement 'ardening( Test sie,es .ethods for the Sampling and Testing .ineral /ggregates0 Sands and 1illers /ggregates from 3atural sources concrete #including granolithic( .ethods of Testing "oncrete Tests for Water for .aking "oncrete. !art ) Specification for the procedures to be used in sampling0 testing and assessing compliance of concrete. of for #$rdinar% and &apid

This Specification shall be interpreted0 and all sampling and testing shall be carried out0 in accordance with the rele,ant clauses in these Standards. 2 Cement /ll cement used in the Works shall be $rdinar% !ortland "ement of appro,ed manufacture and compl%ing with the re5uirements of B.S. 12 and shall be supplied in 2* kilogram paper bags. 6nless permission in writing is obtained from the 7ngineer0 cement ma% be supplied in bulk. The "ontractor shall submit to the 7ngineer for appro,al the name and address of the supplier and the brand of cement which he proposes to use in the Works at least two weeks before the deli,er% of cement to the site is allowed. 3ormall% the manufacturer8s test certificates will be accepted as proof of the 5ualit% of the cement9 but the 7ngineer ma% at his discretion carr% out further tests on the cement stored at the site. :n the e,ent of an% sample being found to be not in accordance with B.S. 12 the whole consignment from which the sample comes shall be re;ected and remo,ed from the site immediatel% b% the "ontractor at his own e<pense notwithstanding an% pre,ious acceptance on the strength of the manufacturer8s certificate. The "ontractor shall not be allowed to change the appro,ed source of suppl% or brand of cement at an% time or for whate,er reason without the permission in writing of the 7ngineer.

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3otwithstanding an% pre,ious acceptance an% bag of cement containing material which has hardened or otherwise deteriorated shall be re;ected and remo,ed from the site b% the "ontractor forthwith and at his own e<pense. /n% cement on transit or temporaril% placed near the mi<er or elsewhere0 after remo,al from the store0 shall be ade5uatel% protected from moisture and damage b% appro,ed means.

Storage of Cement The "ontractor shall pro,ide at his own e<pense on the site a dr%0 well-,entilated and weather-proof cement store to the appro,al of the 7ngineer for the proper storage of cement. The floor of such store shall be raised at least 4** mm abo,e ground le,el or abo,e ma<imum flood le,el at the site whiche,er is the higher. "ement supplied in bulk shall be stored in silo or other containers which are of a design appro,ed b% the 7ngineer. Batches of cement shall be used for the Works in the order in which the% are deli,ered to the site and the method of storage shall be arranged so that this ma% be done.

ine Aggregate 1ine aggregate for concrete work shall be hard0 clean0 wellgraded natural sand free from harmful 5uantities of cla% and silt0 saline and ,egetable impurities0 and other deleterious matter. :t shall be within the following grading limits:-

================================================================ > > > > > > > > >B.S.Sie,e > 2 mm > 3o. > 3o. 1) > 3o. 22 > 3o. 22 > 3o. 1**> >==========>=======>=======>========>========>========>========> > > > > > > > > >? !assing >92-1** > *-92 > )2--2 > 22-+* > 2-4* > *-1* > >==========>=======>=======>========>========>========>========> 1ield tests shall be carried out on samples to be taken from each and e,er% batch of sand supplied and deli,ered to the site. Sand shall not contain more than +? b% ,olume of cla% and@or fine silt9 neither shall it contain organic impurities in sufficient 5uantit% to show a darker colour than the standard depth of colour 3o. 4 when tested according to the standard methods gi,en in B.S. -12: 19+ . Sand which does not compl% with these re5uirements shall be re;ected and remo,ed from the site forthwith at the "ontractor8s own e<pense. ! Coarse Aggregate "oarse aggregate for concrete work shall be sound0 hard0 clean0 roughl% cubical shaped crushed granite particles free from

C-2

harmful 5uantities of cla%0 crusher dust0 organic impurities or other deleterious matter. "oarse aggregate containing an e<cessi,e proportion of flat particles0 splinters or flakes0 will not be accepted. The ;udgment of the 7ngineer in this matter shall be final and binding on the "ontractor. Aimestone shall not be used as coarse aggregate without the permission in writing of the 7ngineer. 6nder no circumstance shall limestone be used as aggregate in water retaining structures.

The grading of coarse aggregate shall be within the following limits:======================================================= > > > > > > B.S. Sie,e > 2* mm > 1* mm > 2 mm > >=============>========>=========>====================> > > > > > > ? !assing > 1**? > 22 - 22 > 3ot more than 1* > >=============>========>=========>====================>

"

Sam#$ing and Testing of Aggregates The "ontractor shall submit to the 7ngineer for appro,al the sources of suppl% and samples of fine and coarse aggregates which he proposes to use in the Works before the deli,er% of aggregates to the site is permitted. Samples of the fine and coarse aggregates appro,ed b% the 7ngineer shall be kept on the site9 and the "ontractor shall secure his entire suppl% of each material from the same source and ensures that all aggregates deli,ered to the site throughout the course of the Works are of the same 5ualit% and grading as the appro,ed samples. Should it become necessar% to change the sources or characteristics of an% aggregate this shall onl% be done after new samples ha,e been tested and appro,ed b% the 7ngineer and sub;ect to such safeguards as the 7ngineer ma% impose for the maintenance of the 5ualit% of the aggregate specified. The method of sampling and amount of aggregate to be pro,ided shall be in accordance with B.S. -12: 19+ . The tests shall be those as laid down in B.S. -12 : 19+ unless otherwise directed b% the 7ngineer. The tests shall be carried out b% the 7ngineer and if a sample should fail in an% of the tests the 7ngineer ma% at his discretion0 either re;ect the batch from which the sample was taken or order it to be washed and@or screened at the "ontractor8s e<pense. /n% batch of the aggregate re;ected b% the 7ngineer shall be remo,ed from the site forthwith at the "ontractor8s e<pense.

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Storage of Aggregates The "ontractor shall at his own e<pense pro,ide proper and ade5uate storage of the fine and coarse aggregates on the site to the satisfaction of 7ngineer. The fine and coarse aggregate shall be handled and stored separatel% and in such a manner that segregation of the ,arious siBed particles does not occur. There shall be a ph%sical partition between the heaps of sand and the heaps of coarse aggregate to pre,ent intermi<ing of the aggregates. The stock piles shall be formed on a platform of weak concrete0 timber or similar appro,ed hard standing and aggregates shall be kept clean and free from earth and foreign matter. /ggregates which in the opinion of the 7ngineer are not clean or ha,e become intermi<ed due to improper storage shall be remo,ed from the site at the "ontractor8s e<pense. & 'ater Water used for making and curing concrete and for testing the watertightness of structures shall be fresh0 clean and not contain organic matter0 sulphates or other impurities in sufficient 5uantities likel% to reduce the strength of the concrete or attack the concrete or the reinforcement. The 7ngineer8s decision on the suitabilit% or unsuitabilit% of a source of water for his purpose shall be final. Where possible0 all water shall be obtained from the public suppl% mains. When such a suppl% is not a,ailable the "ontractor shall make arrangements for obtaining water from a source appro,ed b% the 7ngineer. :n an% case the "ontractor shall pro,ide sufficient storage tanks at the site to store enough water for 1-1@2 da%s8 use in the Works.

Stee$ Reinforcement Bar reinforcement shall be rolled steel bars of a manufacture appro,ed b% the 7ngineer and shall compl% with B.S. )))9. Steel fabric reinforcement shall compl% with B.S. ))-4. The manufacturer8s certificates of test will be accepted as proof of the 5ualit% of the steel reinforcement but the 7ngineer ma%0 at his discretion0 re5uire additional tests to be made on samples of steel reinforcement stored at the site. :n the e,ent of an% reinforcement being found to be not in accordance with the rele,ant Standard under these tests or in the course of being worked0 the whole batch of reinforcement from which the fault% reinforcement comes ma% be re;ected b% the 7ngineer notwithstanding an% pre,ious acceptance on the strength of the manufacturer8s certificate. /n% reinforcement re;ected b% the 7ngineer shall be remo,ed from the site at the "ontractor8s e<pense.

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/ll reinforcement shall be cleaned from loose millscales0 loose rust0 oil0 grease0 earth and other harmful matter before being placed in the forms and shall be free from these at the time the concrete is placed. 1) Bending* +$acing and i,ing Reinforcement

/ll reinforcement shall be bent cold using bar bending machines and appliances appro,ed b% the 7ngineer. 6nless otherwise specified in the Crawings the bending dimensions and tolerances and the dimensions of end anchorage0 hooks0 binders0 stirrups and the like shall be in accordance with B.S. ))++0 8Bending Cimensions and Scheduling of Bars for the &einforcement of "oncrete8. The reinforcement shall be accuratel% assembled firml% secured b% wire ties made from 3o. 1+ S.W.D. soft annealed wire so that the whole assembl% is rigid and will not be displaced while concrete is being compacted around it. The ends of the wire ties shall be turned inward awa% from the face of the forms and shall not be left pro;ecting be%ond the reinforcing bars. Temporar% bracing shall be pro,ided to pre,ent mo,ement of all steel pro;ecting from the concrete during the course of construction. The co,er shown on the Crawings shall be maintained b% precast spacing blocks securel% wired to the bars or b% other means appro,ed b% the 7ngineer. Spacing Blocks for the ,arious co,er dimensions shall be cast from cement mortar made from 1 part of cement and 2 parts of sand. The blocks shall be well compacted and shall recei,e full curing treatment before being used. Where it is necessar% to maintain two la%ers of reinforcement at the correct distance apart #e.g. to maintain the correct position of the top la%er of reinforcement in the floor slab( steel riders bent from 14 mm diameter mild steel bars shall be used. The use of wooden battens for this purpose is prohibited. 11 'e$ding of Reinforcement Welding of reinforcement will be permitted onl% under suitable conditions and with suitable safeguards. The welding shall be b% electric arc and shall be performed b% a skilled operator appro,ed b% the 7ngineer. 3o welding shall be performed e<cept under the super,ision of the 7ngineer8s representati,e. The surface of the bars must be thoroughl% cleaned and scrubbed with a wire brush immediatel% before welding0 and the weld must be deposited e,enl% and all slag shall be remo,ed. The finished surface of the weld shall be of e,en contour without ca,ities and undercutting. Welding shall be carried out in accordance with B.S. 1-2+: 19+) EDeneral re5uirements for the metal-arc welding of mild steelE and B.S. 2+)2: 19+2 EDeneral re5uirements for the arc welding of carbon manganese steelE. Butt welds shall be of the double

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F-t%pe and two butt weld bend tests shall be carried out on a specimen prepared to represent each form of butt welded ;oint. The method of making weld tests shall be that laid down in B.S. *9: 19+). 12 orm-or. The formwork shall be constructed with an% of the following materials:#i( Sound softwood tongued and groo,ed boards not less than 2* mm finished thickness0 wrought on one side and two edges0 accuratel% formed and securel% fi<ed to softwood frames. The surfaces of the formwork shall be worked to a smooth finish after fabrication. Sound softwood timber boards not less than 2* mm thick lined with gal,anised metal sheet not less than 1S.W.D. The boards supporting the metal lining shall be of uniform thickness and the formwork panels shall be made so that the% butt closel% together0 and grout cannot leak from the ;oints between ad;acent panels. less

#ii(

#iii( Waterproofed pl%wood of appro,ed manufacture not than 1* mm thick0 securel% fi<ed to timber frames. #i,( /n appro,ed metal formwork s%stem.

/ll formwork shall be erected true to line and le,el and shall be ade5uatel% secured and braced to pre,ent deflection or mo,ement during the placing0 tamping or ,ibrating of the concrete0 and shall be sufficientl% tight to pre,ent loss of li5uid. "olumn formwork shall be arranged so that the concrete being placed does not ha,e a free fall of more than 1.2 m and suitable openings shall be pro,ided in the column forms to allow concrete to be deposited in stages not more than 1.2 m high. The use of wires passing through the concrete for the purpose of securing the formwork in position shall not be permitted. Bolts passing through the concrete ma% be used0 but their number must be kept to the minimum re5uired to secure the formwork rigidl%. The bolts shall be not less than 14 mm in diameter and of a t%pe with detachable screw off heads so that the barrels of the bolts remain cast in the concrete while the detachable heads can be remo,ed with ease. The barrel of e,er% bolt used in water retaining0 water con,e%ing or water e<cluding structures shall ha,e a waterstop in the form of a 1** mm < 1** mm < 4.2 mm steel washer on at the mid-length of the bolt. The weld shall be continuous round the barrel and on both sides of the washer. Before an% concrete is placed all rubbish shall be remo,ed from the interior of the forms. Suitable opening shall be pro,ided for this purpose and the openings shall be effecti,el% plugged before concrete is placed. The forms and all concrete ;oint

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surfaces within the forms shall be thoroughl% flushed with water. The forms ma% with the appro,al of the 7ngineer be treated with an appro,ed composition. "are should be taken to ensure that such composition is kept out of contact with the reinforcement and concrete ;oint surfaces0 and that there is no e<cess of such composition remaining on the forms prior to concreting. Within four weeks of the acceptance of his tender the "ontractor shall submit for the appro,al of the 7ngineer drawings and descriptions showing the methods he proposes to use for the erection and support of the formwork. 13 Concrete +ro#ortions #i( "oncrete for the se,eral parts of the works shall be proportioned as indicated in Table 8/8 #e<cept as pro,ided under the sub-clause #iii( below(. "ement0 fine aggregate and coarse aggregate shall be measured b% weight9 and water b% ,olume. The fine and coarse aggregate shall be measured separatel%. / weigh batcher shall be used for the purpose of weighing cement0 fine aggregate and coarse aggregate. The accurac% of the weights indicated b% the weight batcher shall be regularl% checked and shall be maintained within ).2 kg. of the actual total weight of all aggregates and cement in one batch. The weights of the fine and coarse aggregate specified in Table 8/8 refer to the materials in the dr% state. Tests shall be carried out twice dail% or more fre5uentl% if considered necessar% b% the 7ngineer to determine the moisture content of the fine aggregate. /llowance shall be made for the water contained in the aggregate when calculating the water to be added to the mi<.

#ii(

#iii( While the proportions of the mi<es are to be generall% as specified in Table 8/80 the 7ngineer shall ha,e the right to order ,ariations in these proportions without e<tra cost to the 7mplo%er should tests show such ,ariations to be necessar% to produce a dense watertight concrete of the specified strength and of a consistenc% that will permit of its being worked into position and compacted satisfactoril% into the different parts of the works. The proportions of the mi<es specified in Table 8/80 are e<pected to produce works cube strengths in e<cess of those specified in Table 8/8 and a workabilit% sufficient to ensure that the concrete can be worked and full% compacted using the methods of ,ibration hereinafter specified in this Specification. :f0 howe,er0 it is shown during the course of the work that the concrete mi< is stiffer than can be placed satisfactoril% and ad;ustment of up to 2? ma% be made in the water@cement ratio0 but an% further ad;ustment of the mi< shall be made b% increasing the proportions of both the water and cement without increasing the water@cement ratio. :f the works cube strengths fall below those specified0 the cement proportions shall be increased.

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14

Designed Concrete /i,es Cesigned concrete mi<es ma% be used and shall compl% with the recommendations of BS -11*. 'owe,er0the grades of concrete to be used shall be as below which supersede table 4.4 of BS -11*: ================================================================

=== > > .inimum > > .inimum > > 3ominal > "rushing > .a<imum > "ement > > .i< > &esistance in > aggregate > content per cu. > > 75ui,alent > 3@mm 2 > siBe > m of finished > > > within 2- da%s > > concrete. > > > after mi<ing. > > > ============ ================= =============== ================== > #1:1:2( > 4* > 2* mm > 42* kg > >============>=================>===============> 22 > 2* mm > 29* kg > >============>=================>===============> 2* > 2* mm > 2 2 kg > >============>=================>===============>

==================> > #1:1.2:4( >

==================> > #1:2:)( >

==================> "ement0 coarse and fine aggregates and water shall compl% with the foregoing clauses of this specification. :f the "ontractor chooses to use designed concrete mi<es0 he shall emplo% a competent and suitabl% 5ualified person to design the mi<0 to super,ise and direct all stages in the preparation and placing of the concrete. The sampling0 making0 curing and testing of the works cubes shall still be carried out b% the Superintending $fficer or his representati,es0 the "ontractor affording all facilities. The "ontractor or his representati,es ma%0 if the% so wish0 be present while the cubes are being made and tested. 1! +re$iminar0 Test /i,es /s soon as possible after possession of site0 and before concrete is placed0 the "ontractor shall prepare under the direction of the 7ngineer a series of trial mi<es totalling not more than 4 cubic meter of concrete. Test cubes will be made from samples of these trial mi<es0 cured and tested in accordance with the standard methods laid down in B.S. 1--10 19 * to determine the cube strengths at da%s and 2- da%s after casting. The cube strengths obtained shall be at least 2*? greater than those specified in Table G/8 for work cubes. The mi< proportions specified in Table G/8 will be ad;usted as necessar% b% the 7ngineer on the basis of these tests without e<tra cost to the 7mplo%er.

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1"

Sam#$ing and Testing Concrete and Concrete /ateria$s /ll sampling and testing will be carried out in accordance with the standard methods laid down in B.S. 1--10 19 * unless otherwise specified in the following clauses. The "ontractor shall attend upon and pro,ide all assistance to the 7ngineer when such sampling and tests are carried out0 and shall suppl% all concrete samples and other materials re5uired.

1%

re12enc0 of Sam#$ing and Testing #i( "ompacting 1actor The compacting factor of the mi< will be tested. #a( #b( #c( dail% while concrete is being placed0 Whene,er samples for test cubes are taken0 Whene,er0 in the opinion of the 7ngineer0 the grading or condition of an% of the aggregates has changed since the last test was made.

#ii(

Test "ubes / set of + concrete test cubes0 4 for testing at da%s and 4 for testing at 2- da%s after casting0 will be made. #a( #b( #c( e,er% da% while concrete is being placed. e,er% 12* m 4 of concrete or part thereof.

whene,er the mi< or an% of its constituents are changed either in 5uantit% or 5ualit%.

#iii(

/ggregate Drading and !urit% The grading of the aggregates and their freedom from organic matter will be tested. #a( when the arri,e on the site first deli,eries of these materials

#b(

whene,er0 in the opinion of the 7ngineer0 the grading or condition of these materials differs from that originall% accepted for use in the work.

1&

Re3ection of Concrete :f an% of the test cubes tested at da%s show a compressi,e strength less than that specified0 the 7ngineer shall0 at his discretion0 order all concreting work to stop until ade5uate

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measures ha,e been taken to produce concrete which complies with this Specification. :f the cube strengths at 2- da%s are less than those specified0 the work from which the concrete for the test cubes was taken will be re;ected b% the 7ngineer0 and will be broken out and rebuilt or otherwise made good as directed b% him at the "ontractor8s own e<pense. 1( S2#er4ision The "ontractor shall keep constantl% at the site while concrete is being mi<ed and placed a competent .ala%@7nglish speaking assistant for the purpose of super,ising the batching of the concrete ingredients and the mi<ing0 placing and compacting of the concrete. This assistant shall be emplo%ed solel% for this purpose and the right is reser,ed to the 7ngineer or his representati,e at the site to order work on working or placing of concrete to cease if this assistant is not present. 2) /i,ing concrete /ll concrete shall be mi<ed in an appro,ed batch mi<er of at least 1)@1* capacit%0 fitting with a power dri,en loading skip. The mi<er shall be e5uipped with an automatic water measuring tank fitted with a de,ice for locking the discharge setting so that the ,olume of water used in each batch of concrete is accuratel% measured and cannot be ,aried b% the mi<er operator after the de,ice is set and checked b% the 7ngineer8s representati,e on the site. The mi<er drum and the loading skip shall be kept clean at all times. 7ach batch of concrete shall contain one or more whole bags of cement. The materials for each mi< shall be placed in the loading skip in the following order: coarse aggregate0 cement0 and fine aggregate. The water shall be added to the dr% materials in the mi<er drum. The 5uantit% of water specified in Table G/8 ma% be ,aried up to 2? in order to maintain a constant workabilit%9 but this tolerance shall not be e<ceeded without prior appro,al of the 7ngineer. 7ach batch of concrete shall be mi<ed until there is a uniform distribution of the materials and the mass is uniform in colour and consistenc%. :n no case shall the time of mi<ing be less than two minutes or more than fi,e minutes after the water has been added to the batch. /n% concrete surplus to re5uirements shall be thrown awa%. :n no circumstances ma% surplus concrete be remi<ed for use later. 21 +$acing of Concrete Genera$$0 3o concrete shall be placed until the formwork and reinforcement ha,e been appro,ed b% the 7ngineer. The concrete shall be transported from the mi<er to the position in which it is to be placed without dela%0 and b% means which will pre,ent loss of grout and@or segregation of the mi<.

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"oncrete ma% be con,e%ed b% chute onl% with the permission of the 7ngineer. /n% concrete which has attained its initial set before being placed shall be discarded. !lacing concrete shall be suspended during rain. "oncreting shall be carried out continuousl% between and up to the predetermined da%8s work or construction ;oints in one se5uence of operation. /ll concrete shall be placed in the position in which it is to be compacted and the material shall not be allowed to flow while it is being placed and compacted. Fibrators shall be used solel% for compacting the concrete and not for distributing it into place. The concrete shall be pre,ented from flowing laterall% b% the use of ,ertical stopping off boards0 or other ,ertical faces0 and the surface of the concrete shall be maintained reasonabl% le,el during placing. "oncrete shall be placed in the formwork in la%ers not e<ceeding )2* mm thick. :n the e,ent of una,oidable stoppage in positions not predetermined0 the concrete shall be terminated on horiBontal planes and against ,ertical surfaces and an additional da%8s work ;oint formed. / record shall be kept on the works site of the time and date of placing the concrete in each position of the structure. 22 Com#action of Concrete "oncrete after placing shall be thoroughl% compacted b% both hand tamping and mechanical ,ibration. "oncrete maintained between two walls of formwork shall be compacted b% power dri,en ,ibrators of the immersion t%pe and concrete in slabs with no formworks on the upper surface shall be compacted b% power dri,en ,ibrators of the pan t%pe or b% ,ibrating screeds. The ,ibrators shall be of ample power operating at not less than )0*** &.!... and of a kind appro,ed b% the 7ngineer. The% shall be operated b% workmen skilled in their use who shall be additional to the labourers emplo%ed on placing and tamping the concrete. 3o concreting of water retaining0 water con,e%ing or water e<cluding structures shall begin until the re5uired number of ,ibrators and also a spare ,ibrator are all a,ailable and ha,e all been tested and found to be in good working condition at the works site. :mmersion ,ibrators shall be inserted and withdrawn slowl% at a uniform rate of appro<imatel% 1** mm per second. "ompaction shall be deemed to be completed when cement mortar appears in a circle round the ,ibrator. :mmersion ,ibrators shall be inserted at points ;udged b% the area of mortar shown after compaction0 with a certain allowance made for o,erlapping. The immersion ,ibrators shall not be allowed to come into contact with the formwork or the reinforcement. !an ,ibrators shall be placed on the surface or the concrete which shall ha,e pre,iousl% been tamped and le,elled lea,ing an allowance in height for compaction0 until cement mortar appears under the pan. The ,ibrators shall then be lifted and placed on

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the ad;oining area and the operation shall be repeated until the whole surface has been compacted. /lternati,el% a ,ibrator spanning the full width of the panel shall be used. :n all cases the placing of concrete shall be sufficientl% ahead of the ,ibrators so that the mass of concrete be%ond the ,ibrators is sufficient to stand without flowing while ,ibration is in progress. $n the other hand0 the concrete shall be full% compacted before initial set is attained. 23 Constr2ction of Concrete Screed /s soon as the e<ca,ation has been appro,ed b% the 7ngineer the concrete screed where,er shown on the Crawings shall be laid in ba%s not e<ceeding .2 m s5uare with open ;oints 22 mm wide in between the ba%s. The ;oints shall be arranged to break ;oint with the ;oints in the concrete floor abo,e. The screed shall be well rammed and worked to a dense smooth finish0 and cured b% being kept damp under wet gunn% bags for not less than da%s. /fter the screed has been cured0 the 22 mm wide ;oints shall be cleaned and filled with 1:4 cement sand mortar and the whole surface allowed to dr% out. Should the surfaces of the formation be cut up through e<cessi,e traffic or softened b% the action of water due to dela% on the part of the "ontractor to la% the concrete screed he shall e<ca,ate such ground as ma% be affected and replace it b% .ass "oncrete all at his own e<pense and to the satisfaction of the 7ngineer before the screed is laid. 24 Constr2ction of $oors of 'ater Retaining* 'ater con4e0ing* or 'ater E,c$2ding Str2ct2res and $at Roofs The floors or roofs are di,ided into segments bounded b% ;oints shown on the Crawings. The concrete in each segment shall be placed and compacted in regular strips across the full width of the segment. 7ach strip shall be placed against the pre,ious strip before the concrete in the latter has attained initial set. 7ach segment shall be concreted in one continuous operation0 and the "ontractor shall so arrange his concreting programme that not less than da%s shall elapse between the placing of concrete in an% two ad;acent segments. The concrete shall be compacted first with immersion t%pe ,ibrators and then@or with pan t%pe ,ibrators. "oncrete shall be placed and uniforml% distributed to such a depth that after complete compaction the concrete surface is at the finished re5uired le,el. /n% areas which are below the finished le,el or where segregation has taken place shall be dug out and immediatel% made good with fresh concrete. /fter the concrete has been thoroughl% compacted0 the surface shall be thoroughl% worked to a dense true finish with a wooden float. 6nder no circumstances shall neat cement be sprinkled on the surface of the concrete.

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Where reinforcement is continuous across the ;oints0 notched ,ertical stopping off boards shall be used for the reinforcement to pass through. The ;oints shall each ha,e a 6-groo,e formed at the top to recei,e sealing compound. 2! Constr2ction of 'a$$s of 'ater Retaining* 'ater Con4e0ing* or 'ater E,c$2ding Str2ct2res The walls are di,ided into segments b% ,ertical ;oints which are continuous with the floor ;oints and e<tend the full height of the walls in unbroken alignment. 7ach segment between the height of 2*mm abo,e the top of the haunch and the underside of the wall@ring beam shall be cast in a series of lifts not e<ceeding 1.42 m high each. /lternate segments in a lift shall be concreted0 and an inter,al of da%s shall ha,e elapsed before the inter,ening segments in the same lift are concreted. $ne lift of the wall all round shall be completed before the ne<t higher lift is concreted. 7ach panel defined b% the ,ertical ;oints and the height of a lift shall be concreted in one continuous operation. The concrete shall be placed and compacted in la%ers not e<ceeding )2* mm in depth. The placing of concrete shall be kept 1.2 m ahead of the ,ibrators so that the mass of concrete be%ond the ,ibrators is sufficient to stand without flowing while the ,ibration is in progress. 7ach la%er shall be placed and compacted before the concrete in the lower la%er has attained its initial set. 7ach ;oint shall ha,e a 6-groo,e formed on the water retaining face as well as on the water e<cluding face to recei,e sealing compound. 2" Constr2ction of 'a$$ ootings and 5a2nches of 'ater Retaining* 'ater Con4e0ing or 'ater E,c$2ding Str2ct2res 7ach segment of the wall footing and haunch defined b% the floor and wall ;oints and a horiBontal plane 2* mm abo,e the top of the haunch shall be concreted in one continuous operation. The concrete shall be placed and compacted in the manner herein before specified in this Specification. Dreat care shall be e<ercised to ensure that the concrete in and around the haunch is thoroughl% compacted. /lternate segments of the footing and haunch shall be concreted and an inter,al of da%s shall elapse before the inter,ening segments are concreted. 2% Constr2ction of Dome Roofs Come roofs shall be cast on the formwork in one la%er. The% shall be cast in segments defined b% the ;oints shown on the Crawings. /lternate segments shall be cast0 and an inter,al of da%s shall ha,e elapsed before the inter,ening segments are

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concreted. The indi,idual segments shall be cast in one continuous operation0 the concrete being placed and compacted in regular strips across the full width of the segments. 7ach strip shall be placed against the pre,ious strip before the concrete in the latter has attained its initial set. Where reinforcement is continuous across the ;oints0 the ,ertical stopping off boards shall be notched to allow the reinforcement to pass through. The ;oint shall each ha,e a 6-groo,e formed on the top to recei,e sealing compound. 2& 6oints The "ontractor shall make the ;oints in the floors0 walls and roofs strictl% in accordance with the Crawings. !articular care shall be taken to ensure that the waterstops where,er shown on the Crawings are ade5uatel% secured so that the% will not be displaced while concrete is being placed. 6nder no circumstance shall waterstops be nailed through. /n% water stop which has been perforated shall be re;ected and replaced at the "ontractor8s e<pense. /s soon as possible after the remo,al of the shuttering in ,ertical ;oints or after the concrete has set in horiBontal ;oints the surface laitance of the concrete shall be remo,ed in order to e<pose the large aggregate and lea,e a solid surface. :f the concrete has not hardened this ma% be achie,ed b% brushing with a wire brush or pressure spra%ing with water but if this is not possible due to the hardening of the concrete it will be necessar% to remo,e the laitance b% using a scaling hammer or other mechanical de,ice. "are shall be taken to a,oid the use of e<cessi,el% powerful hammers as these are likel% to damage the concrete b% dislodging or fracturing the aggregates. Before concreting is resumed0 care shall be taken to ensure that there is no loose matter on the concrete surface. The surface shall be thoroughl% wetted and co,ered with a la%er of 1:1-1@2 cement and sand mortar not less than )* mm thick. The mortar shall ha,e the consistenc% of condensed milk. 2( Da07s 'or. 6oints Ca%8s work ;oints in floors0 roofs and slabs shall be formed against ,ertical boards and the concrete shall be well compacted against the boards. 3o fresh concrete shall be placed against an% concrete in which has attained its initial set. "oncrete is deemed to ha,e attained its initial set 4* minutes after water has been added to the mi<. !ro,ided that the set concrete has been properl% placed and compacted and is acceptable to the 7ngineer0 it shall not be disturbed and shall be allowed to attain its final set and to harden sufficientl% to enable a da%8s work ;oint surface on it to be prepared b% thorough hacking without damage. "oncrete ma% be deemed to ha,e hardened sufficientl% for this purpose 2 hours after placing. /n% concrete which has been disturbed after it has attained its initial set shall be re;ected and subse5uentl% remo,ed and replaced b% the "ontractor at his own e<pense.

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When concreting must be suspended at an% point because of inclement weather0 or for an% unforeseen cause0 a da%8s work ;oint shall be made. When concrete at a da%8s work ;oint shall be allowed to harden for 2 hours. Before fresh concrete is placed against the da%8s work ;oint0 all loose and imperfect materials cement scums or laitance shall be remo,ed from the ;oint surface0 which shall be thoroughl% hacked until a completel% hacked0 roughened fresh surface is obtained. The fresh surface shall then be brushed clean0 and immediatel% before fresh concrete is placed against it0 it shall be thoroughl% wetted and co,ered with a la%er of 1:1-1@2 cement and sand mortar not less than )* mm thick. The mortar shall ha,e the consistenc% of condensed milk. 3) Sea$ing Com#o2nds $nl% non-hardening sealing compounds appro,ed b% the 7ngineer shall be used for sealing the groo,es pro,ided at ;oints. /ll sealing compounds shall be applied in strict accordance with the manufacturer8s instructions. The groo,es for recei,ing the sealing compounds shall be thoroughl% brushed to remo,e grit0 soil and other loose particles. The groo,es and the surrounding concrete shall be thoroughl% dried b% such means as the 7ngineer shall direct0 and the sealing compounds or primers shall be applied before dampness returns to the surface of the concrete. 31 'atersto#s $nl% waterstops appro,ed b% the 7ngineer shall be used. The "ontractor shall carefull% read the waterstop manufacturer8s instructions before commencing an% work in,ol,ing the incorporation of waterstops and shall carr% out all work in this connection as recommended b% the manufacturer and to the appro,al of the 7ngineer. Waterstops shall be full% continuous when laid and site ;oints shall be limited to simple butt ;oints which are to be made with the manufacturer8s fusing ;ig. / careful check shall be made on all ;oints after completion to ensure that no imperfections e<ist. Waterstops shall be securel% held in position b% the formwork or b% means to be appro,ed b% the 7ngineer and the concrete shall be carefull% worked around the waterstops to ensure that it is completel% embedded and that air pockets will not e<ist. 32 +i#es* S#ecia$s* ittings* etc8 cast into Concrete

Where shown in the Crawings the "ontractor shall build pipes0 specials0 fittings0 plates0 anchor hooks0 brackets0 bolts and nuts0 etc. into the concrete as the work progresses. The

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e<ternal coating of the pipes and specials shall be remo,ed to the e<tent directed b% the 7ngineer so that a proper bond ma% be obtained with the concrete. These pipes0 specials0 fittings0 etc. shall be accuratel% set and rigidl% supported and their lines and le,els shall be passed b% the 7ngineer before concreting is commenced. 3o reinforcement shall be cut to allow such pipes0 specials0 fittings0 etc. to be cast into the work without the appro,al of the 7ngineer. "oncrete shall be thoroughl% worked around the pipes0 specials0 fittings0 etc. to ensure a complete bond so that no leakage will result from the presence of the pipes0 specials0 fittings0 etc. :f the pipes0 specials0 fittings0 etc. to be built into the work are not a,ailable when concrete is to be placed0 openings shall be left in the concrete and the pipes0 specials0 fittings0 etc. shall be concreted in as a separate operation. The openings left shall be of ample siBe to allow the concrete to be thoroughl% compacted around the pipes0 specials0 fittings0 etc. and shall be pro,ided with waterstops if the 7ngineer so directs. Before concrete is placed in such openings0 all loose or imperfect materials0 cement scum or laitance shall be remo,ed and the ;oint surfaces shall be thoroughl% hacked until a completel% hacked roughened fresh surface is obtained. The fresh surfaces shall then be brushed clean and immediatel% before concrete is placed0 these surfaces shall be thoroughl% wetted and co,ered with a la%er of )* mm thickness of 1:1-1@2 cement sand mortar of the consistenc% of condensed milk. 33 C2ring Concrete /s soon as the freshl% placed concrete has hardened sufficientl% to withstand such treatment without damage0 the e<posed surfaces of roofs0 floors0 walls and columns shall be completel% co,ered with wet gunn% bags0 which shall be kept thoroughl% wet continuousl% b% generous application of water e,er% two hours for a period of - da%s. The water shall be allowed to run down between the forms and the formed concrete surfaces. 1lat slabs shall ha,e water impounded on them for a period of at least 1* da%s after placing. When all the concrete in the floor and the haunch of an% water retaining0 water con,e%ing or water e<cluding structure ha,e been placed and the concrete attained the final set0 the whole of the floor shall be flooded with water to a depth of not less than 2 mm. This depth of water shall be maintained throughout the rest of the construction period. The "ontractor shall make pro,isions for distributing an ade5uate 5uantit% of water to all parts of the work for this purpose. 34 Stri.ing orm-or.

3o formwork shall be struck without the prior appro,al of the 7ngineer 1ormwork shall be remo,ed in accordance with a

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programme agreed to b% the 7ngineer without such shock or ,ibration as would damage the concrete and without interruption to the curing of the concrete as herein before specified in this Specification. 3ormall% formwork shall be struck after the following periods ha,e elapsed. 1rom sides of beams0 walls and columns #unloaded( 1rom bottom of slabs #props left under( .. .. 4 da%s da%s da%s 1) da%s 1) da%s shall be left

1rom soffits of beams #props left under( .. &emo,al of props under slabs #unloaded( &emo,al of props under beams #unloaded( .. ..

"oncrete e<posed b% the remo,al of formwork untouched pending inspection b% the 7ngineer. 3! S2rface Treatment to Concrete

/fter the concrete surface has been inspected b% the 7ngineer the surface shall be treated as described below. /ll areas where the concrete has not been properl% consolidated to a dense uniform surface shall be cut out0 and made good to the satisfaction of the 7ngineer. /ll bolt holes left b% the formwork bolts shall be plugged as described herein. The sides of the holes shall be reamed with a hacksaw blade until the cement scum is remo,ed. The holes shall then be flushed with a strong ;et of water to remo,e all loose materials. While the holes are still wet0 the sides of the holes shall be dusted with neat cement using a suitable brush for this purpose. :mmediatel% following this the holes shall be plugged with a dr% pack consisting of one part of cement and two parts of fine sand. The mi<ture of cement and sand shall be made onl% sufficientl% damp with water to allow it to be rammed solid without e<uding an% li5uid0 and after thorough mi<ing shall be placed in the holes in thin la%ers and solidl% compacted o,er the entire surface with a hardwood stick and a hammer0 and finall% struck off to a true surface. 7<posed concrete surfaces and surfaces to be in contact with water shall be treated as follows:#a( /ll pro;ecting imperfections shall be carefull% chipped off and rubbed down with carborundum blocks to a true surface0 and the grit or dirt resulting there from thoroughl% washed off with clean water. Where,er necessar%0 the surface shall wet0 and a cement grout composed of 1 2 parts of fine sand b% ,olume shall pores and holes o,er the surface with be made thoroughl% part of cement and be worked into the a fine carborundum

#b(

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float so that a uniform smooth throughout is finall% presented.

and

dense

surface

/ll defects on concrete surfaces which will be permanentl% concealed in the finished structure shall be repaired and made good as directed. 3" Testing for 'atertightness The "ontractor shall0 at his own e<pense0 conduct the tests for water tightness of all water retaining0 water con,e%ing0 and water e<cluding structures and shall pro,ide all the water re5uired for this purpose. The first test on a structure shall not be carried out until four weeks ha,e elapsed after the placing of the last batch of concrete in the structure is completed. The structure shall be filled with water to the top water le,el shown on the Crawings and maintained at that le,el for three da%s. Should an% ob,ious signs of leakage be obser,ed during this period0 or an% subse5uent test period0 the positions of all such signs of leakage shall be marked and the test shall be stopped9 and the "ontractor shall at his own e<pense carr% out such remedial measures as the 7ngineer shall direct including the complete empt%ing of the structure if necessar%. Should the leakage be general the remedial measures ma% include the complete treatment of the inside surfaces of the structure b% rendering or b% the application of some other appro,ed waterproof coating. When all ob,ious signs of leakage ha,e been stopped and made good in accordance with the 7ngineer8s instructions0 the structure shall be refilled to top water le,el0 and so maintained for three da%s. /t the end of the third da%0 pro,ided no further signs of leakage are obser,ed the e<act water le,el shall be marked0 and after a further se,ent%-two hour period0 the water le,el shall again be marked and the difference recorded. Curing this se,ent%-two hour period an e,aporation test shall be carried out in the manner described hereunder. The structure shall be deemed watertight and shall be so accepted in this respect onl% b% the 7ngineer if the recorded difference minus the loss of water b% e,aporation gi,es a figure which does not e<ceed 1@2*** of the depth of the water originall% in the structure. Should0 howe,er0 the abo,e recorded difference minus the loss of water b% e,aporation gi,e a figure which e<ceeds 1@2*** of the depth of the water originall% in the structure0 the "ontractor shall0 at his own e<pense0 carr% out the complete treatment of the inside of the structure b% rendering or such other remedial measures as the 7ngineer ma% direct. $n completion of such treatment0 the "ontractor shall at his own e<pense retest the structure and repeat these remedial measures0 if found necessar%0 until watertightness is obtained. Curing the test0 the loss of water b% e,aporation shall be determined b% measurement of the loss of water from a shallow watertight tra% *.42 m2 in area containing not less than 2 mm of water and floating on the surface of the water in the structure.

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Should an% leakage and@or percolation de,elop during the defects liabilit% period specified in the "ontract0 remedial measures similar to those specified abo,e0 followed b% tests for watertightness0 shall be carried out b% the "ontractor at his own e<pense. 3% +recast Concrete 9nits /ll precast concrete shall be grade 22 as specified in Table G/8. !recast concrete pipes shall be manufactured b% the centrifugal spinning process0 and all other precast concrete units shall be manufactured in mechanicall% ,ibrated moulds. :f an% of the precast concrete units is manufactured awa% from the site of the work0 the contractor shall satisf% the 7ngineer that the concrete proportions0 reinforcement0 etc. are in accordance with the drawings and this Specification0 and if re5uired0 he shall produce samples for testing. /ll precast units shall be handled and stocked so as to a,oid damage and ensure that no undue stress is imposed on them. The "ontractor shall remo,e from the site and replace at his own e<pense an% precast units which are damaged due to his own negligence or which are re;ected b% the 7ngineer. !recast &.". lou,res shall be cast true to form and be uniform throughout in accordance with detailed drawings.

3&

S2rface 'ater Drains and A#rons !recast concrete surface waterdrains shall be cast in +** mm lengths with dimensions as shown on the Crawings. The drains shall be properl% bedded and ;ointed with 1:4 cement sand mortar and laid to falls as directed b% the 7ngineer.

3(

R8C8 :into$s and Ci$$s !recast reinforced concrete lintols shall be built to the full thickness of the walls in which the% occur and with 222 mm bearing on either side of the opening which the% span unless smaller bearings are indicated in the Crawings. !recast reinforced concrete cills dimensions as shown on the Crawings. shall be cast to the

4)

+recast Concrete Drain Co4ers !recast reinforced concrete slabs o,er drains shall be 2* mm thick and reinforced with B.&.". 3o. 1*. Slabs shall ha,e recesses in their end faces to facilitate remo,al.

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41

Concrete +i#es !lain or reinforced concrete pipes shall compl% with the re5uirements of /ustralian Standards /.S. 14)2 and "/ 440 and shall be manufactured b% the centrifugal spinning process. The manufacturer8s certificates of test will be accepted as proof of the 5ualit% of the concrete pipes but the 7ngineer ma%0 at his discretion0 re5uire for additional testing to be made on samples of concrete pipes stored at the site. :n the e,ent of an% concrete pipe being found to be not in accordance with the rele,ant Standard under the additional tests or in the course of being worked0 the whole batch of pipes from which the fault% pipe comes ma% be re;ected b% the 7ngineer notwithstanding an% pre,ious acceptance on the strength of the manufacturer8s certificate. /n% pipe re;ected b% the 7ngineer shall be remo,ed from the site at the "ontractor8s e<pense. The pipe section shall not be cut off without the appro,al of the 7ngineer. The ;oints of the pipes shall be ordinar% ogee or rebated ;oint0 sealed with cement mortar.

42

Read0;/i,ed Concrete &ead%-mi<ed concrete ma% be used sub;ect to the 7ngineer8s prior appro,al. The 7ngineer will re5uire to inspecting the plant from which the said concrete is to be supplied. The suppl% and deli,er% of read%-mi<ed concrete to compl% with the recommendations of B.S. 192+. The read%-mi<ed concrete will compl% with all the re5uirements of this Specification. The "ontractor to maintain records of all supplies mi<ed concrete placed on the Works0 including #i( #ii( #iii( Celi,er% notes proportions gi,ing details of 5ualit% of read%and mi<

The time at which each batch of concrete was mi<ed and details of an% additi,es used. !ositions in the Works where concrete is placed.

The concrete to be agitated continuousl% b% rotation of the mi<er drum during transport to the Site and while awaiting discharge. :n the case of truck mi<ed concrete0 the water ma% be added either at the concrete supplier8s plant.0 or under the "ontractor8s super,ision after arri,al at Site0 but not during transit. The concrete to be compacted in its final position in as short a time as possible after mi<ing0 and not later than 1-1@2 hours after the specific time when the cement comes in contact with the aggregate.

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Works test cubes to be made on Site b% the "ontractor in accordance with the pro,ision of this Specification0 irrespecti,e of an% sampling and@or testing which ma% be carried out b% the supplier. 43 To$erances and Defects The permissible surface tolerances shall not e<ceed the limits shown on the following table. :f0 in the opinion of the 7ngineer0 the formwork is cut0 drilled0 bent0 buckled0 repaired or generall% damaged in a wa% detrimental to the appearance of the concrete or to the tightness or straightness of the forms it will be re;ected. 7<amples of !ermissible Tolerance "ondition Fariation in cross sectional dimensions of structural members Ceparture from straightness #cumulati,e departure not permitted( Cisplacement of shuttering boards at ;oints $ffsets or fins caused b% defecti,e formwork or otherwise 1inal Surface Tolerance - * mm H 4 mm 4 mm in 1 m H 1 mm 4 mm

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T/BA7 G/I
!&$!$&T:$3S J ST&73DT'S $1 "$3"&7T7 ======================================================================================================================== 3ominal .i< Water SiBe "ompacting .inimum "ompressi,e "ement@1ine 7stimated !roportions of including of 1actor for Strength of Works /ggregate@ ------------------------Water in "oarse Fibrated "ubes "oarse !ortland 1ine "oarse /ggregate /ggregate "oncrete --------------------/ggregate "ement /ggregate /ggregate at da%s at 2- da%s ======================================================================================================================== Cesignation of .i< Aocation in Works 3@mm2 Drade 4* 1:1:2 2* kg 2) kg 9- kg 22 litre 2* mm 3@mm2

.-21 4* to .9) ========================================================================================================================= Drade 22 .-+ 1 22.* to .9* ========================================================================================================================= Drade 2* .-2 1) 2* to .-+ ========================================================================================================================= .ass 1:4:+ 2* kg 12* kg 4** kg as 2* mm 2.2 -.2 "oncrete directed ========================================================================================================================= 3ote: #i( When concrete is compacted b% hand #and not ,ibrated( the compacting factor and the mi< shall be determined b% the 7ngineer when the preliminar% test mi<es are made. 1:2:) 2* kg 1*2 kg 19) kg 4* litre 2* mm 1:1.2:4 2* kg -* kg 1) kg 22 litre 2* mm

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