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: 1971 Portland Cement (Ordinary and Rapid Hardening)

B.S. 410: 1969 Test sieves

B.S. 812: 1967 Methods for the Sampling and Testing of Mineral
Aggregates, Sands and Fillers

B.S. 882: 1965 Aggregates from Natural sources for concrete

(including granolithic)

B.S. 1881: Methods of Testing Concrete

B.S. 3148: 1959 Tests for Water for Making Concrete.

B.S 5328: 1990 Part 4 Specification for the procedures

to be used in sampling, testing and
assessing compliance of concrete.

This Specification shall be interpreted, and all sampling and

testing shall be carried out, in accordance with the relevant
clauses in these Standards.

2 Cement

All cement used in the Works shall be Ordinary Portland Cement of

approved manufacture and complying with the requirements of B.S.
12 and shall be supplied in 50 kilogram paper bags. Unless
permission in writing is obtained from the Engineer, cement may
be supplied in bulk.

The Contractor shall submit to the Engineer for approval 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
delivery of cement to the site is allowed. Normally the
manufacturer's test certificates will be accepted as proof of the
quality of the cement; but the Engineer may at his discretion
carry out further tests on the cement stored at the site.

In the event of any sample being found to be not in accordance

with B.S. 12 the whole consignment from which the sample comes
shall be rejected and removed from the site immediately by the
Contractor at his own expense notwithstanding any previous
acceptance on the strength of the manufacturer's certificate.

The Contractor shall not be allowed to change the approved source

of supply or brand of cement at any time or for whatever reason
without the permission in writing of the Engineer.

Notwithstanding any previous acceptance any bag of cement

containing material which has hardened or otherwise deteriorated
shall be rejected and removed from the site by the Contractor
forthwith and at his own expense. Any cement on transit or
temporarily placed near the mixer or elsewhere, after removal
from the store, shall be adequately protected from moisture and
damage by approved means.

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3 Storage of Cement

The Contractor shall provide at his own expense on the site a

dry, well-ventilated and weather-proof cement store to the
approval of the Engineer for the proper storage of cement. The
floor of such store shall be raised at least 300 mm above ground
level or above maximum flood level at the site whichever is the
higher. Cement supplied in bulk shall be stored in silo or other
containers which are of a design approved by the
Engineer.

Batches of cement shall be used for the Works in the order in

which they are delivered to the site and the method of storage
shall be arranged so that this may be done.

4 Fine Aggregate

Fine aggregate for concrete work shall be hard, clean, well-

graded natural sand free from harmful quantities of clay and
silt, saline and vegetable impurities, and other deleterious
matter. It shall be within the following grading limits:-

________________________________________________________________
| | | | | | | |
|B.S.Sieve | 5 mm | No. 7 | No. 14 | No. 25 | No. 52 | No. 100|
|__________|_______|_______|________|________|________|________|
| | | | | | | |
|% Passing |95-100 | 70-95 | 45-85 | 25-60 | 5-30 | 0-10 |
|__________|_______|_______|________|________|________|________|

Field tests shall be carried out on samples to be taken from each

and every batch of sand supplied and delivered to the site. Sand
shall not contain more than 6% by volume of clay and/or fine
silt; neither shall it contain organic impurities in sufficient
quantity to show a darker colour than the standard depth of
colour No. 3 when tested according to the standard methods given
in B.S. 812: 1967.

Sand which does not comply with these requirements shall be

rejected and removed from the site forthwith at the Contractor's
own expense.

5 Coarse Aggregate

Coarse aggregate for concrete work shall be sound, hard, clean,

roughly cubical shaped crushed granite particles free from
harmful quantities of clay, crusher dust, organic impurities or
other deleterious matter.

Coarse aggregate containing an excessive proportion of flat

particles, splinters or flakes, will not be accepted. The
judgment of the Engineer in this matter shall be final and
binding on the Contractor.

Limestone shall not be used as coarse aggregate without the

permission in writing of the Engineer. Under no circumstance
shall limestone be used as aggregate in water retaining
structures.

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 The grading of coarse aggregate shall be within the following
limits:-

_______________________________________________________
| | | | |
| B.S. Sieve | 20 mm | 10 mm | 5 mm |
|_____________|________|_________|____________________|
| | | | |
| % Passing | 100% | 25 - 55 | Not more than 10 |
|_____________|________|_________|____________________|

6 Sampling and Testing of Aggregates

The Contractor shall submit to the Engineer for approval the

sources of supply and samples of fine and coarse aggregates which
he proposes to use in the Works before the delivery of aggregates
to the site is permitted.

Samples of the fine and coarse aggregates approved by the

Engineer shall be kept on the site; and the Contractor shall
secure his entire supply of each material from the same source
and ensures that all aggregates delivered to the site throughout
the course of the Works are of the same quality and grading as
the approved samples.

Should it become necessary to change the sources or

characteristics of any aggregate this shall only be done after
new samples have been tested and approved by the Engineer and
subject to such safeguards as the Engineer may impose for the
maintenance of the quality of the aggregate specified.

The method of sampling and amount of aggregate to be provided

shall be in accordance with B.S. 812: 1967. The tests shall be
those as laid down in B.S. 812 : 1967 unless otherwise directed
by the Engineer. The tests shall be carried out by the Engineer
and if a sample should fail in any of the tests the Engineer may
at his discretion, either reject the batch from which the sample
was taken or order it to be washed and/or screened at the
Contractor's expense. Any batch of the aggregate rejected by the
Engineer shall be removed from the site forthwith at the
Contractor's expense.

7 Storage of Aggregates

The Contractor shall at his own expense provide proper and

adequate storage of the fine and coarse aggregates on the site to
the satisfaction of Engineer.

The fine and coarse aggregate shall be handled and stored

separately and in such a manner that segregation of the various
sized particles does not occur. There shall be a physical
partition between the heaps of sand and the heaps of coarse
aggregate to prevent intermixing of the aggregates.

The stock piles shall be formed on a platform of weak concrete,

timber or similar approved hard standing and aggregates shall be
kept clean and free from earth and foreign matter.
Aggregates which in the opinion of the Engineer are not clean or
have become intermixed due to improper storage shall be removed
from the site at the Contractor's expense.

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8 Water

Water used for making and curing concrete and for testing the
watertightness of structures shall be fresh, clean and not
contain organic matter, sulphates or other impurities in
sufficient quantities likely to reduce the strength of the
concrete or attack the concrete or the reinforcement. The
Engineer's decision on the suitability or unsuitability of a
source of water for his purpose shall be final.

Where possible, all water shall be obtained from the public

supply mains. When such a supply is not available the Contractor
shall make arrangements for obtaining water from a source
approved by the Engineer.

In any case the Contractor shall provide sufficient storage tanks

at the site to store enough water for 1-1/2 days' use in the
Works.

9 Steel Reinforcement

Bar reinforcement shall be rolled steel bars of a manufacture

approved by the Engineer and shall comply with B.S. 4449.

Steel fabric reinforcement shall comply with B.S. 4483.

The manufacturer's certificates of test will be accepted as proof

of the quality of the steel reinforcement but the Engineer may,
at his discretion, require additional tests to be made on samples
of steel reinforcement stored at the site. In the event of any
reinforcement being found to be not in accordance with the
relevant Standard under these tests or in the course of being
worked, the whole batch of reinforcement from which the faulty
reinforcement comes may be rejected by the Engineer
notwithstanding any previous acceptance on the strength of the
manufacturer's certificate. Any reinforcement rejected by the
Engineer shall be removed from the site at the Contractor's
expense.

All reinforcement shall be cleaned from loose millscales, loose

rust, oil, grease, earth and other harmful matter before being
placed in the forms and shall be free from these at the time the
concrete is placed.

10 Bending, Placing and Fixing Reinforcement

All reinforcement shall be bent cold using bar bending machines

and appliances approved by the Engineer. Unless otherwise
specified in the Drawings the bending dimensions and tolerances
and the dimensions of end anchorage, hooks, binders, stirrups and
the like shall be in accordance with B.S. 4466, 'Bending
Dimensions and Scheduling of Bars for the Reinforcement of
Concrete'.

The reinforcement shall be accurately assembled firmly secured by

wire ties made from No. 16 S.W.G. soft annealed wire so that the
whole assembly is rigid and will not be displaced while concrete
is being compacted around it. The ends of the wire ties shall be
turned inward away from the face of the forms and shall not be
left projecting beyond the reinforcing bars.

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 Temporary bracing shall be provided to prevent movement of all
steel projecting from the concrete during the course of
construction.

The cover shown on the Drawings shall be maintained by precast

spacing blocks securely wired to the bars or by other means
approved by the Engineer. Spacing Blocks for the various cover
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 receive full curing treatment before being used.

Where it is necessary to maintain two layers of reinforcement at

the correct distance apart (e.g. to maintain the correct position
of the top layer of reinforcement in the floor slab) steel riders
bent from 13 mm diameter mild steel bars shall be used. The use
of wooden battens for this purpose is prohibited.

11 Welding of Reinforcement

Welding of reinforcement will be permitted only under suitable

conditions and with suitable safeguards. The welding shall be by
electric arc and shall be performed by a skilled operator
approved by the Engineer. No welding shall be performed except
under the supervision of the Engineer's representative. The
surface of the bars must be thoroughly cleaned and scrubbed with
a wire brush immediately before welding, and the weld must be
deposited evenly and all slag shall be removed. The finished
surface of the weld shall be of even contour without cavities and
undercutting.

Welding shall be carried out in accordance with B.S. 1856: 1964

"General requirements for the metal-arc welding of mild steel"
and B.S. 2642: 1965 "General requirements for the arc welding of
carbon manganese steel". Butt welds shall be of the double V-type
and two butt weld bend tests shall be carried out on a specimen
prepared to represent each form of butt welded joint. The method
of making weld tests shall be that laid down in B.S. 709: 1964.

12 Formwork

The formwork shall be constructed with any of the following

materials:-

(i) Sound softwood tongued and grooved boards not less than 20
mm finished thickness, wrought on one side and two edges,
accurately formed and securely fixed to softwood frames.
The surfaces of the formwork shall be worked to a smooth
finish after fabrication.

(ii) Sound softwood timber boards not less than 20 mm thick

lined with galvanised metal sheet not less than 18 S.W.G.
The boards supporting the metal lining shall be of uniform
thickness and the formwork panels shall be made so that
they butt closely together, and grout cannot leak from the
joints between adjacent panels.

(iii) Waterproofed plywood of approved manufacture not less than

10 mm thick, securely fixed to timber frames.

(iv) An approved metal formwork system.

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 All formwork shall be erected true to line and level and shall be
adequately secured and braced to prevent deflection or movement
during the placing, tamping or vibrating of the concrete, and
shall be sufficiently tight to prevent loss of liquid.

Column formwork shall be arranged so that the concrete being

placed does not have a free fall of more than 1.5 m and suitable
openings shall be provided in the column forms to allow concrete
to be deposited in stages not more than 1.5 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 may be used, but their number must
be kept to the minimum required to secure the formwork rigidly.
The bolts shall be not less than 13 mm in diameter and of a type
with detachable screw off heads so that the barrels of the bolts
remain cast in the concrete while the detachable heads can be
removed with ease. The barrel of every bolt used in water
retaining, water conveying or water excluding structures shall
have a waterstop in the form of a 100 mm x 100 mm x 3.5 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 any concrete is placed all rubbish shall be removed from

the interior of the forms. Suitable opening shall be provided for
this purpose and the openings shall be effectively plugged before
concrete is placed. The forms and all concrete joint surfaces
within the forms shall be thoroughly flushed with water. The
forms may with the approval of the Engineer be treated with an
approved composition. Care should be taken to ensure that such
composition is kept out of contact with the reinforcement and
concrete joint surfaces, and that there is no excess of such
composition remaining on the forms prior to concreting.

Within four weeks of the acceptance of his tender the Contractor

shall submit for the approval of the Engineer drawings and
descriptions showing the methods he proposes to use for the
erection and support of the formwork.

13 Formed Surfaces – Classes of Finish

Class F1. This finish is for surfaces against which backfill or

further concrete will be placed. Formwork shall consist of sawn
boards, sheet metal or any other suitable material which will
prevent the loss of grout when the concrete is vibrated.

Class F2. This finish is for surfaces which are permanently

exposed to view but where the highest standard of finish is not
required. Forms to provide a Class F2 finish shall be faced with
wrought and thicknessed boards with square edges arranged in a
uniform pattern. Alternatively, plywood or metal panels may be
used if they are free from defects likely to detract from the
general appearances of the finished surface. Joints between
boards and panels shall be horizontal and vertical unless
otherwise directed.

The finish shall be such as to require no general filling of

surface pitting, butt fins, surface discolouration and other
minor defects, shall be remedied by methods approved by the S.O.

Class F3. This finish is for surfaces prominently exposed to view

where good appearance and alignment are of special importance. To
achieve this finish, which shall be free of boardmarks, the

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 formwork shall be face with plywood or equivalent material in
large sheets. The sheets shall be arranged in an approved,
uniform pattern. Wherever possible, joints between sheets shall
be arranged to coincide with architectural features, or changes
in direction of the surface. All joints between panels shall be
vertical and horizontal unless otherwise directed. Suitable
joints shall be provided between sheets to maintain accurate
alignment in the plane of the sheets. Unfaced wrought boarding or
standard steel panels will not be permitted for Class F3 finish.

14 Unformed Surfaces – Classes of Finish

Type U1. This is a screeded finish for surfaces of foundations,

beds, slabs, and structural members to be covered by back-fill
subsequent stages of construction, bonded concrete topping or
cement mortar beds to receive pavings and on exposed surfaces of
paving where a superior finish is not required. It is also the
first stage for finishes U2 and U3. The finishing operations
shall consist of leveling and screeding the concrete to produce a
uniform, plain or ridged surface, surplus concrete being struck
off by a straight edges immediately after compaction.

Type U2. This is a floated finish for surfaces of beds and slabs
to receive mastic pavings or block or tile pavings bedded in
mastic, and for exposed surfaces of pavings where a hard smooth
steel-trowelled surface is not required. Floating shall be done
only after the concrete has hardened sufficiently, and may be by
hand or machine. Care shall be taken that the concrete is worked
no more than necessary to produce a uniform surface free from
screed marks.

Type U3. This is a hard smooth steel trowelled finish for surface
of concrete pavings, tops of walls , copings and other members
exposed to weathering surface of beds and slabs to receive thin
flexible sheet, and tile pavings bedding on adhesive, and
seatings for bearing plates and the like where the metal is in
direct contact with the concrete. Trowelling shall not commence
until the moisture film has disappeared and the concrete hardened
sufficiently to prevent excess laitance from being worked to the
surface. The surfaces shall be trowelled under firm pressure and
left free from trowel marks.

15 Concrete Proportions

(i) Concrete for the several parts of the works shall be

proportioned as indicated in Table 'A' (except as provided
under the sub-clause (iii) below). Cement, fine aggregate
and coarse aggregate shall be measured by weight; and water
by volume. The fine and coarse aggregate shall be measured
separately. A weigh batcher shall be used for the purpose
of weighing cement, fine aggregate and coarse aggregate.
The accuracy of the weights indicated by the weight batcher
shall be regularly checked and shall be maintained within 
4.5 kg. of the actual total weight of all aggregates and
cement in one batch.

(ii) The weights of the fine and coarse aggregate specified in

Table 'A' refer to the materials in the dry state. Tests
shall be carried out twice daily or more frequently if
considered necessary by the Engineer to determine the
moisture content of the fine aggregate. Allowance shall be

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 made for the water contained in the aggregate when
calculating the water to be added to the mix.

(iii) While the proportions of the mixes are to be generally as

specified in Table 'A', the Engineer shall have the right
to order variations in these proportions without extra cost
to the Employer should tests show such variations to be
necessary to produce a dense watertight concrete of the
specified strength and of a consistency that will permit of
its being worked into position and compacted satisfactorily
into the different parts of the works. The proportions of
the mixes specified in Table 'A', are expected to produce
works cube strengths in excess of those specified in Table
'A' and a workability sufficient to ensure that the
concrete can be worked and fully compacted using the
methods of vibration hereinafter specified in this
Specification. If, however, it is shown during the course
of the work that the concrete mix is stiffer than can be
placed satisfactorily and adjustment of up to 5% may be
made in the water/cement ratio, but any further adjustment
of the mix shall be made by increasing the proportions of
both the water and cement without increasing the
water/cement ratio. If the works cube strengths fall below
those specified, the cement proportions shall be increased.

16 Designed Concrete Mixes

Designed concrete mixes may be used and shall comply with the
recommendations of BS 8110. However, the grades of concrete to be
used shall be as below which supersede table 3.3 of BS 8110:

Nominal
Mix Minimum Maximum Minimum
Equivalent Crushing aggregate Cement
Resistance in Size Content per cu.
N/mm2 m. of finished
Within 28 Days Concrete
after mixing

G50 50 20mm 400kg

G45 45 20mm 350kg

G40 40 20mm 330kg

G35 35 20mm 320kg

G30 30 20mm 310kg

G25 25 20mm 290kg

G20 20 20mm 275kg

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 Cement, coarse and fine aggregates and water shall comply with
the foregoing clauses of this specification.

If the Contractor chooses to use designed concrete mixes, he

shall employ a competent and suitably qualified person to design
the mix, to supervise and direct all stages in the preparation
and placing of the concrete.

The sampling, making, curing and testing of the works cubes shall
still be carried out by the Superintending Officer or his
representatives, the Contractor affording all facilities. The
Contractor or his representatives may, if they so wish, be
present while the cubes are being made and tested.

17 Preliminary Test Mixes

As soon as possible after possession of site, and before concrete

is placed, the Contractor shall prepare under the direction of
the Engineer a series of trial mixes totalling not more than 3
cubic meter of concrete. Test cubes will be made from samples of
these trial mixes, cured and tested in accordance with the
standard methods laid down in B.S. 1881, 1970 to determine the
cube strengths at 7 days and 28 days after casting. The cube
strengths obtained shall be at least 50% greater than those
specified in Table `A' for work cubes.

The mix proportions specified in Table `A' will be adjusted as

necessary by the Engineer on the basis of these tests without
extra cost to the Employer.

18 Sampling and Testing Concrete and Concrete Materials

All sampling and testing will be carried out in accordance with

the standard methods laid down in B.S. 1881 unless otherwise
specified in the following clauses.

The Contractor shall attend upon and provide all assistance to

the Engineer when such sampling and tests are carried out, and
shall supply all concrete samples and other materials required.

19 Frequency of Sampling and Testing

(i) Compacting Factor

The compacting factor of the mix to B.S. 1881 Part 3 shall

be carried out:-

(a) daily while concrete is being placed,

(b) Whenever samples for test cubes are taken,

(c) Whenever, in the opinion of the Engineer, the grading

or condition of any of the aggregates has changed
since the last test was made.

The results of the tests shall not exceed the limits stated
in table ‘A’ hereinafter.

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 (ii) Slump Test

Alternatively, the slump test of the mix to B.S. 1881 shall

be carried out:-

(a) daily while concrete is being placed,

(b) Whenever samples for test cubes are taken,

(c) Whenever, in the opinion of the Engineer, the grading

or condition of any of the aggregates has changed
since the last test was made.

The results of the tests shall not exceed the limits stated
in table ‘A’ hereinafter.

(iii) Test Cubes

A set of 8 concrete test cubes, 4 for testing at 7 days and

4 for testing at 28 days after casting, will be made.

(a) every day while concrete is being placed.

(b) every 150 m3 of concrete or part thereof.

(c) whenever the mix or any of its constituents are

changed either in quantity or quality.

(iv) Aggregate Grading and Purity

The grading of the aggregates and their freedom from

organic matter will be tested.

(a) when the first deliveries of these materials arrive

on the site

(b) whenever, in the opinion of the Engineer, the

grading or condition of these materials differs
from that originally accepted for use in the work.

20 Rejection of Concrete

If any of the test cubes tested at 7 days do not comply with the
compressive strength compliance requirement as mentioned below,
the Engineer shall, at his discretion, order all concreting work
to stop until adequate measures have been taken to produce
concrete which complies with this Specification.

If the cube strengths at 28 days do not comply with the

compressive strength compliance requirement as mentioned below,
the work from which the concrete for the test cubes was taken
will be rejected by the Engineer, and will be broken out and
rebuilt or otherwise made good as directed by him at the
Contractor's own expense.

21 Concrete Compressive Strength

For checking the compliance with strength requirement of

concrete, the test cubes of the selected age shall be tested and
the mean of the two results shall be taken as the test result.

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 When the difference between the two results divided by their mean
exceeds 15%, the test result shall be deemed invalid.

When both the following conditions are met, the concrete is

deemed to comply with the specified compressive strength.

a) The mean strength determined from the first two, three or

four consecutive test results, or from any group of four
consecutive test results complies with the appropriate
limits in column A of table B hereinafter.

b) Any individual test result complies with the appropriate

limits in column B of table B hereinafter.

22 Supervision

The Contractor shall keep constantly at the site while concrete

is being mixed and placed a competent Malay/English speaking
assistant for the purpose of supervising the batching of the
concrete ingredients and the mixing, placing and compacting of
the concrete. This assistant shall be employed solely for this
purpose and the right is reserved to the Engineer or his
representative at the site to order work on working or placing of
concrete to cease if this assistant is not present.

23 Mixing concrete

All concrete shall be mixed in an approved batch mixer of at

least 14/10 capacity, fitting with a power driven loading skip.
The mixer shall be equipped with an automatic water measuring
tank fitted with a device for locking the discharge setting so
that the volume of water used in each batch of concrete is
accurately measured and cannot be varied by the mixer operator
after the device is set and checked by the Engineer's
representative on the site. The mixer drum and the loading skip
shall be kept clean at all times.
Each batch of concrete shall contain one or more whole bags of
cement.

The materials for each mix shall be placed in the loading skip in
the following order: coarse aggregate, cement, and fine
aggregate. The water shall be added to the dry materials in the
mixer drum. The quantity of water specified in Table `A' may be
varied up to 5% in order to maintain a constant workability; but
this tolerance shall not be exceeded without prior approval of
the Engineer. Each batch of concrete shall be mixed until there
is a uniform distribution of the materials and the mass is
uniform in colour and consistency. In no case shall the time of
mixing be less than two minutes or more than five minutes after
the water has been added to the batch. Any concrete surplus to
requirements shall be thrown away. In no circumstances may
surplus concrete be remixed for use later.

24 Placing of Concrete Generally

No concrete shall be placed until the formwork and reinforcement

have been approved by the Engineer.

The concrete shall be transported from the mixer to the position

in which it is to be placed without delay, and by means which
will prevent loss of grout and/or segregation of the mix.

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 Concrete may be conveyed by chute only with the permission of the
Engineer. Any concrete which has attained its initial set before
being placed shall be discarded. Placing concrete shall be
suspended during rain.

Concreting shall be carried out continuously between and up to

the predetermined day's work or construction joints in one
sequence of operation.

All 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. Vibrators shall be used solely for
compacting the concrete and not for distributing it into place.
The concrete shall be prevented from flowing laterally by the use
of vertical stopping off boards, or other vertical faces, and the
surface of the concrete shall be maintained reasonably level
during placing. Concrete shall be placed in the formwork in
layers not exceeding 450 mm thick. In the event of unavoidable
stoppage in positions not predetermined, the concrete shall be
terminated on horizontal planes and against vertical surfaces and
an additional day's work joint formed. A record shall be kept on
the works site of the time and date of placing the concrete in
each position of the structure.

25 Compaction of Concrete

Concrete after placing shall be thoroughly compacted by both hand

tamping and mechanical vibration. Concrete maintained between two
walls of formwork shall be compacted by power driven vibrators of
the immersion type and concrete in slabs with no formworks on the
upper surface shall be compacted by power driven vibrators of the
pan type or by vibrating screeds. The vibrators shall be of
ample power operating at not less than 4,000 R.P.M. and of a kind
approved by the Engineer. They shall be operated by workmen
skilled in their use who shall be additional to the labourers
employed on placing and tamping the concrete.

No concreting of water retaining, water conveying or water

excluding structures shall begin until the required number of
vibrators and also a spare vibrator are all available and have
all been tested and found to be in good working condition at the
works site.

Immersion vibrators shall be inserted and withdrawn slowly at a

uniform rate of approximately 100 mm per second. Compaction shall
be deemed to be completed when cement mortar appears in a circle
round the vibrator.

Immersion vibrators shall be inserted at points judged by the

area of mortar shown after compaction, with a certain allowance
made for overlapping. The immersion vibrators shall not be
allowed to come into contact with the formwork or the
reinforcement.

Pan vibrators shall be placed on the surface or the concrete

which shall have previously been tamped and levelled leaving an
allowance in height for compaction, until cement mortar appears
under the pan. The vibrators shall then be lifted and placed on
the adjoining area and the operation shall be repeated until the
whole surface has been compacted. Alternatively a vibrator
spanning the full width of the panel shall be used.

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 In all cases the placing of concrete shall be sufficiently ahead
of the vibrators so that the mass of concrete beyond the
vibrators is sufficient to stand without flowing while vibration
is in progress. On the other hand, the concrete shall be fully
compacted before initial set is attained.

26 Construction of Concrete Screed

As soon as the excavation has been approved by the Engineer the

concrete screed wherever shown on the Drawings shall be laid in
bays not exceeding 7.5 m square with open joints 25 mm wide in
between the bays. The joints shall be arranged to break joint
with the joints in the concrete floor above. The screed shall be
well rammed and worked to a dense smooth finish, and cured by
being kept damp under wet gunny bags for not less than 7 days.
After the screed has been cured, the 25 mm wide joints shall be
cleaned and filled with 1:3 cement sand mortar and the whole
surface allowed to dry out.

Should the surfaces of the formation be cut up through excessive

traffic or softened by the action of water due to delay on the
part of the Contractor to lay the concrete screed he shall
excavate such ground as may be affected and replace it by Mass
Concrete all at his own expense and to the satisfaction of the
Engineer before the screed is laid.

27 Construction of Floors of Water Retaining, Water conveying, or

Water Excluding Structures and Flat Roofs

The floors or roofs are divided into segments bounded by joints

shown on the Drawings. The concrete in each segment shall be
placed and compacted in regular strips across the full width of
the segment. Each strip shall be placed against the previous
strip before the concrete in the latter has attained initial set.
Each segment shall be concreted in one continuous operation, and
the Contractor shall so arrange his concreting programme that not
less than 7 days shall elapse between the placing of concrete in
any two adjacent segments.

The concrete shall be compacted first with immersion type

vibrators and then/or with pan type vibrators. Concrete shall be
placed and uniformly distributed to such a depth that after
complete compaction the concrete surface is at the finished
required level. Any areas which are below the finished level or
where segregation has taken place shall be dug out and
immediately made good with fresh concrete.

After the concrete has been thoroughly compacted, the surface

shall be thoroughly worked to a dense true finish with a wooden
float. Under no circumstances shall neat cement be sprinkled on
the surface of the concrete.

Where reinforcement is continuous across the joints, notched

vertical stopping off boards shall be used for the reinforcement
to pass through.

The joints shall each have a U-groove formed at the top to

receive sealing compound.

C - 13
28 Construction of Walls of Water Retaining, Water Conveying, or
Water Excluding Structures

The walls are divided into segments by vertical joints which are
continuous with the floor joints and extend the full height of
the walls in unbroken alignment. Each segment between the height
of 50mm above the top of the haunch and the underside of the
wall/ring beam shall be cast in a series of lifts not exceeding
1.35 m high each. Alternate segments in a lift shall be
concreted, and an interval of 7 days shall have elapsed before
the intervening segments in the same lift are concreted. One lift
of the wall all round shall be completed before the next higher
lift is concreted.

Each panel defined by the vertical joints and the height of a

lift shall be concreted in one continuous operation. The concrete
shall be placed and compacted in layers not exceeding 450 mm in
depth. The placing of concrete shall be kept 1.5 m ahead of the
vibrators so that the mass of concrete beyond the vibrators is
sufficient to stand without flowing while the vibration is in
progress. Each layer shall be placed and compacted before the
concrete in the lower layer has attained its initial set.

Each joint shall have a U-groove formed on the water retaining

face as well as on the water excluding face to receive sealing
compound.

29 Construction of Wall Footings and Haunches of Water Retaining,

Water Conveying or Water Excluding Structures

Each segment of the wall footing and haunch defined by the floor
and wall joints and a horizontal plane 50 mm above 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. Great care shall be
exercised to ensure that the concrete in and around the haunch is
thoroughly compacted.

Alternate segments of the footing and haunch shall be concreted

and an interval of 7 days shall elapse before the intervening
segments are concreted.

30 Construction of Dome Roofs

Dome roofs shall be cast on the formwork in one layer. They shall
be cast in segments defined by the joints shown on the Drawings.
Alternate segments shall be cast, and an interval of 7 days shall
have elapsed before the intervening segments are concreted. The
individual segments shall be cast in one continuous operation,
the concrete being placed and compacted in regular strips across
the full width of the segments. Each strip shall be placed
against the previous strip before the concrete in the latter has
attained its initial set. Where reinforcement is continuous
across the joints, the vertical stopping off boards shall be
notched to allow the reinforcement to pass through. The joint
shall each have a U-groove formed on the top to receive sealing
compound.

C - 14
31 Joints

The Contractor shall make the joints in the floors, walls and
roofs strictly in accordance with the Drawings. Particular care
shall be taken to ensure that the waterstops wherever shown on
the Drawings are adequately secured so that they will not be
displaced while concrete is being placed. Under no circumstance
shall waterstops be nailed through. Any water stop which has been
perforated shall be rejected and replaced at the Contractor's
expense.

As soon as possible after the removal of the shuttering in

vertical joints or after the concrete has set in horizontal
joints the surface laitance of the concrete shall be removed in
order to expose the large aggregate and leave a solid surface.
If the concrete has not hardened this may be achieved by brushing
with a wire brush or pressure spraying with water but if this is
not possible due to the hardening of the concrete it will be
necessary to remove the laitance by using a scaling hammer or
other mechanical device. Care shall be taken to avoid the use of
excessively powerful hammers as these are likely to damage the
concrete by dislodging or fracturing the aggregates. Before
concreting is resumed, care shall be taken to ensure that there
is no loose matter on the concrete surface. The surface shall be
thoroughly wetted and covered with a layer of 1:1-1/2 cement and
sand mortar not less than 40 mm thick. The mortar shall have the
consistency of condensed milk.

32 Day's Work Joints

Day's work joints in floors, roofs and slabs shall be formed

against vertical boards and the concrete shall be well compacted
against the boards.

No fresh concrete shall be placed against any concrete in which

has attained its initial set. Concrete is deemed to have attained
its initial set 30 minutes after water has been added to the mix.
Provided that the set concrete has been properly placed and
compacted and is acceptable to the Engineer, it shall not be
disturbed and shall be allowed to attain its final set and to
harden sufficiently to enable a day's work joint surface on it to
be prepared by thorough hacking without damage. Concrete may be
deemed to have hardened sufficiently for this purpose 72 hours
after placing.

Any concrete which has been disturbed after it has attained its
initial set shall be rejected and subsequently removed and
replaced by the Contractor at his own expense.

When concreting must be suspended at any point because of

inclement weather, or for any unforeseen cause, a day's work
joint shall be made.

When concrete at a day's work joint shall be allowed to harden

for 72 hours. Before fresh concrete is placed against the day's
work joint, all loose and imperfect materials cement scums or
laitance shall be removed from the joint surface, which shall be
thoroughly hacked until a completely hacked, roughened fresh
surface is obtained. The fresh surface shall then be brushed
clean, and immediately before fresh concrete is placed against
it, it shall be thoroughly wetted and covered with a layer of
1:1-1/2 cement and sand mortar not less than 40 mm thick. The
mortar shall have the consistency of condensed milk.

C - 15
33 Sealing Compounds

Only non-hardening sealing compounds approved by the Engineer

shall be used for sealing the grooves provided at joints.

All sealing compounds shall be applied in strict accordance with

the manufacturer's instructions. The grooves for receiving the
sealing compounds shall be thoroughly brushed to remove grit,
soil and other loose particles. The grooves and the surrounding
concrete shall be thoroughly dried by such means as the Engineer
shall direct, and the sealing compounds or primers shall be
applied before dampness returns to the surface of the concrete.

34 Waterstops

Only waterstops approved by the Engineer shall be used.

The Contractor shall carefully read the waterstop

manufacturer's instructions before commencing any work involving
the incorporation of waterstops and shall carry out all work in
this connection as recommended by the manufacturer and to the
approval of the Engineer.

Waterstops shall be fully continuous when laid and site joints

shall be limited to simple butt joints which are to be made
with the manufacturer's fusing jig. A careful check shall be made
on all joints after completion to ensure that no imperfections
exist.

Waterstops shall be securely held in position by the formwork or

by means to be approved by the Engineer and the concrete shall be
carefully worked around the waterstops to ensure that it is
completely embedded and that air pockets will not exist.

35 Pipes, Specials, Fittings, etc. cast into Concrete

Where shown in the Drawings the Contractor shall build pipes,

specials, fittings, plates, anchor hooks, brackets, bolts and
nuts, etc. into the concrete as the work progresses. The external
coating of the pipes and specials shall be removed to the extent
directed by the Engineer so that a proper bond may be obtained
with the concrete. These pipes, specials, fittings, etc. shall be
accurately set and rigidly supported and their lines and levels
shall be passed by the Engineer before concreting is commenced.
No reinforcement shall be cut to allow such pipes, specials,
fittings, etc. to be cast into the work without the approval of
the Engineer. Concrete shall be thoroughly worked around the
pipes, specials, fittings, etc. to ensure a complete bond so
that no leakage will result from the presence of the pipes,
specials, fittings, etc.

If the pipes, specials, fittings, etc. to be built into the work

are not available when concrete is to be placed, openings shall
be left in the concrete and the pipes, specials, fittings, etc.
shall be concreted in as a separate operation.

The openings left shall be of ample size to allow the concrete to

be thoroughly compacted around the pipes, specials, fittings,
etc. and shall be provided with waterstops if the Engineer so
directs. Before concrete is placed in such openings, all loose or
imperfect materials, cement scum or laitance shall be removed and
the joint surfaces shall be thoroughly hacked until a completely

C - 16
 hacked roughened fresh surface is obtained. The fresh surfaces
shall then be brushed clean and immediately before concrete is
placed, these surfaces shall be thoroughly wetted and covered
with a layer of 40 mm thickness of 1:1-1/2 cement sand mortar of
the consistency of condensed milk.

36 Curing Concrete

As soon as the freshly placed concrete has hardened sufficiently

to withstand such treatment without damage, the exposed surfaces
of roofs, floors, walls and columns shall be completely covered
with wet gunny bags, which shall be kept thoroughly wet
continuously by generous application of water every two hours for
a period of 8 days. The water shall be allowed to run down
between the forms and the formed concrete surfaces. Flat slabs
shall have water impounded on them for a period of at least 10
days after placing.

When all the concrete in the floor and the haunch of any water
retaining, water conveying or water excluding structure have been
placed and the concrete attained the final set, the whole of the
floor shall be flooded with water to a depth of not less than 75
mm. This depth of water shall be maintained throughout the rest
of the construction period.

The Contractor shall make provisions for distributing an adequate

quantity of water to all parts of the work for this purpose.

37 Striking Formwork

No formwork shall be struck without the prior approval of the

Engineer Formwork shall be removed in accordance with a programme
agreed to by the Engineer without such shock or vibration as
would damage the concrete and without interruption to the curing
of the concrete as herein before specified in this Specification.
Normally formwork shall be struck after the following periods
have elapsed.

From sides of beams, walls and columns

(unloaded) .. 3 days

From bottom of slabs (props left under) .. 7 days

From soffits of beams (props left under) .. 7 days

Removal of props under slabs (unloaded) .. 14 days

Removal of props under beams (unloaded) .. 14 days

Concrete exposed by the removal of formwork shall be left

untouched pending inspection by the Engineer.

38 Surface Treatment to Concrete

After the concrete surface has been inspected by the Engineer the
surface shall be treated as described below.

All areas where the concrete has not been properly consolidated
to a dense uniform surface shall be cut out, and made good to the

C - 17
 satisfaction of the Engineer. All bolt holes left by 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 removed. The holes shall then be flushed with a strong jet of
water to remove all loose materials. While the holes are still
wet, the sides of the holes shall be dusted with neat cement
using a suitable brush for this purpose. Immediately following
this the holes shall be plugged with a dry pack consisting of one
part of cement and two parts of fine sand. The mixture of cement
and sand shall be made only sufficiently damp with water to allow
it to be rammed solid without exuding any liquid, and after
thorough mixing shall be placed in the holes in thin layers and
solidly compacted over the entire surface with a hardwood stick
and a hammer, and finally struck off to a true surface.

Exposed concrete surfaces and surfaces to be in contact with

water shall be treated as follows:-

(a) All projecting imperfections shall be carefully chipped off

and rubbed down with carborundum blocks to a true surface,
and the grit or dirt resulting there from thoroughly washed
off with clean water.

(b) Wherever necessary, the surface shall be made thoroughly

wet, and a cement grout composed of 1 part of cement and 2
parts of fine sand by volume shall be worked into the pores
and holes over the surface with a fine carborundum float so
that a uniform smooth and dense surface throughout is
finally presented.

All defects on concrete surfaces which will be permanently

concealed in the finished structure shall be repaired and made
good as directed.

39 Testing for Watertightness

The Contractor shall, at his own expense, conduct the tests for
water tightness of all water retaining, water conveying, and
water excluding structures and shall provide all the water
required for this purpose.

The first test on a structure shall not be carried out until four
weeks have 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 level
shown on the Drawings and maintained at that level for three
days. Should any obvious signs of leakage be observed during this
period, or any subsequent test period, the positions of all such
signs of leakage shall be marked and the test shall be stopped;
and the Contractor shall at his own expense carry out such
remedial measures as the Engineer shall direct including the
complete emptying of the structure if necessary. Should the
leakage be general the remedial measures may include the complete
treatment of the inside surfaces of the structure by rendering or
by the application of some other approved waterproof coating.
When all obvious signs of leakage have been stopped and made good
in accordance with the Engineer's instructions, the structure
shall be refilled to top water level, and so maintained for three
days. At the end of the third day, provided no further signs of
leakage are observed the exact water level shall be marked, and
after a further seventy-two hour period, the water level shall
again be marked and the difference recorded. During this seventy-

C - 18
 two hour period an evaporation test shall be carried out in the
manner described hereunder. The structure shall be deemed
watertight and shall be so accepted in this respect only by the
Engineer if the recorded difference minus the loss of water by
evaporation gives a figure which does not exceed 1/2000 of the
depth of the water originally in the structure. Should, however,
the above recorded difference minus the loss of water by
evaporation give a figure which exceeds 1/2000 of the depth of
the water originally in the structure, the Contractor shall, at
his own expense, carry out the complete treatment of the inside
of the structure by rendering or such other remedial measures as
the Engineer may direct. On completion of such treatment, the
Contractor shall at his own expense retest the structure and
repeat these remedial measures, if found necessary, until
watertightness is obtained.

During the test, the loss of water by evaporation shall be

determined by measurement of the loss of water from a shallow
watertight tray 0.35 m2 in area containing not less than 75 mm of
water and floating on the surface of the water in the structure.

Should any leakage and/or percolation develop during the defects

liability period specified in the Contract, remedial measures
similar to those specified above, followed by tests for
watertightness, shall be carried out by the Contractor at his own
expense.

40 Precast Concrete Units

All precast concrete shall be grade 25 as specified in Table `A'.

Precast concrete pipes shall be manufactured by the centrifugal

spinning process, and all other precast concrete units shall be
manufactured in mechanically vibrated moulds.

If any of the precast concrete units is manufactured away from

the site of the work, the contractor shall satisfy the Engineer
that the concrete proportions, reinforcement, etc. are in
accordance with the drawings and this Specification, and if
required, he shall produce samples for testing.

All precast units shall be handled and stocked so as to avoid

damage and ensure that no undue stress is imposed on them. The
Contractor shall remove from the site and replace at his own
expense any precast units which are damaged due to his own
negligence or which are rejected by the Engineer.

Precast R.C. louvres shall be cast true to form and be uniform

throughout in accordance with detailed drawings.

41 Surface Water Drains and Aprons

Precast concrete surface waterdrains shall be cast in 600 mm

lengths with dimensions as shown on the Drawings. The drains
shall be properly bedded and jointed with 1:3 cement sand mortar
and laid to falls as directed by the Engineer.

C - 19
42 R.C. Lintols and Cills

Precast reinforced concrete lintols shall be built to the full

thickness of the walls in which they occur and with 225 mm
bearing on either side of the opening which they span unless
smaller bearings are indicated in the Drawings.

Precast reinforced concrete cills shall be cast to the dimensions

as shown on the Drawings.

43 Precast Concrete Drain Covers

Precast reinforced concrete slabs over drains shall be 50 mm

thick and reinforced with B.R.C. No. 10. Slabs shall have
recesses in their end faces to facilitate removal.

44 Concrete Pipes

Plain or reinforced concrete pipes shall comply with the

requirements of Australian Standards A.S. 1342 and CA 33, and
shall be manufactured by the centrifugal spinning process. The
manufacturer's certificates of test will be accepted as proof of
the quality of the concrete pipes but the Engineer may, at his
discretion, require for additional testing to be made on samples
of concrete pipes stored at the site. In the event of any
concrete pipe being found to be not in accordance with the
relevant Standard under the additional tests or in the course of
being worked, the whole batch of pipes from which the faulty pipe
comes may be rejected by the Engineer notwithstanding any
previous acceptance on the strength of the manufacturer's
certificate. Any pipe rejected by the Engineer shall be removed
from the site at the Contractor's expense.

The pipe section shall not be cut off without the approval of the
Engineer. The joints of the pipes shall be ordinary ogee or
rebated joint, sealed with cement mortar.

45 Ready-Mixed Concrete

Ready-mixed concrete may be used subject to the Engineer's prior

approval. The Engineer will require to inspecting the plant from
which the said concrete is to be supplied.

The supply and delivery of ready-mixed concrete to comply with the

recommendations of B.S. 1926.

The ready-mixed concrete will comply with all the requirements of

this Specification.

The Contractor to maintain records of all supplies of ready-mixed

concrete placed on the Works, including

(i) Delivery notes giving details of quality and mix

proportions

(ii) The time at which each batch of concrete was mixed and
details of any additives used.

(iii) Positions in the Works where concrete is placed.

C - 20
 The concrete to be agitated continuously by rotation of the mixer
drum during transport to the Site and while awaiting discharge.

In the case of truck mixed concrete, the water may be added

either at the concrete supplier's plant, or under the
Contractor's supervision after arrival at Site, but not during
transit.

The concrete to be compacted in its final position in as short a

time as possible after mixing, and not later than 1-1/2 hours
after the specific time when the cement comes in contact with the
aggregate.

Works test cubes to be made on Site by the Contractor in

accordance with the provision of this Specification, irrespective
of any sampling and/or testing which may be carried out by the
supplier.

46 Tolerances and Defects

The permissible surface tolerances shall not exceed the limits

shown on the following table.

If, in the opinion of the Engineer, the formwork is cut, drilled,

bent, buckled, repaired or generally damaged in a way detrimental
to the appearance of the concrete or to the tightness or
straightness of the forms it will be rejected.

Examples of Permissible Tolerance

Condition Final Surface Tolerance

Variation in cross sectional dimensions - 0 mm

of structural members + 3 mm

Departure from straightness

(cumulative departure not permitted) 3 mm in 1m

Displacement of shuttering boards at

joints + 1 mm

Offsets or fins caused by defective

formwork or otherwise 3 mm

C - 21
TABLE `A’

PROPORTIONS & STRENGTHS OF CONCRETE

_________________________________________________________________________________________________________________ _____________________

Nominal Mix Water Size Compacting Slump Minimum Compressive

Desig- Location in Cement/Fine Estimated Proportions of including of Factor for Test Strength of Works
nation Works Aggregate/ ------------------------- Water in Coarse Vibrated Cubes
of Mix Coarse Portland Fine Coarse Aggregate Aggregate Concrete ---------------------
Aggregate Cement Aggregate Aggregate at 7 days at 28 days
______________________________________________________________________________________________________________________________________

N/mm2 N/mm2

Grade to be designed .88 75+/-25 34 50

50 to
.94
________________________________________________________________________________________________________________________ ______________

Grade to be designed .88 75+ /-25 30 45

45 to mm
.94
____________________________________________________________________________________________________ __________________________________

Grade to be designed .88 75+/-25 27 40

40 to mm
.94
____________________________________________________________________________________________________ __________________________________

Grade to be designed .88 75+/-25 24 35

35 to mm
.94
______________________________________________________________________________________________________________________________________

Grade 1:1:2 50 kg 54 kg 98 kg 22 litre 20 mm .88 75+ /-25 21 30

30 to mm
.94
____________________________________________________________________________________________________ __________________________________

Grade 1:1.5:3 50 kg 80 kg 147 kg 25 litre 20 mm .86 75+ /-25 17 25

25 to mm
.90
____________________________________________________________________________________________________ ___________________________________

Grade 1:2:4 50 kg 105 kg 194 kg 30 litre 20 mm .82 50+/-25 14 20

20 to mm
.86
____________________________________________________________________________________________________ ___________________________________

Mass 1:3:6 50 kg 150 kg 300 kg as 20 mm - 5.5 8.5

Concrete directed
____________________________________________________________________________________________________ ___________________________________

Note: (i) When concrete is compacted by hand (and not vibrated) the compacting factor and the mix
shall be determined by the Engineer when the preliminary test mixes are made.

C - 22
Table B The Characteristic Strength Compliance Requirements

Specified Group of test A B

Grade Result

The mean of the group of Any individual test

test results exceeds the results is not less than
specified characteristic the characteristic
compressive strength by at compressive strength
least: less:

N/mm2 N/mm2

C20 and First 2 1 3

above
First 3 2 3

Any consecutive 4 3 3

N/mm2 N/mm2

C7.5 to First 2 0 2
C15
First 3 1 2

Any consecutive 4 2 2

C - 23
Quality Standard for Reinforced Concrete Structures

Note: (i) The following standard shall take precedent.

Item* Standards

1 Formwork

1a Formwork dimensions and1) Tolerance for cross –sectional dimensions of cast

openings for services in-situ & precast elements: +10mm / -5mm

2) Tolerance for penetration / opening for services:

+10mm for size and 25mm for location

3) Tolerance for length of precast members (major

dimension of unit):
 Up to 3m:6mm
 3m to 4.5m:9mm
 4.5m to 6m:12mm
 Additional deviation for every
subsequent 6m: 6mm

1b Alignment, plumb and level 1) Tolerance for departure of any point from its
position: 10mm

2) Tolerance for plumb:3mm /m, maximum 20mm

3) Maximum deviation of mean level of staircase

thread to temporary bench mark:5mm

4) For cast in-situ elements, the deviation of level

of any point from the intended level: 10mm

1c Condition of formwork,1) Formwork must be free from defects

props &
bracing
2) Before concreting, the interior must be free from
debris

3) All formwork joints must not have gaps to prevent

leakage

4) There must be adequate support, bracing and tie-

back for the formwork to prevent bulging or
displacement of structural elements

C - 24
 Item* Standards

2 Reinforcement (cast in-situ

& Precast)

2a Main & Secondary rebars 1) According to structural drawings (numbers / sizes)

2) Spacing of bars not more than that specified

2b Anchorages & lap lengths 1) Required lap length not less than that specified

2c Cover provision 1) According to specifications with tolerance of 5mm

2d Links, stirrups and 1) According to structural drawings (numbers / sizes)

trimming bars

2) Spacing of links not more than specified

2e Rebar Condition 1) Rebars must be securely and properly tied in place

2) Rebars must be freed from concrete dropping,

corrosion etc

3 Finished Concrete (cast in-

situ & Precast)

3a Dimension for elements 1) Tolerance for cross-sectional dimension of cast

/opening for services in-situ and precast elements:+10mm / -5mm
2) Tolerance for opening:+10mm for size and 25mm for
location
3) Tolerance for length of precast members (major
dimension of unit)
 Up to 3m:6mm
 3m to 4.5m:9mm
 4.5m to 6m:12mm
 Additional deviation for every
subsequent 6m: 6mm
4) Straightness or bow (deviation from intended line)
of precast member:
 Up to 3m:6mm
 3m to 6m:9mm
 4.5m to 6m:12mm
 Additional for every subsequent
6m:1mm

C - 25
 Item* Standards

5) Squareness of precast member – difference between

the greatest and shortest dimensions should not
exceed the following:
Length of shorter sides
 Up to and including 1.2m:6mm
 Over 1.2m but less than 1.8m:9mm
 1.8m and over: 12mm

6) Twist of precast member – Any corner should not be

more than the deviation stated from the plane
containing the other 3 corners:
 Up to 600mm wide and 6m in length: 6mm
 Over 600mm wide and for any length: 12mm

7) Flatness: 6mm per 1.5m

3b Alignment, plumb and level 1) Tolerance for departure of any point from its
position:
10mm

2) Tolerance for plumb: 3mm / 1m, maximum 20mm for

floor to floor height and 40mm for the entire
building height

3) Maximum deviation of mean level:10mm

4) For cast in-situ elements, the maximum deviation

of levels within the element: 10mm

5) Chamber at mid-span: according to specifications

3c Exposed Surface 1) Should not have visual exposure of groups of

coarse aggregates resulting from grout leakage

2) Cold joint & formwork joint must be smooth

3) No bulging of structural elements

4) All formwork, nails, zinc strips, etc must be

removed

5) No cracks or damages

C - 26
 Item* Standards

4 Precast Specific
Requirements

4a Lifting points/inserts 1) Tolerance for position:20mm from centre line

location in drawing

2) Lifting devices and inserts free from damages

4b Sleeve system/connections 1) Tolerance for position:6mm from centre line

location in drawings

2) Bar protrusion length according to requirements.

No bending, cranking or damages to bars

3) Bars free from concrete droppings or corrosion

4) Sleeves, grout holes, grout tubes not congested

with debris

4c Interface/joint 1) Joint taper:

requirements
 Over 3m length: 6mm
 Maximum for entire length: 9mm

2) Alignment of horizontal and vertical joint:6mm

3) Jog in alignment of matching edges: 6mm

4) Sitting of element: according to specifications

5) Installation of sealant and waterproofing:

according to specifications

4d Cast-in steel items/welded 1) Tolerance for position of cast-in steel items:6mm

& bolted connections from centre line location in drawings

2) Tolerance for position of openings for bolt

connections:3mm from centre line location in
drawings

3) Relevant requirements in CONQUAS steelwork

standards to be used where applicable

C - 27
 Item* Standards

5 Structure Quality

5a Concrete Cube test 1) For every pour of concrete, test cubes results at
28 days must satisfy the passing criteria as
specification in the contract. The summary of test
report (Form A) must be endorsed by the project’s
structural QP (Qualified Person)

5b Reinforcement (Rebar) 1) To pass the tensile strength test for all the
reinforcement bars used as according to the
contract specifications. The summary of test
reports (Form A) must be endorsed by the project’s
structural QP (Qualified Person)

2) All the welded steel fabric used to comply with

the contract specification

3) No non-conforming reinforcement detected through

test records has been installed in the structure

6 Non-destructive testing

6a Ultra Pulse Velocity test 1) To conduct NDT using ultrasonic pulse velocity
for Concrete Uniformity (UPV) to check the degree of uniformity of
hardened concrete

2) 5 columns per set and 2 readings per column

3) Assessment is based on the difference between the

2 UPV readings within a column shall not exceed
0.05 km/s

4) Method as per SS 78

6b Electro-Covermeter test for 1) To check hardened concrete cover for reinforcement

Concrete cover bars after casting: minimum 25mm or higher as
according to specification

2) 5 structural samples per set including:

a. 3 for slab soffit @ 4 readings each

b. 1 for column @ 2 readings each on both axis of

the column

c. 1 for beam @ 2 readings each on the soffit and

one side of the beam

3) For each reading within a structural sample, full

point for 5mm and half point for 5mm to 8mm.
However, no points will be awarded if any of the 4
readings within the structural sample exceeds
12mm

4) Method as per SS 78

C - 28