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Feb.

2009 Madinah STP Expansion- Phase I (Capacity 200,000


m3/day)
Specifications
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SECTION 03

CONCRETE

3-01 GENERAL
The Contractor shall furnish all necessary materials and construct all concrete required
under this Contract and other concrete not referred to in the document, as indicated on
the Drawings and as herein specified.
Concrete work shall be carried out in full compliance and in accordance with SAS and
with ACI Code including Title 350R (4), Concrete Sanitary Engineering Structures.
All concrete shall be site-mixed or ready-mixed as produced by a plant acceptable to
the Engineer.
The Engineer's Representative shall order tests to be made on material and mixed
concrete as supplied by the Contractor to insure their compliance with these
specifications. All such tests shall be performed in accordance with standard methods
and as specified herein.

3-02 CLASSES OF CONCRETE


Class A concrete shall be used for all liquid containing structures of reinforced and plain
concrete unless otherwise noted on the drawings.
Class B concrete may be used wherever low strength concrete is approved, including
concrete fill under foundations in blinding and elsewhere as specified or indicated on
the drawings.

3-03 PORTLAND CEMENT


Cement shall be Portland type, originating from approved manufacturers, obtained in
sealed and labeled bags. Cement delivered in bulk shall be accepted only if a central
mixing plant is used. The quality of cement shall conform to the requirements of SSA
143 or/and of the Specifications for Portland Cement Type V (Sulfate Resisting
Portland Cement) and for Portland Cement Type II (ordinary Portland Cement) as
Specified in ASTM Standard Specification for Portland Cement, Designation C 150.
In addition to the requirements of the above-mentioned specifications, cements to be
used in exposed concrete shall exhibit no efflorescence when tested in accordance with
the ASTM Standard Methods of Sampling and Testing Brick, Designation C 67.
All cement to be used in the work shall be subject to testing to determine whether it
conforms to the requirements of the specifications. The methods of testing shall
conform to the appropriate specification, but the place, time, frequency and method of
sampling will be determined by the Engineer's Representative in accordance with the
particular conditions of this project.
When used in the Works, cement shall be free from lumps and partially or whole set
cement.

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When the cement is delivered in packages, the name and brand of the manufacture shall
be plainly identified thereon. A bag shall contain 50 Kg net. All packages shall be in
good condition at the time of inspection.
All cement shall be stored in suitable weatherproof store rooms which will protect the
cement from dampness. These store rooms shall be placed in location approved by the
Engineer's Representative. Provisions for storage shall be ample, and the consignment
of cement as received shall be separately stored in such a manner as to provide easy
access for the identification and inspection of each consignment. Stored cement shall
meet the test requirements at any time after storage when a retest is ordered by the
Engineer's Representative.
The Contractor shall keep accurate records of the deliveries of cement and of its use in
the Work. Copies of these records shall be supplied to the Engineer in such form as
may be required.
The cement shall be rejected if it fails to meet any of requirements of these
specifications.
Stale cement or cement reclaimed from cleaning bags shall not be used and cement
which for any reason has become partially set, or contains lump or caked cement, shall
be rejected.
Cement shall be sampled either at the mill or at the Site as provided in the above
specifications.
The Contractor shall notify the Engineer of dates of delivery so that there will be
sufficient time for sampling the cement, either at the mill or upon delivery.

3-04 ADMIXTURES
Concrete exposed to the natural elements shall be air-entrained concrete obtained by
the use of accepted admixtures conforming to ASTM C260.
The specific admixture shall be subject to review and approval by the Engineer.
The compressive strengths of the concrete mixes made with the admixtures shall
conform to the applicable water cement ratios in Table 3 A-C.
The average resulting air content in field mixtures shall be 6.0 percent when measured
by means of an ACME air meter, or acceptable equivalent, in conformity with the
ASTM Standard Method of Test of Air Content of Freshly Mixed Concrete by the
Pressure Method, Designation C231. No concrete shall be used for which the
individual air content is less than 5.0 or greater than 7.0 percent.
If the admixture is applied in solution form, the quantity of the solution shall be
included in the computations of the water-cement ratio.
Combinations of types of cement and types of admixtures which produce undesirable or
erratic air contents with the available aggregates shall be avoided.
Admixtures causing accelerated setting of cement in concrete shall not be used in any
class of concrete.

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The use of an admixture in concrete other than concrete exposed to the elements will
not be permitted except by written consent of the Engineer.

3-05 WATER
The water for concrete shall be potable, clean, fresh, and free from injurious amounts
of oil, acid, alkali, organic matter or other deleterious substances and shall conform to
ASTM C94 and ACI301.

3-06 FINE AGGREGATE


Fine aggregate shall consist of inert natural sand conforming to the ASTM Standard
Specifications for Concrete Aggregates, Designation C33, and also conforming to the
detailed requirements given in table 3A. If it is so required by the Engineer's
Representative the fine aggregate shall be washed to the state where it shall comply
with these specifications.
TABLE 3A
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Grading:
Sieve Percent Passing
mm (in.)
9.5 (3/8) 100
4.75 (No. 4) 95-100
2.36 (No. 8) 80-100
1.18 (No. 16) 50-85
600 m (No. 30) 25-60
200 m (No.50) 10-30
150 m (No. 100) 2-10
Fineness modules 2.30-3.10
Organic impurities The color shall have an intensity not darker than two-thirds the
intensity of the standard color solution. (Not darker than Plate 2
as determined by the ASTM Standard method of test for organic
impurities in sands for concrete, Designation C40).
Silt Not more than 3 percent (as determined by ASTM C117).
Mortar Strength Compression strength ratio not less than 95 percent at 7 days as
determined by ASTM C87..
Soundness Weighted average loss when subjected to 5 cycles of the
soundness test using sodium sulfate, not more than 10 percent
or not more than 15 percent when using magnesium sulfate.
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3-07 COARSE AGGREGATE


Coarse aggregate shall consist of well graded gravel or crushed stone conforming to
the ASTM Standard Specifications for Concrete Aggregate, Designation C33, and also
conforming to the detailed requirements given in Table 3B. If it is so required by the
Engineer's Representative the coarse aggregate shall be washed to the state where it
shall comply with these specifications.
TABLE 3B
Nominal Aggregate Size
Sieve Size (2 in.) (1-1/2 in) (1 in.) (3/4 in.) (1/2 in.)
mm (inch) 50 mm 37.5 mm 25 mm 19.5 mm 12.5 mm

50 (2) 95-100 100 - - -


37.5 (1-1/2) - 95-100 100 - -
25.0 (1) 35-70 - 95-100 100 -
19.5 (3/4) - 35-70 - 90-100 100
12.5 (1/2) 10-30 - 25-60 - 90-100
9.5 (3/8) - 10-30 - 20-55 40-70
4.75 (No.4) 0-5 0-5 0-10 0-10 0-15
2.36 (No.8) - - 0-5 0-5 0-5
Abrasion loss Not more than 50% , (as determined by ASTM C131 and
C535)
Organic impurities The color shall have an intensity not darker than one-third
the intensity of the standard color solution (Not darker than
Plate 1 as determined by the ASTM Standard Method of
test for organic impurities in sands for concrete, Designation
C40).
Silt Not more than 1.0 percent (as determined by ASTM C117).
Soundness Weighted average loss when subjected to 5 cycles of the
soundness test using magnesium sulfate, not more than 18
percent, or not more than 12 percent using sodium sulfate.
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Aggregate used in concrete shall not exceed the following nominal maximum sizes:
a. 50 mm (2 in.) for mass concrete.
b. 25 mm (1 in.) for footings, foundation mats, and walls 200 mm (8 in.) or
thicker.
c. 19.5 (3/4 in.) for slabs, beams and girders.
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d. 12.5 mm (1/2 in.) for screed.


e. 25 mm (1 in.) for all other concrete.

3-08 SAMPLES OF AGGREGATES


The Contractor shall submit samples of fine and coarse aggregate according to ASTM
D75 to the Engineer in ample time for determination of the mix design before the
Contractor proposes to use the aggregate in the work. At least 100 Kg of each size of
aggregate shall be submitted in suitable containers. All samples shall be plainly and
neatly labeled indicating the source, where proposed to be used, date, and name of
collector.
Materials shall not be delivered to the site or used until the samples have been
approved, and, as used, they shall in all respects be equal to the approved samples.

3-09 CONCRETE QUALITY


It is the intent of this specification to secure, for every part of the work, concrete of
homogeneous structure which, when hardened, will have the required strength, water
tightness, and durability. To this end it is essential that careful mixtures, transporting,
placing, spading or vibrating, and curing of the concrete.
Concrete shall meet the limiting requirements given in Table 3C.
TABLE 3C
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Class of Strength at 28 days Maximum Net Water Cement Content kg/m3
Concrete kg/cm2 Content per sack
Cement liter*
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A 280 20 ** 400
B 140 32 ** 250
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* Total water in mix at time of mixing, including free water in aggregates.
** Maximum; decrease if possible.
For Class A concrete, air content (as determined in accordance with 25 mm ASTM
C231 or C173) shall be 6+ 1 percent for aggregate size 25 mm (1 in) and 19.5 mm (3/4
inch).
The total sodium chloride content of any materials used for making concrete shall be
less than:
For mass concrete - 1.5 percent
For reinforced/concrete - 0.7 percent.
expressed as a percentage, by weight of the cement. In calculations made under the
provisions of this Clause, any chlorides, other than sodium chloride, in the materials
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shall be converted to the equivalent of sodium chloride and be added to the amount of
sodium chloride. The sulfate content shall not exceed 0.03 per cent by weight of the
cement.

3-10 CONSISTENCY
Concrete shall be of such consistency that it can be worked readily into all parts of the
forms and around embedded work, without permitting the materials to segregate, or
free water to collect on the surface. Consistency shall be measured by the SSA 379
and/or the ASTM Standard Method of Test for Slump of Portland Cement Concrete,
Designation C143. The consistency of concrete shall be as given in Table 3 D.
TABLE 3D
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Slump, cm
Portion of Structure --------------------------------------------------
Normal min & Max Limits
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Pavements and slabs on ground 5 3-8


Plain footings and heavy walls 5-8 2 -10
Massive reinforced section 8 5 -10
Reinforced foundation walls and footings 7-10 5 -12
Slabs, beams and reinforced
walls and columns 10 7 -12
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When concrete is compacted by high-frequency mechanical vibration, the above
"Normal" consistencies shall not be exceeded. However otherwise limiting
consistencies shall not be exceeded at any time unless modified by the Engineer's
Representative.
Slump tests shall be made in the field by the Contractor as directed.

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3-11 TESTING AGGREGATES AND DETERMINING PROPORTIONS


No concrete shall be used in the work until the materials and mix design have been
approved by the Engineer.
The conformity of aggregates to the specifications herein be confirmed, and the actual
proportions of cement, aggregates, admixtures where used, and water necessary to
produce concrete conforming to the requirements set forth in Table 3C and 3D shall be
demonstrated and determined by tests made with representative samples of the
materials to be used on the work. All such tests shall be made by the Contractor under
the supervision of the Engineer.
Aggregates shall be tested in accordance with the methods referred to in these
specifications. Unless required by the Engineer's Representative the magnesium sulfate
or sodium sulfate soundness test need be made only if such test is considered by the
testing laboratory to be necessary.
The water-cement ratio of the concrete to be used in the work shall be based on a
curve showing the relation between water-cement ratio and 28-day compressive
strength of concrete made using the proposed materials. The curve shall be determined
by four or more points, each representing an average value of at least four test
specimens, and shall have a range of values sufficient to yield the desired data without
extrapolation. All procedures and tests shall conform strictly to the ASTM Standard
Method of Making and Curing Compressive and Flexure Test Specimens in the
Laboratory, Designation C192, and the ASTM Standard Method of Test for
Compressive Strength of Molded Concrete Cylinders, Designation C39.
The water-cement ratio of concrete to be used in the work shall correspond to a
laboratory test strength at 28 days of 280 kg/cm2 per Class A concrete, for and 140
kg/cm2 for Class B concrete.
In no case, however, shall the resulting mix conflict with the limiting values for
maximum water-cement ratio and minimum cement content as specified in Table 3C.
Reports on the tests of aggregates, the above-mentioned water-cement ratio strength
curve, and a statement of the proportions proposed for the concrete mixture, shall be
submitted in triplicate to the Engineer for approval as soon as possible, but not less
than five days prior to the proposed beginning of the concrete work. If the Contractor
furnishes in writing, similar, reliable detailed information from an acceptable source,
and of date not more than four months prior to the time when concrete will be used on
this project, the above requirements for laboratory tests may be modified by the
Engineer. Such data shall derive from mixtures containing constituents of the same
types and from the same sources as will be used on this project.
The Engineer shall have the right to make check tests of aggregates and concrete, using
the same materials, and to order changes as may be necessary to meet the specified
requirements.

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Cylinders made in the field shall be made and cured in accordance with ASTM
Standard Method of Making and Curing Concrete Compressive and Flexural Strength
Test Specimens in the Field, Designation C31, except that wherever possible molds
shall be left in cylinders until they have reached the laboratory. Laboratory tests and
laboratory-made-cylinders shall conform to the appropriate tests and procedures
specified above for testing aggregates and for determining the relation between water-
cement ratio and compressive strength except that molds may be left on cylinders as
long as necessary.
A minimum of 6 cylinders shall be taken from each concrete part of 50 cubic meters or
part thereof in one location. An absolute minimum of 6 cylinders shall be taken of each
day's concrete production or as otherwise ordered by the Engineer.
Half the cylinders so made shall be tested at 7 days and the other half shall be tested at
28 days. If the 7 days cylinders indicate a weaker strength than required concrete, no
additional concrete works shall be built over the concrete so tested.
Any concrete indicating a weaker strength at 28 days than that specified shall be broken
up and removed and replaced by the Contractor with acceptable concrete, all at the
Contractor's cost.
If concrete of the required characteristics is not being produced as the work
progresses, the Engineer may order such changes in proportions or materials, or both
as may be necessary to secure concrete of the specified quality. The Contractor shall
make such changes at his own expense and no extra compensation will be allowed
because of such changes.
If as the work progresses the characteristics of the materials originally approved
undergo a change, or if the Contractor wishes to use other materials, he shall submit,
for approval, evidence that the new combination of materials will produce concrete
meeting the stated requirements and will not result in objectionable changes in the color
or appearance of the work.

3-12 MEASURING MATERIALS


All materials for concrete, including water, shall be measured with equipment and
facilities suitable for their accurate measurement and capable of being readily adjusted
to changing conditions as required.
Packages varying by 5 percent or more from the specified weight shall be rejected and
if the average weight of packages in any delivery, as shown by weighing 50 packages
taken random, is less than that specified, the entire delivery shall be rejected and the
Contractor shall remove it forthwith from the site at his own expense and replace it
with cement of satisfactory quality.
Water shall be measured by volume or weight, the error of measurement shall not
exceed one-half of one percent.
Unless otherwise authorized, cement shall be measured in full sacks or by weight, and
each size of aggregate shall be weighed separately. The error of measurement for
successive quantities shall not exceed one percent.

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Where volumetric measurement of aggregates are authorized, the weight proportions


shall be converted to equivalent volume proportions and suitable allowance shall be
made for variations in the moisture condition of the aggregates, including the bulking
of fine aggregate, due to moisture and the method of compaction.

3-13 SITE-MIXED CONCRETE


Concrete to be produced at the Site shall be mixed in an approved batch mixer with a
capacity of not less than 400 liters, except for small quantities not more than 1/2 cubic
meters. which, by permission may be hand mixed. The volume of the mixed batch shall
not exceed the manufacturer's rated capacity of the mixer. The site-mixed concrete
plant and all operations pertaining to the production of the concrete shall be subject to
the inspection and specific approval of the Engineer.
The minimum mixing time for each batch (from the time when all solid materials and
water are in the drum) shall be 1-1/2 minutes for mixers of 800 liters capacity or less;
for mixers of larger capacity, the mixing time shall be increased 30 seconds for each
additional 400 lit. or fraction thereof. The mixer performance shall conform to ACI
304. The entire batch shall be discharged before the mixer is recharged.
Hand mixing for small quantities shall be subject to the approval of the Engineer's
Representative. If the concrete is mixed by hand, it shall be done on a suitably surface.
The cement and aggregates shall be mixed dry until an even and uniform color has been
attained throughout. Then the proper quantity of water shall be added and the whole
mass turned with square-edged shovels until it has become intimately mixed.

3-14 READY-MIXED CONCRETE


Ready-mixed concrete will be permitted provided that all requirements specified herein
set forth are fully complied with. The ready-mixed concrete plant and all operations
pertaining to the production of the concrete shall be subject to the inspection and
specific approval of the Engineer. Methods of batching mix constituents shall conform
to the requirements set forth above under "Measuring Materials". All constituents shall
be batched at the central plant.
All central-plant and rolling-stock equipment and methods shall conform to the Truck
Mixer and Agitator Standards of the truck mixer (U.S.A.) Manufacturers' Bureau of
the National Ready Mixed Concrete Assn., dated 1949, as well as the ACI (American
Concrete Institute) Standards for Measuring, Mixing and Placing Concrete (ACI304),
and with Sections 6 to 14, inclusive, of the ASTM Standard Specification for Ready-
Mixed Concrete, Designation C94, insofar as applicable.
Ready-mixed concrete shall be transported to the Site in watertight agitator or mixer
trucks. The quantity of concrete to be mixed or delivered in any one batch shall not
exceed the rated capacity of the mixer or agitator for the respective conditions as stated
on the nameplates.
Central-mixed concrete shall be plant-mixed a minimum of 1-1/2 minutes per batch,
and then shall be truck-mixed or agitated a minimum of 8 minutes. Agitation shall begin
immediately after the premixed concrete is placed in the truck and shall continue
without interruption until discharge. For transit-mixed concrete the major portion of
the mixing water shall be added and mixing started immediately after the truck is
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charged. The amount of water initially added shall be recorded on the delivery slip for
the Engineer's information; no additional water shall be added, either in transit or at the
site, except as directed. Mixing (at mixing speed) shall be continued for at least 10
minutes followed by agitation without interruption until discharge. Concrete shall be
discharged at the site within 1-1/2 hours after water was first added to the mix, and
shall be mixed at least 5 minutes after all water has been added.
Attention is directed to the importance of dispatching trucks from the batching plant so
that they shall arrive at the Site of the work just before the concrete is required, thus
avoiding excessive mixing of concrete while waiting, or delays in placing successive
layers of concrete in the forms.
Delivery slips shall contain the following information:
Ticket number
Load number
Truck number
Class of concrete
Cement brand, type, and weight in kilograms
Fine aggregate source and weight in kilograms
Coarse aggregate source and weight in kilograms
Water Quantity in liters
Time mix left plant
Concrete delivered without a complete delivery slip will be rejected.

3-15 REMIXING CONCRETE


Concrete which has become compacted or segregated during transportation to or onto
the Site of the work shall be satisfactorily re-mixed just prior to being placed in the
forms.
Partially hardened concrete shall not be deposited in the forms. The re-tempering of
concrete which has partially hardened (that is, the re-mixing of concrete with or
without additional cement, aggregate, or water) will not be permitted.

3-16 PLACING AND COMPACTING CONCRETE


At least 24 hours before the Contractor proposes to make any placement of concrete,
he shall notify the Engineer's Representative of his intention and planned procedures.
Unless otherwise permitted, the work shall be so executed that a section begun on any
day shall be completed during daylight of the same day and shall follow guidelines of
ACI304.
No concrete shall be placed until the subgrade, forms, and preliminary work have been
approved. No concrete shall be placed until all materials to be built into the concrete
have been set and have been approved by the various trades and by the Engineer's
Representative. All such materials shall be thoroughly clean and free from rust, scale,
oil, or any other foreign matter.
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Forms and excavation shall be free from water and all dirt, debris, and foreign matter
when concrete is placed. Except as otherwise directed wood forms and embedded
wood called for or allowed shall be thoroughly wetted just prior to placement of
concrete.
Concrete placed at air temperature below 5 deg. C. shall have a minimum temperature
of 10 deg. C. and a maximum of 20 deg. C. when placed. In any case concrete
temperature shall not be more than 30 deg. C when placed.
No restrictions will normally be placed on concreting in hot weather, i.e. when the
temperature at any time during the day may exceed 35 deg. C., but should the
Contractor wish to mix and place concrete in such weather he shall follow guidelines
ACI 305R and take the following precaution:
a) Aggregate stock piles shall be sprinkled with water to encourage cooling by
evaporation, successive layers being sprayed when stockpiling.
b) Concrete materials shall be protected from direct sunlight as far as possible
before, during and after mixing.
c) Cool water shall be used for mixing. Arrangements shall be made to cover, bury,
insulate and/or paint white the storage tanks and pipes.
d) Shuttering, formwork and reinforcement shall be mist-sprayed with cool water
immediately before the concrete is placed and all surplus water lodging in the
forms shall be removed.
e) Special emphasis on and care with the protection and curing of the concrete
shall be exercised; shuttering shall be kept cool and protected from direct
sunlight by damp sacking or other approved insulation continuously until the
time of its removal.
Only fresh potable water shall be used for the above mentioned cooling processes.
Concrete shall be transported from the mixer to the place of final deposit as rapidly as
practicable and by methods which will prevent separation of ingredients and avoid re-
handling.
The time lapse between cement entry in drum and final placement of concrete shall not
exceed 1-1/2 hrs.
Chutes for conveying concrete shall be metal or metal-lined and of such size, design,
and slope as to ensure a continuous flow of concrete without segregation. The slope of
chutes shall be not flatter than 1 to 2 and all parts of a chute shall have approximately
the same slope. The discharge end of the chute shall be provided with a baffle, or, if
required, a spout; and the end of the chute or spout shall be kept as close as practicable
to, but in no event more than 1.5 meters above the surface of the fresh concrete. When
the operation is intermittent, the chute shall discharge into a hopper.

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In thin sections of considerable height (such as walls and columns), concrete shall be
placed in such manner as will prevent segregation and accumulations of hardened
concrete on the forms or reinforcement above the mass of concrete being placed. To
achieve this end, suitable hoppers, spouts with restricted outlets, etc., shall be used as
required or approved unless the forms are provided with suitable openings.
Chutes, hoppers, spouts, etc., shall be thoroughly cleaned before and after each run and
the water and debris shall not be discharged inside the form.
For any one placement, concrete shall be deposited continuously without stop unless
there is construction joint, and shall be in layers of such thickness that no concrete shall
be deposited on concrete which has hardened sufficiently to cause the formation of
seams and planes of weakness within the section, and so as to maintain, until the
completion of the unit, an approximately horizontal, plastic surface.
No wooden spreaders shall be left in the concrete.
During and immediately after being deposited, concrete shall be thoroughly compacted
by means of suitable tools and methods, such as internal type mechanical vibrators
operating at not less than 5000 rpm. or other tool spading, to produce the required
density and quality of finish. Vibration shall be done only by experienced operators
under close supervision and shall be carried on in such manner and only long enough to
produce homogeneity and optimum consolidation without permitting segregation of the
solid constituents, "bubbling" of air, or other objectionable results. All vibrators shall be
supplemented by proper spade puddle approximately 5 cm away from forms to remove
included bubbles and honeycomb. Excessive spading against the forms, causing the
deposition of weak mortar at the surface, shall be avoided.
The concrete shall be thoroughly worked by rods and tamped about embedded
material so as to secure perfect adhesion and prevent leakage. Care shall be taken to
prevent the displacement of such materials during concreting.
Construction joints shall be made as specified hereafter.

3-17 BONDING CONCRETE AT CONSTRUCTION JOINTS


In order to secure full bond at construction joints, the surface of the concrete
previously placed (including vertical inclined, and substantially horizontal areas) shall
be thoroughly cleaned of foreign materials and laitance, if any, and then roughened so
that the aggregate will be slightly exposed over 90 percent of each 5cm square area.
Such cleaning and roughening shall be done by the use of suitable tools and methods,
such as picks, wire brushes, wet sand-blasting, etc., and shall be followed by re-
cleaning by means of a stream of clean water or compressed air.
The previously placed concrete at the joint shall be saturated with clean water and kept
thoroughly wet overnight, after which all pools shall be removed by an air jet. After
free or glistening water disappears, the concrete shall be given a thorough coating of
neat cement mixed to a suitable consistency.
The coating shall be 3 mm thick on vertical surfaces and 5 mm thick on horizontal
surfaces, and shall be well scrubbed in by means of stiff bristle brushes wherever
possible. New concrete shall be deposited before the wet cement dries.

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3-18 BONDING FILL TO BASE CONCRETE


Where concrete fill is to be placed on structural or other concrete, the previously
placed base concrete shall be prepared as hereinafter specified under "Surface Finish".

3-19 CURING AND PROTECTION


All concrete work shall be protected against damage from the elements and defacement
of any nature during construction operations.
Water shall not be permitted to rise on concrete within 24 hours after it is placed, nor
shall running water be allowed to flow over completed concrete within four days after
it has been placed.
All concrete, particularly slabs and including finished surfaces, shall be treated
immediately after concreting or cement finishing is completed, to provide continuous
moist curing for at least seven days, regardless of the adjacent air temperature. Walls
and vertical surfaces may be covered with continuously saturated burlap, or kept moist
by other approved means. Horizontal surfaces, slabs, etc., shall be flooded with water
to a depth of at least 1 cm wherever practicable, or kept continuously wet by the use of
lawn sprinklers, a complete covering of continuously saturated burlap, or by other
approved means.
Wherever practicable, finished slabs shall be protected from the direct rays of the sun to
prevent cracking and crazing.
Curing may be provided by a Membrane Curing Compound as approved by the
Engineer.
The curing compound shall be a clear translucent membrane, containing a glossy dye. It
shall not contain oils, waxes, or other materials which would tend to prevent bonding
of bituminous concrete surfaces.
The membrane shall conform to the following specifications as well:
a) The curing compound shall be of a consistency suitable for spraying, shall be
relatively nontoxic, and shall adhere satisfactorily to a vertical or horizontal
surface of damp concrete when applied immediately after the disappearance of
surface water sheen. It shall not react harmfully with the components of
concrete. The resulting film shall be continuous, uniform, moisture
impermeable, free from pinholes, and shall not peel.
b) The non-volatile material in the curing compound shall be not less than 25
percent by weight.
c) The curing compound, when applied to the surface of the mortar specimens in
the determination of water loss, as specified herein, shall dry to touch in one
hour and shall completely dry through in not more than 4 hours. When used in
the field, it shall show drying properties satisfactory to the Engineer's
Representative.
d) The curing compound shall not darken the natural color of the concrete. The
glossy dye when required shall have a color strength sufficient to render the film

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distinctly visible for at least one hour after application. The color of the glossy
dye shall disappear within 7 days after application).
e) The curing compound shall be of such viscosity that it may be readily applied by
approved pressure spraying equipment at temperatures above 5 deg. C.
f) The curing compound shall be delivered to the job only in the manufacturer's
original container, which shall be marked with the manufacturer's name, trade
name of the material, and number of symbol with which test samples may be
compared to. Curing compounds which are flammable shall be so designated on
the container.
g) Specimens used for determining moisture loss shall be made and tested in
accordance with ASTM C 156.
h). All curing compounds shall be tested by the Engineer's Representative. A
sample of at least one gallon of any curing compound proposed for use shall be
sent directly to the Engineer's Representative for preliminary tests at least 30
days before the proposed date of use.
i) Curing compound shall confirm to ASTM C309 and C171. Curing compounds
used in water storage structures must be non toxic and taste and odor free.
No curing compound shall be used until the Contractor has been notified by the
Engineer's Representative that it meets the requirements of the specifications.
Membrane curing shall not be permitted where a protective coat or weather proofing is
to be applied or at areas where rubbing is required or at construction joints.
After the concrete has been finished and immediately after the water sheen has
disappeared from the surface of the concrete, the surface shall be sealed with
membrane curing compound of the type specified. The seal shall be maintained for the
specified curing period. The edges of the concrete shall, likewise, be sealed immediately
after the forms are removed. Two separate applications, applied at least one minute
apart, each at the rate of not less than one liter for every 5 square meters, will be
required upon the surfaces and edges of the concrete. These applications shall be made
with the mechanical equipment specified by the supplier and approved by the Engineer.
At locations where the coating is discontinuous or where pin holes show or where the
coating is damaged due to any cause, an additional coating of membrane curing
compound shall be applied at the rate of one liter for every 5 square meters.
If, before an application of membrane curing compound has dried, or if rain occurs and
the coating is damaged, another application shall be made in the same manner and at
the same rate as the original coat. No additional compensation shall be allowed to the
Contractor for materials or labor required to perform this work.
The Engineer's Representative may order curing by another method specified in this
clause if unsatisfactory results are obtained with membrane curing compound.
Steam curing for pre-cast elements may be approved by the Engineer's Representative
if the Contractor proposes a procedure satisfactory to the Engineer's Representative.

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3-20 TRIMMING AND REPAIRS


It is the intent of this specification to require forms, mixture of concrete, and
workmanship so that concrete surfaces, when exposed, will require no patching.
As soon as the forms have been stripped and the concrete surfaces exposed, fins and
other projections shall be removed, recesses left by the removal of form ties shall be
filled, and surface defects which do not impair structural strength shall be repaired.
Defective concrete shall be cut normal to the surface until sound concrete is reached,
but not less than 3 cm deep. The remaining concrete shall be thoroughly roughened and
cleaned.
Concrete around the cavity or the form-tie recess shall be thoroughly wetted and
promptly painted with a 2 mm brush coat of neat cement mixed to the consistency of
lead paint. The hole shall then be filled with mortar.
Mortar shall be a 1: 1-1/2 cement and sand mix with sufficient white cement, of fine
limestone screenings in lieu of sand, to produce a surface matching the adjoining work.
Cement and sand shall be from the same sources as in the parent concrete.
For filling form-tie recesses, the mortar shall be mixed slightly damp to the touch (Just
short of "balling"), hammered into the recess until it is dense and an excess of paste
appears on the surface, and then trowelled smooth. Mortar in patches shall be applied
so that after partial set it can be compressed and rubbed to produce a finish flush and
uniform in texture with the adjoining work. All patches shall be warm-moist cured as
above specified.
The Contractor shall be responsible for the adherence of mortar used in repairing
concrete. He shall prepare the cavity and apply the repair material in such manner that
this end may be attained.
Unless otherwise specifically required, mortar shall not be applied as a coating or
plastering over the surface, but each void shall be individually filled.
The use of mortar patching as above specified shall be confined to the repair of small
defects in relatively green concrete. If substantial repairs are required, the defective
portions shall be cut out to sound concrete and the concrete replaced by means of a
cement gun, or the masonry shall be taken down and rebuilt, all as the Engineer's
Representative may decide or direct.

3-21 SURFACE FINISH


Fins and irregularities on formed surfaces to receive no other finish shall be smoothed.
The top of concrete on which other concrete or unit masonry will later be placed shall
be struck off true at the surface indicated on the drawings or approved, as the concrete
is being placed. As soon thereafter as the condition of the concrete permits and before
it has hardened appreciably (normally within 2 hours after being deposited), all water,
scum, laitance, and loose aggregate shall be removed from the surface by means of wire
or bristle brooms in such manner as to leave the coarse aggregate slightly exposed and
the surface clean. Raking or other methods which cause weak serrations shall not be
employed. The formation of depressions and general unevenness shall be avoided.
There after the Contractor shall take all necessary precautions to ensure that the
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surface thus prepared shall be kept free from storage piles, drippings, staining, or
accumulation of substances which would adversely affect the concrete or the bond
between layers removed by the cleaning specified under Clause 3-17 "Bonding
Concrete at Construction Joints".
Where the top surface of structural concrete or concrete fill is to be left in a finished
condition, the concrete shall be brought monolithic to the finished grade therefore, as
indicated on the drawings or required; subsequent addition of a layer of
mortar("topping") or concrete to bring the finished surface to the correct grade will not
be permitted.
Wood-float finish shall be given to all concrete top, substantially horizontal, and
exposed surfaces unless otherwise specified or indicated on the drawings.
Fair faced concrete finish shall be given to all formed surfaces which will be exposed to
view on completion of the work.
All surfaces shaped without forms and over which liquids will flow shall be given a
steel-trowel finish.
All platforms, walkways, steps and ramps shall have a broom finish.
Concrete surfaces to which roof insulation or roofing are to be applied shall be finished
sufficiently smooth to receive the roofing material, as obtained by steel trowel or very
smooth wood-float finish.
Exposed concrete floors and screeds shall be given at least two liberal treatments with
a solution of a surface hardener as specified under Section 800.
The finishes to be given to certain other concrete surfaces are as indicated on the
drawings or as ordered by the Engineer's Representative.

3-22 WOOD FLOAT FINISH


Surfaces to be given a wood-float finish shall be finished by tamping with special tools
to force aggregates away from the surface, and mortar screed with straight edges to
bring the surface to the required line.
As soon after mortar screed as the condition of the concrete permits and before it has
hardened appreciably, all water, film, and foreign material which may work to the
surface shall be removed by means of lutes. Rough finishing shall be done with straight
edges and derbies. Machine floating if used, shall not be started until the surface will
support the float adequately without digging in and/or bringing excess fines to the
surface. At such time, a minimum of machine and/or hand floating with a wood float
shall be employed to bring the finish to a true and uniform surface with no coarse
aggregate visible.
Under no circumstances will sprinkling with water or dusting with cement be permitted
during finishing of the slab.

3-23 BROOM FINISH


Surfaces to be given broom finish shall first be given a steel-trowel finish. Immediately
after trowelling the surface shall be lightly brushed in one direction with a hair broom
to produce a non slip surface of uniformly good appearance.
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3-24 STEEL-TROWEL FINISH


Surfaces to be given a steel-trowel finish shall first be given a wood-float finish. This
shall be followed by hand trowelling with steel trowels to bring the surface to a
uniform, smooth, hard, impervious surface free from marks and blemishes. Trowelling
shall not be started until all water has disappeared from the surface. Over-trowelling
shall be avoided. Dusting with dry cement or other mixtures or sprinkling with water
will not be permitted in finishing.

3-25 FAIR FACE FINISH


The quality of the surface of concrete exposed to view shall be consistent throughout
the Project and the following methods shall be adopted to obtain the required finish:
a) Metal forms of an approved type.
b) Hard-pressed fiber-board with one smooth face at least 6 mm thick.
The Contractor may submit alternative proposals for the Engineer's approval if he so
desires.
In addition to the above forms or linings, the forms shall be coated before placing
reinforcements with an approved colorless mineral oil free of kerosene.
All surplus oil on form surfaces and any oil on reinforcing steel shall be removed.
The contractor shall submit for approval a sample panel not less than 600 x 1200 mm
to demonstrate the quality of the exposed concrete produced by forms at his own
expense.
The quality of the finished surfaces shall be uniform in color and consistency
throughout the project. Should there be any inconsistency, whether in color or in
texture, in any of the finished surfaces, the Engineer may order the repair or the
demolition of that portion of concrete work and the reconstruction of same at the
expenses of the Contractor and the Contractor shall have no right to claim for any
expenses or time delay incurred.

3-26 METAL WORK IN CONCRETE


All castings, inserts, conduits and other metal works shall be accurately built into or
encased in the concrete by the Contractor as directed, and all necessary precautions
shall be taken to prevent the metalwork from being displaced or deformed.
Anchor bolts shall be set by means of substantial templates.
The Contractor shall build into new concrete against which concrete blocks are to be
laid, suitable, approved, non-corrodible metal, dovetailed grooves for ties for securing
the block work to the concrete.

3-27 FORMS
Forms shall be used for all concrete including footings, except as otherwise permitted.
Forms shall be so constructed and placed that the resulting concrete will be of the
shape, lines, dimensions, and to the elevations indicated on the drawings or specified,
and exposed (Fair faced) concrete will be substantially free from board or grain marks,
poorly matched joints, and other irregularities or defects.
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For surfaces to be fair faced, the form surface in contact with the concrete shall be
made of:
a) Plywood Forms: Plywood forms shall have a minimum thickness 1-1/2 cm and
minimum dimensions of 90 x 180 cm for individual segments of large forms.
All edges of plywood sheets shall be straight and when fixed in place, all
individual segments shall butt up tightly against each other to form an even and
tight joint. Plywood forms may be reused provided the surfaces are cleaned of
all scale and are free from openings, scars or other surface damage, and
provided they are free from warping.
b) Wood Forms Lined with Plywood: Plywood lining shall have a minimum
thickness of 1 cm and shall meet the requirements specified above for plywood
forms. In order to provide the best appearance of the concrete surface, the
plywood shall be held against the wood form by nails driven from the outside of
the form into the plywood utilizing a nail length which will not pierce the inner
surface of the plywood against which concrete is to be placed. Should the lining
become separated from the form between the time the form is set and the
placing of concrete starts, finishing nails, driven through the plywood lining,
may be used to bring it back into proper position.
Properly cleaned, unscarred and unwrapped plywood lining may be reused. In
borderline cases, the decisions of the Engineer's Representative as to whether or
not the form lining may be reused shall be final.
c) Steel Forms: The use of steel forms or forms with steel lining is mandatory in
the case of curved surfaces where the radius of curvature is less than 2 meters.
Steel forms shall be keyed together in final position by wedges or bolts, so
arranged that the forms may be stripped from the finished work without prying
against the concrete. Before each use, steel forms shall be cleaned of all rust,
scale and cement crust, and covered with a film of clean oil. Cleaning and oiling
should be accomplished immediately after steel forms are stripped to prevent
the formation of rust.
d) Steel Form Lining: Steel form lining having a minimum thickness of 2 mm may
be used in conjunction with any suitably supported and well aligned form to
provide the desired surface hardness, smoothness and texture. Such lining will
be securely held in place by countersunk, flat head wood screws. Such lining
will have square edges and be accurately butted and aligned at all joints.
For surfaces other than those to be fair faced forms shall be made of wood, metal, or
other approved material. Wooden forms shall be constructed of sound lumber of
plywood of suitable dimensions, free from knot-holes and loose knots. Plywood shall
be reasonably good, as approved. Metal forms shall be of an approved type for the
work involved. Edges of forms in contact with concrete shall be flush within 10 mm.
All forms shall be of suitable material, design and construction so as to be rigid, tight
enough to prevent the passage of mortar, and plane surfaces shall be plane within 1 mm
in 1 meter. Particular care shall be taken to ensure that forms are true to line where
deviations in the concrete would be obvious or objectionable, as where building
superstructures are to be built thereon, or where the tops of walls are exposed. All such
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deviations which may occur shall be corrected by, and at the expense of the Contractor
as directed, even to the extent of tearing down and rebuilding the concrete.
Forms for walls, columns, or piers shall have removable panels at the bottom for
cleaning, inspection and scrubbing-in of bonding grout. Forms for thin sections (such as
walls or columns) of considerable height shall be arranged with suitable openings so
that the concrete can be placed in a manner that will prevent segregation and
accumulations of hardened concrete on the forms of reinforcement above the fresh
concrete, unless special spouts are used to place concrete, and so that construction
joints can be properly keyed and treated.
Forms shall be sufficiently rigid to prevent displacement or sagging between supports,
and so constructed that the concrete will not be damaged by their removal. The
Contractor shall be entirely responsible for their adequacy.
All forms shall be oiled with an approved non-staining form oil or liquid form coating
before reinforcement is placed.
Before form material is reused, all surfaces that are in contact with the concrete shall be
thoroughly cleaned, all damaged places repaired, and all projecting nails withdrawn.
Form ties to be encased in concrete shall not be made of through-bolts or common
wire, but shall be of a well-established type, so made and installed as to embody the
following features:
1) After removal of the protruding part of the tie, there shall be no metal nearer
than 3 cm to the face of the concrete.
2) That part of the tie which is to be removed shall be at least 1 cm in diameter, or
if smaller, it shall be provided with a wood or metal cone 3 cm long placed
against the inside of the forms. Cones shall be carefully removed from the
concrete after the forms have been stripped.
3) Ties which pass through walls subject to hydrostatic pressure shall be provided
with approved water stops, such as washers, securely fastened to the ties.

3-28 REMOVING FORMS


Except as otherwise specifically authorized by the Engineer's Representative, forms
shall not be removed until the concrete has aged for the following number of days:
Beams and slabs - 14 days
Walls and vertical surfaces - 4 days
Shores under beams and slabs shall not be removed until the concrete has attained at
least 60 percent of the specified cylinder strength and also sufficient strength to support
safely its own weight and the construction live loads upon it.

3-29 CONCRETE REINFORCEMENT


A. General
Unless otherwise stated in the drawings, steel reinforcement shall comply with SSA-2
and/or ASTM: A-615.

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All reinforcement shall be placed strictly in accordance with the Drawings and as
instructed in writing by the Engineer. Nothing shall be allowed to interfere with the
required disposition of the reinforcement, and the Contractor shall make a particular
point of seeing that all parts of the reinforcement are placed correctly in every respect,
and are temporarily fixed where necessary to prevent displacement before or during the
process of tamping and ramming the concrete in place. The ties, links or stirrups
connecting the bars shall be taut so that the bars are properly braced; the inside of their
curved parts shall be in actual contact with the bars, around which they are intended to
fit.
B. Type and Quality of Steel Reinforcement
1. Deformed billet steel bars of Grade 40.
Deformed billet steel bars shall conform to the strength requirements and
minimum elongation of the Standard specification for Deformed Billet - Steel
Bars of grade 40 with minimum yield strength 2800 kg/cm2 (40,000 psi) for
Concrete Reinforcement of the ASTM Specification Designation A-615 Grade
40 or SASO-SSA-2 steel bars for the reinforcement of concrete.
2. Deformed billet steel bars of grade 60.
Deformed steel rods and bars shall conform to the requirements of the Standard
Specification for Deformed Billet - Steel Bars with minimum yield strength
4200 kg/cm2 (60,000 psi) for Concrete Reinforcement of the ASTM: A-615
Standard Specification - Grade 60 - or SSA-2.
3. Welded wire fabric (Mesh) shall be electrically cold drawn wire in conformance
with ASTM A-185.
4. Reinforcing used in liquid containing structures and all structures in contact
with saturated soil shall be epoxy coated.
C. Wires
Wire for binding reinforcement bars shall be of soft black annealed mild steel wire. The
diameter of the Wire shall not be less than 16 SWG (1.6 mm) and shall conform to
ASTM A82 and the binding shall be twisted tight with proper pliers. The free ends of
the binding wire shall be bent inwards.

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D. Order Lists
Before ordering material, all order lists and bending diagrams detailed in accordance
with the latest revision of American Concrete Institute Building Code shall be furnished
by the Contractor for the approval of the Engineer's Representative and no material
shall be ordered until such lists and steel bending diagrams have been approved. The
approval of order lists and bending diagrams by the Engineer's Representative shall in
no way relieve the Contractor of his responsibility for the correctness of such lists and
diagrams. Any expense incident to the revision of material furnished in accordance
with such lists and diagrams to make it comply with the design drawings shall be borne
by the Contractor.
E. Protection of Material
Steel reinforcement shall be protected at all times from injury. When placed in the
work, it shall be free from dirt, detrimental scale, paint, oil loose rust, grease or other
foreign substances.
F. Fabrication
Bar reinforcement shall be bent to the shapes shown on the drawings and Steel Bending
Diagrams and in accordance with ACI315-80. Bending dimensions and scheduling of
bars for the reinforcement of concrete. All bars shall be bent cold, unless otherwise
permitted by the Engineer's Representative. No bars partially embedded in concrete
shall be field bent except as shown on the plans or specifically permitted by the
Engineer's Representative.
G. Placing and Fastening
All steel reinforcement shall be accurately placed in the positions shown on the
drawings and firmly held during the placing and setting of concrete. Bars shall be tied
at all intersections except where spacing is less than 30 cm in each direction, in which
case alternate intersections shall be tied.
The Contractor shall position, support, and secure reinforcement against displacement
by formwork, construction, or concrete placement operations. The Contractor shall
locate and support reinforcing by plastic chairs, runners, bolsters, spacers and hangers,
as required.
Place reinforcement to obtain the minimum coverage for concrete protection. For
liquid retaining structures comply with requirements of ACI 350R-89.
The use of pebbles, pieces of broken stone or brick, metal pipe and wooden blocks
shall not be permitted. Reinforcement in any member shall be placed and then inspected
and approved by the Engineer's Representative before the placing of concrete begins.
Concrete placed in violation of this provision may be rejected and removal required.
The cost of steel supports for holding reinforcement bars shall be borne by the
Contractor.

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H. Splicing
All reinforcement shall be furnished in the full lengths indicated on the Drawings.
Splicing of bars except where shown on the drawings, shall not be permitted without
the written approval of the Engineer's Representative. Splices shall be staggered as far
as possible.
Additional splices, other than shown on the Drawings, and allowed by the Engineer's
Representative shall be at the Contractor's own expense and shall conform to
requirements of ACI 318 for minimum lap of spliced bars.

3-30 CONSTRUCTION AND EXPANSION JOINTS


A. General
Construction and expansion joints shall be of the types indicated on the drawings and
shall be constructed wherever and only in such places as are indicated on the drawings
or otherwise directed or approved. The Contractor shall plan the work to minimize the
use of joints in addition to those indicated.
Footings, beams, and slabs shall have no horizontal joints. Unless otherwise indicated,
all construction joints shall have keyways the widths of which are equal to one-third the
thickness of the member in which the keyways are placed.
B. Materials
Bituminous joint compound for joints in slabs shall conform to ASTM Standard
Specifications for Jet-Fuel-Resistant Concrete Joint Sealer, Hot-Poured Elastic Type,
Designation D1854. The compound shall be applied in accordance with the instructions
of the manufacturer, using a suitable primer if necessary.
Joint compound for joints in walls shall be Type II compound conforming to (U.S.A.)
Interim Federal Specification TT -S-00227E(2) (COM-NBS) for sealing. Compound;
Elastomeric Type, Multi Component (for Caulking, Sealing, and Glazing in Buildings
and Other Structures). The compound shall be applied in accordance with the
instructions of the manufacturer, using a suitable primer and sealer if necessary.
Pre molded-joint filler shall be of the thickness indicated on the drawings, of suitable
length and width, and shall be Type I or Type II filler conforming to ASTM Standard
Specifications for Performed Expansion Joint Fillers for Concrete Paving and
Structural Construction, Designation D1752. As far as practicable, sheets shall be of
correct width so that no longitudinal cutting will be required in the field. When strips
are cut in the field, the cut surface shall be treated as recommended by the
manufacturer.
Polyvinyl chloride water stops shall be of the types and sizes indicated on the Drawings
and shall conform to the (U.S.A.) Corps of Engineers Specification for Polyvinyl
chloride Water stops, Designation CRD-0072.
C. Installation
Concrete to be sealed with joint compound shall be clean and dry and, if required, shall
be primed Compound shall be carefully poured, to prevent spilling the material over the
adjoining surfaces, or placed with a caulking gun.
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Surfaces to which bituminous coating is to be applied shall be prepared and primed and
an approved bituminous mastic coating material shall be applied in accordance with the
instructions of the manufacturer.
Pre molded-joint filler shall be placed against the bulk-head form and fastened to the
inside of the form with non-corrodible fasteners to secure mechanical bond with the
concrete placed on both sides of the joint filler. Care shall be taken at all times to
prevent any disturbance of or damage to pre molded joint filler.
Polyvinyl chloride water stops shall be furnished in the longest practicable lengths. The
water stops shall be set as indicated. Field splices shall be made in accordance with the
recommendations of the manufacturer. All splices, including factory splices, shall be
spark gap tested. Bending of water stops within forms and the use of split water stops
will not be permitted.

3-31 PRECAST CONCRETE


The Contractor shall provide molds, reinforcement and concrete for the precast
concrete work and shall cast, transport, handle, hoist, cut and pin or build in including
bedding and pointing in cement and sand (1:4) mortar as shown on the Drawings.
Precast concrete shall be mechanically vibrated when cast. Side molds shall remain in
position for three days and bottom molds shall remain in position for seven days.

3-32 NON-SHRINK GROUT


Non-shrink grout shall be placed under base plates and in other locations as shown on
the Drawings. It shall be product of an acceptable and approved company and shall be
placed in accordance with the recommendations of the manufacturer.
Commercial formulation of proven satisfactory performance requiring only addition of
water with minimum 28 day compressive strength of 350 kg/cm2 (5000 psi) when
tested in accordance with ASTM C827, zero percent shrinking for hardened state when
tested in accordance with ASTM C157.

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