L&T Construction Heavy Cini Infrastructure IC EDRC - HYDEL PROJECTS ® DAMS AND HYDRO RATLE HEP ~ 850 MW J&K TECHNICAL SPECIFICATION Fis approval shal ol ebove he sub-srl2= rom any responsibly under the convact Tai vat relave the conractor ty under the contrat This 6 rom ary responsi Approved ARQ CONSULTING ENGINEERS {RQ SECTION 01 ROLLER COMPACTED CONCRETE PERFORMANCE SPECIFICATION [Aoboved saeco condoa tery ———" See eegena MA eigercr we ait eee | ere ta noe = as aires [ioweria——foveregr —_| hanges as per Conmens vide mal dated AS 2elanel4 18-Feb-14 GVK/LIL Minor changes Ad T-Nov-13 27-Nov-13 GVK/LIT ‘Changes aI |e Us LU et al dave a2 03-Oct-13 10-0ct-13 GVK/LIVMDA | Changes Incorporated Al 26-July-13 27-Aug-13 GYK/LIVMDA ‘Changes Incorporated Ao 17 June 13 | 25" June 13 GVK/LIVMDA | Changes incorporated st Saas Tae eevee | satan RATLE-SPC-01 Roller Compacted Concrete -Performance Specification onien4 Rev ATHeavy Civil Infrastructure IC DAMS AND HYDRO Py EDRC - HYDEL PROJECTS Z L&T Construction ARQ CONSULTING ENGINEERS ARQ) RATLE HEP ~850 MW J&K Prepared by: Date 18 Feb 2014 (Quentin Shaw) _ ARQ Reviewed by! Date 06-Apr 2014 Approved by: Date 06-Apr 2014 Project Manager: Date 06-Apr 2014 ARQ No.: 6562/13491 RATLE-SPC-01 Roller Compacted Concrete -Performance Specification onoano14 Rev A7 2p as14 12 1 1 1 1 13 1 1 1 1 4 4 L&T Construction ARQ CONSULTING ENGINEERS 4RQ) Heavy Givi! Infrastructure IC DAMS AND HYDRO wy EDRC - HYDEL PROJECTS RATLE HEP~ 850 MW J&K Contents SCOPE... aie INTERPRETATION. nsanos 2.4 Supporting Specifications 2.2 Application. 2.3 Basic RCC Parameters. 2.4 Definitions. . COMPOSITION 3.1 General 3.2 RCC Mix Approach 3.3 RCC Mix Control i 3.4 RCC Consistency. a 3.5 Responsibility for Mix Design 3.6 Materials 1.3.6.1 Cementitious Materials. 1.362 Aggregates 1.3.6.3 Wat tan. ae 1.3.6.4 Set-Retarding Admixtures. 1.36.5 Ait-Entraining Admixture .. 1.3.6.6 Deteriorated material... GRreRRaARAHGRRNNAD MATERIALS DELIVERY, STORAGE AND HANDLING 41 Cement and POZZOIaM unennnesnnnsnns sine VT 1.4.1.1 Transportation : 7 1.412 Storage : 7 1.4.1.3. Separation of Material. Haale ele eae ee eet eeteletet TAQ AQQTegatOS.cureinsnnenninmninnninenninnanann ae Seated 7 4421 Bulk SOFC. ose : ster 1.42.2 Batch Plant Stockpiles. : als: 1.8 PLANT. 4.5.4 General. 1.6.2 Batch Platt... oe oe ate Se eS : 18 4.52.2 Bins and Silos 18 1.52.3 Welgh Batchers Eales caalteteaelta 18 16.2.4 Water Batcher & Dispenser. LEC e eau - Ele eee lO: 1.82.5 Moisture Control 19 1.5.2.6 Admixture Dispensers. 19 1527 Scales See sable 1.5.2.8 Operation and Accuracy. eet 1.6.2.9 RECOPEES wucsnnininininininininninninnsinninnnninnni eet leer 1.6.2.10 Batch COUMET .nnnumnminmesnnnnininennannii 19 RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification oran014 Rev AT apPageL&T Construction Heavy Civil Infrastructure IC EDRC - HYDEL PROJECTS ARQ CONSULTING ENGINEERS DAMS AND HYDRO RATLE HEP ~ 850 MW J&K 1.6.3 Mixing Plant 20 1534 General 20 1.84 Conveyance and Transporting Equipment. 2 TBAT GENET serene 2 1.842 Conveyors... 2 1.8.4.3 Hoppers nan 2 1.5.4.4 Dump Trucks. 21 1.5.4.6 _Chutesipipes 2 1.5.5 Spreading Equipment. ny 2 158 GEVR (Grout Enriched Vibrated RCC) Equipment 2B 1.5.7 Compacting Equipment. B 1.8.8 Surface Preparation Equipment. 24 1.5.9 Induced Joint Cutter/Joint inserter. 25 4.5.10 Other Equipment... on 2S 1.5.11 Nuclear Density Gauge. 25 1.5.12 Formwork 25 1.5.12 1General 2s 1.5.13 Temperature Reading Equipment. 6 1.5.14 Sampling Facilities 26 1.5.15 Laboratory TEAS wsnnn 26 1.5.16 Laboratory Equipment, 26 1.5.17 RCC Quality Records. 2 1.5.18 Cooling Plant eee, 27 1.8 CONSTRUCTION ww. sncsnsnsnnsenninnnn 28 1.6.1 General : 28 1.6.2 RCC Mix Specification. 28 1.6.3. Requirements for RCC 228 1.6.4 Allowable Placing Condition ...umsminsnsninninsnunnnnnsnnin 28 1.6.4.1 Weather oe 228 1.6.5 Placing RCC and GEVR 30 1.65.1 Layoutof Placement Areaé Layer Placement Method 30 1.6.5.2 Depositing, Spreading and Re-Mixing 30 1.6.6 Compaction of RCC and GEVR.... 31 166A ROC ennnninen 3! 1.66.3 Other Concretes 32 1.66.4 GEVR (Facing and other areas). 32 1.6.7 Full'Scale Trial 32 1.6.8 Treatment of RCC Surfaces 33 1.6.8.1 General iat 33 1682 Treatment for Hot Layer Joints 34 1.6.8.3 Treatment for "Warm! Layer Joints, 34 1.6.8.4 Treatment for "Cold" Layer Joints. 34 RATLE-SPC-01 Roller Compacted Concrete Performance Specification ovosn014 Rev AT 4p ageL&T Construction ARQ CONSULTING ENGINEERS 43) Heavy Givi infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K 1.6.8.5 Treatment for Vertical Cold Joints ..nnennn Pe allaeetla 35 1.6.9 Vertical Facing Systems for RCC Construction ...u.nnmnnunnnennnnnnsnnnnnsnnnn 36 4.6.91 Genel onnnnnnmnnnenenn 36 1.6.10 Preparation of Receiving Surfaces (Other than RCC) 36 1,6.10.1 Foundation Preparation. 7 aia seers 36 1.6.10.2 Preparation of Receiving SUTaCES...n.nmnn ae a ne 36 4.6.11 Curing and Protection -..u.imsnuninennn eee : seems 37 1.6.11.1General oore 37 1.6.11.2RCC Surfaces. peer 37 1.6.11.3 Cold Weather and Special Insulation Protection... 37 1.6.11.4 Hot Weather Protection... 37 1.7 INDUCED CONTRACTION JOINTS... paisa 37 1.7.4 General.. Pehla 37 1.7.2 Crack Inducers in GE-RCCIGEVRIVREC ...sncnninnnnnnenn 37 TTB Crack Directors.cunninnnnnnnnn . della 38 1.74 Waterstops.. 38 1.8 TOLERANCES, Sears ae snnensee 39 1.8.1 General... tt f semen 39 1.9 QUALITY ASSURANCE, CONTROL, TESTING AND RECORDS ......01:sen senenines 38 1.9.4 Gen@Pal nnnmmnnnnsnnninninnns elated 39 4.9.1.1 Quality Assurance and Control 39 1.9.1.2 RCC Core Programme. 40 1.9.2. Inspection Details and Frequency of Testing 41 1.9.2.1 Aggregate Properties : 1.9.2.2 Aggregate Moisture Determination... Al 19.2.3 Organic impurities Al 182.5 RCC Plant Control 41 182.6 — Scales for Weigh Batching 41 1927 Testing ROC 4.9.3 Corrective Action. lalate 1.8.3.1 Aggregate Properties... f a7 1.9.3.2 Aggregate Moisture Determination. 47 1.9.3.3 Particle Shape. 47 1.9.3.4 Organic Impurities... Peele Ett A 19.3.6 Scales for Weigh Batching... 47 1836 Testing RCC. 7 RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification omanol Rev AT SPaveL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Cini Inractuctre (C DAMS AND HYDRO ew EDRC - HYDEL PROJECTS RATLE HEP~ 850 MW J&K. ROLLER COMPACTED CONCRETE PERFORMANCE SPECIFICATION 14 SCOPE This specification addresses the performance specification for RCC to be placed for the construction of Ratle Dam. The specification is compiled on the basis of producing RCC and undertaking construction to produce RCC in compliance with the requirements of the Owner/Contractor's Technical Requirements. ‘The Specification has further been compiled with @ view to presenting the dam designer's fequirements in respect of RCC construction. The necessary construction plant and methodology are described and the quality control measures to be applied during construction are listed, {tis the intent of the specifications to provide technical guidance to allow for a final product that meets all the design parameters and is fully constructible, The technical specifications will be revised should the results of laboratory testing, or field trials demonstrate any necessity, or benefit The term Roller Compacted Conerete is commonly abbreviated to RCC. This specification assumes a single, or multiple zoned RCC dam, for which water-tightness is created by the impermeability of a specific zone of RCC. The RCC will be well bonded between placement layer joints. The Ratle project requirement is for an RCC designed in accordance with the "concrete" approach, which can be described as following a modem, cohesive and high efficiency RCC approach. Reinforcement, Water stops, Joints, Instruments, Grouting & Concrete etc, are covered separately in other sections of these specifications. 4.2. INTERPRETATION 1.24 Supporting Specifications For all constituent materials of RCC, the requirements of the applicable standards of the ‘American Society for Testing and Materials (ASTM), British Standard (BS), or Indian Standard (IS), as indicated, will be deemed to apply. The Sub-contractor will procure a copy of the applicable standards. All testing, unless otherwise specified, will conform with the recommended methods and practices of the ASTM, BS andlor IS. Applicable ASTM, BS & IS standards and specifications include, inter alia, the following, iSIASTM Designation | Description [18 9013-1978 Practices for making and curing concrete test specimens in the field 18 383:1970 ~ | Standard Specification for Concrete Aggregates. Hee 15 2386(Part1):1863__| Test method for materials finer than 75 um (No. 200) sieve in mineral admixtures by washing 15 2386(Part 4): 1963 | Test method for resistance to degradation of smal-size coarse | aggregat d impact in the Los Angeles machine. Practice hy mixed concrete [1S 1199. 1S 4031(Part 9}:1988 | Test method for heat of hydration of hydraulic cement. 18 6497.1972 ‘Standard Test Methods for Sampling and Testing Fly Ash or Natural | Pozzolans for Use as a Mineral Admixture in Portland-Cement Conerete RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 6 aeL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Cit ntactuctre Io DAMS AND HYDRO Se EDRC - HYDEL PROVECTS ° RATLE HEP— 850 MW J&K 18 4037(Part 5):1968 | Standard test method for time of setting of concrete mixtures by penetration resistance. 1S 9103/1880 ‘Specification for chemical admixtures for concrete, | 1S §512:1983 ‘Standard specification for blended hydraulic cements. 1S 12870:1089 Specification for fy ash and raw oF Caleined natural pozzolan for use fH ____| a8 2 mineral admixture in Portland cement concrete. 1S 8041:1990 ‘Specification for ordinary and rapid hardening Portland cement. 1S 1199-1058 Testing Concrete 1S 2386-1063 Tesling Aggregates 1S: 8112, ‘Specification for 43 grade Ordinary Portland cement 18: 3612 (1) ‘Specification for fiy ash to be used as cementitious material 1S: 2645 ‘Specification for integral coment waterproofing compounds 1S: 4032 Methods of chemical analysis of hydraulic cement 1S: 650 ‘Specification for standard sand for testing of cement 1S: 2430 Methods for sampling of aggregates for concrete 1S: 516 Method of test for strength for concrete | 186142 Method of test for determining setting time of concrete by penetration resistance 1S: 3025 ‘Methods of sampling and test (physical and chemical) for water used in industry 1S: 6925, Methods of test for determination of water-soluble Chlorides in concrete admixtures sine 1S: 1727, Methods of test for fly ash 1S: 4082 Recommendations on stacking and storing of construction A materials at site 1S: 4925 ‘Specification for concrete batching and mixing piant. IS: 456 ‘Code of practice for plain and reinforced concrete iS 457 Code of practice for general construction of piain and reinforced conerete for dams and other massive structures 1S: 1786, ‘Code of practice for extreme weather concreting 1S: 1893 Criteria for earthquake resistant design of structures = 1515058 PVC Watersiops at Transverse Contraction jorits for use in Masonry and Conorete Dams -Specifications ‘ther important, applicable standards include the following American Soclely for Testing and Matarials| standards ASTM C1170 ‘Standard Test Methods for Determining Consistency and Density of Pee Roller Compacted Concrete using a Vibrating Table. ASTM C1176 ‘Standard Practice for making Roller Compacted Concrete in Cylinder Moulds using a Vibrating Table ASTM C1435 ‘Standard practice for molding roller-compacted concrete in cyiinders re __| using a vibrating hammer. ‘ASTM D5759 ‘Standard Guide for Characterization of Coal Fly Ash and Clean Goal Combustion Fly Ash for Potential Uses. RATLE-SPC-01 Rotier Compacted Concrete ~Performance Specification 07-08-2014 Rev A7 TWP aweL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Ciel intectuctre IC DAMS AND HYDRO eS EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K ‘ASTMC1170-91 (1998) | Standard Test Methods for Determining Consistency and Density of Roller Compacted Conorete using a Vibrating Table. ASTH C1075 Testing Method for Moisture Content in fresh RCC. ASTM C 1040 Test Methods for density by Nuciear methods ICOLD Bulletin 126 | Roller Compacted Concrete Dams BS 188%: Par 104: Ve Be Apparatus 1983 ee 1.2.2 Application ‘This. specification contains clauses which are specifically applicable to the performance, batching, mixing, conveyance, placement, compaction and testing for RCC. 1.2.3 Basic RCC Parameters The general nature of an RCC mix is defined by several characteristics beyond its strength and structural performance. These include the pasteimortar ratio (plm), the sandlaggregate ratio (S/a) and the (modified) VeBe Grade (or time). These parameters relate essentially to the achievable RCC density (and impermeability), the achievable compaction ratio and the tendency for material segregation. In other words, these parameters relate to the "workability" of an RCC mix and in real terms, make the difference between a permeable, rocky RCC with planes of weakness and a cohesive, seamless, watertight and dense RCC The RCC broadly outlined herein follows the "concrete" design approach, whereby the water/cement ratio and the paste/mortar ratio represent the points of departure and a mix is, developed to reflect an adequate sand/aggregate ratio and density for a target modified VeBe time, The RCC addressed in this Specification will be slightly sticky and cohesive, producing high quality, dense and impermeable concrete. ‘The cementitious materials to be used in the RCC for Ratie Dam will comprise Ordinary Portland ‘Cement and Fly ash. Although the process of the mix development programme will determine the totel quantity of cementitious materials to be used and the respective proportions, the quantity of Fly ash is expected to represent between 65 and 75% of the cementitious materials. While a focus on the “specified strength” at an age of 365 days allows advantage to be gained from the slower strength gain characteristics of a pozzolan / cement blend, the reduced development of hydration heat associated with high percentages of pozzolan is a critical factor to bbe considered. This Specification assumes that the RCC for Ratle Dam will be required to indicate a 365 day ‘age compressive strength of between 16 and 30 MPa. The final requirements will be determined by the dam design and the final mix characteristics and strengths will only be defined after the successful construction of the Full-Scale Trial 1.2.4 Definitions ‘The definitions defined in the Project Specification will apply, with the following, Aggregate Fines: The aggregate fines are defined as the total amount of material in the aggregate smalier than 75 microns. The amount of non-plastic, aggregate fines in RCC could be up to 18% of the total fine aggregate. RATLE-SPC-01 Roller Compacted Coner. Rev A7 Performance Specification 07-04-2014 PaveL&T Construction ARQ CONSULTING ENGINEERS ARQ Hoawy cv atsctuctara Ie DAMS AND HYDRO Se EDRC - HYDEL PROJECTS RATLE HEP~ 850 MWJ&K Cementitious Paste: ‘The Cementitious Paste fraction of RCC is defined as the absolute volume of cementitious materials, liquid admixtures, free water and air entrainment. Coarse Aggrenate: ‘The term coarse aggregate will be used for aggregate that is retained on the 4,75mm sieve. Conerete Grade Conctete Grade defines the Specified characteristic cube compressive strength and the nominal maximum aggregate size of a concrete, i.e. Grade 20/50 = 20 MPa with 50mm maximum aggregate size. in the case of RCs, Specified Strength is at 365 days age. Continuous Layer Placement: Continuous layer placement refers to RCC construction in continuous, largely horizontal layers, whereby RCC is placed in a continuous operation across the full surface area of the dam at a particular level, usually from one abutment to the other. Typically placement is advanced in longitudinal strips parallel to the dam axis (perpendicular to the river flow} starting each layer from the point(s) furthest from the point of supply of the concrete and ending at the point of supply. Crack inducer The term "Crack Inducer" is used for the system incorporated into the upstream (and downstream) face concrete to induce shrinkage cracking in the facing concrete on the alignment of a joint in the RCC. Crack Director The term “Crack Director" is used for the system incorporated into the RCC layers to induce thermal shrinkage cracking on the alignment of a joint cve Conventional vibrated concrete. Mass concrete compacted with an immersion vibrator, Facing Concrete: Facing Concrete is mass concrete (or GEVR) placed against formwork, or other surface forming the external face of the RCC body or where indicated on the drawings Dental Concrete: Dental concrete is mass concrete that is used to shape surfaces, fill irregularities and protect particular areas of the foundation and abutments, Fine Aggregate: The term fine aggregate will be used for aggregate that passes the 4,75mm sieve and of which at least 80% will not pass through a 150 micron sieve. This limit will be RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-08.2014 Rev A7 9}? aweL&T Construction ARQ CONSULTING ENGINEERS ARQ) Hoavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP — 850 MWJ&K 75% for RCC fine aggregate. Eines: ‘The Fines are defined as the total volume of material in the RCC mix smatier than 75 microns (cementitious, pozzolan & nor-plastic aggregate fines) Full-Scale Trial (EST) The Full-Scale Trial is an embankment constructed in RCC for the purpose of training the operatives and staff, testing plant, mixes, procedures and various other aspects of RCC construction in advance of the main dam, GE-RCC, or Grout Enriched RCC is RCC to which an additional cementitious grout (by mass) is added at the top of the layer after spreading the RCC and which is compacted by immersion vibrator, This conorete may be used where rollers cannot reach, around reinforcement, as well as against formwork GEVR GEVR, or Grout Enriched Vibrated RCC is RCC to which an additional cementitious grout is added at the bottom of the layer before spreading the RCC and which is compacted by immersion vibrator. This concrete may be used where rollers cannot Teach, around reinforcement, as well as against formwork, wRce: IVRCC, or Immersion Vibrated RCC is RCC with a consistency that allows compaction by immersion vibrator, No grout is added to enrich, Levelling Concrete: Levelling Concrete is mass concrete that is used to create a platform on the lowest foundation onto which the initial RCC is placed. Levelling concrete can also be used around inserts and in the dam as shown on the drawings. Mortar, The Mortar fraction of the RCC mix is defined as the absolute volume of the paste and the fine aggregate (passing 4,75mm. sieve) Non-Continuous Layer Placement — Non-continuous layer placement refers to RCC placement that is not continuous across the full surface area of the dam at a Particular level, This can take the form of several layers placed over a limited area of the dam surface (spiit-evel construction), of placement in inclined layers (siope-tayer construction), Roller Compacted Concrete (Ri RCC is a zero slump concrete designed to be transported by high capacity equipment, RATLE-SPC-01 Roller Compacted Concrete —Performance Specification 07-04-2014 Rev A7L&T Construction ARQ CONSULTING ENGINEERS ARQ Heewy cuinmootustre Io DAMS AND HYDRO wy EDRC = HYDEL PROJECTS RATL e HEP ~ 850 MW J&K spread by bulldozer and compacted by vibratory roller in layers. The generic term “RCC mixes" will include all grades of RCC (including GEVR), as well as RCC Bedding, ete, RCC Bedding ‘The RCC Bedding is a grout or 2 workable mortar placed on the prepared foundation, or on a prepared compacted RCC surface, to receive fresh RCC. Paste The Paste fraction of RCC is defined as the absolute volume of cementitious materials, liquid admixtures, non-plastic aggregate fines and free water. Paste/Mortar Ratio: The paste | mortar (pim) ratio of RCC Is defined as the respective absolute volume of cementitious paste / mortar, Send/Agaregate Ratio: The sand / aggregate (s/a) ratio of RCC is defined as the weight of fine aggregate (4,75mm) / the total aggregate weight Void Ratio in Fine Aggregate Volume of voids determined in the compacted bulk density test of fine aggregate using the tamping rod procedure. Specitied Strenatr The characteristic RCC strength, representing the compressive crushing strength of a 150mm cube after curing in a bath of water at a constant temperature of between 22 and 25°C for 365days since mixing 1.3. COMPOSITION 1.3.4 General RCC will be composed of Ordinary Portland Cement, Fly Ash (FA), fine aggregate, coarse aggregate, a set retarding admixture and water, all well mixed and brought to the proper consistency. The use of other admixtures will be motivated through actual trials if considered to be beneficial to the final RCC properties. All conoretes, including RCC, and the constituent materials thereof, and all methods and testing procedures will conform to the applicable Indian, ASTM or BS Standards, unless otherwise specified 1.3.2. RCC Mix Approach The RCC mixes will only be finalised on completion of the Full-Scale Trial, but it is possible that more than one RCC mix variant will be taken through for construction of the dam. These mixes will be designed in accordance with the "concrete" approach. All RCC mixes will conform to the following: RCC mixes will contain between 180 and 250kgim* of cementitious materials, which will RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-04-2014 Rev A7 Typ aL&T Construction ARQ CONSULTING ENGINEERS 4RQ) Heavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K comprise at least 60 kgim® Ordinary Portland cement. To ensure appropriate bond between consecutive layers, requiring no joint treatment on hot joints, the RCC mix will be so designed to allow the placement of each successive layer before the set of the previous fayer beneath RCC bedding will be applied between placement fayers as indicated on the drawings. The RCC bedding will either take the form of @ conventional watericement grout or a broomable, high Portiand cement/pozzolan content heavily sanded mortar. Grout Enriched Vibratable RCC (GEVR) will be used as facing concrete against the abutments, foundation, formwork, pre-cast facing units, galleries and other concrete structures. 1.3.3 RCC Mix Control ‘The proportions of the RCC mixes will be fully investigated during a trial mix programme that will be developed prior to the start of placing RCC in the dam. The mix or mixes to be used in the dam shall be approved by the Owner/Contractor. The consistency of the materials and of the mix properties will be maintained for the entire period of the dam construction. Adjustments will be made to the datch weights of water, to maintain the necessary consistency to prevent segregation within the RCC and allow full compaction as determined. Frequent changes to the batch weights of water will be considered usual and can be expected to occur regularly during the course of each day's placement depending on such variables as humidity, wind velocity, temperature, cloud cover and changes in aggregate stockpile moisture contents 1.3.4 RCC Consistency The consistency of the RCC under working circumstances will be closely monitored and optimised during the construction of the Full-Scale Trial on the basis of the requirements necessary for adequate hauling, spreading and compacting, 4 5 Responsibility for Mix Design ‘The Sub-contractor will be responsible for the design of the RCC mixes and for ensuring that all concrete placed in the Works meets the requirements of the Project Specification, Typical limiting RCC mix characteristics are indicated in Table 1.1. Table 1.1: RCC Parameter Definition RCC Fines wic' ratio | VeBe Grade| Agg. Size | Sand/agg.Ratio| P/M Ratio Volume | (by weight) | ¢s) mm | (oyweigh) | (by vol) Wien?) Min [Min | Max| Min | Max| Max | Min | Mex | Min (15 s0MPa) 20 [oso[o7o] 8 | | «0 | osz|ose| ose “wic= water/(coment + pozzolanic material) 1.3.6 Materials us Materials Only Ordinary Portland Cement (OPC )will be used in RCC, in combination with Fly Ash. All ‘cements will conform to IS 1489(Part 1):1991and careful consideration will be given to thermal design issues should a cement with a heat of hydration at 7 days of greater than 300 kJ/kg (75 ‘ealories per gram) be used, Preference will be given to the use of cement with a total alkali content, expressed as the sodium RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rov AT 12)P agL&T Construction ARQ CONSULTING ENGINEERS —/4RQ Heavy Ciel Intastuctire Io DAMS AND HYDRO ww EDRC - HYDEL PROJECTS RATLE HEP 850 MW J&K oxide (NazO) equivalent, not exceeding 0,6%, where: % NazO equivalent = % NazO + (0.658 x % Kz0) Should it not be possible to obtain cement with a total equivalent alkali content as low as 0,6%, then the potential occurrence of alkali aggregate reaction (both alkali silica and alkali-carbonate) with the specific aggregates to be applied will be investigated through laboratory testing All Fly Ash (FA) will conform to the requirements of IS 3812 (Part 1):2003, ‘The temperature of fly ash upon arrival to the Site will not exceed 70°C and when entering the mixers will not exceed 50°C unless otherwise approved. 1.3.6.2 Aggregates The sum of the percentages of all deleterious substances in aggregate, as delivered to the mixer will not exceed 2 % by mass. All aggregates will conform to the requirements of IS 383:1970 (@) Moisture Content The free moisture content of the fine aggregate and the smallest size group of coarse aggregate, as delivered to the mixers, will be controlled so as not to exceed 6 and 4, respectively, expressed as a % by weight of the saturated surface dry aggregates. Under no circumstances will the other sizes of coarse aggregate be delivered to the mixing piant bins “dripping wet.” (©) Quality ‘The proposed aggregates will be submitted to an approved laboratory to determine the following properties in accordance with IS 2386:1963 (), Soundness (i) Alkali-reactivity Gil) Shrinkage ‘Sampling and testing of both fine and coarse aggregate will be performed in accordance with Indian (ASTM or BS) Standard. All test samples will be taken in sufficient time to permit adequate testing and examination of results before used in RCC. (0) Coarse Aggregate @ General Coarse aggregate will consist of crushed rock and will be well, evenly and consistently graded. In addition, the aggregate will be of a hard and durabie quality. roughly cubic in shape and clean and free of dirt, dust and other deposits such as clay and mud, At least three separate coarse aggregate sizes will be manufactured so that, when combined, @ consistent well-graded material is produced. The aggregate will not contain any component detrimental to the making of good guality concrete, such as shale, mica or any other similar flaky substances. The aggregate will not be so elongated or flaky in form that compaction, density, strength, durability or workability of the conorete, or RCC made therefrom is adversely affected (i) Particle Shape, Distribution & Grading RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 L3iPageL&T Construction Heavy Civil Infrastructure IC EDRC - HYDEL PROJECTS ARQ CONSULTING ENGINEERS DAMS AND HYDRO RATLE HEP ~ 850 MW J&K ARQ wy The coarse aggregate will have a limited number of flaky or elongated particles such that the sum of the Flakiness and Elongation Indices of each size of coarse aggregate will be less than 25% when tested in accordance with |S 2386(Part 1) 1963. Sampling and testing of both fine and coarse aggregate will be performed in accordance with Indian, ASTM or 8S Standard. All test samples will be taken in sufficient time to permit adequate testing and examination of results before use in RCC. The coarse aggregate to be applied for RCC dam construction will be separated into three broad grading bands, for purposes of quality control, namely 4,75mm ~ 10mm, 10mm — 20mm and 20mm - 40mm, The most appropriate respective proportioning of these grading bands will be dependent on the nature of the final aggregate to be applied for construction, particularly associated loose bulk densities and particle shapes and distribution, Table 1.2 is provided to give an indication of the typical particle size distributions within the broad grading bands required for the coarse aggregates in accordance with IS: 383. ‘Tablet.2; Typical Coarse Agareaate Grading Bands Percentage passing indicated sieve size” eee seun 20-40 10-20 475-10 Gg 700 % 5-100 100 20 20 85-100 2 700) 70 oS 0-20 5-100 475 a o-6 0-20 2.36 o-6 "The 20-40 mm fraction may be modified to allow for @ 80 mm msa aggregale size, if ‘successfully demonstrated in the Trial Mix Program, Full Scale Trial, and acceptable with other design paramet (i) Quatty lors In addition to the requirements of IS 383:1970, the coarse aggregate for RCC will full the requirements of Table 1.3. Table 4.3: Coarse Agarenate Properties PROPERTY [REQUIREMENTS Loose Bulk Density [The percentage voids will be less than 48 Materials passing the 75 micron sieve [Maximum 1%. Light material The percentage of light material, or example ‘coal and lignite, will not exceed 1% by mass. (d)_ Fine Aggregate (i) General Fine aggregate will be of good quality crusher produced material. The material will be free of humus, shale, dirt, dust, coal or any other impurity likely to be detrimental to the making of quality concrete and will be washed if RATLE-SPC-01 Rev A7 Roller Compacted Concrete -Performance Specification Page 07-04-2014L&T Construction Heavy Ci Infrastructure IC DAMS AND HYDRO ERC - HYDEL PROJECTS RATLE-SPC-01 Rev A7 il) ARQ CONSULTING ENGINEERS RATLE HEP — 850 MW J&K necessary. The texture of the sand will be coarse and consist of hard, sharp grains. Mortar shrinkage will be also investigated. Grading and Particle Distribution, The sand will be well and evenly graded. Significant attention will be given to ensuring that the correct grading of the aggregate, as delivered to the batching plant, is maintained and if variations are outside allowable limits, corrective measures will be implemented immediately. ‘The grading of the fine aggregate as delivered to the mixers will be such that the cumulative percentage passing any sieve will not vary by more than 3%. points from that finally specified for the particular gradation selected. ‘The Efflux Index test will be used to determine the shape (‘Edginess’) of the fine aggregate in accordance with EN 933-8. The fine aggregate will have values between 25 and 36, and will be subject to adjustment from actual performance data ‘The grading limits to be applied for fine aggregate are indicated in Table 1.4. Table 1.4: Allowable Fine A ding Limits Sieve Size Percentage passing indicated sieve size (ram) Sand os 700 a6 35-100 2.36 a0. 95 i18 5-90 0.60 40-70 0.300 7535 0,760 0-25 0.075 ee Fi 3625 In order to achieve the grading requirements specified above, fine aggregates from more than one source will possibly need to be combined Particular care will be applied to ensure that the fine aggregate grading is not deficient in the 0.180 to 1.18 mm fraction and at least 55% of the fine aggregate willie within these grading limits. In the case of crushed sand, depending of the type of crushers used and if required to meet the specified grading limits, the sand might need to be hydraulically separated into the following two categories and recombined in approved proportions in order to secure uniform quality and optimum grading: (i) Particles larger than 1,18 mm (ii) Particles smaller than 1,18 mm ‘The grading of recombined sand will be such that not less than 90 % will pass a 4.75 mm sieve, nor more than 25 % by weight will pass a 0.15 mm sieve Each type and size of sand will be stored in separate covered bins and Roller Compacted Concrete ~Performance Specification 07.04.2014 IsPageL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Civ Irastuctre IC DAMS AND HYDRO Sy EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K. protected from contamination. Depending on the overall cementitious materials content of the RCC mix to be developed, some benefit is likely to be gained in overall RCC consistency properties in an increased proportion of material across this grading fraction The fine aggregate will be separated into two or more sizes or classifications if needed, but the uniformity of grading of the separate sizes will be controlled so that they may be combined throughout the job during batching of the RCC. (ii) Quality In addition to the requirements of IS 383:1970, the fine aggregate for RCC will full the requirements of Table 1.5, Table 1,5: Fine Aggregate Properties PROPERTY REQUIREMENTS: Compacted rodded density ‘The percentage of voids willbe less than 32% The percentage of light materia, for example coal and lignite, will not exceed 1% by mass. Light material 1.3.6.3 Water Water used for RCC mix manufacture will comply with the requirements of the Project ‘Specification. The water used for washing, or cooling aggregate and for mixing and curing RCC. will be fresh and free of deleterious amounts of oil, acid, salt, alkali, organic, or any other harmful substances in accordance with IS: 456.2000 1.3.6.4 Set-Retarding Admixtures Acceptance of set retarding admixtures will be based on compliance with ASTM C 494, type D & G and IS:9103. Set retarding admixtures should be used to create hot joints in REC when delays in the placement of successive layers exceed 4 hours. A maximum initial setting time of 24 hours (otal time from mixing) will be allowed and dosages of the set retarding admixtures will be established to achieve the initial setting time required in accordance with the layer placement methodology applied. Final setting time will not exceed 48 hours. The setting time will be measured according to 1S 4031(Part §):1988. The Sub-contractor will carry out the tests ‘outdoors at different ambient temperature and environmental conditions. The test sample will ‘comprise the fraction of the RCC mix passing the 4,75-mm sieve and during the test the sample will be protected to avoid loss of moisture. Set retarding products that give rise to a decrease in the RCC strength by more than 10% at 28 days (or later) will not be accepted. The Sub-contractor will propose appropriate dosages for at least two different admixtures, which comply with the requirements of this specification, Tests will be required for all admixtures to be used in the RCC and satisfactory arrangements will be made for the procurement of adequate quantities of test samples. Admixtures will not contain chlorides and will conform to the following applicable standards: (a) Set-retarding admixtures ASTM C494 (type D &G) (b) Water reducing admixtures ASTM C494 (type D& G) 4.3.6.6 Air-Entraining Admixture Entrained air content of the RCC, if needed, will be determined in the Design Analysis, with an estimated air content of between 1.0% and 4.5%. RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 16P ageL&T Construction ARQ CONSULTING ENGINEERS —4RQ) Heavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K 1.3.6.6 Deteriorated material Material which has deteriorated, or which has been contaminated or otherwise damaged will not be used. Such material will be removed from the site without delay. 1.4 MATERIALS DELIVERY, STORAGE AND HANDLING 4.4.4 Cement and Pozzolan 1 4.1 Transportation Fly ash will be transported to site in bulk tankers and will be stored in bins and similar in design and function as that of cement Each individual silo will be large enough to receive 125 cumec of fly ash. Separate silos for fly ash and cement will be used. Split silos with cement and fly ash separated by a partition will not be used. Storage of fly ash will be planned in such a way so as to receive required amount during peak concrete placement. Each storage bin and silo will be equipped with a positive shutoff to control the flow of the fly ash to the weigh batcher. Rotary valves, rotary valve feeders and butterfly valves are generally Suitable for this purpose. Independent dust collectors on cement and fly ash bins will be utilized To transport fly ash from bin to weight batcher, gravity, pneumatic transfer, screw conveyors, or air slides will be used. The method will depend on the location of the fly ash bin relative to the weigh hopper. Fly ash from overhead storage is normally conveyed by gravity flow or an air slide. If the fly ash storage is at nearly the same level as the weigh batcher, an air slide or a screw conveyor can be used. A positive shut-off valve will be installed to ensure that batching does not result from fly ash flowing through the air slide or screw when the device is stopped. Fly ash can be conveyed from lower level storage by pneumatic or screw conveyor. ‘When bulk cement or pozzolan is not unloaded from primary carriers directly into weather-tight hoppers at the batching plant, transportation from the railhead, mill, or intermediate storage to the batching plant will be accomplished in adequately designed weather-tight trucks, conveyors, or other means which will protect the cement or pozzolan completely from exposure to moisture. 1.4.4.2 Storage Cement and pozzolanic material will each be stored in a dry, weather-tight, and property ventilated structure. All storage faciities at the site will be such as to permit easy access for inspection and identification. The cement and pozzolanic material storage facilities will be painted in a reflective colour and protected from direct sunlight as far as possible, Cementitious materials will not be delivered to site at temperatures above 60°C. Sufficient cement and pozzolenic material will be in storage to complete concrete requirements for eight operating days ‘of continuous placement during the peak production month. Any cement that has been stored at the site for more than 60 days, or cement of questionable quality, will be used only after it has been representatively sampled and tested as per IS standards 1.4.1.3. Separation of Material Separate facilities will be provided for unloading, transporting, storing, and handling each type of ‘cement and pozzolanic material, The loading facilities for each material will have different sized nozzles so that there is no chance of the incorrect material being loaded into the wrong silo, 1.4.2 Aggregates 1.4.2.1 Bulk Storage Aggregate will be stored in separated size groups and in such a manner as to prevent the inclusion of foreign materials, as well as contamination with other aggregate sizes. All aggregates will be stored in areas safe from the influence of floodwater and will not be subject to RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-0422014 Rev AZ PaveL&T Construction ARQ CONSULTING ENGINEERS 4 RQ) Hoavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K. ponding. In addition, the Sub-contractor will ensure that sufficient supplies of, and storage facilities for aggregates are available for the rate of RCC placement for a peak production as applicable. 1.4.2.2 Batch Plant Stockpiles ‘A minimum supply of aggregates sufficient for end equivalent to @ month's peak production will be available in stockpiles close to the batching plant. Storage facilities and arrangements will be configured to prevent contamination between diferent aggregate sizes. 4.8 PLANT 1.8.41 General All plant will be suitable for the production of good quality danse RCC under the conditions appiicable on the site. The use of equipment that will not properly mix, handle or place RCC of acceptable quality, will not be permitted, All plant will be maintained in good working order and will be of adequate capacity to comfortably meet the requirements of peak production on 2 sustained basis. If it becomes necessary to consider an accelerated production rate, additional equipment will be provided. Adequate plant will be available and operational to meet the necessary production requirements and will take all measures necessary to eliminate any production “bottlenecks” that might be encountered. Al plant will be operated by trained and experienced personnel For all plant and equipment to be operated on the dam, standby replacement equipment will be available within 1 hour if necessary. All equipment will be maintained in good operating condition. The equipment will not leak oF drip oll, grease or other visible contamination onto the RCC surfaos. All equipment re-entering the dam surfaces will be cleaned of all contaminants by an approved method 4.5.2. Batch Plant 1.5.2.1 General The batch plant will be configured so that batching of new material cannot proceed until the weighing hoppers have been completely emptied of the previous batch and the scales are ‘completely in balance. When RCC production is initiated, the batching and mixing plant will have been adequately tested and calibrated to ensure complete compliance with the related specifications. RCC batches not complying with the specifications will be rejected before entering the main RCC delivery system and wasted. The batch plants will be fully computerized, 1.5.2.2 Bins and Silos Separate bins or compartments will be provided for each size of aggregate. The bins will have steep side slopes, large gate openings, and be capable of handling the aggregate in a damp ‘condition without choking 1.5.2.3 Weigh Batchers ‘Aggregates will be weighed in separate weigh batchers with individual scales and cements and pozzolans will each be weighed on a separate scale in a separate weigh batcher. Water may be Measured by weight or by volume. Admixtures may be batched by weight or by volume. The weigh batchers will be arranged so as to permit the convenient addition, or removal of material. The batching and mixing plant will have @ realisable reserve capacity of at least 30% of the required maximum placement rate. RATLE-SPC-01 Roller Compacted Concrete -Performance Specification 07-04-2014 Rev A7 18P ageL&T Construction ARQ CONSULTING ENGINEERS 4RQ Heavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K 4.5.2.4 Water Batcher & Dispenser A suitable water measuring device will be provided which will be capable of measuring the mixing water within the specified requirements for each batch. The dispenser wil be interlocked with the electronic plant control and will warn the operator and shut down the plant if insufficient liquid is available. 1.5.2.5 Moisture Control The plant will allow the simple adjustment of the materials batch weights to compensate for variations in the aggregate moisture content, as determined by manual measurement, in addition, automatic moisture sensors with a maximum tolerance of £0.5% fram actual measured values willbe installed at the aggregate bins. 1.5.2.6 Admixture Dispensers ‘A separate batcher or dispenser will be provided for each admixture. Volumetric dispensers will be used only for liquid admixture and each plant will be equipped with the necessary calibrated devices that will permit convenient checking of the accuracy of the dispensed volume of the particular admixture. 1.5.2.7 Scales Adequate facilities will be provided for the accurate measurement and control of each of the ‘materials entering each batch of concrete. Standard test weights and any other auxiliary equipment required for checking the operating performance of each scale or other measuring device will be provided. Testing of the scales will be prior to the start-up of RCC placing and at feast monthly thereafter. Scales will be certified by a local 3” part agency before the start of the main RCC. 4.5.2.8 Operation and Accuracy Delivery of materials from the batching equipment weigh hoppers to the mixer will be within the following limits of accuracy: Material Petmissible Variation of mass(%) Cement #1 Pozzolan #1 Water a Aggregate #2 Admixtures 43 18. 9 Recorders ‘An accurate recorder or recorders will be provided for the aggregates and cementitious materials. The recorder will note formula changes and will print total quantities of each ingredient and total weights produced on demand. Each batch record will include, as a minimum, the date, time, mixing time and all target and actual weights of materials. Print outs will be on continuous roll paper producing two copies. The computer will have the capability of storing each concrete mix to be used and of adjusting each mix for moisture control without interfering with the batching operation. It will be capable of storing @ minimum of 20 mixes. 1.6.2.10 Batch Counter The plant or the mixers will include a device for automatically counting the total number of RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 19}P 3L&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Ci nrasirature IC DAMS AND HYDRO wy EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K batches of concrete mixed. 1.5.3 Mixing Plant 4.5.3.4 General The type and capacity of the mixing plant will be such that the rate of output of RCC batched is suitable for the rate of RCC placement. Each mixer will be capable of producing a uniform distribution of the ingredients throughout the batch. Worn or bent blades will be replaced and inner surfaces of the mixer will be kept clean and free of hardened concrete. Blades worn by more than 15% of their depth will be replaced, or adjusted if so designed. The mixers will not be ‘charged in excess of the capacity recommended by the manufacturer and the mixing blade speed designated by the manufacturer will not be exceeded. At least two RCC plant set-ups ‘equipped each with a batching unit and a mixer will be provided on the site Mixers will be batch type, Continuous mixers will nat be allowed. Only twin horizontal shaft mixers capable of thorough mixing of the constituent materials will be used. The main RCC plant will be equipped with at least two interchangeable batch plants and mixers, each of adequate reserve capacity for at least 30% production above the required maximum RCC placement rate, The mixing period will be sufficiently long to ensure the complete and thorough mixing of materials. The mixing time will be determined by a Mixer Performance test in the field and determined from laboratory results. The mixing time will be increased when such increase is necessary to secure the required uniformity and consistency of the concrete. Excessive over-mixing requiring additions of water will not be permitted. The mixers will not be charged to less than 60% of nominal capacity. These tests will also determine whether the reduced mixing time will produce RCC that meets the requirements of this specification. Suitable facilities will be provided for obtaining representative samples of concrete for uniformity tasts. All necessary platforms, tools, and ‘equipment for obtaining samples will be furnished. In order to consider a reduced mixing time, additional mixer Performance Tests will be Performed, each of three samples, to refiect variations within the following ranges, when ‘compared to a mix produced according to the approved mixing time: Test Allowable Variation Compared with Original Mixing Time Water content of mortar, percent by weight 85-115 Coarse aggregate content of concrete, percent by weight 90-110 Unit weight of air-free mortar 96 - 104 Cement content of dried mortar, percent by weight 80-120 Maximum difference between two samples of same batch: - Consistency (mod. VeBe Time) £2 seconds - Fresh density (mod. VeBe density) £80 kg/m? - Amount of coarse aggregate (Sieve analysis by washing) 5% = Compressive strength at 7days normal+7days accelerated curing 420%, average of 3 specimens, Should any mixer at any time produce unsatisfactory results, its use will be promptly discontinued unti itis repaired RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-04-2014 Rev AT 20) aL&T Construction ARQ CONSULTING ENGINEERS ARQ Hoavy Gi ttc 6 DAMS AND HYDRO Se EDRC-- HYDEL PROJECTS RATLE HEP ~ 850 MWJ&K 1.5.4 Conveyance and Transporting Equipment 1.5.4.1 General RCC placement will be continued in as nearly a continuous operation as is practical. Therefore, the concrete mixtures will be conveyed from the plant mixer(s) to the placement as rapidly and ‘as continuously as practical by methods that limit segregation, contamination and surface drying, ‘A conveyor andlor chute, of any other suitably demonstrated method will be used for transporting freshly mixed RCC from the mixer to the damn, At the dam, RCC will be discharged into end dump trucks without end-gates for transportation to the dumping location within each lift Indicating and signalling devices will be provided for the control and identification of types or classes of RCC as they are mixed and discharged for transfer to the placement site. In case of using different RCC mixes in the same lif, each type or class of RCC will be visually identified by placing @ coloured tag or other marker as it leaves the mixing plant so that the RCC may be positively identified and placed in the structure in the desired position. All conveyance equipment that leaves the surface of the dam for any reason, will be cleaned of all contaminants by an approved method before returning to the dam surface. A portable protective device will be provided upon which conveyance equipment (as well as all other equipment) can be serviced on the dam surface without contamination of the underlying RCC. 1.5.4.2 Conveyors Conveyors and hoppers, and/or chutes will be used for the transportation for RCC between the mixer and the dam. The capacity of all conveyors will be sufficient, wth ample width and speed, for the target rate of RCC placement. There will also be no segregation of material when falling from the end element of the conveyor loading the trucks, at the transfer units or during any stage of transportation. In case that supports of the conveyor system are planned to be embedded in the RCC, the methodology will comply with the design requirements ‘The conveyors and transfer sections will be coverad to avoid material to lie exposed to drying by wind and/or sun, or from over-wetting by rain. The system will be designed and manufactured by personnel fully experienced with conveyor belt delivery of low slump or no slump mass concrete ‘and will be designed specifically for continuous operation. The conveyor system will be maintained in accordance with the manufacturer's recommended practice and an adequate inventory will be Kept on site of replaced components and parts. The conveyor system will be designed for continuous eround-the-clock placement with all components of @ modular configuration for quick and easy repair or replacement. Conveyor belts will not be operated at steep inclines that may cause segregation. 1.5.4.3 Hoppers. A surge hopper with adequate capacity will be provided near the batch plant so that there is @ continuous supply of RCC to the conveyor leading to the dam. Hoppers will be used at transfer stations or as a surge unit to regulate the flow of concrete to the conveyor or to any other transportation system. They will be constructed with adequate capacity so that the mixing sequence is not stopped or slowed during production if the hauling vehicles are delayed. The hoppers will be constructed with side slopes and gates that allow for the free flow of RCC without segregation or choking. Telephone or radio communication will be provided between the hoppers, the mixing plant control room and the placement site, Hoppers will be ‘emptied of one mix before being filled with a mix of a different design. 1.5.4.4 Dump Trucks Dump trucks of minimum 10 tonne capacity will be used to transport RCC across the RCC RATLE-SPC-01 Roller Compacted Concrete —Performance Specification 07-04.2014 Rev A7 2iPageL&T Construction ARQ CONSULTING ENGINEERS 4 RQ Heavy Civl Infrastructure IC bee hnpinepee EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MWJ&K fayer under construction, from the loading point at the end of the conveyor to the point of placement, The body of the trucks will be sound and that no material is lost during transit. There will also be no tendency for the RCC to hang - up on any part of the body of the truck during offloading. The dumping action of the trucks will be made with the truck positioned on top of RCC. that has just been spread and not onto the compacted surface of the previous layer. Such operation will be conducted so as not to cause segregation of the dumped RCC, or a device such as a spreader box will be utilised to obviate segregation. The surface receiving the fresh RCC will not be contaminated by dust, dirt, sand, grease, oil or any other substance that may fall from the trucks during transportation and dumping of the RCC. Under no circumstances will dump tucks, whose tyres have become contaminated with adhering material through travel on any roads, be permitted to travel on the dam without cleaning. Trucks will remain on the surface (crest) of the dam at all times, Trucks will reverse from the point of loading to the point of placement without any sudden turns. On the return journey the trucks will drive forwards again without any sudden turns. Trucks will not drive on freshly compacted RCC at any time except directly under the loading point where special care will be taken to avoid damaging the surface of the RCC. Typical concrete hopper trucks will not be used for RCC conveyance, as discharging of RCC through a narrow end gate causes significant segregation. The final conveyance procedures will be defined after the Full Scale Trial, and will result in RCC of a quality meeting the specification to be delivered to the dam, 1.5.4.5 Chutes/pipes Ita chute or pipe is used to transport the RCC, the capacity of the chute/pipe will be sufficient for the necessary rate of RCC placement. There will also be no segregation of material when falling through the chute/pipe, or during any stage of transportation and any segregated material at the end of the chute/pipe will be remixed before placement. 1.5.5 Spreading Equipment ‘Spreading of the RCC after dumping will be by means of a laser-guided dozer. The spreading method applied will not cause any segregation or breakage of the constituent RCC materials. ‘The controi of the equipment will be such that the layers are spread evenly to an accuracy of plus or minus 50mm. The evel to which succeeding layers are placed will be controlled using a laser system that automatically adjusts the blade of the spreading bulldozer. There will be a minimum of one operating dozer for each 200 m” of RCC being placed each hour. The dozers will be equipped with well-maintained street pads, or grousers, which are cut to 2 maximum projection of 20mm, and will have @ "U" blade and lateral wings to prevent segregation. The dozer should be the of size of a CAT D8, or larger, as appropriate for the placement rate to be achieved. A smail wheel dozer or a front-end loader with operator will be available to assist with deposition and spreading of RCC as needed in confined areas, at the abutments and at other locations as approved or directed. At least one compact loader (Bobcat $250, or A300, or similar) will be kept permanently on the placement surface for the delivery of RCC to restricted areas and for removal of rejected RCC. Spreader box or other spreading and re-mixing equipment will not be used. The operation of a dozer or other tracked vehicle on any RCC other than fresh uncompacted RCC will not be permitted. Where the movement of a dozer ‘on a compacted, or partially compacted RCC surface Is unavoidable, the surface will be protected as indicated here below and in case any damage occurs this material will be removed to expose competent RCC and the appropriate surface preparation will be applied before placement of the subsequent layer ‘When it is necessary to remove a tracked vehicle from the dam surface, or move the dozar from one abutment to the other, such movements will be made by loading the vehicle onto a rubber-tired trailer, by providing protective pads such as conveyor belt between the grousers and RCC surface, or by providing some other approved protective device. RATLE-SPC-01 Roller Compacted Concrete -Performance Specification 07-04-2014 Rev A7 2PuseL&T Construction ARQ CONSULTING ENGINEERS —4RQ Heavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev AT RATLE HEP ~ 850 MW J&K 6 GEVR (Grout Enriched Grout for GEVR will either be mixed in a grout mixing plant external to the dam and pumped through pipes to the point of placement, or mixed on a truck mounted with a grout mixing plant that is moved on the lift as required. The distribution of the grout to the point of placement will be made in small buckets, directly by pipes or conveyed by some other adequate means Appropriate immersion vibrators will be required (see Clause 1.5.7 (c)) to ensure an even and complete distribution of grout within the grout enriched RCC and an appropriate self-propelled double drum small vibratory roller and a vibratory plate-compactor (see Clause 1.5.7 (b)) will be provided to compact the interface between the RCC and the GEVR. All plant used will be so configured as to ensure that the grout is fresh when poured and compacted. 1.5.7 Compacting Equipment The RCC will be compacted to a density as defined in Clause 1.7 by means of an approved self-propelied smooth drum vibratory roller. Where large rollers are unable to compact the RCC satisfactorily, for example alongside pre-placed vertical surfaces, GEVR will be used and the interface with the RCC will be compacted with approved small vibratory rollers and vibrating plate compactors. A vibratory plate compactor will be used to ensure a level interface between the RCC the GEVR upon completion of the consolidation by immersion vibrators. The thickness, of the uncompacted layer will be determined during trials on the Full-Scale Trial. The target final layer thickness will be 300mm, (@) Large Self-Propelled Vibratory Rollers The large vibratory rollers will be self-propelled single drum vibratory rollers. They will transmit @ dynamic impact to the surface through a smooth steel drum by means of revolving weights, eccentric shafts, or other equivalent methods, The rollers will be equipped with a reversible cam to allow the compaction action in both forward and reverse directions. The large compactors will have a gross weight between 10 t and 13 t, producing a minimum dynamic force of 25 kg/cm of drum width at an operating frequency of at least 25 Hz and variable amplitude within an approximate range of 0.70 mm to 1.70 mm. The roller drum will be a minimum diameter of 1400mm and more than 2100 mm in width, The roller will be operated at speeds not exceeding 2.5 km per hour. The engine driving the eccentric mass will have a rating of not less than 70 KW. All vibratory rollers will be properly maintained to ensure the maximum compactive effort of each roller is achieved. Al vibratory rollers operating on each layer of RCC will be of the same make and model number. Atleast four large self-propelled vibratory rollers meeting these requirements will be maintained (with operators) on the placement area at all times during production and placement (b) Vibrating Plates and Small Vibratory Rollers, ‘Small double smooth drum vibratory rollers with 2 gross weight between 1.5 tand 3.0 t, which are capable of operating within 50-150mm of a vertical face, will be used to compact the RCC in areas where the larger vibratory rollers specified above cannot manoeuvre. These will also be used to compact the interface between RCC and GEVR. The dynamic force produced by the small rollers will be at least 10 kg/cm of drum width and the vibrating frequency will be at least 55 Hz. Both crums should vibrate simultaneously with these minimum parameters and the drums will be approximately 1000 mm wide. Reversible vibratory plate compactors will be used to finish the compaction of the RCC surfaces along the abutment slopes, along the upstream and downstream formwork, They will have an operating weight between 60 and 150 kilograms, and a minimum vibrating frequency of 60, Hz. The amount of compaction required will be a8 necessary for the particular 23)P aveL&T Construction ARQ CONSULTING ENGINEERS {RQ Heaw ciel intastucture IC DAMS AND HYDRO wy EDRC - HYDEL PROJECTS 158 RATLE-SPC-01 Rev A7 () RATLE HEP ~ 850 MW 1&K equipment to provide the same degree of compaction as would be attained with ten passes of the large self-propelied vibratory roller specified above. At least three small rollers and four plate compactors in good operating condition will be maintained on the placement area during all production operations, Immersion Vibrators GEVR will be used in narrow areas of the layer with difficult access for the small rollers. The conventional slump concrete, the GEVR will be consolidated by immersion vibrators. The head diameter, frequency (measured immersed) and average amplitude (measured in air) of the vibrators will conform to the following requirements: Head Diameter (mm) Frequency (cycles per minute) Amplitude (mm) 65-100 9,000-12,500 075-45 In no case will vibrators be used to transport concrete within the formwork. Vibration will be systematic, with emphasis on closely spaced insertions. The duration will be sufficient to produce good consolidation, There will be adequate hydraulic pressure available for hydraulic vibrators and adequate voltage for electric vibrators. At least four immersion vibrators (and two standbys) will be Kept in operation at the point of facing concrete placement to ensure that facing concrete is compacted with minimum delay. Spare vibrators will be available to maintain production in the event of a breakdown In addition, @ backhoe with a front mounted gang of hydraulically operated vibrators can be used to consolidate the concrete by immersion vibration against the formed faces and against the abutments. The capacity of the hydraulic engine of the backhoe should be enough to operate at the same time at least four vibrators of the specifications mentioned above. All compaction, vibrating, and consolidation equipment will be subject to testing during the Full Seale Trial Surface Preparation Equipment (@) (b) Portable High Pressure Wesher/Water Blaster Portable high pressure washers will be used (and designed) for washing and cleaning the RCC layer and lift surfaces, as required during the regular course of RCC placement. The units will facilitate the removal (without damaging or undercutting coarse size agaregates) of all laitance, surface mortar coatings, grime, dirt, oil, or any hard packed or loose contaminants trom the RCC surface during all weather conditions expacted at the project site. The portable high pressure washers will have a nozzle gun and hose capable of easily being handled by one man. The high pressure water washing may be accomplished by different means and will have an upper limit of 200 bar. The water blaster will be capable of developing a working pressure of not less than 400 bars at the nozzle. Vacuum Truck ‘A vacuum street cleaner will be used to clean the RCC surfaces. The equipment will have a suction capacity in excess of 250 m*/minute and the tank for the detritus will have a capacity of more than 4m®, The vacuum truck will be provided with a 2.5m wide bottom suction unit/s and a reer suction trunk of at least 150mm in diameter ‘Only vacuum trucks with a proper vacuum will be used. Roller Compacied Concrete ~Performance Specification arene sale: 24IP aeL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Civ Intasiuctare Io DAMS AND HYDRO wy EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K Cleaning with the vacuum truck will be carried out in a manner that will not cause deterioration of the RCC surface. The truck should be maintained clean and in good operating conditions. At least two (2) units will be avaliable at the placement area at alltimes, {) Mechanical Brush ‘A rotating highway-type brush with catchment attachment and water supply, carried by a front end loader, 15 - 20 tonne operating weight, or similar equipment will be Used for lift surface clean up and horizontal joint preparation. Different types of brush materials will be used, depending on the operation, with a minimum as follows: (i) Nylon or synthetic material tines Beach (i) Steel tines Beach {li One brush carrier will be provided, with @ second as standby. Brush carries will designed to allow for a combination of both steel and wire brushes simultaneously if possible, 1.5.9 Induced Joint Cutter/Joint inserter Pneumatic powered pavement breaker tools, 30 kg weight class, will be used to drive steel sheets, or other approved de-bonding materials, for transverse joint construction. Toot attachments for driving the crack inducer sheets will be custom fabricated and demonstrated on the Full-Scale Trial If desired, a larger pneumatic or hydraulically powered plate driver, modified to be operated from mobile equipment such as a front-end loader, may be used. Demonstration of satisfactory performance on the Full-Scale Trial will be required for the approval of any such plant. ‘A machine-mounted joint inducer, designed for the installation of sheets of at least 1 min length, will be required should geotextile-type crack inducer sheets be used. Four pavement breakers will be provided with three as stand by. If used, one machine-mounted driver will be provided, with a second as standby. 4.5.10. Other Equipment All other equipment necessary for sucessful RCC production, but not discussed within this specification (or determined to be necessary during the course of the work) will be approved prior to actual use. The use of such equipment will not result in any damage to the RCC. Equipment will be maintained in good operating concition and operated by skilled personnel 1.5.11, Nuclear Density Gauge Readings to determine the density of both un-compacted and compacted RCC, will be made using nuclear density gauges supplied by the Sub-contractor. The gauge will be capable of taking readings to @ depth of 300 mm. At least three gauges in full working order will be retained fon site for the duration of RCC placement, On-site nuclear density gauge training will be provided for all quality assurance personnel. 4.5.12 Formwork 41.5.12.4General All formwork will be designed and constructed in such a manner to ensure that the concrete can be placed and compacted to the required shapes, finishes, positions, levels and dimensions as shown on the drawings. The formwork will be capable of resisting all dead and live loads to which itis subjected and will be maintained rigidly in position. The formwork will also be capable RATLE-SPC-01 Roller Compacted Concrete —Performance Specification 07-04-2014 Rev A7 25? aL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Chil infaatuctre Ic DAMS AND HYDRO wy EDRC - HYDEL PROJECTS RATLE HEP. 850 MW J&K of adjustment both in the horizontal and the inclined directions so that the faces of the dam can be maintained within the specified tolerances. Special attention will be given to the design of the formwork and the anchoring system when the RCC set time is retarded. The formwork will be specially designed to allow a continuous placement of RCC without interruptions. All formwork. will be designed for the specific characteristics of the RCC and GEVR, as applicable, and the placement methods and rates applied ‘The types of ties used and their spacing will be such that the required finish is achieved and will not be marred by the subsequent corrosion of tes. The formwork and the formwork joints will be sufficiently tight to prevent any loss of mortar. Stripping of formwork will not be done until the supported concrete has achieved sufficient strength, Permanently exposed recesses resulting from removal of form ties will be patched with a cement and sand based patching mortar. 1.5.13 Temperature Reading Equipment ‘The Sub-contractor will supply the following equipment: (2) A digital type immersion thermometer to measure RCC placement temperature on the dam. It will have @ penetration probe length of approximately 700 mm and temperature range of -10°C to +50°C (to an accuracy of 1.0°C). (b) A thermometer to give @ continuous record of the ambient temperature at the site of RCC placement The thermometer will have a temperature range of -10°C to +50°C (to an accuracy of 0.5°C). 1.5.14 Sampling Facilities The site will be equipped with adequate facilities and equipment to allow the sampling of RCC at the point of placement. After measuring the temperature of the dumped RCC, a representative sample, of approximately 500ka, will be transported directiy to the site laboratory without delay. The sampling device will be capable of obtaining samples from the dumped RCC, the discharge point of the mixer(s), the discharge point of the wet batch hopper, or at a point where the RCC is, discharged into the transportation equipment. The sampling container will be approved, will have a sealing lid and @ capacity of at least 500 kg and will have a gate at the bottom for discharge of the sample from the container to the mechanical screening device or ta the damp lab floor. The conerets sample will be mechanically transferred to a mechanical screening device having an approximate screening area of 600mm wide by 760mm long with 40mm square openings. A 6.25mm steel plate will be placed on the floor underneath the screening device and this will ‘extend a minimum of 1.2m along the length of one side and will provide a minimum of 4.5m of working space, Waste concrete from the tested samples will be disposed of immediately 1.5.15 Laboratory Areas A concrete testing laboratory with a minimum floor area of 160m? will be required on site. This laboratory will be provided with electrical power and will be equipped with 60m* of open floor area and 10m? of table top / bench area. An additional covered area of 70 to 75m2 will be provided to house the curing baths 1.5.16 Laboratory Equipment ‘The following lists the absolute minimum major equipment for the site laboratory: (a) A cube press capable of crushing 150 mm diameter and 300 mm high RCC cylinders and 150 mm size cubes of 60 Mpa strength (b) Two sets of grading screens each for the coarse and fine aggregates. (©) Alarge capacity microwave and convection oven. (a) Running water and electric power supply. RATLE-SPC-01 Roller Compacted Concrete —Performance Specification 07-04-2014 Rev A7 26L&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Chtintastudre 1S DAMS AND HYDRO we EDRC- HYDEL PROJECTS RATLE HEP ~ 850 MW 1&K. (2) Ascale accurate to 0 g, with a capacity of 260kg. (f) Ascale accurate to lg, with a capacity of 12kg (g) A horizontal nuclear density measurement device, capable of measurement ats00mm depth (h) Two(2) modified VeBe apparatus, in accordance with BS 1881 (paragraph 3.1), with a total surcharge mass (P) of 10.0kg “00 kg.’ (0) Vibrating table capable of compacting at least 9N° 150-mm cubes at the same time () APC for data recording and processing of mix design variation. {k) Conorete thermometers. (0) A laboratory pan concrete mixer (vertical axis) capable of mixing at least 150 ¢ of zero-siump RCC (m) Cubic metal moulds complying with the requirements of BS 1881. 100 No. 150 mm moulds. (nh) Curing baths, with a water temperature thermostatically controlled to between 22 and 26°C, of an adequate capacity to store 1400 No. 150mm concrete cubes and core segments. (0) A'siump cone with a rod, (p) Penetrometer (as described in ASTM C403). (a) 15 No. 150x150x300 mm steel moulds for mortar samples used in the setting time tests. (r) Mechanical sieve of large capacity for sieving 5-mm mortar out of the RCC mix. (s} Two (2) galvanised curing tanks fitted with thermostatically controlled temperature to maintain curing water up to 90°C (accelerated curing). Each tank will be capable of storing 16 Nos. cubes of 150-mm size, () Direct tensile testing machine for 150mm-diameter RCC cylinders of 4 MPa strength. The Sub-contractor will ensure that he is in possession of all of the necessary equipment and testing apparatus to execute all required testing and quality control procedures. The Sub-contractor will further maintain all equipment in a fully functional and accurate condition for the duration of construction and regularly complete all necessery calibrations in accordance with the national standards requirements. A copy of the full range of specified testing procedures wil be kept in the laboratory at all tmas. 1.5.17 RCC Quality Records For the purposes of producing records of placed RCC quality, an adequate number of diamond core drils capable of driling 150mm diameter cores to vertical depths of 100m and horizontal depths of 10m will be required. Adequate spare core barrels and bits will be made avatiable to ensure the continuity of this drilling work. Furthermore, piatforms will be created to allow the driling of cores on a continuous basis from the downstream face of the dam, as and where necessary. A facility will be included to allow the vertical and horizontal movement of these platforms freely up and across the face of the dam. 1.5.18 Cooling Plant The maximum placing temperature of RCC will be determined subsequent to a thermal analysis. The RCC placing temperature will be determined by placing a thermometer in the un-compacted RCC at the placement site, If needed, a cooling plant of an appropriate capacity will be installed at the batch plant or other focation. The cooling plant will have the capability of producing adequate quantities and rates of flake ice, chilled water, chilled aggregate, andior chilled air, as Fequired to reduce the aggregate, cementitious materials, water and/or mixed RCC temperatures to the requirements of the specification, with a reserve capacity of 30% at maximum production and maximum ambient temperatures. The preferred method of producing artificially cooled RCC is through the use of a wet-belt conveyor, on which the temperature of the coarse aggregate is cooled, using water chilled to approximately 4°C, immediately before it is loaded into the batching plant. RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification o7-04.2014 Rev A7 21aL&T Construction ARQ CONSULTING ENGINEERS 4RQ) Heavy Civil Infrastructure IC DAMS AND HYDRO way EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K 4.6 CONSTRUCTION 1.6.1 General RCC will generally be transported by conveyor and/or chute systems to the dam, in dump trucks ‘on the dam and placed in layers of an approved thickness depending upon the compaction equipment used (most likely to be 300mm (compacted)), 1.6.2 RCC Mix Specification The RCC mixes will only be deemed to be final once proved through construction of the Full-Scale Trial. All RCC mixes are Strength of Concrete. The mixture proportions of the RCC will be within the ranges given in Table 1.6.2. Table 1.6.2 Allowable range of mixture proportions to be used in the RCC dam Matertal I Range of mixture proportions (kg/m®) RCC Grade 15 - 30/40 Bedding mortar Grout Type 1 Portland 60-100 350 - 450 1180 - 1350 Cement Pozzolanio material 110-470 ° ° Free water 90-150 _——|_—_- 200-300 | 500-700 Coarse aggregate 1250 - 1450 0 0 Fine aggregate | 760 - 900 1400 - 1700 0 Set retarding | 1-4 0-2 0 admixture Note: Type 1 Poriland Cement equivalent to ASTM or OPC 43 Gr as per IS 8112. The types of cementitious materials and aggregates will not be altered for the duration of the contract without prior approval No more than 20% of the cube compressive strength test results will be less than the Specified characteristic RCC strength as prescribed in the Project Specification. The coefficient of variation (CV)% for a medium level of control will be assumed in the design of the RCC mix, according to ICOLD Bulletin No. 126. 1.6.3 Requirements for RCC The mixture proportions used in the dam will be within the ranges specified in Table 1.6.2 and the mix design parameters will be within the values specified in Table 1.1 1.6.4 Allowable Placing Conditions 1.6.4.1 Weather If adverse weather such as heavy rain, severe cold, heavy snow, etc., occurs or is forecast to ‘occur during placement, an interruption in placing operations may be necessary. (2) Cold Weatnar RCC will not be placed when ambient air temperatures drop below 2°C, except that if the surface of the compacted RCC and the mix itself stays above 0°C, placement of the RCC will be allowed to continue. If the ambient air temperature drops to below RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 28)P ageL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Chel nactucture Io DAMS AND HYDRO eS EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&eK -1°C and the surface of any RCC less than 21 days old drops to below 2°C, the surface will be covered with heavy tarpaulins, blankets, insulation, or other acceptable temporary protection to maintain concrete temperature above 2°C until after the ambient air temperature rises above 5° (b) Placing During Rain RCC will not be placed during rainfall of more than 0.6mm in 12 minutes. During periods of lesser rainfall, placement of RCC will continue if the RCC surface can meet the minimum requirements of a saturated surface onto which RCC is placed free of ponds of water and clean. During periods of rain or when rain falls on the fresh RCC surface within 3 hours after placement, no heavy equipment or workers will be allowed on, or be in direct contact with, freshly compacted RCC untit the RCC has gained sufficient strength (no less than 3 hours after RCC placement) to prevent rutting, pumping, intermixing of rainwater with the RCC, or other damage to the RCC, Special precautions will be taken to prevent contamination of the bedding mixes or RCC by ponded water. After the RCC surface is able to allow the resumption of work by equipment and workers, the RCC surface will be cleaned of all loose material and water ponds, and if required will be washed to break up laitance and/or mud like coatings on the surface. The washing will not undercut any coarse size aggregate. Pickup of the wash debris will be accomplished with a truck mounted vacuum or other approved system. The washing action is critical in order to remove coatings formed during light rains that, if lett in place, would act as bond breakers between each lif. Sufficient pieces of equipment of adequate size will be provided so as not to slow the regular placement and compaction of RCC. ‘When rainfall is forecast, or imminent, the un-compacted placement area should be kept as small as practically possible and plastic sheeting should be stored close at hand so that it can be deployed to cover the uncompacted RCC without delay as ‘soon as rainfall exceeding the allowable rate is measured. (0) Hot Weather All necessary measures will be taken to ensure that the RCC temperature at point of placement does not exceed the maximum temperature as determined in the design and Thermal Analysis. This temperature will however be confirmed by thermat analysis. Typical measures that may be necessary to restrict the temperature of the RCC as finally "built-in" include: ()) cold water fog spray of aggregate stockpiles; (ii) chilled water fog spray of aggregate feeding conveyors to the plant (wet belt); (i) covering of conveyors; (v) chilled mixing water: (vi) the use of fiake ice in the RCC mix as partial replacement of the mixing water, (vi). RCC placement in the cooler seasons of the year, (vil) RCC placement during night-time: (%) RCC placement on cloudy days; and/or (%) shading from solar radiation. ‘Should placement be attempted during the warmer seasons of the year, it may be necessary fo apply a combination of the above measures to achieve the allowable placement temperature. RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 29P ayeL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy coat infastuctre IS DAMS AND HYDRO wy EDRC - HYDEL PROJECTS. RATLE HEP ~ 850 MW J&K 4.6.5 Placing RCC and GEVR 1.6.5.1. Layout of Placement Area& Layer Placement Method The dam will be constructed in continuous horizontal layers, using @ set retarder to target at least 80% hot joints and to minimize warm and cold interiayer joints, As placement of each layer progresses across the dam, the exposed edge will be kept “live” in the process of progressive placement. Whenever a cold joint at any edge of any layer does ‘occur, it willbe located at least 3m from the location of other cold joints that may have previously occurred in the same direction along previous layers. The cold joint will be prepared as specified under Section 1.7 of this specification prior to resumption of RCC placement, No cold joint will be allowed along the edge of a layer in the upstream-downstream direction for more than one third of the upstream-downstream dimension of the dam at that elevation The placement and compaction methods applied will ensure that the RCC is well compacted and well bonded between layers, that segregation is eliminated and that a seamless bond exists between the main RCC body and the RCC facing, 1.6.5.2 Depositing, Spreading and Re-Mixing The interval between mixing and final compaction of RCC will be no greater than 60 minutes. This time limit may be relaxed if the ambient temperature drops below 15°C, as long as it can demonstrate that complete RCC freshness can be maintained for a ionger period. The mix will be spread into layers that wil, after compaction, be 300mm thick. All RCC will be deposited and spread in @ manner that results in no segregation when compaction occurs. Initial deposition of RCC will be by end dump truck and the RCC will be deposited on previously placed and spread uncompacted fresh RCC. ‘A small dozer or front end loader will assist with deposition and spreading of materials as needed in confined areas, at the abutments and at other locations as approved. No RCC or ‘other concrete will be placed on a previous layer that has been found to be suspect and is being prepared for testing, ROC placement will be defined on a schematic drawing after the optimal procedures have been established during construction of the Full-Scale Trial. In general, however, the following provisions and procedures will apply to the placing of RCC: (a) _Ifrequired (cold joints) place 20mm layer of bedding mortar or 10 mm of grout (the choice of mortar or grout will be made following testing of the Full-Scale Trial, onto the receiving surface. No compaction of this layer is required, The receiving surface so prepared, will be large enough to accommodate the subsequent standard RCC placement operation, which will commence immediately after placing the bedding layer. () The subsequent load of standard RCC will then be dumped approximately 2.5 m behind the advancing face, dozed over the edge and evenly spread out in a horizontal layer of approximately 340mm un-compacted thickness, of of other approved thickness as determined during testing on the Full-Scale Trial. The objective of pushing the load over the advancing face Is to promote the remixing of the RCC and thereby to minimize segregation and the spreading equipment will be used in the most appropriate manner to achieve this objective (©) When segregation occurs during spreading, the segregated material will be redistributed over the RCC surface prior to compaction. When general segregation takes place through lack of mortar, the procedure described in (b) above will be repeated (d) If GEVR is to be applied, grout with @ w/c ratio of 0.55 (the exact wic ratio will be RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-04-2014 Rev A7 30P eeeL&T Construction ARQ CONSULTING ENGINEERS 4RQ) Heavy Civ Infrastructure (© DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP — 850 MW J&K determined during the Full Scale Trial) will be poured onto the surface of the previous RCC layer at a dosage of approximately 8 litreslin. m, immediately prior to the spreading of the new RCC layer. It is usual practice to retain the grout in discrete ponds formed with a windrow of un-compacted RCC, spread by hand approximately 600 mm from the applicable face. The grout dosage and the methods to be applied to ensure the correct dosage for GEVR will be demonstrated during the Full-Seale Trial 1.6.6 Compaction of RCC and GEVR 1.6.6.1 RCC After spreading, all surfaces of each layer of RCC will be compacted with a self-propelled vibratory compaction roller. The number of passes to be completed to achieve the target density will be determined during RCC mix trials and finally proved during construction ofthe Full-Scale Trial. ‘The target density will be a percentage of the theoretical-air-ree-density (TAFD) This density may vary from time to time as the mixture proportions (water content) and materials change throughout the placement. The density at each location will be recorded as the average of the density at three different depths at the same point (50 mm, 150 mm and 250 mm). Control of the compacted RCC will be such that the density of the compacted RCC, as measured by the nuclear densitometer. will conform to the following limits (a) The average of all the measurements in-place of the wet density of each layer will be higher than 98.0% of the TAF; and (b) The average density at a single location will not be less than 97% of the TAFD. (c) Aminimum of 6 tests per 500 m? of RCC will be performed. Should it not be possible to achieve adequate compaction with under 10 passes, the mix designs, compaction procedures, and compaction plant will be reviewed. After such a review and any subsequent changes, a test strip off the dam will be placed before resuming RCC placement on the dam. ‘A round trip over the same material will count as two passes. In general, a large width-selt-propelled vibratory roller will be used in open areas and small vibratory rollers will be Used adjacent to faces, the abutments, galleties and other concrete structures, etc. GEVR will be used in any areas that cannot be reached with the drum of a vibratory roller. Rollers will not be operated in the vibratory mode until they are moving. No edge of RCC will be compacted, ‘except where RCC is spread onto or into a bedding mix. A ribbon of bedding mix will be placed on the leading edge immediately when any non-compacted RCC leading edge becomes 60 minutes old. If fresh RCC is placed against the risbon of bedding mix within an additional 15 minutes, the old non-compacted RCC, the ribbon of bedding mix and the fresh RCC will be consolidated in the regular manner by vibratory roller. If fresh RCC is not pleced within the 15 ‘minute time period, the old non-compacted RCC, the bedding mix and interface will be removed and the exposed surface treated as a “warm” joint. Compaction of RCC will follow the procedure set out below: (a) During the two passes (i.e. one round trip), which is to consolidate the layer, no vibration will be used. The whole surface to be compacted at any one time is to be treated in this manner before the subsequent passes commence. (b) The first pass will be followed by subsequent passes using vibration until the specified compaction, as determined by tests, has been achieved. The number of passes will be established during the trials on the Full-Scale Trial. A total number of passes in the region of eight is envisaged (©) Compaction of any section of a layer is to commence immediately after the RATLE-SPC-01 Roller Compacted Concrete —Performance Specification 07-04-2014 Rev A7 31P aL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy cintimtactuchnre DAMS AND HYDRO wy EDRC - HYDEL PROJECTS. RATLE HEP — 850 MWJ&K spreading of that section has been achieved and will be continued to completion within 15 minutes of the RCC having been deposited in the working area, or a maximum of 60 minutes after mixing. These periods may be relaxed when ambient temperature is below 15° and if it can be demonstrated that the RCC. remains fresh for the applicable extended period. (2) The addition of water to the mix will not be allowed during any stage between the time of completion of mixing and the time of full compaction of the RCC. (@) IF optimum compaction density has not been achieved after eight passes, additional passes will be made until density is achieved, or until otherwise approved. 1.6.6.3 Other Concrotes The compaction of mass or structural concrete will be carried out in accordance with the appropriate requirements and sections of the Project Specification. 4.6.6.4 GEVR (Facing and other areas) GEVR will be used as facing concrete, and other areas as identified in the drawings. The procedure of placing and consolidating the GEVR will be as follows: (a) Make +0.5m wide x 10mm thick groove in already placed concrete along the faces at both upstream and downstream side with the help of plate vibrator. (b) Fill-up this groove with neat cement grout with water-cement ratio of 0.55 to 0.66. The consumption of grout will be 8 litres/m against formwork and 15 litres/m against Tock surface. (©) Spread next lft of RCC on this layer and compact with immersion vibrators til the grout paste comes at the top. (d) Compact RCC/GEVR concrete interface. ‘noe the RCC has been spread to cover the grout, the GEVR will immediately be compacted using immersion vibrators until the concrete is fully consolidated, air bubbles are no longer present and grout is uniformly distributed on the top of the layer surface. Subsequently the interface between the RCC and GEVR will be compacted using a small a self-propelled smooth, twin-crum vibratory roller. Areas not accessible to the vibratory roller will be compacted with 2 reversible plate compactor. The GEVR will be fully compacted within 30 minutes of grout mixing, unless a set retarder is used, The methods to be applied to ensure the effective compaction of the GEVR will be demonstrated during the Full-Scale Trial 4.6.7 Full-Scale Trial At least 120 days before commencing with the RCC placement operation for the dam, at least one Full-Scale Trial will be conducted. The RCC Full-Scale Trial will be at least 60m x 10m x 8 layers of RCC with RCC being placed in 300mm compacted thick lis and will serve to prove the RCC mix, all plant, placement capabilities, and the layer treatment processes and the various proposed placement and compaction methods. The Full-Scale Trial wil be constructed using the same techniques, materials and attention to detail as specified for the main dam. This includes the same foundation clean-up and protection, the same lift joint treatment and protection, the ‘same construction of the upstream face, the same details for installation of waterstops and Contraction joints, etc. The Full-Scale Trial will be used to evaluate and optimise various issues related to the RCC, including: RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 32[PageL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Cha inastuctre Io DAMS AND HYDRO a EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MWJ&K (a) Allbatching, mixing. conveyance, piacernent and compaction piant and operators; {b) The proposed RCC mixes under construction conditions; (©). Variations of the RCC mix, GEVR and bedding mixes; (0) Joint / crack inducing and directing systems; {e) The requirements for inter-layer and lift surface treatment, etc; (f)__ Joint sealing systems; {g) Various conveyance, placement and compaction methods and procedures; (h) Temperature measurement equipment and procedures: (i) The effectiveness of the cooling methods to be applied 4) Typical mix to "built-in" temperature variations; {k)_Allinstrumentation to be installed, and {(l)__ The quality assurance and control systems to be implemented. The placement of the Full-Scale Trial will continue unti the design assumptions are satisfied and that RCC is satisfactorily placed in accordance with these specifications for 3-consecutive lifts and that effective methods and procedures have been established and that installations are consistently correct. The first of the 3-consecutive RCC lifts for test section will be placed on rock for a 300mm minimum thick RCC Not earlier than 10 weeks after completion of the Full-Scale Trial, a driling programme will be initiated to recover a sufficient number of 150mm cores to enable the qualitative and quantitative evaluation of all aspects tested. Notice will be given 30 days before the proposed date of construction, detailing the intended objectives, method statements, layout and programme. On completion of the core drilling and testing programme, a comprehensive report will be prepared detailing all findings during construction and testing. This report will contain detailed photographs and be accompanied by a video record of the Full-Scale Trial construction. Atleast two weeks’ notice before the start of the Full Scale Trial will be given so that all the staff may make the necessary arrangement to be present, As experience is gained with RCC, or circumstances change, it may be necessary to undertake further trials to test different methods or mixes ‘Only operators and supervisors who have worked on, and been approved at, the Full Scale Trial will be allowad to work on the dam during the initial placement. 1.8.8 Treatment of RCC Surfaces. 1.6.8.1 General Itis the objective to place the entire RCC mass in such a manner as to act as a solid monolith, minimising as far as possible the occurrence of horizontal discontinuities between successive placement layers and its. ‘All joint surfaces under all ambient conditions will be kept clean, uncontaminated, free from ponded water, and continuously moist until placement of the subsequent RCC or other concrete. ‘The requirements for treatment of an RCC surface in preparation for the receipt of a subsequent placement layer of RCC will be dependent on the surface maturity at the time of placement of the new layer. In general terms, three definitions of maturity will be defined: (a) Allayer surface will be considered to be a “hot" joint before initial set of the RCC of the compacted layer beneath has occurred as measured according to IS 4031(Part §):1988 () Alayer surface will be considered to be a "warm" joint for the duration of the period between initial set of the RCC and the time at which the joint is considered to be "cold"; and (©) Alayer surface will be considered to be a “cold!” joint when itis judged that ‘one of the following conditions are met: RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-04-2014 Rev A7 BPageL&T Construction ARQ CONSULTING ENGINEERS _4Q) Heavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K i. Little or no penetration of the aggregate from the new layer into the previously compacted layer will occur, or ii, The final set of the RCC of the compacted layer beneath has occurred as measured according to IS 4031(Part §):1988, or li, A modified maturity factor of 1500°C.hour has been exceeded. The modified maturity factor is the product of the exposure time (or time between the placement of the successive layers of RCC) in hours and the average ambient temperature in °C at the placement, modified by adding 12°C. Asset retarder admixture will be used to significantly extend the time of initial set and accordingly the period during which a layer joint remains “hot’. The respective maturation characteristics of the RCC and the associated requirements for bonding fresh RCC to old will be analysed during the Full-Scale Trial construction, In principle, the treatment measures necessary for the three categories of layer surface maturity are defined below. 1.6.8.2 Treatment for "Hot" Layer Joints While the surface of an RCC layer remains “hot”, the following treatment will be applied in preparation for the subsequent layer: (a) Maintain 100 % of the lift surface continuously moist, without pooling water, () Protect the surface from damage and contamination, such as caused by drying or remixing with water due to the existence of uneven surfaces created by tracking of the vehicles combined with curing water or rainfall, ete., and; (©) Remove all loose contaminants or deteriorated RCC from the surface. The above procedures wil be followed with the objective of minimising surface preparation work land preventing any delay of the placement of successive layers. 1.6.8.3 Treatment for "Warm" ayer Joints While the RCC surface can be classified as "warm", in addition to the measures applicable for a “hot" layer surface, the following treatment and preparation measures will be applied (@) The surface will be scarified wit a roller brush with steel and/or nylon tines to produce a rough surface, but without leaving the coarse aggregate exposed. The different types and different hardness of tines will be used for different exposure times and the precise time ranges and type of materials will be defined during the Full-Scale Tria (©) After treatment, the joints will be cleaned as for a hot joint. The decision whether to use a grout as bedding mix, a bedding mortar ar no bedding mix to cover the warm joint just ahead of the spreading of RCC of the next layer, will be taken on the basis of the results of the Full-Scale Trial trials. 1.6.8.4 Treatment for "Cold" Layer Joints All RCC lift joints that are no longer *hot’, or ‘warm’ will be treated as "cold" joints. In addition, any RCC surface that has been allowed to dry, or has been damaged or contaminated to the extent that the contaminants cannot be removed using low pressure water jets, will be treated as, a ‘cold” joint. “Cold” layer joints will be prepared for the placement of the subsequent RCC layer in the following manner (2) maintain 100 % of the lift surface continuously moist, without pooling water: (o) remove the surface mortar, laitance and contaminants by high pressure washing up to 400 bars and until the surface has achieved the exposed RATLE-SPC-01 Roller Compacted Concrete ~Performance Spe Rev A7 07-04-2014 34)? a gL&T Construction ARQ CONSULTING ENGINEERS — 4RQ Heavy Civil infrastructure IC DAMS AND KYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K aggregate condition. If the treatment is made while the surface is still green, medium pressure washing might be enough to achieve the same surface finish (c} clean the surface, to remove all loose material, dust and dirt using an approved method, such as labour or high pressure water and air washing and vaouum debris removal. This green-cutting procedure wil expose but not undercut any coarse aggregate; and () on resumption of RCC placement, ensure that the surface is free from debris and contaminants and cover the specified surface area of the "cold" joint with a thin paint of grout or a 20mm thick layer of bedding mortar or no bedding mix, The decision to use a bedding mix (grout or mortar) or not will be made following testing of the Full-Scale Trial The bedding mix, if used, will not be exposed for a period of longer than 15 minutes before being covered by the RCC of the subsequent placement layer. ‘Any treatment for horizontal cold joints, whether due to unnecessary or avoidable contamination, will be completed in such a manner as not to delay, or slow down the overall RCC piacing schedule, At all times throughout the above procedures, the old RCC surface will be maintained in a damp condition until covered by the next layer. The use of high pressure water will be delayed until the concrete is sufficiently hard so that only the surface mortar coating is removed and there is no undercutting of coarse aggregate particles. 1.6.8.4 Other Joints All joint surfaces that have been determined as damaged such that more extensive clean-up is required, will be classified as @ ‘damaged’ joint and will be prepared in the same fashion as a Cold joint, or other applicable method. If material deleterious to the bonding of layers is spilled on joint surfaces (Including but not limited to oil, motor fuel, curing compound and paint), the contaminated RCC wil be removed down to the next layer and replaced with fresh RCC. The replacement RCC will be thoroughly compacted prior to the placement of the next RCC layer. 1.6.8.5 Treatment for Vertical Cold Joints. Cold vertical joints at the leading edge of an RCC placement will be treated in accordance with this specification and/or the project drawings. When it becomes apparent that placement of RCC will be terminated before the entire lift has been completed across the full placement surface area, the following actions will be taken (a) After full compaction, the leading edge of the RCC placement will be trimmed to a slope of 1V : 4H and the bottom 50 mm will be trimmed vertically. All waste material will be removed from the dam. (b) Depending on the modified maturity factor at the time placement resumes, the appropriate joint preparation procedures specified in 1.6.8.1 to 1.6.8.4 will be applied. (c) Immediately prior to the resumption of RCC placement, a cement grout will be painted on to the cutirimmed faces. Placement interruptions necessitating vertical joints in the RCC layers may ocour when a breakdown of equipment takes place or when a shutdown is necessary due to climatic factors. A vertical joint not treated in the manner described above will have any non-consolidated RCC removed, RATLE-SPC-01 Roller Compacted Concrete —Performance Specification 07-04-2014 Rev A7 35h ueL&T Construction ARQ CONSULTING ENGINEERS —_4RQ) Heavy Civ infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE-SPC-01 Roller Compacted Conerete ~Performance Specification 07-04-2014 Rev AT RATLE HEP — 850 MW J&K. 1.6.9 Vertical Facing Systems for RCC Construction 1.6.9.1 General Vertical facing systems for RCC include all methods applied to form an external face to the body of RCC that are either vertical, or inclined at an angle steeper than 45°. ‘The vertical face forming systems for the project will be as shown on the detailed drawings. The facing systems proposed will meet the requirements of this specification All vertical facings covered by this specification will use purpose-designed temporary formwork which will be designed by the Sub-contractor and the form anchor capability of the system used will be demonstrated by approved means before commencing work. Formwork will have sufficient strength to withstand the pressure resulting from placement and vibration of the concrete and will have sufficient rigidity to maintain the specified tolerances. Extreme care will be taken to prevent the occurrence of any permanent openwork, honeycombing or voids at the face, the bedding mix, or GEVR/RCC interface. Allowable systems for forming vertical faces to the RCC include, GEVR. 1.6.10 Preparation of Receiving Surfaces (Other than RCC) 1.6.10.1 Foundation Preparation (@) General Prior to placing any concrete, (including any RCC, dental concrete, levelling concrete, bedding mix, or ather conventional concrete placed adjacent to and at the same time as the RCC) all surfaces will be cleaned and free of loose, un-keyed, and deteriorated rock, all mud and silt accumulations, vegetation, loose fragmented rock pieces, laitance, puddles or ponds of free surface water, mortar coatings and other detrimental materials. High pressure water jetting, followed by an approved clean up procedure, will be applied on all concrete surfaces for the removal of laitance, mortar coatings, stains, or other difficult-to-remove surface contaminants, (b) High Pressure Washing Its anticipated that removal of loose materials in the foundation and on receiving surfaces can be achieved using high pressure water washing and/or air water jetting 1.6.10.2 Preparation of Receiving Surfaces (@) The receiving surface for fresh RCC layers will be moist atthe time of receiving the RCC. Care will however be exercised to ensure that there is no free water on any receiving surface at the time of RCC placement, The receiving surfaces wil, in addition, be clean and free from dust, loose aggregate, organic material, oil or any other contaminant. {b) Hardened concrete surfaces on which fresh concrete is to be placed will be prepared so that the mortar on the surface of the receiving concrete is removed and aggregate exposed. This may be achieved before final set of the concrete by green cutting the receiving surfaces, ie. by washing the surface with a medium pressure water jet until aggregate is exposed. Alternatively, when the concrete has achieved final set and hardened it wil be washed by high pressure water jet or sand blasted in order to expose the aggregate, 36P aveL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy cha ntestuctre 16 DAMS AND HYDRO wr EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K 1.6.11 Curing and Protection 1.6.11.1General All fnished surfaces will be kept continuously moist and at @ temperature above 2°C for a period of at least 28 days after the final set of the concrete has taken place, or after formwork has been strigped, or until covered by the subsequent lif, Alternatively, finished external surfaces may be treated with an approved curing agent 1.6.11.2RCC Surfaces ‘All compacted RCC and GEVR surfaces will be kept continuously moist until covered by the next layer of RCC, or for @ period of 28 days, whichever is the shorter. Care will be exercised during ‘continuous RCC placement to ensure that mortar on the surface Is not washed out by an excess application of water. On no account will the use of curing compounds on surfaces that are to receive RCC be allowed. 1,6.11.3 Cold Weather and Special Insulation Protection For 120 days after placing, the concrete will not be subjected to a temperature differential exceeding 18°C. The installation of conerete thermometers, or thermocouples will be made at locations as indicated in the detailed drawings. In instances where particular circumstances are likely to require insulation protection in order to observe the above stated requirements, climate specific measures and requirements will be arranged. 1.6.11.4 Hot Weather Protection When necessary or as directed, provisions for windbreaks, shading, fog spraying, ponding or ‘wet covering with a light coloured material will be made in advance of placement, and such protective measures will be taken as quickly as concrete hardening and finishing operations will allow. 1.7 INDUCED CONTRACTION JOINTS 4.74 General ‘Two types of joints to allow for long-term thermal contraction may be Induced in RCC. Crack Inducers are used in the surface zone (GEVR) to ensure the correct alignment of the crack with waterstops, drains and chamfers on the dam face. Crack Directors are used to establish the alignment of contraction cracks through the body of the RCC. Suitable plant, equipment and facilities will be provided for the manufacture, alignment, installation, joining, testing, protection and repair ofthe joint inducing and directing systems. The crack inducer and director systems will be proved during trials on the Full-Scale Trial A well designed support system for waterstops, crack inducers and drain formers at the faces where installation of these systems is indicated on the drawings will be provided. The system will be applied to ensure the accurate fixing and alignment of the inducing system and waterstops and will be capable of keeping all items completely taut and rigid in their correct locations above the RCC layer in such a manner that they will not be disturbed to any extent during the placement or compaction of the surrounding concrete. 4.7.2 Crack Inducers in GE-RCCIGEVRIIVRCC Joints or cracks in the RCC facing will be placed at pre-determined positions as shown in the drawings. They will be induced by installing de-bonding plates into the GEVR concrete at placement, De-bonding plate crack inducers will comprise 2mm thick HDPE sheet, or other approved materials. RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 smP ageL&T Construction ARQ CONSULTING ENGINEERS —_4RQ Heavy Ciui infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K The crack inducing system will be manufactured in suitable material, in accordance with the details indicated on the drawings and installed in such a manner that ensures that the inducing plates are firmly in contact with the waterstons and the drain former and aligned such that the plate is exactly on the line of the centre bulb of the waterstop and on the alignment of the chamfer on the dam face (if one is present), to an accuracy of + 3mm, The accurate installation of this system will be rigorously enforced and the quality control system will allow the certainty that the crack inducer system is accurately and correctly installed, without any incidence of failure. A suitably robust framework will be manufactured and used to hold the waterstop, the drain-hole former and the jointinducer plates firmly in their vertical position during the placement and compaction of GEVR and RCC around and in the vicinity of the induced joint. Should the alignment of the components within an installed crack inducer system, or the alignment of the crack inducer system itself ever be found to fall outside the indicated tolerances, corrective action should be immediately taken, 4.7.3. Crack Directors Contraction joints through the body of the RCC will be formed at locations and on alignments indicated on the drawings. They will be induced by inserting a debonding galvanized or stainless steel plate, or plastic, or other approved sheet into the green RCC after compaction has been completed (including density test). The sheets will be 0.6 to 2mm thick, 250mm high {in the case of a 300mm layer) and up to 2000mm in length, unless otherwise indicated on the drawings, or other approved. The gap between successive individual sheets placed along the length of the induced jeint will not exceed 50mm. Crack directors will be in accordance with the details indicated on the drawings. The methods and systems for this installation will be optimised during construction of the Full-Scale Trial 1.7.4 Waterstops \Waterstops will be of approved manufacture in natural rubber, or flexible PVC to the pattern specified or shown on the drawings. ‘The waterstops will have integral continuous side fins with eyelets that are punched in, Prior to the waterstop being used in the works, a certificate of compliance will be obtained, indicating that the product to be used has been tested and conforms to the above-mentioned requirements. The test certificate will not be more than 3 months old. The PVC waterstop will be easily joined on site by using a temperature controlled electric heater blade, in accordance with the manufacturer's instructions. The resulting joint will have a minimum strength of 14 MPa in tension at 23°C and will be impervious. The waterstop will also be capable of being easily joined on site to form right angled Tee junctions. Waterstops will be securely and accurately located in positions so as not to displace or deform during construction. Special precautions will be taken for the placement and consolidation of concrete around waterstops to ensure fully effective contact and void free concrete Waterstops forming a seal with the foundation rock, will be anchored into pre-formed pockets excavated into competent rock. The pockets will have dimensions of 500 x 70 x 760mm deep, with sides inclined by no more than 20° to the vertical. The pockets will be thoroughly cleaned and backfilled by tremie with a non-shrink cementitious grout immediately before the waterstop is inserted, RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev AT 38)PayeL&T Construction ARQ CONSULTING ENGINEERS ARQ Heowy Cwhinrsstuctra Io DAMS AND HYDRO Sy EDRC - HYDEL PROJECTS : RATLE HEP ~ 850 MW J&K 1.8 TOLERANCES 1.8.4 General ‘The provisions and requirements of the Project Specification in relation to tolerances will generally be applied to RCC construction, except as modified below. (2) The thickness of compacted layers of RCC willbe within 50mm of that stipulated: (©) The elevation of the surfaces of RCC layers upon which subsequent concrete is placed will not vary by more than 75mm from the design elevation, except that the elevation of the top three lifts of the dam will be within 50mm of that shown on the drawings, () The alignment of all waterstops will not deviate more than #50 mm from the line specified on the drawings; (2) The alignment of the induced contraction joints, crack inducers and crack directors will not deviate more than #50 mm from the line specified on the drawings; and; (e) The alignment of the components within a crack inducer system should not deviate more than #3 mm from the lines specified on the drawings. 4.8 QUALITY ASSURANCE, CONTROL, TESTING AND RECORDS 1.9.41 General RCC Quality Assurance and Control will focus on the implementation of appropriate measures, procedures, systems and checks with the objective of eliminating the occurrence of strength and ‘other test failures. As a consequence of the difficulties associated with recreating representative construction compaction conditions in a laboratory cube, RCC cube crushing tests will be viewed as indicative and primarily of use as a part of the quality assurance and confirmation programme. The process of sampling and testing RCC cores reflects the real characteristics of the material built into the dam and core tests are accordingly seen as providing the primary ‘measure of the quality control achieved in the RCC construction, as well as providing a definitive record of the important properties of the concrete in the dam. Despite this fact, sampling and testing of RCC cubes will not be neglected Al cube test results will be statistically assessed, 4.9.1.4 Quality Assurance and Control Effective programmes for quality assurance and control will be established and maintained for al RCC construction and these will be the means by which compliance with the contract requirements is assured and control records are maintained. The Quality Assurance Programme of the Sub-contractor will serve to ensure that all controls are effective and are effectively enforced and observed. The programme will further ensure that problems and/or quality Variations are identified and rectified before these might affect the works. The Quality Assurance Programme will include the following aspects: monitoring aggregate manufacture and gradations, moisture, batching requirements and mix proportions at the batch plant, ensuring adequate materials availability, that embedded items are properly installed, that insulation is installed, that joint treatment is correctly carried out and that all other tests and inspections required’ by this specification are correctly completed. All Quality Contro! procedures. and programs will be in place before the main construction activities are initiated and will be maintained as a "live" document for the duration of construction. The specified strength and material parameters for testing of compacted samples and drilled cores will be established on the basis of the results derived through trials on the Full-Scale Trial construction. These figures will be incorporated into the final RCC Project Specification along with a related series of acceptance criteria for placed RCC. The final acceptance procedure will RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 39[PaveL&T Construction ARQ CONSULTING ENGINEERS 4RQ) Heavy Civi Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K take into account the reliability and variability of RCC sample testing, as compared to typical equivalent core results, and will develop secondary checks to estimate the relevance of test oriteria failures. Qualified personnel, equipment and supplies that are necessary to ensure the effective testing and fulfilment of the quality control programme will be provided by the Sub-contractor. No concrete placement or aggregate production will be allowed until the approval of the quality control programme has been granted. The tests described in 1.9.2 will be performed and, based upon the results of these inspections and tests, the action required in 9.3 will be taken. Reports, will be submitted a8 required in 1.9.3.6, The required corrective measures listed in the sub-clauses under 1.9.3 refer to the testing item with the same sub-clause reference under 19.2, Al quality control and assurance personnel will be available on a continuous basis 15 days prior to the start of placement of the Full-Scale Trial until 18 days after completion of all RCC and conorete placement for the main dam. 1.9.1.2 RCC Core Programme The records of greatest value that define the actual quality achieved in the dam construction, are those derived as part of the RCC core recovery and testing programme. Seventy days after first RCC placement, a core drilling programme willbe initiated (so that cores can be tested at an age of 91 days) and one 150mm diameter diamond core drills will be active from the downstream face on virtually a continuous basis until 3 months after completion of RCC placement and ariling will folow a pre-defined programme. RCC cores will be stored in a water ‘curing bath at a constant temperature of between 22°C and 26°C until tested. Cores will generally be drilled from a platform attached to the steps of the downstream face of the dam, except during extended breaks in RCC placement when dls will be set up on the RCC surface. Cores will generally be drilled vertically, but a number of cores will be drilled at specific angles or horizontally intercepting the horizontal lift joints. For every five vertical cores. there will be one inclined or horizontal core. Accurate records and logs of the recovered cores will be maintained, including position of extraction, angle of drilling and depth of each section of the core. Only drilled RCC older than 70 days will be taken for testing. Cores will be tested for compressive strength at ages of 90, 180 and 965 days. Furthermore, adequate tests to determine representative shear strength, tensile strength, permeability, density and Poisson's ratio in the parent material and across layer and lft joints, will be undertaken In total at least 40 cores will be extracted from the dam for inspection and testing. The average length of these cores will be 25m. The total length of these cores will be 1000m. The location of each core will provide a representative view of the in-situ properties of the RCC placed in the dam. Additional cores may be taken to investigate specific areas if needed. In addition, a comprehensive testing programme will be previously undertaken on cores recovered from the Full-Scale Trial and this will form the basis for finalisation of a number of aspects, including the mix designs, the bedding mix type, facing systems, etc. The recovery and testing of cores from the Full-Scale Trial will ocour in parallel with a programme of cube manufacture and testing, a8 well as in situ density measurements, etc, On completion of this work, a coordinated system of quality control will be possible, whereby early test results can be related to final in-situ RCC material properties. The related quality assurance and control programme will be approved, for ‘execution during the construction of the main dam. The holes created during the core drilling programme on the dam or alternatively additional holes of 75mm in diameter will be used to test the permeability of the RCC. Permeability will be tested using packers in accordance with the procedures set out in the Drilling and Grouting ‘Specification. Lugeon values will be recorded and in the case of zones that are described on the drawings as ‘impermeable’. Grouting will be carried out where permeabilities in excess of 3 RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-04-2014 Rev A7 40)P aseL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Cia intasituctre IC DAMS AND HYDRO we EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K Lugeons are evident. If permeabilities consistently exceeding 3 Lugeons are recorded in the “impermeable” zone RCC, a comprehensive grouting programme may be applied 1.9.2 _ Inspection Details and Frequency of Testing 1.9.2.1 Aggregate Properties At least once during each shift that concrete is placed, or that aggregates are produced, gradations will be checked for each aggregate size, including calculation of the fineness Modulus of the fine aggregate. The locations from which samples are taken will be selected with a View to giving an accurate indication of gradations of materials as they enter the mixer. In addition the following tests will be determined according to the respective Standards and with a frequency of at least 1 test week during aggregate production and RCC placement (a) specific gravity and absorption of all aggregate sizes, (b) elongation and flakiness indices of coarse aggregates (BS 8S812 Part 105), (c) loss by washing (particles <0,075mm) of the coarse aggregate sizes, (@) compacted (rod) void ratio of the fine aggregate (or combination of fine aggregate sizes in the proportions that are used in the RCC mix), and (©) ifrequirea, plasticity index of the sands (sample passing 0,420mim sieve) and determination of deleterious clay content of the fines in aggregate (methylene blue) 1.9.2.2 Aggregate Moisture Determination ‘During each day of placement for each aggregate size, the moisture content will be determined at intervals not exceeding 4 hours, The location from which the sample is selected will be determined to ensure accurate representation of the materials entering the mixer. 1.9.2.3 Organic Impurities When a problem exists in connection with the cleanliness of aggregate, tests will be made. Testing for impurities will be completed as a matter of course for every 600 tonnes of aggregate produced 1.9.2.8 RCC Plant Control When the concrete plant is operating, @ daily report will be prepared indicating the type and source of cement and pozzolan used during the day, aggregate size groups used, required mix proportions per m* for each mix design used, the amount of water as free moisture in each size of aggregate, and the aggregate and water weights per m° for each mix design of concrete made during piant operation {n addition to the standard control and certificates issued by the cement supplisr, samples of the ‘cementitious materials will be taken from the plant silos with a frequency of 1sampie/10000 m° of RCC and the standard tests for cement and Fly ash will be checked ‘A sample will be taken from the water tank feeding the RCC plant every week during and RCC. placement and the parameters required for mixing water for concrete will be checked ‘Admixtures used in the RCC mix will also be checked on a weekly basis during RCC placement and in particular the density of the retarder admixture. The uniformity of the admixture is checked as part of the standard testing procedure of the RCC (setting time and strength). In addition the effect in both parameters of an overdosage of admixture by 60% and 100% will be checked and the results compared with those investigated during the mix design stage. 1.9.2.6 Scales for Weigh Batching The scales will be checked and calibrated by a recognised authority across the full range of operation and a certificate of calibration will be issued. Calibration will occur before start-up of RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 4UPaseL&T Construction ARQ CONSULTING ENGINEERS ARQ, Heavy Civil Infrastructure IC DAMS AND HYDRO EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW I&K concrete operations and at quarterly intervals during operation thereafter. The accuracy of each batching davice will be routinely checked during a weighing operation by noting and recording the required weight and the weight actually batched. Rechecks of the scales will be made at least every7 calendar days and whenever variations in the properties of the RCC mix are apparent 1 7 Testing RCC (2) General Fresh concrete will be sampled and tested for compliance with the specifications and for additional information as required. Samples for testing will be taken at the placing location at the time of placement, but may also be taken at the batch plant. (6) Mixer Performance ‘A complete mixer performance test of three diferent batches of concrete will be made on each mixer prior to the start of concrete placing. Whenever mixer adjustments are necessary as @ consequence of specification non-compliance, the mixer will be re-tested after adjustment. Performance tests will be completed routinely on each mixer at least once every three months. (0) Temperature: RCC temperatures (for each mix placed) will be determined every hour on the hour during the placing of RCC by means of a digital type immersion thermometer. RCC temperatures will be measured at the mixer, when heaped for spreading and in the spread state immediately prior to compaction, The temperature of a heap of discharged RCC at the site of placing will be measured at a penetration depth of not less than 300 mm from the surface of the heap. ‘At the same time as the placement temperature is recorded, the ambient air temperature will also be recorded by means of the mercury thermometer. The reading will be taken in the shade as close as possible to the position of the RCC. placement. This reading will also be used to determine the modified maturity factor of the lift joint Additional tests will be made when rapid set time or workability loss is reported, or when cold weather problems occur. The following information will be recoded: () The temperatures of the RCC at the mixer, in the heap before spreading and in the spread layer, (ii) The ambient air temperature; (il) The time of day (hour); and (iv) The position of the RCC in the works, ie, the reference level of the RCC layer and the block number of the structure (where applicable) as shown on the drawings. The readings will be taken by a suitably trained person. (9) Moisture Content ‘At least once during each 4 hours of production placement at the batch plant, @ RCC sample will be micro-dried for moisture content. At least once every 2 hours at the placement site (immediately after compaction) the moisture content will be determined on the RCC mix using a nuclear gauge in the direct transmission RATLE-SPG-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 42)P «eeL&T Construction ARQ CONSULTING ENGINEERS RQ Heavy Chul Intasiructre IC DAMS AND HYDRO we EDRC - HYDEL PROJECTS RATLE HEP~ 850 MW J&K mode. The probe will be driven to a depth of 250mm for each reading. The gauge will be calibrated against oven-dry samples of each mix design used. After consistent moisture control is achieved, the rate of testing may be decreased to ‘one test per 8 hours at the plant and one test per 4 hours at the placement. At least three tests will be made in different areas of each layer of RCC placed {@) Preparation for Concrete Placement Foundations, lft surfaces, construction joints, formwork, and embedded items will be inspected in sufficient time prior to each concrete placement in order to certify that the area is ready to receive concrete. Formwork will be checked closely for condition, support, alignment, and dimensions. The results of inspections will be reported in writing as @ part of the quality control reports. The placing foreman will supervise all placing operations, will determine that the correct mix design of concrete is placed in each location and will be responsible for ensuring that the measuring and recording concrete temperatures, ambient air temperature, ‘weather conditions, time of placement, volume placed, and method of placement is accomplished. The placing foreman will not permit placing to begin until he has verified that an adequate number of vibratory rollers and spreading equipment of the correct size, in working order, and with competent operators is available. He will further ensure that all required joint treatments have been effectively accomplished. (f) Dumping and Spreading ‘The placing foreman, or other designated representative, will continually observe ‘and monitor dumping and spreading operations to ensure that operations are appropriate to minimise segregation and to avoid excessive spreading after dumping, Each layer of RCC will be routinely checked in its spread un-compacted condition for evenness and correct thickness that will result in a smooth, even, compacted layer within the thickness tolerances specified and having an average thickness as required. A laser will be used in conjunction with hand-carrled vertical rods to determine the elevation (and subsequently the thickness) of each layer. The taser will be of the type that emits a rotating or constant light beam in a fixed plane. (@) Compaction Equipment Before any compactor is used in RCC construction, it will be checked for correct dimensions, weight, and vibratory capacity. At least once per 12 shifts of use, a spot recheck of frequency will be made. At least once per placement shift for the first 5 days of operation by any new operator, performance will be spot checked for the correct number of passes, correct spread, coverage of the area being rolled, and good rolling practice. Thereafter spot checks will be made on each ‘operator at least weekly. (h) RCC Consistency and fresh density (VeBe density) Consistency of RCC will be measured using the VeBe apparatus as described in BS 1881 (Part 104). The procedure for the test will be as follows: (i) The mass (P) will be located centrally above the diso such that the moving assembly comprising rod, disc and surcharge mass will weigh 12.5kg “100 4 The weight of the surcharge alone is 10 kg The internal surfaces of the container will be thoroughly clean and free from superfluous moisture and any set concrete before commencing the test, (i) The apparatus will be placed on a rigid surface free from external vibration RATLE-SPC-04 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 43P ageL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Ci infastuctre IC DAMS AND HYDRO wy EDRC - HYDEL PROJECTS RATLE-SPC-01 Rev A7 RATLE HEP 850 MW J&K and the surface of the table will be level, (iii) The container will be firmly secured to the table by means of the two wing nuts, (iv) The container will be filed with the concrete in the manner of a loose bulk. density test for aggregate, (v) The top surface of the concrete will be struck off level with a trowel or slump tamping rod so that the container is exactly filed, (vi) The transparent disc, which will have a surcharge of 10 kg, will be swung into position over the concrete, (vii) Vibration will be started immediately and the stop-watch started simultaneously, (vill) The remoulding of the concrete in the container will be observed through the ‘transparent disc. At the moment when all the conerete has been fully ‘compacted the stop-watch will be stopped and the vibration simultaneously ‘switched off. The moment of full compaction will be taken as the moment when the whole surface of the transparent disc is covered with concrete and the paste completely fils the ring between the disk and the mould (ix) The following information will be included in the report = Date of test, ~ Identification of sample i.e. point of sampling and approximate location when placed in terms of chainage and offset, - Loaded VeBe time (in seconds), and + Time of concrete mixing and time of the test. ‘An additional test of fresh RCC density (VeBe density) may follow using the same sample, The procedure is as follows: (i) Continue vibration so that the total vibration time is two minutes, (ii) Clean off the transparent disc so that all the ingredients of the concrete are in the container, (iil) Weigh the container and concrete, (iv) Fill the container, still containing conerete, with water until itis ‘completely full, (v) Weigh the container, concrete and water, (vi) Calculate the fresh compacted density by: Wo = We density = T= (Wy = We) 103 (kaim3) volume of container (litres) weight of container (kg) weight of container and concrete (kg) weight of container, concrete and water (ka) Roller Compacted Concrete Performance Specification 07-04-2018 44P axeL&T Construction ARQ CONSULTING ENGINEERS 4RQ) Heavy Cinl Infrastructure IC DAMS ANDEADRO: EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K () Concrete Specimens for Compressive and Tensile Strength Tests RCC will be sampled at position of placement and cubes and cylinders will be manufactured, cured and tested for compressive strength and tensile test, respectively. The specimens will be manufactured using a vibrating table. Each set of cubes will comprise 14specimens, unless otherwise indicated, with 2 cubes each tested at 7, 28, 56, 90, 180,385 and 1000 days in compression. For every 5 sets of cubes made, an additional set of 12 cylinders 150mm diameter will be manufactured using the same procedure with 3 cylinders each tested at 28, 90. 180 and 365 days in direct tension. These series might be different in the case of the Full-Scale Trial and in the process of establishing control for the main dam construction, Test specimens will be compacted to the same density as applicable for the wet dansity of the compacted RCC on the dam close to the point of sampling. At least 98% of the cubes will indicate densities within a variation of 50kg/m® of the measured wet density of the RCC close to the point of sampling All cubes and cylinders will be clearly marked with adequate information to allow precise identification, accurate tracing and full correlation and evaluation of the results at any stage The following regularity of cube sampling will apply: (2) Full-Scale Trial A minimum of one get of 160 mm cubes will be made for every helf layer (approximately 90m") of RCC mixed. A minimum of one set of 150mm cylinders will be made per layer of RCC placed (©) During Initial RCC Placement ‘A minimum of one set of cubes of 150 mm dimension will be manufactured ‘every shift during RCC placement and/or every 1,000 m° placed, regardless of shift. The cubes will be tested in compression at the ages specified above, In addition, one set of 150 mm cylinder will be made and tested as specified above for every 5,000 m° of RCC placed. This procedure will be maintained until the adequate evidence indicates that the interval can be relaxed (0) During RCC Placement Once an Adequate Level of Control has been Achieved A total of one set of cubes of 150mm dimension will be manufactured using RCC sampled from 3 separate batches at intervals evenly spread throughout each day of placement. For every 5 sets of cubes sampled, one set of cylinders will be manufactured from the representative daily samples and tested for tensile strength at the ages specified above. @ Density (@) Quality control density tests will be used to determine whether the optimum ‘compaction density has been achieved and to determine when additional RCC compaetion or other actions are necessary. Density readings at different locations and depths will be made during compaction as per the specification. Density readings will be made on @ regular basis after compaction has been fully completed, Readings will be scheduled so as not to disrupt or delay any of the other ongoing RCC operations, RATLE-SPC-01 Roller Compacted Concrete -Performance Specification 07-04-2014 Rev A7 45P ageL&T Construction ARQ CONSULTING ENGINEERS ARQ Hayy Ceiiestuchre lo DAMS AND HYDRO wy EDRC - HYDEL PROJECTS RATLE HEP ~ 850 MW J&K (b) Compacted RCC having an in-place wet density less than 96 percent of its Laboratory density will be rejected. Such rejected material will be re-rolled to within 99 percent of its Laboratory density if compaction can be achieved within 30 minutes after spreading. If this cannot be achieved, the rejected RCC will be removed. Frequency and test results will meet the requirements of para. 1.6.6.1 (0) The in-situ density will be determined by a Nuclear densitometer. A nuclear densitometer will be placed at laboratory and at site and calibrated every week. It should be placed in a locked container and a training course set up for personnel. The staff using the densitometer will be wearing the uniforms and badges. (d) The laboratory density will be measured once a week taking an average of 3 samples (taken throughout the day) and compacted on the vibrating table. (€) During the course of all RCC placement, a running cumulative average of RCC densities will be maintained on a bar graph (or other acceptable form) and will consist of all valid readings, starting after all major mix design field adjustments have been completed for the Full-Scale Trial. In addition, at 16:00 hours on each day of RCC placement, a running cumulative average will be compiled in bar graph form (or other acceptable form) consisting of all valid readings for each mix design for: () Density readings made from 00:00 hours to 24:00 hours of the previous day. (ii) Density readings made during the previous seven (7) days of RCC placement (il) Density readings made during the previous 28 days of RCC placement (f) Moisture contents of the in-situ RCC will also be made at the same time and frequency as the density measurements, {k) Notification Notification will be given when placement of RCC is near or exceeds the limits of Uniformity specified above, and actions will be immediately taken to make adjustments in procedures as necessary to maintain the placement density within the specified limits, This will be addressed in the Sub-Contractor's Quality Control Procedures. (). Curing Protection and Joint Surfaces Water curing - At least once every 2 hours around the clock, 7 days per week, an inspection will be made of all areas subject to moist curing and joint protection. However, the surface moisture condition will be inspected as often as necessary to assure that 100 % of each lift surface is kept moist at all times. The surface moisture condition will be noted and recorded. If an isolated area has been allowed to dry, that area will be considered as improperly cured and will thereafter be treated as a "warm" or a “cold” joint depending on the maturity of the joint. Protection - At least once during each shift, around the clock, 7 days per week, an inspection will be made of all areas subject to cold-weather protection or protection against damage. Deficiencies will be noted. During removal of cold-weather protection, measurement of concrete and ambient air temperature will be made at least every 3 hours. RATLE-SPC-01 Roller Compacted Concrete Performance Specification 07-04-2014 Rev A7 46)? 8L&T Construction ARQ CONSULTING ENGINEERS = 4RQ, Heavy Civil Infrastructure 1G SAAN aeORD EDRC - HYDEL PROJECTS RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev A7 RATLE HEP ~ 850 MW J&K 1.9.3 Corrective Action 1.9.3.1 Aggregate Properties Whenever a test result is outside of the specification limits, notification will be immediately be given and a recheck sample taken. If the recheck semple is outside of the specification limits, the notification will again be immediately notified and positive steps will be taken to rectify’ the situation 1.9.3.2 Aggregate Moisture Determination Verification may be done of any field of moisture content made. This verification will use the oven-drying procedure. If there is a discrepancy between test results and the verification tests, immediate steps will be taken to identify the source of the problem and correct it, so that accurate field determinations are obtained. When moisture content determinations indicate a change in water entering the mix with the aggregates, the placement foreman will be contacted to see if a corresponding adjustment in water added at the mixer is necessary to obtain maximum compaction at the placement site. 1.9.3.3 Particle Shape ‘When testing for particle shape is required, two consecutive failures in the same sieve size will be immediately reported and immediate action will be taken to correct the deficiency. 1.9.3.4 Organic Impurities When testing indicates organic impurities, notification will be given and corrective action will be initiated immediately 1.9.3.5 Scales for Weigh Batching Whenever either the weighing accuracy or batching accuracy is found not to comply with specification requirements, the plant will not be operated until the necessary adjustments or repairs have been made. 1.9.3.6 Testing RCC (@) General On the occurrence of a failure of any test to demonstrate compliance with the specification, a report will be prepared identifying the cause of non-compliance and the necessary and intended remedial measures. (b) Mixer Performance When a mixer falls to meet mixer performance requirements, elther the mixing time will be increased or adjustments will be made to the mixer until ‘compliance is achieved. (©) Temperature Whenever the mix temperature falls below 2°C, or is above 25°C, notification will be given immediately. All other temperatures will be included as standard data in the quality control reports (d) Moisture Content Whenever moisture content tests indicate a change from that established as the optimum for maximum density and efficiency of compaction, @ report will be prepared and a corresponding adjustment to the mix water added at the 4mPageL&T Construction ARQ CONSULTING ENGINEERS ARQ Heavy Giutinfastuctae Io DAMS AND HYDRO er EDRC - HYDEL PROJECTS (e) 0 (@) (ny oO RATLE-SPC-01 Rev A7 RATLE HEP — 850 MW J&K mixing plant will be made, Preparation for Conerete Placement ‘Should unsatisfactory preparation of any type be observed, etc, notification will be given and this will be rectified before RCC placement is resumed. Dumping and Spreading Whenever thickness checks on un-compacted RCC indicate an excess or shortage of material, the layer will be immediately bladed off or supplemented to establish the correct thickness before compaction Any segregation of the fresh RCC observed during dumping and spreading will be re-mixed with fresh concrete of the previous and/or next load using both the dozer and shovels. if segregation remains, the cause will be investigated and remedial actions wil follow immediately. If the cause of the ‘segregation is not found or the remedial actions do not bring any benefit after 11 hour, the RCC placement will be stopped until the cause of the segregation of the fresh RCC has been fully controlled, and that the re-mixing effort can be minimized or is no longer required. ‘Compaction Equipment Compaction equipment not meeting the physical dimensions and weights required, will be removed from the project. Any roller having improper frequency will be corrected before being used for RCC compaction. Roller operators running at speeds in excess of specification requirements will be immediately notified and will correct any noted improper practices or be replaced by another operator. RCC Consistency Should consistency testing indicate VeBe values outside the allowable range, the mix will be immediately analysed and the batch proportions adjusted accordingly. Should repeated pattern of unacceptable values be observed, the RCC placement will be halted until appropriate remedial measures are adopted Concrete Compressive and Tensile Strengths A detalled report will be prepared on all compressive and tensile strength testing, presenting the proposed remedial measures in the case of problems, or downward trends in strength, etc. Compacted Density Whenever the average of all density readings from within a grid section falls below the target optimum compaction density value, the entire lift surface will bbe immediately compacted within the grid section by making additional roller passes. A determination will also be made as to why the optimum compaction density value has not been achieved and immediate steps taken to increase density to the required value. The process of taking density readings followed by additional roller passes will be repeated until the optimum compaction density value has been achieved.. Actions to be taken to increase density values for future placements include but are not limited to making mix property adjustments, decreasing the interval between mixing and compaction, or temporarily stopping all operations until placement can be achieved during cool or cloudy days or at night time. Roller Compacted Concrete ~Performance Specification 07-04-2014 48IP aveL&T Construction ARQ CONSULTING ENGINEERS ARQ Heawy Gil Inastvcure 10 DAMS AND HYDRO ww EDRC - HYDEL PROJECTS RATLE HEP — 850 MW J&K. In addition, if ess than 90% of the inspected surface is not covered with paste, the mix design, the procedures and the time allowed for compaction since mixing will be revised. If this lack of paste on the surface is recorded three times in a row, the RCC placement will be stopped and measures taken to improve the mix and the placement procedures. (K) Curing Protection and Joint Surfaces Any failure to observe this Specification will be immediately rectified () Reports Concrete plant control reports and results (both passing and failing) of all tests conducted at the project site, will be reported dally and summary reports will be compiled within two days after the end of each reporting period, Such reports of failures and the action taken will remain available for examination with all of the quality control records at any time. RATLE-SPC-01 Roller Compacted Concrete ~Performance Specification 07-04-2014 Rev AT 49P agesug wane faveonbua B| 2 ng srono4 yes nea 2505 sey yvoasese gra ee anoning ase es ae Sinanios be Sinawmga | emenoo 93 Samo “Soe ey 2 sWe 3 “LS3HS MEIEY ONREBNONE y 2 6 oaroua ouuLoaTaOwAH aTENR AN oe+0z0) 062