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Sec.8 9 Concrete PDF
Sec.8 9 Concrete PDF
CONCRETE WORKS
SECTION TWO
CONCRETE WORKS
1. GENERAL
This section includes the following:
- Concrete formwork and false work.
- Concrete reinforcement.
- Cast-in-place concrete.
- Concrete cures and finishes.
10. ESS 262 hot Rolled Steel Bars for the Reinforcement of Concrete.
11. ESS 1618 Welded Steel Bar Mesh for Concrete Reinforcement
12. ASTM A 82-94 Standard Specification for Steel Wire. Plain for
Reinforced Concrete.
14. ASTM A 185-94 Standard Specification for Steel Welded Wire Fabric,
Plain, for Concrete Reinforcement.
15. ASTM A 496-94 Standard Specification for Steel Wire, Deformed, for
Concrete Reinforcement.
16. ASTM A 497-94a Standard Specification for Steel Welded Wire Fabric,
Deformed, for Concrete Reinforcement.
19. ASTM A617-93 Standard Specification for Axle-Steel Deformed and Plain
Bars for Concrete Reinforcement.
Where there are differences between the specifications and drawings and the
codes, standards or acts, the most stringent shall govern.
Standards referenced by the Standards noted above are to apply even if they are
not included in the list.
3. For Cast-In-Place Concrete.
1. E.S.S. 373/1991 Normal and Quick Setting Portland Cement.
10. ACI 207.4R-93 Cooling and Insulating Systems for Mass Concrete.
11. ACI 211.1-81 Standard Practice for selecting proportions for normal,
heavyweight and mass concrete.
15. ACI 304R-85 Guide for Measuring, Mixing, Transporting, and Placing
Concrete.
20. All standards cited in ACI 318-95 as per clause 3.8 of ACI 318.
22. ASTM C 31-91 Standard Practice for Making and Curing Concrete Test
Specimens in the field.
25. ASTM C 42-90 Standard method of Obtaining and Testing Drilled Cores
and Sawed Beams of Concrete.
28. ASTM C 14493 Standard Specification for Aggregate for Masonry Mortar.
31. ASTM C 192-90a Standard Method of Making and Curing Concrete Test
Specimens in the laboratory.
34. ASTM C 496-90 Standard Test Method for Splitting Tensile Strength of
Cylindrical Concrete Specimens.
42. ASTM C 1240-93 Standard Specification for Silica Fume for Use in
Hydraulic-Cement Concrete and Mortar.
43. ASTM F 1155-87 Standard Test Method for Determining Floor Flatness
and Levelness, using the F-Number System.
Where there are differences between the specifications arid drawings and the
codes, standards or acts, the most stringent requirement shall govern.
Standards referenced by the Standards noted above are to apply even if they are
not included in the list.
3. TOLERANCES
2. Perform forming operations and place hardware so that finished concrete will
be within the tolerances set out in ACI and as listed below.
3. Variations in building lines, which result in extension of the building over, lot
lines or restriction lines will not be permitted
Relative alignment
Stairs difference in height between adjacent risers 3 mm
difference in width between adjacent treads 5 mm
Grooves specified width 50 mm or less 3 mm
specified width more than 50 mm
but not more than 300 mm 5 mm
Specified surfaces may slope with respect to the specified plane at
a rate not to exceed 10 mm in 3000 mm
The offset between adjacent pieces of formwork facing material
shall not exceed:
Surface Class A: All exposed concrete except where 3 mm
surface Class C is allowed
3. For standard fabricating tolerances for bar sizes 4)32 and smaller refer to
Figure 2.1(a) of ACI 117.
4. For standard fabricating tolerances for bar sizes larger than (1)32 refer to
Figure 2.1(b) of AC1 117.
6. Clear distance to side forms and resulting concrete surfaces and clear
distances to formed and resulting concrete soffits in direction of tolerance
When member size is 100 mm or less + 6 mm
- 10 mm
• When member size is over 100 mm but not over 300 mm 10 mm
• When member size is over 300 mm but not over 600 mm 13 mm
• When member size is over 600 mm 25 mm
.2 Variations in building lines which result in extension of the building over lot
lines or restriction lines will not be permitted.
The north and east edges of the Lower Ground floor at the drivers
quarters is not stable until the Upper Ground floor has been
concreted and its concrete has achieved 70% of its design strength.
The edge of slab of the Lower Ground floor generally between grid
lines U and V is not stable until the Upper Ground floor framing has
been concreted and the concrete has achieved 70% of its design
strength.
Design shoring for these slabs and walls to safely support the total
vertical and lateral loads until the walls and slabs are complete and
have and have reaches 70% of their specified strength. Design the
shoring so that they can be unloaded gradually.
.1 DESIGN OF MIX
Fly Ash: Do not use fly ash in concrete that will be exposed to
view.
5. SUBMITTALS
5.1 CONCRETE FORMWORK AND FALSE WORK
5.1.3 SURVEYS
Submit surveys showing position of formwork, cast-in-place inserts
and structural elements in their as-built condition.
9) All surveys submitted must clearly indicate the date when the survey
was actually carried out.
2. Prepare reinforcement placing drawings and bar lists taking into account
all openings and recesses shown on the architectural, structural, mechanical,
electrical, kitchen, waste, laundry, landscape architectural and parking
drawings, and on the sleeving shop drawings
5.2.4 Certificates
- Provide test data that each size and grade of reinforcement proposed
meets specification requirements. Reinforcement approved for use by
the Consultant shall be identified in a manner suitable to the
Consultant. Only steel that has been approved will be accepted on
jobsite.
- Weldable Reinforcement: Submit reports of chemical compositions
and. verification of weldability.
5.2.5 Substitutions
- Substitution of different size bars permitted only upon written
approval of Consultant. Requests for substitutions must be supported
by calculations and by written proof of compliance with the
requirements of the applicable standards. The Consultant reserves the
right to reject proposed substitutions.
.1 Surveys
Submit surveys in accordance with Section 03100, Concrete Formwork
and False work.
.2 Certificates
Prior to beginning work and when any change in materials or source of
supply is proposed, provide the following certificates prepared by an
approved inspection company. The cost of this work shall be borne by the
contractor
4. State for each mix if and how much fly ash or slag is used in
lieu of cement.
6.1.1 GENERAL
Supply samples of all materials and the following, the cost of which shall
be paid for by this trade.
6.1.2 REINFORCEMENT
- Provide the Consultant access to the reinforcement fabricator’s plant. Inform
the Consultant of the period during which fabrication will be undertaken.
- Cut samples of reinforcing steel designated by the Consultant from steel
shipped to jobsite. Replace cut reinforcement or splice where permitted by the
Consultant.
6.1.3 Cut samples of mechanical splices and welded reinforcement as directed
by the Consultant. Replace mechanical splices and welded reinforcement
cut out for testing.
6.1.4 Provide templates of column dowels to be butt welded to structural steel
base plates under Section 05120.
6.2.1 General
Supply samples of all materials and the following, the cost of which shall be
paid for by this trade
6.3.1 Provide control sample panel size 1.25 x 1.25 m. for plain (Fairface)
finish.
.1 Produce even finish with sheet material (e.g. plywood)
.2 Arrange panels in regular pattern as surface feature unless otherwise
shown.
.3 Blow holes less than 10 mm in diameter will be permitted other wise
surface is to be free from voids, honeycombing and other large defects.
.4 Variations in color resulting from use of impermeable form lining will be
permitted but surface is to be free from discoloration due to
contamination or grout leakage.
.5 Do not use concrete cover spacers without approval
.6 Surface should be smooth, free from laitance. That should be performed
using appropriate tools, to the approval of the Engineer.
6.3.2 Provide control sample min. size 1.25 x 1.25 m for trowelled finish.
7. MATERIALS
7.1.1 FORMS
.1 Formwork lumber, plywood and wood formwork materials shall conform
to the Egyptian Code requirements and to ACI 347R-94.
.2 Metal formwork and formwork made of other materials: conform to the
requirements and guidelines given in ACI 347R-94.
.3 Falsework materials: conform to ACI 347R-94.
.4 Waterstops in construction joints in foundations mat and in perimeter
foundation walls shall be used according to the Engineer’s instructions
and to the manufacturer’s specifications for the approved material.
.3 Chairs, balusters, bar supports, spacers: to ACI 315 and 318. In the case
of concrete exposed to view or weather the accessories shall such that no
metal is permitted to come closer than 40mm from face and 50 mm from
a trowelled surface. Use pre-cast concrete supports for exposed concrete
beams and soffits and concrete cast against soil.
.4 Special support bars and system for top steel of foundation bars mat:
Design and provide adequate support for top reinforcement of foundation
mat. Ensure that weight is well distributed so as t not damage the
waterproofing below the mat. Provide adequate bracing in all directions
against lateral movement of top mat, however caused, but in particular as
can arise from the forces generated by hoses used in placing concrete by
pumping.
7.3.1 CEMENT:
Ordinary Portland Cement shall be used for casting all plain and reinforced
concrete elements of different building, and shall comply with BS 12.
The Contractor shall show that the quantity and quality of required cement
can be attained and maintained throughout the construction period
Representative samples of the proposed cement shall be taken and
forwarded to an independent accepted laboratory for analysis before the
source is accepted. Having obtained acceptance, the Contractor shall not
change the agreed arrangements without the acceptance of the Engineer.
Each consignment of cement shall be accompanied by a certificate showing
the place and date of manufacture and the results of standard tests earned
out on each production batch included in the consignment. The standard
physical and chemical tests shall comprise those specified in BS standards
and herein, including the full chemical composition, SiO2, A12O, Fe2O3 ,
MgO, SO3 , Na2O, K2O, insoluble residue and loss on ignition.
The Contractor shall wash all fine and coarse aggregates by the use of an
efficient up-to-date washing system accepted by the Engineer.
The amount of material passing a 75 micron BS 410 fine test sieve when
tested in accordance with BS 812 Part I shall not exceed 3% by weight.
When subjected to five cycles of the soundness test specified in ASTM C88,
fine aggregate shall show a weight loss not exceeding 10% when
magnesium sulphate solution is used
The frequency of tests (1) to (13) shall he in accordance with Table (1), or as
otherwise specified more frequently by the Engineer The tests shall be carried
out in accordance with British Standards and/or ASTM Standards, as
appropriate, and the results shall comply with the limits given therein, or as
otherwise stated herein.
Grading test shall be carried out daily or per 200m³ of concrete whichever is
more frequent, when concrete is being produced on a regular basis, or
beforehand when production is irregular.
Water samples from the intended source of supply shall be taken for
analysis before any concrete work is commenced, and at intervals
throughout the duration of the Works as specified by the Engineer If the
samples are unacceptable, the Contractor shall either change to a new supply
or take steps to improve the existing source as accepted
The sulphates (SO3) content shall not exceed 300 mg/L and the chloride ion
content shall not exceed 500 mg/L. Tests to establish the contents shall be
carried out at weekly intervals. These limits shall be subjected to the overall
limit given for the concrete as mixed.
7.3.7 ADMIXTURES
Low water-cement ratios required by the Specifications may be met with the
use of proven water-reducing admixtures in liquid form complying with BS
5075. Where approved or specified, admixture(s) shall be used as means of
In the event of admixtures being used, the concrete tests described in the
Specifications shall be incorporated to ensure the specified strengths are
achieved and comparison shall be made with concrete manufactured without
the admixture to prove that the density has not been reduced and the other
characteristics have not been adversely affected If air entraining agents are
used, the density shall not be reduced by more than 5% Not more than one
admixture may be used in any one concrete mix
When admixtures are used in the Works, very strict control shall be
maintained to ensure that the correct quantity of admixture is used at all
times. The equipment to be used for dispensing and the method of
incorporating the admixture in the concrete shall he to the acceptance of the
Engineer. The dispensing unit shall be translucent such that the operator can
see the discharge of the admixture.
8. EXECUTION:
8.1 FORMWORK:
8.1.1 GENERAL
.1 Erect, support, brace, and maintain formwork to safely support vertical
and lateral loads until they can be supported by the structure.
.2 All false work erection shall be supervised by the Structural Engineer
responsible for its design.
8.1.2 CONSTRUCTION
.1 Where shown, camber formwork such that hardened concrete, prior to
stripping of forms, is cambered as shown. Maintain beam depth and slab
thickness from cambered surface.
.2 All openings, sleeves, chases are not necessarily shown on the structural
drawings nor are their sizes or locations shown. Refer to architectural,
mechanical, electrical, kitchen, laundry, waste, vertical transportation,
landscape architectural, parking, and exterior lighting drawings and
specifications for openings and sleeving requirements not shown, located
and dimensioned on the structural drawings.
.3 Form panels for exposed concrete may be reused 3 times, providing the tie
holes are reused and panels are not damaged in a way that will cause
visual defects.
.8 Do not strip within one and a half bays of a construction joint until new
concrete beyond the construction joint has reached 70% of its specified
28 day strength.
.10 Side forms for vertical members may be stripped as soon as the
concrete is sufficiently strong to stand unsupported and safely resist
imposed loads.
.2 Separation strips are to be concrete no sooner than 90 days after the last
placing of concrete in adjoining areas.
.1 Conform with the requirements of this section and the following for the
construction of the walls and base slabs of the water storage tanks.
.3 The continuity of the waterstop ribs and of its tubular centre axis be
maintained.
.10 The following defects represent a partial list of defects which shall be
grounds for rejection:
.1 Offsets at joints greater than 1 mm or 15 % of material thickness at
any joint, whichever is less.
.1 Maintain bays containing separation strips and each adjacent bay fully
formed and shored until the strip is complete, and has reached its 28-day
specified strength. Ensure that the forms and shoring are designed so that
no settlement of the forms occurs during the period that the strip is open.
8.1.10 QUALITY CONTROL
.1 Where evidence exists that defective work has occurred or that work has
been carried out incorporating defective materials, the Consultant may
have tests, inspections or surveys performed, analytical calculations of
structural strength, made and the like, in order to help determine whether
the work must be corrected or replaced.
8.2.1 FABRICATION
.2 Identify with a tag each bundle of bars with a code mark corresponding to
that appearing on the bar list.
.3 Bend reinforcement once only and at room temperature, without the use
of heat or torch. Do not straighten or re-bend reinforcement. Do not use
bars with kinks or bends not shown on the drawings.
8.2.2 PLACING
.2 Set column anchor bolts and wall dowels prior to concreting with wooden
templates or other approved means.
2 Lap ends and sides of fabric not less than 300 mm.
.1 Tension Splices
• Splices shall develop in tension at least 125 per cent of the specified
yield strength of the reinforcement being spliced or of smaller bar if
the bars spliced are of different sizes.
• In each concrete member unless otherwise indicated, splice not more than
one third of the bars at any one location. Distance between adjacent splice
location shall be not less than 450 mm.
• Accurately saw cut the end bearing surfaces of all bars to be spliced
90 degrees to the axis of the bar with a tolerance of 2 degrees.
• In setting the bars, rotate until the angle between bearing surfaces is
at a minimum.
• In each concrete member, splice not more than one third of the bars
at any one level. Distance between adjacent splice levels shall be not
less than 750 mm.
.1 Where evidence exists that defective work has occurred or that work has
been carried out incorporating defective materials, the Consultant may
have tests, inspections or surveys performed, analytical calculations of
structural strength made, and the like, in order to help determine whether
the work must be replaced.
.1 Conform to the requirements of ACI 318 and ACI 304R and the following:
2 During hot weather conditions, do not use concrete mixed more than 1
hour after introduction of mixing water or 1½ hours during other
periods, unless the concrete mix has been designed with appropriate
admixtures to allow longer time before placing.
.2 Pumping Concrete
.1 Pumping or pneumatic placing of concrete shall only be used if
the velocity of discharge is reduced to a point where no
separation or scattering of the concrete occurs, and the
consistency of the mix has been designed to allow such a system
with no adverse effects on the quality of concrete.
.1 General
.1 Cure all concrete in accordance with ACI 318 and ACI 308,
except as specified herein.
.2 Wet Curing
.1 The following provisions apply to the foundation mat, the water tanks,
the pool support girders and beams as well as the pool slabs.
8.3.3 PROTECTION
.1 General
.4 Place concrete in layers thin enough and areas small enough so that
the time interval for placing is reduced and compACIion will ensure
complete union of adjacent portions.
.5 With formed concrete, reliance shall not be placed on the forms alone
to provide curing. Spray formwork with water to keep it tight and free
from cracking.
.1 At all times during the work, protect exposed concrete from staining
or becoming coated with concrete leakage due to continuing
concreting operations. Members which become coated may be classed
as defective by the Consultant.
.1 Found foundation mat on the blinding slab and the waterproofing which
have been placed on naturally consolidated undisturbed soil capable of
safely developing the allowable bearing capacity shown on the drawings
within acceptable limits of settlement.
.4 If, upon excavating to the elevations shown, the required soil bearing
capacities are not achieved, inform the Consultant who will provide
written instructions as to how to proceed.
3.3.6 WATERSTOPS
.1 Massive pours may set up temperature rises and gradients that may cause
severe cracking and in extreme cases, loss of strength.
.2 Plan and carry out concreting operations, protect and cure the concrete so
as to prevent these conditions from occurring.
.10 Advance each layer at least 6 metres before starting next layer.
.1 Conform with the requirements of this section and the following for
the construction of the walls and base slabs of the water storage tanks
members designated to be watertight.
.2 Temperature Control
.3 Curing
.4 Crack Repair
.1 Just prior to the installation of the tank liner arid insulation, carefully
examine all exposed interior and exterior surfaces and repair any
cracks in them.
.5 Water Test
.1 At least 28 days after concreting the last section of each tank, and after
the sealing of joints, fill each tank with water and leave standing for 10
days.
.2 Fill each tank gradually such that the differential temperature between
the water and the tank concrete does not exceed 70C.
.3 Locate and repair all areas where leakage occurs and retest until each
tank is watertight.
.1 Implement a system of quality control, as per ACI 301 and ACI 311.1 R,
ACI 311 .4R, ACI 311 .5R to ensure that the minimum standards
specified herein are attained.
.2 When defects are revealed, the Owner may request, at the Contractors
expense, additional inspection or testing to ascertain the full extent of
the defect.
.4 Grout Under Baseplates: At least one strength test may be made each
day that grout is placed under baseplates.
.3 Inspection of Soil
.1 Where evidence exists that defective work has occurred or that work has
been earned out incorporating defective materials, the Consultant may
have tests, concrete coring, inspections or surveys performed, analytical
calculations of structural strength made and the like in order to help
determine whether the work must be repaired or replaced.
01 ORDINARY CONCRETE m³
Supply and apply O.C for foundations and pile
cap
Consisting of : 0.8 m³ coarse aggregate, 0.4 m³
fine aggregate and 250 Kg cement.
STRUCTURAL REINFORCED
CONCRETE
01
BEAM 250 - 300 Kg/cm²
02 Columns 350 / 400 / 550 / 600 Kg./m² m³
03 Core and Shear Walls m³
04 Slabs m³
05 Stair Landing, and risers. m³