VOLUME 3 TECHNICAL SPECIFICATIONS

DIVISION 5 - STRUCTURES

5.1 CONCRETE FOR STRUCTURES

5.1.1 Description

This work shall consist of the construction of all or portions of structures of Portland
cement concrete, of the required grades and types, with or without reinforcement,
prestressed reinforcement and with or without admixture, in accordance with these
Specifications and to the lines, levels, grades and dimensions shown on the Drawings
and required by the Engineer.

Portland cement concrete shall consist of a mixture of Portland cement, water and
coarse and fine aggregate with or without admixture.

5.1.2 Materials

5.1.2.1 Specifications for Materials

A) Cement

Cement shall conform to the requirements of AASHTO Standard Specification M 85

type 1, normal Portland cement, unless other types are indicated on the Drawings or
specified by the Engineer.

Cement shall be sampled and tested in accordance with STP Sections 2.6 and 8.

Bagged or bulk cement which has partially set or which contains lumps of caked
cement shall be rejected. The use of cement reclaimed from discarded or used bags
shall not be permitted.

B) Water

The water used in mixing and curing concrete shall be tested by methods described in
AASHTO Test Method T 26. All water shall be clean and free from salt, oil, acid,
vegetable or other substance injurious to the finished product. The use of river water
will be subject to the approval of the Engineer. Such approvals may be withdrawn from
time to time depending on the condition of the river.

C) Admixtures

Admixtures or any other additions shall not be used except with the written approval of
the Engineer.

Admixtures, if specified or permitted, shall fully conform to the requirements of AASHTO

Standard Specification M 194-74.

D) Coarse Aggregate

Coarse aggregate for all types of concrete with the exception of blinding concrete shall
consist of hard durable crushed or broken rock and generally conform to the
requirements of AASHTO Standard Specification M 80. Coarse aggregate shall be
clean, free from dust and other deleterious material.

The amounts of deleterious substances shall not exceed the following limits:

1) Soft fragments; 2% by mass

2) Clay lumps; 0.25% by mass

3) Material Passing the 0.075 mm sieve; 0.50% by mass if clay,

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1.50% by mass if fracture dust

In addition, coarse aggregates shall comply with the following:

1) Thin or elongated pieces; Flakiness Index (STP 7.3.1) less than 30

2) The aggregate crushing value (STP 7.7.1) shall be less than 30% and the ten
percent fines value (STP 7.7.2) shall be greater than 150 kN.

The grading of coarse aggregate of maximum size 20 mm shall conform to Table 5.1-1
below. The grading of 40 mm maximum size coarse aggregate shall be in accordance
with AASHTO Standard Specification M 80.

Table 5.1-1

Grading Requirements for 20 mm

Maximum Size Coarse Aggregate
Sieve Size (mm) % Passing by Weight
25 100
20.0 90 - 100
12.5 20 - 55
10.0 5 - 20
5.0 0-5
2.4 -
1.2 -

In heavily reinforced structures with difficult casting conditions smaller size aggregates
may be used if approved by the Engineer.

E) Fine Aggregate

Fine aggregate shall consist of natural sand and fine aggregates from different
sources of supply shall not be mixed or stored in the same pile.

The amounts of deleterious substance when tested in accordance with STP 3.4 shall
not exceed the following limits:

1) Friable Particles; 0.5% by mass

2) Coal and Lignite; 0.5% by mass

3) Material passing the 0.075 mm sieve; 3.0% by mass

4) Any other deleterious materials shall not cause a strength reduction of the concrete
of more than 5% in relation to the strength of concrete free of the concerned
deleterious material.

The grading shall normally be in accordance with Table 5.1-2. In the event that it is not
possible to obtain regular supplies of sand conforming to this grading, the Engineer
may approve the adoption of a grading conforming to the requirements of table 4 with
additional limits of either C or M of BS 882: 1992. However, any additional costs
resulting from changes in aggregate proportions or additional cement contents
required to achieve the specified strengths, when using these alternative gradings,
shall be borne by the Contractor and shall not be reimbursed.

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Table 5.1-2

Grading Requirements for Fine

Aggregate
Sieve Size (mm) % Passing by Weight
10.0 5 - 20
5.0 95 – 100
1.2 45 – 80
0.30 10 – 30
0.15 2 – 10

5.1.2.2 Testing of Materials

A) Cement

Cement shall be in accordance with AASHTO M 85. The Contractor must provide the
Engineer with manufacturer’s certificates indicating compliance.

Cement shall be sampled and tested for fineness, setting time and strength in
accordance with STP 8.1, STP 8.2 and STP 8.3, respectively, at the Contractor’s
expense. The Contractor shall notify the Engineer of delivery dates so that there will be
sufficient time for sampling the cement, either at the mill or upon delivery. If this is not
done, the Contractor may be required to re-handle the cement in the store for the
purpose of obtaining the required samples.

Sampling shall normally be instructed by the Engineer for every batch of cement prior
to this cement being incorporated in the Works.

B) Water

The water proposed by the Contractor to be used in mixing or curing concrete shall be
tested by methods described in AASHTO Test Method T 26.

In sampling water for testing, care shall be taken that the containers are clean and that
samples are representative.

When comparative tests are made with a water of known satisfactory quality, any
indication of unsoundness, marked change in time of setting, or a reduction of more
than 10 percent in mortar strength, shall be sufficient cause for rejection of the water
under test.

The water shall be tested at a recognised laboratory approved by the Engineer. The
test result shall be signed by the laboratory. The water shall be tested before
commencement of work or if the source is changed or at any time required by the
Engineer. All testing shall be carried out at the Contractor’s expense.

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C) Admixtures

The Contractor shall submit specifications and samples of any admixtures or additives
that he proposes to use to the Engineer at least 28 days before the commencement of
construction or manufacture of the particular structure on which he intends to use such
admixtures.

Any tests the Engineer may require on concrete mixes on account of the Contractor’s
proposal to use additives shall be carried out at the expense of the Contractor.

D) Aggregates

1) Selection and Approval

From the aggregate materials proposed by the Contractor, samples shall be

selected according to STP Section 2.4 and in the presence of the Engineer. The
samples shall be tested at the site laboratory or at an approved testing laboratory
for conformance with Section 5.1.2.1 of these Specifications.

2) Quality Control

The quality control of the aggregate shall be as directed by Engineer. Gradings

shall normally be checked daily.

Moisture contents of fine aggregate shall be determined daily and at any time when
a change in moisture content is expected.

If the Contractor proposes to change the source of aggregate, the Engineer shall
be informed in advance and in no case less than 3 weeks before the new
aggregate shall be used.

5.1.2.3 Composition of Concrete

A) Classes of Concrete

Concrete with cement type 1 for incorporation in the Works shall be of the classes
indicated on the Drawings and shall comply with Table 5.1-3.

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Table 5.1-3

Concrete Characteristic Maximum Minimum

Strength
(N/mm2 @ 28 days) Size of Cement
Coarse
Concret Cylinder Cube Aggregate Content
e
Class (150 x 300 mm) (150 mm) (mm) (Kg/m3)
7 7 9 40 180
20 210
10 10 13 40 210
20 240
15 15 19 40 250
20 280
20 20 25 40 300
20 320
25 25 31 40 340
20 360
30 30 37 40 370
20 400
35 35 44 40 400
20 430

B) Proportioning

When designing the concrete mix, the Contractor shall consider the following
conditions:

1) Strength

The class of the concrete is to be as shown on the Drawings. The class is the
specified characteristic cylinder strength at 28 days. Concrete mixes shall be
designed to comply with Specifications Section 5.1.2.4.

2) Water/Cement Ratio

The ratio of free water to cement when using saturated surface dry aggregate shall
be as low as possible and not exceed 0.50 by weight for all concrete, except for
blinding concrete where it shall not exceed 0.6, unless approved by the Engineer.

For concrete in barriers, edge beams and bridge decks directly exposed to traffic or
concrete in pile caps or abutments in contact with the ground, the water cement
ratio shall not exceed 0.45, unless approved by the Engineer.

3) Minimum Cement Content

As indicated for the respective class in Table 5.1-2

4) Minimum Filler Content

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Filler content (fine aggregate less than 0.25 mm and cement) shall not be less than
as follows (except for mass concrete).

Maximum coarse aggregate size (mm) 20 40

3
Minimum filler content (kg/m of concrete) 435 350

5) Coarse Aggregate

The maximum size of coarse aggregate will generally be stated on the Drawings;
either 40 mm or 20 mm, in accordance with Table 5.1-1. Grading and quality is to
comply with the requirements of Section 5.1.2.1(D).

6) Fine Aggregate

The grading and quality is to comply with the requirements of Section 5.1.2.1.

7) Workability

The concrete shall be of suitable workability to obtain full compaction. Slumps

measured in accordance with STP 9.1 shall not exceed 75 mm unless otherwise
indicated on the Drawings or approved by the Engineer.

C) Trial Mixes

After the Contractor has received approval for the cement and aggregate to be used,
he shall prepare trial mixes with concrete of designed proportions to prove and
establish workability, strength, water cement/ratio, surface criteria etc. Methods of
transporting fresh concrete and the compaction equipment shall be considered. The
trial mixes shall be made and compacted in the presence of the Engineer, using the
same type of plant and equipment as will be used for the Works.

From each trial mix, cylinders or cubes shall be made and tested in accordance with
Section 5.1.2.4.

From the same mix as that from which the test specimens are made, the workability of
the concrete shall be determined by the slump test in accordance with STP 9.1. The
remainder of the mix shall be cast in a wooden mould and compacted. After 24 hours
the sides of the mould shall be struck and the surface examined in order to satisfy the
Engineer that an acceptable surface can be obtained with the mix.

The trial mix proportions should be approved if the required strength is obtained from
tests carried out in accordance with Section 5.1.2.4 and the consistency and surface is
to the satisfaction of the Engineer.

When a mix has been approved, no variations shall be made in the mix proportions, or
in the type, size, grading zone or source, of any of the constituents without the consent
of the Engineer, who may require further trial mixes to be made before any such
variations are approved.

Until the results of trial mixes for a particular class have been approved by
the Engineer, no concrete of the relevant class shall be placed in the Works.

When the Contractor intends to purchase factory-made precast concrete units, trial
mixes may be dispensed with provided that evidence is given to satisfy the Engineer
that the factory regularly produces concrete which complies with the Specifications.
The evidence shall include details of mix proportions, water/cement ratios, slump tests
and strengths obtained at 28 days.

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5.1.2.4 Control of Concrete Quality

A) General

The Contractor shall assume the full responsibility for the quality of the concrete
conforming to these Specifications and this responsibility shall not be relieved by the
testing carried out and approved by the Engineer.

The Contractor shall thus at his own discretion establish additional testing procedures
as necessary.

B) Control of Concrete Production

1) Materials

Materials used shall be tested in accordance with Section 5.1.2.2.

2) Plant and Equipment

Batching plants will be tested by the Contractor in a manor approved by the

Engineer before any major concrete casting and at any other time if requested by
the Engineer.

3) Fresh Concrete

The frequency of slump tests shall be as directed by the Engineer, with at least one
test per 25 m³ of concrete.

C) Control of Strength

1) Sampling and Testing

Cube tests may be substituted for cylinder tests if acceptable to both the Engineer
and the Contractor. If cube tests are adopted, the concrete characteristic strengths
shall be as shown in Table 5.1-2. All other requirements of the Specifications shall
equally apply to cubes or cylinders.

The Contractor shall take samples of the concrete for testing. The number,
frequency and location shall be decided by the Engineer. A minimum of 3 concrete
cubes/cylinders should be taken for each day’s casting, or for every 15 m³ of
concrete cast in large pours. The slump of concrete samples shall be measured.

The procedures for sampling and making cubes/cylinders and testing them shall be
as described in STP 9.2.

2) Strength Requirement

The results of the testing shall conform to the strength requirements according to
British standard BS5400: Part 7, as given below, or to any mathematically correct
statistical test for each casting section.

D) General

The characteristic strength of concrete is the 28 days strength below which not more
than 5% of the test results may be expected to fall.

E) Target Mean Strength

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The concrete mix should be designed to have a mean strength greater than the
required characteristic strength by at least the current margin.

The current margin for each particular type of concrete mix shall be determined; it may
be taken as having the smaller of the values given by (1) or (2) below.

1) 1.64 times the standard deviation of tests on at least 100 separate batches of
concrete of nominally similar proportions of similar materials and produced over a
period not exceeding 12 months by the same plant under similar supervision.

2) 1.64 times the standard deviation of 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.

Where there are insufficient data to satisfy (1) or (2) above, the margin for the initial
mix design should be taken as two-thirds of the characteristic strength for concrete.
This margin should be used as the current margin only until sufficient data are
available to satisfy (1) or (2) above. However, when the required characteristic strength
approaches the maximum possible strength of concrete made with a particular
aggregate, a smaller margin may be permitted by the Engineer for the initial mix design.

F) Testing Plan

Each cube shall be made from a single sample taken from randomly selected batches
of concrete.

Compliance with the specified characteristic strength may be assumed if:

1) The average strength determined from any group of four consecutive test cubes
exceeds the specified characteristic strength by not less than 0.5 times the current
margin, and

2) Each individual test result is greater than 85% of the specified characteristic
strength.

The current margin should be taken to be two-thirds of the specified characteristic

strength for concrete, unless as mentioned above a smaller margin has been
established to the satisfaction of the Engineer.

If only one cube result fails to meet the second requirement then that result may be
considered to represent only the particular batch of concrete from which that cube was
taken provided the average strength of the group satisfies the first requirement.

If more than one cube in a group fails to meet the second requirement or if the average
strength of any group of four consecutive test cubes fails to meet the first requirement
then all the concrete in all the batches represented by all such cubes shall be deemed
not to comply with the strength requirements. For the purposes of this sub-Section, the
batches of concrete represented by a group of four consecutive test cubes shall
include the batches from which samples were taken to make the first and the last cubes
in the group of four, together with all the intervening batches.

G) Action to be Taken in the Event of Non-Compliance with the Testing Plan

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When the average strength of four consecutive test cubes fails to meet the first
requirement in (F), above, the mix proportions of subsequent batches of concrete
should be modified to increase the strength.

The action to be taken in respect of the concrete which is represented by the

test-cubes which fail to meet either of the requirements (or not by correct statistical
proof can be verified to have the required strength) shall be determined by the
Engineer. This may range from qualified acceptance in less severe cases, to rejection
and removal in the most severe cases.

The Engineer may also require the Contractor at his own expenses to prove statistically
the strength, by boring out cores and testing them according to a programme approved
by the Engineer. The age of the concrete and degree of hardening at the time of the
new testing shall be considered. The equivalent cylinder/cube strength shall comply the
minimum characteristic strength or as decided by the Engineer.

H) Control of Hardening

If the Contractor wants to remove forms and scaffolding earlier than specified herein,
extra test specimens shall be cast by the Contractor in accordance with the instruction
of the Engineer. These specimens shall be tested the day before removal of the form.
On the basis of the test results the Engineer shall take the final decision on the time for
the removal of forms.

For prestressed concrete, extra test specimens shall be cast by the Contractor in
accordance with the instructions of the Engineer, to determine the time for tensioning
the tendons. On the basis of the test results, the Engineer shall decide upon the time
for prestressing the concrete.

5.1.3 Construction Methods

5.1.3.1 General

The Contractor shall in due time and as soon as possible present and discuss his
construction methods and work programme with the Engineer and shall obtain his
approval before commencement of any work.

The Contractor shall maintain an adequate number of trained and experienced

supervisors and foremen at the Site to supervise and control the work.

All construction, other than concrete, shall conform to the requirements prescribed in
other Sections of the Specifications, for the particular items of work comprising the
complete structure.

5.1.3.2 Scaffolding and Formwork

A) Scaffolding (Falsework)

Details, plans and structural calculations for scaffolding shall be submitted by the
Contractor to the Engineer for approval, but in no case shall the Engineer’s approval
relieve the Contractor of his Contract responsibilities. All scaffolding shall be designed
and constructed by the Contractor to provide the necessary rigidity and to support
dead and live loads without deflection or deformation. The Engineer may require the
Contractor to employ screw jacks or hardwood wedges to take up any settlement in
scaffolding and formwork, either before or during the placing of concrete.

Tests may be required by the Engineer of materials proposed by the Contractor for
scaffolding. Test loadings of the completed scaffolding may also be required for the

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determination of flexibility and strength. All expenses associated with testing shall be
borne by the Contractor.

Scaffolding which cannot be founded on a satisfactory footing shall be supported on

piles, which shall be spaced, driven and removed in a manner approved by the
Engineer. When the Contractor wishes to support scaffolding on existing structures, he
shall submit his proposals in due time to the Engineer, in writing, including loads from
the scaffolding. The Engineer will consider the proposals and respond in writing.

Scaffolding shall be set to give the finished structure a camber, if indicated on the
Drawings or specified by the Engineer.

Scaffolding shall remain in place for periods which shall be determined by the
Engineer.

B) Formwork

Formwork shall include all temporary or permanent moulds for forming the concrete.
Formwork shall be of wood, metal or other approved materials and shall be built mortar
tight and rigid enough to maintain the concrete in position during placing, compacting,
setting and hardening.

Formwork for exposed surfaces (“wrought form”) shall be made of dressed lumber of
uniform thickness with or without a form liner of an approved type or shall be of metal
sufficiently rigid in itself with no surface blemishes that will impair the quality of the
concrete surface finish. No rusty or bent metal forms shall be used. Exposed concrete
arrises shall be provide with formed chamfers, as indicated on the Drawings or
instructed by the Engineer.

Rough lumber may be used for surfaces that will not be exposed in the finished
structure (“rough form”).

All lumber shall be sound, free from warps and twists, sap, shakes, large or loose
knots, wavy edge or other defects affecting the strength or appearance of the finished
structure.

All forms shall be set and maintained true to the line designated until the concrete is
sufficiently hardened. Forms shall remain in place for periods, which shall be
determined by the Engineer. When forms appear to be unsatisfactory in any way,
either before or during the placing of concrete, the Engineer may order the work
stopped until the defects are corrected.

If requested, the Contractor shall submit to the Engineer working drawings of the forms
and also, if requested, calculations to verify the rigidity and strength of the forms.

The shape, strength, rigidity, watertightness and surface smoothness of reused

formwork shall be maintained at all times. Any warped or bulged lumber must be re-
sized before being reused. Formwork that is unsatisfactory in any respect shall not be
reused.

Metal ties or anchorages within the form shall be so constructed as to permit their
removal to a depth of at least 50 mm from the face without injury to the concrete. All
fittings for metal ties shall be of such design that, upon their removal, the cavities which
are left will be of the smallest possible size. The cavities shall be filled with cement
mortar and the surface left sound, smooth, even and uniform in colour.

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Formwork shall be so constructed that easy cleaning out of any extraneous material
inside the formwork can be achieved without disturbing formwork already checked and
approved by the Engineer.

Formwork shall be treated with approved non-staining oil or saturated with water, to
facilitate formwork removal. The Engineer may require trials to be carried out before
approval is given for the use of a particular type of oil, to ascertain that the oil
proposed by the Contractor does not discolour or injure the finished concrete face in
any way.

Before placing any concrete, all shavings, loose binding wires, soil, rubbish and all
foreign matter shall be removed from the formwork and the formwork shall be carefully
and thoroughly washed with water. If not indicated otherwise, the following tolerances of
the finished concrete structures shall apply:

Foundations: horizontally + 30 mm; vertically + 20 mm

Piers: Horizontally + 20 mm, vertically + 10 mm, inclination 1:400

Dimensions of other structural members: + 10 mm, -5 mm

Edge beams and parapets shall be made to such accuracy that no deviations from the
correct alignment are visible.

The cross sectional areas of the superstructure of bridges shall in no place deviate
more than 3% from the theoretically correct cross sectional areas.

Anchors for bearings, expansion joints, railings, etc. shall be placed within the
tolerances indicated on the Drawings or specified by the Engineer.

C) Blinding Concrete on Single Layer Brick Flat Soling

A levelling layer of blinding concrete shall be provided as the permanent bottom form
for all concrete structures that will directly bear on prepared soil, whether this blinding
concrete is shown on the Drawings or not. The levelling layer of blinding concrete shall
be of thickness not less than 75 mm and shall be constructed on single layer brick flat
soling.

D) Approval of Scaffolding and Formwork

If plans and calculations of scaffolding and formwork are requested by the Engineer, no
construction of such scaffolding and formwork shall take place before approval by the
Engineer, in writing. Such approval shall not relieve the Contractor of his
responsibilities under the Contract for the adequacy of scaffolding and formwork.

The Engineer shall have reasonable time for his examination of the Contractor’s plans
and calculations, especially if scaffolding is introducing temporary loading on new
structures. The Contractor shall not be allowed extensions of Contract time due to
awaiting such approval.

The Engineer shall inspect all formwork and scaffolding and no concrete shall be
placed until the Engineer’s approval has been given. Such approval shall not relieve
the Contractor of any of his responsibilities under the Contract for the successful
completion of the structure.

5.1.3.3 Care and Storage of Concrete Materials

A) Storage of Cement

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All cement shall be stored in suitable weatherproof buildings or silos which will protect
the cement from dampness. These buildings or silos shall be placed in locations
approved by the Engineer. Provisions for storage shall be ample, and the shipments of
cement as received shall be separately stored in such manner as to provide easy
access for the identification and inspection of each shipment. Storage buildings shall
have a capacity for the storage of a sufficient quantity of cement to allow sampling at
least 14 days before the cement is to be used. Cement shall meet the test
requirements at any time and any cement stored for an elongated time shall be
checked and tested before use regardless of whether it has previously been tested.

B) Storage of Aggregates

Aggregates shall be so stored as to prevent the inclusion of foreign material.

Aggregates shall not be placed upon the finished roadbed. Aggregates of different
sizes and kinds shall be placed in different stockpiles. Stockpiles of blended coarse
aggregates shall be built up in successive horizontal layers not more than 1 metre
thick. Each layer shall be completed before the next is started. Should segregation
occur, the aggregates shall be recombined to conform to the grading requirements.

Washed aggregates and aggregates produced or manipulated by methods which

involve the use of water shall be allowed to drain at least 12 hours before use.

5.1.3.4 Preparations Before Casting

Before any major casting, the Contractor shall prepare a complete “casting
programme” describing staff and labour, consumption of materials, plant, tools and
equipment, reserves of materials, standby plant and equipment, proposed means of
handling and placing the concrete, quality controls etc.

No concrete shall be mixed and placed until the Contractor’s casting programme has
been approved in writing by the Engineer.

Equipment and tools necessary for handling materials and performing the work, and
satisfactory to the Engineer as to design, capacity, and mechanical condition, shall be
at the site of the work before casting is started.

If any equipment is not maintained in full working order, or if the equipment as used by
the Contractor proves inadequate to obtain the result prescribed, such equipment shall
be repaired or other suitable equipment substituted or added at the discretion of the
Engineer.

5.1.3.5 Measuring Materials

All material in the mix shall be proportioned by weight or volume, subject to the
approval of the Engineer.

When volume batching is proposed by the Contractor, the exact proportions must be
converted from trial mix weights to volumes, from bulk densities determined in the
laboratory. Written approval from the Engineer is required.

5.1.3.6 Mixing Concrete

A) General

All concrete shall be mixed in batch mixers, either at the site of construction, at a
central plant, or in transit. Each mixer shall have attached to it in a prominent place, a

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manufacturer’s plate showing the capacity of the drum in terms of mixed concrete and
the speed of rotation of the mixing drum.

B) Mixers at Local Site of Construction

Mixers at local sites shall be approved drum-type capable of combining the aggregate,
cement, and water into a thoroughly mixed and uniform mass within the specified mixing
period and of discharging the mixture without segregation. The mixer shall be equipped
with a suitable charging hopper, water storage and a water measuring device, accurate
within 1%. Controls shall be so arranged that the water can be applied only while the
mixer is being charged. Suitable equipment for discharging the concrete shall be
provided. The mixer shall be cleaned at suitable intervals. The pickup and throw-over
blades in the drum shall be replaced when they have lost 10% of their depth.

The mixer shall be operated at a drum speed of between 15 and 20 revolutions per
minute. The batched materials shall be so charged into the drum that a portion of the
water shall enter in advance of the cement and aggregates and the water shall
continue to flow into the drum for a minimum time of 5 seconds after all the cement and
aggregates are in the drum. Mixing time shall be measured from the time all materials
except water are in the drum and shall, in the case of mixers having a capacity of 1
cubic metre or less, not be less than 50 seconds nor more than 70 seconds. In the
case of dual drum mixers, the mixing time shall not include transfer time. The contents
of an individual mixer drum shall be removed before a succeeding batch is emptied
therein. Any concrete mixed less than the specified minimum time shall be discarded
and disposed of by the Contractor at his own expense.

The volume of concrete mixed per batch shall not exceed the mixer’s nominal capacity
in cubic feet or cubic metres as shown on the manufacturer’s guaranteed capacity
standard rating plate on the mixer; except that an overload up to 20% of the mixers
nominal capacity may be permitted provided concrete test data for strength,
segregation and uniform consistency are satisfactory, and provided no spillage of
concrete takes place.

Retempering concrete by adding water or by other means shall not be permitted.

Concrete which is not of the required consistency at the time of placement shall not be
used and shall be discarded and disposed of by the Contractor at his own expense.

C) Central Plant Mixers

These mixers shall be of approved drum type capable of combining the aggregate,
cement and water into a thoroughly mixed and uniform mass within the specified mixing
period and of discharging the mixture without segregation. Central plant mixers shall be
equipped with an acceptable timing device that will not permit the batch to be
discharged until the specified mixing time has elapsed. The water system for a central
mixer shall be either a calibrated measuring tank or a meter and shall not necessarily
be an integral part of the mixer.

The mixers shall be cleaned at suitable intervals. They shall be examined daily for
changes in interior condition. The pick up and throw-over blades in the drum shall be
replaced when they have lost 10% of their depth.

In addition to the requirements for mixers at local sites detailed above, central plant
mixers which have a capacity of between 2 and 5 cubic metres, or greater than 5 cubic
metres, should have a minimum mixing time of 90 and 120 seconds respectively,
provided tests indicate that the concrete produced is equivalent in strength and
uniformity to that attained as stated in the preceding paragraphs.

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Mixed concrete shall be transported from the central mixing plant to the site of work in
agitator trucks or, upon written permission of the Engineer, in non-agitator trucks.
Delivery of concrete shall be so regulated that placing is at a continuous rate unless
delayed by the placing operations. The intervals between delivery of batches shall not
be so great as to allow the concrete in place to harden partially, and in no case shall
such an interval exceed 30 minutes.

D) Agitator Trucks

Unless otherwise permitted in writing by the Engineer, agitator trucks shall have
watertight revolving drums suitably mounted and shall be capable of transporting and
discharging the concrete without segregation. The agitating speed of the drum shall
not be less than two or more than six revolutions per minute. The volume of mixed
concrete permitted in the drum shall not exceed the manufacturer’s rating nor exceed
80% the gross volume of the drum.

Upon approval by the Engineer, open-top, revolving-blade truck mixers may be used in
lieu of agitating trucks for transportation of central plant mixed concrete.

Gross volume of agitator bodies expressed in cubic feet or cubic metres shall be
supplied by the mixer manufacturer. The interval between introduction of water into the
mixer drum and final discharge of the concrete from the agitator shall not exceed 45
minutes. During this interval the mix shall be agitated continuously.

E) Non-Agitator Trucks

Bodies of non-agitating equipment shall be smooth, water-tight metal containers

equipped with gates that will permit control of the discharge of the concrete. Covers
shall be provided when needed for protection against the weather.

The non-agitating equipment shall permit delivery of the concrete to the site of the work
in a thoroughly mixed and uniform mass with a satisfactory degree of discharge.

Uniformity shall be satisfactory if samples from the one-quarter and three quarter
points of the load do not differ by more than 30 mm in slump. Discharge of concrete
shall be completed within 30 minutes after the introduction of the mixing water to the
cement and aggregate.

F) Truck or Transit Mixers

These shall be equipped with electrically actuated counters by which the number of
revolutions of the drum or blades may readily be verified and the counters shall be
actuated at the commencement of mixing operations at designated mixing speeds. The
mixer when loaded shall not be filled to more than 60% of the drum gross volume. The
mixer shall be capable of combining the ingredients of the concrete into a thoroughly
mixed and uniform mass and of discharging the concrete with a satisfactory degree of
uniformity.

Except when intended for use exclusively as agitators, truck mixers shall be provided
with a water measuring device to measure accurately the quantity of water for each
batch. The delivered amount of water shall be within plus or minus 1% of the indicated
amount.

Truck mixers may be used for complete mixing at the batch plant and as truck agitators
for delivery of concrete to job sites, or they may be used for complete mixing of the
concrete at the job site. They shall either be a closed watertight revolving drum or an
open top revolving blade or paddle type.

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The amount of mixing shall be designated in number of revolutions of the mixer drum.
When a truck mixer is used for complete mixing, each batch of concrete shall be mixed
for between 70 and 100 revolutions of the drum or blades at the rate of rotation
designated by the manufacturer of the equipment as the “mixing speed”. Such
designation shall appear on a metal plate attached to the mixer. If the batch is at least
0.5 cubic metres less than guaranteed capacity, the number of revolutions at mixing
speed may be reduced to not less than 50. Mixing in excess of 100 revolutions shall be
at the agitating speed. All materials, including the mixing water, shall be in the mixer
drum before actuating the revolution counter which will indicate the number of
revolutions of the drum or blades.

When wash water (flush water) is used as a portion of the mixing water for the
succeeding batch, it shall be accurately measured and taken into account in
determining the amount of additional mixing water required. When wash water is carried
on the truck mixer, it shall be carried in a compartment separate from the one used for
carrying or measuring the mixing water. The Engineer will specify the amount of wash
or flush water, when permitted, any may specify a “dry” drum if wash water is used
without measurement or without supervision.

When a truck is used for complete mixing at the batch plant, mixing operations shall
begin within 30 minutes after the cement has been added to the aggregate. After
mixing, the truck mixer shall be used as an agitator, when transporting concrete, at the
speed designated by the manufacturer of the equipment as agitating speed. Concrete
discharge shall be completed within 45 minutes after the addition of the cement to the
aggregates. Each batch of concrete delivered at the job site shall be accompanied by a
time slip issued at the batching plant, bearing the time of departure therefrom. When
the truck mixer is used for the complete mixing of the concrete at the job site, the mixing
operation shall begin within 30 minutes after the cement has been added to the
aggregates.

The rate of discharge of the plastic concrete from the mixer drum shall be controlled by
the speed of rotation of the drum in the discharge direction with the discharge gate fully
open.

5.1.3.7 Handling and Placing Concrete

The temperature of concrete at the time of placing shall not exceed 35oC.

In preparation for the placing of concrete all sawdust, chips and other construction
debris and extraneous matter shall be removed from the interior of forms. Struts, stays
and braces, serving temporarily to hold the forms in correct shape and alignment,
pending the placing of concrete at their locations, shall be removed when the concrete
placing has reached an elevation rendering their service unnecessary. These
temporary members shall be entirely removed from the forms and not buried in the
concrete.

Concrete must reach its final position in the forms within 20 minutes of the completion
of mixing, or as directed by the Engineer.

Concrete shall be placed so as to avoid segregation of the materials and the

displacement of the reinforcement. The use of long troughs, chutes and pipes for
conveying concrete from the mixer to the forms shall be permitted only on written
authorisation of the Engineer. In case an inferior quality of concrete is produced by the
use of such conveyors, the Engineer may order discontinuance of their use and the
institution of a satisfactory method of placing.

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Open troughs and chutes shall be of metal or metal lined. Where long steep slopes are
required, the chutes shall be equipped with baffles or be in short lengths that reverse
the direction of movement.

All chutes, troughs and pipes shall be kept clean and free from coatings of hardened
concrete by thoroughly flushing with water after each run. Water used for flushing shall
be discharged clear of the structure.

When placing operations would involve dropping the concrete more than 1.5 m, it shall
be deposited through sheet metal or other approved pipes. As far as practicable, the
pipes shall be kept full of concrete during placing and their lower ends shall be kept
buried in the newly placed concrete. After initial set of the concrete, the forms shall not
be jarred and no strain shall be placed on the ends of reinforcement bars which
project.

Concrete, during and immediately after depositing, shall be thoroughly compacted. The
compaction shall be done by mechanical vibration subject of the following provisions:

1) The vibration shall be internal unless special authorisation of other methods is

given by the Engineer or as provided herein.

2) Vibrators shall be of a type and design approved by the Engineer. They shall be
capable of transmitting vibration to the concrete at frequencies of not less than
4,500 impulses per minute.

3) The intensity of vibration shall be such as to visibly affect a mass of concrete of 20

mm slump over a radius of at least 450 mm.

4) The Contractor shall provide a sufficient number of vibrators to properly compact

each batch immediately after it is placed in the forms.

5) Vibrators shall be manipulated to thoroughly work the concrete around the

reinforcement and embedded fixtures, and into the corners and angles of the forms.

Vibration shall be applied at the point of deposit and in the area of freshly
deposited concrete. The vibrators shall be inserted and withdrawn from the
concrete slowly. The vibration shall be of sufficient duration and intensity to
thoroughly compact the concrete, but shall not be continued so as to cause
segregation. Vibration shall not be continued at any one point to the extent that
localised areas of grout are formed.

Application of vibrators shall be at points uniformly spaced and not further apart
than twice the radius over which the vibration is visibly effective.

6) Vibration shall not be applied directly or through the reinforcement to sections or

layers of concrete which have hardened to the degree that the concrete ceases to
be plastic under vibration. It shall not be used to make concrete flow in the forms
over distances so great as to cause segregation, and vibrators shall not be used to
transport concrete in the forms.

7) Vibration shall be supplemented by such spading as is necessary to ensure smooth

surfaces and dense concrete along form surfaces and in corners and locations
impossible to reach with the vibrators.

8) The provisions of this Section shall also apply to precast piling, concrete cribbing
and other precast members except that, if approved by the Engineer, the
manufacturer’s methods of vibration may be used.

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Concrete shall be placed in horizontal layers not more than 600 mm thick except as
hereinafter provided. When less than a complete layer is placed in one operation, it
shall be terminated in a vertical bulkhead. Each layer shall be placed and compacted
before the preceding batch has taken initial set to prevent injury to the green concrete
and avoid surfaces of separation between the batches. Each layer shall be compacted
so as to avoid the formation of a construction joint with a preceding layer which has not
taken initial set.

When the placing of concrete is temporarily discontinued, the concrete, after becoming
firm enough to retain its form, shall be cleaned of laitance and other objectionable
material to a sufficient depth to expose sound concrete. To avoid visible joints as far as
possible upon exposed faces, the top surface of the concrete adjacent to the forms
shall be smoothed with a trowel. Where a “feather edge” might be produced at a
construction joint, as in the sloped top surface of a wing wall, an inset form shall be
used to produce a blocked out portion in the preceding layer which shall produce an
edge thickness of not less than 150 mm in the succeeding layer. Work shall not be
discontinued within 450 mm of the top of any face, unless provision has been made for
a coping less then 450 mm thick, in which case, if permitted by the Engineer, a
construction joint may be made at the under side of the coping.

Immediately following the discontinuance of placing concrete all accumulations of

mortar splashed upon the reinforcement steel and the surfaces of forms shall be
removed. Dried mortar chips and dust shall not be puddled into the unset concrete. If
the accumulations are not removed prior to the concrete becoming set, care shall be
exercised not to injure or break the concrete-steel bond at and near the surface of the
concrete, while cleaning the reinforcement steel.

For simple spans, concrete shall preferably be deposited by beginning at the centre of
the span and working from the centre toward the ends. Concrete in girders shall be
deposited uniformly for the full length of the girder and brought up evenly in horizontal
layers. For continuous spans, the concrete placing sequence shall be as shown on the
plans or agreed on by the Engineer.

Concrete in slab and girder haunches less than 1.0 metre in height shall be placed at
the same time as that in the girder stem.

Concrete in slab spans shall be placed in one continuous operation for each span
unless otherwise provided.

Concrete in T-beam or deck girder spans may be placed in one continuous operation if
permitted by the Engineer.

Concrete in columns and pier shafts shall be placed in one continuous operation,
unless otherwise directed.

Unless otherwise permitted by the Engineer, no concrete shall be placed in the

superstructure until the column forms have been stripped sufficiently to determine the
character of the concrete in the columns. The load of the superstructure shall not be
applied to the supporting structures until they have been in place at least 14 days,
unless otherwise permitted by the Engineer.

Pneumatic placing of concrete shall be permitted only if authorised by the Engineer.

The equipment shall be so arranged that vibration does not damage freshly placed
concrete.

Where concrete is conveyed and placed by pneumatic means the equipment shall be
suitable in kind and adequate in capacity for the work. The machine shall be located as
close as practicable to the place of deposit. The position of the discharge end of the

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line shall not be more than 3 metres from the point of deposit. The discharge lines shall
be horizontal or inclined upwards from the machine. At the conclusion of placement the
entire equipment shall be thoroughly cleaned.

Placement of concrete by pumping shall be permitted only if authorised by the

Engineer. The equipment shall be so arranged that vibrations do not damage freshly
placed concrete. Where concrete is conveyed and placed by mechanically applied
pressure, the equipment shall be suitable in kind and adequate in capacity for the
work. The operation of the pump shall be such that a continuous stream of concrete
without air pockets is produced. When pumping is completed, the concrete remaining in
the pipeline, if it is to be used, shall be ejected in such a manner that there is not
contamination of the concrete or separation of the ingredients. After this operation, the
entire equipment shall be thoroughly cleaned.

5.1.3.8 Perforations and Embedment of Special Devices

The Contractor is responsible for determining in advance of making any concrete

pours, all requirements for perforation of concrete sections or embedment therein of
special devices of other trades, such as conduits, pipes, weep holes, drainage pipes,
fastenings, etc. Any concrete poured without prior provision having been made, shall
be subject to correction at the Contractor’s expense.

Special devices to be embedded:

• Expansion joints
• Drain outlets including fixing bolts for down pipes
• Bolts and inserts for sign posts
• Bolts and inserts for various purposes regarding inspection and maintenance as
directed by the Engineer

Other devices not mentioned above shall be shown on the Drawings, or directed by the
Engineer. The inserts and fittings should conform to Sections 5.9 and 5.10 of this
Specification.

5.1.3.9 Finishing Concrete Surfaces

One of the following types of finishing shall be applied to concrete surfaces:

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Type A - Concrete Decks

Immediately after placing concrete, concrete decks shall be struck off using templates
to provide proper crowns and shall be finished smooth to the correct levels. Finish shall
be slightly but uniformly roughened by brushing. The finished surface shall not vary
more then 10 mm from a 3 metre straight edge placed in any direction on the roadway.
Deviation from the grade line shall not be more than + 30 mm in any 20 metre length.

Type B - Kerb and Sidewalk Surface

Exposed faces of kerbs and sidewalks shall be finished to true lines and grades. The
kerb surface shall be wood floated to a smooth but not slippery finish. Sidewalk
surfaces shall be slightly but uniformly roughened by brushing.

Type C - Ordinary Finish

An ordinary finish is defined as the finish left on a surface after the removal of the
forms when all holes left by form ties have been filled, and any minor surface defects
have been repaired. The surface shall be true and even, free from depressions or
projections.

The concrete in bridge seats, caps, and tops of walls shall be struck off with a straight
edge and floated to true grade. Under no circumstances shall the use of mortar topping
for concrete surfaces be permitted.

Type D - Rubbed Finish

After the removal of forms the rubbing of concrete shall be started as soon as its
condition permits. Immediately before starting this work the concrete shall be kept
thoroughly saturated with water for a minimum period of three hours. Sufficient time
shall have elapsed before the wetting down to allow the mortar used in patching to
have thoroughly set. A medium coarse carborundum stone shall be used for rubbing a
small amount of mortar on the face. The mortar used shall be composed of cement and
fine aggregate mixed in the same proportions as that used in the concrete being
finished. Rubbing shall be continued until all form marks, projections, and irregularities
have been removed, all voids filled, and a uniform surface has been obtained. The
paste produced by this rubbing shall be left in place at this time. The final finish shall
be obtained by rubbing with a fine carborundum stone and water until the entire
surface is of a smooth texture and uniform colour.

After the final rubbing has been completed and the surface has dried, burlap shall be
used to remove loose powder. The final surface shall be free from unsound patches,
paste, powder and objectionable marks.

Type E - Bushhammer Finish

Bushhammering shall be carried out by treating the surface with an approved heavy
duty power hammer fitted with a multi-point tool which shall be operated over the
surface to remove 5 to 6 mm of concrete paste and expose maximum areas of coarse
aggregate.

Aggregate left embedded shall not be fractured or loose. 25 mm wide bands at all
corners and arrises shall be left as cast. The finish surface shall be even and of
uniform appearance and shall be washed with water upon completion.

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Type F - Ribbed Finish

Ribs shall be vertical and to the dimensions shown on the Drawings. The direction of
the grain of the timber forming the ribs shall be vertical.

5.1.3.10 Construction Joints

A) General

Construction joints shall be made only where located on the plans or shown in the
pouring schedule, unless otherwise approved by the Engineer.

If not detailed on the plans, or in the case of emergency, construction joints shall be
placed as directed by the Engineer. Shear keys or inclined reinforcement shall be used
where necessary to transmit shear or bond the two sections together.

B) Bonding

Before depositing new concrete on or against concrete which has hardened, the forms
shall be re-tightened. The surface of the hardened concrete shall be roughened as
required by the Engineer, in a manner that does not leave loosened particles of
aggregate or damaged concrete at the surface. It shall be thoroughly cleaned of
foreign matter and laitance, and saturated with water. To ensure an excess of mortar at
the juncture of the hardened and the newly deposited concrete, the cleaned and
saturated surfaces, including vertical and inclined surfaces, shall first be thoroughly
covered with a thin coating of mortar or neat cement grout against which the new
concrete shall be placed before the grout has attained its initial set.

The placing of concrete shall be carried continuously from joint to joint. The face edges
of all joints which are exposed to view shall be carefully finished true to line and
elevation.

5.1.3.11 Curing Concrete

All concrete surfaces shall be kept thoroughly wet for at least 7 days after placing.
Bridge deck and sidewalk slabs shall be covered with wet hessian immediately after
final finishing of the surface. This material shall remain in place for the full curing period
or may be removed and replaced with sand when the concrete has hardened
sufficiently to prevent marking. In both cases the materials shall be kept thoroughly wet
for the entire curing period. All other surfaces if not protected by forms, shall be kept
thoroughly wet, either by sprinkling or by the use of wet burlap until the end of the
curing period. The wood forms are allowed to remain in place during the curing period,
but they shall be kept moist at all times to prevent openings at joints.

After a period of 7 days, the concrete shall be watered daily at certain intervals
approved by the Engineer to avoid drying out of the surface. This shall take place
during the following 2 weeks. The water used shall be the same as used in concrete
mixes unless otherwise approved by the Engineer.

Any proposal from the Contractor for the use of liquid membrane curing compound
shall be subject to the approval of the Engineer.

5.1.3.12 Removal of Scaffolding and Formwork

Forms and scaffolding shall not be removed without the approval of the Engineer. The
Engineer’s approval shall not relieve the Contractor of his Contract responsibilities. Any
kentledge blocks and bracing shall be removed at the same time as the forms and in
no case shall any portion of the wood forms be left in the concrete.

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Forms used on exposed vertical faces shall remain in place for periods which shall be
determined by the Engineer and normally not less than 3 days.

Supporting scaffolding and forms under slabs, beams and girders shall normally remain
in place until the full required strength of the concrete has been obtained. If a shorter
period is requested, this may be permitted by the Engineer. In such case, special test
specimens (see Section 5.1.2.4) shall be cast to monitor the hardening.

All structures shall be fully stripped before adjacent structures are cast.

5.1.3.13 Repair of Concrete

As soon as the form has been stripped, the Contractor shall advise the Engineer who
shall inspect the concrete before any improvement of the surface takes place.

All wire or metal devices used for securing the formwork which project from or appear
on the surface of the finished concrete shall be removed or cut back to at least a depth
equal to the required reinforcement cover. All holes and pockets so formed shall be
filled with cement mortar mixed in the same proportions as the fine aggregate to
cement of the concrete mix used for that particular section of the structure, after the
surface to be patched has been thoroughly cleaned and wetted to receive the patch.

Excessive honeycombing shall be sufficient to cause rejection of portions of the

structure containing this honeycombing. The Contractor, on receipt of written orders
from the Engineer, shall remove and rebuild such portions of the structure at his own
expense.

Smaller honeycombing and other defects can be repaired if permitted by the Engineer.
Structural, maintenance and aesthetical points of view shall be taken into consideration
before such approval, if any, may be given. The method of repair shall be approved by
the Engineer and an extension of period for a certain part of the performance bond
may be required.

5.1.3.14 Depositing Concrete under Water

Concrete shall not be deposited in water except with the approval of the Engineer and
under his immediate supervision; and in this case the method of placing shall be as
defined in this Section.

Concrete placed under water shall be carefully placed in a compact mass, in its final
position, by means of a tremie tube and shall not be disturbed after being deposited.
Special care must be exercised to maintain still water at the point of deposit. Concrete
shall not be placed in running water. The method of depositing concrete shall be so
regulated as to produce approximately horizontal surfaces.

Concrete seals shall be placed in one continuous operation. When a tremie tube or
pipe is used, it shall consist of a tube or pipe not less than 150 mm in diameter. All
joints in the tube shall be watertight. The means of supporting the tremie tube shall be
such as to permit free movement of the discharge end over the entire top of the
concrete and to permit its being lowered rapidly when necessary to choke off or retard
the flow. The tremie tube shall be filled by a method that prevents washing of the
concrete. The discharge end shall be completely submerged in concrete at all times
and the tremie tube shall be kept full. Concrete slump shall not be less than 150 mm.

Dewatering shall proceed only when the concrete seal is considered strong enough to
withstand any pressure to be exerted upon it. This time shall be decided by the
Engineer.

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All laitance or other unsatisfactory material shall be removed from the exposed surface
by scraping, jetting, chipping or other means, which do not injure the seal unduly.

5.1.3.15 Factory Made Precast Concrete Elements

Any supplier of precast concrete elements shall be approved in writing by the Engineer.
Such approval can be withdrawn at any time.

Concrete work in precast concrete elements shall fully conform with all relevant
Sections of these Specifications.

The supplier shall maintain laboratory facilities of the same standard as the site
laboratory.

Unless otherwise approved by the Engineer, precast concrete members shall not be
moved from the casting position until the concrete has attained a compressive strength
of 80% of the specified 28 day strength, nor transported until it has developed a
strength of 90% of the specified 28 day strength.

Extreme care shall be exercised in handling and moving precast concrete members.
Precast girders and slabs shall be transported in an upright position. Shock shall be
avoided and the points of support and directions of the reactions with respect to the
member shall be approximately the same during transportation and storage as when
the member is in its final position. If the Contractor deems it expedient to transport or
store precast units in other than this position, this shall be at the Contractor’s risk, after
notifying the Engineer of his intention to do so. Any rejected unit shall be replaced at
the Contractor’s expense by an acceptable unit.

Proposed details on the handling and transportation of precast concrete members shall
be submitted in writing by the Contractor, to the Engineer, for his approval.

Each precast member is to be uniquely and permanently marked so as to show its type,
date of casting and any other information required by the Engineer.

5.1.3.16 Control of Heat in Structures

In structures of major dimensions i.e., pile caps, etc. the heat deriving from the
hardening of the concrete shall be controlled by the Contractor. Temperature gradients
introducing risk of cracking shall not occur and the temperature shall not exceed 70oC.

The Contractor shall submit timely proposals for avoiding excessive heat generation,
such as the cooling of aggregates before mixing, to the Engineer for approval.

5.1.3.17 Grouting of Ducts for Prestressing Tendons

A) General

The purpose of grouting is to provide permanent protection to the post-tensioning steel

and to achieve bond between the prestressing steel and the concrete.

The time of commencement of grouting shall be approved by the Engineer. The

Contractor shall give timely notice of grouting to the Engineer.

B) Definition of Terms

1) Admixture. Any material added to the grout other than Portland cement and water.

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2) Duct. The hole or void provided in the concrete for the tendon used in post-
tensioning, formed by sheathing.
3) Grout. A mixture of cement and water with or without admixtures.
4) Grout opening or vent. An inlet, outlet or vent in the duct for grout, water or air.

C) Grout Openings or Vents

All ducts shall have grout openings at both ends. For draped cables, all high points
should have a grout vent except where cable curvature is small, such as in continuous
slabs. All grout openings or vents shall include provisions for preventing grout leakage.

D) Equipment

1) The grouting equipment shall include a mixer capable of continuous mechanical

mixing which will produce a grout free of lumps and undispersed cement. The
equipment shall be able to pump the mixed grout in a manner which will comply with
all provisions of the recommended practice.
2) Accessory equipment which will achieve accurate solid and liquid measures shall be
provided to batch all materials.
3) The pump shall be a positive displacement type and be able to produce an outlet
pressure of at least 10.5 kg/cm². The pump should have seals adequate to prevent
introduction of oil, air or other foreign substances into the grout and to prevent loss
of grout or water.
4) A pressure gauge having a full scale reading of no greater than 21 kg/cm² shall be
placed at some point in the grout line between the pump outlet and the duct inlet.

5) The grouting equipment shall contain a screen having clear openings of 3.2 mm
maximum size to screen the grout prior to its introduction into the grout pump. If a
pump with a thixotropic additive is used, a screen opening of 4.8 mm is satisfactory.
This screen shall be easily accessible for inspection and cleaning
6) The grouting equipment shall utilise gravity feed to the pump inlet from a hopper
attached to and directly over it. The hopper must be kept at least partially full of
grout at all times during the pumping operation to prevent air from being drawn into
the post-tensioning duct.

7) Under normal conditions, the grouting equipment shall be capable of continuously

grouting the largest tendon on the Works in no more than 20 minutes.

E) Materials

1) Portland Cement.
Portland cement shall confirm to one of the following: Specifications for Portland
cement - AASHTO M 85, type 1, 2 or 3.
Cement used for grouting shall be fresh and shall not contain any lumps or other
indication of hydration or “pack set”.

2) Water
The water used in the grout shall be potable, clean and free of injurious quantities
known to be harmful to Portland cement or prestressing steel.

3) Admixtures

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Admixtures, if used, shall impart the properties of low water content, good
flowability, minimum bleed and moderate expansion. Their formulation shall contain
no chemicals in quantities that may have harmful effects on the prestressing steel
or cement. Admixtures containing chlorides, fluorides, sulphites and nitrates shall
not be used.
Aluminium powder of the proper fineness and quantity or other approved gas
evolving material which is well dispersed through the other admixture may be used
to obtain 5 to 10 percent unrestrained expansion of the grout.
All admixtures shall be approved by the Engineer and used in accordance with the
instructions of the manufacturer.

F) Mixing of Grout

1) Water shall be added to the mixer first, followed by Portland cement and admixture,
or as required by the admixture manufacturer.

2) Mixing shall be of such duration as to obtain a uniform thoroughly blended grout,

without excessive temperature increase or loss of expansive properties of the
admixture. The grout shall be continuously agitated until it is pumped.

3) Water shall not be added to increase grout flowability which has been decreased by
delayed use of the grout.

4) Proportions of materials shall be based on tests made on the grout before grouting
is begun, or may be selected based on prior documented experience with similar
materials and equipment and under comparable field conditions (weather,
temperature, etc.). The water content shall be the minimum necessary for proper
placement and when type 1 or 2 cement is used shall not exceed a water/cement
ratio of 0.45.

The water content required for type 3 cement shall be established for a particular
brand based on tests.

The pumpability of the grout may be determined by the Engineer in accordance with
the U.S. Corps of Engineers Method CRD-C79. When this method is used, the efflux
time of the grout sample immediately after mixing shall not be less than 11 seconds.
The flow cone test does not apply to grout which incorporates a thixotropic additive.

Trial mixes shall be carried out on site with the selected constituents to demonstrate
the physical properties of the grout.

G) Grouting

Preparation of duct:

• Flushing of metal ducts shall be carried out, if considered necessary by the

Engineer.

• The pumping pressure at the tendon inlet shall not exceed the value which may
develop cracking in surrounding concrete.

• If the actual grouting pressure exceeds the maximum recommended pump pressure,
grout may be injected at any vent which has been or is ready to be capped, as long
as one-way flow of grout is maintained. If this procedure is used, then the vent,
which is to be used for injection, shall be fitted with a positive shutoff.

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• When one-way flow of grout cannot be maintained as outlined above, the grout shall
be immediately flushed out of the duct with water.

Grout shall be pumped through the duct and continuously wasted at the outlet pipe
until no visible slugs of water or air are ejected. To ensure that the tendon remains
filled with grout, the outlet and/or inlet shall then be closed. Plugs, caps or valves thus
required shall not be removed or opened until the grout has set.

H) Temperature

Grout shall not be above 35°C during mixing or pumping. If necessary the mixing water
shall be cooled.

5.1.3.18 Loading

No superstructure load shall be placed upon finished bents, piers, or abutments until
the Engineer so directs but in no case shall any load of any kind be placed until the
concrete has completed curing.

The Contractor shall not place any temporary loads on deck slabs unless allowed by
the Engineer in writing (see Section 5.1.3.2). Bridge deck slabs shall be opened to
traffic only when so directed by the Engineer and generally not sooner than 28 days
after the placing of the concrete has been completed.

5.1.3.19 Backfill to Structures

All spaces which have been excavated and the volumes of which are not occupied by
the concrete structure shall be backfilled and compacted with acceptable material in
accordance with the provisions of Section 2.5 as directed by the Engineer.

5.1.3.20 Cleaning Up

Upon completion of a structure and before final acceptance, the Contractor shall
remove all forms and scaffolding etc. down to 0.5 metres below the finished ground
line. Excavated, or useless materials, rubbish etc. shall be removed from the Site and
the Site shall be left in a neat and tidy condition satisfactory to the Engineer.

5.1.4 Measurement

Concrete shall be measured by the number of cubic metres of class and maximum
coarse aggregate size indicated on the Drawings complete in place and accepted by
the Engineer. In computing quantities, the dimensions used shall be those shown on
the Drawings. No deduction from the measured quantity shall be made for drainage,
pipes less than 300 mm in diameter, conduits, chamfers, reinforcement bars,
prestressing tendons, expansion joints, water stops or pile heads embedded in
concrete.

Reinforcing and prestressing steel shall be measured for payment as described in

Specifications Sections 5.2 and 5.3.

Formwork, scaffolding (falsework), construction joints and surface finishes shall not be
measured separately but shall be deemed to be an integral part of the concrete items.

Single layer brick flat soling under blinding concrete for concrete structures bearing
directly on prepared soil shall be measured in m². The measured area will be the same
as that of the base area of the concrete structure.

5.1.5 Payment

MAY 2001 Page 5.25

VOLUME 3 TECHNICAL SPECIFICATIONS
DIVISION 5 - STRUCTURES

Concrete of the classes and maximum coarse aggregate sizes shown on the Drawings
and measured as provided in Section 5.1.4 shall be paid for at the Contract unit prices
per cubic metre. The Contractor’s rates shall include all trial mixes (as specified in
Section 5.1.2.3), mixing, transporting, placing and compacting the concrete. The rates
shall also include all concrete finishing, the supply, placing and building in of weep
pipes or pipe sleeves, forming construction joints, forming holes or pockets not
exceeding 0.15 m³ each.

The Contractor’s rates shall be fully inclusive of the cost of all labour and materials in
providing and erecting all formwork, falsework and centering and for their subsequent
removal.

Payment for precast units shall include all concrete, prestressing tendons, formwork,
finishing, transport and erection and where applicable any bolts, bedding or other
devices necessary to fix them in their permanent position.

Payment for single layer brick flat soling shall include the supply of all required
materials and all labour, equipment, tools and incidentals necessary to complete the
work.

Pay items shall be:

5/1/1 Single Layer Brick Flat Soling Square Metre

5/1/2 Concrete Class as Detailed on the Drawings Cubic Metre

and as Stated in the Bill of Quantities.

MAY 2001 Page 5.26