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Toromocho Project: Minera Chinalco Peru S.A
Toromocho Project: Minera Chinalco Peru S.A
C-560
TOROMOCHO PROJECT
Concrete Construction
DISTRIBUTION A B C 0 1 2 3 4 5 6 7 8 9 10
Client 5-5-8 5-19-8 9-11
Procurement
Field
Internal 4-17-8 5-5-8 5-19-8
INDEX
Page
1. GENERAL ......................................................................................................................................................... 3
2. PRODUCTS ...................................................................................................................................................... 7
3. EXECUTION.................................................................................................................................................... 13
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
1.0 GENERAL
1.1 Summary
This specification prescribes requirements for cast-in-place concrete construction.
A. Scope of Specification
1. Construction of plain and reinforced concrete work.
2. Sampling, testing, and inspecting concrete and concrete construction.
3. Placing anchor bolts and embedments for structural items.
4. Detailing, providing fabrication, and placing steel bar reinforcing, including
reinforcing supports and accessories.
5. Design, supply and installation of formwork for concrete structures.
B. Related Specifications
The following specifications prescribe items of related work:
000-GC-C-001 Site Work
000-GC-S-004 Structural & Misc. Steel Fabrication and Erection
Coordinate work prescribed by this specification with work prescribed by the
above listed specifications.
1.2 References
The publications listed below form part of this specification to the extent referenced in
this specification. Each publication shall be the latest revision and addendum in effect
on the date this specification is issued for basic engineer, unless noted otherwise.
Except as modified by the requirements specified herein or the details of the
drawings, work included in this specification shall conform to the applicable provisions
of these publications. If there is a discrepancy between the references and this
specification, the most stringent requirement shall govern.
A. ACI (American Concrete Institute)
1. ACI 117 Standard Specifications for Tolerances for Concrete
Construction and Materials
2. ACI 270R Mass Concrete
3. ACI 211.1 Standard Practice for Selecting Proportions for Normal,
Heavyweight, and Mass Concrete
4. ACI 214 Recommended Practice for Evaluation of Strength Test Results
of Concrete
5. ACI 301 Standard Specifications for Structural Concrete for Buildings
6. ACI 302.1R Guide for Concrete Floor and Slab Construction
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
1.4 Submittals
A. The Supplier shall submit 1 copy of the following documentation to the Buyer for
review and approval 30 days prior to placing any concrete, or as required by
Project requirements:
1. Mix Designs
2. Mix designs shall be proportioned in accordance with Chapter 3 of ACI
301. Submit mix designs for each combination of ingredients on each
class of concrete for review.
3. Shot crete mix shall be proportion in accordance to ACI 506
4. Trial batch qualification test results, or complete standard deviation
analysis based on previous field experience.
5. Ingredients test results or certifications.
6. Compressive strength results.
7. Material suppliers, sources, properties, and certifications.
8. The Supplier must supply all the necessary certification to demonstrate
the adequate concrete quality.
Note: Supplier (PDMI) has submitted all of the above mentioned documents, except
shotcrete
B. Prior to the production of concrete, the Supplier shall submit to the Buyer for
record only, 1 copy of Manufacturer's specifications with application and
installation instructions for proprietary materials and items including bonding
agents, form release agents, water stops, joint systems, chemical floor
hardeners, dry shake finish materials, liquid curing compounds, and prepackaged
repair materials. Also, include a statement showing product selections comply
with VOC (Volatile Organic Compounds) and environmental regulations of the
locality.
C. Prior to the production of concrete, the supplier shall submit to the Buyer a
complete description of proposed curing methods.
D. A delivery ticket for each batch, conforming to Section 16 of ASTM C94 shall be
given to the Buyer's Testing Agent at the point of delivery.
E. The Independent Testing Agent shall submit slump test and compression test
results to the Buyer on a daily basis. Breaks of 500 psi below the specified
design strength at 28 days shall be submitted on the same day. Reports shall
contain the project identification name and number, date of concrete placement,
name of concrete supplier and truck number, name of concrete testing service,
concrete type and class, location of concrete in structure, cyclinder number,
design compressive strength at 28 days, compressive break strength, and type of
break.
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
F. Prior to placing reinforcing steel, the supplier shall submit the following for review
by the Aker Solutions Engineer:
1. Certified mill test reports for each bar size for each heat of reinforcing
steel delivered.
1.5 Delivery
A. Concrete
1. Plant and Truck Mixer Certification
Evidence (including checklist) of certification of the plant equipment used
for weighing of materials for batching and truck mixers used for mixing
and delivery of concrete shall meet the requirements of NRMCA, and
ASTM C94.
2. Delivery Tickets
A delivery ticket shall be furnished in triplicate by the batch plant with
each batch delivered to the construction site setting forth the following
information:
a. Serial number of ticket.
b. Data, time of loading, time of arrival, time of unloading.
c. Truck number and batch number.
d. Specific job designation (name of Contractor, location of pour).
e. Volume of concrete (cubic yards).
f. Class of concrete, as specified herein.
g. Time and amount of water added.
h. Type and brand of cement.
i. Weight of cement.
j. Weights and maximum size of coarse and fine aggregates,
respectively.
k. Amount of water added after batching, if any.
l. Type and amount of admixtures.
m. Signature of Supplier’s Representative.
3. Water reducing, accelerating, and air entraining admixtures are to be
added at the batch plant, while accelerators and retarders may be added
at the batch plant or jobsite. Refer to ACI 304, Section 4.5, for
requirements for charging of ingredients into the mixer.
4. Add high range water reducing admixtures to the concrete at the project
site, after verification of the initial slump.
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
B. Reinforcing Steel
1. Reinforcing steel shall be prepared for shipment in such a manner that
quality and cleanliness shall be maintained during shipment. Materials
shall be adequately protected against damage during shipment.
2. Shipments shall be by structure to the maximum extent possible.
3. Store reinforcement above ground and protect from dirt, oil, and grease.
4. Bar shall be detailed and fabricated off site.
2.0 PRODUCTS
2.1 General
A. Any product not listed under the following Materials section may be submitted to
the Buyer for review and approval. A product that is not listed is not to be used
without written approval of the Aker Solutions Engineer.
B. Products shall meet applicable local VOC (Volatile Organic Compounds)
regulations.
2.2 Materials
A. Concrete Materials
1. Cement: ASTM C150, Type V, or as shown and indicated on drawings;
use only 1 brand for all cement.
2. Fly ash: ASTM C618, Class F. (Only if approved by Aker Solutions
Engineer)
3. Fine and coarse aggregates: ASTM C33 for normal weight concrete.
(Maximum size ¾”)
4. Water: Mixing water for concrete shall meet the requirements of ASTM
C94.
B. Admixtures
1. Air entrainment: ASTM C260, liquid air-entraining admixture, equivalent
to Micro Air by the Masterbuilders Co., or Air Mix by the Euclid Chemical
Co., or Aker Solutions Engineer approved equal.
2. Water reducing: ASTM C494, Type A, Equivalent to Pozzalith 200N by
the Masterbuilders Co., or Eucon WR-75 or Eucon WR-91 by the Euclid
Chemical Co., or Aker Solutions Engineer approved equal.
3. Water reducing, retarding: ASTM C494, Type D, equivalent to Pozzalith
122R by the Masterbuilders Co., or Retarder 75 by the Euclid Chemical
Co., or Aker Solutions Engineer approved equal.
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
C. Concrete Accessories
1. Bonding compounds: Rewettable; the compound shall be a polyvinyl
acetate type such as Euco Weld by the Euclid Chemical Company(or
Aker Solutions Engineer approved equal) on areas not exposed to
moisture. Obtain Aker Solutions Engineer approval prior to use.
2. Epoxy adhesive: The compound shall be a 2-component, 100 percent
solids, 100 percent reactive compound suitable for use on dry or damp
surfaces, Euco Epoxy Number 452MV or Number 620 by the Euclid
Chemical Company or Sikadure Hi-Mod by the Sika Chemical Company
or Aker Solutions Engineer approved equal.
3. Repair topping (Thickness of 2 mm to 13 mm): Latex and microsilica
modified cementitious mortar designed for use as a floor or deck topping.
Thin top supreme by the Euclid Chemical Company, or Aker Solutions
Engineer approved equal.
4. Repair topping (thickness of 13 mm to 50 mm): Latex and microsilica
modified cementitious mortar designed for use as a floor or deck topping.
Concrete Top supreme by the Euclid Chemical Company, or Aker
Solutions Engineer approved equal.
5. Underlayment compound: Free-flowing, self-leveling, pumpable
cementitious base compound, "Flow-Top" by Euclid Chemical Company,
or Aker Solutions Engineer approved equal.
6. Vapor barrier: 6 mil thick clear polyethylene film or fabric reinforced
plastic film, type recommended for below grade applications.
7. Patching mortar shall be a free-flowing polymer-modified cementitious
coating equivalent to Euco Thin Coat (for horizontal repairs) or Verticoat
(for vertical or overhead repairs) by the Euclid Chemical Company or
Aker Solutions Engineer approved equals.
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
B. Slump
1. Unless shown otherwise on drawings, concrete slump shall be as follows:
a. Footings, piers, and walls: 50 mm to 100 mm.
b. Beams and columns: 25 mm to 100 mm.
c. Slabs: 50 mm to 100 mm.
d. Fireproofing and underground duct envelope: 100 mm to 150 mm
e. Pours over 760 mm thick: 25 mm to 64 mm.
f. Lean mix concrete: 100 mm to 150 mm.
2. Concrete containing high range water reducer:
a. When high range water reducer is added to maintain slump with
lower water / cement ratio, slump shall be as specified in Section
2.3B.1 of this specification, after addition of the reducer.
b. When high range water reducer is added to increase slump
without changing water / cement ratio, slump before addition of
reducer shall be as specified in Section 2.3B.1 of this
specification, and shall not exceed 200 mm after addition of
reducer.
C. Water-Cement Ratio
Maximum 0.40 for water retaining (hydraulic) structures and concrete subject to
deicers, brackish water, or salt spray; 0.45 for other structures.
D. Formwork
Design and construction shall comply with Chapter 4 of ACI 301 and the building
code of the local jurisdiction.
2.4 Concrete Mixes
A. Proportioning
1. Proportion normal weight concrete mixes in accordance with Chapter 3 of
ACI 301, mass concrete mixes in accordance with Appendix 5 of ACI
211.1, on the basis of either previous field experience or trial mixes; do
not proportion concrete mixes based on empirical data. Refer to
Appendix A of ACI 301 for flow chart on proportioning normal weight
concrete mixes. Mixing and transportation of concrete shall be in
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
accordance with Chapter 4 of ACI 304R. Shotcrete mix shall be one part
Portland Cement, 3. 5 parts of sand (3/3 maximum size) and water (3 to 4
gallons per bag of cement) in accordance with ACI 506.
2. Include proposed chemical admixtures in mix design in same proportions
and batching sequence as shall be used in production concrete.
3. The proposed mix designs shall be accompanied by complete standard
deviation analysis or trial mix test data.
4. Determine standard deviation and required average compressive strength
in accordance with the requirements of ACI 301.
5. Concrete shall contain a coarse aggregate with a maximum size of 20
mm except mass concrete with maximum 40 mm aggregate. Refer to
ACI 302, Section 3.6 for additional requirements.
6. Give particular attention to aggregate gradation for pumpable concrete
mixes.
B. Concrete shall be air entrained according to Table 3.4.1 of ACI 301. Interior floor
slabs preferably shall have no air entrainment, with no more than 3 percent.
C. Fly ash may be used with Aker Solutions Engineer’s approval as a cementitious
material, with the fly ash replacing a maximum of 20 percent of the cement (by
weight). The fly ash shall be used in calculating the water-cement ratio and shall
come from the same source.
2.5 Grout
A. Design requirements:
Base plates for equipment and structures shall be grouted to provide full uniform
load transfer between bottom of plate and concrete foundation.
B. Types of grout:
1. Nonmetallic nonshrink cement base grout with minimum compressive
strength of 34 MPa at 28 days shall be “Masterflow 713”, manufactured
by Master Builders, Cleveland, Ohio or buyer approved equal.
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
3.0 EXECUTION
3.1 Preparation
A. Anchor Bolts and Embedments
1. Before the installation of any steel embedment element, all the surface of
the elements must be cleaned. Oxide or grease will not be accepted, in
the steel surface.
2. Steel, anchor bolts, ironwork, pipe sleeves, inserts, wood blocking, nailer
strips, isolation joint material, construction joint dowels, and other fixtures
as shown, specified, or required to be built into concrete shall be placed
accurately and secured against displacement during concreting.
Sufficient time between erection of forms and placing concrete shall be
given to the various trades to permit proper installation of their work. The
installation of anchors, inserts, and sleeves for electrical, mechanical,
plumbing, heating, and ventilation work shall be subject to the inspection
and approval of the Aker Solutions QA/QC Inspector before concrete is
placed.
3. The installation of and tolerances for anchor bolts and embedded items
shall comply with paragraph 7.5 of the AISC Code of Standard Practice.
Anchor bolts shall be located within 3 mm of design position and shall be
plumb within 1.5 mm.
4. Locate plate inserts within plus or minus 6 mm horizontally or vertically.
5. Protect bolt threads against damage and concrete; cap or plug sleeves to
keep out water, concrete, and debris.
6. Tack welding of anchor bolts, reinforcing steel, and embedments is not
permitted unless noted on the drawings.
B. Placing Concrete
Preparation before placement and conveying of concrete shall be in accordance
with Chapter 8, Section 8.1 and 8.2 respectively of ACI 301.
3.2 Installation
A. Concrete Production
Production of concrete shall comply with Chapter 7 of ACI 301. Water may be
added to the mix at the point of delivery in accordance with Section 11.7 of
ASTM C94 when permitted by the Aker Solutions QA/QC Inspector's testing
agent but in no case shall the total amount of water added at the jobsite and
batch plant exceed the quantity specified for the design mix.
B. Placing
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
G. Reinforcement
1. The grade, type, and details of reinforcing steel shall be in accordance
with the design drawings. Placement of reinforcement shall be in
accordance with Section 5.7 of ACI 301 unless otherwise approved by the
Aker Solutions Engineer.
2. Place, support, and fasten reinforcing before placing concrete; do not
insert dowels into fresh concrete; do not float welded wire fabric down into
fresh concrete. Support slab reinforcement at the required depth and
secure prior to placing concrete; do not pull welded wire fabric up into
fresh concrete as it is placed.
3. Secure at least 25 percent of bar intersections (including wall dowels)
with wire in 2-way mats.
4. Splice reinforcing bars only as shown on the design drawings. Necessary
splices not shown on the drawings shall be lapped sufficiently, as
approved by the Buyer, to develop the strength of the bars by bond for
bars through size Number 36. Mechanical splices shall be made only as
shown and noted on the drawings. Welded splices are not allowed.
5. Minimum concrete cover shall be according to ACI 301, Section 5.7.
Areas subject to chemical exposure, as noted on the design drawings,
shall have a minimum cover of 50 mm, unless otherwise noted.
H. Joints and Embedded Items
1. Joints and embedments shall be in accordance with Chapter 6 of ACI 301
unless otherwise approved by the Aker Solutions Engineer.
2. Construction joints shall be located as shown on the concrete drawings.
Any variation from location shown shall be approved by the Aker
Solutions Engineer. Should the concrete operation require the placement
of an intermediate construction joint, the concrete shall be struck off
square with the structure, water stops added if the normal joint has a
waterstop, the location completely recorded and reported to the Aker
Solutions Engineer in writing. Adjacent pour shall not be made until a
disposition has been received from the Aker Solutions Engineer.
3. Construction, isolation, and control joints in slabs on grade are to be built
in accordance with and located according to the design drawings. Control
joints in slab toppings are to be located directly above and in line with the
control joints in the underlying concrete slab.
Soft-Cut saw to a depth of t/5 (25 mm max.) shall be used immediately
after final finishing. Conventional saw cut joints are to begin as soon as
the concrete is hard enough to prevent raveling of the surface and
dislodging of the aggregate, but no later than 12 hours after concrete
placement. Prime and seal joints according to Sealant Manufacturer's
instructions. Control joints are to be cut using a Soff-Cut Saw and in strict
accordance with the saw manufacturer's written recommendations.
Determine the sawing sequence based upon slab pour time and size.
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
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Project No. C560
General Specification No. 000-GC-C-002
Concrete Construction
Rev. 1
These procedures shall be submitted for Buyer’s review and approval prior to
implementation.
B. The Supplier shall be responsible for all quality control and testing specified in
Section 3.3, Testing, except as noted below. Supplier shall retain a testing
agency that meets the requirements of ASTM E329. The testing agency shall be
subject to approval of the Buyer.
C. The Buyer will retain a testing agency to perform Quality Assurance functions.
D. The Supplier’s testing agency shall prepare, store and protect at the placement
site, and then transport to the Supplier’s on site testing agency, all concrete test
cylinders.
E. Should the Supplier feel additional tests are needed for early form or support
removal, it will be Supplier’s responsibility to take additional cylinders as
necessary, at no cost to the Buyer.
F. Acceptance of concrete shall be based upon results for slump, air content,
temperature, and strength taken at the site. Testing frequency shall be as
specified in Section 16.3 of ACI 301 unless waived by the Buyer.
G. The finished structure shall be evaluated for acceptability in accordance with
Chapter 18 of ACI 301. The supplier shall pay costs incurred for additional
testing, analyses, and any corrective work required when the structure is found to
be deficient in strength or other specified characteristics.
H. During construction, the Supplier’s testing agency and the Buyer’s Independent
Testing Agency shall inspect, sample, and test concrete materials and production
of concrete as required by the Aker Solutions QA/QC Inspector. Compressive
test results for 7 and 28 day breaks for each class of concrete shall be evaluated
in accordance with ACI 214 including as a minimum graph of average strength,
standard deviation, coefficient of variation, and required average strength.
Failure to detect any defective work or material shall not prevent in any way later
rejection when such defect is discovered, nor shall it obligate the Buyer for final
acceptance. The testing and inspection agency shall meet the requirements of
ASTM E329.
End of Specification
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