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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.
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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.
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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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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.
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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.
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.
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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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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.
3-27 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.
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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.
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.
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