Specifications Concrete

Omran Tourism Development Company S.A.O.
Volume II Section E Concrete Works
Volume II Part 1 : Gen & Particular Specification Civil Section E : Concrete Works
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Khasab Hotel Development
Omran Tourism Development Company S.A.O.C
SECTION E
CONCRETE WORKS 1.0 GENERAL: The object of this Section of the Specification is to produce impermeable and durable concrete of a consistently high quality and to the requisite strength throughout all the Works. All structural concrete work shall be designed and constructed in accordance with the requirements of BS 8110 Structural Use of Concrete and/or BS 8007 Code of practice for design of concrete structures for retaining aqueous liquids, where appropriate except where otherwise listed in the Specification or on the Drawings. Contractor is responsible to prepare & submit a detailed mix-design to achieve the parameters of strength & durability set out in these specifications. 2.0 CODES and STANDARDS : The following Standards, codes, and other documents are referenced in this section. Contractor should produce a copy of relevant codes along with the material submittals or as called for by the Engineer. BS 12 BS 4027 BS 4550 BS EN 196-2 BS EN 196-21 Portland Cement Sulphate-Resisting Portland Cement. Methods of Testing Cement Chemical Analysis of Cement Determination of Chloride, Carbondioxide & Alkali Content of Cement BS 882 Aggregates from Natural Sources for Concrete BS 812 Testing of Aggregate BS 1199 & 1200 Building Sands from Natural Sources BS 3148 Tests for Water for making concrete Concrete Admixtures BS 5075 Accelerating, retarding and water reducing admixtures. Part 1 Super Plasticisers Part 2 BS EN 480 Admixtures for Concrete, mortar and Grout Test Methods BS 1305 Batch Type Concrete Mixers BS 5328 Part 1- Concrete Guide to Specifying Concrete 4 (or BS EN 206-1 Method for Specifying Concrete Mixes Producing and Transporting Concrete & BS 8500 Part Sampling Testing and Assessing Compliance of Concrete. 1&2) ASTM C 94 BS 8110 BS 1881 Ready Mix Concrete. Structural use of Concrete (or Testing Concrete
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BSEN 123501:2000) ASTM C 231 ASTM C 232 BS 6089 BS 7542 BS 1052 BS 4449 BS 4466 BS 4482 BS 4483 BS 7123 3.0 3.1 MATERIALS : Cement The cement to be used throughout the works shall be of best quality obtained from manufacturers approved in writing by the Engineer and shall be as described under one of the following headings unless specified elsewhere : i) Ordinary Portland Cement (OPC) Cement complying with BS 12 / 4027 or with ASTM C 150 Type 1, but containing not less than 4% and not more than 8% proportion by weight of tricalcium aluminate and having Strength Class 42.5 N. i) The acid-soluble alkali level measured as (Na20 + 0.658 K20) shall not exceed 0.6% by weight determined by the test method described in BS EN 196, Part 21. The tricalcium aluminate content shall lie within the range of 4% to 8%. The specific surface shall be not greater than 325 m/kg and not less than 225 m/kg when tested, in accordance with BS EN 196, Part 6.
Air Entrainment Test Bleeding Water Test. Guide to Assessment of Concrete Strength in Existing Structure Test of Curing Compounds for Concrete Mild Steel Wire for General Engineering Purposes Specification for Carbon Steel Bars for the reinforcement for concrete. Bending dimensions and scheduling of bars for the reinforcement of concrete. Cold Reduced Steel Wire for Reinforcement Steel Fabric for the Reinforcement of concrete. Metal Arc Welding of Steel for Concrete Reinforcement
ii) iii)
ii)
Moderate Sulphate Resisting Portland Cement (MSRPC) Cement complying with BS 12 / 4027 - Strength Class 42.5 N but containing not less than 4% and not more than 8% proportion by weight of tri-calcium aluminate, or cement complying with ASTM C 150 Type II. In either case the cement shall not contain more than 2.7% proportion by weight of sulphur trioxide. i) The acid-soluble alkali level measured as (Na20 + 0.658 K20) shall not exceed 0.6% by weight determined by the test method described in BS EN 196, Part 21. The specific surface shall be not greater than 325 m/kg and not less than 225m/kg when tested, in accordance with BS EN 196, Part 6. Heat of Hydration (7 day Maximum) : 290 kJ / Kg.
ii) iii) iii)
Sulphate Resisting Portland Cement (SRPC)


Cement complying with either BS 4027 or ASTM C 150 Type V & Strength Class 42.5N i) The acid-soluble alkali level measured as (Na20 + 0.658 K20) shall not exceed 0.6% by weight determined by the test method described in BS EN 196, Part 21. The heat of hydration shall not exceed 290 KJ/KG per gram at 7 days when tested in accordance with BS 4550 Part 3 Section 3-8. The specific surface shall be not greater than 325 m/kg and not less than 225m/kg when tested, in accordance with BS EN 196, Part 6.
ii)
iii)
3.1.1 The reason for using cements other than OPC are governed by the chemistry of the ground conditions and adverse exposure conditions. 3.1.2 Cement shall be certified by the manufacturer as complying with the requirements of the appropriate specification. Before ordering cement, the Contractor shall submit details of the proposed supplier and information on the proposed methods of transport, storage and certification for approval and show that the quantity and quality required can be attained and maintained throughout the construction period. Representative samples of the proposed cement may be required to be taken and forwarded to an independent laboratory for analysis before the source is approved. 3.1.3 Having obtained approval, the Contractor shall not change the agreed arrangements without permission. Each consignment of cement shall be accompanied by a certificate showing the place of manufacture and the results of standard tests carried out on each day's bulk production included in the consignment. 3.1.4 Delivery & Storage Cement shall be delivered in bulk or in sealed and marked bags. Cement in bags shall be stored in a suitable weatherproof structure of which the interior shall be dry and airtight as practicable. The floor shall be raised above the surrounding ground level and shall be so constructed that no moisture rises through it. Each delivery of cement in bags shall be stacked together in one place. The bags shall be closely stacked but shall not be stacked against an outside wall. No stack of cement bags shall exceed 3 m in height. Different types of cement in bags shall be clearly distinguished by visible marking and shall be stored in separate areas of the store. Bulk cement shall be stored in weatherproof purpose built silos which shall bear a clear indication of the type of cement contained in them. Approved precautions shall be taken to prevent cement dust causing a nuisance. Cement stored on Site for longer than one month shall be retested prior to use and the results shall be submitted to the Engineer, who will decide if it may be used.
3.2
Aggregates

3.2.1 General Aggregate shall be free from earth, clay, loam and soft clayey, shaley or decomposed stone, organic matter and other impurities and shall be chemically inert, hard and dense. The percentage of hollow shells shall be limited and is unlikely to exceed 10% by weight retained as a BS 2.36mm sieve if approved concrete is to be produced. Aggregate to be used in the construction of structures for retaining aqueous liquids shall comply with BS 8007. Aggregate shall conform in all respects with BS 882 and shall also comply with local Authority Regulations. 3.2.2 Source The Contractor shall obtain approval of proposed aggregate sources, and shall select suitable aggregate and samples of sand and stone for specified testing before obtaining aggregate. Laboratory tests shall be made at regular intervals to confirm the suitability of aggregates. 3.2.3 Coarse Aggregate Coarse Aggregate for concrete shall comply with the requirements of BS882 for Aggregates for Concrete and shall consist of broken hard close grained angular shaped stone or chippings or other equivalent material approved by the Engineer. The coarse aggregate shall be a well-graded mixture of particles from the maximum particles size specified or approved by the Engineer to 5mm as specified in BS882 for graded aggregate. Aggregates that are deleteriously reactive with the alkalis in the cement in an amount sufficient to cause excessive expansion of concrete shall not be used. The Contractor shall mechanically wash aggregate to remove salts and other impurities in order to meet the requirement specified. 3.2.4 Fine Aggregate The gradation of fine aggregate shall be in accordance with BS 882 latest edition excluding grading designation F unless otherwise agreed by the Engineer. Fine aggregates shall be Wadi sand, OR Fresh water river sand, OR fines from the secondary crushing of the product of primary OR secondary crushing of approved sound rock. The Contractor shall mechanically wash aggregate to remove salts and other impurities in order to meet the requirement specified. 3.2.5 Testing of Aggregates All fine and coarse aggregates shall be imported from sources approved by the Engineer and shall be with in the limits laid down in the table-2 below.
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TABLE 2 : LIMITS FOR PHYSICAL, CHEMICAL & MECHANICAL PROPERTIES OF AGGREGATE FOR CONCRETE Test Methods No 1. 2. Requirements Grading Material finer than 0.075mm. - Natural, uncrushed/crushed - Crushed Clay lumps & friable particles Lightweight pieces Organic impurities BS 812 Part 103(Dry) Part 103(Wet) max 3% max 7% C 142 C 123 C 40 max 1% max 0.5% The colour of the supernatant liquid is lighter than standard colour solution max 2.3% min 2.6 max 2% min 2.6 max 1% max 1% max 1% max 0.5% ASTM Permissible Limits Fines Standard Coarse Standard
3. 4. 5.
6. 7. 8.
Water absorption Specific gravity (apparent) Shell content in aggregates - Coarser than 10 mm - Between 5 mm & 10 mm Particle shape - Flakiness index - Elongation index Part 105.1 Part 105.2
C 128 / C 127 C 128 / C 127 Part 106
max 5% max 15% 100% with atleast one crushed faces as per DM301 max 25% max 25%
9.
10.
Acid soluble chlorides, Cl For reinforced concrete made with - SRPC cements - OPC & MSRP cements For mass concrete made with - SRPC cements - OPC & MSRPC cements - For prestressed concrete and steam cured structural concrete
max 0.03% max 0.03%
max 0.01% max 0.01%
max 0.03% max 0.03% max 0.01%
max 0.02% max 0.02% max 0.01%
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TABLE 2 Contd. Test Methods No 11. 12. 13. Requirements Acid soluble sulphates SO3 Soundness, MgSO4 (5 cycles) Mechanical strength 10% Fines Value or Impact Value (AIV) Los Angeles Abrasion 14. Potential reactivity of Note 2 C 289 - of aggregates, chemical method C 227 - cement-aggregate combination 15. 16. 17. 18. Drying shrinkage Unit weight & voids Aggt. Crushing value (ACV) Sand Equivalent Part 110 ASTM D 2419 Part 120 C 29 < 20% 6 month expansion 0.10% max max 0.05% <10% voids <20% loss >70% Innocuous Innocuous Part 111 Part 112 C 131/ C 535 min 100 KN max 30% max 30% BS 812 Part 118 C 88 ASTM Permissible Limits Fines max 0.3% max 12% Coarse max 0.3% max 12%
Note : 1. 2.
3.
There is no requirement of shell content in sands passing 5mm size sieve. Aggregates may initially be assessed for reactivity in accordance with ASTM C 289 and if potential reactivity is indicated, then mortar bar tests in accordance with ASTM C 227 shall be carried out. For the combined grading, the quantities of acid soluble salts shall not exceed the followings : Chlorides (Cl) Max. 0.3% by weight of cement. Sulphates (SO3) Max. 4% by weight of cement. (Including the Sulphate Iron in the cement).
The aggregate shall be considered conforming to specifications if representative samples pass the above tests. Just before use, the aggregate shall be washed down with potable water to remove the content of sulphates, chlorides and other extraneous materials.
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3.2.6 Frequency of Routine Tests on Aggregate The Contractor shall carry out various tests at the frequencies indicated below. However the Engineer shall reserve the right to call for additional test wherever it is warranted.
TABLE 1 : AGGREGATES - TEST CRITERIA No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Kind of Requirement - Test Method Grading - BS 812 Part 103 Material finer than 0.075 mm BS 812 Part 103 Clay lumps & Friable particles - ASTM C 142 Organic impurities - ASTM C 40 Water absorption - ASTM C 128/C 127 Specific Gravity - ASTM C 128/C 127 Shell content - BS 812 Part 106 Particle shape - BS 812 Part 105.1, 105.2 Acid soluble chlorides Cl Qualitative - BS 812 Part 117 Appendices A/B Quantitative - BS 812 Part 117 Appendix C Test Frequency Rate Each two weeks or per 100m3 whichever is more frequent. - do - do Each month or per 200 m3 whichever is more frequent. - do - do Each two months or per 100m3 whichever is more frequent. - do On each delivery to site. Each 6 concrete days if result is more than 75% of the limit and each month if result is less than 75% of the limit. Each 12 concrete days if result is more than 75% of the limit and each two months if result is less than 75% of the limit. Each 48 concrete days. Each 72 concrete days. - do Twice daily. At the start of the project and whenever there is change in the source of supply.
10.
Acid soluble sulphates, SO3 - BS 812 Part 118
11. 12.
Soundness, MgSO4 (5 cycles - ASTM C 88) Mechanical strength 10% fines or impact value - BS 812 Parts 111, 112. Los Angeles Abrasion - ASTM C 131/C 535
13. 14. 15.
Moisture variation in sand - by Moisture Meters Drying Shrinkage - BS 812 Part 120 Potential Reactivity : - of Aggregate ASTM C 295, C 289 - of Carbonate ASTM C 586 - of Cement Aggregate Combination ASTM P 214 & C 227
- do -
Note : Drying, shrinkage and potential reactivity of aggregate shall be determined initially at the start of the project or whenever there is a change in the source of supply.
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3.3 Water for Concrete The Contractor shall make his own arrangement and obtain approval from the Statutory Authorities as well as from the Engineer for the supply of water. The mixing water should be clear, apparently clean and free from matter harmful to concrete in its fresh or hardened state and be in accordance with BS 8110: Part-1. Potable water can be used. Water of questionable quality should comply with the physical tests of Table 3 & chemical limitation listed in Table 4. The Contractor, when required by the Engineer, shall arrange for the analysis of samples of the water to be made by an approved testing laboratory and the water shall comply in all respects with the requirements of BS 3148:1980 or ASTM C94. The temperature of water for concrete should not be less than 5 degree celsius nor more than 25q celsius. Water may be cooled to not less than 5q celsius by the gradual addition of chilled water or ice but on mixing, no ice particles should be present in the mix. Alternatively, flaked ice may be used. The ice to be used should be crushed and should be the product of frozen water which complies with acceptance criteria of Tables 3 & 4. Water for curing concrete shall not contain impurities in sufficient amounts to cause discolouration of the concrete.
TABLE 3 Acceptance Criteria & Physical Test for Mixing Water Limits Compressive strength, min % control at 7 days Setting time, deviation from Control - h:min 90 from 1:00 early to 1:30 later ASTM Test C 109
C 191
TABLE 4 Chemical Limitations For Mixing Water Limit, ppmTest Method 1. 2. 3. 4. 5. Chlorides (mg/l as Cl) 250 ASTM D 512 Sulphates (mg/l as SO4) 350 ASTM D 516 Alkalis, carbonates & bicarbonates 500 ASTM D 513 Total dissolved ions, including 1, 2 & 3 above 2000 BS 1377, Part 3, Test 8 pH Min. 7/Max. 9 ASTM D 1293
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3.4 Admixtures Unless the use of admixtures is specifically directed, the Contractor shall obtain the Engineer's approval prior to their use in each mix. In any case, the suitability of the admixture shall be verified by trial mixes. Admixture shall be used strictly in accordance with the manufacturer's instruction unless otherwise by the Engineer. Neither calcium chloride nor any admixture containing it shall be used.
3.4.1 Both the amount of admixture to be added and the method of use require the approval of the Engineer, for whom the following data shall be provided: i) ii) iii) iv) v) vi) vii) viii) The chemical names of the main active ingredients in the admixture Whether or not the admixture contains chlorides The typical dosage and detrimental effects of under dosage and over dosage Whether or not, the admixture leads to the entrainment of air when used at the manufacturer's recommended dosage. Long-term and short-term effects of the admixture on concrete and the effect on different types of cement and aggregate Storage life and any special storage requirements Safety precautions in handling Availability of non-site technical service.
3.4.2 Admixtures shall comply with one of the following British Standards BS 1014, BS 3892 (PFA) or BS 5075 as appropriate. Air entrainment agents shall be such that the air content can be maintained within the limits specified even if the mixing time is extended to 30 minutes. If two or more admixtures are proposed to be used in any one mix, the manufacturers of each shall be consulted. 3.5 Applicable Tests & Codes All concrete, aggregate, cement and water shall be sampled and tested during construction as frequently as deemed necessary by the Engineer. All test samples shall be supplied by the Contractor at his expense. Samples shall be obtained in accordance with BS 812, BS 3148, BS 1881 & BS EN 196. Testing shall be at the frequencies stated in the Specifications or relevant standards. All sampling shall be carried out by the Engineer.
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Minimum Testing Equipment: Number Required 5 5 5 5 5 48 5 5 5 5 5
Test
Equipment to be Provided
Slump Test
Slump cone with base plate Tamping rod Trowel 300mm Rule Small scoop 150mm cube moulds & base plate 1.8kg tamping bar 380mm long with 25mm square ramming face Set of tools for assembling and stripping moulds Trowel as for slump test Scoop as for slump test Mould oil in closed container with brush
Cube Making
Cube Curing Hessian or sacking, impervious sheet Maximum/minimum thermometer Waterproof marking in crayon/paint of equivalent Curing tank (in air-conditioned room) Cubes to commercial laboratory Concrete Temperatur e Note : : Concrete thermometer (Digital)
Lot 2 lot as reqd Lot 3
The use of 100mm cube moulds is not permitted. All equipment shall be calibrated and comply with relevant standard methods.
Consistence Consistence shall be assessed by the following tests the requirements for which shall be as specified elsewhere in the documents. Slump test shall be performed according to BS 1881 Part 102. Compaction factor shall be performed according to BS 1881 Part 103. Vebe time shall be performed according to BS 1881 Part 104. Flow test shall be performed according to BS 1881 Part 105. The compression tests shall be performed on cubes 150 x 150 x 150mm as described in BS 1881 Part 116. Sampling, making test cubes and curing of cubes shall be in accordance with BS 1881 Parts 101, 108 & 111 respectively.
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3.6 REINFORCEMENT Steel reinforcement shall generally be one of the following types : i) ii) Hot rolled mild, medium or high yield steel, smooth, round or deformed bars complying with BS 4449, latest edition. Steel fabric reinforcement complying with BS 4483 (Also BS 4482).
Reinforcement for use in reinforced concrete shall comply where appropriate with BS 4466, and BS 8110 and shall be UK CARES Certified for product & management. 3.6.1 Contractor should provide the Engineer with certified copies of mill test reports for reinforcing steel, showing physical and chemical analysis, minimum 8 weeks prior to commencing reinforcing work. Contractor should inform the Engineer of proposed source of material to be supplied. Two copies of certificates verifying that the reinforcement complies with this Specification shall be given by the Contractor to the Engineer in accordance with the British Standard as appropriate for each consignment of reinforcement from each source. All testing for reinforcement shall be carried out in a laboratory acceptable to the Engineer. The frequency of testing shall be as set out in BS 4449, Clause 3.2 or as directed by the Engineer. The Contractor shall cut and bend bars to BS 4466 and to schedules provided, unless otherwise instructed. Straight sections of bars must be kept out of winding. The internal radius of bends shall in no case be less than four times the diameter of the bar, except for stirrups, column binders, and wall shear bars which are to be bent to fit closely around the main bars. Great care is to be taken to bend stirrups and binders separately and to the sizes shown. 3.6.2 LABORATORY TESTING OF REINFORCEMENT RELEVANT BS NUMBER OF TESTS Minimum number of tests for certification purposes to be 10 initially prior to 1st steel fixing then testing as required by the engineer but not less than 2 samples from each bar dia. per delivery to site. (Tests shall include tensile, bend, re-bend and chemical analysis) Testing to be done for all sizes of bars and for different source. NOTES Contractor to submit manufacturers and/or suppliers certificates as proof that material meets BS requirements and is representative of materials used on site. The acceptance criteria for the reinforcement testing is to be in accordance with the relevant British Standards for the tests being undertaken.
BS 18 BS 4449 BS 4482 BS 4483
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3.6.3 Schedules The Contractor shall schedule the reinforcement in accordance with BS 4466 (1989) and BS 8110, the information on the drawings, this specification and any subsequent instruction. The Contractor shall include for all necessary chairs and spacers, and his price and rates for steel thus shown shall also include for these. Bending schedules and reinforcement detail drawings shall be submitted for the Engineer's approval. Two weeks shall be allowed for his consideration of this initial submission. The Contractor shall correct these schedules and resubmit as reasonably required to ensure a high standard of work. He shall program his work and submit schedules for approval allowing time for such verification, rectification and resubmission as necessary. Such approval shall not relieve the Contractor of his responsibility for the accuracy of such schedules. Indicate on shop drawings, bar bending details, lists quantities of reinforcement, sizes, spacing, locations of reinforcement and mechanical splices if approved by the Engineer, with identifying code marks to permit correct placement with out reference to structural drawings. Indicate sizes, spacing and locations of chairs, spacers and hangers. These drawings shall show all openings for services, and up stands or plinths for equipment and cast-in items. In case any other type of reinforcement is required, it shall comply with the requirements of the Particular Specification. 3.6.4 Placing of Reinforcement The placing of all reinforcement will be checked by the Engineer and in no case is concrete to be poured around any steel that has not been approved by him. The Contractor is to ensure that no steel is displaced from its position during the placement of concrete and until the concrete is set. The insertion of bars into or removal of bars from concrete already placed will not be permitted. Reinforcement temporarily left projecting from the concrete at joints shall not be bent without the prior approval of the Engineer. All reinforcement shall be free from loose rust and mill scale and any coating such as oil, clay, paint etc. which might impair the bond with the concrete. All bars will be bent cold on approved machines. Lengthening of bars by welding and rebending of incorrectly bent bars will not be permitted, except where requested by the Engineer.
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The Contractor shall provide on site facilities for hand bending to deal with minor adjustments. Unless stated elsewhere, Threaded Mechanical Couplers (Taper threaded couplers not accepted) shall be used for reinforcement of 32 mm Diameter or more. However, for Construction joints in Beams, Threaded Mechanical Couplers shall be used for reinforcement of 16 mm Diameter and above. 3.6.5 Unless otherwise allowed for in the particular specification splices in reinforcing bars shall be formed by lapping. Such laps in bars in any member shall be staggered. Except as otherwise indicated on the drawings, the minimum overlap of lapped splices shall be of 40 bar diameters or 300 mm whichever is greater. 3.6.6 The steel is to be fixed in position exactly as indicated and the bars are to be securely wired together with 1.6 or 1.4 mm soft iron wire or approved spring steel clips wherever necessary to prevent any displacement during concreting. Unless otherwise agreed by the Engineer, all intersecting bars shall either be tied together or shall be secured with a spring steel clip. Spacers, chairs and the like, temporary or permanent, are to be used as required to ensure that the steel has the exact amount of cover indicated. No permanent spacers may show on a surface where a fair faced concrete finish or a brushed aggregate finish are required. 3.6.7 Unless otherwise indicated, the minimum cover to the reinforcing bars is to be as shown on Table 5 or equal to the diameter of the bar, whichever is greater. 3.6.8 Reinforcement shall not be welded except where required by the Contract or agreed by the Engineer. If welding is employed, the procedures shall be as set out in BS 2640 for gas welding or BS 7123 for metal arc welding. Full strength but welds shall only be used for steel complying with BS 4449. If high yield deformed bars are to be welded they shall have a carbon equivalent of the steel less than 0.51%, and a nitrogen content less than 0.007% 3.6.9 Embedded Items All embedded items shown on the drawings shall be fixed in the positions shown within the specified tolerances. Where this necessitates the modification or displacement of the reinforcement the Contractors proposals for such work shall be approved by the Engineer. Embedded items shall not be supported by welding to reinforcement. 3.6.10 Dowel Bars Unless specified other wise, dowel bars shall be straight and ends shall be free from any irregularities. Where shown on the drawings, dowel bars shall be debonded with an approved debonding compound or proprietary dowel bar sleeve. The engineer may require the Contractor to demonstrate the efficiency of the method of debonding by carrying out tests.
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TABLE 5 MINIMUM COVER REQUIREMENT (IF NOT SPECIFIED ELSEWHERE) FOR REINFORCEMENT BARS Minimum Cover mm To Main bars 75 125 75 75 60 75 50 50 30 40 40 40 60 40
Error! Bookmark not defined.Position Pile Caps, Top, and sides Pile Caps Bottom Raft Bottom Raft sides Retaining wall with W.P membrane Retaining wall with out W.P membrane Column in Basement upto Ground Floor Beam bottom side, end upto Ground Floor Slab upto Ground Floor Columns above Ground Beam both side, end above Ground Grade slab top Grade slab bottom Shear Walls, Core Walls
Spacers to be used for maintaining the cover shall be of approved material. The cover to all the reinforcements unless specified elsewhere, in a concrete structure which is in direct contact with soil, will be 75 mm. Secondary reinforced concrete members for which no reinforcement details are given in the drawings shall have a minimum ratio of reinforcement area to concrete area of 0.2%. RC slabs for which no reinforcement details are given in the drawings shall have minimum 0.13% (reinforcement) of area of concrete at top & bottom, as required. RC beams for which no reinforcement details are given in the drawings shall have minimum 1.0.% (reinforcement) of area of concrete at top & bottom, with nominal shear reinforcement.
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4.0 4.1 CONCRETE Quality of Concrete Concrete shall be a mixture of cement, aggregates and water as covered respectively by clauses 1.1 to 1.3. The term water/cement ratio means the ratio by weight of the water to the cement in the mix, expressed as a decimal fraction. The water is that which is free to combine with the cement in the mix. This includes free water in the aggregate but excludes water absorbed or to be absorbed by the aggregate. The aggregate for this purpose shall be taken to be in a saturated surface-dry condition. The absorption of the aggregates shall be determined in accordance with ASTM C127 or C128. The term aggregate/cement ratio means the ratio by weight of aggregate to cement in the mix. For this purpose, the aggregate is taken in a saturated surface-dry condition as for the water cement ratio above. The air content of air entrained concrete shall be expressed as a percentage by volume of concrete determined by ASTM C231, 'Air Content of Easily Mixed Concrete by the Pressure Method'. At least one test for each 120 cubic metres of concrete shall be made. The slump of the freshly mixed concrete shall be determined in accordance with Part 102, 1983 of BS 1881 or ASTM C143. At least one morning and one afternoon test shall be made and whenever directed by the Engineer. To ascertain strength of concrete, preliminary test cubes shall be taken in accordance with BS 1881, Part 108 and tested in accordance with Part 116 of BS 1881. Works Test Cubes shall be those used for control during construction and shall be made and tested in accordance with BS 1881 Part 108 and tested in accordance with 116 of BS 1881. 4.2 Design of Concrete Mixes The Contractor when tendering having knowledge of the source and types of cement, aggregate, plant and method of placing he intends to use shall allow for the aggregate/cement ratio and water/cement ratio which he considers will achieve the strength requirements specified and will produce a workability which will enable the concrete to be properly compacted to its full depth and finished to the dimensions and within the tolerances shown on the Drawings and required by the Particular Specification. In any event the aggregate/cement ratio and the water/ cement ratio shall not exceed the upper limits specified for each type of concrete. Design of mixes shall comply with the requirements of BS 5328 (or BS EN 206-1 in
Volume II Part 1 : Gen & Particular Specification Civil Section E : Concrete Works E/16 Khasab Hotel Development

conjunction with BS 8500). The Contractors mix proposals for each mix require the Engineers approval. Existing data provided as evidence of satisfactory previous performance shall include the workability and water / cement ratio. As soon as possible after signature of the contract, the Contractor shall prepare such trial mixes (see clause 4.7) as required to satisfy the Engineer that the specified concrete strengths will be obtained using the materials and mix proportions in accordance with the above clauses. The proportion of cement shall be increased if necessary to obtain the strengths required. From each trial mix, ten preliminary test cubes shall be made and 3 cubes tested at 3 days, three cubes at 7 days and four at 28 days, the test at 3 days and 7 days being intended to give an early indication of possible variation from the required strength. If the difference between the highest and lowest test results from any one trial mix is more than 15 per cent of the average of the strength test results, the test is to be discarded and a further trial mix made, unless all test results so obtained are above the required strength. Separate trial mixes are required for each type of concrete. Prepare strength gain curve for each mix. The trial mix or mixes agreed by the Engineer shall be designated job mixes and used as a basis for actual concrete production. Mix designs shall be in accordance with BS 5328-1991 (or BS EN 206-1 in conjunction with BS 8500 Par 1&2). 4.3 Batching & Mixing of Concrete All concrete shall be batched by weight and mixed mechanically in machines which comply with BS 1805. Hand mixing shall not be allowed except only upon the written permission of the Engineer. Concrete may either be batched and mixed on site or outside the site and transported thereto. Daily returns shall be provided showing the quantities of cement and the total volume batched of each class of concrete for each section of the works and temporary works. When mixed on site, batching and mixing shall be as follows: 4.3.1 Batching by Weight The cement and each size of aggregate shall be measured by weight. The water may be measured by weight or volume. The weigh-batching machines used shall be of a type approved by the Engineer and shall be kept in good condition while in use on the works. Checks are to be made as required by the Engineer to determine that the weighing devices are registering correctly. The accuracy of the measuring equipment shall be within 3% of the quantity of cement, water or total aggregates being measured and within 5% of the quantity of any admixture being used. All measuring equipment shall be maintained in a clean and serviceable condition.
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4.3.2 Batching Aggregate by Volume When batching aggregates by volume is allowed, the cement shall be batched by weight and the water by weight or volume. Each size of aggregate shall be measured in metallic containers the depth of which is at least equal to their greatest width. The containers shall be of such shape that their volume can be easily checked by measurement. 4.4 Mixing Concrete The location of the batching and mixing plant shall be agreed by the Engineer. Concrete shall be mixed in a batch mixer of a type approved by the Engineer and in good condition having a drum rotating about a horizontal or inclined axis. Continuous mixers shall not be used. Each mixer is to be fitted with a water measuring device having an accuracy within one per cent of the quantity of water required for the batch. The water measuring device shall be such that its accuracy is not affected by variations in the water supply pressure. The batch shall be so charged into the mixer that some water (about 10%) enters the drum in advance of the cement and aggregates. Water shall then be added gradually while the drum is in motion such that all required water shall be in the drum by the end of the first quarter of the mixing time. The concrete shall be mixed until a mixture of uniform colour and consistency is obtained. Where double-drum, high performance mixers of a type approved by the Engineer are used, a minimum mixing time of 70 seconds may be allowed. The amount of concrete mixed in any one batch is not to exceed the rated capacity of the mixer. The whole of the batch is to be removed before materials for a fresh batch enter the drum. On cessation of work, including all stoppages exceeding 20 minutes, the mixers and all handling plant shall be washed with clean mixing water. If old concrete deposits remain in the mixing drum, it shall be rotated with clean aggregate and water prior to production of new concrete. Concrete mixed as above is not to be modified by the addition of water or in any other manner to facilitate handling or for any other reason. Total Chlorine in concrete mix is not to be greater than 0.3% to weight of cement in the case of ordinary Portland cement and 0.06% for sulphate resisting cement. Total SO3 in concrete mix is not to be greater than 3.7% to weight of cement in the mix. 4.5 Other Types of Concrete When other types of concrete such as Durable, waterproofed, air entrained and prestressed concrete is required, it shall be fully specified in the Particular Specification.
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4.6 Grades of Concrete 4.6.1 Concrete shall be as shown in the Table 6. The criteria given in the table are designed to produce concrete of the required strength and durability. The criteria given in the table are designed to produce concrete of the required strength and durability. The CCS's are for concrete which has been cured at a temperature of 201qC and are the values below which no more than 5% of the test results may fall. The 7 day strengths shall be used only as a guide. Concrete shall comply with BS 8110 except where BS 8007 or this specification differs. Sample for test purposes shall comply with BS 1881 Part 101 (on site) and Part 125 (in lab). The making and curing of specimens shall comply with BS 1881 Part 108 - Part 112. Unless specified elsewhere, the following Table of mixes for Concrete Class and the Characteristic strength shall be followed. TABLE 6 TABLE OF MIXES Min. Max. Free Qty. of Water/Cement Cement Ratio Kg./m3
Concrete Class
Max Size Agg. mm
Characteristic Cube Strength CCS 7-day 28 day N/mm
90/20 80/20 70/20 65/20 60/20 50/20 45/20 40/20 37/20 35/20 30/20 25/20 15/20
20 20 20 20 20 20 20 20 20 20 20 20 20
400 400 400 400 400 400 400 370 350 330 310 275 250
0.36 0.36 0.36 0.36 0.36 0.38 0.40 0.40 0.50 0.525 0.55 0.60 0.65
67 60 53 45 40 37 33 30 26 25 20 16 10
90 80 70 65 60 50 45 40 37 35 30 25 15
If air-entrainment is specified the average air content at the time of placing measured in accordance with BS 1881 Part 106 shall be : Concrete containing 40mm maximum size aggregate 4% 1% Concrete containing 20mm maximum size aggregate 5% 1% Concrete for water-retaining structures shall be water tight and shall comply with the recommendations of BS 8007.
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If concrete specimens are cured at higher temperatures or for longer periods than BS 1881 Part 111 requires that the adjusted CCS shall be calculated as follows: 100f'/f = A+B log[24D(T+12)/1000] f' f T D = = = = adjusted CCS specified CCS curing temperature age at testing in days
A & B are coefficients given in the following table : -----------------------------------------------------------------------Recorded Cube Strength N/mm A B -----------------------------------------------------------------------Less than 15 10.0 67.5 15 to 35 20.0 60.0 Greater than 35 30.0 52.5 -----------------------------------------------------------------------The calculation may be applied for curing at temperatures upto 27qC. Before placing concrete, the Contractor shall obtain approval of the mixes proposed for each class of concrete and the average target strengths. The mixes shall be designed to achieve the minimum workability for the Contractor to place and compact the concrete with the equipment proposed for use. The mean strength shall exceed the CCS by a margin of 1.64 times the standard deviation expected from the concreting plant, except that no standard deviation less than 3.5 N/mm shall be used as a basis for designing a mix. 4.7 Trial Mixes Preliminary laboratory tests shall be carried out to determine the mixes to satisfy the specification with the available materials. Trial mixes shall be tested to, unless specified elsewhere within the Contract, determine the following properties of mixes applicable to structural grade reinforced concrete proposed for initial field tests : i) ii) iii) iv) v) vi) vii) viii) Bleeding in accordance with ASTM C232 (non-vibrating) shall not exceed 0.5%. Drying shrinkage in accordance with BS 1881 Part 5 (0.05%) Air content if applicable BS 1881 Part 106, shall not exceed 2%. Free water/cement ratio - As specified. Workability. BS 1881 part 102 - As specified. Fresh & hardened concrete densities BS 1881 Part 107 & 114 respectively. Compressive strength BS 1881 Part 116. Water permeability DIN 1048. (Maximum 10 mm at 28 days in Sub-Structure), (Maximum 2 mm at 7 days and 15 mm at 28 days in Super Structure)

ix) Water Absorption for :Sub Structure 1.5 % at 28 days Super Structure 2.0 % at 28 days . Rapid Chloride penetration shall be less than 1200 coulombs (at 28 days) for Sub Structure, and shall be 1500 - 2000 coulombs for superstructure (at 56 days). Initial Surface absorption of Concrete : BS 1881, Part 5 a. Substructure 0.15 ml/m2/s b. Superstructure 0.30 ml/m2/s
x)
1.
If the values obtained are unacceptable, the mixes shall be redesigned. Trial mixes shall be prepared under full-scale site conditions and tested in accordance with BS 1881 Part 120. Samples of concrete incorporating the reinforcing details to be used shall be cast and examine, before hardening using hand tools and after hardening by coring to assess the mixes. Cores shall be 150 mm diameter by 200 mm long. Trial mixes shall be made on each of three days; the workability shall equate to the designed target value. Ten preliminary cubes from each mix shall be taken, four for test at 28 days, 3 for test at 7 days and 3 for test at 3 days. Further trial mixes shall be made if the range (the maximum minus the minimum of the three cube results in any batch) exceeds 15% of the average of that batch or if the range of the three batch averages exceeds 20% of the overall average of the batches. The mixes shall be tested to determine the properties of mixes proposed for initial field tests. The average 28-day CCS of the three trial mixes shall not be less than the designed mean strength and the results of the above tests shall be acceptable before the mix is approved. Otherwise the mix shall be redesigned. Sampling and testing of concrete core samples will be in accordance with BS 1881 Part 120. 4.8 Quality Control Cubes shall be manufactured in an on-site laboratory, specially equipped for the purpose, in controlled conditions. They shall be made cured, stored, transported and tested to BS 1881. The method of compacting cubes shall be as approved. The cube testing machine shall be housed in a laboratory and calibrated to BS 1610 and BS 1881 Part 115, when delivered; the calibration shall be verified at 6 monthly minimum intervals in accordance with The Cement & Concrete Association publication, 'The Comparative Cube Test' by P. Foote, 1974. A sample of concrete shall be taken at random on eight separate occasions during each of the first five days of using a mix. The standard deviation shall be calculated from at least 40 individual cube results each representing separate batches of similar concrete produced by the same plant under the same supervision. The current margin

for the plant shall be thus established at 1.64 times the standard deviation. The characteristic strength (CCS) determined namely average strength of 40 cubes minus 1.64 times standard deviation shall be more than specified CCS for the mix. Thereafter one sample shall be taken at random for each class of concrete from every group of 25 batches made by each batching plant, or 35m, and at least one sample shall be taken each day that concrete of a particular grade is made. Samples shall also be taken and six cylinders cast to determine the splitting tensile strength of the concrete at 7 days and 28 days, as specified in ASTM C 496 - 1986. These samples shall be taken from every 100 batches, but at least once a week during concreting operations, and shall coincide with samples taken for test cubes. The frequency of sampling may be required to be varied. In addition to the above requirements, at least one sample shall be taken from each individual structural unit, or part of a unit, when the latter is the product of a single pour. From each sample three cubes shall be made for testing at 28 days and three for testing at 7 days for control purposes. The 28 day CCS shall be the mean of three cubes. The procedures shall be repeated when materials or design mixes are changed. The acceptance or rejection of concrete shall be in accordance with BS 5328 Part 4 (or BSEN 206-1 & BS 8500 Part 1&2). The results will be acceptable if : a. The average strength determined at the age of 28 days from a sample of three or more cube test results exceed the specified CCS by 0.5 times the current margin, or No individual result of the sample is less than (Specified CCS minus 3 N/mm), or Number of individual results in the sample below specified CCS is not more than one.
b. c.
If the above criteria are not satisfied, the unit represented by the sample is questionable and the following actions may be instructed as appropriate: i) ii) iii) iv) Cutting and testing cores from placed concrete Non-destructive testing of placed concrete Load-testing relevant structural units Cutting-out and replacing defective concrete.
If the range of individual cube strengths made from the same sample exceeds 15% of the mean, then the method of making, curing and testing cubes shall be checked. In the event of a result having a range exceeding 20%, the result shall be unacceptable and the Engineer may order any of the following actions: i) Changing the mix

ii) iii) iv) Improving quality control Cutting and testing cores from placed concrete Non-destructive testing of placed concrete.
In the event of cutting & testing of cores are required, the Contractor shall cut cores from approved locations and test them to BS 1881 as modified by BS 6089. Durability Test Durability requirement of concrete used for reinforced concrete works shall be as specified in the notes of the Structural Drawings. Structural grade concrete meant for Durable concrete works shall be tested for durability properties by undertaking absorption and permeability tests where appropriate, or directed by the Engineer, as directed below : Water absorption tests shall be carried out in the laboratory on 75 mm diameter cores cut at an age of 24 to 28 days to enable the tests to be carried out between 28 and 32 days in accordance with BS 1881 Part 122. Limit of water absorption shall be as specified in Structural drawings. Effective permeability tests in accordance with the method described in DIN 1048 shall be carried out. The maximum acceptable penetration at 7 days shall be 15mm and at 28 days shall be as specified in notes of Structural drawings. Other Tests : When instructed by the Engineer, concrete shall be tested for drying shrinkage and wetting expansion, for which 75 x 75 mm prisms shall be prepared and tested in accordance with Test 5 of BS 1881 Part 5 or BS 6073 Part 1 Appendix D. The maximum acceptable limits shall be: Drying Shrinkage : Wetting Expansion : 0.05% 0.03%
Cubes may be required and trials carried out to determine stripping times for formwork, the duration of curing and to check testing and sampling errors. The air content of air-entrained concrete shall be determined (ASTM C 231) for each batch produced until consistency has been achieved, when batches may be tested. The maximum value shall not exceed 2%. Compaction factor, slump, vebe or other workability tests shall be carried out as required during concreting of permanent works to control workability at the batching plant at the site of the pour. The degree of workability shall be as for the trial mixes; permitted tolerances shall be in accordance with BS 5328.
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Workability ________________________________________________________________________ 20 mm max. size aggregate 40 mm max. size aggregate
_________________________________________________________________________ Degree of workability Slump mm Compacting factor Slump mm Compacting factor
_________________________________________________________________________ Low 13 - 25 0.82 - 0.88 13 50 0.82-0.88 Medium 25 - 50 0.88 - 0.94 50 101 0.88-94 High 50 - 127 0.94 - 0.97 101 117 0.94-0.97 ________________________________________________________________________ 5.0 5.1 TRANSPORTING & PLACING OF CONCRETE : Transporting Concrete shall be handled from place of mixing to a place of final deposit as rapidly as practicable by approved methods which will prevent segregation and loss of ingredients. It shall be deposited as nearly as practicable in its final position to avoid rehandling unset concrete inside the forms. Concrete shall be transported by means which prevent contamination (by dust, rain etc.) segregation or loss of ingredients, and shall be transported and placed without delay. Chutes for transporting concrete will only be allowed with the approval of the Engineer. 5.2 Placing Concrete shall be placed in the position and sequence indicated on the drawings or as directed. Placing shall not be commenced until the fixing and condition of reinforcement and items to be embedded and the condition of the containing surfaces or formwork has been approved. 24 hours notification shall be given of the intention to place concrete. Concrete shall be placed directly in its final position without segregation or displacement of the reinforcement, embedded items and formwork. Concrete shall not be placed in water, except as specified. The limit of individual pours and the height of lifts shall be as approved. For walls, the length of panel placed at one time shall not exceed 6 m, adjacent panels shall not be placed within 2 days, but shall be placed as soon as practicable thereafter. Subsequent vertical lifts shall not be poured within 2 days. Floors, roofs and ground slabs shall be placed in an approved sequence of panels.

'Checkerboard' placing shall be avoided. Adjacent panels shall not be placed within 2 days, but shall be placed as soon as practicable thereafter. Panels shall not exceed 25 m. If the use of slip-forms or paving trains is permitted, these limits will be revised. The sequence of pours shall be arranged to minimise thermal and shrinkage strains. Concrete shall generally be placed without segregation by pumping or bottom-opening skips. If chutes are used their slopes shall not cause segregation and spouts or baffles shall be provided. Concrete shall generally not be dropped from a height greater than 1.5 metres. Concrete and mortar must be placed and compacted within 30 minutes of water being added to the mix or otherwise included via damp aggregates, unless admixtures are in use. Partially-set concrete shall not be used in the works. Concrete shall be fully discharged from delivery / agitator trucks within 30 minutes of the commencement of discharge. Concrete shall be compacted during placing by approved internal vibrators. The vibrators shall operate at a frequency of not less than 1000 cycles per minute, and shall be designed for continuous operation. The performance of vibrators shall suit the working conditions and they shall generally not be less than 75mm diameter. The radius of influence shall ensure that the mass under treatment is compacted at a speed commensurate with the rate of supply of concrete. Vibrators shall penetrate the full depth of the layer of concrete placed and just into the layer below, and be withdrawn slowly to avoid the formation of voids. Vibration shall not be applied directly or indirectly to concrete after the initial set has taken place, nor shall it be used to make concrete flow in formwork. Placing in each section of work shall be continuous between construction joints. The Contractor shall make provision for standby equipment. If the placing of concrete is delayed due to breakdown then the Contractor shall erect vertical stop-ends and form a construction joint or remove the concrete already placed and restart after repair of the breakdown, as directed. Placing shall not take place in the open during storms, dust storms or heavy rains. If such conditions are likely to occur the Contractor shall provide protection for the materials, plant and formwork so that work may proceed. If strong winds are prevalent protection from driving rain and dust shall be provided. The temperature of concrete shall not exceed 30qC at the time of placing Concrete shall not be placed when the ambient air temperature exceeds 38qC. 'Recommendations for Hot Weather Concreting' in the 1972 edition of ACI 305 shall be complied with. The following measures inter alia may be required to control the placing temperature:

i. ii. iii. iv. v. vi. Shade aggregate, cement silos, water tanks and concrete plant Paint concrete plant white Run concrete plant with flake ice before mixing or transporting concrete Use chillers to cool the mixing water Add flake ice as a proportion of the mixing water Place concrete at night.
The Contractor shall supply suitable maximum/minimum thermometers and record the shade and sun temperatures at locations where concrete is being placed. Temperature measurements: Monitor concrete temperature continuously: x x Truck loads: Measure and record concrete temperature of each truck at time of delivery. Raft Concrete: Install thermocouples at the top, centre, and bottom of each section of concrete pour. Monitor the concrete temperature for 4 weeks. Record the temperature measurements hourly for the initial 3 days and every 6 hours for the remainder of the monitoring period. If approval has been given for placing at night or in dark interiors, adequate lighting shall be provided where mixing, transportation and placing are in progress. Underwater concrete shall be placed with minimum disturbance of the water. Running water and wave wash shall be controlled. The specified concrete grade shall be used and the mix design shall provide for good flowing ability. Tremie pipes, bottom-dump skips or other approved placing equipment shall be used. Segregation shall be avoided. Placing shall be commenced in approved sections and continued to completion. The tremie pipe shall be buried in the concrete and the pipe must not be emptied until the pour is complete. If a bottom-dump skip is used, the contents shall be covered by canvas or similar before lowering into the water. The doors shall be opened when the skip is resting on the bottom with no tension in the support cable, and the skip shall be lifted gradually so that the concrete flows out steadily. Before placing concrete for reinforced work on the ground, the formation shall be compacted as specified and a screed of blinding concrete shall be applied to form a surface for construction. Before placing concrete on or against rock, masonry, brickwork or old concrete, loose material shall be removed and the surface washed down, water seepage shall be stopped or channelled away from the work. For mass concrete placed against masonry or brickwork the following shall apply : i) ii) The mortar joints in the face-work shall have fully hardened The water-cement ratio of the concrete shall be increased to compensate for the absorption of moisture by the existing work.

iii) iv) The surface shall be soaked prior to placing The concrete shall be worked around ties and bond stones and into open joints.
6.0
SPECIFICATION FOR WATERPROOF CONCRETE : (Refer to particulars specification)
7.0 7.1
FORMWORK : General Formwork means the surface against which concrete is placed to form a face, together with all the immediate supports to retain it in position while concrete is placed. False-work means the structural elements supporting both the formworks and the concrete until the concrete becomes self supporting. Before construction begins the Contractor shall submit to the Engineer drawings showing details of the proposed formwork and falsework, along with necessary calculations from a specialised agency experienced in this field & which shall be to the approval of the Engineer. The specialised agency full time supervisor on site (2 nos., minimum) shall supervise and certify the work prior to offering them for the Engineers approval. The Contractor shall be fully responsible for the design of the formwork, false work and also the scaffolding for executing the works. The Contractor shall obtain approval of the methods and materials proposed. Details of formwork for special finishes shall be approved before materials are ordered. Formwork shall provide concrete of the shape, lines and dimensions shown on the drawings. Formwork shall be constructed from materials of sufficient strength, supported to provide rigidity during placing and compacting concrete without discernible deflection and shall be removable without disturbing the concrete. Internal ties shall be metal. Removable ties shall be located so that the specified cover to reinforcement is maintained to all surfaces including that of the tie-holes. If ties are left in, the cover shall be as specified for the reinforcement or as approved. Tie cavities shall be roughened and filled with approved non-shrink concrete or epoxy mortar. Formwork panels shall have true edges for accurate alignment and shall be fixed with either vertical or horizontal joints. Where chamfers are required the fillets shall be cut to provide an even line. Joints shall not permit leakage of grout, nor steps and ridges in exposed surfaces. Wrought formwork shall be steel, GRP or lined plywood to produce a fine finish. Lining to plywood shall be clear-lacquered extra-hard hardboard. Rough formwork shall be butt-joined, seasoned, sawn timber.
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Formwork and supports shall be cleaned, temporary openings shall be provided for the removal of rubbish. The formwork shall be coated with an approved release agent and the excess removed. Release agent shall not be allowed to come into contact with concrete already placed or with reinforcement. Not less than 24 hours notice shall be given for the inspection and approval of the formwork and reinforcement, prior to which concrete shall not be placed. Formwork shall be removed without damage to the concrete, but not until the concrete has achieved sufficient strength to support itself. Centres and props may be removed when the member has sufficient strength to carry itself and any loading with a reasonable factor of safety. External loading shall not be applied until the concrete has reached the 28 day CCS. The formwork to vertical surfaces such as walls, columns, and sides of beams may be removed in accordance with the specific requirements of the formwork so designed. The table below shows the minimum period for striking the formwork and due care must be taken to avoid damage to the concrete, especially to arise and features. Unless specifically mentioned elsewhere, the minimum periods in days for striking other formwork should be in accordance with the following table: Ordinary Portland Rapid Hardening Cement Concrete Portland cement Concrete ----------------------------------------------------Slabs (props left under) 7 2 Beam Soffits (props left under) 10 5 Props to slabs 16 5 Props to beams 21 8 Vertical surfaces such as walls, 1 1 columns and sides of beams Formwork, shuttering, props or any other means of temporary or semi-permanent support shall not be removed from the concrete until the concrete is sufficiently strong to carry safely the load (dead and temporary). The Contractor shall inform the Engineer when he is ready to strike the formwork or remove any form of temporary support and shall obtain his written consent before proceeding. The times given for the removal of props are based on the assumption that the total live plus dead weight to be supported at the time of removal is not more than one half of the total design load. For horizontal members where the loading is to be a higher proportion of the total design load these times may need to be increased. The Contractor shall be responsible for any damage to the concrete work caused by or arising from the removal and striking of the forms and supports. Any advice, permission or approval by the Engineer related to the removal and striking of forms and supports shall not relieve the Contractor from this responsibility. Any work showing signs of damage through premature loading is to be entirely reconstructed at the Contractor's expense.

7.2 Dimensional Tolerances The accuracy of the concrete work shall be within the tolerances stated on the Drawings or specified elsewhere or in accordance with BS 5606 "Guide to Accuracy in Building" and in the absence of any other requirements, shall comply with the following : The Contractor shall keep a copy of this guide on site at all times All setting out dimensions +/- 5mm Sections of concrete members +/- 5mm Foundation surface against ground (under side) +50mm-100mm Top surfaces of bases and piers +/- 20mm Floor slabs surface level (5m straight edge) +/- 5mm Floor slab surface level to datum +/- 10mm Columns & Walls plumb in storey height +/- 5mm Columns & Walls Cross diagonal distortion in storey height +/- 10mm Plumb to any point in building height +/- 15mm Inside faces of lift shafts in storey height +/- 5mm Inside faces of lift shafts in full height +/- 10mm Dimensions and position of openings +/- 5mm Holding down bolt assemblies +/- 3mm Position of embedded items +/- 5mm Thickness of slab Not less than 95% Of specified 7.3 Remedial Work to Defective Surfaces If, on stripping any formwork, the concrete surface is found to be defective in any way the Contractor shall make no attempt to remedy such defects prior to the Engineers inspection and the receipt of any instructions which the Engineer may give. Depending upon the size of honeycombing/surface defect the Contractor shall propose an appropriate method of rectification for Engineers review and approval. In any case defective surfaces shall not be made good by plastering. Defects which are outside the limits of tolerance limits shall be ground down in the manner and to the extent instructed by the Engineer. 7.4 The size of each pour and the sequence of work shall be planned to keep shrinkage effects reduced to a minimum and shall be subject to the approval of the Engineer. Concrete with unacceptable shrinkage cracks shall be cut out and replaced to the satisfaction of the Engineer. Shrinkage cracks accepted by the Engineer shall be sealed with a non-shrink cementatious free flow grout. 8.0 JOINTS : Construction joints shall be located and the sequence of placing arranged as approved or as shown on the drawings to minimise broken edges at corner, shrinkage cracks and thermal strains in the concrete. Concrete placing shall not be interrupted except where joints occur, and shall continue

after normal hours if necessary to achieve this. Joints shall be formed square to the work with keyways included. Horizontal joints shall be generally at least 500 mm above ground level if class 4 or 5 conditions of BS 8110 - Table 6.1 apply, and 500 mm above high water level in marine locations, or as shown on the drawings. Upon removal of the formwork the joint face shall be inspected, and if the soundness of the concrete is not approved the Contractor shall investigate and remedy defects. Before placing is resumed at a joint the set surface shall be roughened to remove laitence and expose the aggregate; the aggregates shall not be damaged. If damaging materials have come into contact with the surface cleaned by compressed air or water jets and brushed and watered immediately before placing. If required the surface shall be coated with a layer of stiff cement-grout prior to placing the new concrete. Chemical surface-retarders shall not be used. Construction joints shall be sealed with an approved sealant at external and liquidcontact faces. Construction joints in water-retaining structures shall incorporate an approved water bar. Expansion and contraction joints shall be as shown in the drawings. A contraction joint in a non-water-retaining structure shall form a plane discontinuity in the member. The concrete face first cast shall be painted with two coats of approved rubberised bitumen paint before the adjacent concrete is placed. The adjacent concrete shall include a groove against the joint for sealant. The exposed edges shall be sealed with an approved compound. If a contraction joint is likely to be contaminated, the joint shall be sealed immediately with an approved free-flowing sealing fluid as soon as the formwork has been removed. An expansion joint in a non-water-retaining structure shall be formed as for a contraction joint, but resin-bounded cork filler board shall be included so that the adjacent concrete members can expand. Precautions shall be taken to maintain uniform width of expansion joint and maintain straight edge at corners. A design joint in a water-retaining structure shall include a continuous water-stop strip of copper, rubber, rubber and steel or PVC fixed across the joints as shown on the drawings. The concrete shall be free from honeycombing and worked against the embedded part of the strip. Projecting portions of the strip shall be protected from damage during operations and in the case of rubber and plastic from light and heat. Bituminous paint shall be applied to the lips of the loop of copper water-stops and the loop filled with bituminous compound before embedding in the concrete. The method of joining water-stops shall be in accordance with the manufacturer's instructions.

9.0 CURING AND PROTECTION : Concrete shall be protected from sunshine and drying winds by approved shading and wind-breaks and from cold, heat, rain or running water for a period of 14 days after placing. During this period the following measures shall be taken to prevent the loss of moisture and to minimise thermal stresses caused by the difference in temperature between the surface of the concrete and the core of the concrete mass: a. Horizontal surfaces i) Polythene sheeting shall be placed immediately after finishing. ii) After final set has taken place, the polythene shall be replaced by wet hessian covered with polythene; the hessian shall be kept permanently damp. iii) After 7 days and hessian and polythene shall be removed and an approved aluminised or white resin-based tropical curing compound applied. The rate of application shall be as recommended by the manufacturer. Alternatively, the hessian and polythene shall remain for a further 7 days. iv) Alternative methods of curing must be approved before use or where special finishes are required. Vertical surfaces i) Polythene over wet hessian shall be secured to the surfaces immediately after removal of the formwork. The hessian shall be kept permanently damp. After 7 days the hessian and polythene shall be removed and an approved aluminised or white resin based tropical curing compound applied. Alternatively, the hessian and polythene shall remain for a further 7 days.
b.
ii)
Water used during curing operations shall be fresh potable water. Curing membranes shall be compatible with waterproofing or other materials that may subsequently be applied to the surface of the concrete. Concrete shall be protected from contamination by sea or brackish water, oil, fuel and other deleterious materials for a minimum period of 30 days after placing. Insulating formwork shall be left in place of 72 hours after placing or until the temperature peak of the concrete is reached. The initial curing period in (b) (ii) above may then be reduced in proportion. Rebates formed to received sealant and the surfaces of construction joints shall be protected from curing compound by wet hessian to ensure proper curing of the joint surface and adjacent concrete. The protection shall remain in place until the joint surface is sealed.
10.0
FORMED FINISHES :
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10.1 Basic Finish i) ii) iii) iv) Produce an even finish with a sheet material. Arrange panels in a regular pattern. Blowholes not more than 10 mm in diameter will be permitted but otherwise surface to be free from voids, honeycombing and other large defects. Variation in colour resulting from the use of an impervious form lining will be permitted but the surface to be free from discolouration due to contamination or grout leakage.
The finish will be left as struck. Making good of small defects will normally be permitted but only after inspection by the Engineer. All blowholes shall be filled with a matching grout to an approved sample unless otherwise instructed by the Engineer. All faces shall be protected from damage, especially arises. All faces shall be protected from rust marks and other surface disfigurements. Form tie holes shall be filled with a matching mortar to an approved sample. 10.2 Fine Finish i) Produce a smooth even finish with an impervious sheet material. ii) Make panels as large as practicable and arrange to approval. iii) Blowholes not more than 6 mm in diameter will be permitted but otherwise surface to be free from voids, honeycombing and other defects. iv) Variation in colour resulting from the use of an impervious form lining will be permitted but the surface to be free from discolouration due to contamination or grout leakage. v) Do not use concrete cover spacers without approval. The finish will be left as struck. Making good will not be permitted. All form tie holes to be filled with a matching cement grout to an approved sample. Wire form ties shall not be used. Approval for position of tie holes to be obtained. 10.3 Power Floated Floor Slabs i) Produce a smooth even finish to receive directly applied floor coverings without use of screeds. ii) Use power machines on concrete stiff enough to take weight of machines after surface moisture has evaporated. iii) Power float to be used to regulate and close surface and remove surplus mortar. iv) Power trowel after further moisture has evaporated with successive trowellings at minimum one hour intervals with blades tilted at greater angles to produce a hard wearing surface. v) Hand finishes margins to match remainder of work. vi) Making good with latex screeds at the Contractor's expense will normally be accepted.
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10.4 Hand Trowelling i) ii) iii) Produce a smooth hard and even finish. Successive trowelling by experienced labour with steel trowels with a delay of an hour between each trowelling to allow further moisture to evaporate. Surplus weak mortar to be scraped from surface as trowelling proceeds.
The dusting of neat cement on to the surface or wetting down before trowelling will not be permitted. 11.0 READY MIXED CONCRETE : Ready-mix Concrete from a central batching plant may be used in the Works. Prior to the delivery of any concrete to the site details of the proposed supplier shall be submitted to the Engineer for approval. Arrangements shall be made for the Engineer to inspect the plant if so required, and to be present during the preparation of trial mixes. The source of ready-mixed concrete shall not subsequently be changed without the further approval of the Engineer. The requirements of this specification in respect of materials, testing, storage, batching and mixing, shall apply equally to the central batching plant Ready mixed concrete shall comply with the requirements of BS 5328 (or BS EN 206-1 & BS 8500 Part1 & 2) , except for those clauses which are directly over-ridden by this Specification, and supplier shall be made aware of the requirements of these documents. In particular, works test cubes shall be taken on site as specified irrespective of any cubes which may have been taken by the supplier. All ready-mix concrete delivered to site must be accompanied with delivery notes, which shall be submitted to the engineer. The delivery notes must contain the following minimum, but not limited, information. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Name of supplier, serial number of ticket and date. Truck number. Name of Contractor Name of Contract and location of site. Grade of concrete and total quantity. Specified workability Type, quantity and Brand of cement. Information necessary to calculate total mixing water added (free water on aggregates, water, and ice batched at plant) Type, brand, and amount of admixtures Weights of fine and coarse aggregate. Time loaded or time of first mixing of cement and aggregates. Reading of revolution counter at the first addition of water. Time and reading of revolution counter at the time of the start of discharge of the load of concrete.
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14. Signature or initials of batch plant representative. The concrete shall be transported to the site in and approved type of truck mixer or agitator truck which apart from the cab and chassis shall be painted white and kept clean at all times. The discharge chute and other dirty areas shall be washed down after delivery to prevent spillage on the roads. Truck mixers mixing performance when tested in accordance with BS 3963 shall be with in the limits of table 5 of BS 1305. The drum of the truck agitator or truck mixer shall be completely clean and empty before it is filled with concrete. Trucks shall not be loaded in excess of the manufacturers rated capacity, which shall be displayed on the vehicle on terms of the volume of mixed concrete. Concrete shall be wet mixed at the plant and no water shall be added to the mixer at any stage from batching to placing. In addition, where required by the Engineer, the Contractor shall provide details of the aggregate moisture contents determined at the plant. These shall be provided on daily basis both as test results and in the form of a print out of the data programmed into the batching plant. The delivery ticket shall show details of any automatic adjustments to the quantity of water added to the mix, i.e. Compensating for the actual moisture contents measured during batching. The suppliers test certificate giving the results of tests on aggregates for workability and strength shall be submitted by the Contractor to the Engineer at weekly intervals. Calibration of the Ready Mix Plant shall be carried out at regular intervals and calibration certificates of the plant shall be submitted to the Engineer. 12.0 RECORDS OF CONCRETE PLACING : Records, in a form agreed by the Engineer, shall be kept by the Contractor of the details of every pour of concrete placed in the Permanent Works. These records shall include class of concrete, location of pour, date of pour, ambient temperature and concrete temperature at time of placing, details of mixes, batch numbers, results of all testes undertaken, location of test cube sample points and details of any cores taken. Contractor shall supply to the Engineer four copies of these records each week covering the work carried out the preceding week. In addition he shall supply to the Engineer monthly histograms of all 28 day cube strengths together with accumulative and monthly standard deviations and any other information which the Engineer may require concerning the concrete placed in the Permanent works. 13.0 13.1 PRECAST CONCRETE : Generally For quality of materials and workmanship in pre-cast concrete work the Contractor is referred to all previous and subsequent clauses of concrete work. The rates for all pre-cast concrete work are to include for providing all material labour and plant to provide full sections as shown on the drawings, all moulds, surface finishes as described, detailed together with additional reinforcement as necessary for handling, providing and casting in structural connections in the units and supporting structures, providing and casting in (and removing if necessary) lifting devices, hoisting into position, setting level with mastic or mortar bedding and jointing and pointing as described cleaning off and leaving work perfect at completion.

The Contractor shall manufacture and store the pre-cast concrete units in adequate sized factories and stores to allow adequate quality control, reserve storage and execution of the works on time. The factory and main storage area may be on or off site depending upon the area available to the Contractor on site. Where the Contractor's factory and main storage are off site, the Contractor must include in his rates for all costs incurred in the provision of such off site areas including the payment of rent, rates and the like and haulage to site of finished units and for providing an adequate on site store separated from general stores areas which will allow delivery to site of units in adequate quantities to allow steady progress of the works. Where the Contractor's factory and storage are on site, they must be separated from the general stores areas. 13.2 Moulds The moulds are to be soundly and accurately constructed and provided in such quantities so as to ensure adequate supply of the units. Moulds shall be constructed so as to facilitate cleaning out immediately prior to concreting and shall be designed to allow units to be demoulded without causing spilling, cracking, understress or other damage. The moulds should be constructed strongly enough to allow tilting with the units inside without risk of deformation of the units whilst the concrete is still green. Moulds should be thoroughly cleaned and treated with mould oil between uses. 13.3 Tolerances Tolerances in construction of all pre-cast concrete are as follows: a. Length : Up to 3.0 m 3.0 m to 6.0 m Over 6.0 m Cross section in each direction : Up to 2000 mm Over 2000 mm Straightness or bow (deviation from intended line) : Up to 3.0 m 3.0 m to 6.0 m Over 6.0 m
5 mm 10 mm 15 mm
b.
5 mm 10 mm
c.
5 mm 10 mm 15 mm
Any pre-cast unit falling outside one of these tolerances or a combination of these tolerances shall be liable to rejection unless, in the opinion of the Engineer, it can be incorporated without detriment to the finished work.
13.4
Steel Fixings
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The metalwork items used for both hoisting and fixing of the units shall be approved proprietary products adequate for the purpose. 13.5 Handling Care is to be taken in handling the pre-cast units to ensure that they are not overstressed in any way and that they are handled and slung with the correct slings at the approved lifting points. Any units which are damaged during the progress of the works are either to be repaired to the satisfaction of the Engineer, or to be replaced, both at the Contractor's expense and the Engineer's decision with regard to whether repair or replacement is required shall be final. 13.6 Surface Finish All arrises are to be left sharp and regular or chamfered as specified. Unexposed surfaces of pre-cast units shall be formed to 'Basic Finish' as described in clause 8.1. Surfaces not in the mould are to be trowelled to match. Where surfaces are to be self finished white as described, the units shall be formed to a 'Fine Finish' as last described, including incorporating a 25 mm minimum thickness from face integral lay of white concrete composed of white portland cement, grade 6-9 mm white marble coarse aggregate and white marble fine aggregate crushed to Grading Zone 4. Where the units are to have white exposed aggregate surfaces the units shall be formed to a 'Basic Finish' as previously described including incorporating a 38 mm minimum thickness form the face integral layer of white concrete composed of white portland cement, graded 6-9 mm white marble coarse aggregate and white marble fine aggregate crushed to Grading Zone 4. Where possible the aggregate is to be exposed by casting the units face up and brushing and spraying the surface while it is still sufficiently soft (within 12-18 hours) with stiff bristle or wire brushes and plenty of clean water to remove the matrix and clear each piece of exposed aggregate. Where the exposed aggregate face is in contact with the form then a retarder may be evenly spread over the mould face to allow the same process to be used and since the surface of concrete will begin to harden as soon as the forms are removed surface treatment must commence soon after demoulding. Alternatively mechanical tooling devices may be used to produce the required finish on hardened concrete. All exposed aggregate and 'Fine Finish' works are to be produced consistent in texture and colour throughout the project unless otherwise directed by the Engineer and shall be equal to the approved finish on the sample panels. 13.7 Samples The Contractor is to produce two sample panels for the approval of the Engineer. Each panel shall be full size and finished out in part-design if necessary to the directions of the Engineer with fine finish and exposed aggregate finishes.
13.8
Execution

The Contractor shall decide the nature, type and extent of the plant to be used for the erection of the pre-cast units. He must, however, state the method of erection he proposes to use which he must describe in detail in his tender document, and all method of erection will be subject to the Engineer's approval. Pre-cast units such as cladding panels and the like must be executed complete by an approved specialist unless otherwise noted in the Particular Specification. The Contractor must provide experienced supervision at all stages of pre-cast concrete construction and erection to ensure adequate quality control, safe hoisting and accurate erection. Symmetrical section units or the like are to be clearly marked to indicate the top. 13.9 Design Where full construction drawings are not supplied for the particular pre-cast concrete units or where the Contractor wishes to submit alternative designs, the Contractor must allow for employing a firm of specialist engineers to fully design the proposed units as to construction and erection. All aspects of construction and erection shall conform with relevant directions in this specification and with the drawings in particular. i) The Contractor shall provide two sets of full working drawings showing intended construction and hoisting methods and details of the reinforcement together with calculation which must be submitted to the Engineer for approval. The quality of concrete shall not be less than M 40. The extent and disposition of the reinforcement shall be governed by the problem of hoisting the units and the basic stability of the units.
ii) iii)
14.0
PRESTRESSING FOR STRUCTURE : (Also refer Annexure III of this Section E for Post Tensioned concrete) Generally Pre-stressing operations shall be carried out only under the direction of an experienced and competent supervisor and all personnel operating the stressing equipment shall have been properly trained in its use. The competence of the supervisor shall be demonstrated to the satisfaction of the Engineer before presenting work commences. In addition to the normal precautions against accident, which should be taken at all times for the whole of the works, special care shall be taken when working with or near tendons which have to be tensioned or are in the process of being tensioned. The system of pre-stressing used shall be a system approved by the Engineer. Such system shall be used strictly in accordance with the recommendations of the manufacturer. Under no circumstances shall apparatus designed for use with one system of prestressing be used in conjunction with apparatus designed for use with another system. Pre-stressing components shall be stored in clean dry conditions. They shall be clean
14.1
E/37

and free from loose rust and loose mill scale at the time of fixing in position and subsequent concreting. Slight rusting of the steel is acceptable, but the surface shall not be pitted. 14.2 Wires & Strands i) All wires or strands stressed at the same time shall be taken from the same parcel. Each cable shall be tagged with its number and the coil number or numbers of the steel used. Tendons shall not be welded within the length to be tensioned and unless other methods of cutting are agreed by the Engineer, shall be sawn or cropped. Tendons shall be built into the works strictly in accordance with the system which is being employed. Enough stand or wire shall be provided in each duct to enable jacking to be carried out from either or both ends. Cable shall not be kinked and individual strands shall be readily identifiable at each end of the member. No strand which has become unravelled shall be used in the works.
ii) iii) iv) v)
14.3
Sheaths & Cores i) All sheaths and cores shall be maintained in their correct positions during the placing of the concrete. Unless otherwise agreed by the Engineer, sheaths shall be rigidly supported at points not less than 300mm nor more than 450mm apart. Where numbers are made of units stressed together, the ducts in the joints between the units shall be in true alignment. Where sheaths are used, the number of joints shall be kept to a practicable minimum and sleeve connectors shall be used for jointing. Each joint shall be adequately sealed against the ingress of any material. Joints in adjacent sheaths shall be staggered by at least 300mm. Sheaths shall be kept free of any matter detrimental to the bond between the sheath and the grout and except for material sealing a sheath joint, between the sheath and concrete. Within 24 hours of the concrete being placed the Contractor shall satisfy the Engineer that the tendons are free to move if they are in the ducts or that the ducts are free from obstruction. The number and position of grout vents for entry and outlet points and for checking that the entire length of duct has been adequately grouted, shall be agreed with the Engineer before the ducts are formed.
ii)
iii)
iv)
v)
14.4
Anchorages i) Anchor cones, blocks and plates shall be positioned and maintained during concreting so that the centre line of the duct passes axially through the anchorage assembly. All bearing surfaces of the anchorages shall be clean prior to concreting and tensioning.
ii)
14.5
Jacks i) All jacks used for pre-stressing shall be of the type applicable to the system

ii) adopted. The accuracy of all load measuring equipment shall be checked to the satisfaction of the Engineer at the start of the work each day it is to be used and whenever the equipment is moved to a different jack or when otherwise required by the Engineer. The Contractor shall provide a calibration rig acceptable to the Engineer for calibrating the jacks. The rig shall incorporate an accurate proving rig which shall be accompanied by a test certificate issued by an independent testing laboratory nominated by the Contractor and acceptable to the Engineer. All gauges, load cells, dynamometers and other devices used for measuring the stressing load shall have a reading accuracy of within +2%. Gauges, preferably, shall have a reading dial of not less than 200 mm diameter. Each gauge shall be capable of reading loads directly in pounds / kilogrammes or be accompanied by a chart from which the dial reading can be converted. Pressure gauges shall have a full pressure capacity of approximately twice the working pressure and the loads to be gauged shall not be less than 1/4 more nor more than 3/4 of the total graduated capacity of the gauge unless the calibration data clearly established consistent accuracy over a wider range. Gauges shall be mounted at near working eye level within 3m of the operator so that steady and non-fluttering readings can be obtained without parallax.
iii)
14.6
Tensioning i) ii) iii) Tensioning shall be carried out only in the presence of the Engineer or his representative unless permission has been obtained to the contrary. Immediately before tensioning, the Contractor shall prove that all tendons are free to move between jacking points. Unless otherwise described in the contract, concrete shall not be stressed until it has reached at least the age at which three test cubes taken from it attain the specified transfer strength. The test cubes shall be made and tested in accordance with BS 1881 but shall be cured in similar conditions to the concrete to which they relate. The Contractor shall cast sufficient cubes to demonstrate that the required strength of the concrete at transfer has been reached. The Contractor shall establish the datum point for measuring extension and jack pressure to the satisfaction of the Engineer. The tendons shall be stressed at a gradual and steady rate until they attain the force described in the contract. The force in the tendons shall be obtained from readings on a load cell or pressure gauge and the extension of the tensions measured. The two readings shall conform to the limits set by the Engineer but in any case the force in the tendon as computed from the extension measurement shall be within +5% of the force indicated by the gauging system.
iv) v) vi)
E/39

vii) When stressing from one end only the pull-in at the end remote from the jack shall be accurately measured and the appropriate allowance made in the measured extension at the jacking end. When the force required by the contract, including any overload of short duration, has been applied to the satisfaction of the Engineer, the tendons shall be anchored. The jack pressure shall then be relieved in such a way as to avoid shock to the anchorage or tendons. If the pull-in of tendons at completion of anchoring is greater than that stipulated by the Engineer, tensioning shall be carried out afresh. The engineer may direct that the force in any tendon be tested by re-jacking. The tendon shall then be re-anchored at the proper tension. It if is necessary to crop the tendons to enable the ducts to be grouted, this shall be delayed as long as practicable up to the time of grouting. In all other cases, unless agreed otherwise by the Engineer, the tendons shall not be cropped less than 3 days after grouting. The Contractor shall keep full records of all tensioning operations including the measured extensions, pressure gauge or load cell readings and the amount of pull-in at each anchorage. Copies of these records, on suitable forms, shall be supplied to the Engineer within 24 hours of each tensioning operation.
viii)
ix) x) xi)
xii)
14.7
Grouting i) ii) iii) Grouting shall be undertaken when required by the Engineer. All ducts shall be thoroughly cleaned by means of compressed air and all anchorages shall be sealed before grouting. Ducts shall be grouted as soon as practicable after the tendons in them have been stressed and the Engineer's permission to commence has been obtained. Grout shall be injected in one continuous operation and allowed to flow from the vents until the consistency is equivalent to that being injected. The ducts shall be completely filled with grout. Vents shall be sealed consecutively in the direction of flow and the injection tube sealed under pressure until the grout has set. The filled ducts shall be protected to the satisfaction of the Engineer to ensure that they are not subjected to shock or vibration for one day and that the temperature of the grout in them does not fall below 3qC for 3 days after its injection. Two days after grouting, the level of grout in the injection and vent tubes shall be inspected and made good if necessary. The Contractor shall keep full records of grouting including the date each duct was grouted, the proportions of the grout and any admixtures used, the pressure, details of any interruptions and any topping up required. Copies of these records shall be supplied to the Engineer within 3 days of grouting.
iv) v)
vi)
14.8
Grout Mixer i) The grout mixer shall produce a grout of colloidal consistency. The grout injector shall be capable of continuous operation with a sensibly constant pressure up to 0.7 N/mm and shall include a system of circulating or agitating the grout whilst the actual grouting is not in progress. All baffles to the pump shall be fitted with sieve strainers size BS No. 14.
E/40

ii) The equipment shall be capable of maintaining pressure on completely grouted ducts and shall be fitted with a nozzle which can be locked off without loss of pressure in the duct. The pressure gauges shall be calibrated before they are first used in the works and thereafter as required by the Engineer. All equipment shall be thoroughly washed with clean water at least once every three hours during the grouting operations and at the end of use of each day.
iii)
14.9
Grout Trials i) Unless otherwise directed or agreed as a result of grouting trials, the grout shall: a) b) Consist of only Ordinary Portland Cement and water. Have a water: cement ratio as low as possible consistent with the necessary workability and under no circumstances shall the water: cement ratio exceed 0.45. Not be subject to bleeding in excess of 2% after 3 hours or 4% maximum when measured at 18qC in a covered glass cylinder approximately 100 mm diameter with a height of approximately 100 mm and the water shall be reabsorbed after 24 hours.
c.
ii)
Admixtures containing chlorides or nitrates shall not be used; other admixtures may be used only with the written permission of the Engineer and shall be used strictly in accordance with the manufacturer's instruction. The grout shall be mixed for a minimum of 2 minutes and until a uniform consistency is obtained.
iii)
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Volume II Section F Block Works
Volume II Part 1 : Gen & Particular Specification - Civil Section F : Block Works
F/1 Khasab Hotel Development
SECTION F
BLOCK WORKS
1.0 GENERAL : All concrete blocks shall comply with the requirement of BS 6073 Part 1 & 2. 1.1 1.1.1 Definitions Masonry Block It is the pre-cast concrete masonry unit whether hollow or solid, prepared to use in building the load bearing walls and the non load bearing walls. 1.1.2 Roofs Fillers Block It is the pre-cast concrete masonry unit prepared for use as roofs fillers. 1.1.3 Paving Blocks It is the pre-cast concrete paving unit intended for the construction of roads, industrial and other paved surfaces. 1.1.4 Hollow Blocks It is the masonry unit made out of homogeneous concrete mix and which may include additives or pigments. This block has one or more holes or cavities which exceeds 25% of its volume. 1.1.5 Aerated Blocks It is the steam cured masonry unit which contains homogeneous and equally distributed voids, and which is intended for use in roofs and walls. 1.1.6 Thermoblocks: A polystyrene sandwiched block where the polystyrene is integrally locked symmetrically into concrete structure (incorporated at the wet stage of concrete itself) resulting in an excellent thermal insulation and bonding. BS 6073 I & II. REFERENCES BS 2028 BS 5628 BS 6073 BS 1198 1200 BS 5224 BS 890 BS 1014 Pre cast concrete blocks Code of practice for the structural use of masonry Part 1 & 2 Pre-cast concrete masonry units. Building sands from natural sources Masonry cement Building Limes Pigments for Portland cement and Portland cement products
1.2

BS 1243 BS 405 BS 729 BS 743 BS 4887 BS 4254 BS 3712 1.3 SUBMITTALS Metal ties for cavity wall construction Expanded metal (steel) for general purposes Hot dip galvanized coatings on iron and steel articles Materials for damp proof courses Mortar plasters Two-part Poly-Sulphide based sealants for the Building industry Methods of tests for building sealants
1.3.1. Samples of all types of block to be used shall be submitted to the Engineer for his approval, along with the manufacturers product data and certificates that each type complies with the specified requirements and the local municipal laws and regulations. The approved sample shall be retained on site for use as standard until completion of the contract. 1.3.2. The samples shall be accompanied by the following written information: 1. 2. 3. 4. 5. 6. Name of manufacturer Type of block making machine Capacity of the plant and present stocks available Type of block Means of identification of block Any authoritative evidence that the blocks are suitable for this purpose for which they are to be used.
1.3.3. The Contractor shall provide samples and carry out the specified tests for each of the items at an approved laboratory at his own cost and submit the reports to Engineer for his approval. Testing shall be carried out for each batch received or as directed by the engineer. 1.3.4. The Contractor is not permitted to change his source of supply without the permission of the Engineer. Further samples shall be selected and tested if the supplier is changed. 1.3.5. Sample Panels As directed by the Engineer, before any block work is commenced, the Contractor shall erect one sample panel size 1200mm long X 1000mm high of each type of finish to be used. The panels shall incorporate a typical opening and corner detail together with a movement joint. 2.0 PRECAST CONCRETE MASONARY BLOCKS : The following requirements shall be met for concrete blocks used in construction of masonry walls, both as load bearing & non load bearing : 2.1 Cement i) The cement used in the manufacture of concrete masonry blocks shall comply with the requirements of BS 12 or BS 4027. The cement content of manufactured blocks shall be not less than 200 kg/m3.
ii)

2.2 Aggregate i) ii) Aggregate shall consist of naturally occurring crushed or uncrushed materials which shall fully comply with BS 882. The salt content shall not exceed following limits: Acid soluble Chlorides (Cl) -0.03% by wt. of fine aggregates } when SRPC 0.02% by wt. of coarse aggregates} used. 0.05% by wt. of fine aggregates } when OPC/ 0.04% by wt. of coarse aggregates} MSRC used. Acid soluble Sulphates (SO3) -0.3% by wt. of coarse & fine aggregates. (Local Order No. 44/90) 2.3 Water i) ii) Water shall be clean and free from any organic and deleterious matter having a pH value in the basic range (7-9). Inorganic impurities shall not exceed the following limits : a) b) c) d) 2.4 Additives i) ii) iii) 2.5 i) All pigments shall comply with BS 1014. All admixtures shall comply with BS 5075. Admixtures shall not contain chlorides. They are preferred to be LignoSulphonate based water reducing agents. Dimensions & Tolerances Standard block sizes for walls shall be 40 cms long, 20 cms width and 20 cms height. Load bearing blocks sizes are to have thickness not less than 20 cms. Hollow blocks must have voids between 25 and 50% with a minimum external shell thickness of 35 mm or 1.75 times the nominal maximum size of aggregate, whichever is greater. No overall dimensions (length, width or height) shall differ by 3 mm at any point. ii) Linear Shrinkage When tested for shrinkage as per BS 1881 Part 1, the values obtained must comply with BS 6073 Part 1 & Part 2 and in no case shall it be more than 0.05%. iii) Sampling Ten blocks shall be drawn at random from every designated 10,000 blocks section or part thereof, in a consignment. All samples shall be clearly marked at the time of sampling in such a way that the designated section or part thereof and the consignment represented by the sample, are clearly defined. iv) Strength Strength of Concrete blocks shall be as per Local Order no. 44/90. Concrete blocks when tested according to BS 6073 Part 1 & Part 2, unless specified elsewhere, shall have an average compressive strength of not less than 12 N/mm, with a minimum Volume II Part 1 : Gen & Particular Specification - Civil Section F : Block Works F/4 Khasab Hotel Development Total dissolved ions 2000 mg/litre Chlorides 600 mg/litre Sulphates 500 mg/litre Alkalis, Carbonates and Bicarbonates 1000 mg/litre

individual strength not less than 10 N/mm for load bearing blocks and an average strength not less than 7 N/mm with a minimum individual strength not less than 6 N/mm for non-loading blocks. v) Testing for Strength The sample specimen shall be tested in compression as per BS 6073 Part 1 & Part 2. 3.0 PRECAST CONCRETE FILLER BLOCKS : The following requirements shall be met for blocks used as fillers in the construction of reinforced joint filler block decks and slabs. 3.1 Cement The cement used in the manufacture of these blocks shall comply with the requirements of BS 12 or BS 4027. 3.2 Aggregates The aggregates shall be free from any deleterious and organic matters. When tested individually, they shall conform to the following: i) ii) 3.3 Acid soluble Chlorides (Cl) not exceeding 0.04% by weight of aggregate, Acid soluble Sulphates (SO3) not exceeding 0.3% by weight of aggregate,
Fine Aggregate It shall consist naturally occurring crushed or uncrushed materials which shall fully comply with specifications in BS 882.
3.4
Coarse Aggregate It shall be of light weight type complying with specifications in BS 887 or BS 3797. The bulk density should not exceed 800 kg/m3.
3.5
Water The water shall be clean and free from any deleterious and organic matter, having a pH value in the basic range (7-9). The inorganic impurities shall not exceed the following limits: a) b) c) d) Total dissolved solids 2000 mg/ltr. Chlorides 600 mg/ltr. Sulphates 500 mg/ltr. Alkalis, Carbonates and Bicarbonates 1000 mg/ltr.
3.6
Aerated Block When making air entrained blocks (or aerated blocks), the distribution of air must be equal and the block must be homogeneous. Aerated blocks must be steam cured.

3.7 Density The average density of dry block should not exceed 1400 kg/m3 and variation between the densities shall not exceed by 10% of the average density. 3.8 Dimensions Length Height Width : : : 400 mm Minimum 150 mm to Maximum 400 mm Not more than 800 mm.
The surface of blocks should be clean and plane with a maximum tolerance in length, width and height of not more than 3 mm. 3.9 Sampling Ten blocks shall be drawn at random from every designated 10,000 blocks section or part thereof, in a consignment. All samples shall be clearly marked at the time of sampling in such a way that the designated section or part thereof and the consignment represented by the sample, are clearly defined. 3.10 Testing for Strength The sample specimen shall be tested in compression with both faces under compression reflecting each others exact shape and size. The method of testing shall be as specified in BS 6073 Part 1 & Part 2. 4.0 4.1 GENERAL CONDITIONS : Materials added to the original component materials of the blocks shall be homogeneous therewith and shall not affect the required characteristics of the block specified by specifications. Blocks shall have regular and uniform shape, free of cracks and defects and have rough surfaces to provide key for plaster. 4.2 Each consignment shall be accompanied with the following documents: i) ii) The producer must identify his production by a distinct trade mark grooved on every block, or by other means. A certificate of compliance from Local Municipality proving that this consignment complies with the standard specifications and that the producer has undertaken the necessary arrangements to test this production over regular intervals of time. A certificate or invoice by the producer specifying the following: a. Type and dimensions of the blocks. b. Average compressive strength of this consignment sample.
iii)
4.3
Provisions of Technical Compliance i) The lot shall be considered as complying with the specifications if all compulsory tests stipulated in the specifications detailed herein have been carried out thereon, provided that the broken blocks of the representing sample shall not exceed 10%. Any block chipped at more than two edges shall be considered broken. F/6 Khasab Hotel Development

If the tested samples fail all or one of the tests detailed in the specifications, other samples shall be selected and if these also fail, the lot shall be considered nonconforming with the specifications. The employees authorised by Director of the Local Municipality shall have the capacity of law officers in taking notice of the violations committed against the provisions of Local Order as applicable, its Executive Regulation or the decisions issued in implementation thereof. They shall have the right to access to factories, stores and yards where the produced materials are stored, and shall make necessary records thereof. MORTAR : Mortar Constituents Unless specified elsewhere, Mortar shall consist of cement and sand mixed in the specified proportions as given below. Proportion By Volume Cement 1 1 1 Sand 3 3 4 1.7 2.5 Mean Compressive strength N/mm2 7 Days 28 Days 3 4 ii)
4.4
5.0 5.1
Location Below Ground Load bearing Non Load Bearing i)
ii) 5.2
The Contractor may use a plasticiser with mortar, subject to the approval of the Engineer and provided that it is used strictly in accordance with the manufacturer's printed recommendations. Lime shall comply with BS 890.
Cement and sand for each batch shall be accurately measured by weight wherever possible or otherwise by volume and not by hand shovels. If the materials are to be batched by volume, separate gauge boxes shall be provided for each of the materials used. The sizes of the boxes shall be such that they are used only filled to capacity and struck off level. Due allowance shall be made for the increase in volume of sand when wet.
5.3
The materials shall be mixed dry until evenly distributed and until the mass is uniform in colour. No caked or lumpy materials shall be used. The machine mortar mixing time shall not be less than 5 minutes, approximately 2 minutes of which shall be used for mixing the dry materials and not less than 3 minutes for mixing with water. Hand mixing will only be permitted if approved by the Engineer.
5.4
Mortar which has begun to set or which has been mixed for more than 30 minutes shall be discarded. Re-tempering by addition of water will not be permitted. ANCILLARY ITEMS : Damp Proof Courses Damp proof course to block walls shall, unless otherwise specified elsewhere, consist of one layer of quality bitumenised fibre felt damp proof course complying with BS 6398: 1983 and
6.0 6.1

weighing not less than 3.3 kg. per square metre. A mortar bed shall be placed above & below the D.P.C Unless noted otherwise else where in the contract, D.P.C shall be provided to all external block work walls and all wet area block wall. 6.2 Wall Ties i) ii) Wall ties shall be stainless steel or equivalent as approved by the Engineer. Cavity wall ties shall be of vertical twist type, constructed from stainless steel strip complying in all respects with BS 1243 (double triangle table 2, wire diameter 4.5 mm, or flat double fish-tail type of minimum 2 mm thick). The ties are to be spaced not more than 800 mm apart horizontally and 400 mm vertically and staggered with extra ties at reveals and opening as required by BS 5628 : Part 3 : 1985. Ties from block work to structure shall be reinforced at maximum 600 mm centres by means of stainless steel ties (minimum 1.5mm thick) shot fired to the column and built into and fully embedded in the mortar joints of the block walls or partitions. Special metal ties or anchors shall be as detailed on the drawings.
iii)
iv) 6.3
Movement Joint Filler Movement joint filler shall be 10mm thick (unless specified otherwise) cellular non-absorbent low density joint filler sealed on both sides with an approved polysulphide sealant complying with BS 4254.
6.4
Special Blocks i) ii) Special blocks for forming feature panels etc. shall be to details shown on the drawings and to the approval of the Engineer. Claustra perforated blocks shall be constructed generally as for pre-cast concrete blocks but perforated as indicated in the drawings. They shall be formed in purpose made moulds to give faces finished fair to receive a paint finish without plastering.
6.5
Reinforcement Unless specified elsewhere, in General a) Reinforcement of expanded metal type from a manufacturer approved by the Engineer shall be provided in two consecutive courses above and below windows and above doors. This reinforcement shall be provided with a minimum cover of 20 mm from the face of the mortar and shall extend at least 600 mm past the opening. Additional reinforcement shall be provided every second course of all external walls if specified else where in the contract. b) All load bearing wall should be provided with Expanded stainless steel mesh joint reinforcement embedded in the horizontal mortar joints not closer than 20 mm from the external face of the wall and, except at movement joints, shall be continuous and lapped at least 75 mm at all passings. Full lap joints shall be provided at angles. c) Expanded steel mesh horizontal reinforcement shall be provided every second course and at all openings for doors, windows, etc, or as shown in drawings. d) G.I wall ties or holdfast shall be fixed using gun applied rivets to RCC structural column at the every 2nd layer of block wall. The total area of block wall in between RCC columns & beams shall not be more than 14 m2 .In cases it is more, a stiffener column or an intermediate stiffener beam shall be provided. In case of free standing block walls such as parapets, a coping beam of depth 10cm x width of wall shall be provided with nominal reinforcement.

Vertical bar reinforcement for load bearing walls shall be properly positioned and secured against displacement. The cavities containing the reinforcement shall be completely and solidly filled with grade 30 concrete, and with the whole surface of the reinforcement in contact with the mortar or concrete. The reinforcement steel shall be 12 mm. e) Expanded steel mesh joint reinforcement shall comply with BS 2989. f) Bar reinforcement shall comply with the requirements of the concrete specification. 6.6 Cavity Wall Insulation i) ii) Cavity wall insulation shall be preformed rigid boards of closed cell extruded polystyrene to BS 3837. Insulation board fixings shall be approved purpose made proprietary stainless steel wall ties complete with polypropylene retaining clips.
6.7
Joints between Partitions & Floor Soffits & Beams Non-load bearing internal walls and partitions shall initially be built up to leave a 20 mm joint between the top of the wall or partition and the soffit of the slab / beam. After the walling has thoroughly dried out and after the expected deflection in the slab due to dead load has taken place, the joint shall be filled solid with a class 3 mortar. Where concrete slabs are supported on block works, a layer of polythene sheet shall be provided between the top of the wall and the slab or the full width of the wall. Where non-load bearing internal walls and partitions are to be constructed up to beam soffits then unless specified elsewhere, the following procedure shall apply: i. Fix 12mm thick bitumen impregnated fiber board to the beam soffit directly above the line of the partition. The board width shall be the width of the block work partition less 20mm. Fix stainless steel ties as specified to the soffit of the beam at centres or as directed, corresponding with the block work joints of the final course. Construct block work partition within 10 mm of the under side of the compressible board. Fill 10 mm joint solid with mortar and joint/point as necessary. Apply 2 part PolySulphide mastic/silicone sealant to suitably primed joint surfaces and finish faces accordingly.
ii. iii. iv. v.
Where partitions with a specifically required fire resistance are to be constructed to the soffit of beams, then the procedure outlined in the preceding paragraph shall apply except part (iv) shall be non-combustible mineral wool or similar filler and part (v) shall be an approved proprietary intumescent mastic specifically for use in fire barriers. 7.0 7.1 WORKMANSHIP : Construction i) Block work shall be constructed in accordance with BS 5628 and laid in a workmanlike manner with true and regular horizontal courses and staggered vertical joints with walls and partitions bonded to one another at junctions and angles. All joints shall be of consistent thickness (average 10mm); all horizontal joints shall be properly level and vertical joints shall be properly lined and quoins, jambs and other F/9 Khasab Hotel Development
ii)

iii) iv) v) angles plumbed as the work proceeds. Not more than five courses of blocks shall be laid in any one day within any section of walling. Cut blocks shall only be used where required for bonding purpose ensuring interlocking or to facilitate building in of other components but shall not be used as a lintel bearing. In hollow blocks where required by the Engineer, hollows shall be only filled with concrete Grade 25 at the ends of walls and jambs, to openings below lintels, beams and slabs which bear on the wall. Filling with mortar or material other than that specified will not be accepted. Walls shall be carried up regularly without leaving any part more than 4 courses lower than adjacent sections unless the permission of the Engineer is first obtained and work left at different levels shall be evenly stepped back. In cavity wall construction one skin shall not be taken more than 3 courses above the adjacent skin. Blocks shall be soaked with water for 24 hours before being used and the tops of walls left off shall be well wetted immediately prior to recommencement of work. The faces of walls shall be kept clean and free from mortar droppings and splashes. Block work abutting concrete columns shall be tied with specified stainless steel cramps shot fired to the concrete and built in every second course of block work. (Note : - Stainless Steel butterfly ties (heavy duty) to be used for insulated blocks as per manufacturers recommendation)
vi)
vii) viii) ix) x)
7.2
Movement Joints i) The movement joints shall be 12 mm wide and shall be formed where indicated or where continuous runs of block walling exceeds 6 meters in length or 20 m2 in panel area, whichever is lesser. The movement joints material and thickness shall be as specified and allowance shall be made for leaving temporarily open courses immediately under all horizontal structural members and they shall be made good and pointed up at the structural members have been fully loaded and before the completion of that section of the works. The movement joints material shall be laid to the width appropriate to the walling with clean, even butt joints and the joint shall be kept clean of any material which may be detrimental to the operation of the joint. Movement joints shall be sealed on both faces with an approved sealant.
ii)
iii)
iii) 7.3
Cavity Walls i) In cavity wall construction the cavity shall be maintained at the width shown on the drawings or as specified and shall be kept clean by efficient means throughout the construction of the walls and any accidental mortar droppings shall be prevented from adhering to cavity faces of walls, wall ties, cavity trays or insulation. Unless specified elsewhere, wall ties shall be bedded minimum 50 mm in to each skin of walling and spaced 600 mm vertically and 900 mm horizontally with additional ties within 200 mm of sides of openings at 400 mm vertical centres. All ties shall be of stainless steel approved by the Engineer. Cavity wall insulation shall be installed in accordance with BS 6676 Part 2 (as appropriate) and in accordance with the manufacturer's printed instructions. Insulation boards shall not, under any circumstances, be pushed into a cavity but shall F/10 Khasab Hotel Development
ii)
iii) iv)

v) be fixed tightly against the insulating skin of walling which shall be clean, using approved fixings. Insulation boards shall be tongue and groove jointed with staggered vertical joints and shall be evenly and clearly cut where required. Spacing of wall ties with retaining clips shall suit sizes of insulation boards so as to retain all edges but not be less than the requirements of clause 6.2.
vi)
7.4
Damp Proof Courses i) Approved damp proof courses shall be laid on and bedded in mortar in continuous lengths as far as is practicable and in accordance with the requirements of BS 6398: 1983. Joints shall be lapped 200 mm in straight runs and for the full width at junctions and angles with the meeting surfaces sealed with bituminous waterproofing compound.
ii) 7.5
Joints i) Walls which are to be rendered shall have the joints cleanly raked out to a depth of 15mm to form a key which shall be approved by the Engineer before rendering commences. ii) Where the block work is described as 'with flush joints formed as the work proceeds' the joints shall be 'bagged' or similarly flushed up to ensure that the mortar surface is finished flush between blocks. EXTERNAL INSULATED BLOCK WORKS Where specified in the contract drawings, Contractor should use thermally insulated blocks for all external walls. Contractor should provide his proposal for insulated blocks along with samples and technical literature for approval of the engineer, prior to use in the works. Contractor should also provide a step by step procedure for the construction of Insulated block work along with samples of accessories for approval. Insulated blocks for external wall should meet the requirements of Local Authority. The block wall on completion including internal and external finishes shall be capable of providing the specified insulation values as stipulated by Local Authorities. The Contractor shall be responsible for fulfilling the Local Authority requirements on the completed walls as any rejections shall be corrected by Contractor with out any additional time and cost. The insulation material used in the insulated block shall comply to the following. BS 6073 I & II Average Polystyrene density - > 26 kg/M3 U Value 0.36 W/m2K Average Compressive strength 7.5 N/mm2
8.0

9.0 TOLERANCES i) ii) iii) Permissible tolerances shall be within the limits shown in the Table below. Permissible deviations shown are the maximum that will be accepted and any work not in compliance shall, upon instruction from the Engineer shall be rebuilt. The Contractor shall, should the nature of subsequent finishes or fittings require, adopt closer tolerances. TABLE OF PERMISSIBLE TOLERANCES Item of Construction Space between Size and shape of wall elements Type of Dimension Horizontal at any level (wall to wall) Height up to 3000 mm Straightness in 5000 mm Vertically up to 2000 mm Level of bed joints in 3000 mm Position in plan of any point or specified face in relation to nearest grid line on the same level Position in elevation from design position. Level of sill or soffit. For each 1000 mm of width with maximum of verticality. Of any point for each 1000 mm of height with maximum of. Permissible Deviation (mm) 15 15 5 10 15 15 15 5 5 5
Walls Door, window & other openings
Volume II Section G G1 Water Proofing & Roof Insulation.
Volume II Part 1 : Gen & Particular Specification - Civil Section G : Water Proofing & Roof Insulation
G1/1

Specifications Concrete

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Omran Tourism Development Company S.A.O.

Volume II Section E Concrete Works

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ii) iii) iii)

Sulphate Resisting Portland Cement (SRPC)

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C 128 / C 127 C 128 / C 127 Part 106

max 0.03% max 0.03%

max 0.01% max 0.01%

max 0.03% max 0.03% max 0.01%

max 0.02% max 0.02% max 0.01%

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Acid soluble sulphates, SO3 - BS 812 Part 118

13. 14. 15.

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Lot 2 lot as reqd Lot 3

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BS 18 BS 4449 BS 4482 BS 4483

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Khasab Hotel Development

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Khasab Hotel Development

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Khasab Hotel Development

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Max Size Agg. mm

Characteristic Cube Strength CCS 7-day 28 day N/mm

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_________________________________________________________________________ Degree of workability Slump mm Compacting factor Slump mm Compacting factor

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SPECIFICATION FOR WATERPROOF CONCRETE : (Refer to particulars specification)

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