Professional Documents
Culture Documents
00 STRUCTURAL CONCRETE
4.100.00 STRUCTURAL CONCRETE GENERAL
4.101.00 Scope
.01 This section gives requirements for all structural concrete in the works, except
where otherwise modified or amended within the Contract.
4.102.00 Building Regulations
.01 Where structural concrete is to be used in any works the concrete shall comply
with the local statutory requirements, except where more stringent requirements
are specified herein.
4.103.00 Authoritative Standards and Codes of Practice
.01 The following authoritative documents are referred to hereinafter:
.02 British Standard Specifications as published by the British Standards Institution,
2 Park St., London W. 1., England (abbreviated in the text to BS).
BS Date Title
12 1996 Specification for Portland cements.
4.100.0 STRUCTURAL CONCRETE GENERAL
BS Date Title
.03 American Society for Testing and Materials Standards as published by the
American Society for Testing and Materials, 1916 Race St., Philadelphia Pa.
19103, U.S.A. (abbreviated in text to ASTM).
ASTM Title
C88 Test for Soundness of Aggregates by use of Sodium Sulphate or
Magnesium Sulphate.
C234 Comparing Concretes on the Basis of the Bond developed with
Reinforcing Steel.
C289 Test for Potential Reactivity of Aggregates
(Chemical Method.)
4.101.0 STRUCTURAL CONCRETE GENERAL
.04 If the Contractor wishes to substitute any other authoritative standard or code of
practice for any listed above he shall submit details of any such together with two
complete copies to the Engineer for approval. Approval for such substitution
shall be at the discretion of the Engineer and will not be given unless the
Engineer considers the proposed standard or code of practice will give a quality
of finished work equal to or better than the specified standard.
.05 All insitu concrete shall be in accordance with BS 8110 except where shown or
specified otherwise.
4.104.00 Bending Schedules
.01 The Engineer will not prepare bar bending schedules. Where these are required
the Contractor shall prepare these generally in accordance with BS 4466. The
Contractor should check these against the drawings before any cutting, bending
or construction involving the schedules is started. Any discrepancy should be
reported immediately to the Engineer for his clarification. The Engineer will not
check bending schedules. The Contractor shall be responsible for any delays or
additional work caused solely by his failure to check the schedules.
4. 105.00 Approvals
.01 Well before construction commences the Contractor shall supply to the Engineer
for his approval details of his proposed layouts of concreting plant and on site
workshop, details of formwork systems and the construction devices. e.g. cranes,
chutes, pumps, scaffolding, etc. which he proposes to use for structural concrete.
The information is to be sufficiently detailed to enable the Engineer to approve or
otherwise.
.02 The Contractor should note that further approvals are required by the
specification before construction starts. The Contractor is wholly responsible for
obtaining these approvals and no claim for delays or additional payments will be
entertained due to the Contractor's failure to obtain such approvals in adequate
time.
4.200.00 STRUCTURAL CONCRETE MATERIALS
4.201.00 Cement
.01 Ordinary Portland cement and rapidhardening Portland cement shall comply
with the requirements of BS 12.
.02 Portland blastfurnace cement shall comply with the requirements of BS 146.
.03 Sulphate resisting Portland cement shall comply with the requirements of BS
4027.
.04 High alumina cement shall comply with the requirements of BS 915.
4.200.00 STRUCTURAL CONCRETE MATERIALS
.05 Low heat cements shall comply with the requirements of either BS 1370 or BS
4246.
.06 Supersulphated cement shall comply with the requirements of BS 4248.
.07 Cement, unless otherwise specified, shall be ordinary Portland cement complying
with BS 12.
.08 White or coloured Portland cement shall comply with the physical requirements
of BS 12 and pigments shall be inorganic oxide pigments, either natural or
synthetic in origin complying with the requirements of BS 1014. Pigments
whether added just before mixing or by the cement manufacturer shall be
incorporated in the proportions approved.
.09 The Contractor shall obtain a manufacturer's certificate of test in accordance with
the appropriate standard for each consignment of cement delivered to the Site and
shall immediately forward these certificates to the Engineer for his retention
.10 Notwithstanding the manufacturer's certificate the Engineer may require that any
cement delivered to the Site, or elsewhere for use in the Works, shall be sampled
and tested to BS 4550. Any batch of cement so tested which fails to comply with
this specification will be rejected.
.11 All cement shall be delivered to the Site or elsewhere for use in the Works in the
original sealed bags of the manufacturer or in approved bulk containers.
.12 Cement, unless delivered in bulk, shall be stored in a weatherproof shed, the floor
of which shall be raised at least 150 mm above the ground to allow free air
circulation. Cement delivered in bulk shall be stored in a weatherproof silo. All
cement shall at all times be protected from deterioration.
.13 Each consignment of cement shall be clearly identified, stored separately, and
used in order of delivery. Different types of cement shall not be used in
combination.
.14 Any cement which, upon inspection, is considered by the Engineer to have
deteriorated in any way will be rejected.
4.202.00 Aggregates for Concrete
.01 Aggregates for concrete shall, unless otherwise specified, be aggregates from
natural sources complying with BS 882. Additionally, the flakiness index when
determined by the sieve method described in BS 812 shall not exceed 35 for any
size of concrete aggregate.
.02 When tested for sulphate soundness in accordance with ASTM C88 the loss of
weight after 5 cycles shall not exceed 5 per cent for any aggregate.
4.200.00 STRUCTURAL CONCRETE MATERIALS
.03 Aggregate which is potentially reactive when tested in accordance with ASTM
C289 for the alkali aggregate reaction shall not be used. The standard for
acceptance being that test results shall plot to be left of the solid line which is
shown in Figure 2 of the test standard.
.04 The chloride ion content of the fine and coarse aggregate shall not exceed 0.06%
and 0.02% respectively by mass of dry aggregate. If either aggregate exceeds
these limits the material may still be considered acceptable by the Engineer
provided that the total chloride ion concentration derived from the aggregates is
not greater than 0.35% by mass of the cement in the mix.
.05 Well before the commencement of any concreting work, the Contractor shall
forward to the Engineer for approval details of his proposed source of supply of
aggregates giving the aggregate group classification and typical physical
properties as required by BS 882.
.06 The Contractor shall provide the Engineer with a certificate for his retention, at
such regular intervals as the Engineer may direct, showing that all aggregates
have been retested since the date of the last such certificate and showing that
they continue to comply with the requirements of this specification.
.07 The Engineer may require that any aggregate be tested for sulphate soundness in
accordance with ASTM C88 before giving approval to any proposed source of
supply.
.08 The Engineer may require that any aggregate be tested for potential alkali
reactivity in accordance with ASTM C289.
.09 Notwithstanding any certificate of compliance, the Engineer may at any time
require that any aggregate delivered to the Site, or elsewhere for use in the
Works, be sampled and tested. Any aggregate so tested which fails to comply
with this specification will be rejected.
.10 Coarse aggregate shall be delivered ready screened or screened on site into
separate nominal single sizes within the limits given in BS 882.
.11 Aggregates of different sizes or type shall be stored in different hoppers, different
stockpiles or approved well drained paved areas which shall be separated from
each other. Stockpiles shall be protected against contamination from any source.
.12 Any aggregate, which in the opinion of the Engineer, has become contaminated
or does not conform to the above requirements may be rejected by the Engineer.
4.203.00 Water for use with Cement
.01 Water for use in mixing with cement or for curing concrete shall be from and
approved source, clean, fresh and free from organic and other deleterious matter.
4.200.00 STRUCTURAL CONCRETE MATERIALS
.02 The Engineer may require that any water be sampled and tested by the method
given in BS 3148. Water failing the criteria given in the appendix to BS 3148
will be rejected.
.03 Water for use in mixing with cement shall not be hotter than 25°C. Water for use
in mixing with cement shall not normally be colder than 5°C at the time of
mixing except that where cooling of the concrete is required chilled water or
flake ice may be used with the consent of the Engineer.
4.204.00 Admixtures
.01 No admixtures or cements containing additives shall be used in concrete unless
specified or approved by the Engineer. Such approval will not be given unless in
the Engineer's opinion specific benefit to the density or quality of the concrete
will result.
.02 Where the use of admixtures is specified or approved they shall comply with the
requirements of BS 5075.
4.205.00 Steel Bar Reinforcement
.01 Steel bar reinforcement shall consist of the following as described in the
Drawings:
a) Mild steel bars complying with BS 4449.
(b) Hot rolled high yield bars complying with BS 4449.
.02 The Contractor shall obtain certified evidence of the origin and a manufacturer's
certificate of test in accordance with the appropriate standard for each steel batch
relating to reinforcement delivered to Site and shall immediately forward these
certificates to the Engineer for his retention.
.03 Notwithstanding the manufacturer's certificate, each batch of reinforcement
delivered to the Site shall be sampled and tested. Sampling shall be at the rate of
10 specimens from each batch for testing for mass and tensile properties. Where
recent acceptable test results for a particular size and manufacturer are available,
abbreviated sampling at the rate of 3 specimens from each batch may be
permitted. Any reinforcement so sampled and tested which fails to comply with
this specification will be rejected.
.04 All reinforcement shall be delivered to the Site either as straight bars or ready cut
and bent to shape.
.05 All reinforcement shall be stored at least 150mm clear of the ground or floor, in
clean conditions and in an orderly manner to the satisfaction of the Engineer.
Such that the batch to which each piece belongs can be readily identified.
4.200.00 STRUCTURAL CONCRETE MATERIALS
4.206.00 Steel Fabric Reinforcement
.01 Steel fabric reinforcement shall be electrically crosswelded steel mesh
reinforcement complying with BS 4483.
.02 The Contractor shall obtain certified evidence of the origin and a manufacturer's
certificate of test in accordance with the appropriate standard for each steel batch
relating to fabric delivered to Site and shall immediately forward these
certificates to the Engineer for his retention.
.03 Notwithstanding the manufacturer's certificate, each batch of fabric delivered to
the Site shall be sampled and tested. Any fabric so sampled and tested which fails
to comply with this specification will be rejected.
4.207.00 Mechanical Splices for Reinforcement
.01 Compression splices for reinforcement, where approved by the Engineer, shall be
CCL Omega couplers by CCL Systems Far East Ltd. or similar approved.
.02 Tension splices for reinforcement, where required, shall be CCL Alpha screwed
couplers by CCL Systems Far East Ltd. or similar approved.
.03 All splices or couplers shall be used strictly in accordance with the
manufacturer's written instructions.
4.208.00 Tying Wire
.01 Tying wire for fixing reinforcement shall be either No. 16 gauge soft annealed
iron wire, or No.18 gauge stainless steel wire, as directed by the Engineer.
4.209.00 Spacers
.01 Spacer blocks for ensuring that the reinforcement is correctly positioned shall be
as small as possible consistent with their purpose, of type and shape acceptable to
the Engineer, and designed so that they will not overturn when the concrete is
placed. They shall either be an acceptable proprietary brand of spacer, or they
shall be made of concrete with 10mm maximum aggregate size and mix
proportions to produce the same strength as the adjacent concrete. Concrete
spacers shall have No. 18 gauge stainless steel wire cast in the block for the
purpose of tying the spacer to the reinforcement.
.02 Spacer blocks of concrete shall not be used until at least 7 days old.
4.210.00 Slip Layers
.01 Slip layers, where required, shall comprise two layers Slipstrip by W.R. Grace or
similar approved. Such slip layers shall be applied strictly in accordance with the
manufacturers instructions.
4.200.00 STRUCTURAL CONCRETE MATERIALS
4.211.00 Curing Compounds
.01 Curing compounds shall, when applied become stable and impervious to
evaporation of water from the concrete surface within 60 minutes after
application. They shall have a minimum curing efficiency of 75 per cent. The
curing compound shall not react chemically with the concrete to be cured and
shall not crack, peel or disintegrate within three weeks after application.
.02 Curing compounds shall be applied strictly in accordance with the manufacturer's
instructions.
.03 Aluminised curing compound shall contain sufficient flake aluminium in finely
divided dispersion to produce a complete coverage of the sprayed surface with a
metallic finish.
.04 Resinous curing compound shall be an approved proprietary, tinted concrete
curing liquid composition.
.05 Curing compounds shall not be used where they may affect the adhesion of
subsequent concrete, mortar or other coatings.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
4.301.00 Reinforcement
.01 Reinforcement shall be bent accurately in accordance with BS 4466 to the shapes
and dimensions shown on the Drawings or in the schedules where applicable. All
reinforcement shall be bent at temperatures in the range of 5°C and 100°C. Bars
shall be bent by the application of slow steady pressure.
.02 High yield bars shall not be straightened or bent again once having been bent.
When it is necessary to bend mild steel reinforcement already cast in the concrete
the internal radius of such bends shall be not less than twice the diameter of the
bar.
.03 No welding of reinforcement shall be carried out without the approval of the
Engineer.
.04 All reinforcement shall at the time of concreting be free from mud, oil, mortar
droppings, loose rust, paint, grease, mill scale or other deleterious matter.
Reinforcement still 'blue' from the mill shall nor be used.
.05 All reinforcement shall be fixed in the position shown on the Drawings by the
adequate use of spacers, tying wire, chairs, stools. etc. and shall be so maintained
during the concreting operation
.06 Long vertical bars in walls and columns shall be adequately supported at a high
level to ensure correct placement of the bars in lower lifts of concrete.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.07 Where not specifically detailed in the Drawings, the laps of reinforcement shall
be staggered so that laps do not occur in a band. Care shall be taken to comply
with this requirement when using sliding on formwork.
.08 Laps in reinforcement shall be where indicated on the Drawings or approved by
the Engineer. Unless otherwise indicated the minimum lap length for steel bar
reinforcement shall be 45 diameters and for mesh reinforcement 2 complete
meshes.
.09 A steelfixer shall be in attendance at all times when concreting is in progress to
correct any errors, omissions or movement in the reinforcement.
.10 In severe heat conditions reinforcement shall be shaded from direct sunlight and
hosed down with clean water prior to concreting to keep the reinforcement below
25°C.
4.302.00 Formwork
.01 Formwork shall include all temporary or permanent forms required for forming
the concrete, together with all temporary construction required for their support.
.02 All formwork shall be so constructed that there shall be no loss of material from
the concrete. After the concrete has hardened and the formwork has been
removed, the concrete shall be in the position and of the shape, dimensions, and
surface finish described in this specification or on the Drawings.
.03 In general, and unless otherwise shown or specified in the Contract, all formwork
for beams and slabs shall be set with an upward camber at midspan of 3 mm per
1.0 m of span for all spans in excess of 3.0 m.
.04 All joints in the formwork shall be either horizontal or vertical, end formwork
being square across the mass of concrete. The design of the formwork shall be
such as will permit of its being struck and moved without injury to the concrete.
.05 All formwork shall unless otherwise directed, be provided with 20 mm x 20 mm
angle fillets so as to form splays on internal and external angles. The forming of
these fillets will be deemed to be covered by the rates for formwork.
.06 The Contractor shall use grout checks at all horizontal construction joints and
shall adopt such other approved expedients, e.g. foam rubber sealing strips,
polyester crack filler in joints, or taping of joints, as may be necessary to obtain
satisfactory results at joints in formwork.
.07 Where internal metal ties are permitted they or their removable parts shall be
extracted without damage to the concrete and the remaining holes shall be
carefully filled with mortar. No permanently embedded metal part shall have less
cover than that indicated for adjacent steel reinforcement.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.08 When holes are to be provided in formwork for pipes, weep holes and the like
they shall be neatly trimmed to fit the pipe and caulked with an approved
material to form a grouttight joint.
.09 When concrete is to be deposited to a slope steeper than 15° from the horizontal
top forms shall be used to enable the concrete to be properly compacted.
.10 The Engineer may require details and/or calculations of any proposed formwork
to be submitted for approval prior to work starting. Such approval if given shall
not in any way relieve the Contractor of his responsibilities for the safety or
adequacy of such formwork for its purposes.
.11 The inside surfaces of forms, except for permanent formwork, or unless
otherwise agreed by the Engineer, shall be coated with an approved material to
prevent adhesion of the concrete. Such approved material shall be applied strictly
in accordance with the manufacturer's instructions and shall not come into
contact with reinforcement or other castin items.
.12 Immediately before concreting all forms shall be thoroughly cleaned out. In the
case of deep sections an opening shall be left at the base to enable such cleansing
to be adequately completed.
.13 In the case of beams, slabs or like members the formwork shall be so arranged
that the sides or edges may be removed without disturbance to the soffit or
propping system.
.14 No concreting shall be commenced until the Engineer has had an opportunity to
inspect the formwork and any enclosed reinforcement and given his approval to
concreting.
.15 The erection, easing and striking of the formwork shall be done under the
personal supervision of a competent foreman.
.16 Formwork shall be struck at such a time and in such a manner as to cause no
damage to the structure.
.17 The Contractor shall inform the Engineer before he intends to remove any
formwork. The time at which the formwork is removed shall be the Contractor's
responsibility but the minimum periods between the completion of any
concreting and the removal of forms shall be as follows:
Vertical Formwork 24 hours
Soffits to slabs 14 days
Soffits to beams 21 days
Cantilevers 28 days
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.18 The periods given above are based on the removal of all props and formwork
using ordinary Portland cement under average weather conditions. Adverse
weather conditions or different cement may cause the above periods to be
increased. Should the Contractor wish to reduce these striking times, he must
satisfy the Engineer that the strength of the concrete at such time and the
structural system is adequate to withstand the dead and imposed loads applied to
it. Before reducing the striking times the Engineer's agreement shall be obtained
in writing.
.20 When, in the opinion of the Engineer, the striking of formwork would be
detrimental to or may prejudice the safety of the structure, the formwork shall be
left in.
4.303.00 Formed Finishes for Concrete
.01 Where sawn formwork finish is specified or class F1 is shown or in all cases
where no alternative finish is specified, the surface of the concrete shall be not
worse than that obtained by the use of properly designed moulds of close jointed
sawn boards. Small surface blemishes caused by entrapped air will be permitted
but the surface should be free of voids, honeycombing or other defects.
.02 Where "fair faced" finish is specified or class F2 is shown, the irregularities of
the finish shall be no greater than those obtained from the use of wrought
thickness square edged boards arranged in a uniform pattern. The concrete
surface shall be smooth, even; free from fins, lippings, board marks or other
irregularities, and with sharp true arises. Only very minor blemishes or voids
shall occur and there shall be no staining and no discolouration. The finish is
intended to be left as struck and the only treatment generally permitted is light
manual abrasion with a carborundum stone to remove minor marks. Patching of
any description will not normally be permitted.
.03 Where class F3 is shown, the formwork shall be lined with a material approved
by the Engineer to provide a smooth finish of uniform texture and appearance.
This material shall leave no stain on the concrete and shall be so jointed and
fixed to its backing that it imparts no blemishes. It shall be of the same type and
obtained from only one source throughout any one structure. The contractor shall
make good any imperfections in the resulting finish as required by the Engineer.
Internal ties and embedded metal parts will be allowed only with the Engineer's
specific approval.
.04 Where special finishes are required they will be described elsewhere in the
Contract.
4.300.0 STRUCTURAL CONCRETE – WORKMANSHIP
.05 Where a "fair faced' finish, class F2, class F3 or other finish apart from "sawn
formwork" finish or class F1 is specified the Contractor shall provide a sample
panel at least 2.4m x 1.2m in vertical surface area including a typical horizontal
and vertical joint in the shuttering in order to demonstrate the construction
techniques that the Contractor proposes for the actual works. The sample when
approved will form the standard for the entire Works and shall remain on the Site
until completion of the Works. All unsuccessful samples shall be removed from
the Site.
.06 Should any concrete in the Works, in the opinion of the Engineer, fail to match
the standard sample in surface finish then the Engineer may for this sole reason
order the removal of all such substandard concrete which shall be replaced with
acceptable concrete all at the Contractor's expense.
4.304.00 Construction Joints
.02 Vertical construction joints shall be properly made to form a vertical grout tight
joint. Where reinforcement passes through the face of the joint the stopping off
board shall be drilled so that the bars pass through, or the board shall be made in
sections with half round indentations in the joint faces for each bar.
.03 Concrete when being deposited shall not be allowed to "tail off". Construction
joints formed with expanded metal or similar will only be permitted for
reinforced concrete work where approved.
.04 At all construction joints, both horizontal and vertical, the surface of the
previously placed concrete shall be suitably treated to remove laitance and to
expose the coarse aggregate thus forming an irregular surface key for adjacent
concrete. This work shall be carried out to the satisfaction of the Engineer by the
following or other approved methods:
(a) After the initial set has taken place but before final set the coarse
aggregate shall be exposed by the use of water jet and stiff
brushing.
(b) After final set has taken place the laitance shall be removed and
coarse aggregate shall be exposed by bush hammering taking
care not to loosen the aggregate in the face of the concrete
matrix.
In either case the surface shall thoroughly washed and cleaned after roughening.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.05 At least 72 hours shall be left between completion of concreting one bay and the
start of concreting any adjacent bay.
.06 Panels of walls and slabs shall be cast in such a sequence as to minimise and
control the effect of shrinkage at construction joints.
4.305.00 Concrete Mixes General
.01 Reference will be made to concrete mixes as prescribed mix concrete (P), or
design mix concrete (D).
.02 The particular mix to be used will be as described in the Contract or on the
Drawings.
.03 Mass concrete shall normally be prescribed mix concrete 15P/20 unless
otherwise specified.
.04 Blinding concrete shall normally be prescribed mix concrete 10P/20 unless
otherwise specified.
4.306.00 Concrete Mixes Prescribed Mix Concrete
.01 Where prescribed mix concrete is required to be used the Contractor shall
combine ordinary Portland cement, aggregate and water in the proportions given
in Table 4.1, batched by weight, to produce a concrete of the specified grade
strength with high density combined with adequate workability for the purpose
intended.
.02 The workability and the water/cement ratio of the concrete shall be the minimum
consistent with producing a dense, wellcompacted mass. Due regard shall be
paid to the size and shape of the section together with any congestion of
reinforcement.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
Weight of aggregate per bag
of cement (kg)
Specified grade strength Material
45 kg bag of 50 kg bag
cement of cement
Fine aggregate 145 160
10P
20mm coarse aggregate 185 205
Fine aggregate 120 130
15P
20mm coarse aggregate 165 180
Fine aggregate 95 105
20P
20mm coarse aggregate 145 160
Table 4.1 Prescribed Mix Concrete
4.307.00 Concrete Mixes Design Mixes
.01 Mixes for each grade of Design Mix concrete specified or shown on the
Drawings shall be designed by the Contractor to achieve the specified grade
strength combined with high density and adequate workability for the purpose. In
order to allow for unavoidable variation, the design strength shall exceed the
specified grade strength by twice the expected standard deviation. In the absence
of previous information a standard deviation of 7 MPa shall be assumed.
.02 Details of any proposed mix design shall be forwarded to the Engineer not less
than 60 days before that grade of concrete is required to be used on the Works for
his approval in principle. The details shall include at least the following
information:
(a) Source, nature and grading of coarse and fine aggregates.
(b) Source of cement.
(c) Nominal maximum size of aggregate.
(d) Cement content.
(e) Aggregate/cement ratio.
(f) Water/cement ratio.
(g) Design density.
(h) Design slump or compacting factor.
(i) Design strength.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.03 Grades of design mix concrete will be referred to by the specified grade strength
and by the maximum size of aggregate. Grades of concrete shall meet the criteria
shown in Table 4.2. The maximum water/cement ratio is herein defined as the
ratio of the weight of the "free" water to the weight of the cement. The "free"
water is that quantity of water available to combine with the cement. Any water
required to be absorbed by aggregate is excluded .
.04 The workability of the concrete shall be the minimum consistent with producing
a dense, well compacted mass. Due regard shall be paid to the size and shape of
the section together with any congestion of reinforcement.
.05 After the Engineer has approved a Design Mix in principle, the Contractor shall
prepare a trial mix on Site using the plant and materials intended for the Works.
Each batch of concrete shall be sampled and the following prepared, in
accordance with BS 1881:
(a) nine 150mm cubes three for test at 7 days, three for test at 14
days and three for test at 28 days;
(b) three slump tests (for design slump greater than 25 mm); or three
compacting factor tests (for design slump less than 25 mm).
06 No structural design mix concrete shall be placed in the Works until the Engineer
has approved the preliminary tests. Thereafter the approved mix proportions shall
be used throughout the Works and may only be varied with the prior approval of
the Engineer.
4.308.00 Ready Mixed Concrete
.01 Readymixed concrete shall be used only with the approval of the Engineer.
When such approval is given the concrete shall be supplied in accordance with
BS 5328 except where this conflicts with this specification when this
specification shall prevail.
.02 The use of ready mixed concrete shall not relieve the Contractor of any of his
obligations and the appropriate clauses of this specification shall apply equally to
the ready mixed concrete.
.03 Concrete test cubes and slump tests shall be taken on the Site at the point and
time of discharge in accordance with the specification irrespective of any cubes
that the supplier may take at his own works.
.04 When readymixed concrete is used, there shall be one supplier only and the
supplier shall not be changed without the prior approval of the Engineer.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
4.309.00 Mixing and Transporting Concrete
.01 All materials for concrete shall be measured by weight in approved weigh
batching equipment. Such equipment shall be checked at weekly intervals at the
Contractor's expense and shall be accurate to within 2 per cent. Certificates of
accuracy shall be submitted immediately to the Engineer.
.02 All concrete shall be mixed, unless otherwise exceptionally approved, in purpose
built power driven mixers of a type and capacity suitable for the work. The
mixers shall be equipped with accurate water measuring devices which shall be
checked a weekly intervals at the Contractors expense. Certificates of accuracy
shall be submitted immediately to the Engineer. Mixers shall at all times be kept
in a clean condition.
.03 Volume batching of materials and hand mixing of concrete will be allowed only
at the discretion of the Engineer.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
CONCRETE CHARACTERISTICS
Min. Preliminary Min. Target Works
Specified Grade
Grade of concrete Cube Strength at 28 Cube Strength at 7 days
Strength
days (MPa) (MPa)
40D/40 40 53 27
40D/20 40 53 27
40D/10 40 53 27
30D/40 30 40 20
30D/20 30 40 20
30D/10 30 40 20
25D/40 25 33 17
25D/20 25 33 17
25D/10 25 33 17
20D/40 20 28 14
20D/20 20 28 14
MIX DESIGN LIMITS
Minimum Maximum
Grade of Concrete Maximum Size of Maximum Water Cement Cement
Aggregate (mm) Cement Ratio Content Content
(kg/cu.m) (kg/cu.m)
40D/40 40 0.44 325 530
40D/20 20 0.44 340 530
40D/10 10 0.44 370 530
30D/40 40 0.46 300 530
30D/20 20 0.46 310 530
30D/10 10 0.46 340 530
25D/40 40 0.53 280 530
25D/20 20 0.53 295 530
25D/10 10 0.53 340 530
20D/40 40 0.60 260 530
20D/20 20 0.60 290 530
Table 4.2. Design Mixes
.04 Hand mixing of concrete shall be done on a clean close boarded platform. The
materials shall be turned over not less than three times dry, water shall then be
sprayed on through a hose and the materials again turned over not less than three
times in a wet condition and worked together until a mixture of uniform
consistency is obtained.
.05 For handmixed or volume batched concrete the specified quantities of cement
shall be increased by 10 per cent and not more than 0.5 cubic metre shall be
mixed at one time. The Contractor shall not be entitled to any additional payment
in respect of any extra cost of handmixing by reason of the additional cement or
otherwise.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.06 All materials shall be thoroughly mixed dry before water is added and the mixing
of each batch shall continue for a period of not less than two minutes after the
water is added or such longer period as recommended by the manufacturer of the
mixer. The mixture shall be of uniform colour and distribution on discharge and
the entire contents of the mixer shall be discharged before recharging. The
Volume of mixed material shall not exceed the rated capacity of the mixer.
.07 Prior to the first mix each day being agitated in the mixer a rich cement/sand mix
shall be used to coat the inside of the drum, the surplus material being emptied
away and not used in the Works.
.08 The moisture content of the coarse and fine aggregates shall be checked by the
Contractor at frequent intervals and the amount of water added to the mix shall
be adjusted to maintain the design water/cement ratio.
.09 Concrete shall be discharged from the mixer directly into the works or onto a
clean, level, watertight platform or into a clean watertight container. It shall be
transported in a manner which ensures that it is of the correct quality and
consistency at the point of deposition. All platforms and containers shall be
cleaned of the old concrete before the fresh concrete is discharged onto them.
.10 Concrete shall not be dropped from a height, thrown or otherwise treated so that
segregation, undesirable finish, or defective structural quality results.
.11 No extra water shall be added to the concrete mix after it has left the batching
plant.
.12 The Contractor shall take adequate precautions to protect concrete in transit from
the effects of the weather.
.13 Pumping of concrete, which will require a special Design Mix, will only be
permitted with the approval of the Engineer.
.14 Should the concreting be stopped due to mechanical malfunction, accident, or
other similar cause then the Contractor shall inform the Engineer immediately so
that necessary measures and precautions can be taken. The cost of any additional
work caused by these stoppages shall be the responsibility of the Contractor.
.15 No concreting shall be commenced until the formwork and reinforcement and all
other preparations for the pour have been inspected by the Engineer.
4.310.00 Placing and Compacting Concrete
.01 All concrete shall be vibrated unless otherwise specified. The vibration shall be
carried out by experienced operatives using immersion type vibrators to the
Engineer's satisfaction.
.02 Placing of concrete shall be carried out in layers not exceeding 300mm deep and
in sequence from one end of the form to the other.
.03 Concrete in foundations and other underground work shall be protected from
contamination by falling earth or rock during and after placing. Any concrete
which in the opinion of the Engineer shows signs of initial setting before or
during placing shall not be used and it shall be removed a the Contractor's
expense.
.05 Sufficient vibrators shall be provided to correspond with the rate of placing of
concrete. The vibration shall be continuous throughout the placing of the
concrete. Standby vibrators shall be on Site during all concrete placing.
.06 Vibration shall not be allowed to disturb any recently placed concrete that has
begun to set. Any water accumulating on the surface of newly placed concrete
shall be removed by approved means and no further concrete shall be placed
thereon until such water is removed. Revibration of concrete is not permitted.
.07 Suitable means shall be provided to ensure that the temperature of the concrete
on placing does not exceed 30 degrees. Concrete shall not be placed around
reinforcement or against surfaces which are at temperatures above 30°. All
surfaces shall be thoroughly dampened immediately prior to placing fresh
concrete to prevent excessive absorption of water by the formwork.
4.311.00 Testing of Concrete
.01 For all structural concrete the following representative samples shall be taken and
tested in accordance with BS1881 on each day on which 25 cu.m. or less of
concrete is being poured:
(a) Six 150mm cubes three for test at 7 days and three for test at 28 days:
and
(b) two slump tests; or two compacting factor tests.
.02 On any day when greater quantities of concrete are being poured then the above
sampling and testing shall be repeated for each 25 cu.m. or part thereof.
.03 Where concrete is to be placed in masts, cantilevers longer than 3m , columns
shear walls or other critical elements the sampling rate shall be increased to one
sample for 10 cu.m. of concrete.
.04 When concrete is to be placed in solid rafts, pile caps or caisson caps the
sampling rate may be reduced, with the Engineer's approval, to one sample for
100 cu.m. of concrete.
.05 All cubes shall be marked with the date of casting and a serial reference number.
For each cube a record shall be kept of the position in which the batch of
concrete from which it was sampled was placed. All cubes shall be tested by an
approved testing authority.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.06 The concrete cubes tested at 7 days are intended to be indicative only and the
target works strengths at 7 days given in Tables 4.2 are not mandatory. It should
be noted however that it is unlikely that cubes failing the 7 day target will
subsequently pass the 28 day cube strength.
.07 The concrete cubes tested at 28 days shall be taken to represent the concrete
placed in the Works. The standard of acceptance for cube strength tests shall be
as follows:
The cube strength shall be calculated from the maximum load sustained by the
cube at failure. The appropriate strength requirement, as given in Tables 4.1 and
4.2 shall be considered to be satisfied if:
(a) none of the strengths of the three cubes is below the specified
cube strength, or if,
(b) the average strength of the three cubes is not less than the
specified cube strength and the difference between the greatest
and the least strengths is not more than 20 per cent of that
average.
.08 The standard of acceptance for the slump test during the production of concrete
shall be the design slump plus or minus 25 mm.
.09 The standard of acceptance for the compacting factor test during the production
of concrete shall be the design compacting factor plus or minus 0.03.
.10 The standard of acceptance of any preliminary tests will be similar to the
standard for normal Works cubes, slump or compacting factor, except that the
minimum cube strengths required shall be those given under "minimum
Preliminary Cube Strength at 28 days" in Tables 4.2.
.11 Any concrete which fails to meet the above standards of acceptance shall be
either further tested, or rejected, at the discretion of the Engineer. The costs of
any such tests or of the removal of rejected concrete and its replacement and
associated costs, shall be borne by the Contractor. If the strengths required are
not attained or maintained throughout the Contract, the Contractor will also be
required to redesign the mix and resubmit trial mixes in accordance with clause
4.308.00 of this specification so as to give a concrete which does comply with the
requirements of this specification.
4.312.00 Unformed Finishes for Concrete
.01 Where a concrete surface is specified as suitable for receiving a further applied
finish or class Ul is shown or in all cases where no other finish is specified, the
concrete shall be uniformly levelled and screeded to produce a ridged surface. No
further work shall be applied to the surface.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.02 Where a concrete surface is specified as exposed with no further applied finish or
class U2 is shown or where a waterproofing membrane is to be applied, the
concrete shall be uniformly levelled and screeded to produce a plain surface.
After the concrete has hardened sufficiently the surface shall be hand or machine
floated sufficiently only to produce a uniform surface free from screed marks.
Where waterproofing membrane is to be applied the surface finish shall have an
accuracy such that when tested with a 3m straight edge, the maximum depression
does not exceed 10mm.
.03 Where a class U3 finish is shown then the concrete shall first be brought to a
class U2 finish. When the moisture film has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, the
concrete Class U2 surface shall be steeltrowelled under firm pressure to produce
a dense, smooth, uniform surface free from trowel marks.
.04 Where a class U4 finish is shown then the concrete shall first be brought to a
class U1 finish. After the concrete has hardened sufficiently, the concrete class
Ul surface shall be power floated sufficiently only to produce a uniform surface
free from screed marks. Thereafter the surface shall be steel trowelled under firm
pressure to produce a dense smooth uniform surface free from trowel marks.
.05 Where special unformed finishes are required they will be described elsewhere in
the Contract.
4.313.00 Curing and Protecting Concrete
.01 Immediately after compaction and for at least 7 days thereafter concrete shall be
prevented from drying out too rapidly and protected against harmful effects of
weather including rain, rapid temperature changes, and wind. The methods of
protection used shall be subject to the approval of the Engineer and shall be
submitted at least 30 days before concrete is poured. The method of curing used
shall prevent loss of moisture from the concrete.
.02 During the curing period horizontal surfaces shall be protected by one or more of
the following or other approved means:
(a) ponding with water followed by covering of the surface with an
impermeable material raised approximately 50 mm over the
surface so as to prevent loss of moisture. The surface shall be
kept constantly wet and exposed concrete surface wholly
covered
(b) an approved sprayed membrane curing compound.
Curing method (a) is preferred for slabs and beams.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.03 During the curing period other surfaces shall be protected by the following or
other approved means:
(a) formwork in close contact with the concrete
(b) covering as in .02 above.
.04 All concrete faces or edges, particularly those which are exposed without
rendering in the final structure, shall be adequately protected from damage and
discoloration at all times.
.05 Concrete structures shall not be loaded until the concrete is at least 21 days old or
28 days in the case of cantilevers. With the prior approval of the Engineer the
structure may be loaded after this time but in no case will loading greater than the
final design loading be permitted.
4.314.00 Tolerances
.01 All insitu concrete work shall be dimensionally accurate to within the following
tolerances, unless closer tolerances are further specified or shown:
(a) between the centre lines of principal members, columns or
beams:
±5mm up to 15 metres centres
±l0mm over 15 metres centres
Note the ±l0mm tolerance shall not be accumulative.
(b) In storey height:
±5mm floor to floor.
(c) In plumbness of columns and walls:
±5mm on any storey or overall the structure.
(d) In level of floors:
+5mm/3mm of the true prescribed horizontal surface level.
(e) In cross sectional dimensions of columns, beams and walls:
+5mm/3mm in any dimension up to 2 metres overall.
(f) Cover to reinforcement:
+5mm/0 of the stated cover.
4.300.00 STRUCTURAL CONCRETE WORKMANSHIP
.02 Closer tolerances will generally be required for the following:
(i) precast concrete.
(ii) measuring flume contours.
(iii) filter bed and drying bed floors.
(iv) machinery bases.
4.315.00 Protection to Starter Bars
.01 All starter bars which are to be left protruding from structures which are
constructed under this Contract for connection by a future contract shall be
properly protected. The method of protection shall be as follows. The bars shall
be cleaned by machine wire brushing to Sa2 to remove rust and any rust
producing salts. The bars shall be dried and thereafter shall be primed with a
2mm thick layer of cement based polymer modified reinforcement primer.
.02 After priming the protruding length of the bars shall be covered with a polythene
tube closed at the free end and taped to the bar at the other end.