Dubai Marina Bridges - General Specifications DX00110

SECTION 4 - CONCRETE WORKS

Concrete work shall consist of furnishing all materials and constructing structures of the forms,
shapes and dimensions shown on the Drawings or as directed in accordance with the details
shown on the Drawings and these Specifications.

4/1 CEMENT

SULPHATE RESISTING CEMENT

4/1.1 Sulphate Resisting Cement shall comply with BS 4027 - 1996, Class 42.5N or ASTM C150 Type 5.
In addition the cement shall comply with the following:-

 The acid soluble alkali level measured as (Na2 0+0.658 K2 0) shall not exceed 0.6% by
weight determined in accordance with BS EN-196 Part 21.

 The heat of hydration shall not exceed 290 KJ/Kg 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 2/Kg and not less than 225 m2/Kg
when tested in accordance with BS EN-196 : Part 6.

 The chloride content shall not exceed 0.1% when tested in accordance with Clause
4 :EN-196: Part 21.

ORDINARY PORTLAND CEMENT

4/1.2 Ordinary Portland Cement shall conform to the requirements of BS 12 - 1996, Class 52.5N with
the following amendments:-

 The acid soluble alkali level measured as Na 2 0+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 at 7 days when tested in accordance
with BS 4550: Part 3 Section 3.8.

 The tricalcium aluminate content shall lie within the range of 4% to 13%.

 The specific surface (fineness) shall not be greater than 325 sq.m/Kg and not less
than 225 sq.m/Kg when tested as described in BS EN 196 : Part 6.

 The chloride content shall not exceed 0.1% when tested in accordance with Clause 4 of
EN-196: Part 21.

MODERATE SULPHATE RESISTING PORTLAND CEMENT

4/1.3 Moderate sulphate resisting Portland Cement shall comply with BS 12 - 1996 Class 52.5 N but
containing not less that 4% and not more than 8% proportion by weight of tricalcium aluminate, the
cement shall not contain more than 2.7% proportion by weight of sulphur trioxide.

 The heat of hydration shall not exceed 290 KJ/Kg at 7 days when tested in accordance with BS
4550: Part 3 Section 3.8.

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 The acid soluble alkali level measured as Na 2 0+0.658 K20 shall not exceed 0.6% by weight
determined by the test method described in BS EN 196-21.

 The specific surface (fineness) shall not be greater than 325 sq.m/Kg and not less than 225
sq.m/Kg when tested as described in BS EN 196 : Part 6.

 The chloride content shall not exceed 0.1% when tested in accordance with Clause 4 of EN-
196: Part 21.

GENERAL

4/1.4 Each cement batch shall bear manufacturer's name and batch number. Type of cement shall be
the same as mentioned in the approved analysis report. Each separate consignment of cement shall be
tested by the manufacturer before delivery and certified copies of such tests shall be supplied to the
Engineer before any part of the consignment is used in the works. The Engineer reserves the right to
order a re-test of cement at any time. Approval of cement does not relieve the Contractor of the
responsibility to produce concrete of the specified strength.

4/1.5 Cement shall be delivered to site in bulk, or with the Engineer's approval, may be supplied in
sealed bags, which shall bear the manufacturer's name and the date of manufacture. Each
consignment shall be accompanied by a copy of the manufacturer's batch test certificate and certificate
of guarantee.

4/1.6 Each consignment of cement shall be kept separate, identified and used in order of delivery.

4/1.7 Any consignment not used within 2 months from the date of manufacture will not be allowed to
be used in the works.

4/1.8 One brand only of cement as approved by the Engineer shall be used throughout the works
unless otherwise authorised by the Engineer in writing.

4/2 AGGREGATES GENERAL REQUIREMENTS

4/2.1 Except as may be modified hereunder the aggregate (fine and coarse) for all types of concrete shall
comply in all respects with BS 882 "Concrete aggregates from natural sources" and shall also
comply with Dubai Municipality Administrative Order No. 143/91.

4/2.2 The aggregates used in the permanent works shall be naturally occurring or crushed materials
obtained only from approved sources.

4/2.3 Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the necessary tests and analyses
to show that the samples comply with the specification. During the progress of the works, the
grading and chemical characteristics may be checked at frequent intervals.

4/2.4 The results of these tests, etc. shall be submitted to the Engineer and his approval shall be
obtained before any of the material is used in the works. Part of each sample will be required for
concrete trial mixes and part shall be retained for comparison with subsequent deliveries.

4/2.5 Sampling for testing and analysis shall be carried out, where applicable, in accordance with BS 812
Part 102.

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4/2.6 The maximum size of the aggregate shall not be larger than 1/5 of the narrowest dimension
between sides of the member for which the concrete is to be used and not larger than 3/4 of the
maximum clear distance between reinforcing bars.

4/2.7 Fine aggregate shall be natural or crushed sand and beach sand shall not be permitted for use in
concrete mixes.

4/2.8 Coarse aggregate shall be crushed aggregate obtained from a quarry approved by the
Engineer.

4/2.9 Unless otherwise authorised by the Engineer coarse aggregate shall be delivered to site in
separate sizes according to the maximum specified aggregate size for each grade of concrete.

4/2.10 Aggregates shall meet the requirements of Table 4.1.

4/2.11 The frequency of testing of aggregates shall be in accordance with Table 4.2 or as directed by the
Engineer.

TABLE 4.1.

LIMITS FOR PHYSICAL, CHEMICAL AND MECHANICAL PROPERTIES OF AGGREGATES

FOR CONCRETE
TEST PERMISSIBLE LIMITS
SR. KIND OF REQUIREMENT METHODS
NO. BS 812/ASTM FINES COARSE
1 Grading Part 103 (dry) Standard Standard

2 Material finer than 0.075mm

Natural, uncrushed/crushed Part 103 (wet) Max. 3% Max. 1%
Crushed rock Max. 7% Max. 1%

3 Clay lumps and friable particles C142 Max 1% Max 1%

4 Light Weight Pieces C123 Max. 0.5% Max 0.5%

5 Organic impurities for fine C40 The color of the

aggregate supernatant
liquid is lighter
than standard
colour solution

6 Water absorption C128/C127 Max. 2.3% Max. 2%

7 Specific Gravity (apparent) C128/C127 Min 2.6 Min 2.6

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LIMITS FOR PHYSICAL, CHEMICAL AND MECHANICAL PROPERTIES OF AGGREGATES FOR

CONCRETE (con’d)

TEST METHODS PERMISSIBLE LIMITS

SR. KIND OF REQUIREMENT
BS 812/ASTM FINES COARSE
NO.
8 Shell content in aggregates
Coarser than 10mm Max. 5%
Part 106
Between 5mm & 10mm Max. 15%

9 Particle shape
Flakiness index
Elongation Index Part 105.1 Max. 25%
Part 105.2 Max. 25%
Particularly crushed faces of coarse
aggregate shall be 100% with al
DM 301
least one crushed face

10 Acid soluble Chlorides, CL Part 117 –

Appendix C
For reinforced concrete made
with Max. 0.03% Max. 0.01%
SRPC cements Max. 0.03% Max. 0.02%
OPC & MSRPC cements

For mass concrete made with

SRPC cements Max. 0.03% Max. 0.02%
OPC & MSRPC cements Max. 0.03% Max. 0.04%

For prestressed concrete &

steam cured structural concrete Max. 0.03% Max. 0.01%
11 Acid soluble sulphates, S03 Part 118 Max. 0.3% Max. 0.3%

12 Soundness, MgSO4 (5 cycles) C88 Max. 12% Max. 12%

13 Mechanical Strength
10% fines value Part 111 Min 100KN
or impact value Part 112 Max. 30%

Los Angeles abrasion C131/C535 Max. 30%

14 Drying Shrinkage Part 120 Max. 0.05%

15 Potential reactivity

Note 2 of aggregates, chemical C289 Innocuous Innocuous

method

Of Cement –aggregate combination C227 6 month

expansion
0.1% max.

Note 1: There is no requirement of shell content in sands passing 5mm sieve size

Note 2: Aggregates may initially be assessed for its reactivity in accordance wit ASTM C289
and if potential reactivity is indicated, then mortar bar tests in accordance with ASTM C227
shall be carried out.

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TABLE 4.2

FREQUENCY OF ROUTINE TESTS ON AGGREGATES

Sr No. Kind of Requirement – Test Method Test Frequency Rate

1 Grading – BS 812 Part 103 Per 1,000 m³

2 Material finer than 0.75mm – BS 812 Part 103 Per 1,000 m³

3 Clay lumps and Friable Particles – ASTM C142 Per 4,000 m³

4 Organic impurities ASTM C40 Per 2,000 m³

5 Water Absorption – ASTM C128/C127 Per 2,000 m³

6 Specific Gravity – ASTM C128/C127 Per 2,000 m³

7 Shell Content – BS 812 Part 106 Per 2,000 m³

8 Particle shape BS 812 Part 105.1, 105.2 Per 2,000 m³

9 Acid Soluble chlorides, CL

Qualitative – BS 812 Part 117- Appendices A/B Per 1,000 m³

Qualitative – BS 812 Part 117 – Appendix C Each 12 concrete days if result is

more than 75% of the limit and each
month if result is less than 75% of
the limit whichever is less

10 Acid Soluble Sulphates, SO3 – BS 812 Part 118 Per 1,000 m³ or each 24 concrete
days if result is more than 75% of
the limit and each 2 months of result
is less than 75% of the limit
whichever is less

11 Soundness, MgSo4 (5 cycles) ASTM C88 Each 48 concrete day or Per 4,000
m³

12 Mechanical Strength
Each 72 concrete days or Per 6,000
10% fines or impact value – BS 812 Parts 111, 112 m³
Los Angeles Abrasion – ASTM C131/C535 Each 72 concrete days or Per 6,000
m³

13 Moisture variation in sand – by Moisture Meters Twice Daily

14 Drying Shrinkage BS812 Part 120 At the start of the Project and
whenever there is a change in the
source of supply

15 Potential Reactivity of aggregrates (ASTM C295, C289) At start of the project and wherever
Of Carbonate (ASTM C586) there is a change in the source of
Of cement aggregate combination (ASTM P214 and Supply
C227)

Note: Drying shrinkage and potential reactivity of aggregates 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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4/3 FINE AGGREGATES

4/3.1 The gradation of fine aggregate shall be in accordance with BS 882 latest edition excluding grading
designation F.

4/3.2 Each batch of aggregate delivered to site shall be kept separate from previous batches and shall be
stored for at least 3 (three) working days before use to allow inspection and tests to be carried out.

4/3.3 Fine Aggregate shall be clean sharp natural and/or crushed sand and shall be within BS882 zones c and m
only.

4/3.4 The Contractor shall mechanically wash aggregate to remove salts and other impurities in order to meet the
requirement specified.

4/4 COARSE AGGREGATE FOR CONCRETE

4/4.1 Coarse aggregate shall be prepared as single sized aggregate and blended to produce normal size
grading. The combined grading shall be within the appropriate grading limits given in BS 882.

4/4.2 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.

4/4.3 The Contractor shall mechanically wash aggregate to remove salts and other impurities in order to meet
the requirement specified.

4/5 COMBINED AGGREGATE

4/5.1 Approved coarse aggregate and fine aggregate in each batch shall be combined in proportions
as specified in BS 882 and as approved by the Engineer. However, in no case shall materials passing the
0.075mm, sieve exceed three (3) percent by weight of the combined aggregate.

4/5.2 The combined aggregate gradation used in the work shall be as specified, except when otherwise
approved or directed by the Engineer. Changes from gradation to another shall not be made during
progress of the work unless approved by the Engineer.

4/6 WATER FOR CONCRETE

4/6.1 The Contractor shall make his own arrangement and obtain approval for the supply of water.

4/6.2 The mixing water should be clear, apparently clean and free from matter harmful to concrete in its
fresh or hardened state. Potable water can be used. Water of questionable quality should comply with the
physical tests of Table 4.3 and chemical limitation listed in Table 4.4. Water shall also meet the requirement
of BS 3148 of latest addition.

4/6.3 The temperature of water for concrete should not be less than 5 degree Celsius nor more 25
degree Celsius. Water may be cooled to not less than 5 degree 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 4.3 and 4.4.

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4/6.4 Water for curing concrete shall not contain impurities in sufficient amounts to cause discolouration of the
concrete. Sources of Water shall be maintained at such depth and the water shall be withdrawn in such a
manner as to exclude silt, mud, grass and other foreign matter.

TABLE 4.3 – ACCEPTANCE CRITERIA AND PHYSICAL TESTS FOR MIXING WATER

Test Limits ASTM

Compressive strength, min % controls At 7 days 90 C 109

Final setting time, deviation from Control, h: min from 1:00 early to 1:30 later C 191

TABLE 4.4 – CHEMICAL LIMITATIONS FOR MIXING WATER

Max. Concentration Limit, ppm Test Method

250
1. Chloride as CL ASTM D 512
350
2. Sulphates as S04 ASTM D 516
3. Alkali carbonates 500
ASTM D 513
and bicarbonates
4. Total dissolved ions, including 1,2 & 3 above. 2000
BS1377:Part3: Test8
5. pH
min.7/max.9 ASTM D 1293

4/7 APPLICABLE TESTS AND CODES

4/7.1 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 and 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.

4/7.2 WORKABILITY

Workability 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.

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4/7.3 COMPRESSION TEST

The Compression tests shall be performed on cubes 150 x 150 x 150 mm 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
and 111 respectively.

4/8 REINFORCEMENT BARS

4/8.1 All reinforcement. bars shall be of a deformed type in accordance with BS 4449, 1997, except
that plain bars may be used where specifically indicated on the Drawings. Plain bars shall be in
accordance with BS 4449:1997.

4/8.2 All steel reinforcement shall conform to the requirements of the Specifications for Deformed High
Yield Steel Bars grade 460 Type 2, unless otherwise shown on the Drawings or specified by the
Engineer.

4/8.3 Certification. Three (3) copies of a mill test report shall be furnished to the Engineer for each lot of
steel reinforcement bars proposed for use on the project.

4/8.4 Identification. The bars in each lot shall be legibly tagged by the manufacturer and/or fabricator before
being offered for inspection. The tag shall show the manufacturer's test number and lot number and other
applicable data that will identify the material with the certificate issued for that lot of steel.

4/8.5 The fabricator shall furnish three (3) copies of a certification which shows the heat number or
numbers from which each size of bar in the shipment was fabricated.

4/8.6 The Engineer reserves the right to sample and inspect all reinforcement steel upon its arrival at the
work site. The Contractor shall provide a certificate confirming that samples taken from the bars delivered to
the works pass all the required tests. The frequency of sampling and the method of quality control shall
be in accordance with BS 4449 - 1997 Clause C.3.2.

4/8.7 All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust, paint, grease, oil or other
foreign substance, fins, or tears. There shall be no evidence of visual flaws in the bars, test specimens or on
the sheared ends of the bars.

4/8.8 Uncoated reinforcement shall be grit-blasted before use to remove rust, oil, grease, salt and other deleterious
materials and where pitting has occurred the causes and products thereof. Repeated blasting may be
required when the reinforcement is in position, or partially cast in. Partially set concrete adhering to exposed
bars during concreting operations shall be removed.

4/8.9 The minimum thickness of concrete cover to reinforcement shall be as shown on the drawings. Only
approved concrete spacers shall be used. The concrete shall be of similar grade to the main concrete
and shall have non metallic ties.

4/9 BAR SCHEDULES AND SHOP DRAWINGS

4/9.1 Before ordering reinforcing steel, the Contractor shall check the bar schedules and adjust them if necessary to
the approval of the Engineer. Bar schedules shall show the weight of each bar, the total weight of each bar
size and the total weight of bars, and bending diagrams for bars in accordance with BS 4466.

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4/9.2 The Contractor shall provide and submit to the Engineer for approval any working drawings additional
to the Contract Drawings, which may be found necessary for the production of, revised bar schedules or for
the completion of the works.

4/9.3 The approval of working drawings, or revised bar schedules by the Engineer shall in no way relieve the
Contractor of responsibility for the correctness of such drawings or schedules

4/10 BAR CUTTING AND BENDING

4/10.1 Reinforcement shall be cut and bent in accordance with B.S. 4466. Cutting or bending by the application of
heat is not permitted. Welding of reinforcement shall only be permitted when approved in writing by the
Engineer. If such approval is given then the workmanship shall be in accordance with BS 5135. The
Contractor shall submit full technical details of his proposed procedures prior to seeking approval.

4/10.2 Hot rolled high yield bars shall not be straightened or bent again, having once been bent. If the Engineer
gives approval to bend mild steel reinforcement projecting from the concrete, the internal radius of bend
shall not be less than four times the nominal size of the bar.

4/11 PLACING AND FIXING REINFORCEMENT

4/11.1 Reinforcement shall be placed and maintained in the position shown in the Contract Drawings. Unless
otherwise permitted by the Engineer, all bar intersections shall be tied together using 1.2mm diameter
steel wire or No. 18 gauge stainless steel wire as indicated on the drawings and the ends of the tying
wire shall be turned into the main body of the concrete.

4/11.2 Metal supports, approved by the Engineer, shall be provided and used to retain the reinforcement at
proper distances from the forms. Supports under horizontal bars at the bottom of base slabs shall be
spaced at not more than eighty (80) diameters of the bar. All reinforcement shall be so rigidly supported
and fastened that displacement will not occur during construction. Reinforcing steel shall be inspected in
place and must be approved by the Engineer before any concrete is deposited.

4/11.3 No splices shall be made in the reinforcement except where described in the Contract Drawings or
where approved by the Engineer.

4/11.4 Reinforcement temporarily left projecting from the concrete at construction or other joints shall not be
bent out of position during the periods in which concreting is suspended, except with the approval of the
Engineer.

4/12 WELDED WIRE FABRIC

4/12.1 Welded wire fabric to be used for the reinforcement of concrete shall conform to the following requirements:

 Dimensions. Welded steel wire fabric shall conform to the size and dimensions shown on the Drawings.

 Properties. Wire fabric furnished under this specification shall conform to the requirements for
"Welded Steel Wire Fabric for Concrete Reinforcement" BS 4483 or equivalent.

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4/13 SPACER BLOCKS

4/13.1 Spacers as approved by the Engineer shall be of such material and design as will be durable, not lead to
corrosion of the reinforcement and not cause spalling of the concrete cover.

4/13.2 Spacer blocks made from cement, sand and small aggregate shall match the mix proportions of the
surrounding concrete so far as is practicable with a view to being comparable in strength, durability and
appearance.

4/14 ADMIXTURES

4/14.1 Unless agreed by the Engineer neither admixtures nor cements containing additives shall be used.

4/14.2 Where the use of admixture had been agreed by the Engineer, they shall conform to the
requirements of Type A, Type D, Type F or Type G as specified in ASTM C494 and shall be used in
strict accordance with the manufacturer's instructions.

Preliminary tests of cube strength and other tests shall be carried out using the combination of aggregates
cements and admixtures proposed for use.

4/14.3 The Contractor shall be entirely responsible for the use of any approved admixtures.

4/14.4 Approved methods and equipment shall be used for dispensing and incorporating the admixture into
the concrete. The dispensing unit shall be designed so that the discharge of the admixture is visible.

4/15 CONCRETE MIX SPECIFICATION

4/15.1 Concrete shall be as shown in the Table of 4.5. The number of mixes may require to be increased.

The criteria given in the Table are designed to produce concrete of the required strength and durability.

If the maximum aggregate size is 10 mm then the cement content stipulated for the class of concrete given
in table 4.5 shall be increased by 40 Kg per m3.

The CCSs are for concrete which has been cured at a temperature of 23 degrees C +/- 2 degree C,
and are the values below which no more than 5% of the test results fall. The 7-day strengths shall be
used only as a guide.

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Table 4.5 Table of mixes

Concrete Max Size Agg Min Qty of Max free Characteristic cube strength
Class Cement water/cement CCS
ratio
mm Kg.per m³ 7 day 28 day
N/mm² N/mm²
45/20 20 400 0.425 33 45
40/20 20 370 0.475 30 40
37/20 20 350 0.50 26 37
35/20 20 330 0.525 25 35
30/20 20 310 0.55 20 30
25/20 20 275 0.60 16 25
15/20 20 250 0.65 10 15

The CCs are for concrete which has been cured at a tem0perature of 23 degrees C ± 2 degree C, and
are the values below which no more than 5% of the test results fall. The 7 day strengths shall be used
only as a guide.

4/15.2 Concrete shall comply with BS 8110 except where BS 8007 or this specification differs.
Sampling for test purposes shall comply with BS 1881 Part 101 (on site) & Part 125 (in laboratory).

If air-entrapment is specified the average air content at the time of placing measured in accordance
with BS 1881 PART 106 shall be:

Concrete containing 20mm maximum size aggregate 5%

+1%

Concrete for water-retaining shall be watertight and shall comply with the recommendations of BS
8007.

Concrete for paving or precast units shall be tested to BS 1881 Part 118 and shall have a minimum
flexural beam strength of 3.5N/mm2 at 28 days. If the concrete has a specified CCS of 40N/mm2 or
greater, then the minimum flexural strength shall be 4N/mm2.

If concrete specimens are cured at higher temperatures or for longer periods than BS 1881 Part 111
requires, the adjusted CCS shall be calculated as follows:

1Oof’/f = A + B log {24D (T+12)/1000}

f‘ = adjusted CCS

f = specified CCS

T = curing temperature D

D = age at testing in days A&B

A&B = are coefficients given in the following table.

The above equation applies only to OPC, MSRPC and SR

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Recorded Cube Strength N/mm2 A B

Less than 15 10.0 67.5

15 to 35 20.0 60.0
Greater than 35 30.0 52.5

This calculation may be applied for curing at temperatures up to 27 degrees C.

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/mm2 shall be
used as a basis for designing a mix. Unless otherwise approved a standard deviation of 7 N/mm2 shall
be used for initial mixes.

4/15.3 The ultimate compressive strength of the concrete shall be determined on test specimens obtained
and prepared in accordance with B.S. 1881. Part 108.

4/15.4 Mixes for structural concrete shall be designed by the Contractor. The class of concrete (shown on
the drawings) is denoted by the 28-day characteristic cube strength and the maximum size of
aggregate.

4/15.5 The chloride and sulphate levels in the concrete mix shall comply with the following requirements:-

Maximum Limits of acid soluble Chloride and Sulphate content as a percentage by Weight of Cement in
the Mix.

CHLORIDES SULPHATES
TYPE OF CONCRETE AS Cl AS SO3
ACCORDING TO BS-1881 PART 124
a. For reinforced concrete
if made with OPC/MSRPC 0.30 3.70
if made with SRPC 0.06 3.70
b. Prestressed concrete & Heat-cured reinforced 0.10 3.70
concrete
c. For mass concrete
if made with OPC/MSRPC 0.60 3.70
if made with SRPC 0.12 3.70

Note: EN 196-21 Method of Testing Cement Part21 will be used to determine the percentage chloride by
weight of cement. The OPC and MSRPC cements can also contain chlorides, the relevant standard BS 12
allows upto 0.1% Cl. Therefore any chloride content present in the cement has to be taken into account while
computing total Cl in the mix. In case the cement contains the maximum limit of 0.1% Cl, then the

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aggregates, water and admixtures used for prestressed concrete or heat cured reinforced concrete should
be absolutely free of chlorides.

4/16 CONCRETE MIX DESIGN

TRIAL MIXES

4/16.1 Preliminary laboratory tests shall be carried out to determine the mixes to satisfy the specification with the
approved materials.

Trial mixes shall be tested to determine the following properties of mixes proposed for initial field tests:

a) Bleeding in accordance with ASTM C232 (non-vibrating) shall not exceed 0.5%.

b) Drying shrinkage in accordance with BS 1881 Part 5.

c) Air content if applicable BS 1881 Part 106.

d) Free water/cement ratio.

e) Workability BS 1881 Part 102.

f) Chloride permeability shall be less than 2,000 coulombs, when tested in accordance with ASTM C-
1202.

g) Fresh and hardened concrete densities BS 1881 Parts 107 and 114 respectively.

h) Compressive strength BS 1881 Part 116.

i) Water Permeability DIN 1048 (maximum 10 mm at 28 days) (maximum 15 mm at 7 days).

If the values obtained are unacceptable, the mixes shall be re-designed.

4/16.2 At least 35 days before commencement of concreting trial mixes shall be prepared under full-scale site
conditions and tested in accordance with BS 1881.

Samples of concrete incorporating the reinforcing details to be used shall be cast and examined, before
hardening using hand tools, and after hardening by coring to assess the mixes. Cores shall be taken in
accordance with BS 1881 Part 120.

Trial mixes shall be made on each of three days; the workability shall equate to the designed target value.
Six cubes from each mix shall be taken, three for test at 28 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 following properties:

a) Bleeding in accordance with ASTM C232

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b) Air content if applicable BS 1881 Part 106.

c) Free water/cement ratio

d) Tensile strength in accordance with BS 1881 Parts 117 and 118.

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 re-designed.

4/16.3 The Engineer will review the Contractor's trial-mixes and crush the test cubes at seven (7) and twenty-
eight (28) days. The Engineer will then determine which of the trial mixes shall be used. If none of the trial
mixes for a class of concrete meets the Specifications, the Engineer will direct the Contractor to prepare
additional trial-mixes. No class of concrete shall be prepared or placed until its job-mix proportions have
been approved by the Engineer.

4/16.4 The approval of the job-mix proportions by the Engineer or his assistance to the Contractor in
establishing those proportions, in no way relieves the Contractor of the responsibility of producing
concrete which meets the requirements of these Specifications.

4/16.5 The Engineer may also require practical tests to be made on the Site by filling trial moulds to confirm the
suitability of the mix for the works, the type of plant used for mixing, the method of compaction used and
the formwork face intended for use in the works.

4/16.6 All costs connected with the preparations of trial-mixes and the design of the job-mixes shall be borne by
the Contractor.

4/17 QUALITY CONTROL

4/17.1 TEST CUBES

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 Parts 108,111 and 116.
The method of compacting cubes shall be as approved and shall be means of vibrating table in the
laboratory or 25mm vibrating poker on site.

4/17.2 SAMPLING CUBES

A sample of concrete shall be taken at random on eight separate occasions during the first five days of using
a mix at least one sample being taken each day. 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 as 1.64 times the
standard deviation.

Thereafter one sample shall be taken at random for each class of concrete in accordance with Clause 4/31 of
the Specification.-

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.

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From each sample three cubes shall be made for testing at 28 days and three for testing at 7 days for control
purposes.

Six cylinder samples shall also be taken to determine the split tensile strength of the concrete 3 at 7 days
and 3 at 28 days, as specified in BS 1881 Part 117. 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 if directed by the Engineer.

The procedures shall be repeated when materials or design mixes are changed.

4/17.3 CUBE STRENGTH RESULTS

The results will be acceptable if:

i. 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,

ii. No individual result of the sample is less than that (Specified CCS minus 3 N/mm2),

iii. Number of individual results in the sample below specified CCS is not more than one.

If the above criteria is not satisfied, the unit represented by the sample is questionable and the following
actions may be instructed as appropriate :

i. Cutting and testing cores from placed concrete,

ii. Non-destructive testing of placed concrete,

iii. Load-testing relevant structural units,

iv. 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 sample having a range
exceeding 20%, then the result shall be unacceptable and the Engineer may order any of the following
actions:

a) Changing the mix.

b) Improving quality control.

c) Cutting and testing cores from placed concrete.

d) Non-destructive testing of placed concrete.

In the event of cutting and testing of cores are required, the Contractor shall cut cores from approved
locations and test them to BS 1881 as modified by BS 6089.

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4/17.4 DURABILITY TESTS

Concrete 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 75mm 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. The upper acceptable limit for absorption after 30 minutes shall be 2%.

Effective permeability tests in accordance with the method described in DIN

1048 shall be carried out. The maximum acceptable penetration at seven days shall be 15 mm
and the maximum acceptable penetration at 28 days shall be 10mm.

4/17.5 OTHER TESTS

When instructed by the Engineer concrete shall be tested for drying shrinkage and wetting expansion, for
which 75x75mm prisms shall be prepared and tested in accordance with Test 5 of BS 1881 (1970) Part
5 or BS6073 Part 1 Appendix D. The maximum acceptable limits shall be:

Drying Shrinkage: 0.05%

Wetting Expansion: 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 C231) for each batch produced until
consistency has been achieved, when batches may be tested. The maximum value shall not exceed
2%.

Compaction factor, slump, vibe 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.

4/18 CONCRETE DESIGN LIMITS

4/18.1 The following will be designated by the Engineer within the limits of the Specifications.

a) The minimum Cement content in kg. per cubic metre of concrete.

b) The maximum allowable water/cement ratio including surface moisture, but excluding water
absorbed by the aggregates.

c) Slump or Slumps designated at the point of delivery.

d) Changes requested by the Contractor in mix proportioning previously approved shall be made
only with the agreement of the Engineer.

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e) When, in the opinion of the Engineer, cement is being lost due to windy conditions, the Contractor
shall add additional amounts of cement as directed by the Engineer. No additional payment shall
be made for the added cement.

f) Failure of the mixed concrete to meet specifications as determined by the Engineer will be grounds
for the Engineer to reject the concrete.

g) Bleeding limitations when tested in accordance with ASTM C232.

4/19 CONSISTENCY OF CONCRETE

4/19.1 The consistency of concrete shall be determined in the field by the Slump Test. The consistency of
concrete at the time of delivery will be designated by the Engineer and shall not vary by more than
25mm from the designated consistency.

4/20 TOLERANCES IN PROPORTIONING THE MATERIALS

4/20.1 CEMENT

In the case of bagged cement it shall be measured as packed by the manufacturer: a sack of
cement shall weigh fifty (50) kilograms. Measurement for proportioning all cement shall be
accurate to within two (2) percent throughout the range of use. Only full bags, undamaged or
unbroken will be permitted.

4/20.2 WATER

The mixing water shall be measured by weight or by volume. In either case the measurement shall
be accurate to within one (1) percent throughout the range of use.

4/20.3 AGGREGATE

The aggregates shall be measured by weight to an accuracy within two (2) percent through-out the
range of use.

4/21 ASSEMBLY AND HANDLING MATERIALS

ASSEMBLY

4/21.1 Aggregates shall be assembled in such quantities that sufficient material approved by the
Engineer is available to complete any continuous pour necessary for any element. The batching site
shall be of adequate size to permit the stockpiling of sufficient, unsegregated materials, having proper
and uniform moisture content, to ensure continuous and uniform operation. Aggregates shall enter the
mixer in a manner approved by the Engineer and in such a manner to ensure that no matter foreign to
the concrete or matter capable of changing the desired proportions is included. In the event two (2) or
more sizes or types of coarse or fine aggregates are used on the same project, only one (1) size or
type of each aggregate may be used on one continuous concrete pour.

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STOCKPILING OF AGGREGATES

4/21.2 All aggregates shall be stockpiled before use in order to prevent segregation of material, to
ensure a uniform moisture content and to provide uniform conditions for proportioning plant control.

4/21.3 The use of equipment or methods of handling aggregates, which result in the degradation and
contamination of the aggregates, is strictly prohibited. Bulldozers with metal tracks shall not be used on
coarse aggregate stockpiles. All equipment used for handling aggregates shall be approved by the
Engineer.

4/21.4 Stockpiling of aggregates shall be in the manner approved by the Engineer, and in addition, every
precaution shall be taken to prevent segregation. Segregation shall be prevented by making no layer higher
than one and one-half (1.5) metres and if two (2) or more layers are required, each successive layer shall
not be allowed to "cone" down over the next lower layer.

4/21.5 Aggregates shall not be stockpiled against the supports of proportioning hoppers and weighing
devices.

SEGREGATION

4/21.6 Segregated aggregates shall not be used until they have been thoroughly remixed and the resultant
pile is of uniform and acceptable gradation at any point from which a representative sample is taken. The
Contractor shall re-mix aggregate piles when ordered by the Engineer.

TRANSPORTING Of AGGREGATES

4/21.7 If aggregates are to be transported from a central proportioning plant to the mixer in batch-boxes or
dump trucks, such equipment shall be of sufficient capacity to carry the full volume of materials for each
batch of concrete. Partitions separating batches shall be approved by the Engineer and shall be adequate
and effective to prevent spilling from one compartment to another whilst in transit or being dumped.

CEMENT

4/21.8 Cement shall be stored in a dry weather-proof shed with a raised wooden floor or in a silo and shall be
delivered in quantities sufficient to ensure that there is no suspension or interruption of the work of
concreting at any time. If stored in sheds, each consignment shall be kept separate and distinct.

4/22 MIXING CONCRETE

4/22.1 The weighing and water-dispensing mechanisms shall be maintained in good order. Their accuracy shall
be maintained within the tolerances described in BS 1305 and checked against accurate weights and
volumes when required by the Engineer.

4/22.2 The mass of cement and of aggregate indicated by the mechanism employed shall be within a tolerance of
2% of the respective mass per batch agreed by the Engineer. The mass of the fine and coarse aggregates
shall be adjusted to allow for the free water contained in them. The water to be added to the mix shall be
reduced by the quantity of free water contained in the fine and coarse aggregates, which shall be determined
by the Contractor by a method approved by the Engineer immediately before mixing begins and further as the
Engineer requires.

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4/22.3 Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch type mixer manufactured in
accordance with BS 1305. Where appropriate the batch capacity, method of loading, mixing time and drum
speed shall conform to the details furnished in accordance with the requirements of BS 3963 for the mix
which corresponds most closely to the mix proportions being used.The mixing blades of pan mixers shall
be maintained within the tolerances specified by the manufacturer of the mixer and the blades shall be
replaced when it is no longer possible to maintain the tolerance by adjustment. The period of mixing, judged
from the time that all the ingredients including water are in the mixing drum shall be as ordered by the
Engineer's representative but shall not be less than 2 minutes or 20 revolutions of the drum whichever is the
longer.

All plants shall be equipped with an approved automatic cycling and monitoring system installed as part
of the batching equipment. The system shall include equipment for accurately proportioning the various
components of the mixture by mass. Admixtures may be measured volumetrically. The automatic
proportioning system shall be capable of consistently delivering each constituent within the tolerances
specified. All records of batches shall show the batch weights, the batch number, the day, the month, the
year and the time of day to the nearest minute for each batch. This information shall be imprinted on the
record so that each batch may be permanently identified. The Engineer will be provided with a clear and
legible copy of all batch records for concrete supplied for the project.

4/22.4 Mixers, which have been out of use for more than 30 minutes, shall be thoroughly cleaned before
any fresh concrete is mixed.

4/22.5 The method of discharge from the mixer shall be such as to cause no segregation whether partial or
otherwise of the concrete materials.

4/22.6 The Contractor shall ensure that the constituent materials of the concrete are sufficiently cool to prevent the
concrete from stiffening in the interval between its discharge from the mixer and compaction in its final
position. Precautions shall include the shading of aggregate stockpiles and the use of chilled water.

4/23 READY MIXED CONCRETE

4/23.1 Ready mixed concrete as defined in BS 5328, batched off the site, may be used only with the
agreement of the engineer and shall comply with all requirements of the Contract.

4/23.2 The Concrete shall be carried in purpose-made agitators, operating continuously, or truck mixers. The
concrete shall be compacted and in its final position within 1 hour of the introduction of cement to the
aggregates, unless a longer time is agreed by the Engineer. The time of such introduction shall be
recorded on the delivery note together with the weight of the constituents of each mix.

4/23.3 When truck mixed concrete is used, water shall be added under the supervision, either at the Site or at
the central batching plant as agreed by the Engineer but in no circumstances shall water be added in
transit.

4/23.4 Unless otherwise agreed by the Engineer, truck mixer units and their mixing and discharge performance
shall comply with the requirements of BS 4251. Mixing shall continue for the number and rate of
revolutions recommended in accordance with Item 9 in Appendix B of BS 4251 or, in the absence of the
manufacturer's instructions, mixing shall continue for not less than 100 revolutions at a rate of not less
than 7 revolutions per minute.

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4/23.5 Pumping concrete through delivery pipes may be permitted but only with the prior approval of the
Engineer.

4/23.6 Re-mixing of concrete, which has commenced to set, shall not be allowed and in no case shall such
concrete be used in the Works.

4/23.7 Coarse aggregate shall be-kept in identified stockpiles from which samples can be collected and tested
as specified.

4/23.8 The concrete supplier is required to certify that the CL content in the mix being delivered is within the limits
specified in Clause 4/15.5. The CL and SO3 content shall be checked at frequent intervals.

4/24 TRANSPORT AND PLACING

4/24.1 The method of transport and placing concrete shall be to the approval of the Engineer. Concrete shall be so
transported and placed that contamination, segregation or loss of the constituent materials does not occur.

4/24.2 All formwork and reinforcement shall be clean and free from standing water immediately before placing
concrete.

No concrete work shall be stopped or temporarily discontinued within forty-five (45) centimeters of the top of
any finished surface, unless such work is finished with a coping having a thickness less than forty-five (45)
centimeters in which case the joint shall be made at the under edge of the coping.

Concrete in simple slab spans shall be placed in one (1) continuous operation for each span, unless
otherwise indicated on the drawings or approved by the Engineer.

4/24.3 Prior to placing any concrete on natural surfaces a blinding layer of Class 15 concrete shall be laid to a
minimum of 75 mm thickness unless otherwise specified on the drawings. This blinding shall be suitably
cured prior to subsequent concrete placement. The blinding shall be clean and free from any dust or
impurities prior to subsequent concrete placement.

4/24.4 No concrete shall be placed in a foundation until the extent of excavation and the character of bearing
material have been approved and no concrete shall be placed in any structure until the placement of
reinforcing steel and the adequacy of the forms and falsework have been approved.

4/24.5 Concrete shall not be placed in any part of the Works until the Engineer's approval has been given. If
concrete has not started within 24 hours of such approval being given, approval shall again be requested.
Concreting shall then proceed continuously over the area between construction joints. Fresh concrete shall
not be placed against in-situ concrete which has been in position for more than 30 minutes unless a
construction joint is formed in accordance with the Specification. When the concrete has been in place for 4
hours, or less as directed by the Engineer, further concrete shall not be placed against it for a further 20 hours.

4/24.6 Concrete when deposited shall have a temperature of not more than 32 deg. C unless otherwise specified.
Concrete shall be compacted in its final position within 30 minutes of discharge from the mixer unless carried
in purpose made agitators operating continuously, when the time shall be within 1 hour of the introduction of
cement to the mix and within 30 minutes of discharge from the agitator.

4/24.7 Except where otherwise agreed by the Engineer, concrete shall be deposited in horizontal layers to a
compacted depth not exceeding 400mm where internal vibrators are used or 300mm in all other cases.

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4/24.8 Unless otherwise agreed by the Engineer, concrete shall not be dropped into place from a height
exceeding 2m. When trunking or chutes are used they shall be kept clean and used in such a way as to
avoid segregation. Where steep slopes are required for placing concrete with chutes, the chutes shall be
equipped with baffle boards or be in short lengths that reverse the direction of the movement. Chutes and the
use of chutes must be approved by the Engineer. All chutes shall be kept clean and free from coating of
hardened concrete by thoroughly flushing with water after each run. The water used for flushing shall be
discharged clear of the concrete already in place.

4/24.9 No concrete shall be placed in flowing water. Underwater concrete shall be placed in position by tremies,
or by pipeline from the mixer.

4/24.10 Full details of the method proposed shall be submitted in advance to the Engineer and his approval
obtained before placing begins. Where the concrete is placed by the tremie, its size and method of
operation shall be in accordance with BS 8004. During and after concreting under water, pumping or
dewatering operations in the immediate vicinity shall be suspended until the Engineer permits them to be
continued.

4/24.11 Approved measures shall be taken to avoid premature stiffening of concrete placed in contact with hot, dry
surfaces. Surfaces including reinforcement against which concrete is to be placed shall be shielded against the
direct rays of the sun and shall be sprayed with water to prevent excessive absorption by the surfaces of water
from the fresh concrete. 1

4/24.12 A complete record shall be kept of the date, time, temperature and conditions of placing the concrete in
each portion of the work and shall be available for inspection by the Engineer at any time.

4/24.13 Unless otherwise shown on the drawings all concrete placed below ground level shall have a minimum
protection to its outside faces as follows:

Underside - Protected by the laying of a grade 1000 approved polyethylene sheeting on the blinding
concrete. The sheeting shall be returned up the outside faces of the concrete and suitably sealed.

Sides - Coated with 3 coats of an approved bitumen rubber latex emulsion flexible damp and vapour-proof
liquid membrane conforming to BRE Digest No. 54.

4/25 COMPACTION OF CONCRETE

4/25.1 All concrete shall be compacted to produce a dense homogeneous mass. Unless otherwise agreed by the
Engineer, it shall be compacted with the assistance of vibrators. Sufficient vibrators in serviceable condition
shall be on site so that spare equipment is available in the event of breakdown. A 50mm diameter internal
vibrator shall be deemed capable of compacting 20 Cu. m./hr. Internal vibrators shall be capable of
producing not less than 10,000 cycles per minute.

4/25.2 Vibration shall not be applied by way of the reinforcement. Where immersion vibrators are used, contact
with reinforcement and all inserts shall be avoided.

4/25.3 Concrete shall not -be subject to vibration between 4 and 24 hours after placing.

4/25.4 Vibrators shall be so manipulated as to work the concrete thoroughly around the reinforcement and
embedded fixtures and into comers and angles of the forms. Vibrators shall not be used as a means to
cause concrete to flow or its position in lieu of placing. The vibration at any point shall be of sufficient

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duration to accomplish compaction. After initial set of the concrete, the forms shall not be jarred and no
strain shall be placed on the ends of projecting reinforcement.

4/26 CONSTRUCTION JOINTS

4/26.1 The position and detail of any construction joints not described in the Contract shall be subject to the
approval of the Engineer and shall be so arranged to minimise the formation of shrinkage cracks.

4/26.2 The timetable for the depositing of concrete between construction joints should be so arranged that no
face of concrete shall be left for more than 20 minutes before fresh concrete is deposited against it.
Pauses for meals, servicing of machines, changes of shift, etc. and the distribution of concrete among the
positions where work may be proceeding simultaneously must be carefully organised to ensure that the
above mentioned interval shall not be exceeded.

4/26.3 When the continuous placement of concrete in any structural member is interrupted or delayed, for any
reason, for a period long enough for the previously partially placed concrete to take its initial set, the
Engineer shall declare such joint a cold joint and the Contractor shall immediately remove the previously
partially placed concrete from the forms. No extra payment will be made for the initial placement or the
removal of concrete which is wasted because of a cold joint. The Engineer may suspend all or any part of
subsequent concrete work until he deems the Contractor has corrected the cause for the cold joint
occurrence.

4/26.4 Where dowels, reinforcing bars or other adequate ties are not required by the drawings, keys shall be as
made by embedding water soaked beveled timbers in soft concrete. The key shall be sized as shown on
the details, or as directed by the Engineer, which shall be removed when the concrete has set. In
resuming work the surface of the concrete previously placed shall be thoroughly cleaned of dirt, scum,
laitance or other soft material with stiff wire brushes, and if deemed necessary by the Engineer, shall be
roughened with a steel tool. The surface shall then be thoroughly washed with clean water and painted
with a thick coat of neat cement mortar, after which the concreting may proceed.

4/26.5 Expansion joints shall be constructed at the locations, of the materials and to the dimensions shown on
the drawings.

4/26.6 The upper surface of lifts of concrete walls and columns shall be horizontal and if the formwork extends
above the joint on the exposed face, it shall be cleaned of adhering concrete before the next lift is placed.
The concrete placed immediately above a horizontal construction joint shall not be the first batch through
the mixer and shall be thoroughly compacted and worked against the existing concrete.

4/26.7 In the case of vertical surfaces, a 1:1 slurry of cement and concreting sand shall, wherever possible, be
well worked into them immediately before the fresh concrete is placed.

4/26.8 Where sections of the work are carried out in lifts the reinforcement projecting above the lift being cast
shall be adequately supported to prevent movement of the bars during the Casting and setting of the
concrete.

4/26.9 Wherever possible laitance and all loose material shall be removed while the concrete is still green and
no further roughening shall then be required. Where this is not possible, it shall be removed by
mechanical means provided the concrete has been in position for more than 24 hours. The roughened
surface shall then be washed with clean water.

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4/27 CURING OF CONCRETE

4/27.1 Immediately after compaction and for 14 days thereafter, concrete shall be protected from the harmful
effects of weather, including rain and rapid temperature changes, and from' drying out. The methods of
protection shall be subject to the Engineer's approval. The Engineer's approval will be conditional upon
the proposed curing method proving to be satisfactory on site. Only water curing shall be allowed for
bridges and retaining walls, which shall be continuously cured for a minimum of 14 days.

4/27.2 The method of curing used shall minimise the loss of moisture from the concrete. On concrete surfaces
which are to be water-proofed, and for bridge superstructures including piers, abutments, retaining walls and
culverts curing membranes shall not be used. Details of all curing methods to be used shall be subject to the
approval of the Engineer.

4/27.3 For the bridges retaining walls and culverts exposed and stripped concrete surfaces shall be kept damp
using soaked hessian sheeting. Polythene sheet covering shall be used where directed by the Engineer
to minimise evaporation. The hessian sheeting shall be maintained continuously damp for a minimum
period of 14 days after casting. The water used for this purpose shall be of the same quality as that
allowed in mixing the concrete.

4/27.4 Whenever approved by the Engineer, membrane curing of concrete with an approved liquid may be used
as an alternative to curing with water except that membrane curing liquid shall not be applied to surfaces
of concrete from which the shuttering has been stuck, until the concrete has been inspected and
approved by the. Engineer's representative.

4/27.5 Concrete curing compound shall be of an approved type which shall be readily distinguishable upon the
concrete surface for at least four hours after application. The colour, if any, shall become inconspicuous within
seven days after application.

4/28 EARLY LOADING

4/28.1 Concrete shall at no time be subject to loading, including its own weight, which will induce a compressive stress
in it exceeding 0.25 of its compressive strength at the time of loading or of the specified 28 day strength
whichever is lower.

4/28.2 For the purpose of this Clause, the assessment, of the strength of the concrete and the stresses produced by
the loads shall be subject to the agreement of the Engineer.

4/28.3 No superstructure load shall be placed upon finished piers or abutments until the Engineer so permits, but in no
case shall any load of any kind be placed until the curing has been completed. The Contractor shall not place
any temporary loads on deck slabs. Bridge deck slabs shall be opened to traffic or construction equipment only
when so permitted by the Engineer.

4/29 CONCRETING AT NIGHT

4/29. 1 No concrete shall be mixed or placed when the light is insufficient, unless an adequate and approved artificial
lighting system is operated and such night work is approved by the Engineer.

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4/30 CONCRETING IN HOT WEATHER

4/30.1 When the rate of evaporation of surface moisture from concrete is expected to approach 1 Kg/m2 per hour
(estimated from following chart) or when the shade air temperature is 35 deg. C and rising, precautions shall
be taken, including the following:-

a) Dampening the forms.

b) Reducing the concrete temperature to the lowest practical level by

procedures such as

i. Shading the aggregate.

ii. Cooling the mixing water before use.

iii. Screening the mixing plant and transporting vehicles from wind, rain and sun.

c) Erecting wind breaks and sunshades at the concrete placing location.

d) Reducing the time between the placing of the concrete and the start of
curing to the minimum possible.

e) Minimising evaporation (particularly during the first few hours

subsequent to placing the concrete) by suitable means such as applying
moisture by fog spraying.

4/30.2 All precautions to be taken shall be subject to the Engineer's approval and the Contractor shall demonstrate
that all approved precautions are available for use prior to the Engineer granting approval to any concreting
operation.

4/30.3 The temperature of the concrete when placed shall not exceed 32 deg.C nor shall concrete be mixed or
placed when the shade air temperature is 35 deg.C or above, or is expected to reach such a level during
concreting, without special permission from the Engineer.

4/31 MINIMUM TEST REQUIREMENTS FOR CONCRETE

4/31.1 Any one set of 6 cubes for each class of concrete and for each particular application represent a
maximum quantity of concrete as shown in Table 4.6. The point of sampling of fresh concrete shall be
at delivery into the construction unless otherwise directed by the Engineer. Each set of cube shall be
made from a separate batch.

4/31.2 Portland Cement: One 2 Kg sample for quality test shall be taken from each 1,700 bags or equivalent
weight in accordance with BS EN 196 - 7.

4/31.3 Water: One (1) gallon sample shall be obtained prior to use from each source and at least once every
week for quality testing.

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TABLE 4.6 SAMPLING RATES

SAMPLING TO REPRESENT
TYPE OF STRUCTURE A VOLUME OF M3

1. Critical structures
e.g. masts, cantilevers, columns 10

2. Intermediate structures
e.g. beams, slabs, bridge decks 50

3. Heavy concrete construction

e.g. breakwaters, solid rafts 100

4/32 FORMWORK

CONSTRUCTION

4/32.1 Formwork shall include all temporary or permanent forms required for forming the concrete, together with
all temporary constructions required for their support.

4/32.2 All formwork shall be of such quality and strength as will ensure rigidity throughout the placing, ramming,
vibration and setting of the concrete without visible deflection.

4/32.3 All formwork shall be so constructed that there shall be no loss of material from the concrete. After
setting, the concrete shall be in the position and of the shape and dimensions prescribed. The finished
surface of exposed concrete shall be of a quality specified on the drawings and approved by the Engineer.

4/32.4 Unless otherwise provided on the drawings or directed by the Engineer, all exposed edges shall be
bevelled by using dressed, mill-cut, triangular moulding, having twenty (20) millimetres sides.

All curved surfaces shall be formed with approved plywood or steel.

The Contractor shall in all cases request the approval of the formwork by the Engineer's
representative in sufficient time to allow an inspection to be made and shall not commence concreting
until such approval is obtained. The period between the Contractor's request for approval and his
intention to commence concreting shall be not less than one clear normal working day and the
Engineer's representative may require a longer period if, in his opinion, the formwork is of such
complexity as to require it.

Such approval shall not absolve the Contractor of his responsibilities under the Contract.

4/32.5 Where internal metal ties are permitted, they or their removable parts shall be extracted without
damage to the concrete and the remaining holes filled with mortar. No permanently embedded metal
part shall have less than 40 mm cover to the finished concrete surface or the specified cover to the
reinforcement whichever is the greater.

4/32.6 The Contractor shall submit to the Engineer for his approval strength and deflection calculations and
drawings of the formwork he proposes to use. The Contractor shall ensure that adequate time is

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given to enable the Engineer to examine the calculations and drawings and also to inspect the
formwork before concrete is placed within it.

FALSEWORK

4/32.7 Detailed drawings for falsework and centering shall be prepared by the Contractor and submitted to
the Engineer for approval. The drawings must be approved by the Engineer before the work is
started.

4/32.8 The Contractor shall submit to the Engineer for approval at least one (1) month before commencing
work, details of his proposed system of falsework, including detailed drawings and calculations.
Falsework shall be capable of accommodating temperature changes without causing damage to the
concrete.

4/32.9 Falsework and centering shall be designed and constructed to provide the necessary rigidity to
support all loads placed upon it without appreciable settlement or deformation. Falsework columns
shall be supported on wood or metal bases to support all falsework that cannot be founded on rock,
shale or thick deposits of other compact material in their natural beds. Falsework shall not be
supported on any part of the structure, except the footings, without the written permission of the
Engineer. The number and spacing of falsework columns, the adequacy of sills, caps and stringers
and the amount of bracing in the falsework framing shall be subject to approval of the Engineer.

4/32.10 All timber shall be of sound wood, in good condition and free from defects that might impair its
strength. If the vertical members are of insufficient length to cap at the desired elevation for the
horizontal members, they shall preferably be capped and frames constructed to the proper elevation.
Ends of the vertical members shall be cut square for full bearing to preclude the use of wedges. If
vertical splices are necessary, the abutting members shall be of the same approximate size, the ends
shall be cut square for full bearing, and the splices shall be scabbled in a manner approved by the
Engineer.

4/32.11 All steel members shall be in good condition, free from damage, kinks, corrosion or any other defect
which might impair their strength.

4/32.12 The Contractor shall compute the form settlement and deflection required for bridges so that when the
final settlement is complete, the structure will conform to the required camber, section and grade as
shown on the drawings.

4/32 13 The Engineer will check and approve the Contractor's computations. Long, tapered hardwood wedges or
screw jacks shall be used in all falsework construction and shall be so placed that they can be adjusted to
give proper form alignment. The Contractor shall, if required by the Engineer, provide means for adjusting
forms to offset any excessive settlement, if screw jacks are used, they shall be adequately braced and
secured in such a manner that will prevent tipping of the jacks in any direction. 4/32.14 The
Contractor shall provide means for accurately measuring settlement in falsework during placement of
concrete, and shall provide a competent observer to observe and correct the settlement.

4/32.15 In designing forms and centering, concrete shall be regarded as a liquid. In computing vertical loads,
a weight of twenty four hundred (2,400) kilograms per cubic metre shall be assumed, and not less
than thirteen hundred and sixty (1,360) kilograms per cubic metre shall be assumed in computing
horizontal pressure.

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4/32.16 The Engineer may refuse permission to proceed with other phases of the work if he deems the
falsework unsafe or inadequate to support property the loads to which it will be subjected.

4/32.17 The review or approval of falsework drawings by the Engineer or permission to proceed with the work
shall not relieve the Contractor of the responsibility for successful erection or satisfactory results.

TOLERANCE

4/32.18 The formwork shall be set to such lines and levels as to ensure that the following tolerances are not
exceeded in the structures as cast.

Structural Element Tolerance

For all buried concrete + 25mm -12mm

In addition, for concrete surfaces that are to
be waterproofed, abrupt irregularities in the
surface finish shall not exceed 3mm.

For soffit edge beams and sides of parapet plinths. +/-3mm but not more than 3mm in 3.5m
For all other concrete +/-6mm but not more than 3mm in 3.5m

PREPARATION OF FORMWORK BEFORE CONCRETING

4/32.19 The inside surfaces of forms shall, except for permanent formwork, or unless otherwise agreed by the
Engineer, be coated with a release agent approved by the Engineer. Release agents shall be applied
strictly in accordance with the manufacturer's instructions and shall not come into contact with the
reinforcement. Different release agents shall not be used in formwork to concrete which will be visible
in the finished works. A panel shall be constructed utilising the proposed release agent for the
Engineer's approval. The surface of the panel shall not exhibit discolouration or any significant retard
of the surface mortar strength.

4/32.20 Immediately before concreting all forms shall be thoroughly cleaned out. All formwork shall be inspected
and approved by the Engineer before any concrete is placed in it but such approval shall not relieve the
Contractor of his responsibilities for the safety, accuracy or efficiency of the work.

REMOVAL OF FORMWORK

4/32.21 The Engineer shall be informed in advance when the Contractor intends to strike any formwork.

4/32.22 At the time of striking any formwork, the concrete shall be of sufficient age and strength for it to withstand
the effects of striking, including the effect of thermal shock or the loss of surface durability upon
premature exposure, and to be able to withstand the resulting stresses without adverse effects.

4/32.23 The time at which the formwork is struck shall be the Contractor's responsibility but the minimum
periods between completion of placing concrete in a section of the works and the removal of forms
shall be as follows:-

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Sides of beams, walls and columns 2 days

Soffits of beams and slabs (props left in) 7 days

Removal of props (beams and slabs) 14 days

Soffits of precast beams 7 days

4/32.24 Formwork shall be constructed so that the side forms of members can be removed without
disturbing the soffit forms and, if props are to be left in place when the soffit forms are removed,
these props shall not be disturbed during the striking.

4/32.25 Formwork shall be removed without damage to the concrete.

4/32.26 Where it is intended to re-use formwork it shall be thoroughly cleaned and made good to the
satisfaction of the Engineer.

4/33 CLASSES OF FINISH

FORMED SURFACES

4/33.1 The class of finish of formed surfaces shall be as shown on the drawings.

4/33.2 Class F1: As struck.

4/33.3 Class F2: The irregularities in the finish shall be no greater than those obtained from the use of
wrought thicknessed square edged boards arranged in a uniform pattern. The finish is intended
to be left as struck but imperfections such as fins and surface discolouration shall, if required, be
made good by methods approved by the Engineer.

4/33.4 Class F3: 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 joined and fixed to its backing that it imparts no blemishes. It shall be of
the same style and obtained from only one source throughout.

4/33.5 The Contractor shall make good any imperfections in the finish as required by the Engineer.
Internal ties and embedded metal parts will not be allowed.

4/33.6 Class F4: The requirements for Class F4 are as for class F3 except that internal ties and
embedded metal parts will be permitted. The ties shall be positions as described in the Contract
or as agreed by the Engineer.

4/33.7 Permanently exposed concrete surfaces to Classes F4, F3 and F2 finish shall be protected from
rust and stains of all kinds.

4/33.8 Unless otherwise described in the Contract, all formwork joints for exposed surfaces of concrete
to Class F2, F3 and F4 finish shall form a regular pattern with horizontal and vertical lines
continuous throughout each structure and all construction and movement joints shall coincide
with these horizontal or vertical lines.

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4/33.9 REMEDIAL TREATMENT OF SURFACES

An inspection of the concrete surface shall be carried out immediately after removing the
formwork, and any remedial treatment to surfaces proposed by the Contractor shall be submitted
to the Engineer for approval and shall be carried out without delay. Portions of the structure
which can not be finished or properly repaired to the satisfaction of the Engineer shall be
removed.

4/33.10 Any concrete, the surface of which has been treated before being inspected by the Engineer,
shall be rejected.

UNFORMED SURFACES

4/33.11 Class U1 Finish. The concrete shall be uniformly levelled and screeded to produce a plain
surface as described in the Contract. No further work shall be applied to the surface unless it is
used as a first stage for a Class U3 finish.

4/33.12 Class U2 Finish. After the concrete has hardened sufficiently to prevent laitance from being
worked to the surface, a Class U1 finish shall be floated by hand or machine sufficiently to
produce a uniform surface free from screed marks.

4/33.13 Class U3 Finish. When the moisture has disappeared and the concrete has hardened sufficiently
to prevent laitance from being worked to the surface. Class U1 finish shall be steel-trowelled
under firm pressure to produce a dense, smooth uniform surface free from trowel marks.

4/33.14 Class U4 Finish. This finish is for bridge decks that are to receive approved waterproofing
systems. The concrete shall be uniformly levelled and screeded to produce a plain surface.
When the concrete has sufficiently hardened to prevent laitance being worked to the surface it
shall be floated to produce a uniform surface free from screed marks and exposed aggregate.
Finally the surface shall be textured by brushing or otherwise to the waterproofing
manufacturer's requirements as agreed by the Engineer. The accuracy of the finished surface
shall be such that it does not deviate from the required profile by more than + 5 mm over a 3 m
gauge length or have any abrupt irregularities more than 3 rnm.

SPECIAL FINISHES

4/33.15 Where special finishes are specified in the drawings or in a particular specification the
Contractor shall make trial panels for the formed finishes specified for inspection and approval by
the Engineer.

4/34 MORTAR

4/34.1 Mortar shall be mixed by approved mechanical mixers. Mortars containing plasticisers shall not
be oven-nixed. Mixers shall be kept clean at all times.

4/34.2 Mortar shall be used within thirty minutes after mixing. Hardened mortar shall not be used in the
work and shall be removed immediately from the site. Mortar shall be prepared in the following
proportions with the addition of a minimum quantity of water for workability.

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4/34.3 MORTAR (3:1)

Sand/Cement mortar (3:1) shall be composed of one part of cement to three parts of sand by
volume. This type of mortar shall be used in blockwork where high strength is required.

4/34.4 MORTAR (4:1)

Sand/Cement with plasticiser mortar (4:1) shall be composed of one part of cement to four parts
of sand with a mixture of an approved plasticising agent, added in accordance with the
manufacturer's instructions.

4/34.5 The sand used in mortar must be dry when proportioning. Allowance for bulking shall be made
when gauging by volume. The mean compressive strength at 28 days for each mortar shall
conform to BS 5628 : Part I.

4/34.6 Sand shall be natural sand or crushed natural stone or a combination of both as specified in BS
1200.

4/35 EXTENT OF POURS

4/35.1 The limit of individual pours and the height of lifts shall be as approved. The sequence of pours
shall be arranged to minimise thermal and shrinkage strains.

4/35.2 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.

4/35.3 Bridge decks, floors, roofs and ground slabs shall be placed in an approved sequence of panels.
'Chequerboard' placing shall be avoided. Adjacent panels shall not be placed within 3 days, and
then only provided that the concrete in the first pour has cooled down to below 38 degrees
centigrade or ambient temperature. Placing of adjacent panels shall take place as soon as
practicable after the above criteria have been satisfied. Panels shall be 5 m x 5 m and any pour
exceeding 25 m2 will only be considered for approval if substantiated by calculations.

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EFFECT OF CONCRETE AND AIR TEMPERATURE RELATIVE HUMIDITY AND

WIND VELOCITY ON THE RATE OF EVAPORATION OF SURFACE MOISTURE
FROM CONCRETE

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