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PROJECT TITLE:
DOCUMENT TITLE :
ENGINEERING CONSULTANT
SPECIFICATION FOR
CONCRETE WORK
TABLE OF CONTENTS
1 INTRODUCTION..................................................................................................................6
1.1
1.2
SCOPE...............................................................................................................................6
APPLICABLE CODES, STANDARDS AND SPECIFICATIONS..................................6
2 MATERIALS..........................................................................................................................9
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
CEMENT...........................................................................................................................9
AGGREGATES................................................................................................................10
WATER.............................................................................................................................12
ADMIXTURES................................................................................................................12
REINFORCING STEEL..................................................................................................14
ANCHOR BOLTS............................................................................................................16
INSERT PLATES / EMBEDDED PLATES....................................................................17
MISCELLANEOUS ITEMS............................................................................................17
GENERAL.......................................................................................................................18
CEMENT CONTENT......................................................................................................18
WATER/CEMENT RATIO..............................................................................................18
TOTAL SALT CONTENT IN CONCRETE....................................................................19
USE OF ICE AS MIXING WATER.................................................................................19
GENERAL.......................................................................................................................19
SLUMP TEST..................................................................................................................19
WORK CUBE TEST.......................................................................................................19
5 GROUTING.........................................................................................................................23
5.1
5.2
5.3
5.4
5.5
5.6
5.7
TYPES OF GROUTS.......................................................................................................23
PREPARATION OF GROUT..........................................................................................24
SURFACE PREPARATION............................................................................................24
FORMWORK FOR GROUTING....................................................................................25
WEDGES AND SHIM PLATES......................................................................................25
PLACING, CURING AND TESTING............................................................................25
FINISHING OF GROUT.................................................................................................27
6 FORMWORK......................................................................................................................27
6.1
6.2
GENERAL.......................................................................................................................27
FORM WORK FOR VIBRATED CONCRETE..............................................................28
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7.1
7.2
7.3
7.4
7.5
TRANSPORTATION.......................................................................................................28
PLACEMENT..................................................................................................................28
COMPACTION................................................................................................................29
TOLERANCE..................................................................................................................30
FINISHES........................................................................................................................31
8 CURING...............................................................................................................................35
8.1
8.2
8.3
HORIZONTAL SURFACES............................................................................................35
VERTICAL SURFACES..................................................................................................35
CURING COMPOUND...................................................................................................35
9 REMEDIAL WORK............................................................................................................36
10 READYMIX CONCRETE.................................................................................................36
11 PROTECTIVE COATINGS...............................................................................................37
11.1
11.2
11.3
11.4
GENERAL.......................................................................................................................37
CASTING ONTO SOIL...................................................................................................37
SURFACE BELOW SOIL...............................................................................................37
ABOVE GRADE CONCRETE PROTECTION.............................................................38
12 PRE-CAST CONCRETE....................................................................................................39
13 THIRD PARTY INSPECTION..........................................................................................39
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SPECIFICATION FOR
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1.1.1
PROJECT SPECIFICATIONS
3771-MGDA4-1-14-0001
1.1.2
1.1.3
QP-SPC-L-002
QP-PHL-S-001
QP-REG-S-001
ES.D.-10
QP-STD-A-001
BS EN 1992-1-1
BS EN 206
Concrete. Specification,
conformity.
BS EN 196
BS EN 12620
BS EN 1008
BS EN 934
BS EN 933
BS EN 12504-1
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production
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and
SPECIFICATION FOR
CONCRETE WORK
ASTM C-33
ASTM C-109
ASTM C-227
ASTM C-289
ASTM C-494
ASTM C-579
Standard Test Methods for Compressive Strength of ChemicalResistant Mortars, Grouts, Monolithic Surfacing and Polymer
Concretes
BS 1881
BS 4027
BS 4190
BS 4320
BS EN ISO 1461
BS 4449
BS 4482
BS 4483
BS 6031
BS 8000
BS EN 1338
BS EN 12350:Parts 1 to 8
BS EN ISO 5667
BS 6100
BS 8666
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SPECIFICATION FOR
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BS EN 1993
Design of steel structures -Part 1-1: General rules and rules for
buildings
BS EN 1997-1
BS 6089
BS 6093
MATERIALS
2.1
2.1.1
CEMENT
TYPE OF CEMENT
Cement shall be supplied from a source that has a well-established, proven record for
consistent supply of quality material
Ordinary Portland cement conforming to BS EN 197-1 or equivalent shall be used for all
concrete works both in sub structure and super structure.
Sulphate Resisting Cement (SRC) complying with BS 4027 shall be used for blinding
and mass concrete.
CONTRACTOR shall use cement manufactured by Qatar National Cement Company
(QNCC), subject to availability.
All cement shall comply with part-1, section-5 of Qatar construction specification. Source of
materials shall be subject to QP approval.
2.1.2
TESTS
Test for cement fitness, soundness, strength test (compression) and setting time shall be
carried out in accordance with BS EN 196 for each shipment of cement.
2.1.3
CEMENT STORAGE
The cement shall be suitably protected during storage to avoid deterioration in quality. Cement
must be ordered well in advance to ensure an adequate and continuous supply. Cement shall
be of recent manufacture and shall be used within a period of 3 months from production.
Cement that has been in storage for more than 3 months (from the date of manufacture) shall
not be used.
Cement stored in bags under a shade should maintain relative humidity level not exceeding
60%.
Any damaged bag of cement will be rejected. It must not contain lumps that cannot be crushed
between fingers. Any cement with incipient setting or traces of humidity shall be rejected.
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Bagged cement shall be delivered to site in the Suppliers original sealed bags or containers
and shall be stocked in a dry, weather tight, properly ventilated covered structure, with
adequate provisions for preventing the absorption of moisture and raised at least 150 mm off
the ground to prevent deterioration. Suitable shade/ covering shall be provided to limit the
temperature to 40C.
2.2
2.2.1
AGGREGATES
SOURCES
Aggregates shall be obtained from an approved Qatari source unless CONTRACTOR can
show that local materials are not available.
All aggregate to be used for concrete shall comply with part 2, section 5 of QCS. Source of
material shall be from GABBRO only.
CONTRACTOR shall supply physical characteristics of the materials including samples and
test, for QP review and approval.
All aggregates used for the same structure shall be obtained from one source.
Dune and beach sand shall not be used as fine aggregates.
Fine and coarse aggregates shall conform to BS EN 12620. Fine and coarse aggregates shall
be considered as separate ingredients. Both shall meet the grading requirements of BS EN
12620. They shall be well graded, clean, hard and free from undesirable material. The clay, silt
and fine dust content, the organic impurities and the aggregate crushing value, shall be within
the limits specified in BS EN 12620.
2.2.2
TESTS
The CONTRACTOR shall take samples from stockpiles for testing in the Contractors site
laboratory. Any material which, as a result of such test, does not conform to the requirements
of BS EN 12620 shall be removed from the site by the CONTRACTOR at his own expense.
All samples shall be taken in the presence of QP Representative.
Aggregates test result shall be presented to QP for approval.
Aggregate shall be tested in accordance with BS EN 933 or equal and shall meet the
requirements of table 2.1, part 2, and section 5 of QCS.
Aggregates shall be tested for any materials that are deleterious reactive with the alkalis in the
cement. They shall also be tested for alkalis which are additionally present in the aggregates
and mixing water, in amounts sufficient enough to cause excessive localized or general
expansion of concrete or mortar, as described in ASTM C 33 when tested in accordance with
ASTM C 227.
Marine aggregates are prohibited.
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The maximum dust content of aggregates as determined by wet sieving through a 75m sieve
as per BS EN 933 shall not exceed the following limits:
Coarse aggregates
Fine aggregates
-1%
-3%
-3%
-5%
Chlorides in coarse aggregates shall be limited to 0.03% by weight and to 0.06 % by weight in
fine aggregates and a cumulative total content of chlorides in concrete required shall be as
specified in section 4.4.1.
Sulphate in the coarse aggregates shall be limited to 0.3 % by weight and 0.4% by weight in
fine aggregates and a cumulative total content of sulphates in concrete required shall be as
specified in section 4.4.2.
Aggregate shall be tested for reactive silicates in accordance with ASTM C-227 and ASTM C289, or to be obtained from a supplier whose aggregates have previously been proven to meet
these requirements. Compliance certificates shall be submitted to QP. Aggregates meeting the
requirements of ASTM C-289 do not require testing as per ASTM C-227.
Testing shall be carried out at the following frequency:
Test for clay, silt, dust, moisture content and sieve analysis shall be carried out on every
20 tons of fine aggregates and 40 tonnes of coarse aggregates delivered to the site, with
a minimum of each test once per day;
Chemical analysis shall be carried out on every 100 tonnes delivered to site, with a
minimum of each test once per week; and
QP shall have the right to call at any time for additional samples for testing of aggregates
delivered to the worksite or for the aggregates at the source of supply in order to conform that
the aggregates meets the specified requirements.
2.2.3
SIZE
Coarse aggregates shall be limited to 20 mm maximum single size.
Fine aggregates shall be limited to 5 mm maximum size.
Sand shall be graded so that, when mixed with coarse aggregate and cement, it shall produce a
concrete of maximum density. Crushed sand may be added to natural sand in proportions to
achieve required grading. Crushed sand alone is not acceptable without the approval of QP.
2.2.4
GRADING OF AGGREGATE
Grading of aggregates shall be in accordance with Table 2.3 and Table 2.4 of QCS Section 5,
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Part 2.
2.2.5
STORAGE
Aggregate shall be stored under shade. Storage shall prevent contamination of the aggregates
by foreign material.
Wet aggregate shall be kept on site for at least 24 hours to ensure adequate drainage before
being used for concreting.
The concrete plant shall at all times maintain sufficient quantities of each type of aggregate to
be sufficient to ensure continuity of work.
Fine and coarse aggregates shall be separated by permanent substantial partitions in the store.
Fine and coarse aggregates from different sources of supply shall not be mixed or stored in the
same stockpile. Methods of storing and shading aggregates shall be approved by the QP.
2.3
WATER
Water used for the following, shall comply in all respects with requirements of BS EN 1008
and BS 6068 and QCS Section 5, Part 4.
Mixing of concrete;
Ice production;
Rinsing aggregates;
Cooling aggregates; and
Curing of concrete.
Only clean, fresh water free form harmful matter shall be used. Chlorides (Cl) and Sulphates
(SO3) shall be within permissible limits as specified in BS EN 1008.
The water shall not contain dissolved solids in excess of 2000 mg/kg. It shall be clean and free
from sugars, phosphates, acid, vegetable, and deleterious matter (e.g. oil) that affects the
properties of concrete. The pH of the water used shall be between 7.0 and 9.0.CONTRACTOR
shall arrange for analyses of samples of the mix water to be made before and during the
programme of the work by approved testing laboratory.
If any samples prove unsatisfactory, the CONTRACTOR will be required either to change to a
new supply or to make arrangements acceptable to QP to remove the unacceptable
constituents at his own cost.
2.4
ADMIXTURES
No admixture shall be used without QP approval of the specific admixture, manufacturer,
dosage and application.
Ready-mixed concrete for all reinforced applications shall contain a super plasticizing setretarding admixture complying ASTM C494 type G.
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All admixtures to be used for concrete shall comply with Part 5, Section 5 of QCS. Source of
material shall be subject to QP approval.
All admixtures used to modify one or more characteristics of the concrete shall be
accompanied by a certificate from an approved institute, stating:
CONTRACTOR shall perform the trial batch and casting to substantiate the manufacturers
claims for workability, retardation and air entrainment (0 to 0.1 percent maximum). No airentraining agent is to be used.
Admixtures shall not contain chlorides.
As a general rule, only one admixture may be used to improve a given quality of concrete. If a
retarder and plasticizer are required only a dual-purpose additive shall be used.
Admixtures shall be applied strictly in accordance with the manufacturers instructions.
However CONTRACTOR shall be responsible for any defective concrete that may result from
the use of such admixtures.
Following precautions shall be taken, in the use of the different admixtures:
Admixture shall comply with the requirements set forth in part 5, Section 5 of QCS;
Admixture shall only be used following the written approval of QP;
Admixtures shall be in accordance with BS EN 934 or ASTM C-494-80 type G;
Admixture shall not affect long term strength of concrete; and
CONTRACTOR to be aware that the admixture may increase shrinking and cracking
(accelerating admixtures).
Where admixture dosage is to be adjusted depending upon atmospheric temperature, mix
design shall include details of admixture dosage vs. atmospheric temperature range;
Dosage of any plasticizing admixtures, including super plasticizers and water-reducing
admixtures, shall not be greater than 85% of the admixture manufacturers
recommended maximum dose;
Where it is proposed to use more than one (1) admixture, CONTRACTOR shall submit
manufacturers data, independent technical evaluations and/or trial test results
confirming compatibility of the combined admixtures and demonstrating no undesirable
short or long term effects in the concrete. Mix design document shall include details of
order and method for dosing each admixture;
Some admixtures may promote excessive bleeding and segregation, in which case they may be
used only if site trials prove those aspects does not occur.
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SPECIFICATION FOR
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Very strict controls are to be maintained to ensure that the correct quantity of admixtures is
used at all times. The equipment to be used for dispensing and the method of incorporating the
admixture in the concrete shall be subject to approval of QP. The dispensing unit shall be
translucent so that the operator can see the discharge of the admixture.
Precast concrete pipeline sleepers shall have corrosion inhibitor DCI-S by grace construction
products or other QP approved equivalent included in the mix at a rate of 20litres/m3.
2.5
REINFORCING STEEL
Main reinforcing steel bars shall be un-coated high yield deformed bars of characteristic
strength of 414 N/mm2 to BS 4449, or equal as supplied by Qatar Steel Company
(QASCO), designated as grade T.
Uncoated mild steel plain bars with characteristic strength of 250N/mm 2 to BS 4482 or
BS EN 10025-1 may be used for links and binders, designated as grade 'R'.
Steel wire fabric shall be of characteristic strength 485 N/mm 2 in accordance with BS 4483 or
equal.
Adjacent sheets of mesh reinforcement shall be overlapped by at least 300 mm or 31
times the diameter of the wires lying at right angles to the edges to be lapped, whichever
is greater. Laps shall be tied together on both longitudinal and transverse wires.
Mechanical bar couplers, where required, shall be specified as complying with the
requirements of BS EN 1992-1-1.
Reinforcement shall be fixed, supported and maintained in position by the adequate use of
chairs, spacers and tying wire.
A copy of the manufactures test certificates for ultimate strength, bend elongation and cold
bending together with the chemical analysis of the steel shall be submitted to QP for each
consignment of the reinforcing steel delivered to site.
2.5.1
STORAGE
Reinforcement shall be stored on site above ground on rack, is such a way that it shall not be
damaged both before and after bending. It shall be stored in separate lots by size and by type.
Reinforcing bars with different diameters or different grades shall not be mixed during the
storage. The storage methods shall facilitate easy retrieval of bars. Both ends of each bar must
bear a painted mark identifying its grade.
Rack shall be covered to prevent corrosion by rain.
2.5.2
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Bending shall be in cold condition. Re-bending of high yield bars is not permitted.
All reinforcement shall be free of loose rust, grease, paint oil and any other matter, which may
adversely affect adherence within concrete.
Reinforcement shall be accurately placed as shown on drawings. Reinforcement shall be set
true to line and level with the correct concrete cover as specified on the drawings.
CONTRACTOR is to provide sufficient support, by means of approved chairs, spacers, tying
wire etc., to ensure that all reinforcement is held in the correct position while concreting is
taking place.
Reinforcement shall be rigidly bound together at every inter-section of two bars by 1.60 mm
soft annealed iron wire binding (No.16 SWG). All starter bars shall be set in position prior to
concreting and securely held during concreting.
Welding of reinforcement will not be permitted unless CONTRACTOR can demonstrate that
the bars are of weldable quality, meeting requirements of BS 4449.
Concrete spacer blocks shall be made from materials in no way inferior to those specified for
the concrete in which the spacer block is to be used. (For example, spacer blocks used in
concrete work below ground shall incorporate sulphate-resisting cement). Plastic spacer block
is not permitted.
2.5.3
CONCRETE COVER
Minimum clear concrete cover to all steel reinforcement including links shall be as follows:
Cover for all concrete works in contact with soil including foundations, and pedestals up to
base plate level shall be 70mm.
Cover to all above grade concrete exposed to weathering shall be 50 mm.
Cover to above grade concrete protected from weathering shall be:
- 40mm
- 30mm
Cover to bar couplers shall not be less than the minimum specified for reinforcing bars.
Blinding concrete shall not be considered as cover.
2.6
ANCHOR BOLTS
The design of the anchoring length of the anchor bolts shall be checked for maximum pull-out
force. Anchor bolts, pipe sleeves, anchor rails, inserts, bolts, etc. shall be positioned
accurately and be firmly attached to the formwork before the concrete is poured. Installed
anchor bolts, etc., shall be properly protected against damage and corrosion until the
equipment/structure is permanently installed.
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A template shall always be used to hold the anchor bolts in their correct position. The template
shall be of rigid construction and fabricated from a suitable robust material and subject to
approval of QP. All anchor bolts installed to 2 mm of their design position.
Anchor bolts shall be plumb to +/- 1:100.
Level tolerance to top of bolts shall be 0 mm + 10 mm.
Anchor bolts shall be of Grade 4.6 conforming to BS 4190. Grade 8.8 shall only be used with
prior approval of QP. Washers shall conform to BS 4320. Anchor bolts, nuts and washers shall
be hot dip galvanized in accordance with BS EN ISO 1461. Each anchor bolt shall be
adequately anchored into concrete.
Forging and heating of anchor bolts is not allowed.
Anchor bolts shall be designed for combined tension and shear as per BS EN 1993.
Before installation anchor bolts shall be de-greased by soaking them in Tri-Chloro Ethylene at
least for 4-6 hours. Use wire brush to remove grease and scale.
Entire anchor bolt assembly including bolt, nuts, washers, cast-in plates, etc. shall be hot dip
galvanized to BS EN ISO 1461.
The minimum edge distance to concrete plinth from the centreline of the anchor bolt shall be
as follows:
Bolt Size
30 mm diameter
150mm
> 30 mm diameter
175mm
The distance between anchor bolts, within an anchor bolt group shall conform to the tolerance
limits listed below:
Center to center Distance between Anchor
Bolts (mm)
Toleranc
es (mm)
1.5
400 to 900
900 to 1200
4.5
The minimum distance from base plate grout to edge of concrete plinth shall be 75mm.
Adequate reinforcement shall be provided in concrete plinths to transfer the design tension and
shear from anchor bolts to the foundation. Vertical reinforcement in concrete plinths shall be
provided with sufficient anchorage length above and below the bottom of anchor bolts.
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2.7
2.8
MISCELLANEOUS ITEMS
All miscellaneous items related to concrete works shall comply with Part 16, Section 5 of
QCS.
All sleeves, inserts, anchors, angle steels and other embedded items required for adjoining
work or for its support shall be accurately placed and firmly anchored to prevent displacement
prior to concreting.
All cast-in-place steel items shall be hot dip galvanized to BS EN ISO 1461.
All steel surfaces that are in direct contact with cured concrete surfaces shall be painted prior
erection to ensure the durability of non-corrosion surfaces in short period of time. Touch-up
paint on steel members shall be carried out with the same colour-coding.
3
3.1
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CEMENT CONTENT
Cement for structural reinforced concrete and paving shall be Ordinary Portland Cement to BS
EN 197 or equivalent. Cement content shall be limited to whats required for durability to
avoid excessive risk of thermal and shrinkage cracking. For reinforced concrete of grade
C40/20, it shall not be less than 370 kg/m3 unless otherwise approved by QP.
Sulphate Resisting Portland Cement (SRC) complying with BS 4027 shall be used for blinding
concrete, mass concrete and other unreinforced concrete. For blinding concrete of grade
C15/20 (SRC), cement content shall not be less than 280 kg/m unless otherwise approved by
QP. For mass concrete of grade C20/20 (SRC), cement content shall not be less than 310
kg/m unless otherwise approved by QP.
3.3
WATER/CEMENT RATIO
The proportioning of mixes for durability will be primarily controlled through the specified
limits of free w/c ratio and workability.
A maximum water/cement ratio of 0.45 shall be allowed for all reinforced concrete works and
0.55 for all blinding/ mass concrete works.
The water/cement ratio shall be continuously checked at the mixer with due allowance being
made for water (if any) contained in the aggregates. Under no circumstances is additional
water to be added between the mixing and the place of concrete placement. Additionally, the
water/cement ratio shall be checked by tests carried out on fresh concrete at the time of
placement and by slump test, all as described in section 5.0, of this document.
3.4
3.4.1
3.4.2
SULPHATES
The total sulphate content shall comply with requirements of Table 6.2, Part 6, and Section 5
of QCS.
3.5
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that may be added to the mix after taking due account of the water present in the aggregate.
The target temperature for "as mixed" concrete shall be 20C minimum and 25C maximum.
These temperatures may not be attainable during certain periods of the year. The maximum
temperature during these periods may be increased to a maximum 32C as it enters the
formwork. This requirement can be met, provided, mixing water with flaked ice and/ or
chilled water below 40C. The water shall not be chilled below a temperature of 1C.
Mix temperatures, of concrete, greater than 32C shall not be used.
4
4.1
4.2
SLUMP TEST
Slump tests shall be carried out on fresh concrete, at the time of placement, at the rate of one
test per truck. Tolerance shall be -15 mm/+35 mm for design slumps less than 100mm and
-20mm/+40mm for design slumps of 100mm and over. True slump shall be between 50 mm
and 100 mm for concrete without super-plasticizer.
4.3
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The sampling, making, curing and testing of test cubes shall be in accordance with BS EN
1992-1-1, BS 1881, BS EN 12350, BS EN 12504-1 and section 5 of QCS. Full scale trial
mixes shall be carried out in accordance with BS EN 206 and BS EN 1992-1-1. Test shall be
carried out as per following clauses:
4.3.1
The mix proportions and slump including water cement ratio and cement content are as
defined in this specification;
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If the absorption rates are less than the following it will not necessary for the test to run for 2
hours.
4.3.2
10 min
0.25
30 min
0.17
1 hr.
0.10
4.3.3
UNSATISFACTORY CONCRETE
If any cube strength is below 40 N/mm2, then the concrete in the pour shall be removed and
replaced at the Contractor's expense.
If the standard deviation of the group of 40 cube result exceeds 3.5 N/mm2 or if the lower
result is more than 7 N/mm2 below the mean, then concrete production shall be stopped and
method of concrete production shall be investigated by CONTRACTOR. Further tests on trial
mixes may be required by QP at Contractors expense.
Concrete with a standard deviation greater than 3.5 N/mm 2 and/or with a cube crushing test
result more than 7 N/mm2 below the mean shall be acceptable, provided the requirements of
above are fully complied with and CONTRACTOR implements all recommended actions
resulting from the investigation to ensure future concrete is of greater consistency. If the unit
represented by the sample is questionable, QP may instruct CONTRACTOR the following
actions as appropriate.
Change of mix;
Improvement of quality control;
Cutting testing cores from placed concrete;
Load testing relevant structural units; and
Cutting out and replacing defective unit
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If the range of individual cube strength made from the sample exceeds 15 % of the mean, then
the methods of making, curing and testing cube shall be checked. In the event of result having
a range exceeding 20 %, the result shall be unacceptable and QP may order any actions
outlined in a) to e) above. If the core test strengths are less than 90 % of characteristics
strength, the concrete shall be cut out/ replaced.
4.3.4
4.3.5
PERMEABILITY TEST
Permeability tests are to be carried out with initial surface absorption tests of concrete (ISAT)
in accordance with BS 1881 -Part 5 Routine test shall be carried out on the in-situ cured
uncoated site concrete at location chosen by QP at the rate of six locations for two tests per
week. Both horizontal and vertical surfaces shall be considered for testing. The concrete so
tested shall be considered satisfactory if the absorption rates are less than the following:
Time after standing test
10 min
0.25
30 min
0.17
1 hr.
0.10
GROUTING
Grouting refers to all work to be carried out to properly fill with mortar the space
between concrete surfaces and base plates of equipment, steel structures or concrete
prefabricated elements in order to achieve adequate transfer of horizontal and vertical forces.
Grouting to be used shall comply with part 16, section 5 of QCS.
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TYPES OF GROUTS
NON-SHRINK GROUTS
A grout is regarded as non-shrink if its volume is not less than the initial volume after
hardening for 28 days.
The type of non-shrink grout shall be as specified on the drawing and/or specification.
During this period the test specimens shall have been completely protected against drying,
evaporation, carbonation and exposure to temperatures greater than those stated as accepted by
SUPPLIER.
CONTRACTOR shall submit the Manufacturers data sheets and certificates for QP approval.
The grout shall be free of chlorides and shall have a pouring consistency. A metal-oxidising or
gypsum-forming non-shrink grout shall not be used.
Two types of commonly used non-shrink grout are as follows:
PREPARATION OF GROUT
Preparation of grout shall be in accordance with Manufacturers instructions.
Mixing water shall be at a temperature not greater than 27oC.
Due regard shall also be taken for the following points:
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5.3
Cement, sand aggregate or admixtures shall not be added unless specified by the
MANUFACTURER.
Use shall be made of the Manufacturers Field Service when undertaking trial sections at
the start of a contract.
SURFACE PREPARATION
All surface preparation shall follow the Manufacturers data sheets instructions for each
material while implementing the grouting works.
The following surface preparation shall apply for all grouts:
5.4
5.5
Shims that are used for levelling works shall be of stainless steel to avoid corrosion.
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5.6
Shims under steel structures and equipment shall be of a machined type and need not be
removed.
Wedges are restricted to minor steel structures, supports, etc. and shall be removed.
For shim installation the following criteria shall apply:
The shim to be placed on the foundation shall be embedded in a mortar bed such that the
top of the shim is levelled;
Shim plates shall be installed in such a manner that they are fully embedded and
surrounded by the grout to be installed later; minimum cover to shim side: 50mm; and
Load per shim pack shall not exceed 7N/mm2 under the worst loading calculating the
aforementioned bearing stress.
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Non-shrink cement based grout shall be tested at least once per day in accordance with
ASTM C109.
Epoxy grout shall be tested on each pour in accordance with ASTM C579.
Prepare the number of cubes for each type of grout and test for required compressive
strength according to the following schedule.
Grout Type
24 Hrs.
7 Days
28 Days
Epoxy Grout
Where a field service is offered by the MANUFACTURER, this shall be utilized. The
Manufacturers guarantees may be dependent on such involvement.
Grout shall be cured in accordance with the Manufacturers instructions.
5.7
FINISHING OF GROUT
Cement-based grout is to be trimmed back, after the initial set, to the level shown on the
drawings with surfaces sloped away from the base plate neatly pointed and trowelled off and
left in a workmanlike manner.
Exposed edges shall be protected against damage during the curing period.
Where shims are to be removed, or if wedges were used, they shall be removed after 3 days.
On removal of the shims or wedges, the resultant spaces shall be filled with grout.
Epoxy grout cannot be trimmed after set Finish top surfaces prior to initial set per
Manufacturers recommendations.
Apply finish coating over grout holes and vent holes after grout has set.
6
6.1
FORMWORK
GENERAL
Formwork shall be constructed to provide the correct shape, lines and dimensions of the
concrete shown on the Drawings. Due allowance shall be made for any deflection which will
occur during the placing of concrete within the forms.
All Formwork shall comply with BS EN 1992-1-1 and Part 9, Section 5 of QCS.
All Formwork shall be water tight to prevent grout loss.
Forms shall be constructed form sound materials of sufficient strength, properly braced,
strutted and shored to ensure rigidity throughout the placing and-compaction of the concrete
without visible deflection. Forms shall be so constructed that they can be removed without
shock or vibration to the concrete.
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24 hrs.
7 days
14 days
21 days
28 days
28 days
The finished faces of all concrete work shall be sound, solid and free from defects. All corners
(except underside of foundation) shall have a 25 x 25 mm chamfer. No rendering of imperfect
concrete faces will be allowed and any concrete that is defective in any way (including colour)
is to be cut out and replaced to such depths or be made good in such manner as QP may direct.
6.2
7
7.1
7.2
PLACEMENT
All placing of concrete shall comply with Part 8, Section 5 of QCS.
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The target maximum temperature for concrete used in the works is 20 to 25C. However,
provided the concrete is manufactured in accordance with Section 4.0 of this document and in
particular clause 4.5. Fresh Concrete of a temperature greater than 32C shall not be used. Hot
weather concreting shall be done in accordance with Section 6 of BS EN 1992-1-1.
The temperature of the concrete at the time of placement shall be measured and recorded for
each truck.
No concreting shall take place if the temperature in the shade exceeds 43C on a falling
thermometer or 40C on a rising thermometer.
Concrete shall not be dropped into place from a height exceeding 1.5 meters and shall not be
pumped or discharged trough aluminium alloy pipe or equipment.
Concrete shall be placed as per sequence shown on the drawing or as indicated in the
specification or as approved by QP. Concrete shall only be poured in the presence of QP
Representative. In addition, no concrete shall be placed unless QP has previously inspected
and approved the positions, fixing and condition of reinforcement, the cleanness, alignment
and stability of the formwork.
Concrete shall be placed as near as possible to its final position in such a manner to avoid
segregation of concrete, displacement of the reinforcement, formwork and/or embedded items.
Concrete shall be placed in horizontal layers not exceeding 300 mm thick and continuously
between construction joints, the position and arrangement of which shall be predetermined.
Where chutes are used to convey concrete, height and slopes shall not be such as to cause
segregation at discharge. Preferable slopes shall be 1:2 to 1:3. Conveying equipment shall be
cleaned thoroughly before each run.
The maximum time period between mixing and placing concrete shall not exceed 30 minutes.
The maximum time period between placing successive horizontal layers of concrete shall not
exceed 20 minutes.
Partially hardened concrete or re-tempered concrete shall not be used in the work. Concrete
shall not be placed under water without prior agreement with QP.
7.3
7.3.1
COMPACTION
GENERAL
All concrete shall be fully compacted throughout the full depth to a dense homogeneous mass
thoroughly worked against formwork and around reinforcement and other embedded items
without displacing them. Successive layers of the same lift shall be thoroughly worked
together. When super plasticizers producing a collapsed slump are used, CONTRACTOR
must exercise extreme care to ensure the concrete is adequately vibrated but not over vibrated.
Over vibration of such concrete can cause segregation.
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7.3.3
7.4
TOLERANCE
Except where shown on the drawing or otherwise accepted by QP, the following tolerances,
after completion of the works, represent acceptable limits to QP. All work beyond these limits
is liable to be rejected by QP.
Type of Structure
Foundation and
structures
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Plan position
Tolerances(mm)
5
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6 in 3 m
Plumb alignment for columns
and walls
9 in 6 m
12 in 12 m
Slab thickness
12
Departure
level
Roads and paving
from
longitudinal
30
FINISHES
UNFORMED SURFACES
Unformed surfaces shall be classified as either:
All unformed surfaces shall comply with the requirements of QCS Section 5, Part 9, Section
9.3 and the following additional requirements:
Surface finishing (beyond bull-floating) shall not be commenced until bleed water has
disappeared from the concrete surface.
CONTRACTOR shall ensure surface finishing is completed before concrete reaches final set.
7.5.2
The completed surface of slabs with power float finish shall have no deviations of greater
than 4 mm when measured using a 4 meter straight edge.
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7.5.3
Power floating must not be started until surface moisture has evaporated and the concrete is
stiff enough to take the weight of the machine. Following initial floating to close off and
regulate the surface of the concrete, the surface moisture must be allowed to evaporate.
Successive passes with the blades set at progressively steeper angles must then be used to
produce a closed hard-wearing surface.
FORMED SURFACES
Formed surfaces shall be classified as either:
Class F1 formwork which shall consist of sawn boards, sheet metal or other suitable
materials to give good support to the concrete. The irregularities in the finish shall be no
greater than those obtained from the use of properly designed forms of closely jointed sawn
boards. Small blemishes caused by entrapped air or moisture will be permitted, but the
surface shall be free from voids, honeycombing or other large blemishes.
Class F2 formwork which shall produce irregularities in the finish shall be no greater than
those obtained from the use of wrought thickness square edged boards arranged in a uniform
pattern. The finish is intended to be left as struck but imperfections such as fins and surface
discoloration shall, if required, be made good by methods approved by QP.
Class F3 formwork which shall be lined with a material approved by QP to provide a
smooth finish of uniform texture and appearance. This material shall leave no stain on the
concrete and shall be so joined and fixed to its backing that it imparts no blemishes. It shall
be of the same type and obtained from one source throughout any one structure.
CONTRACTOR shall make good any imperfections in the finish as required by QP. Internal
ties and embedded metal parts will not be allowed.
Class F4 formwork which shall be defined as per Class F3 except that internal ties and
embedded metal parts shall be permitted. The ties shall be positioned only in rebates or in
other positions as described in the project documents or as agreed by QP.
All formed surfaces shall comply with the requirements of QCS Section 5, Part 9 and this
Project Specification.
7.5.4
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Unless otherwise described in the project documents, all formwork joints for exposed surfaces
of concrete to Class F2, F3 and F4 shall form a regular pattern with horizontal and vertical
lines continuous throughout each structure and all construction joints shall coincide with these
horizontal or vertical lines.
Where Class F2, F3 or F4 finish is specified the use of worn or damaged formwork will not be
permitted and care shall be taken not to damage the formwork when being struck or cleaned.
The underside of the filler used at horizontal construction joints in walls shall coincide within
the joint between two boards.
The finish to be applied to concrete adjoining existing concrete / previous pour shall be as per
the existing concrete / previous pour unless otherwise instructed by QP.
Where a surface is part exposed, part below ground, the above ground finish shall extend to
150mm below finished ground level.
Unless otherwise specified, triangular fillets size 20mm x 20mm shall be fixed in the forms so
as to provide a chamfer to all external angles in the finished WORK.
Chamfers shall be provided even though such chamfers may not be indicated on the drawings.
Where grooves are specified in exposed concrete, they shall be formed by attaching tapered
planed timber battens accurately aligned to the face of formwork.
Where internal ties are used in members with feature groove surfaces, the ties shall be
positioned in the groove recesses and shall be in a regular pattern vertically and horizontally.
Through bolts shall not be permitted in walls or slabs of water retaining structures or in other
elements subject to ground or water pressures.
All formwork in contact with concrete shall be treated with a suitable QP approved mould
release agent.
Care shall be taken to prevent the mould release agent from coming in contact with
reinforcement or with concrete at construction joints.
Where concrete surfaces are to be exposed or are to have finishes applied, suitable methods
shall be used to ensure: adequate mould release, non-staining of concrete surface and full bond
for applied finishes. Details shall be submitted to QP for Approval prior to construction of
formwork.
Where instructed by QP, CONTRACTOR shall cast sample panels to indicate the standard of
finish which he intends to maintain. QP shall approve the standard of finish before any
permanent concrete WORK is undertaken.
Before the commencement of concreting, all foreign material shall be removed from the
interior of the formwork and the inside of the formwork shall be thoroughly clean and free
from sawdust, mud or other debris.
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Where steel shutters are used, all joints and holes in the shutters shall be covered with tape,
which shall be firmly fixed to the shutters by means of spirit glue or other oil and grease
resisting adhesive.
Where internal metal ties are permitted, they or their removable parts shall be extracted
without damage to the concrete and the remaining holes filled with non-shrink mortar. No
permanently metal part shall have less than 75mm cover to the reinforcement.
All floors in electrical rooms and switch rooms shall have finish U3 and QP approved epoxy
coating specifically designed for electrical / substation applications.
Unless noted otherwise in the project drawings and specifications, concrete finishes shall be in
accordance with the following table:
CONCRETE FINISHES
Element
Unformed
Surfaces
Formed
Surfaces
U3
F2
F3
U3
U4
U4
U3
U3
U2
U2
F2
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be applied)
Top surfaces of equipment foundations and
plinths for steel structure (to be grouted)
8
U2
CURING
All curing of concrete shall comply with Part 10, Section 5 of QCS.
The Curing of concrete shall proceed for a minimum period of seven days. Surfaces shall be
treated as follows:
8.1
HORIZONTAL SURFACES
Horizontal surfaces shall be wet cured and treated with curing compound as soon as the
concrete has taken its initial set. The surface shall then be bundled and flooded with water or
draped with wet hessian, covered with two layers of 500 gauge (0.125mm) white polythene
sheeting and kept continuously wet for the length of the curing period. Water used for curing
shall be at the same temperature as the concrete being used.
8.2
VERTICAL SURFACES
Vertical surfaces shall be treated with curing compound as soon as the formwork is removed.
The surfaces shall be draped with wet hessian, covered with two layers of 500 gauge
(0.125mm) white polythene sheeting and kept continuously wet for the length of the curing
period as agreed with QP. Care should be taken to avoid drying winds with a wind tunnel
arrangement of the coverings.
8.3
CURING COMPOUND
The curing compound shall have an efficiency of 85 % as defined in accordance with clause
2709 of British Department of Transport Specification for road and Bridge works and shall be
white or silver coloured to reflect the sun rays.
Fog spray for wetting surfaces shall be used whenever practical.
In addition to the above requirements, CONTRACTOR shall comply with the requirement as
set forth in Part 10, Section 5 of QCS.
REMEDIAL WORK
Concrete exposed by the removal of formwork shall be inspected by QP before any remedial
work; subsequent coating or any other treatment which would hinder the proper inspection of
the concrete is carried out. Any concrete, the surface of which has been treated prior to being
inspected by QP shall be liable for rejection.
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Concrete which in the opinion of QP is defective or which is not true to an acceptable line or
level, shall be cut out and rebuild without delay, unless QP agrees that a repair may be
satisfactorily effected. This agreement shall not produce the subsequent rejection of the
repaired work.
The methods to be used in removal and replacement or repair of defective work shall be
submitted to QP for approval in each particular case before the work commences.
10 READYMIX CONCRETE
Ready mix concrete from an approved supplier shall be used with the approval of QP. The
concrete shall comply in all respects, with BS EN 206 and Part 7, Section 5 of QCS and with
this Project Specification.
Only with the specific written approval of QP concrete may be transported in a dry state and
water added on site. Care shall be taken to ensure that the correct quantity of water is added to
the mixer.
Before discharging the concrete at the point of delivery, for each batch of concrete, the
CONTRACTOR shall provide QP with a delivery ticket on which is printed, stamped or
written the following minimum information.
11 PROTECTIVE COATINGS
11.1 GENERAL
All concrete shall be investigated for surface holes and provided they are small and formed by
air bubbles caught against formwork they shall be filled with filler compatible with the coating
to be applied, if that coating cannot bridge the holes. For surface holes having any dimension
greater than 20 mm, refer to section 11 of this specification.
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All edges shall be chamfered and proprietary corner fillets shall be installed.
Manufacturers recommendation shall be strictly adhered when applying the protection
system. All waterproofing products shall be from the same manufacturer and shall be fully
compatible. All waterproofing products shall be subject to QP approval.
A QP approved protective coating and protection board / 1000 polythene wrapping shall be
applied to all pre-cast concrete surfaces which are not otherwise protected with suitable
membrane, before installation.
11.4 ABOVE GRADE CONCRETE PROTECTION
The protective coating materials shall be from QP approved manufacturers / vendors and the
application of coating shall be as per the manufacturers written instructions. The following
areas shall be coated with penetrating silane-siloxane primer and subsequent pigmented
coating of minimum total dry film thickness (DFT) 150 microns (0.15mm) applied in three (3)
coats:
All internal surfaces (top, bottom and sides) of reinforced concrete culvert structures.
All exposed concrete in bridge superstructures and substructures.
Above ground surfaces of foundation plinths supporting mechanical equipment and
vessels
Pre-cast concrete pipeline sleepers.
Other areas as specified in the project drawings.
11.4.1 PRIMER
The first coat shall be a penetrating silane-siloxane hydrophobic primer applied as a flood coat
at a rate of 0.4 litre per m 2. The silane-siloxane primer shall have no less than 10% solid
contents.
11.4.2 INTERMEDIATE COAT
The second coat shall be an acrylic polymer coating system applied to a DFT of minimum 75
microns.
11.4.3 FINISH COAT
A third coat of acrylic polymer coating system shall be applied to a DFT of minimum 75
microns. The total DFT of the coating system (all layers) shall be minimum 150 microns.
The acrylic polymer shall have the following minimum properties:
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