CONCRETE WORKS

SECTION D - CONCRETE WORKS

1.0 General

This section shall apply to the construction of all structures or parts of structures to
be composed of concrete with or without steel reinforcement. The Work shall be
carried out all in accordance with this specification and the lines, levels, grades,
dimensions and cross-sections shown in the drawings and as required by the S.O.

2.0 Material

2.1 Cement

The cement to be used throughout the Work shall be Portland cement

obtained from an approved manufacturer. The cement shall be described
under the following headings:

i) Ordinary Portland Cement to comply with MS 522

ii) Rapid Hardening Portland Cement to comply with MS 522
iii) Sulphate Resisting Portland Cement to comply with MS 1037
iv) Portland Pulverized-Fuel Ash Cement to comply with MS 1227
v) Portland Slag Cement to comply with MS 1389

2.1.1 Certificates of Test

Manufacturers’ certificates of test shall in general be accepted as

proof of soundness. Additional tests shall be carried out on any
cement including those of imported cement, which appears to have
deteriorated through age, damage to containers, improper storage, or
any other reason. The test shall be carried out at any approved
laboratory at the expense of the Contractor. Any batch of cement that
has been sampled and tested and found not to have complied with
the requirements shall be rejected and removed from the Site.

The S.O. may, without tests being made, order that any bag of
cement, a portion of the contents of which has hardened, or which
appears to be defective in any other way, be removed from the Site.

2.1.2 Transportation and Storage

The cement shall be transported to the Site in covered vehicles

adequately protected against water. It shall be stored in a
weatherproof cement store to the approval of the S.O. Cement stored
in bags shall not be laid directly on the ground. It shall be taken for
use in the Work in the order of its delivery into the store. Cement
delivered in bulk shall be stored in silos of an approved design.

2.2 Aggregates

Aggregates shall be naturally occurring sand, granite or limestone, crushed

or uncrushed except as otherwise specified, and shall comply with MS 29. They
shall be obtained from a source approved by the S.O.

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Marine aggregates shall not be used unless otherwise specified in the

Drawings.

2.2.1 Coarse Aggregates

Coarse aggregates shall comply with MS 29. For work below ground
level, only crushed granite shall be used. Unless otherwise specified
in the Drawings, tests shall be carried out according to MS 30. The
property limits shall be as specified in Table 1. The maximum
nominal size of aggregate shall be as specified in the Drawings.

2.2.2 Fine Aggregates

Fine aggregates shall comply with MS 29. In the context of MS 29,

the term “sand” is used to mean “fine aggregate”. If it is found
necessary, the fine aggregate shall be washed and screened to the
approval of the S.O. Unless otherwise specified in the Drawings,
tests shall be carried out in accordance with MS 30. The property
limits shall be as specified in Table 1.

2.2.3 Grading

(a) Coarse Aggregates

The grading of coarse aggregates shall be analysed as
described in MS 30 and shall be within the limits specified in
Table 2.

(b) Fine Aggregates

The grading of fine aggregates shall be analysed as
described in MS 30 and shall be within the limits specified in
Table 3. However, for prescribed mixes Grading Limit M shall
only be used.

2.2.4 Sampling and Testing of Aggregates

Where site mixing is used, samples of fine and coarse aggregates

approved by the S.O. shall be kept on Site. These samples shall give
a fair indication of the general quality of the aggregates for
comparison with the aggregates delivered during the course of
executing the Work. Tests shall be carried out on samples of the
latter, taken at intervals as required by the S.O., or whenever there is
a change of source. The appropriate method of sampling and testing
shall be in accordance with the standards as specified in Table 1.
Any batch of aggregate rejected by the S.O. shall be removed from
the Site.
2.2.5 Storage of Aggregates

Separate storage facilities with adequate provision for drainage shall

be provided for each different size of aggregate used.

Aggregate shall be handled and stored so as to minimise segregation

and contamination.

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2.3 Water

Water shall comply with the requirements of MS 28. It shall be clean and free
from materials deleterious to concrete in the plastic and hardened state and
shall be from a source approved by the S.O. The S.O. may instruct the
Contractor to carry out chemical tests at any approved laboratory at the
expense of the Contractor. The Contractor shall make adequate
arrangement to supply and store sufficient water at the Site for use in mixing
and curing of concrete.

2.4 Admixtures

Suitable admixtures may be used in concrete mixes with the prior approval of
or as directed by the S.O.

The admixtures, the sampling and testing of the admixtures and the
information to be provided with the admixture supplied shall comply with MS
922.

All admixtures shall be used strictly in accordance with manufacturer’s

instruction.

Before allowing the admixture to be used in the Work, relevant tests based
on trial mixes shall be carried out. A control mix shall be made using a
conventional trial mix that is without using the admixture, to determine the
free water:cement ratio and mix proportion required to give the specified
strength with the required slump. Using the same mix proportion as in the
control mix but with a modified water:cement ratio whenever necessary, a
test shall be carried out using the recommended dosage of the admixture.
The results of the relevant test obtained from the control mix and test mix
shall be compared. The S.O. may allow the use of the admixture only when
the results are found to be satisfactory and comparable to the effects as
claimed by the manufacturer. The admixture acceptance test shall comply
with the requirements specified in Table 4

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The uses of admixtures that are chloride based are not permitted to be used
for structural concrete containing reinforcement, prestressing tendons or
other embedded metal. The Contractor shall submit documentary evidence
on the contents of the admixture to be used.

When the Contractor proposes the use of super-plasticiser, special control

tests shall be carried out with prior approval of the S.O. The tests shall be
carried out in accordance with the latest standard and the manufacturer’s
recommendations.

If two or more admixtures are proposed to be used simultaneously in the

same concrete mix, the Contractor shall furnish the S.O. with supporting
data on their suitability and compatibility.

2.5 Additional Materials

Condensed silica fumes (CSF) complying with ASTM C1240 – 93 or any other
equivalent standards may be used provided that the concrete complies with the
same grade as would be achieved by the Portland cement concrete complying
with MS 522 and prior approval of the S.O is obtained

3.0 Classification of Concrete Mixes

Unless otherwise stated in the Drawings, the concrete mix shall be designed mix.
However, prescribed mix may be used provided: -

(a) The work is of minor nature or involving a small quantity of concrete,

(b) Prior approval of the S.O. is given, and
(c) The strength of the concrete is still the responsibility of the Contractor.

When Portland Pulverized-Fuel Ash Cement or Portland Slag Cement is specified to be

used, the concrete mix shall be of designed mix only.

3.1 Prescribed Mix

Prescribed mix shall be as detailed in Table 5. . The mix prescribed in the

table does not require the use of admixture.

For small volume concreting work, volume batching is permitted provided

prior approval of the S.O. is obtained. The proportion shall be as specified in
Table 5A.

3.2 Designed Mix

Designed mix shall comply with the recommendations of MS1195. The

minimum cement content and maximum free water: cement ratio to be used
shall be as shown in Table 6 and this shall supersede Table 14 of BS 5328.

The Contractor shall comply with the following requirements:

a) Notify the S.O. whether the designed mix is to be produced as site mix or ready

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mix.

b) If the Contractor chooses to use ready mix concrete, he shall notify the S.O. the
name of the supplier, location of the ready mix plant, journey time taken
to transport the concrete to the Site and production capacity of the plant.

c) Submit a mix design report covering all concrete mixes to the S.O. for
approval. The designed mix shall comply with the requirements specified
in Table 6.

d) The Contractor shall ensure that the S.O. be permitted to visit or station
his representative at the plant at any stage of the concrete production.

e) The sampling, making, curing and testing of the cubes shall be carried
out by the Contractor in accordance with MS 30 or as directed by and in
the presence of the S.O. or his representative. Test cubes shall be stored
by the S.O. at a secured place. The Contractor shall provide all facilities in
connection therewith.

When Portland Pulverized-Fuel Ash Cement complying with MS 1227

or Portland Slag Cement complying with MS 1389 is used, depending on
the percentage combination used as allowed by MS 1226 or MS 1387
respectively, it may be necessary to increase the total cement content to
achieve concrete of equal strength development when compared with
concrete using Portland cement complying with MS 522. Tests on trial
mixes shall be carried out in accordance with 3.2.3 and the results shall be
approved by the S.O.

In all cases, it is the responsibility of the Contractor to ensure that the

designed mix shall be durable, workable, comply with the strength grade and
other requirements as specified in the Drawings.

3.2.1 Target mean strength

The concrete mix shall be designed to have at least the required

minimum cement content, as specified in Table 6, and to have a
target mean strength greater than the required grade of concrete by at
least the current margin.

The current margin for each particular type of concrete shall be

determined by the Contractor and shall be taken as the lesser of:

a) 1.64 times the standard deviation of cube tests on at least 100

separate batches of concrete of nominally similar proportion
of similar materials and produced over a period not
exceeding 12 months by the same plant under similar
supervision, but not less than 2.5 N/mm 2 for concrete, of
grade 15 or 3.75 N/mm2 for concrete of grade 20 or above.

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b) 1.64 times the standard deviation of cube tests on at least 40

separate batches of concrete of nominally similar
proportions of similar materials and produced over a period
exceeding 5 days but not exceeding 6 months by the same
plant under similar supervision, but not less than 5 N/mm2
for concrete of grade 15 or 7.5 N/mm2 for concrete of grade
20 or above.

Where there are insufficient data to satisfy (i) and (ii) above, the
margin for the initial mix design shall be taken as 7.5 N/mm 2 for
concrete of grade 15 and 12 N/mm 2 for concrete of grade 20
or above. This margin shall be used as the current margin
only until sufficient data are available to satisfy (i) or (ii)
above. However, subjected to the approval of the S.O., when
the specified characteristic strength approaches the designed
target mean strength of concrete made with a particular
aggregate, a smaller margin not less than 5 N/mm2 for
concrete of grade 15 or 7.5 N/mm2 for concrete of grade 20
or above may be used for the initial mix design.

3.2.2 Suitability of Proposed Mix Proportions

The Contractor shall submit for the approval of the S.O., prior to the
supply of any designed mix, the following information:

a) The nature and source of each material,

b) Appropriate existing data as evidence of acceptable previous

performance for target mean strength, current margin,
workability and water:cement ratio; OR full details of tests on
trial mixes carried out in accordance with 3.2.3, and

c) The proposed quantities by weight of each material per cubic meter

of fully compacted concrete.

3.2.3 Trial Mixes

Unless otherwise stated and approved by the S.O in writing that the
Contractor has complied with the submission specified in 3.2.2, trial
mix shall be carried out.

The Contractor shall give early notice, to enable the S.O. to be present
at the making of trial mixes and preliminary testing of the cubes. The

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Contractor shall prepare trial mixes, using samples of approved

material typical of those he proposes to use in the Work, for all
grades to the approval of the S.O. prior to commencement of
concreting.

Sampling and testing procedures shall be in accordance with MS 26.

Three separate batches of concrete shall be made. The workability of
each of the three trial batches determined by means of the slump
test or compacting factor test or vebe consistometer test or as
specified in accordance with MS 26, shall be appropriate to the
proposed uses and methods of placing and compaction of the mix and
shall be approved by the S.O. Six cubes shall be made from each
batches. Three from each set of six shall be tested at an age of 7 days
and three at an age of 28 days. The average strength of the nine
cubes tested at 28 days shall exceed the specified characteristic
strength by the current margin minus 3.5 N/mm2. The approved trial
mixes shall then be designated as the "designed mix" and its
corresponding workability as the "designed workability".

During production, the S.O. may require additional trial mixes to be made
before a substantial change is made in the materials or in the proportion
of the material to be used. Trial mixes need not be carried out when
adjustments are made to the mix proportions in accordance with 3.2.4.

3.2.4 Control Strength of Designed Mixes

a) Adjustment to Mix Proportions

Adjustment to mix proportions shall be made to the

approval of the S.O. in order to minimise the variability of strength
and to maintain the target mean strength. The specified limits
of minimum cement content and maximum free water:
cement ratio shall be maintained. Changes in cement have to
be declared.

An increase or reduction of cement content by greater than

20 kg/m3, or of fine aggregate by greater than 5%, or any
changes in the type or dosage of admixture, or any
changes in the type of cement, or consistency is
considered a change in mix design.

b) Change in Current Margin

A change in current margin used for judging compliance with

specified characteristic strength becomes appropriate
when results of a sufficiently large number of tests show that
the previously established margin is significantly too large or
too small.

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Recalculation of the margin shall be carried out in

accordance with 3.2.1. Although a recalculated margin is
almost certain to differ numerically from the previous value, the
adoption of the recalculated value will not generally be justified
if the two values differ by less than 18% when based on
tests on 40 separate batches or less than 11% when
based on tests on 100 separate batches or less than 5%
when based on tests on 500 separate batches.
On the adoption of a recalculated margin, it shall become the
current margin for the judgment of compliance with the specified
characteristic strength of concrete produced subsequent to the
change.

3.3 Requirements for Concrete

3.3.1 Workability

The workability of the fresh concrete shall be judged by its suitability

for the condition of handling and placing so that after compaction, it
surrounds all reinforcement, tendons and ducts and completely fills
the formwork.

Workability of the concrete shall be within one of the following limits :

i) Slump
± 25mm or ± one third of the `designed workability’, whichever
is greater.

ii) Compacting Factor

± 0.03 where the `designed workability’ is 0.9 or more.
± 0.04 where the `designed workability’ is between 0.8 and
0.9.
± 0.05 where the `designed workability’ is 0.8 or less.

iii) Vebe
± 3 seconds or ± one fifth of the `designed workability’
whichever is lesser.

3.3.2 Concrete Grade

The grade of concrete to be used in the work shall be as stated in the

drawings and /or in the Bill of Quantities.

(Concrete shall be designated as GRADE X/Y where `X’ is the

numerical value of the characteristic strength at 28 days in N/mm 2,
and `Y’ is the nominal maximum size of aggregate in mm. For
prescribed mix, a suffix `P’ shall be added after `X’).

3.3.3 Cement Content

Cement content in this specification shall refer to the total quantities of

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cement as approved in 2.1, or the total quantities of cementitious

materials comprising Portland cement and p.f.a or g.g.b.s.

3.3.3.1 Minimum Cement Content

The minimum cement content shall be in accordance with

Table 6, unless otherwise shown in the drawings.

3.3.3.2 Maximum Cement Content

The maximum cement content shall not exceed 550 kg/m 3

unless otherwise shown in the drawings or as approved by the
S.O.

3.3.4 Total Chloride Content

The total chloride content of the concrete mix arising from the
aggregate or any other source shall not in any circumstances exceed
the limits in Table 7 expressed as a percentage relationship between
chloride ions and weight of cement in the mix.

When necessary, tests shall be carried out in accordance with BS

1881: Part 124 for each grade of concrete, to demonstrate that these
limits are not exceeded.

3.3.5 Maximum Sulphate Content

The total estimated sulphate content of any mix, including that

present in the cement shall not exceed 4% by weight of cement in the
mix. Where necessary, tests shall be carried out in accordance with
BS 1881: Part 124 for each grade of concrete to demonstrate that
this limit is not exceeded.

4.0 Concrete Compressive Strength Tests and Compliance

4.1 General

All sampling, curing and testing of concrete, fresh or hardened, shall be

carried out in accordance with MS 26 and the relevant Parts of BS 1881.
The compressive strength of concrete shall be measured by crushing tests
on nominal 150mm cubes as specified in MS 26. Tests shall be carried out
in an engineering laboratory approved by the S.O.

4.1.1 Prescribed Mix

A prescribed mix shall be judged on the basis of the specified mix

proportions based on the batches observation. The mix proportion
shall be within 5% of the values specified and the workability shall be
chosen to suit the construction requirements as described in Table 5.

4.1.2 Designed Mix

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The characteristic strength of a designed mix concrete is the

compressive strength below which not more than 5% of the test results
may be expected to fall. Compliance with the specified characteristic
strength shall be judged by tests made on cubes at an age of 28 days.
The workability shall be as described in 3.3.1.

4.2 Sampling and Testing

Notwithstanding this, compressive strength tests shall be carried out during the
progress of Work. The rate of sampling shall be as specified in 4.3. For each
sampling, three cubes shall be made from a single sample taken from a
randomly selected batch of concrete. The sample shall be taken at the point of
discharge from the mixer or, in the case of ready mixed concrete, at the point
of discharge from the delivery vehicle. All cubes shall be clearly marked with
undeletable paint with the date of casting and serial number. A record
shall be kept to identify each cube by date and by serial number relating to the
part of the work from which they are taken.

One cube from each sample batch shall be tested for the 7-day compressive
strength. The remaining two cubes from the sample batch shall be tested for
the 28-day compressive strength.

4.3 Rate of Sampling For Testing

The indicative sampling rate shall be as follows:

a) One sample per 10.0 m3 or every group of 10 batches for critical

structures e.g. prestressed concrete, masts, cantilevers, columns,
footing, pile caps, shear wall, retaining wall.

b) One sample per 20.0m 3 or every group of 20 batches e.g. Slabs,

beams.

c) One sample per 50.0 m3 or every group of 50 batches e.g. raft

foundation and mass concrete.

Notwithstanding the above, a minimum of two samples shall be taken on

each concreting day for a particular grade and source of concrete for
prescribed mix.

However, for designed mix, at least four samples (12 cubes) shall be taken
of concrete on the first day of concreting for each grade of concrete to be used in
the Work, irrespective of the volume of concrete produced or the sampling rate.
Subsequent rate of sampling shall be at least one sample from each source
of production on each day that concrete of any particular grade is used.

The actual rate of sampling may be increased in appropriate circumstances

e.g. for critical elements, when required by the S.O.

4.4 Cubes Strength at 7 Days

One cube from each sample batch shall be tested for the 7-day

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compressive strength. The cube compressive strength shall not fall below the
corresponding values given in Table 8 for prescribed mix, and two-third of the
28-day compressive strength for designed mix.

4.5 Cube Strength at 28 days and Compliance Requirements

The remaining two cubes from the sample batch shall be tested for the 28-
day compressive strength.

4.5.1 Prescribed Mix

The appropriate strength requirement shall be considered complied if at

least one of the following conditions is satisfied with:

a) None of the two test cubes is below the specified compressive

strength as specified in Table 8
b) The average strength of the two test cubes is not less than the
specified compressive strength and the difference between
the two strengths is not more than 20% of the average.

4.5.2 Designed Mix

The average strength of the two cubes shall constitute the 28-day
compressive strength of the sample. When the difference between the
two results divided by their mean exceeds 15%, the test results shall be
deemed invalid.

For compliance purposes of the specified compressive strength, both of

the following conditions shall be satisfied:

a) The mean strength determined from the first two, three or four
consecutive test results, or from any group of four consecutive
test results complies with the appropriate limits in column A
of Table 8A. In this respect, consecutive samples are samples
taken at intervals for the day of concreting or one complete
continuous process of concreting
b) Any individual test result complies with the appropriate limits in
column B of Table 8A.

4.6 Test for Consistency

While work on concreting is in progress, tests on workability of the mix shall be

carried out at suitable interval and in addition whenever any materials or
the proportions of the mix are changed, or when directed by the S.O. The
test shall consist of the Slump test, the Compacting Factor test or Vebe test
where applicable as described in MS 26. The workability shall be as described
in 3.3.1.

4.7 Action to Be Taken In The Event Of Non Compliance

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In the event that the compressive strength results of the test do not meet the
specified requirements mentioned in 4.4 and 4.5, or otherwise arising from the
result of the statistical analysis carried out in 4.11, the S.O. shall determine the
action to be taken.

If the 7-day strength is less than the specified strength requirements, no more
concrete shall be placed on the suspect concrete and no removal of propping
on the affected area shall be allowed until the 28-day strength result
compliance is available, or unless otherwise approved by the S.O in writing.

For non-compliance of 28-day compressive strength, the section of work

represented by the samples which fail the test carried out in accordance with 4.5
shall be removed. However, in the event of non-compliance arising from the result of
the statistical analysis carried out in 4.11 for the designed mix, the whole of work
represented by the samples used in the analysis shall be removed. The work shall
be replaced by concrete meeting with this specification. For the case of designed
mix, the Contractor shall redesign his mix based on an increased target mean
strength.

Alternatively, the S.O may direct other measures to be taken to make the works
secure. The S.O may instruct that additional tests be carried out on the hardened
concrete to determine the quality of the suspected concrete. The test may
include non-destructive methods (MS 26), taking cored samples (MS 26), load
test or combination of several methods. The results shall be assessed in
accordance with BS 6089. The results of any such tests shall not nullify the
establishment of non-compliance with 4.5.

All works instructed under this clause shall be at the Contractor’s expense and
no extension of time shall be granted for such works.

4.8 Other Failures

All defective concrete works such as badly constructed concrete members

with poor alignment and plumb, honeycombing, badly formed surfaces, and
failure during construction such as sagging of beams and slabs shall be
removed and made good or otherwise rectified in accordance with the S.O’s
instruction at the Contractor’s expense.

4.9 Additional Cubes

Additional cubes may be required for various purposes. These shall be

made and tested in accordance with MS26 but the methods of sampling and
the conditions under which the cubes are stored shall be varied according to
the purpose for which they are required.

For determining the cube strength of prestressed concrete before transfer or

of concrete in a member before striking formwork, sampling shall be at the
point of placing and the cubes shall be stored under the same conditions as
the concrete in the members.

The extra cubes shall be identified at the time of marking and shall not be
used for normal quality control or compliance procedures.

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4.10 Recording of Test Results

All concrete cube test results and summary shall be recorded using
appropriate forms in a manner and format approved by the S.O. The 7-day
and 28-day strength results shall be recorded separately with its
corresponding cement content obtained from the batching record submitted
during delivery (if ready mix concrete is used) of fresh concrete. The
corresponding workability shall also be recorded.

Changes to sources of materials, concrete supplier, current margin,

target mean strength, cement content or any other such changes to the
parameters of the concrete mix, shall also be recorded separately.
All records shall be duly verified jointly between the S.O or his
Representative and the Contractor.

The records shall be analysed to meet the following compliance

requirements as stipulated in 4.5

a. The individual test result and the average values obtained from the
samples noting the validity values and to comply with column A of
Table 8A.
b. The group test results and analyse the mean values to comply with
column B of Table 8A.

4.11 Statistical Analysis

Statistical analysis shall be carried out based on the test results recorded in
4.10. The Contractor shall submit to the S.O, the following analysis:

a) Running analysis of group test results and the mean values plotted
for normal distribution graph. Standard deviation (S.D) is then
calculated. The value of S.D obtained, when multiplying with 1.64
(statistical constant complying with MS 1195) will give the value of the
current margin.
b) The current margin value should not fall below the designed current
margin specified when performing the earlier trial mix. If the current
margin falls below the designed value, the S.O may inspect the plant
supplying the concrete, instruct the Contractor to redesign his mix
and to take appropriate action as per 4.7

5.0 Production of Concrete

5.1 Supervision

The Contractor shall ensure the required standard of control over materials
and workmanship. The S.O. shall be afforded all reasonable opportunities
and facilities to inspect the constituent materials and the production of

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concrete and to take samples for testing.

5.2 Batching and Mixing

The quantities of cement, fine aggregate and various sizes of coarse

aggregate shall be measured by weight unless otherwise approved by the
S.O. A separate weighing machine shall be provided for weighing the
cement. Alternatively, the cement may be measured by using a whole
number of bags in each batch. The quantity of water shall be measured by
volume or by weight. Any solid admixtures to be added shall be measured by
weight; liquid or paste admixtures shall be measured by volume or weight.

The batch weight of aggregate shall be adjusted to allow for the moisture
content of the aggregate being used. All measuring equipment shall be
calibrated on site or their calibration status established by certificates from
accredited laboratories.

The mixer shall comply with the requirements of BS 1305 where applicable.
The mixing time shall be not less than two minutes and not more than five
minutes or any other time recommended by the mixer manufacturer after all
the ingredients have been placed in the mixer.

Mixers that have been out of use for more than 30 minutes shall be
thoroughly cleaned before any fresh concrete is mixed. Unless otherwise
agreed by the S.O., the first batch of concrete through the mixer shall
contain only two thirds of the normal quantity of coarse aggregate. The mixer
shall be thoroughly cleaned before changing from one type of cement to
another.

The water content of each batch of concrete may be adjusted so as to

produce concrete of the workability required. However care shall be taken to
ensure the free water: cement ratio is maintained. The total amount of water
added to the mix shall be recorded.

5.3 Ready Mixed Concrete

Ready mixed concrete is concrete produced by a third party supplier for

delivery to a Contractor in a plastic state. The materials of the concrete are
batched, either dry or wet, at a control plant and transported in purpose-
made agitators operating continuously or truck mixers to the Site.

Ready mixed concrete shall comply with the requirements of designed mix
as in clause 3.2 and MS 523. All concrete materials, including water and
admixtures shall be mixed in the plant and delivered to Site in purpose made truck
mixers. No extra water or admixtures are allowed to be added after the concrete
has left the plant.

Ready mixed concrete delivered to the Site shall be accompanied by delivery

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ticket and manufacturer's batching record stating the details of mix proportions
by weight, the grade of concrete, type and size of aggregate, date and time
of loading at plant, type and dosage of chemical admixtures and other
relevant production details in suitable format, failing which the S.O, or his
representative, shall immediately reject the total load of the concrete. The S.O,
or his representative, and the contractor shall ensure the information provided
in the delivery tickets and the manufacturer’s batching record complies with the
details of the approved ‘designed mix’ and its corresponding ‘designed
workability’ as in 3.2.3 before discharging the concrete.

Rejected concrete shall be removed from the Site. The delivery ticket shall
be marked `REJECTED’.

5.4 Transporting

Concrete shall be transported from the mixer to the formwork as rapidly as

practicable by methods, which will prevent segregation or loss of any
constituents or ingress of foreign matter or water and maintain the required
workability. It shall be deposited as near as practicable in its final position to
avoid rehandling or moving the concrete horizontally by vibration. The
concrete shall be conveyed by chutes or concrete pumps only with
permission from the S.O.

5.5 Placing

5.5.1 Placing of Concrete in Dry Condition

For all concrete whether mixed on or off the site of the Work, each
batch shall be placed and compacted within two (2) hours of adding
the cement to the dry aggregates and within 45 minutes (or any other
period of time based on the trial mix as per 2.4, 3.2.3 and approved by
the S.O. if an admixture is used) of adding water to the cement and
aggregate. Concrete shall not be placed in any part of the structure
until the approval of the S.O. has been obtained. If concreting is not
started within 24 hours of approval given, approval shall again be
obtained from the S.O.

All formwork and reinforcement contained in it shall be clean and free

from standing water immediately before the placing of concrete.
Concreting shall be carried out continuously between and up to
predetermined construction joints in one sequence of operation. It
shall be thoroughly compacted by either hand tamping or mechanical
vibration or both and shall be thoroughly worked into the corners.
After tamping into place the concrete shall not be subjected to
disturbance other than such as incidental to compaction by vibration.
In the event of unavoidable stoppage in positions not predetermined,
the concreting shall be terminated on a horizontal plane and against
vertical surfaces by the use of stop boards. The location for
termination shall be subjected to the approval of the S.O.

Fresh concrete shall not be placed against in-situ concrete which has
been in position for more than 45 minutes (or any other period of time

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based on the trial mix as per 2.4, 3.2.3 and approved by the S.O. if an
admixture is used) unless a construction joint is formed in accordance
with sub-section 6.1. When in-situ concrete has been in place for four
hours, no further concrete shall be placed against it for a further 20
hours. Where retarding admixture has been used, the S.O. may
approve variation to this limit.

Except where otherwise approved by the S.O., concrete shall be

deposited in horizontal layers to a compacted depth not exceeding
450 mm when internal vibrators are used or 300 mm in all other
cases. The surface of the concrete shall be maintained reasonably
level during placing.

Concrete shall not be dropped into place from a height exceeding 1.5
meters. However, higher drops may be allowed provided the mix has
been well designed and proportioned. When trunking or chutes are
used, they shall be kept clean and used in such a manner as to avoid
segregation.

The Contractor shall maintain an experienced steel fixer at the site of

reinforced concrete works during the placing of concrete to reposition
any reinforcement which may be displaced.

5.6 Placement Temperature

Placement temperature shall comply with MS 1195 to prevent premature

setting and loss of water during placing of concrete in the formwork and the
following precautions shall be taken:

a) At the time of placing, no part of the concrete shall have a

temperature exceeding 36 oC. This may be achieved by cooling the water
and aggregate prior to mixing.

b) Concrete shall not be placed in forms or around reinforcement whose

temperature exceeds 36 oC. This can be achieved by providing shading
or other means to protect from direct sunlight.

c) Freshly placed concrete shall be protected from direct sunlight and from loss of
moisture by covering, shading or other means.

d) No concrete shall be placed when the air temperature at the point of

deposition exceeds 36 oC

However, higher temperatures may be allowed provided it can be proven

that it shall not result in any detrimental effect to the concrete work.

5.7 Compaction

Unless otherwise approved by the S.O., concrete shall be thoroughly

compacted by vibration and thoroughly worked around the reinforcement,
tendons or duct formers, around embedded fixtures and into corners of the
formwork to form a dense, homogenous mass, free from voids and which will

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have the required surface finish when the formwork is removed. Vibration
shall be applied continuously during the placing of each batch of concrete
until the expulsion of air has practically ceased and in a manner which does
not promote segregation of the ingredients.

The concrete maintained between the two walls of formwork shall be

compacted by internal or external vibrators. Concrete in slabs with no
formwork on its upper surface shall be compacted either by vibrators of the
pan type or by a vibrating screen.

The internal vibrators shall be inserted and withdrawn slowly and at a

uniform pace of approximately 100 mm per second. Compaction shall be
deemed to be completed when cement mortar appears in an annulus around
the vibrator. Over vibration leading to segregation of the mix must be
avoided. The internal vibrators shall be inserted at points judged by the area
of mortar showing after compaction, with a certain allowance made for
overlapping and they shall not be allowed to come into contact with the
formwork or the reinforcement and shall be inserted at a distance of not less
than 75 mm from the formwork.

The pan vibrator shall be placed on the surface of the concrete, which shall
have previously been tamped and leveled leaving an allowance in height for
compaction until the cement mortar appears under the pan. The vibrator
shall then be lifted and placed on the adjoining surface and this operation
shall be repeated until the whole surface has been compacted. Alternatively,
a vibrating screen spanning the full width of the surface may also be used.

Whenever vibration has to be applied externally, the design of formwork and

disposition of vibration shall receive special consideration to ensure efficient
compaction and to avoid surface blemishes. The vibration shall be such
that there will be no excess water on the top surface on completion of
compaction.

External vibrators shall be firmly secured to the formwork which must be

sufficiently rigid to transmit the vibration and strong enough not to be
damaged by it.

Internal vibrators shall be capable of operating at not less than 10,000 cycles
per minute and external vibrators at not less than 3,000 cycles per minute.
Sufficient vibrators in serviceable condition shall be on Site so that spare
equipment is always available in the event of breakdowns. Vibrators shall be
operated by workmen skilled in their use.

Concrete shall not be subjected to any disturbance within 24 hours after

compaction. No standing or flowing water shall be allowed to come into
contact with exposed concrete surfaces during the first two (2) hours after
placing and compaction of the concrete.

In the event where inadequate or improper compaction is suspected, the

S.O. has the right to inspect and to carry out further tests. The tests may

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include non-destructive and destructive methods. All expenses incurred in

carrying out such sampling, testing and remedial works shall be borne by the
Contractor irrespective of whether the tests prove the structure to be sound
or otherwise.

5.8 Curing and Protection

All concrete work shall be cured for the full period of curing which shall not be
less than five (5) days for F1, F2, F3 and F4 surfaces, but not less than
three (3) days for F11, F12, F13, F14 and F15 surfaces.

Curing and protection shall start immediately after compaction of the

concrete to protect it from:

a) Impact damage such as shock, overloading or falling earth which

may disrupt the concrete and interface with its bond to reinforcements.

b) Premature drying out from direct sunlight and wind.

c) Leaching out by rain and flowing water.

d) High internal thermal gradients.

5.8.1 Normal Curing And Protection

Concrete, after it is placed and until the expiration of the curing duration,
shall not be allowed to dry out. Provision shall be made for adequate
protection against direct sunlight and wind to allow the process of curing to
complete within the specified period.

Curing and protection shall be accomplished by covering the

exposed concrete surface with an impermeable material such as
polyethylene sheet, which should be well sealed and fastened
and if required, this treatment can be continued efficiently throughout
the whole period of curing.

When the concrete has attained its final set, one of the following curing
methods shall be adopted:

a) Water curing shall be accomplished by keeping the

surface of the concrete continuously wet by ponding with water.

b) Curing may be accomplished by sealing in the water as

specified above by covering with an approved
waterproofed curing paper or plastic sheeting laid with airtight
joints. It must be securely positioned to prevent displacement by
wind and protected from tearing or other injury.

The use of other methods of curing may be deemed necessary when the
concrete is subjected to high internal thermal gradient, or with large
exposed surface area. The Contractor shall submit a method statement to
the approval of the S.O.

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In the event where the Contractor does not do proper curing, the S.O.
has the right to inspect and to carry out further tests which may
include destructive methods. All expenses incurred in carrying out
such sampling, testing and remedial works shall be borne by the
Contractor irrespective of whether the tests proved the structure to be
sound or otherwise.

5.8.2 Accelerated Curing

Elevated temperature curing may be used only with Ordinary

Portland Cement. After the completion of the placing of concrete, four
(4) hours shall elapse before its temperature is raised, unless the
Contractor is able to prove that curing can start earlier by furnishing
all the relevant supporting data to the S.O. The rise in temperature
within any period of 30 minutes shall not exceed 10 0 C and maximum
temperature attained shall not exceed 70 0 C unless it can be proven
that any deviation from this provision shall not result in any
detrimental effect to the concrete work. The rate of subsequent
cooling shall not exceed the rate of heating. The use of accelerated
curing methods for concrete containing other types of cement or any
admixture or any additional materials shall be to the approval of the
S.O.

6.0 Construction with Concrete

6.1 Construction Joints

The position and detail of any construction joints not described in the
drawings shall be to the approval of the S.O. and shall be so arranged as to
minimise the possibility of the occurrence of shrinkage cracks.

If for any reason the Contractor has to interrupt a planned pour for more than
45 minutes (or any other period of time based on the trial mix as per 2.4, 3.2.3
and approved by the S.O. if an admixture is used), additional construction
joints shall be positioned and constructed as directed by the S.O.

The number of construction joints shall be kept as few as possible consistent

with reasonable precautions against shrinkage. Concreting shall be carried
out continuously up to construction joints. The joints shall be at right angles
to the general direction of the member and shall take due account of shear
and other stresses.

Concrete shall not be allowed to run to a feather edge and vertical joints
shall be formed against a stop board. The top surface of a layer of concrete
shall be level and flat unless design considerations make this undesirable.
Joint lines shall be so arranged that they coincide with features of the
finished work, wherever possible.

At horizontal construction joints, gauge strips about 25 mm width shall be

placed inside the forms along all exposed surfaces to ensure a straight joint
on those surfaces.

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Where a kicker (i.e., a starter stub) is used for the construction of walls and
columns, it shall be at least 50 mm high, to be constructed monolithically with
the base concrete.

Where vertical construction joints are necessary in mass concrete structures,

reinforcing bars shall be placed across the joints so as to make the structure
monolithic, all to the approval of the S.O.

Prior to recommencement of concreting on a joint, the surface of the

concrete against which new concrete will be cast shall be free from laitance
and shall be roughened to the extent that the coarse aggregate is exposed
but not disturbed. Care shall be taken to avoid damaging the lines of the
joint. Care shall also be taken that the joint surface is clean and damp but
not wet and the exposed adjoining surfaces shall be of consistent colour.
Immediately before the fresh concrete is placed against the joint, fresh rich
cement mortar (1:2) shall be applied to the exposed surface.

Where the S.O. considers that special preparation is necessary, e.g. for an
in-situ structural connection, preparation shall be carried out, preferable
when the concrete has set but not hardened, by spraying with a fine spray of
air and water or brushing with a stiff brush sufficiently to remove the outer
mortar skin and expose the larger aggregates without disturbing them.
Where this treatment is impracticable, sand blasting or a needle gun shall be
used to remove the surface skin and laitance. Hardened surfaces shall be
chipped manually or mechanically to be free from laitance and properly
roughened to the extent that the coarse aggregates are being exposed.

6.2 Fixing Blocks, Brackets, Built In Bolts, Holes, Chases, Etc.

All fixing blocks, brackets, built in bolts, holes, chases, etc. shall be
accurately set out and formed and carefully sealed prior to the concrete
being placed. It is the responsibility of the Contractor to obtain all such
information for these items of work and obtain the permission of the S.O.
before incorporating such work prior to the concrete being placed.

Bolts and other inserts to be cast into the concrete shall be securely fixed to
the formwork in such a way that they are not displaced during the concreting
operations and that there is no loss of materials from the wet concrete
through holes in the formwork.

Unless shown otherwise in the drawings or instructed by the S.O.,

reinforcement shall be locally moved so that the minimum specified cover is
maintained at the locations of inserts, holes, chases, etc. In the event where
the minimum cover cannot be maintained, the Contractor shall take the
necessary precautions to protect the reinforcements against corrosion by
applying an approved coating material to the reinforcements and the
concrete cover.

Temporary plugs shall be removed and the threads of built in bolts shall be

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cleaned and greased before handing over any part of the Work.

6.3 Permanent Structure Joints.

6.3.1 Expansion joints, contraction joints or other permanent structure

joints shall be provided in the positions and constructed and sealed
with waterproofing materials as detailed in the drawings.

6.3.2 Unless otherwise shown in the drawings, all exposed expansion

joints shall be covered with 0.7 mm thick aluminium cover strips fixed
with masonry nails at 300mm centers.

6.4 Sealants and Special Materials

6.4.1 General

The installation method and the selection, mixing, application and

curing of all joint waterproofing materials shall be in accordance with
the manufacturer’s recommendation. The Contractor may propose to
use alternative joint waterproofing materials by submitting supporting
technical information, test reports and samples of the proposed
waterproofing materials to the S.O. for approval.

6.4.2 Waterproofing Materials

All waterproofing materials used at public access areas shall be

protected with non shrink grout covering.

6.4.3 Waterstops

Waterstops shall be as specified in the drawings and shall be

installed and butt jointed according to BS 8007 and the
manufacturer=s recommendations. Waterstops shall be securely
positioned in the formwork to prevent displacement during concreting.

7.0 Steel Reinforcement

7.1 General

The Work shall consist of furnishing and placing reinforcing steel in

accordance with this specification and in conformity with the drawings or as
directed by the S.O.

7.2 Materials

Hot rolled mild steel and high yield bars shall comply with the requirements
of MS 146. Cold worked steel bars shall comply with the requirements of BS
4461. Hard drawn mild steel wire shall comply with the requirements of MS
144.
Steel fabric reinforcement shall comply with the requirements of MS 145 and
shall be delivered to the Site in flat sheets, unless otherwise specified.

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Dowel bars shall be plain, round bars conforming to the requirements of MS

146. They shall be free from burring or other deformations restricting
slippage in the concrete. Dowel bar sleeves used for debonding shall be of
approved synthetic material. The closed end of the sleeve shall be filled with
25 mm thick compressible foam fillers and the sleeve shall fit tightly over the
length of the bar to be debonded.

Before any reinforcement steel is brought to Site, the Contractor shall furnish
the mill certificates of tests and these shall be submitted for acceptance by the
S.O. In addition the Contractor shall on request, furnish the S.O. with a test
sheet from approved laboratories for any batch of bars, giving the results of
each of the mechanical tests and/or chemical composition analysis required
under the Malaysian Standards or any equivalent international standards
approved by the S.O. The specified characteristic strength of steel
reinforcement shall be as given in Table 9.

During the course of the work, any reinforcement being found to be not in
accordance with the Malaysian Standards or British Standards, may be
rejected by the S.O. notwithstanding any previous acceptance on the
strength of the test certificates. The S.O. may call for additional tests to be
made at the Contractor=s expense on samples taken from the batch of the
defective reinforcement. If the samples do not comply with the Malaysian
Standards or British Standards, then the S.O. may reject the whole batch
and instruct its removal from the Site.

Steel reinforcement shall be stored in clean and dry conditions. When placed
in the work it shall be clean and free from loose rust, mill scale, oil, grease,
paint, dirt or anything which may reduce its bond with concrete. If directed by
the S.O., the steel bars shall be brushed or otherwise cleaned before use, at
the Contractor’s expense.

Binding wire shall be 1.6 mm diameter soft annealed steel wire complying
with the requirements of BS 1052.

7.3 Construction Methods

7.3.1 Cutting and Bending of Reinforcement

Bars shall be of their correct lengths and bent to the exact shapes
required before being fixed in the work.

Bars shall be cut and bent cold by the application of slow, steady
pressure or in an approved bar-bending machine. Bending at
temperatures in excess of 100 0C may only be carried out with the
S.O.’s approval and under his supervision. Except where otherwise
indicated in the drawings, bars shall be bent and measured in
accordance with BS 4449.

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Cold worked and hot rolled bars shall not be straightened or bent
again once having been bent. Where it is necessary to bend the free
end of mild steel reinforcement already cast in the concrete, the
internal radius of the bend shall not be less than twice the diameter of
the bar.

Special care shall be taken that the overall length of bars with
multiple bends is accurate and that after bending and fixing in
position the bars remain in place without wrap or twist.

7.3.2 Fixing of Reinforcement

The number, size, length, shape, type and position of all reinforcing
bars, links, spacer bars and other parts of the steel reinforcement,
shall be in accordance with the drawings.

Reinforcements shall be secured against displacement. Unless

specified otherwise, the actual concrete cover shall be taken as the
distance between face of concrete and the nearest steel surface. All
intersecting bars shall be tied together with binding wire and the ends
of the wire shall be turned into the main body of the concrete.

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 S.O.

The Contractor shall take particular care that the reinforcement is laid
out correctly in every aspect and temporarily suspended by annealed
wire or supported on concrete blocks or other approved spacers in
the forms to prevent displacement during the placing and compacting
of concrete. Links shall tightly embrace the longitudinal reinforcement
to which they shall be securely wired or spot welded. The top
reinforcement in slabs shall be rigidly supported on mild steel Achairs@
or equivalent spaced in each direction to prevent sagging during
concreting.

No concrete shall be placed until the reinforcement has been

inspected and approved by the S.O.

7.3.3 Splicing

Joints to reinforcement bars shall be effected by lapping of bars at

positions shown in the drawings. Where other types of joints are to be
used, prior approval of the S.O shall be obtained and their use shall
be strictly in accordance with manufacturer’s instructions, at the
positions approved by the S.O.

7.3.4 Supporting and Spacer Blocks

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Supporting and spacer blocks required for ensuring that the

reinforcement is correctly positioned shall be as small as possible,
consistent with their purpose, of a shape approved by the S.O., and
designed so that they will not overturn when the concrete is placed.

The nominal size of aggregates used shall be 10mm. The concrete

spacers shall be of at least the same strength and material’s source
as the concrete to be poured. Wires cast in these blocks for the
purpose of tying them to the reinforcement shall be as described in
clause 7.2.
Spacers left in situ shall not impair the desired appearance or
durability of the structure by causing spalling, rust staining or allowing
the passage of moisture.
Other types of spacers may be used only with the approval of the
S.O.

7.3.5 Welding of Reinforcement

Reinforcement in structures shall not be welded except where

detailed in the drawings or permitted in this specification.

Welding shall be carried out in accordance with BS 5135 and BS

638. Butt welds shall be of the double V type and two butt weld bond
tests shall be carried out on a specimen prepared to represent each
form of the butt welded joint used in welding the reinforcement and
for each position of welding. The method of making butt weld tests
shall be as laid down in BS 709. The specimen shall pass the test to
the approval of the S.O. before using the joint, which the specimen
represents.

Welded joints shall not be made at bends in reinforcement. Unless

otherwise approved by the S.O., joints in parallel bars of the principal
tensile reinforcement shall be staggered in the longitudinal direction
at a distance not less than the end anchorage length for the bar.

All welding shall be performed by a competent welder approved by

the S.O.

The S.O. shall be informed in advance of when welding is to be

carried out so that he may supervise and inspect the work. Welding
shall not be performed in the field during rain or other adverse
conditions.

8.0 Formwork And Surface Finish For Structure

8.1 Design and Construction

8.1.1 Description

Formwork shall include all temporary or permanent forms required for

forming the concrete, together with all temporary construction
required for their support.

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The Contractor is deemed to have made a study of the Drawings at

tender stage and is aware of all areas of construction, requiring
heavy and specially designed propping to provide the support and
the necessary bracing for the stability of such propping.

The design and construction of formwork shall be carried out by a

competent person. The Contractor shall identify all critical formwork
design and submit the strength and deflection calculations and
drawings or the proposed design, certified by a Professional Engineer
to the S.O. for prior approval. Notwithstanding any approval by the
S.O. with respect to the design submitted by the Contractor, the
responsibility or the adequacy and safety of the design shall remain
with the Contractor. The Contractor shall also appoint a competent
formwork coordinator whose duties would be similar to those outlined
in BS 5975.
When the use of proprietary type of formwork is proposed by the
Contractor, the design shall be certified by a Professional Engineer.

The formwork shall be sufficiently rigid and tight to prevent loss of

grout or mortar from the concrete at all stages of construction and
shall be appropriate for the methods of placing and compacting.

Formwork (including supports) shall be sufficiently rigid to maintain

the forms in their correct position, shape, profile and dimensions. The
supports shall be designed to withstand the worst combination of
forces due to self weight, formwork weight, formwork forces,
reinforcement weight, wet concrete weight, and construction and
wind loads, together with all incidental dynamic effects caused by
placing, vibrating and compacting the concrete. Guidance on these
loadings is given in The Concrete Society Manual Formwork – Guide
to good practice, and in CIRIA Report 108, Concrete Pressure in
Formwork, and in BS 5975. Vertical propping to formwork shall be
carried down sufficiently far to provide the necessary support without
overstressing the completed concrete structure.

Metal ties may only be used with the prior approval of the S.O. Where
metal ties are permitted, the use of storey height steel soldiers shall
be used to reduce the number of tie bolts required. Tie bolts with
rubber or plastic cone against the form face are to be used to prevent
unsightly grout loss. No metal part of any device for maintaining
formwork in the correct location shall remain permanently within the
specified concrete cover to the reinforcement. Except for ties used for
anchoring void formers, all ties shall be at least 1.2 meters apart and
through bolts will not be permitted on exposed form finished faces. All
holes left by ties shall be made good within one day of the removal of
the formwork using a mortar of the same strength as the cast
concrete. Metal ties which allow for holes through the concrete being
cast shall not be permitted to be used in concrete for water-retaining
structure and walls.

8.1.2 Projecting Reinforcement, Fixing Devices

Where holes are needed in form to accommodate projecting

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reinforcement or fixing devices, care shall be taken to prevent loss of

grout when concreting or damage when removing forms.

8.2 Surface Finishes for Concrete

8.2.1 Control of Colour

When specified in the drawings, the Contractor shall obtain each

constituent material from a single consistent source. The aggregates
shall be free of any impurities that may cause staining. The mix
proportions and the grading, particularly of the fine aggregate, shall
be maintained constant. The same type of plywood or timber shall be
used in formwork throughout similar exposed areas.

8.2.2 Formed Surfaces

Formed concrete surfaces shall have one of the following classes of

finish. Unless otherwise specified, all exposed concrete surfaces shall
be of Class F12, all unexposed surfaces shall be of Class F1. Other
classes of finishes shall be used only where shown in the drawings:

(a) Class F1

This finish shall be obtained by the use of properly designed

forms of closely joined sawn timber or other approved
material. Small blemishes caused by entrapped air or water
may be expected but the surface shall be free from voids and
honeycombing.

(b) Class F2

This finish shall be obtained by the use of properly designed

forms of closely jointed wrought boards, approved plywood or
other approved material. Only very minor surface blemishes
shall occur, with no staining or discolouration.

(c) Class F3

This finish shall be obtained by the use of properly designed

steel forms or plastic coated plywood or wrought boards or
other approved material. The surface shall be improved by
carefully removing all fins and other projections, thoroughly
washing down and then filling the most noticeable surface
blemishes with a cement and fine aggregate paste to match
the colour of the original concrete. Form release agents shall
be carefully chosen to ensure that the surface shall not be
stained or discoloured.

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After the concrete has been properly cured, the surface shall
be rubbed down where necessary, to produce a smooth and
even surface.

8.2.3 Unformed surfaces

(a) Class U1

The concrete shall be uniformly levelled and screeded to

produce a plain, ridged or broom roughened surface. No
further work shall be applied to the surface unless it is used as
the first stage for a Class U2 or Class U3 finish.

(b) Class U2

After the concrete has hardened sufficiently, the concrete

Class U1 surface shall be floated by hand or machine to
produce a uniform surface free from screed marks.

(c) Class U3

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

(d) Class U4

This finish is for surfaces that are to receive waterproofing

systems.

The concrete shall be levelled and floated to produce a

uniform surface and immediately before the waterproofing
operation this surface shall be water jetted or grit blasted to
provide a lightly textured finish.

The finished surface shall not deviate from the required profile
by more than 5mm over a 3m gauge length or have any
abrupt irregularities of more than 3mm.

8.2.4 Trial Panels For Exposed Form Finished Surfaces

In order to ensure that the specified formed finishes can be obtained

by the method of construction proposed and to provide a standard by
which the finishes in the Works can be assessed, trial panels shall be
cast on Site. These panels shall be subjected to the S.O.’s approval
before similar casting is permitted in the Works.

The trial panels shall employ the materials, plant and concrete mix

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proposed for the Works. They shall be at least a storey height and
1m wide. They shall be of similar thickness and similarly reinforced as
the elements they represent and shall incorporate all features which
contribute to the final appearance of the Works.

8.3 Preparation of Forms before Concreting

Before concreting, all forms shall be thoroughly cleaned out, free from
sawdust shavings, dust, mud or other debris.

The inside surfaces of forms shall, unless otherwise approved by the S.O.,
be coated with an approved non-staining form oil or other approved material
to prevent adhesion of the concrete. Such release agents shall be applied
strictly in accordance with the manufacturer’s instructions and shall not come
into contact with the reinforcement or prestressing tendons and anchorages.
For any exposed surface only one release agent shall be used throughout
the entire area.

All formwork shall be inspected by the S.O. after preparation and

immediately prior to depositing concrete and no concrete shall be deposited
until approval of the formwork has been obtained.

8.4 Removal of Forms

The Contractor shall inform the S.O. and obtain his approval before striking
any formwork, but such approval shall not relieve the Contractor of his
responsibilities for the safety of the work.

Formwork shall be removed without such shock or vibration as would

damage the concrete. A period of time shall elapse between the placing of
the concrete and the removal of the formwork for various parts of the
structure so as to suit the requirements for its curing.

The minimum periods between concreting and the removal of forms are
given in Table 10. The periods stated in this table are based on the use of
Ordinary Portland Cement. They may be changed with the approval of the
S.O., if other types of cement as described in 2.1, admixtures or additional
material as described in 2.4 and 2.5 are used. The result of the compressive
strength obtained from the additional cubes taken as described in 4.9 may
also be used for early removal of forms provided always the Contractor
provide proof of calculation to the S.O for approval.

For prestressed in-situ components, temporary supports shall not be

removed until the components is stressed to the approval of the S.O.

Where it is intended that forms are to be reused, they shall be cleaned and
made good to the approval of the S.O.

Following the removal of forms, no further loads shall be imposed upon the
concrete until at least after the completion of the curing period or until such
later time as in the opinion of the S.O. the concrete shall have attained
sufficient strength to safely withstand such loads. Full design loads shall not

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be applied to any structure until all loads bearing concrete is at least 28 days
old.

8.5 Inspection and Making Good

The surface of the concrete shall be inspected for defects and for conformity
to the surface finish specified and where appropriate, with approved sample
finishes.

Subject to the strength and durability of the concrete being unimpaired, the
making good of surface defects may be permitted but the level of
acceptance shall be appropriate to the type and quality of the finish specified
and ensures satisfactory permanence and durability.

Any remedial treatment of surfaces shall be approved by the S.O. following

inspection immediately after removing the formwork and shall be carried out
without delay.

9.0 Mass and Lean Concrete

Mass and lean concrete shall consist of cement, fine aggregate and coarse
aggregate in the nominal ratio by volume of 1:3:6 and 1:4:8 respectively. However
where a denser and more workable concrete can be produced by a variation in the
ratio of the fine aggregate to that of coarse aggregate, this ratio may be varied
within the limits (1:1½) and (1:3), provided that the volumes of fine and coarse
aggregate, each measured separately, shall nevertheless equal the sum of the
volumes of fine and coarse aggregate appropriate to the nominal mix. The concrete
shall be mixed as described for reinforced concrete.

10.0 Building Accuracy

After removal of formwork, the Contractor shall take measurements as directed by

the S.O. to check the deviation of the reinforced concrete works from specified
dimensions shown in the drawings. All measurements shall be recorded and
submitted to the S.O. Any deviation in compliance with BS 5606 shall be
acceptable. Any deviation in building accuracy shall comply with BS 5606.

11.0 Apparatus

The Contractor shall provide the following apparatus for use on the Site at all times:
-

(a) Concrete slump test apparatus or flow test apparatus complying with MS 26.
One set of the apparatus shall be provided for each concreting location.

(b) At least twelve (12) numbers of steel or cast iron moulds for casting 150mm
concrete test cubes and six (6) numbers of 100mm mortar or grout test cube
moulds complete with tamping bars and base plates in accordance with MS
26. A minimum number shall be provided such that no stripping of cubes is
required prior to 24 hours setting and hardening period.

(c) Three (3) measuring cylinders of 250 ml capacity, graduated to measure to

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the nearest 2.0 ml., for determination of silt content (field setting method).

(d) An approved apparatus for measuring moisture content in fine aggregate.

(e) One electronic calculator with statistical functions.

(f) One 300 mm steel rule.

(g) One set of sieves in compliance with BS 410.

(h) Scale or balance 25 kg maximum capacity and weights.

(i) Trowel, shovel, spanner and other tools.

12.0 Other Requirements for Building Works.

Other requirements for building works shall be as in Appendix C/1.

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TABLE 1 - TESTING OF AGGREGATES

Properties Type of Test Limits

Aggregate Methods

Grading Both MS30 Table 2 & Table 3

Elongation Index Coarse MS30 Not exceeding 30%

Flakiness Index Coarse MS30 Not exceeding 35%

Water Absorption Both MS30 Not exceeding 8%

Clay Lumps Coarse MS30 Not exceeding 1% by weight

Clay, Silt and Dust Fine MS30 Not exceeding 3% by weight

or 8% by vol.

Organic Impurities Fine MS30 Not exceeding 0.4%

Aggregate Crushing Coarse MS30 Not exceeding 40%

Value

Soundness Test Coarse MS30 Loss in mass after 5 cycles

shall not be more than 12%
for sodium sulphate or 18% for
magnesium sulphate.

Chloride Content Both MS30 Not exceeding 0.06% by

weight of chloride ions

Sulphate Content Both MS30 Not exceeding 0.44% by

weight of SO3

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TABLE 2 - GRADING FOR COARSE AGGREGATE

Percentage by mass passing BS 410 sieve for nominal sizes

Sieve size Graded Aggregates Single-sized Aggregate

(BS410)
40 mm 20 mm 14 mm
to to to 40 mm 20 mm 10 mm
5 mm 5 mm 5 mm

50.0 mm 100 - - 100 - -

37.5 mm 90 to 100 100 - 85 to 100 100 -

20.0 mm 35 to 70 90 to 100 100 0 to 25 85 to 100 -

14.0 mm 25 to 55 40 to 80 90 to 100 - 0 to 70 100

10.0 mm 10 to 40 30 to 60 50 to 85 0 to 5 0 to 25 85 to 100

5.0 mm 0 to 5 0 to 10 0 to 10 - 0 to 5 0 to 25

2.36 mm - - - - - 0 to 5

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TABLE 3 - GRADING FOR FINE AGGREGATE

Percentage by mass passing BS 410 sieve

Sieve size
(BS 410) Overall Additional limits for grading
limits
C *M F

10.0 mm 100 - - -

5.0 mm 80 to 100 - - -

2.36 mm 60 to 100 60 to 100 65 to 100 80 to 100

1.18 mm 30 to 100 30 to 90 45 to 100 70 to 100

600 µm 15 to 100 15 to 45 25 to 80 55 to 100

300 µm 5 to 70 5 to 40 5 to 48 5 to 70

150 µm 0 to 15# - - -

# Increase to 20% for crushed rock fines, except when they are used for heavy-
duty floors.
* For prescribed mix only Grading Limit M is applicable. See also clause 2.2.3(b).
NOTE: Individual sands may comply with the requirements of more than one grading.
Alternatively some sands which satisfy the overall limits but may not fall within
any one of the additional limit C, M or F may also be used provided that the
supplier can satisfy the S.O that such materials can produce concrete of the
required quality.

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TABLE 4 - ADMIXTURE ACCEPTANCE TEST REQUIREMENTS

Stiffening Time Minimum Length change, maximum

Categories Water Strength as a shrinkage
of Admixture Reduction percentage of
Time from completion of mixing to reach a the control mix Age % of Increase
resistance to penetration of:- control

0.5 N/mm2 3.5N/mm2 27.5 N/mm2 Compressive

Type 1: - More than Within 1hr.and At least 1hr. 125 24 hrs.

Accelerator 1hr. 3hrs. earlier earlier than 125 3 days
than control mix control mix 100 7 days 135 0.010
100 28 days

Type 2: - At least Within 1hr. and Not more than 90 3 days

Retarder 1hr.later 3hrs. later than 3hrs. later 90 7 days 135 0.010
than control control mix than control 95 28 days
mix mix

Type 3: Within + Within + 1hr. Within + 1hr. 110 3 days

Normal At least 1hr. and - 1hr. of and - 1hr. of 110 7 days 135 0.010
water- 5% and - 1hr.of control mix control mix 110 28 days
reducing control mix

Type 4: Within 1hr. and At least 1hr. 125 24 hrs.

Accelerating At least More than 3hrs. earlier earlier than 125 3 days 135 0.010
water- 5% 1hr. than control mix control mix 100 7 days
reducing 100 28 days

Type 5: At least 1hr. Within 1hr. and Not more than 110 3 days
Retarding At least later than 3hrs. earlier 3hrs.later than 110 7 days 135 0.010
water- 5% control mix than control mix control mix 110 28 days

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reducing

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TABLE 5 - PRESCRIBED MIXES FOR GENERAL USE PER CUBIC

METER OF CONCRETE BY WEIGHT BATCHING

Grades Nominal Max.Size of Aggregate (mm) 20 Max free

28-day
of water:
Strength of Workability Medium High
Concrete cement
Concrete
ratios
(N/mm2) Slump limits(mm) 25 - 75 75 - 125

15P 15 Cement (kg) 280 310

Total 1800 1750 0.6
aggregate(kg) 35 - 50 35 - 50
*Fine
aggregate(%)

20P 20 Cement (kg) 320 350

Total 1800 1750 0.55
aggregate(kg) 25 - 40 20 - 45
*Fine
aggregate(%)

25P 25 Cement (kg) 360 390

Total 1750 1700 0.5
aggregate(kg) 25 - 40 30 - 45
*Fine
aggregate(%)

30P 30 Cement (kg) 400 430

Total 1700 1650 0.45
aggregate(kg) 25 - 40 30 - 45
*Fine aggregate
(%)
* Fine aggregate is expressed as a percentage by weight to the total weight of the dry
aggregate.

TABLE 5A - PROPORTIONS AND STRENGTH REQUIREMENTS FOR

PRESCRIBED MIXES BY VOLUME BATCHING

Mix Slump Cubic Meters of Max. Quantity Strength

Proportion Limits Aggregate Per 50 Free of of Concrete
(Grade) (mm) kg of cement Water: Water
Cement
Fine Coarse Ratio (Liters) At 7 At 28
(20mm) Days Days
(N/mm2) (N/mm2)

1:1:2(30P) 25-50 0.035 0.07 0.45 22.5 20 30

1:1.5:3(25P) 25-50 0.05 0.1 0.5 25 17 25

1:2:4(20P) 25-50 0.07 0.14 0.55-0.6 27.5-30 14 20

1:3:6(15P) 25-50 0.10 0.20 0.6 30# 11 15

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# or as approved by S.O.

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TABLE 6 - MINIMUM CEMENT CONTENT AND MAXIMUM FREE WATER: CEMENT

RATIO FOR DESIGNED MIX

Prestressed Reinforced Plain

Concrete Concrete Concrete Max.
Free
Exposure Water:
Cement
Ratio

Nominal max.size Nominal max.size Nominal max.

of aggregate of aggregate size of
(in mm) (in mm) aggregate (in
40 20 10 40 20 10 mm)
40 20

a)Surface (kg/m3) (kg/m3) (kg/m3)

sheltered
from
severe rain:-
1) surface
protected by
a
waterproof
membrane; 300 320 360 300 320 360 250 280 0.55
2) internal
surfaces,
whether or
not subject
to
condensation;
3) surfaces
continuously
buried and/or
submerged
under water.

b) soffits;
c) surfaces
exposed to
330 350 330 350 390 270 300 0.50
driving rain,
390
alternate
wetting and
drying, e.g, in
contact with
backfill.

d) surfaces
exposed to
360 380 360 380 420 320 350 0.45
the action of

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sea water with 420

abrasion having
a pH of 4.5 or
less.

e) surfaces References shall be made to Table 6.1 - MS1195 Part 1:1991

exposed to
sulphate
attack.

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TABLE 7 - MAXIMUM TOTAL CHLORIDE

Type or Use of Concrete Maximum Total Percentage of

Chloride Ions by Mass of
Cement

Concrete containing embedded metal and 0.4

made with cement complying with MS522

Prestressed Concrete and Heat-Cured 0.1

Concrete containing embedded metal

Plain, non-structural concrete No limit

Notes on Table 7:-

(1)% Chloride ions x 1.648 = % equivalent sodium chlorides.
(2)% Chloride ions x 1.56 = % equivalent anhydrous calcium chlorides.

TABLE 8 - COMPRESSIVE STRENGTH REQUIREMENTS FOR PRESCRIBED MIX

Grades of 28-day Strength of Cube Strength at 7 Average Cube

Concrete Strength at 28 Days*
Concrete Days*
N/mm2 N/mm2 N/mm2
20.0 14 20.0
20P 25.0 17 25.0
25P 30.0 20 30.0
30P 40.0 27 40.0
40P

*Only for Portland cement

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TABLE 8A - 28 DAY STRENGTH COMPLIANCE REQUIREMENTS FOR DESIGNED MIX

Specified Group of Test Results: A B

Grade of The mean of the Any individual test
Concrete group of test results result is not less than
exceeds the the characteristic
specified compressive strength
characteristic less:
compressive
strength by at least:

N/mm2 N/mm2
20 and above First 2 1 3
First 3 2 3
Any consecutive 4 3 3

N/mm2 N/mm2
Below 20 First 2 0 2
First 3 1 2
Any consecutive 4 2 2

TABLE 9 - CHARACTERISTIC STRENGTH

OF STEEL REINFORCEMENT

Type Nominal Sizes (mm) Specified Characteristic

Strength, fy (N/mm2)

Hot rolled grade 250 All sizes 250

(MS 146)

Hot rolled grade 460 All sizes 460

(MS 146)

Cold worked All sizes 460

(BS 4461)

Hard drawn steel wire Up to and 485

(MS 144) including 12

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TABLE 10 - MINIMUM PERIODS BETWEEN CONCRETING

AND REMOVAL OF FORMS

Vertical faces of beams, wall, columns, piles, foundation 3 days

plinths and precast components

Slabs (props left under) 4 days

Removal of props to slab 10 days

Beam soffits (props left under) 8 days

Removal of props to beams 21 days

Note: This table is applicable only for Ordinary Portland Cement. Where other types of
cement, admixtures or additional material are to be used, the minimum periods between
concreting and removal of forms shall be as approved by the S.O.

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APPENDIX C/1

1.0 Foundation

All reinforced concrete footings shall be constructed according to the drawings and to the
exact depths required. The Contractor shall supply, maintain and remove any necessary
planking and strutting, sheet piling and coffer dams, and shall by pumping or other
approved means keep the excavation free from water.

The bottom of excavation shall be cleaned or if in loose or disturbed ground shall be well
rammed, and the whole shall be approved before it is covered with a blinding layer of lean
concrete not less than 50 mm thick. The required cover of concrete under the
reinforcement shall be entirely above the blinding layer.

2.0 Floors

After initial set, the upper surface of cast-in-situ reinforced concrete floors shall be trowelled
smooth with a steel float to true level and even surface. No screeding of any kind shall be
applied to the floor slabs except where specified. Care shall be taken to ensure that the
steel reinforcement is not displaced or lowered during trowelling.

For areas, which are to receive rendering or other finishes, the fresh concrete shall be
trowelled to true level or as required using a long timber trowel. Before it hardens it shall be
brushed with a stiff broom in one direction to give a rough and tidy surface.

The reinforced concrete ground floor slab shall not be laid directly onto earth surfaces. A
blinding layer of 50mm minimum thick of lean concrete as specified in clause 9.0 shall be
laid on well prepared firm ground. Plastic sheeting or other suitable material with sufficient
overlaps at joints, shall be laid on the blinding layer before any reinforcement is placed in
position.

3.0 Toilet Floors

The Contractor shall ensure that all suspended floor for toilet areas are constructed to be
watertight and leakproof. All construction method or alternative details proposed by the
Contractor must be based on his acceptance of and compliance with the requirements for
watertightness. The Contractor shall ensure that holes and fixings are properly constructed.
The floor must be concreted in one sequence of operation. No construction joints for toilet
floor are to be allowed. All pipes and fittings encased in the concrete floor shall be provided
with sleeves to the approval of the S.O and shall be build in situ. No holes shall be left for
later incorporation of fittings and no subsequent hacking of floor shall be made. Not
withstanding whatever shown in the drawings, all toilet floor slabs shall have a minimum
thickness of 150mm.

3.1 Testing for watertightness

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The toilet floor areas should be ponded with water continuously over a period of 7
days. During this period the exposed soffit shall show no signs of leakage and
remain dry. If any area is found not to be watertight, the Contractor must repair at
his own expense.

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