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Specifications Cast-In-Place Concrete

RW Armstrong & Associates 033000

SECTION 03 33 00

CAST-IN-PLACED CONCRETE

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Specifications Cast-In-Place Concrete
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DIVISION 03

SECTION 033000 – CAST-IN-PLACE CONCRETE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of contract, including general and supplementary


conditions and Division 1 specification, apply to work of this section

B. Section 031000 - Concrete Formwork.

C. Section 032000 - Concrete Reinforcement.

1.2 SECTION INCLUDES

A. Structural Concrete

B. Architectural Concrete

C. Water Tight Concrete

D. Concrete Tolerances

E. Concrete Curing

1.3 RELATED SECTIONS

A. Section 031000 – Concrete Forming and Accessories

B. Section 032000 – Concrete Reinforcing

C. Section 033800 – Post Tensioned Concrete

D. Section 035300 – Concrete Topping

1.4 REFERENCES

Product manufacture, testing and installation shall comply with the following references unless
otherwise stated in the specification or otherwise approved by the Engineer

A. ASTM C40 -Test Method for Organic Impurities in Fine Aggregates for Concrete

B. ASTM C88 - Test Method for Soundness of Aggregates by Use of Sodium Sulphate or
Magnesium Sulphate.

C. ASTM C94 - Specification for Ready-Mixed Concrete

D. ASTM C109 - Test method for Compressive Strength of Hydraulic Cement Mortars
(Using 2inch or 50mm cube specimens)

E. ASTM C123 - Test Method for Lightweight Pieces in Aggregate

F. ASTM C127 - Test Method for Specific Gravity and Absorption of Coarse Aggregate

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G. ASTM C128 - Test Method for Specific Gravity and Absorption of Fine Aggregate

H. ASTM C131 - Test Method for Resistance to Degradation of Small Size Coarse
Aggregate by Abrasion and impact in the Los Angeles Machine

I. ASTM C138 -Test Method for Unit Weight, Yield and Air Content (Gravimetric) of
Concrete.

J. ASTM C142 - Test Method for Clay Lumps and Friable Particles in Aggregates

K. ASTM C150 - Specification for Portland Cement

L. ASTM C157- Test method for Length Change of Hardened Hydraulic – Cement Mortar
and Concrete

M. ASTM C191- Test Method for Time of Setting of Hydraulic Cement by Vicat Needle

N. ASTM C227- Test Method for Potential Alkali Reactivity of Cement-Aggregate


Combinations (Mortar-Bar Method).

O. ASTM C232 - Test Methods for Bleeding of Concrete

P. ASTM C260 - Specification for Air-Entraining Admixtures for Concrete

Q. ASTM C289 - Test Method for Potential Alkali-Silica Reactivity of Aggregates (Chemical
Method)

R. ASTM C494 - Specification for Chemical Admixtures for Concrete

S. ASTM C511 - Specification for Moist Cabinets, Moist Rooms and Water Storage Tanks
Used in the Testing of Hydraulic Cements and Concretes

T. ASTM C1017 - Specification for Chemical Admixtures for Use in Producing Flowing
Concrete

U. ASTM C1064 - Test Method for Temperature of Freshly Mixed Portland Cement
Concrete

V. ASTM C1202 - Test Method For Electrical Indication of Concrete’s Ability to Resist
Chloride Ion Penetration.

W. ASTM D512 - Test Methods for Chloride Ion in Water

X. ASTM D513 - Test Methods for Total and Dissolved Carbon Dioxide in Water

Y. ASTM D516 - Test Method for Sulphate Ion in Water

Z. ASTM D1888 - Test Method for Particulate and dissolved Matter, Solids, or Residue in
Water

AA. ASTM D2419 - Test Method for Sand Equivalent Value of Soils and Fine Aggregate.

BB. ACI 305 - Hot Weather Concreting

CC. ACI 308 - Standard Practice for Curing Concrete

DD. BS 12 - Portland cement

EE. BS 812 - Testing aggregates

FF. BS 882 - Aggregates from natural sources for concrete

GG. BS 1881 - Methods of testing concrete

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HH. BS 3148 - Water for making concrete (including notes on the suitability of the water)

II. BS 4027 - Sulphate-resisting Portland cement

JJ. BS 4408 - Recommendations for non-destructive methods of test for concrete

KK. BS 4550 - Methods of testing cement

LL. BS 5075 - Concrete admixtures

MM. BS 5328 Part 1 - Guide to specifying concrete

NN. BS 5328 Part 2 - Methods for specifying concrete mixers

OO. BS 5328 Part 3 - Specification for the procedures to be used in producing and
transporting concrete

PP. BS 5328 Part 4 - Specification for the procedures to be used in sampling, testing and
assessing compliance of concrete

QQ. BS 6089 - Assessment of concrete strength in existing structures

RR. BS 6100 - Glossary of building and civil engineering terms

SS. BS 6699- Ground Granulated Blast furnace Slag

TT. BS 8110 - Structural use of concrete

UU. CIRIA Special Publication 31

VV. CSTR No. 11 - Concrete Society Technical Report No. 11

WW. DIN 1048 - Test methods for concrete

XX. ISO 9000 - Quality management and quality assurance standards

YY. LEED for New Construction 2009 Reference Guide

1.4.1 DEFINITIONS

The following definitions shall pertain to words or phrases as utilized in this section.

A. “Cementitious Materials” shall mean cement or cement plus GGBS.

B. “Water/Cement Ratio” shall mean the ratio between the total weight of
water in the concrete (less the water absorbed by the aggregate) and
the weight of cement (or cementitious materials), expressed as a
decimal fraction.

C. “Admixtures” shall mean a material other than water, aggregate,


cementitious materials or fiber reinforcement, used as an ingredient of
concrete or mortar.

D. “Hot Weather” shall mean when the shade temperature is above 400C
on a rising thermometer or 430C on a falling thermometer.

E. “Coarse Aggregate” shall be considered as that size passing a 28mm


sieve and predominately retained on a 5mm sieve.

F. “Fine Aggregate” shall be considered as that size predominately passing


a 5mm sieve and predominately retained on a 0.075mm size.

G. “OPC” shall mean ordinary Portland cement.

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H. “SRC” shall mean sulphate resisting Portland cement.

I. “MSRC” shall mean moderate sulphate resisting Portland cement.

J. “GGBS” shall mean ground granulated blast furnace slag.

K. “Gap-graded aggregate” shall mean graded aggregate without one or


more of the intermediate sizes.

L. “Single-size aggregate” shall mean aggregates containing a major


proportion of particles of one size.

M. “Characteristic Strength” shall mean that value of strength below which


5% of all strength measurements are expected to fall.

N. “Target Mean Strength” shall mean the specified strength plus the
margin.

O. “Margin” shall mean the difference between the specified strength and
the target mean strength.

P. “Acceptable or Accepted” shall mean acceptable or accepted by the


Engineer.

Q. “Approval or Approved” shall mean approval from the Engineer or


approved by the Engineer.

R. “All-in” aggregate shall mean the materials composed of a mixture of


coarse aggregate and fine aggregate.

1.5 GENERAL REQUIREMENTS

A. Concrete shall be batched only with approved materials, approved mix designs, and at
approved facilities.

B. The Contractor shall define the method of design of the mix, by reference to a
recognized published design method. The design method shall be approved by the
Engineer.

C. Plant trials shall be carried out for each grade and type of concrete in the contract,
unless approved otherwise by the Engineer.

D. Aggregate proportions shall be based on measured and not assumed relative densities.

E. If requested by the Engineer, concrete mix designs which include an admixture shall be
prepared and tested both with and without the admixture to give a clear indication of its
effects on the physical characteristics of the mix.

F. Results of the trial mixes must demonstrate that the proposed mix complies with the
strength, workability and durability requirements of this specification.

G. The Contractor shall use Regional sourced materials according to PBRS Ver.1, SM-9, 2
credit point criteria, unless otherwise approved by the Engineer.

H. The contractor should use recycled aggregates for at least 15% of all aggregates used
on site (by volume) in structural and no-structural applications as per requirement of
PBRS Ver. 1, SM-10 and shall be approved by the Engineer. The Contractor shall
demonstrate that a submitted material satisfies the required design and performance
criteria.

I. The Contractor shall propose use of supplementary cementing materials (SCMs) including
Fly Ash, Ground Granulated Blast Furnace Slag (GGBS) and Silica Fumes or increased use

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of aggregates or admixtures, to reduce the overall amount of Portland cement used and
associated embodied greenhouse gas emission as table SM 10.1 Strength grade (40) – 1
credit point (rows B1, C1 and D1)

1.6 SUBMITTALS

A. Product Data, test results and other information as required to prove compliance with the
specification shall be submitted for approval according to Section on at least the
following products.

1. Cement

a. Recent independent test results acceptable to the Engineer confirming


compliance with the specified requirements and referenced standards.

b. Manufacturer's certificates shall also be supplied with each consignment


of cement certifying compliance with the relevant standard.

2. GGBS

a. Recent independent test results acceptable to the Engineer confirming


compliance with the specified requirements and referenced standards.

b. Manufacturer's certificates with all information necessary to verify


compliance with BS 6699 shall also be supplied with each consignment
of GGBS.

3. Microsilica

a. Recent independent test results acceptable to the Engineer confirming


compliance with specified requirements and referenced standards.

b. Manufacturer's certificates with all information necessary to verify


compliance with internationally recognized standard and shall also be
supplied with each consignment of Microsilica.

4. Aggregates

a. Recent independent test results acceptable to the Engineer confirming


compliance with the specified requirements and referenced standards.

b. Full details of the proposed sources of aggregates.

5. Water

a. Recent independent test results acceptable to the Engineer confirming


compliance with the specified requirements and referenced standards.

6. Admixtures

a. Manufacturer’s technical specifications and recommendations.

b. Recent trial results acceptable to the Engineer illustrating the efficiency


of the product for its particular application.

7. Concrete Mix design with at least the following information:

a. Type of cement

b. Cement content

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c. GGBS content, MS content

d. Max. aggregate size

e. Combined grading curve

f. Quantities of all individual materials

g. Name of admixture

h. Target slump (at discharge)

i. Details to calculate W/C ratio

j. Compressive strength

k. Hardened density

l. Water permeability

m. Rapid Chloride Penetration

n. Bleeding

o. SO3 and Cl contents

p. Slump profile

q. Target unit weight

r. Target temperature

B. Samples of the following shall be submitted.

1. Cement

a. Provide cement samples from each consignment delivered to the site as


required by the Engineer for testing.

b. Samples shall be taken in the presence of the Engineer’s


Representative.

2. GGBS, Microsilica

a. As requested by the Engineer for independent testing.

b. Samples shall be taken in the presence of the Engineer’s


Representative.

3. Aggregates

a. Provide samples of both fine and coarse aggregates for testing at least
three weeks prior to beginning deliveries to the site and at regular
intervals as required by the Engineer.

b. Samples shall be taken in the presence of the Engineer’s


Representative.

4. Water

a. Provide samples of water proposed for concreting works.

b. Samples shall be taken in the presence of the Engineer’s


Representative.

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5. Admixture

a. As requested by the Engineer.

C. The Contractor shall submit a method statement according to section for concrete
batching and delivery which shall include at least the following details:

1. Type of plant proposed.

2. Layout of concrete production facility.

3. Proposed method of organisation of the concrete production facility.

4. Quality control procedures for concrete and concrete materials.

5. Batching and Transport of concrete.

D. Prepare shop drawings showing the size, spacing, location, quantities and details for
reinforcing steel in accordance with the drawings and specifications. Drawing shall be
prepared by Detailers having a minimum of two years experience in this type of work.
Drawings and bar lists prepared under this section shall be checked and initiated by the
Checker of the firm producing the drawings before submission to the Engineer.

1. Include necessary plans and elevations of walls and beams on the diagrams,
drawn to a scale of not less than 1:50 metric. Sections shall be drawn to a scale
of not less than 1:20 metric. Placing drawings shall include sufficient details,
dimensions and field instructions to permit complete setting of fall reinforcement
without reference to the design drawings and shall show location and length of
lap splices.

2. Submit drawings showing all proposed construction joint locations and pour
sequences to the Engineer for approval.

3. Submit drawings showing the locations and size of all sleeves and openings
through concrete elements required for all trades.

4. Submit shop drawings as they are prepared. Saving a large number of drawings
for one submission will delay their review and return.

1.7 QUALITY ASSURANCE

A. The Contractor shall refer to the "Guide to the Construction of Reinforced Concrete in
the Arabian Peninsula" (http://www.concrete.org.uk) and follow the procedures within,
except where they conflict with this specification, in which case this specification shall
take precedence.

B. Installer Qualifications: A qualified UAE-based installer who employs on Project


personnel qualified as ACI-certified Flatwork Technician and Finisher and a supervisor
who is an ACI certified Concrete Flatwork Technician or equivalent certification program.

C. Manufacturer Qualifications: A firm based in Abu Dhabi and experienced in


manufacturing ready-mixed concrete products and certified with NRMCA requirements
(www.NRMCA.org) for production facilities and equipment or equivalent international
qualification. Minimum 5 years UAE experienced required.

D. Quality Control By Contractor:

1. Submit drawings showing all proposed construction joint locations and pour
sequences to the Engineer for approval.

2. The Contractor shall maintain a program of quality control to ensure that the
minimum standards specified herein are attained.

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3. The Company's general review during construction and activities of the


Company’s Testing Agency are undertaken to inform the Company of
performance by the Contractor but shall in no way replace or augment the
Contractor's quality control program or relieve the Contractor of total
responsibility for quality control.

4. The Contractor shall immediately report to the Engineer any deficiencies in the
work which are departures from the Contract Documents.

5. The Contractor shall propose corrective actions and their recommendations in


writing and submit them for review by the Engineer. After proposed corrective
action is accepted by the Engineer and Company, the Contractor shall correct
the deficiency at no cost to the Company.

6. The Superintend and foreman at jobsite accepting concrete shall be minimum


qualified as ACI Concrete Field technician Grade 1.

7. The Quality Control Engineer shall be qualified as ACI Concrete Inspector

E. Testing Agency Qualifications: An independent, UAE-based agency, qualified according


to ASTM C 1077 and ASTM E 329 for testing indicated or equivalent international
qualification.

1. Personnel conducting field tests shall be qualified as ACI Concrete Field Testing
Technician, Grade 1, according to ACI CP-1 or an equivalent certification
program.
2. Personnel performing laboratory tests shall be ACI-certified Concrete Strength
Testing Technician and Concrete Laboratory Testing Technician - Grade I.
3. Testing Agency laboratory supervisor shall be an ACI-certified Concrete
Laboratory Testing Technician - Grade II or equivalent certification program.

F. Source Limitations: As far as practicable and without jeopardizing the


continuation of works, obtain each type or class of cementitious material
of the same brand from the same manufacturer's plant, obtain aggregate
from single source, and obtain admixtures from single source from
single manufacturer. Alternative sources may be accepted provided that
they are in compliance with this specification requirements.

G. Concrete Testing Methods and Requirements: refer to Part 3, Execution.

1.8 DELIVERY, STORAGE AND HANDLING

A. DELIVERY

1. Cement: Deliver by bulk or in the original sealed containers or bags, bearing the
manufacturer's name, cement type and date of manufacture, in batches not
exceeding 100 tonnes.

2. GGBS and Microsilica: Deliver by bulk, unless otherwise approved by the


Engineer.

3. Ready-mixed Concrete: Each load shall be accompanied by a computer printout


listing items in paragraph.

B. STORAGE

1. Cement: Immediately upon arrival at the Site, cement


shall be stored in:

i. Silos designed for this purpose, or

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ii. Dry, weather-tight and properly ventilated structures with floors


raised 450mm above ground level with adequate provision to
prevent absorption of moisture.

a. Each silo shall be labelled to show the type and source of cement.

b. Separate silo shall be provided for each type of cement.

c. Cement delivered to the Site in drums or bags provided by the


supplier or manufacturer shall be stored in the drums or bags until
used in the Works.

d. Any cement in drums or bags which have been opened shall be used
immediately.

e. In no case shall bagged cement be stored in stacks more than


eight bags high.

f. A free passage of at least one meter shall be left between the


cement and the side walls of the structure.

g. Where site limitations preclude the storage of cement on site,


cement shall be stored at a central location and shall be delivered
daily as required to specific job sites.

h. Different types of cement shall be kept in clearly marked separate


storage facilities.

i. The Contractor shall use the consignments in the order in which


they are received.

j. All storage facilities shall be subject to approval by the Engineer


and shall be such as to permit easy access for inspection and
identification.

k. Contractor shall provide weighing machines, which shall be


kept permanently in each shed for checking the weight of the
bags or barrels of cement.

l. The Engineer shall have access at all times to the cement


storage sheds.

m. During transport and storage, the cement shall be fully


protected from all adverse weather elements.

n. Do not use cement more than 4 weeks old for silo stored
cement and 6 weeks for bagged cement unless otherwise
approved by the Engineer.

o. Any consignment of cement not used within two months from


the date of manufacture or cement which, in the opinion of the
Engineer, is of doubtful quality shall not be used in the work until
it has been retested as directed by the Engineer and shown to
comply in all respects with the relevant standard of manufacture.

2. GGBS and Microsilica: Upon arrival at site, GGBS and


Microsilica shall be stored in silos designated for this
purpose.

3. Aggregates

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a. Contractor shall provide means of storing the aggregates


each point where concrete is made such that:

b. Each nominal size of coarse aggregates and fine aggregate


shall be kept separated at all times.

c. Contamination of the aggregates by the ground or other


foreign matter shall be effectively prevented at all times.

d. Each heap of aggregate shall be capable of draining freely.

e. Storage shall be such as to minimize segregation.

f. Stockpiles shall be on hard and clean surfaces with not more


than 5% slope and shall be shaded from direct sunlight.

g. Each bin shall be labelled displaying the nominal size and


source of aggregate.

h. Coarse aggregates shall be stockpiled in at least two of the


following nominal sizes

1) 20mm.

2) 10mm.

i. Contractor to ensure that the amount of dust in the aggregates


is reduced to a minimum by washing the aggregates.

4. Admixture

a. Store in an enclosed container, recommended by the


manufacturer and protected from extremes of heat by shading.

b. All tanks shall be fitted with a circulating pump which shall be


operated daily.

c. All tanks shall be indelibly marked for easy identification of its


contents.

5. Water

a. Store in clean covered tanks to prevent contamination.

b. The chilled water storage tank shall be insulated.

PART 2 - PRODUCTS

2.1 CONCRETE MIX

A. Concrete shall comply with the requirements of Table 1 and Table 2 unless otherwise
approved by the Engineer.

B. The Contractor is responsible for ensuring that the concrete is able to be fully compacted
within the concrete element regardless of reinforcing density or other limitations. This
may involve reducing the maximum aggregate size, increase the level of concrete
workability or use self-compacting concrete. Generally the slump of concrete as
delivered to site shall be in the range of 150mm to 200mm depending on the type/area of
application.

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C. OPC+GGBS concrete mix shall be used for all Structural elements and any other
concrete internal and external members in contact with soil and in uncontrolled
environment, such us Buildings Sub-Structure (Foundations, Pile Caps, Basement Walls,
Retaining Walls, Raft, Tie/Ground beams, Ground slab, etc.) and External Underground
Structures ( Pump Rooms, Concrete Tanks/Containers, Swimming Pool, etc.).

TABLE 1
GRADES OF CONCRETE

Concrete Nominal Min Min Max MS Max Cube Strength @ 28 Location,


2
Grade Size of Cement GGBS Content Water/ days, N/mm Members,
Aggregate, Content, Content by Cement Elements
3
mm kg/m by weight Ratio
weight of Target Specified
of cement Mean Compressive
cement material, Strength Cube
material, % Strength
%

C60 20 375 50 5 0.37 65 60 Not Used

C55 20 375 50 4 0.37 60 55 Not Used

C50 20 360 50 0.38 55 50 Not Used

Buildings Sub-
Structure &
C45 20 380 50 0.38 50 45 External
Underground
Structures

Super-Structure,
C45 20 380 N/A 0.40 50 45
Boundary Walls

C40 10 360 60 0.40 45 40 Not Used

C40 20 380 N/A 0.40 45 40 Not Used

C40 10 380 N/A 0.40 45 40 Not Used

Blinding, concrete
C20 20 200 N/A 0.55 25 20
screed

Notes:

1. Where adequate workability is difficult to obtain at the maximum water/cement


ratio allowed, the use of plasticizers or water-reducing admixtures shall be
utilized at no additional cost to the Client

2. Cementitious contents in excess of 420kg/m3 shall not be used, unless


otherwise approved by the Engineer.

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3. Concrete mix with 10mm nominal size aggregate shall be used in congested
areas at the direction of the Engineer.

4. All exterior exposed beams &Columns and slab to seawater spray concrete to
be covered with suitable protection like EIFS and/ or suitable paint too proof
below concrete.

TABLE 2
GENERAL REQUIREMENTS OF CONCRETE

Srl. Tests Test Method Specification Limit


1 Temperature (at placement) ASTM C1064 30°C Max.

2 Slump mm (at placement) BS 1881: Part 102 C50: 180 ± 25


C40: 180 ± 25

3 Slump mm (for OPC or SRC without C20: 125 ± 25

GGBS and MS C40: 100 ± 25

4 Bleeding ASTM C232 1.0% Max.

5 Unit Weight (wet) ASTM C138 ± 35 kg/m³

6 Compressive strength BS 1881: Part 116 See Table 1

7 Hardened Density BS 1881: Part 114 Not applicable

8 Water Permeability DIN 1048 OPC: 20mm


Max penetration at 56 days OPC+GGBS: 10mm

9 Rapid Chloride Penetration (RCP) ASTM C1202 Low to very low for sub-
Max Charge Pass at 56 days structure and Moderate
for superstructure

10 Initial surface absorption test (ISAT) BS 1881 Part 208 OPC: 0.30
Max at 56 days: 10minute test (ml/m2/s) OPC+GGBS: 0.15

11 30 minute absorption test (WA) BS 1881 Part 122 OPC: 2.8%


At 7 days OPC+GGBS: 1.8%

12 Chlorides (as Cl) by weight of BS1881: Part 124 For reinforced concrete
cementitious material only
If made with OPC/MSRPC 0.10% Max.
If made with SRPC 0.06% Max.

13 Sulphates (SO 3 ) by weight of


R R BS 1881: Part 124 3.7% Max. (All concrete)
cementitious material

Notes

1. For concrete grade C20, only requirements of No. 2, 4, and 5 shall apply, unless otherwise
directed by the Engineer.

2. The Engineer may permit a higher slump if super plasticizer is added.

3. Average unit weight shall be established during plant trials.

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4. Values for compressive strength are at 28 days.

5. Values for water permeability and RCP are at 56 days.

D. Design of Concrete Mixes


1. At the commencement of the Works, the Contractor shall design a mix for each
grade of concrete listed in Table 1 that is required to be built into the Works.
2. Mix designs shall be proportioned according to a recognized standard as
approved by the Engineer.
3. Submit full details of the mix designs to the Engineer for his approval.
4. Each mix design shall be such that:

a. The nominal size of aggregate shall be as specified in Table 1.

b. Combined aggregate grading shall be continuous (not gap graded).

c. Aggregate quantity shall be calculated by weight.

5. Mixes shall be designed to produce a target mean strength of not less than that
specified in Table 1.

6. The combined grading (all-in) of the aggregate shall comply with table 5 of this
Specification for 20mm and 10mm nominal size.

7. All aggregates except dune sand shall be from the same source, unless
otherwise approved by the Engineer.

2.2 CEMENT

A. Unless noted otherwise, OPC shall be utilized for all concrete grades.
1. Ordinary Portland Cement (OPC) shall conform to BS 12 or ASTM C150 Type I,
but containing not less than 7% and not more than 12% by weight of tricalcium
aluminate (C3A).

B. Unless noted otherwise, SRC shall be utilized for grade C20 concrete.

C. Sulphate Resisting Portland Cement (SRPC) shall conform to BS 4027 or ASTM C150
Type V, but containing not less than 4% by weight of tricalcium aluminate (C3A).

D. Moderate Sulphate Resisting Portland Cement (MSRPC) shall conform to BS 12 or


ASTM C150 Type II, but containing not less than 5% and not more than 9% by weight
of tricalcium aluminate (C3A). In either case the cement shall not contain more than
2.7% by weight of sulphur trioxide (SO3).

E. Any cement that is, in the opinion of the Engineer, unsuitable for use in the Works shall
be rejected and the Contractor shall promptly remove such cement from the Site.

2.3 GROUND GRANULATED BLASTFURNACE SLAG (GGBS)

A. GGBS shall comply with BS 6699, in addition to the following requirements, unless
otherwise approved by the Engineer.
1. Raw material (slag) is limited to one source. Slag supplied or blended from
several different plants or steel mills will not be accepted unless approved by the
engineer.
2. GGBS shall be supplied to the concrete batching plant in bulk powder form.
3. Interground slag cements shall not be used.

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4. Preblended slag cements shall not be used.

B. Combinations of Cement with Ground Granulated Blastfurnace Slag (GGBS) or


Pulverised Fuel Ash (PFA)
1. Where specified by the Consultant, GGBS or PFA may be combined in the
concrete mixer with Portland cement complying with BS 12 as an alternative to
the use of factory combinations. GGBS and PFA shall not both be added to the
same concrete mix. The procedure given in Clause 4.4.3 of BS 5328 Part 1 shall
be followed.
2. The alumina (Al 2 O 3 ) content of the GGBS shall not exceed 14%.
3. No GGBS shall be added to any mix containing cements to BS 6588 or BS 6610,
or any other cement combinations containing PFA.
4. No PFA shall be added to any mix containing Portland Blast Furnace cements to
BS 146, BS 4246 or BS 4248 or any other cement combination containing
GGBS.
5. Combination of cement with GGBS or PFA shall be carried out under controlled
conditions and the proportions used shall be within the limits prescribed in BS
146, BS 4246, BS 4248, BS 6588 or BS 6610 as appropriate.
6. No GGBS, PFA or cement combination including either of them shall be included
in concrete mixes containing sulphate-resisting cement to BS 4027.
7. Supersulphated cement to BS 4248 shall not be combined with any other type of
cement.
8. Total replacement of cement by GGBS should not exceed 50% and the total
replacement of cement by PFA 35% without the prior approval of the Consultant.

2.4 MICROSILICA

A. Microsilica shall comply with an internationally recognized standard, in addition to the


following requirements, unless otherwise approved by the Engineer.

1. Raw material (Microsilica) is limited to one source. Microsilica supplied by more


than one vendor will not be accepted, unless approved by the Engineer.

2. Microsilica shall be supplied to the concrete batching plant in bulk powder form.

B. Combinations of Cement with Silica Fume (SF)

1. Where specified by the Consultant the concrete mix may contain an approved
silica fume. The silica fume shall originate from production of silicon from Ferro-
silicon alloys and shall have a silicon dioxide content not less than 90%.

2. The Contractor shall submit proposals for the supply of silica fume to the
Consultant for approval.

3. Chemical/physical analysis shall be provided for the following:

Parameter Criteria
3
Specific gravity 2,200 kg/m minimum
3
Bulk density (densified powder) 500-650 kg/m
2
Specific surface 18m /gram minimum
CaO 2.0% maximum
SiO 2 90% minimum
Al 2 O 3 1.0% maximum
Fe 2 O 3 1.5% maximum
MgO 2.0% maximum

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SO 3 1.5% maximum
Alkali as Na 2 O (includes K 2 O) 4.5% maximum
C 3% maximum
Activity Index Minimum 95% after 28 days
Loss of ignition Maximum 4%
Percentage of particles greater than Maximum 2%
44µm
Moisture content Maximum 2%
Chloride content Maximum 0.1%

4. Method of testing Methods of test shall be in accordance with Norsk Standard


NS 3045 or BS 4550 where applicable. Certification shall be provided for each
consignment of silica fume delivered.

5. The silica fume supplied shall be from a single furnace and shall not be sub-
supplied. The process of production of silica fume, i.e. the furnace product of
which the silica fume is a by-product, shall not vary.

6. The method of incorporation of the silica fume into the mix shall be subject to the
approval of the Consultant. The Contractor shall submit a method statement
describing the plant and equipment proposed for batching and mixing and the
timing of addition of the silica fume to the mix. The method statement shall be
supported by a letter from the silica fume supplier approving the methodology.

7. Silica fume shall be used in conjunction with a superplasticising admixture


specially formulated to aid dispersion of the silica fume throughout the mix.
Details of the proposed admixture shall be submitted to the Consultant for
approval.

8. The Contractor shall require that the silica fume supplier provides periodic on-
site monitoring of batching, mixing, placing and curing of the concrete and
reports on the above shall be submitted to the Consultant for inspection. The
representative of the silica fume supplier shall have the necessary technical
expertise and local experience.

2.5 AGGREGATES

A. Aggregates shall meet the requirements of Table 3 along with the following general
requirements, unless otherwise approved by the Engineer.

B. Aggregates shall consist of hard, durable, uncoated particles containing no harmful


material in quantities sufficient to adversely affect the concrete or reinforcing steel.

C. The aggregates used in the permanent work shall be obtained only from the sources
approved by the Engineer.

D. Aggregates shall comply with the requirements of BS 882 except as modified hereunder
and if necessary, shall be washed clean with potable water, to comply with these
requirements.

E. Contractor shall provide all data as specified in Appendix A of BS 882.

F. Contractor shall satisfy the Engineer that the aggregates to be supplied will not give rise
to an alkali reaction with the cement.

G. Samples of aggregates will be tested initially and at intervals during construction of the
works.

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1. The contractor shall provide the necessary equipment and labour for all
sampling.
2. If required by the Engineer, any or all tests shall be carried out in an approved
independent laboratory and the contractor shall bear all the expenses.

H. Sampling of aggregates shall be carried out in accordance with the applicable Sections
of BS 812.

I. Frequency of routine testing of aggregates shall be in accordance with Table 4.

J. Mineralogical tests are to be carried out as and when directed by the Engineer.

K. Fine aggregate shall be naturally occurring uncrushed sand, crushed sand or a blend of
the two.
1. The use of clean dune sand, blended with coarser sand may be permitted if it
meets the applicable specification requirements (except grading).
2. Beach sand shall not be permitted for use in concrete mixes.

3. Combined or individual fine aggregate gradation shall be in accordance with


Zone 1 or Zone 2 of Table 4 of this Specification.

4. The fineness modulus of fine aggregate shall be 2.4 – 3.2.

5. The fineness modules shall not vary by more than ±0.2 from the value of the
representative sample used in the mix design.

L. Coarse aggregates shall be single sized crushed. Limestone content should not exceed
1050 kg/m3.
1. The grading of coarse aggregate shall be in accordance with Table 3 of this
Specification.
2. Nominal sizes to be blended together shall be 20mm and 10mm, unless
otherwise approved by the Engineer.
3. In no case should the maximum size of aggregate be larger than one-fifth the
narrowest dimension between sides of the form, one-third of the thickness of
slabs or toppings or larger than three-fourths the minimum clear spacing
between reinforcing bars.
4. The variation of grading on any sieves between the approved samples and
subsequent consignments of single sized aggregate shall not exceed ±8% by
weight.
5. If for any reason, grading is changed beyond these limits and cannot be
corrected for reasons beyond the control of the Contractor, the Engineer may
request a new concrete mix design or modification to the approved mix
proportions.

M. Combined Aggregate
1. Approved coarse aggregate and fine aggregate in each batch shall be combined
in proportions to meet the specified grading in Table 5 of this Specification.
2. In no case shall materials passing the 0.075 mm sieve exceed 3.0% for gravel
aggregate or 7.0% for crushed rock by weight of the combined aggregate.
3. Changes from one gradation to another shall not be made during progress of the
work, unless approved by the Engineer.
4. Crushed and uncrushed aggregates, except dune sand, shall be mixed only if
approved by the Engineer.
5. During production, the combined grading (all-in aggregates) shall not vary by
more than 3% from the approved grading.

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TABLE 3
SPECIFICATION LIMIT OF COARSE AGGREGATE

Sieve Size 20mm 10mm


Mm Nominal Size Nominal Size
28.0 100 --
20.0 85 – 100 --
14.0 -- 100
10.0 0 – 25 85 – 100
5.0 0–5 0 – 25
2.36 -- 0-5

TABLE 4
SPECIFICATION LIMIT OF FINE AGGREGATE

Sieve Size Zone 1 Zone 2


Mm (Percentage by Mass (Percentage by Mass
passing BS Sieve) passing BS Sieve)
10.0 100 100
5.0 90 – 100 90 – 100
2.36 60 – 100 65 – 100
1.18 30 – 90 45 – 100
0.600 15 – 54 25 – 80
0.300 5 – 40 5 – 48
0.150 0 – 15 0 - 15

TABLE 5
SPECIFICATION LIMIT OF ALL-IN AGGREGATE

Sieve Size 20mm Nominal Size 10mm Nominal Size


Mm (Percentage by Mass (Percentage by Mass
passing BS Sieve) passing BS Sieve)
28.0 100 --
20.0 95 – 100 --
14.0 -- 100
10.0 -- 95 – 100
5.0 35 – 55 30 – 65
2.36 -- 20 - 50
1.18 -- 15 – 40
0.600 10 – 35 10 – 30
0.300 5 – 15
0.150 0–8* 0-8
* Increase to 10% for crushed rock fines

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TABLE 6
CONCRETE AGGREGATES

Item Requirement Test Methods Permissible Limits


No. BS 812 ASTM FINE COARSE
1. Grading Part 103 Table 4 of Table 3 of BS 882
(wet) BS 882

2. Material < 0.075 mm: Part 103


Natural / Crushed gravel (wet) Max. 3% Max. 1%

Crushed rock Max. 9% Max. 1%

3. Sand Equivalent Valve D2419 Min. 75%

4. Clay Lumps and


Friable Particles C142 Max. 1% Max. 1%

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

6. Organic Impurities C40 Refer note 1 NA

7. Water Absorption C128/C127 Max. 2.3% Max. 2%

8. Specific Gravity (app.) C128/C127 Min. 2.6 Min. 2.6


8.a SG for Gabbro C128/C127 Min. 2.8 Min. 2.8

9. Flakiness Index Part 105.1 NA Max. 25%

10. Elongation Index Part 105.2 NA Max. 30%

11. Acid Soluble Chlorides Part 117,


Concrete with: SRC Appendix C Max. 0.03% Max. 0.015%
Other concrete Max. 0.05% Max. 0.02%
12. Acid Soluble Sulphates Part 118 Max. 0.3% Max. 0.3%

13. Soundness (MgSo4), after C88 Max. 12% Max. 12%


5 cycles

14. Impact Value Part 112 NA Max. 30%

15. Loss Angeles Abrasion C131 NA Max. 30%

16. Potential Reactivity:


(Refer note 2)
Of Aggregates,
Chemical Method C289 As per Figure x 1.1 As per Figure x 1.1
Of Cement-Aggregate
Combination C227 6 month expansion
0.10% max.
17. Aggregate drying shrinkage BS1881: 0.075%
Part 120

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TABLE 7
FREQUENCY OF ROUTINE TESTS ON AGGREGATES

Note
1. The above tests shall be carried out at the specified frequency at an approved laboratory at the
contractor’s expense.
2. The above frequencies may be reduced at the Engineer’s discretion.
Item Test Method Test
No. Requirement Frequency

1. Grading BS 812: Part 103.1 Daily

2. Material finer than 0.075 mm BS 812: Part 103.1 Daily

3. Sand Equivalent Valve ASTM D2419 Daily


4. Clay lumps and Friable Particles ASTM C 142 Only if requested by Engineer

5. Organic Impurities ASTM C 40 Only if requested by Engineer

6. Water Absorption ASTM C128/C127 Monthly

7. Specific Gravity ASTM C128/C127 Monthly

8. Elongation and flakiness indices BS 812: Part 105.1 Weekly


& 105.2

9. Acid Soluble Chlorides, (Cl) BS 812: Part 117, Only if requested by Engineer
Quantitative (only) Appendix C

10. Acid Soluble Sulphates, S0 3 BS 812: Part 118 Only if requested by Engineer

11. Soundness (Mg S0 4 ), after 5 cycles ASTM C88 Every Three months

12. Aggregate impact value BS 812: Parts 111 Every Three months
Los Angeles Abrasion ASTM C 131 Every Three months

13. Moisture content in sand - by Moisture Twice daily


testor (speedy)

14. Potential Reactivity:


Of aggregates ASTM C289/ At the start of the project and whenever
Of cement aggregate combination ASTM C227 there is a change in the source of
supply.
15. Light weight pieces ASTM C123 Only if requested by the Engineer.
16. Aggregate drying shrinkage BS1881: Part 120 At the start of the project and whenever
there is a change in the source of
supply.

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2.6 WATER

A. Water used for concrete-mixes and washing of equipment shall be potable water and
shall comply with the requirements of BS 3148, unless otherwise stated herein or in
Table 5.

B. The pH of water used in concrete work shall be in the range of 7 – 9.

C. Ice if used, shall be flake ice and shall be the product of frozen water, which complies
with the acceptance criteria of Table 8, unless otherwise accepted by the Engineer.

D. Every effort should be made to protect water pipes and tanks from the sun, by burying,
shading, insulation, and/or painting white.

E. Contractor shall make his own arrangements and obtain approval for the supply of water.

F. Whenever required to do so by the Engineer, the Contractor shall take samples of the
water being used for mixing concrete and test them for quality as directed by the
Engineer.

G. No source of water shall be used unless approved by the Engineer.

TABLE 8
CHEMICAL LIMITATIONS FOR MIXING WATER
Max. Concentration Test Method Limit, mg/l

Chloride (as CI) 1. ASTM D512 250

Sulphates 2. ASTM D516 350

Alkali carbonates and bicarbonates 3. ASTM D513 500

Total dissolved ions, including 1, 2 & 3 above 4. ASTM D1888 2000

Note
1. Color of supernatant liquid shall be lighter than standard color solution.
2. Aggregates may initially be assessed for its reactivity in accordance with ASTM C289 and if
potential reactivity is indicated, then mortar bar tests in accordance with ASTM C227 shall be
carried out.
3. Properties of aggregates specified in Table 3 shall be for aggregates from individual sources or
individual stockpiles.

2.7 ADMIXTURES

A. Admixtures shall comply with one of the following standards, unless otherwise approved
by the Engineer.
1. ASTM C 494, ASTM C260, ASTM C1017, or BS 5075: as applicable.
2. The Contractor shall provide at least the following technical data for each type of
admixture.

a. Solid content.
b. Specific gravity.

c. The typical dosage and the effects of under dosage and over dosage.

d. The generic type(s) of the main active constituent(s) in the admixture.

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e. Whether or not the admixture contains chloride.

f. Whether or not the admixture leads to the entrainment of air when used
g. at the proposed dosage.

h. Where more than one admixture is used simultaneously in the same


concrete, details shall be provided on their interaction and compatibility.

B. The methods of use and the quantities of admixture used shall be subject to the
Engineer’s approval and shall in no way limit the Contractor’s obligations under the
contract to produce concrete with the specified strength, workability and durability.

C. Contractor shall be entirely responsible for the use of any approved admixture at no
additional cost to the Client and in strict accordance with the Manufacturer’s instructions.

D. Admixtures shall be free of chlorides.

E. Admixture shall not impair the durability of the concrete nor combine with constituents to
form harmful compounds nor increase the risk of corrosion of reinforcement.

F. If required by the Engineer, the concrete supplier shall furnish a series of at least 10 trial
mixes, which clearly indicate that the use of the admixture has consistently produced
concrete of the specified strength, durability, and workability.

G. If the above information is insufficient, extensive testing (including an IR scan) conducted


at the Contractor’s expense may be required by the Engineer to prove the performance
of the admixture.

H. The use of the Admixtures shall be strictly controlled to ensure that only correct dosages
are utilized as prescribed by the manufacturer and as determined by the trials.

I. Admixture is to be dispensed by a transparent unit, which enables the operator to see


the discharge, unless otherwise approved by the Engineer.

PART 3 - EXECUTION

3.1 LABORATORY TRIALS

A. Preliminary laboratory trials shall be carried out with the approved materials to determine
if the mixes will satisfy the specification.
1. Samples shall be taken and tests shall be conducted at a laboratory approved by
the Engineer to prove conformance with all the requirements in Table 1 and 2.
2. If any of the values obtained are unacceptable, the mixes shall be re-designed.
3. Approval of the laboratory-mix proportions shall in no way relieve the Contractor
of his responsibility to produce concrete, which meets the requirements of these
Specifications.
4. All costs connected with the laboratory trials and the design of the proposed
mixes shall be borne by the Contractor.
5. Whenever a change of brand or source for any of the concrete ingredients
occurs, additional laboratory mixes may be required and the cost of these trials
shall be borne by the Contractor.

3.2 PLANT TRIALS

A. As soon as the Engineer has approved the concrete mix proportions from the laboratory
trial, the Contractor shall conduct a plant trial in the presence of the Engineer.

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1. All concrete mixes shall require a plant trial, unless waived by the Engineer.
2. The plant trials must prove compliance of all criteria set forth in Table 1 and 2,
unless otherwise accepted by the Engineer.
3. Plant Trials shall be mixed for the same time, by the same means and with the
same equipment, which the Contractor proposes to use in the Works.
4. The proportions of cement, GGBS, aggregate and water shall be carefully
determined by weight to correspond with the Contractor's approved mix
proportions.
5. Contractor shall make three separate batches for each concrete mix, unless
otherwise approved by the Engineer.

a. Each batch shall be not less than 3.0m3 of concrete, unless otherwise
accepted by the Engineer.

b. Thirty 150 mm test cubes shall be made from each batch.

c. Methods of making and curing cubes shall be in accordance with BS


1881: Part 108 and Part 111 respectively and as follows:

d. Cubes shall be stored in insulated boxes until removed from the moulds.
6. 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 812 Part 120.
c. Air content if applicable BS 1881 Part 106.
d. Free water/cement ratio.
e. Workability tests BS 1881 Part 102, 103, 104 and 105.
f. Fresh and hardened concrete densities BS 1881 Parts 107 and 114
respectively
g. Compressive strength BS 1881 Part 116. The CCS of the concrete shall
be determined on test specimens obtained and prepared in accordance
with BS 1881 Part 108.
h. Tensile strength BS 1881 Part 118.
i. Water Permeability DIN 1048.
j. Water absorption BS 1881 Part 122.
k. Initial surface absorption BS 1881 Part 5.
l. Chloride Permeability to AASHTO T277.
m. Chloride and sulphate levels to BS 1881 Part 124.
n. Coefficient of linear expansion to US Army Corps of Engineers CRD-C
39-81.
o. Heat of hydration.
p. Other tests as dictated by concrete performance requirements or
directed by the Consultant.

7. The slump and temperature of each batch during each plant trial shall be
measured and recorded, by the method described in BS 1881, immediately after
mixing and thereafter at 15 minutes intervals up to 2 hours after batching or as
envisaged for delivery and standing on site.

a. Based on these trials the Engineer shall identify any adjustments


required for acceptable workability.
8. Three cubes shall be tested at 3, 7, 14 and 28 days for hardened density and
compressive strength as described in BS 1881: Part 114 and Part 116
respectively.

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a. If the average value of the strength of three cubes tested at 28 days is


less than the target mean strength given in Table 1, the mix shall be
rejected and redesigned.

b. If the difference between the greatest and the least strengths at 28 days
is more than 20% of the average strength, the Plant trial shall be
repeated.
9. For Water Permeability: Three cubes shall be tested at 14, 3 at 28, and 3 at 56
days.
10. For RCP: Three cubes shall be tested at 14, 3 at 28, and 3 at 56 days.

B. Re-design of the concrete mixes and the making and testing of preliminary and trial
mixes of concrete shall be repeated for each grade of concrete until all results meet the
requirements of Table 1 and 2.

C. Mix Approval

1. Contractor shall only use the approved mix of each grade of concrete in the
Works.

a. If at any time during the construction of the Works, the source of


cement, GGBS, microsilica, aggregate, admixture or mix proportions are
changed, the concrete shall be rejected and/or new trial mixes shall be
made, tested and approved for use.

b. If any unapproved mixes or non-compliant concrete is utilized in the


permanent works, it shall be removed and replaced at the contractor’s
expense, unless otherwise agreed by the Engineer.

D. As requested by the Engineer, additional cubes may be required and trials carried out to
determine:
1. Stripping times for formwork
2. Efficiency of curing.
3. To check testing and sampling errors.

3.3 MEASUREMENT OF INGREDIENTS

A. All cement, GGBS, microsilica, aggregates, and ice shall be measured by weight with a
weigh batching machine, unless otherwise approved by the Engineer.

1. Weigh batching shall provide facilities for the accurate control and measurement
of the materials individually.

a. Weigh batching shall be capable of immediate adjustment by semi-


skilled operators in order to permit variations to be made to the mix.

b. All weight and measuring dials shall be easily visible from the place at
which filling and emptying of the hoppers are controlled.

c. Water may be measured by weight or volume.

d. All measuring equipment shall be maintained in a clean and serviceable


condition.

e. When GGBS is batched cumulative in the same weighing apparatus with


Portland cement, the GGBS shall follow the weighing of Portland
cement.

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f. When GGBS is introduced into the mixer, it is preferable to introduce it


along with the other components of the concrete mixtures.

B. Concrete-mixing machine shall be fitted with a water-measuring device which shall be so


constructed that the inlet and outlet valves are interlocked so that either one of them
cannot be opened unless the other is fully closed.
1. The device shall be provided with an overflow with a cross-sectional area at
least four times that of the outlet pipe and with its discharge point clear of the
mixing plant.
2. Entire water system shall be maintained free of leaks at all times.
3. Measuring device shall be fitted with a drainpipe, which allows the full quantity of
water being measured to be drained off for checking the measurement.
4. The outlet arrangement of the measuring device shall be such that generally
between five and ten percent of the water should be fed first, followed by all the
solid material, preferably fed uniformly and simultaneously into the mixer. If
possible the greater part of the water should also be fed during the same time.
5. Remainder of the water shall be added at a uniform rate after the solids.
6. The device shall also be readily adjustable so that the quantity of water added to
the mixer may be varied, if necessary for each batch.
7. Arrangements for cooling of the mixing water shall be approved by the Engineer.

C. Batching plant shall be calibrated in-house each month and at least once a year by an
independent agency approved by the Engineer.

1. Batching accuracy shall be as shown in Table 9.

TABLE 9
BATCHING ACCURACY
Material Accuracy

Cement
a. Above 30% scale capacity + 1%
b. Below 30% scale capacity -0- +4%

Aggregates
a. Individual batches + 2%
b. Cumulative weight, % of the required cumulative weight
1. Above 30% capacity ± 1%
2. Below 30% scale capacity ± 3%

Water
c. Added by weight or volume + 1%
d. Total water (including any wash water) ± 3%

Admixtures
a. By weight or volume ± 3%

D. Any admixtures which may be used shall be measured separately in calibrated and
transparent dispensers which are easily visible to the operator, unless otherwise
approved by the Engineer.
1. Admixture shall be added to the mixture with the water preferably in a single
shot.

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2. Dispenser shall be capable of dispensing the agent in quantities varying by not


more than ± 3 percent from the quantities required and in such a manner to
ensure uniform distribution of the agent throughout the batch during the time of
mixing.

a. Capability of the dispenser to achieve the required dosing and delivery


requirements shall be demonstrated to the Engineer.

b. Shall be checked each day before concrete mixing commences.

E. Contractor shall provide weights, containers and equipment necessary for testing the
accuracy of the weighing system, water-measuring system and admixture dispenser.

3.4 MIXING CONCRETE

A. All concrete batching shall comply with the following requirements, unless otherwise
approved by the Engineer.

1. All concrete shall be manufactured in a fully automated, computer controlled


batching plant.

a. The plant shall be equipped with a suitable water chiller along with
sufficient insulated storage and flake ice-making facility with automatic
feed to ensure concrete temperatures are maintained within specified
limits.

b. Dry mixing or mixing in the truck drum is not allowed.

c. Automatic moisture control probes set in the hoppers shall be used to


continuously determine the moisture content of any washed or sprinkled
aggregates.

2. Mixing and transporting of concrete shall be in accordance with the requirements


for ready mixed concrete in BS 5328 or ASTM C94 except as modified
hereunder or as directed by the Engineer.

a. Concrete shall be transported from the mixer to the point of placing as


rapidly as practicable in approved agitators.

3. Concrete shall be mixed in batches with suitable equipment capable of


combining the aggregates, cement, GGBS, and water (including admixtures, if
any) into a mixture of uniform colour and consistency and of discharging the
mixture without segregation.

4. Amount of concrete mixed in any one batch shall not exceed the rated capacity
of the mixer.

a. Manufacture’s rated capacity shall be displayed on the mixer in terms of


the volume of mixed concrete.

b. The mixing time shall not be less than that used by the mixer
manufacturer in assessing its performance or as determined by trials
carried out in the presence of Engineer.

c. All materials from the previous batch shall be removed before materials
for a fresh batch enter the drum.

d. If work is suspended, including any periods exceeding twenty minutes,


the mixers and all handling plant shall be washed with clean water.

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e. All mixing and batching equipment shall be maintained free of set


concrete or cement and shall be clean before commencing mixing.

5. The natural moisture contents of the aggregates shall be determined before the
commencement of each day's concreting and at such intervals during each day
as may be necessary.

a. Automatic moisture control probes set in the hoppers shall be used to


continuously determine the moisture content of any washed or sprinkled
aggregates.

b. Wherever required by the Engineer free water/cementitious ratio shall be


determined in an approved independent laboratory on concrete samples
cored from locations selected by Engineer. The contractor shall bear all
the costs.

c. In no circumstances shall the consistency of the concrete be such as to


permit a separation of the aggregate from the mortar during handling.

d. Excess water shall not be permitted and any batch containing such
excess will be rejected.

6. No concrete shall exceed the water/cement ratios as given in Table 1.

7. Manufacturing and delivery resources of the proposed supplier shall be


adequate to ensure proper and timely placement and shall be subject to the
approval of the Engineer.

8. Each load shall be accompanied by a batch ticket containing at least the


following information.

a. Name of Ready Mix Co.

b. Batch Ticket No. And serial No. Of computer printout.

c. Location of Plant

d. Name of Customer

e. Date:

f. Concrete Grade

g. Type and Manufacturer of Cement and GGBS

h. Quantity of Concrete in the Transit Mixer (m3)

i. Total Quantity Ordered (m3)

j. Truck Identification Number

k. Signature of Ready Mix Representative

l. Tel. No. Of Technical Manager

m. Type and Brand of each Admixture per batch (liters)

n. Type of all Aggregates

o. Enough space to write comments by the Site Staff

9. Each load shall be accompanied by a computer controlled non-simulated


printout listing at least the following:

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a. Name of Ready Mix Co.

b. Serial No. Of computer printout.

c. Concrete Grade

d. Mix Identification Name or Number

e. Confirmation of non-simulated print out

f. Time (hr : min.) when water is first added to the mix

g. Mixing Time (sec.)

h. Target Quantities

i. Individual Weight of Aggregates (per batch) in kgs.

j. Cumulative quantity of each ingredient per truck (or load)

k. Weight of Cement per Batch (kgs)

l. Weight of GGBS per Batch (kgs)

m. Weight of Pozzolanic Materials per Batch (kgs)

n. Quantity of each admixtures (per batch) in litters

o. Quantity of Flake Ice per Batch (kgs)

p. Moisture content of each Aggregate (%)

q. Water Absorption of each Aggregate (%)

r. Total Quantity of Water, added per Batch (kgs)

s. Total Quantity of Moisture in each Batch

t. Variation of individual Batch Quantities, of all Materials per Batch (%


errors)

u. Total Quantity of Water absorbed by each aggregate in a Batch

v. Actual free Water / Cementitious ratio

w. Total variation of accumulated individual Ingredients per Batch (% error)

10. A copy of the batch ticket and computer printout shall be given to the Engineer's
site representative upon delivery for each truck.

a. The print out and batch ticket may be combined provided the minimum
information is included.

b. Loads may be rejected for insufficient information at the Engineer’s


discretion.

11. Unless approved otherwise in advance of batching, all concrete of a particular


mix for any one day's pour, or for each structure shall be from the same batch
plant with the same type of materials.

a. Concrete mixes containing aggregate and cement from different sources


shall not be permitted in a single structure, unless otherwise approved
by the Engineer.

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12. No water shall be added into the transit mixer during transport of concrete to the
site or at the site.

13. Each mixer truck shall arrive at the job site with its water container full.

a. In the event that water container is not full or field test results are outside
the acceptable limit, the load shall be rejected.

14. Except of grade C20, concrete temperature in each load shall be recorded at the
point of discharge.

a. Measurement of slump on 20N concrete shall be at the discretion of the


Engineer.

15. Perform slump tests in accordance with BS 1881 at the site of pour for each load
delivered to site, except of grade C20 that shall be at the Engineer’s decision.

a. Concrete placement shall proceed only following satisfactory verification


of slump or other specified field test results.

16. The Contractor shall provide at no extra cost, all facilities and services, including
suitable transport, acceptable to the Engineer, for the sole use of Engineers staff
or persons authorised by him to monitor the concrete batching, mixing, sampling
and testing.

3.5 ROUTINE CONCRETE TESTING

A. Under the supervision and direction of the Engineer, the Contractor shall perform all
tests as shown in Table 10, unless otherwise approved by the Engineer.

TABLE 10
FREQUENCY OF TESTING FOR FRESH AND HARDENED CONCRETE

Test
Minimum Frequency
C20 C40 and Above
Temperature As directed by the Engineer Each load
3
Concrete Slump Every 25m Each load
Visual Examination of Aggregates As directed by the Engineer Each load
(after washing)
Concrete density and compressive 6 cubes per 100m³ Min. once 6 cubes per 50m³
strength per day Min. once per day
3
Concrete unit weight (wet) Twice per day Every 50m
Min. twice per day
Concrete bleeding NA As directed by the
Engineer
3
Water permeability NA 3 cubes every 100m or as
directed by the Engineer
3
Rapid Chloride Penetration (RCP) NA 3 cubes every 250m or as
directed by the Engineer
3
SO 3 and Cl contents As directed by the Engineer Every 250m or as directed
by the Engineer

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1. Test cubes shall be randomly taken from the concrete, which is being used in
the work and prepared in accordance to the relevant standard and the following
provisions, unless otherwise approved by the Engineer.

a. All cubes shall be made at the point of delivery and all cubes for each
set must be from the same load (transit mixer truck).

b. Use approved cube moulds of the same type and manufacture for
making all test specimens.

c. All cubes shall be kept in closed insulated boxes for initial curing until
removed from the moulds and placed directly in a suitable curing tank.

d. Six cubes (150mm) shall be made for density and compressive strength
testing.

e. Six cubes (150mm) shall be made for water permeability testing.

f. Six cubes (150mm) shall be made for RCP testing.

g. Each grade of cubes shall be numbered consecutively throughout the


work and marked with the date.

2. For compressive strength and density, test three cubes at 7 days and three at 28
days.

a. The Mean of three cube strength results shall be taken as the test result.

b. If an individual cube result varies by more than 10% from the mean
result, that cube value shall be discarded and the result will be the
average of the remaining cube values.

c. Investigations to determine the reason for such high variations shall be


carried out as directed by the Engineer.

d. No individual strength test result (average of 3 cubes) shall fall below


85% of the specified strength.

e. The average of any three consecutive strength test results must equal or
exceed the specified strength.

f. If the average 7 days strength indicates that, the concrete may be


defective; the Contractor shall immediately inform the Engineer and stop
all concrete activities until the reason for such low strength is determined
and corrected.

g. At the Contractor’s option, potentially defective concrete may be


removed and replaced without awaiting the 28-day test results.

3. For Water Permeability, test three cubes at 28 days and three cubes at 56 days.

4. For Rapid Chloride Penetration, test three cubes at 28 days and three cubes at
56 days.

5. If the test cubes fail to meet the requirements of Table 1 and Table 2, then the
following action shall be taken by the Contractor.

a. Suspend concreting operations and do not proceed further without


Engineer’s approval.

b. Take test cores in accordance with BS 1881: Part 120, from suspect
concrete and test as directed by the Engineer.

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c. Any Re-testing shall be conducted to the Engineer’s satisfaction at the


Contractor’s expense.

B. Other Testing (when instructed by the Consultant).

1. Tests to establish the strength of the concrete and the static modulus of elasticity
of the concrete to BS 1881: Part 121 at 7 days, 28 days, 3 months and 6 months
shall be carried out.

2. Concrete shall be tested for drying shrinkage and wetting expansion, for which
75x75mm prisms shall be prepared and tested in accordance with BS 812 Part
120. The maximum acceptable limits shall be:

a. Drying shrinkage: 0.04%

b. Wetting Expansion: 0.03%

C. Concrete Core Testing

1. From every 500 cubic meters of concrete cast with GGBS, the Engineer shall
designate a structure (or portions of a structure) to be core sampled and tested
for RCP values.

2. Each sampling shall consist of three 100mm dia. cores of suitable length for
RCP testing.

a. The Contractor shall provide a cover meter to locate the rebar.

b. Core locations shall be marked by the Engineer.

c. The cores will be given to the Engineer for delivery to an independent


laboratory of the Engineer’s choice.

3. The cores shall be promptly tested for RCP values and the results promptly
given to the Engineer.

4. The average value shall not be more than 1500 coulombs.

5. All associated costs for coring and testing shall be borne by the Contractor.

D. The Contractor shall keep records of all specimens taken and tests made using a
proforma approved by the Engineer.

E. Submit at weekly intervals, test reports giving test results for slump, temperature, unit
weight, hardened density, strength and any other test performed during the week.

F. If high variability in slump values or wet unit weight occur, the Engineer may instruct the
Contractor to stop concreting operations, until corrective action is taken.

G. Cost of all sampling and testing shall be borne by the Contractor.

3.6 DELIVERY OF CONCRETE

A. Transportation, delivery, and handling shall be in accordance with BS 5328 or ASTM


C94 except as described hereunder, unless otherwise approved by the Engineer.

1. Each load of concrete arriving at the job site must be accompanied by all
information required under this Section.

a. Loads with insufficient information may be rejected at the Engineer’s


discretion.

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2. Contractor shall be responsible for delivering concrete in such a manner as to


avoid cold joints.

3. Avoid contamination, segregation, and loss of ingredients, excessive


evaporation and loss of workability. Cover concrete during heavy rain.

4. Clean equipment immediately after use and whenever cement or aggregate is


changed.

5. Use suitable walkways and barrow runs for traffic over reinforcement and freshly
placed concrete.

6. Concrete shall be handled from place of mixing to place of final deposit as


rapidly as practicable by approved methods, which will prevent segregation and
loss of ingredients. It shall be deposited as nearly as practicable in its final
position to avoid re-handling unset concrete inside the forms; chutes for
transporting the concrete will only be allowed with the approval of the
Engineer/Architect.

B. Frequency of sampling and testing shall be as defined in Section 3.5.

C. If field tests show excessive temperature, non-compliant slump, non-compliant unit


weight, or any other discrepancy the entire load of concrete from which the sample in
question was taken will be rejected.

1. The slump and temperature tests shall be carried out just prior to placement.

2. Rejected concrete shall be removed from the site at the Contractor's expense.

3.7 PLACING OF CONCRETE

A. Record time, date and location of all pours.

B. Place as soon as practicable after mixing and while sufficiently plastic for full
compaction. After discharge from the mixer do not add water.

C. Placing of ready mix concrete will not normally be accepted by the Engineer beyond 90
minutes of the Plant certified batching/dispatching time. Unless special retarder to be
used.

D. Ensure that temperature of concrete is not more than 30 deg.C in hot weather.

E. Place in final position in one continuous operation up to construction joints. Avoid


formation of cold joints.

F. Do not discharge from an excessive height or through reinforcement or other


obstructions in a way which may cause uneven dispersal, segregation or loss of
ingredients or adversely affect the formwork or formed finishes. Use suitable chutes or
trucking where necessary.

G. Place in layers no thicker than can be effectively compacted with the equipment being
used (150-300mm), without delay between layers. Merge together by compaction.

H. Do not use vibrators to make concrete flow horizontally into position, except where
necessary to achieve full compaction under void formers and cast in accessories and at
vertical joints.

I. Before placing the concrete, the moulds or formwork shall be cleaned of shavings,
pieces of wood or other debris and other deleterious matter. The concrete shall be
carefully placed and, unless special permission is obtained, it shall not be dropped from
a height of more than 1.50m.

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J. After placing it shall be well consolidated until it penetrates and fills all the spaces
between and around reinforcing bars in such a manner as to ensure that the concrete is
solid and entirely free from voids.

K. Concreting of any member shall proceed in one continuous operation between day work
joints, and the interval between adding the water to the dry materials and the completion
of the placing and consolidation of the concrete shall not exceed the initial set of the
concrete or 25 minutes, except as specified for ready mixed concrete in this
Specification.

L. During concreting a component steel fixer shall always be in attendance to adjust and
correct the position of the reinforcement immediately before and during the placing of the
concrete.

M. The timetable for the depositing of concrete should be so arranged that no face of
concrete shall be left exposed for more than 20 minutes before fresh concrete is
deposited against it in order to avoid cold joints.

3.8 COMPACTING OF CONCRETE

A. Fully compact concrete to full depth (until air bubbles cease to appear on the top
surface), especially around reinforcement, cast-in accessories, into corners of formwork
and at joints. Ensure amalgamation with previous batches, but do not damage adjacent
partly hardened concrete. Use plunger (poker) type vibrators compatible with the
reinforcement spacing.

B. Unless otherwise specified by the Engineer, all structural concrete shall be compacted
by approved mechanical vibration equipment which will, in most cases, involve the use of
immersion vibrators.

C. Where such vibrators are used they shall be allowed to penetrate the unset concrete by
their own motion and weight (at a spacing not exceeding 450mm) and are to be
withdrawn so as to ensure that no voids remain.

D. Excessive tamping or vibrating of concrete shall be avoided, sufficient only being done to
ensure through consolidation, and a sufficient amount of equipment and labor shall be
available at all times.

E. No contact with reinforcement of formwork, by the immersion vibration shall be allowed


and care is to be taken to ensure that previously placed set concrete is not damaged in
any way.

F. It is essential that the mix proportions used shall be suitable for compaction by vibrator
without any segregation or loss of material.

G. If approval is given by the Engineer for hand compaction, the Contractor shall ensure
that the mix proportions are adjusted to provide concrete of suitable workability and
strength to comply with all the requirements of this Specification.

H. Inform Engineers/Architects Representative of the number and type of vibrators to be


used. Provide standby vibrators. Do not use external vibrators without approval.

I. Maximum size of any pour shall be 30m in length and 300m3 unless otherwise agreed
by the Engineer.

3.9 PLASTIC SETTLEMENT

A. At the top of deep sections and at significant changes in the depth of concrete sections,
closely and continuously inspect the fresh concrete for signs of settlement during the first
few hours after placing. While the concrete is still capable of being fluidized by the

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vibrator, revibrate as necessary to remove settlement cracking which may be forming


either on the top surface or against the upper part of the vertical formwork, or trowel the
surface to remove any cracks completely

3.10 CURING OF CONCRETE

A. Prevent surface evaporation from concrete throughout the period(s) specified below by:

1. Retaining formwork in position and, if necessary, covering surfaces immediately


after striking, and

2. Covering top surfaces immediately after placing and compacting each bay,
removing covering only to permit any finishing operations and replacing
immediately thereafter. Cure by continuous wetting for a period of 7 days. Cover
with fabric and polythene sheets.

B. Maintain surface temperature above 5 deg C throughout the periods specified below or
four days, whichever is the longer.

C. Maintain detailed records of location and timing of casting of individual batches, removal
of formwork and removal of coverings. Keep on site, available for inspection.

D. Formwork must be kept moist during the whole curing period. Metal formwork to be
shaded from the sun for the whole curing period.

E. Curing periods are at least 7 days, or longer as instructed by Engineer/Architect.

3.11 WATERTIGHT CONCRETE

A. Water tight concrete shall be used for all concrete elements below grade level and in
contact with water.

B. The Contractor shall take full responsibility for ensuring that the resulting construction is
completely watertight and free from penetration of moisture. When, in the opinion of the
Engineer, damp patches (and/or leakage of water in the finished work) are due to failure
of the Contractor to comply with this Specification the affected work shall be made good /
replaced at the Contractor’s expense.

C. Before commencement of work the Contractor shall obtain the Engineer approval of the
methods to be used to support and maintain the water-bars in the correct location while
the concrete is placed, and also the layout and form of all additional construction joints
other than those shown on the drawings. Unless indicated otherwise on the drawings all
construction joints in watertight concrete shall be formed as indicated on the drawings.

D. The formwork shall comply with the relevant clauses in this specification and any bolt or
fastening embedded in or passing through the concrete shall be to the approval of the
Engineer and shall not impair the watertightness of the structure; the use of through bolts
and sleeves is strictly prohibited.

E. All cast-in service holes shall incorporate sleeves with puddle flanges and temporary
openings for services should incorporate water bars.

F. All kickers or starter plinths to walls on the periphery of the watertight construction shall
be cast monolithically with the base.

G. Special attention shall be given to the elimination of shrinkage or thermal cracking. The
size of any bay or slab or wall and sequence of pouring shall be such as to minimize
cracking. It is recommended that the size of the bay or slab be limited to 60 square
meters and the length of any wall to 12 meters with a maximum of 4 meters high.

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H. Slotted inserts or sockets cast into the structural concrete shall be provided for all fixings;
including services. The cutting of holes in watertight concrete is strictly prohibited.

I. Prevent the build-up of high temperatures and steep temperature gradients during the
first 24 hours after casting, particularly in hot weather.

J. Prevent rapid changes in temperature during the first 7 days after casting.

K. Submit proposals designed to achieve these objectives (taking into account the nature of
the design, the mix specification and the prevailing climatic conditions).

3.12 PROTECTION OF CONCRETE

A. Prevent damage to concrete, including:

1. Surfaces generally: From rain, indentation and other physical damage.

2. Surfaces to be exposed in the finished work: From dirt, staining, rust marks and
other

3. Disfiguration.

B. Prevent damage of Immature concrete from thermal shock, physical shock, overloading,
movement and vibration.

C. Early loading

1. During the first 28 days after compaction, the 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. The strength of the concrete
and the stresses produced by the loads shall be subject to the agreement of the
Consultant.
2. No load shall be placed until the Consultant 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 or open any section of the Works to traffic or
construction equipment until permitted by the Consultant.
3. In addition to the above, the Contractor is responsible for conforming to the
performance requirements for concrete in general and for the creep
requirements in particular.

3.13 HOT WEATHER CONCRETING

A. Follow the recommendations of ACI-305 and the following precautions during hot
weather, unless otherwise directed by the Engineer.

1. Take all precautions necessary to prevent the temperature of concrete rising


above 32C at the time of placement.

2. Do not mix or place concrete when the ambient shade temperature is above 40C
on a rising thermometer or above 43C on a falling thermometer.

3. Hours at which concreting will be allowed to take place will be agreed with the
Engineer.

4. Cool aggregate with draughts and/or shade from direct sunlight.

5. Cold water to be utilized in mixing.

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6. When ice is used, take into account all ice when computing water/cement ratios
and ensure that ice is melted before the concrete leaves the mixer.

7. Paint white, provide shade or insulate the rotating mixer drum to prevent
overheating of the metal and excessive heat transfer.

B. Control of Temperature.

1. For all concrete sections the Contractor shall take precautions to limit the effects
of heat of hydration.

2. The Contractor shall determine the expected heat of hydration for the concrete
3
batch by testing a 1m insulated concrete cubes, in accordance with the
Specification clauses for the trial mixes.

3.14 NON-COMPLIANT CONCRETE

A. Concrete shall be considered to be non-compliant if any of the following conditions are


found to exist.

1. Compressive strength results less than those shown in Table 1, evaluated


according to ACI 318-08, Section 5.6.3.3.

2. Unapproved mix is utilized.

3. Approved mix proportions or materials have been changed.

4. Sulphate or chloride contents in excess of those shown in Table 2.

5. Water/cement ratio in excess of Table 1.

6. Cementitious content less than those in Table 1.

7. GGBS content less than those shown in Table 1.

8. Cube results for Water permeability or RCP in excess of those shown in Table 2.

9. Mean core results for RCP values taken from structures in excess of 1500 coul.

10. Concrete that fails to meet one or more requirements of the specification.

B. Any structures containing non-compliant concrete shall be completely broken out and
removed, unless otherwise accepted by the Engineer.

C. The Engineer’s decision shall be final in all aspects related to non-compliant concrete.

D. Any additional costs associated with non-compliant concrete shall be at the Contractor’s
expense.

3.15 CONCRETE TOLERANCES

A. Requirement.

1. Concrete construction shall meet the specified tolerances.

2. Tolerances shall not extend the structure beyond legal boundaries.

3. Tolerances are not cumulative. The most restrictive tolerance controls

4. Plus (+) tolerance increases the amount or dimension to which it applies, or (-)
lowers a level alignment. A non-signed tolerance means + or -. Where only

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one signed tolerance is specified (+ or -), there is no limit in the other direction.
Approved mix proportions or materials have been changed.

B. Definitions.

1. Clear Distance: In reinforced concrete, the least distance between the surface of
the reinforcement and the referenced surface, i.e., the form, adjacent
reinforcement, embedment, concrete or other surface

2. Flatness: The degree to which a surface approximates a plane.

3. Lateral Alignment: The location relative to a specified horizontal line or point in a


horizontal plane.

4. Level Alignment: The location relative to a specified horizontal plane. When


applied to slabs, ramps or other nominally horizontal surfaces established by
elevations, level alignment is defined as the vertical location of the surface
relative to the specified profile grade and specified profile grade and specified
cross slope.

5. Relative Alignment: The distance between two or more elements in any plane, or
the distance between adjacent elements, or the distance between an element
and a defined point or plane.

6. Tolerance: The permitted variation from a given dimension or quantity, the range
of variation permitted in maintaining a specified dimension, a permitted variation
from location or alignment.

7. Vertical Alignment: The location relative to specified vertical plane or a specified


vertical line or from a line or plane reference to a vertical line or plane. When
applied to battered walls, abutments or other nearly vertical surfaces, vertical
alignment is defined as the horizontal location of the surface relative to the
specified profile.

8. Warping: The displacement of the surface, portion, or edge of a planar element


from a plane passing through any three corners of the element.

C. Reinforcing Placement

1. Tolerances shall not permit a reduction in cover.

2. Clear distance to side form / resulting concrete surfaces and clear distance to
bottom form / resulting concrete soffits in direction of tolerance:
- When member size is less than 300cm…………………. +6 mm / -10 mm
- When member size is over 300mm but less than 600mm…....+ / - 10 mm
- When member size is over 600mm…………………………….. + / - 15 mm

3. Concrete cover measured perpendicular to concrete surface in direction of


tolerance:

- When member size is 500mm or less………………………….......+ / - 5 mm

- When member size is over 500mm but less than 1000mm……..-5 / +10 mm

- When member size is over 1000mm……………………………….-5 / +15 mm


- Reduction in cover shall not exceed one-third specified concrete cover.

4. Distance between reinforcement:

- Distance between reinforcement shall not be less than the greater of the bar
diameter or 25mm for unbundled bars.

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- For bundled bars, the distance between bundles shall not be less than the
greater of 25mm or 1.4 times the individual bar diameter for 2 bar bundles, 1.7
times the individual bar diameter for 4 bar bundles.

D. Placement of Embedded Items:

- Clearance to reinforcement the greater of the bar diameter or 25 mm

- Vertical alignment, lateral alignment and level alignment………+ / - 10 mm

E. Cast in Place Concrete :

1. Vertical Alignment

- For story height 3.5m typical……………………………………..+ / - 3 mm

- For any 20m height………………………………………………+ / - 10 mm

- For heights greater than 20m………………………….…1:2000 but < + / - 25 mm

-Cross diagonal distortion in story height (3.5m typical) between adjacent


columns or walls………………………………………………………………+ / - 7mm

- Outside corner of exposed corner columns and control joint grooves in


concrete 1/2000 times the height but not more than…………………….+ / - 5mm
- Building vertical alignment (foundation to roof) ………1:2000 but < + / - 25 mm

2. Lateral Alignment

- Members …………………………..................................................+ / - 15 mm

- In slabs, centerline location of coverings 300mm or smaller and edge location


of larger openings…………………………………………………………...+ / - 10mm

- Saw cuts, joints, and weakened plane embedments in slabs……....+ / - 15 mm

3. Level Alignment

- Slab Surface level to datum………...……………………………………+ / - 10 mm

- Position of slab edges……………………………………………………...+ / - 5 mm

- Lintels, sills, parapets, horizontal grooves and other lines exposed to view

…………………………………………………………………………………+ /- 10mm

- Top surface of bases and piers ………………………………………. + 5 / - 10


mm

4. Cross Sectional Dimensions

- Members, such as columns, beams, piers, walls thickness and slabs thickness
300mm dimension or less…………………………………………………..+ / - 5 mm

- More than 300mm dimensions but less then 900mm……………..+ 10 / - 5 mm

- Over 900mm dimension………………………………………………+ 15 / - 10 mm

5. Relative Alignment

- Stair:
Difference in height between adjacent risers…………………+ / - 3 mm

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Differences in width between adjacent trends………………..+ / - 5 mm

- The offset between adjacent pieces of formwork facing material shall not
exceed

………………………………………………………………………………+ / - 3mm

-END OF SECTION 033000-

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