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CSP - 003
CONCRETE SPECIFICATION,
INSTALLATION AND FINISHING
Date
Description
Prepared
Reviewed
(Technical)
Reviewed
MGR
C/M CE
Approved
GM Central Eng.
TABLE OF CONTENTS
NO. DESCRIPTION
PAGE
1.
SCOPE
2.
DEFINITION
4.
5.
GRADES OF CONCRETE
5.1 Testing
5.1.1 General
5.1.2 Slump
5.1.3 Acceptance Criteria
ACCEPTABILITY OF CONCRETE
6.1 Materials
6.1.1 Concrete mix
6.1.2 Aggregates
6.1.3 Admixtures
6.1.4 Steel reinforcement
6.1.5 Storage of Materials
6.1.6 Mixing and delivery
6.2 Mix acceptance
6.2.1 Approved mix
6.2.2 Variation of approved mix
6.3 Admixtures
6.3.1 Water-reducing
6.3.2 Superplasticiser
6.3.3 Accelerator admixtures
6.3.4 Retarder
6.3.5 Other admixtures
INSTALLATION OF CONCRETE AND RELATED WORK
7.1 Formwork
7.1.1 Materials
7.1.2 Construction
7.1.3 Coating
7.1.4 Removing bracing and Shoring
7.2 Steel reinforcing
7.3 Preparation
7.4 Placing of concrete
7.5 Curing
7.6 Membrane curing
7.7 Weather protection
7.8 Finishing concrete surface
7.9 Joints
7.9.1 Construction Joints
7.9.2 Expansion Joints
7.9.3 Control Joins
7.9.4 Joint sealer
7.10 Grouting
SLAB FINISHES
8
9
9
9
10
10
10
10
11
11
12
12
12
14
14
14
14
14
14
15
15
15
15
15
15
15
16
16
16
17
18
19
19
20
20
22
22
23
24
25
25
25
6.
25
28
28
28
10
STATEMENT OF COMPLIANCE
30
1.0
2.0
SCOPE
1.1
This specification applies to the furnishing and installation of concrete and related
work in accordance with the contract drawings and this specification. All drawings
and other referenced documents are included in this specification.
1.2
Work performed under this specification will be subject to the approval of the
ENGINEERING DEPARTMENTS duly authorized representative hereinafter
referred to as THE ENGINEER.
1.3
Any aspects of the work not clearly defined by this specification shall be governed by
the rules of the best prevailing practice for that class of work as determined by THE
ENGINEER.
1.4
Also included shall be the provision of all holes, chases, slots, etc., required for pipe
and other work, and filling in of all such openings that are of a temporary nature,
and the setting of anchor bolts, inserts, hangers, etc., required by others.
AS 1012 (1993)
AS 1379 (2007)
AS 3600 (2001)
AS 1478 (2000)
AS/NZS 3905 (1999)
AS 3972(1997)
AS 3610 (1995)
Note:
1. Additional standards are also referenced within the above standards.
2. The above standards are current at the time of drafting this specification, and may be
revised/superseded/supplemented without revision to this listing.
3.0
DEFINITION
Admixturematerial, other than water, aggregate, and hydraulic cement, used as an
ingredient of concrete, mortar, grout, or plaster and added to the batch immediately before
or during mixing.
Aggregategranular mineral material such as natural sand, manufactured sand, gravel,
crushed stone, air-cooled blast-furnace slag, vermiculite, or perlite.
Air contenttotal volume of air voids, both entrained and entrapped, in cement paste,
mortar, or concrete. Entrained air adds to the durability of hardened mortar
Batchingprocess of weighing or volumetrically measuring and introducing into the mixer,
the ingredients for a batch of concrete, mortar, grout, or plaster.
Bleedingflow of mixing water from a newly placed concrete mixture caused by the
settlement of the solid materials in the mixture.
Coarse aggregatenatural gravel, crushed stone, or iron blast-furnace slag, usually larger
than 5 mm (0.2 in.) and commonly ranging in size between 9.5 mm and 37.5 mm (38 in. to
112 in.).
Compressive strengthmaximum resistance that a concrete, mortar, or grout specimen will
sustain when loaded axially in compression in a testing machine at a specified rate; usually
expressed as force per unit of cross sectional area, such as megapascals (Mpa) or pounds per
square inch (psi).
Concretemixture of binding materials and coarse and fine aggregates. Portland cement
and water are commonly used as the binding medium for normal concrete mixtures, but
may also contain pozzolans, slag, and/or chemical admixtures.
Construction jointa stopping place in the process of construction. A true construction
joint allows for bond between new concrete and existing concrete and permits no
movement. In structural applications their location must be determined by the structural
engineer. In slab on grade applications, construction joints are often located at contraction
(control) joint locations and are constructed to allow movement and perform as contraction
joints.
Contraction jointweakened plane to control cracking due to volume change in a concrete
structure. Joint may be grooved, sawed, or formed. Also known as a Control joint.
Corrosiondeterioration of metal by chemical, electrochemical, or electrolytic reaction.
Construction Manager The construction manager (CM) is a professional management
person/ organization employed by the owner to oversee and manage the project. During the
construction phase, the CM will oversee the work and perform many of the coordination
functions of the general contractor.
Curingprocess of maintaining freshly placed concrete mortar, grout, or plaster moist and
at a favorable temperature for a suitable period of time during its early stages so that the
desired properties of the material can develop. Curing assures satisfactory hydration
and hardening of the cementitious materials.
Damp proofingtreatment of concrete, mortar, grout, or plaster to retard the passage, or
absorption of water, or water vapor.
Densitymass per unit volume; the weight per unit volume in air, expressed, for example,
in kg/m3 (lb/ft3).
Limegeneral term that includes the various chemical and physical forms of quicklime,
hydrated lime, and hydraulic lime. It may be high-calcium, magnesian, or dolomitic.
Mortarmixture of cementitious materials, fine aggregate, and water, which may contain
admixtures, and is usually, used to bond masonry units.
Pavement (concrete)highway, road, street, path, or parking lot surfaced with concrete.
Although typically applied to surfaces that are used for travel, the term also applies to
storage areas and playgrounds.
Plasticizeradmixture that increases the plasticity of portland cement concrete, mortar,
grout, or plaster.
Portland cementCalcium silicate hydraulic cement produced by pulverizing portlandcement clinker, and usually containing calcium sulfate and other compounds.
Portland-pozzolan cementhydraulic cement consisting of an intimate and uniform blend
of Portland cement or portland blast-furnace slag cement and fine pozzolan produced by
intergrinding portland cement clinker and pozzolan, by blending portland cement or
portland blast-furnace slag cement and finely divided pozzolan, or a combination of
intergrinding and blending, in which the amount
Precast concreteconcrete cast in forms in a controlled environment and allowed to achieve
a specified strength prior to placement on location.
PTI Representative He/She that has the responsibilities to sign for approval and/or
acknowledge for related project as per matrix responsibilities and organizational breakdown
structures inside the PTI project.
Quality controlan action taken by a producer or contractor to provide control over what is
being done and what is being provided so that applicable standards of good practice for the
work are followed.
Ready-mixed concreteconcrete manufactured for delivery to a location in a fresh state
Reinforced concreteconcrete to which tensile bearing materials such as steel rods or metal
wires are added for tensile strength.
Retarderan admixture that delays the setting and hardening of concrete.
Scalingdisintegration and flaking of a hardened concrete surface, frequently due to
repeated freeze thaw cycles and application of deicing chemicals.
Segregationseparation of the components (aggregates and mortar) of fresh concrete,
resulting in a nonuniform mixture.
Setthe degree to which fresh concrete has lost its plasticity and hardened.
Max w/c
Ratio
21
28
35
40
0.68
0.57
0.48
0.41
Slump and
tolerance
(mm)
100 20
100 20
80 15
70 10
Compressive
Strength at 28
days Fc (Mpa)
21
28
35
41
(High early strength concrete shall only be used when specified or authorized by PTI
representative.)
Concrete for tremie slabs or site concrete if required, shall have a minimum strength of 14
Mpa at 28 days and contain a maximum of 0.82 of W/C ratio per cubic meter of concrete.
5.1 Testing
5.1.1 General
Testing of concrete supplied to this standard shall be subject to Project assessment
requirements in accordance with AS 1379 unless specified otherwise.
Laboratory tests of trial batches shall give average compressive strength at least 15%
greater than the value in table 5.1. The water cement ratios given are the maximum
value and shall not be exceeded even though the construction specimens exceed the
specified strengths and even though laboratory mixed specimens are more than 15%
higher than specified strengths. The surface water in the aggregate and water or other
liquid in the admixture shall be included as part of the mixing water in computing the
water content.
The source and designation of all materials to be used concrete construction shall be
approved by THE ENGINEER.
Types and proportions of materials used in concrete mixes are to be made known
when requested if tests are not made. All shipments of material or ready mixed
concrete shall meet the applicable specifications and a certificate to that effect must
accompany shipments.
5.1.2 Slump
Slump testing is mandatory for concrete in which test cylinders are taken. Slump
testing of concrete shall be in accordance with AS 1012.3. Any batch of concrete at
delivery that falls outside the specified limits for slump, as shown in Table 5.1 and/or
Table 5.2 will be liable for rejection. To avoid possible rejection the contractor is
advised to target the lower end of the slump range. Any concrete in which the slump is
less than the lower limit shown in the table 5.1 and/or table 5.2 may be rescued by
using superplasticiser. The upper slump limit for superplasticed concrete shall be
130mm. Concrete in which the slump is 25mm and lower shall be rejected.
Superplasticiser admixture shall refer to ASTM C1017, Type 1
Table 5.2 Recommended slumps for various type of construction using additives
5.1.3 Acceptance criteria
The strength of concrete shall be deemed to comply with this standard if it is in
accordance with AS 1379 Specification and supply of concrete.
In addition each sample tested shall have a minimum compressive strength as shown
on table 5.1
6.0 ACCEPTABILITY OF CONCRETE
6.1 MATERIALS
6.1.1 Concrete mix
Mixing water for concrete shall be fresh, clean and freed from injurious amounts
of oil, acid, alkali organic matter or other deleterious substances
Fine aggregate shall be clean and well graded. Selection of suitable material shall
be approved by THE ENGINEER.
Coarse aggregate shall consist of hard uncoated particles of gravel or of crushed
stone conforming to the latest version of ASTM C33. Crushed material shall be
free from flat pieces, dust, soft particles and foreign matter.
PTI representative shall have the right to take any samples of the materials
including cement and aggregates etc, and test them in accordance with the
10
Specified compressive
strength, fC , MPa
Required average
compressive strength,
Fc, MPa
Less than 21
21 to 35
Over 35
Adapted from ACI
Fc + 7.0
Fc + 8.5
1.10 Fc + 5.0
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12
13
14
Construction
2 Bolts and rods used for internal ties shall be arranged so that when forms are
removed, all metal shall be at least 40 mm from any concrete surface. Wire ties
will not be permitted where the concrete surface will be exposed to weathering,
and discoloration will be objectionable. All forms shall be constructed so that they
can be removed without hammering or prying against the concrete.
3 Openings shall be provided at the base of the column, pier and at sufficient
15
intervals at the base of wall forms to allow for cleaning and inspection.
4 All formwork and centering shall be thoroughly cleaned before re-using. All
possible care shall be taken in the formwork to produce surfaces free from
honeycomb and other defects.
5 All inserts, nailing strips, anchor slots, grounds etc., shall be built into the
concrete.
6 Edges of exposed surfaces shall have a 20mm chamfer unless otherwise shown or
noted.
this also covers the site preparation, dimension and sizes etc. This term also
applies to the installation of a new anchor bolt to an existing concrete plinth or
any place mentioned in the drawings.
7.1.3 Coating
Before placing steel reinforcement or concrete, forms for exposed surfaces shall be
coated with non staining mineral oil. Forms for unexposed surfaces may be
thoroughly wetted in lieu of oiling immediately before placing the concrete.
7.1.4 Removing and Bracing and Shoring
Shoring and bracing shall remain in place until concrete has achieved sufficient
strength to safely permit removal.
7.2 Steel Reinforcing
1 All chairs, ties, bootees, and spacers required to properly install reinforcing steel
shall be provided as necessary. All accessories shall be furnished and installed in
accordance with Manual of Standard Practice for Detailing Reinforced Concrete
Structures as published by the Concrete Reinforcing Steel Institute.
2 Before being positioned, metal reinforcement shall be free from loose mill and
rust scale and from coatings such as mud or muck that would destroy or reduce
the effectiveness of the bond. Where there is delay in depositing concrete,
reinforcement shall be re-inspected and cleaned when necessary.
3 Metal reinforcement shall be accurately positioned and secured against
displacement by using annealed iron wire ties not less than 1.6mm (16 gauge) or
suitable clips at not less than every third intersection. Reinforcement shall be
supported by concrete or plastic supports, spacer, or hangers. Where indicated on
the drawings or required by this specification, clips or supports shall not be placed
in contact with the forms. No wood blocks or red brick spacers or chairs shall be
used.
4 The minimum clear distance between parallel bars, except in columns, shall be
equal to the nominal diameter of the bars. In no case shall the clear distance
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between bars be less than 25mm (1), nor less than and 1.5 times the maximum
size of coarse aggregate. Where reinforcement in beams or girders is placed in two
or more layers, the clear distance between layers shall not be less than 25mm (1),
and bars in the upper layers shall be placed directly above those in the bottom
layer.
5 At those surfaces of footings and other principal structural members in which the
concrete is deposited directly against the ground, metal reinforcement shall have a
minimum covering as per AS 3600- Section 4.0 Design for durability
6 Reinforcing bars shall be placed in accordance with the drawings. Spliced bars
shall be placed in contact and wired. Splices shall be staggered. Where it is
necessary to splice reinforcement at points other than shown on the drawings, the
detail of the splice shall be approved by THE ENGINEER.
7 Exposed reinforcement intended for bonding with future extensions shall be
coated with a bitumastic type material or greased and wrapped with burlap and
tied.
8 For some cases steel reinforcement shall be treated using paint protection prior to
concrete pouring to avoid any corrosion due to industrial climate, marine climate,
and the using of calcium chloride in accelerator admixtures of concrete (see AS
3600-Section 4.9). For coating thickness protection shall be advice by paint
manufacture. PTI representative shall be informed for approval or acknowledge.
9 Minimum steel reinforcement requirements for installation shall refer to AS 3600
section 13, PTI representative shall have the rights to reject the steel reinforcement
inspection report if he/she deems that the installation is not comply with the
standard.
7.3 Preparation.
1 A competent and experienced foreman shall be in charge of pouring operations at
all times, and pouring of concrete shall not be started in any locations until the
foreman has ascertained that the framework, reinforcing steel screens, and the
placing of sleeves and inserts meet the requirements of the plans and
specifications. The foreman shall also make certain that all other work required to
be built into the concrete has been placed, including electrical and mechanical
work.
2 The space in which concrete is to be placed shall be free of all debris and
pounding or flowing water. The surfaces against which the concrete is to be
placed shall be clean and moist
3 The concrete surfaces to which a bond is to be secured shall be rough and free
from loose material or other matter interfering with a satisfactory bond. The
surfaces shall be wet, scrubbed with steel brushes or brooms, kept damp and
thoroughly brushed with a thin layer of mortar immediately prior to the
placement of concrete. The mortar shall have the same cement-sand ratio as the
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concrete.
4 A minimum thickness of blinding concrete is 50mm. Contractor can also use
plastic sheets to replace the blinding concrete. Material selection for plastic sheets
shall be approved by PTI representative prior to installation and shall be recorded
for quality control document.
5 Water shall be removed from the space to be occupied by the concrete before
concrete is placed. Any flow of water into excavation shall be diverted through
proper side drains to a sump or shall be removed by other approved methods
which will avoid washing the freshly deposited concrete.
7.4 Placing of concrete.
1 Concrete shall be placed before initial set has occurred and never after cement has
been mixed with either water or aggregates for more than 60 minutes, except in
cases where an approved retarder has been included in the design mix
2 All concrete shall be deposited in approximately horizontal layers not more than
600mm (24) thick. The concreting shall be carried on as a continuous operation as
far as practicable until the placing of the course, section, panel, or monolith is
complete. No concrete shall be deposited on other concrete that has hardened
sufficiently to cause the formation of seams and planes of weakness within the
section. If a section cannot be placed continuously, construction joints shall be
located and made as approved by THE ENGINEER. The concrete placement shall
be planned and managed to match the critical capacity of production/supply
and/or placement.
3 Concrete shall be placed with the aid of approved mechanical vibrating
equipment. Vibration shall be transmitted directly to the concrete unless otherwise
directed. The frequency of vibration shall be not less than 5000 cycles per minute.
The intensity of vibration shall be sufficient to cause consolidation of the concrete
in place. The vibration shall be of sufficient duration to accomplish through
compaction. External vibration may be used for thin sections when internal
vibration would be impracticable. Vibration shall be supplemented by forking or
spading by hand adjacent to the forms on exposed faces in order to secure smooth,
dense, even surfaces. The concrete shall be compacted and worked in an approved
manner into all corners and angles of the forms and around reinforcement and
embedded fixtures. Care should be taken not to over-vibrate causing segregation
of the concrete
4 When dropping concrete through reinforcement, care shall be taken that no
segregation of the coarse aggregate occurs. There shall be no free vertical drop
greater than 1.5 meters (5) unless elephant trunks are used. When the
congestion of steel near the forms makes placing difficult, a mortar of the same
cement-sand ratio used in the concrete shall be deposited first to cover the forms.
In the case of walls, columns, or units of considerable height, concrete shall not be
dropped from the top, but provisions shall be made for placing concrete through
openings left in the forms for this purpose. Chutes shall not be used for placing
concrete except for short distances, and only with the approval of THE
18
19
All concrete work exposed to view, on the outside as well as inside, shall be
pointed smooth. Forms shall be removed as soon as possible after pouring; all
projections shall be cut away and all depressions, air holes and other roughness
pointed up with a mixture of one-half cement and one-half silica sand (50:50 mix)
while the concrete is still fresh. Surfaces shall be thoroughly wetted before
pointing. All rough spots or surfaces shall be rubbed smooth with carborundum
stone and water and left uniform in color and free from cement drippings. Only
rubbing necessary to produce smooth surfaces free from form marks, cement
drippings or their defects shall be done. For more detail in surface finishing
please refer to clause 8.0
Fill in all holes and openings left in the concrete for steel, piping, sleeves, and
other Work. Such parts shall be filled with concrete unless otherwise detailed.
After the work of other trades is in place. All filling shall be neat, and flush with
adjacent surfaces.
20
the result is not meet with the design requirements; the recommended tolerance
for concrete finishes shall refer to AS 3600 as shown in table 7.1. Contractor shall
submits the reports to PTI representative for approval or acknowledge.
MEMBER
Footings
Concealed
Exposed
Slabs
TOLERANCE ON:
Position/Size
Surface Quality
Maximum
deviation from plumb to
be the greater of 1/200
times specified dimension
or 5 mm(1, 2);
Absolute position to be
within
15
mm
horizontally.
Maximum deviation from
any specified height, plan
or
cross-sectional
dimension to be the
greater of 1/200 times
specified
Dimension or 5 mm (1).
Surface level To be
within
10
mm
of
specified level.
Position 15 mm of
specified position.
Plumb
plumb.
10
mm
of
Architectural elements
21
External Pavements
(driveways, footpaths,
patios and other
pedestrian pavements)
Surface level
Non-graded pavement:
10 mm of specified
level.
Graded pavement: 10
mm of a straight line
between control points.
Control points at top
and bottom of graded
pavement: 10 mm of
specified level.
Thickness Maximum
deviation to be the greater
of 1/200 times specified
thickness or 5 mm (1).
Industrial pavements
Bull floated
Straight edged (6)
Flat
Very Flat
3-m
straightedge
tolerance
Maximum
deviations (mm)
12
8
6
3
Notes
1 In accordance with AS 3600.
2 If a Class 2 or 3 finish in accordance with AS 3610 is specified, the associated plumb tolerances apply.
3 In accordance with AS 3610.
4 a tighter tolerance may be required for some floor finishes, e.g. tiled, vinyl, polished.
5 As measured by the F-Meter method described on p2; see Table 1 for straightedge-tolerance equivalents.
6 Refers to a finishing process in which a long straightedge (3 to 4 m) is drawn across the surface transverse
to the direction of screeding to remove undulations in the transverse direction.
Table 7.1 Recommended Tolerances
7.9 Joints
7.9.1
Construction Joints
22
23
Addjointsealer
compound
24
25
Class
Finish
U1
Screeded
U2
Floated
U3
Trowelled
U4
Machine
U5
U7
Shallow
Textured
Deep
textured
Grooved
U8
Grooved
U9
Scrabbled
U10
Special
textured
Ground
Finish
U6
U11
Technique
Examples
Hand sawing motion with straight-edge or Finishes covered by backfill or concrete, footpaths, yards and driveways. First stage for placement.
mechanical vibrating screed
Wood or bull float, or both. Generally manual As for U1 where a higher standard of finish is required. Floors to receive carpets with underlay or similar
but power driven equipment may be used
coverings, inverts of siphons, flumes, floors of canal structures, spillways outlet works and stilling basins.
Surfaces which are intended for use by ambulant disabled or wheelchair-bound persons.
Manual or mechanical steel trowelling of Direct wearing floors such as in factories, warehouses and processing plants, Floors to receive thin sheet
floated finish after concrete is sufficiently coverings, carpet and similar coverings. Inverts of water, tunnels and tunnel spillways. Not generally used
hardened to prevent excess fine material and for pedestrian or vehicular traffic where a smooth finish should be dangerous in icy or wet conditions. Is not
water being worked to the surface, may be suitable even when dry, for surfaces which are intended for use by ambulant disabled or wheelchair-bound
done in one or two stages depending on degree persons.
of smoothness required
Vibrating or oscillating screed or vibrating Used for durability where resistance to erosion and cavitations under action of high velocity water is
plate, or both, which may be supplemented by especially required; and as firsts and second stage finishing for roads and airfield pavements prior to
long handled metal, wooden, or rubber floats.
texturing with U5, U6 and U8 finishes.
Hard or soft bristled brooms.
Footpaths, yards, driveways, roads, pavements for aircraft.
Wire broom or rubber tyning.
Surface to receive a subsequent textured bonded concrete topping. Roads and runways where greater
frictional resistances are required than can be obtained by U5 finish.
Saw cutting or flailing by mechanical means.
Treatment to existing roads and runways to provide frictional resistance and drainage paths for run-off to
minimize aquaplaning.
Mechanical grooving the fresh concrete surface Roads and runways.
after compaction and surface screeding
techniques.
Mechanical hammering of hardened concrete.
Can be used on any pavement surface to produce a textured effect or to reduce high surfaces to the correct
level or to rectify out-of-tolerance pavements.
The use of equipment to give special effects.
Architectural effects on pavements and slabs, produced by rollers with drums of expanded mental, or
profiled tempers on screed boards, and the like.
Low speed coarse stone grinding to remove Direct wearing floors such as in warehouses.
thin weak surface layers/minor ridges and to
produce and even 'glass paper' textured
surface, that is, not a polished surface. Used as
a second stage finish to U2, approximately 3648 hours after laying.
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QUALITY OF SURFACE
FINISH
1. Blowholes
2. Form face deflection
3. Face Step
Class 1
Class 2
Class 3
Class 4
Class 5
80 100
70 100
70
100
95 10
0
1 2
4. Surface undulation**
l =300
[a-b]
L=1500
[a-b]
10
10
10
10
15
5. Flatness
1.25 m grid
At 5m over 10m
(not applicable to precast
concrete)
6. Out of Plumb
Height < 3m
28
Date of delivery
2.
3.
4.
5.
6.
7.
29
8.
9.
30
31