Mountain View – I City (N.

C)

Project Code:- DMA–I-M-012-000

Residential Buildings

Structural
Technical Specifications
Part (I)

Rev. (0A) August, 2017

Document Code: DMA – QS – Op – 01 – F-03
Issue Date : 01/01/2017
Issue No.: 01
 Structural Specifications

SECTION (1)

GENERAL

1.1 The Specifications included in this part cover the technical stipulations for construction of
the I City Mountain View project.
1.2 Materials, goods and workmanship shall be of the best quality of their respective kinds and
shall comply with the specifications stipulations. Latest issues of the relevant specifications
and codes shall be referred to where mentioned.
1.3 Wherever a certain trade mark is given in the specifications or on the drawing to describe a
particular product, the trade mark is only given to outline the level of quality and the
required specifications of the product. The Contractor, thus, has full freedom to submit
alternative products of the same level of quality. The approval of the Engineer on the
alternative items will not be unreasonably withheld.
1.4 Quality Control of Materials and Workmanship
1.4.1 Quality control stipulations are indicated throughout the specifications sections.
1.4.2 The Contractor is required to establish and operate a full quality control program for
every item of work.
1.4.3 Quality control tests which are not performed on the site shall be conducted 111
approved specialized laboratories.

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1.5 Standard abbreviations.

1.5.1 Standard abbreviations.

CM (cm) Centimeter (s)

CU M (m3) Cubic meter (s)
Gr (gm) Grams
HR (h) Hour (s)
°C Degree centigrade
Lt Liter (s)
Lb Pound (s)
LM (l.m) Linear meter
LS (sum) Lump sum
M (m) Meter (s)
Max Maximum
Min Minimum
MM, mm Millimeter (s)
Mpa Mega pascal
No Number
Sec Second
CU M or (m3) Cubic meter
SM or (m2) Square meter
SQ CM (cm2) Square centimeter
1.5.2. Organizations and Standards

ACI American concrete institute

ANSI American national standards institute
ASTM American society of testing and materials
BS British specifications
DIN Duetch industry normen
ES Egyptian specifications
UL Underwriters laboratories, Inc

END OF SECTION

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SECTION (2)

EXCAVATION &BACKFILLING FOR BUILDING

2.1 GENERAL
2.1.1 The work of this section includes labor, materials, equipment and services necessary for
excavation and backfilling. The work includes but not limited to:
2.1.1.1 Excavation from the existing ground level till designed level
2.1.1.2 Removal of excavated soil not used for fill to disposal areas approved by Cairo of
Giza governorates.
2.1.1.3 Fill with compacted clean sand or with suitable excavated materials.
2.1.1.4 The Contractor shall inform the Engineer, of any ambiguities or discrepancies within
the design documents at least two weeks in advance of the date programmed for the
relevant work and obtain directions from the Engineer before commencing the relevant
work.
2.1.2 QUALITY ASSURANCE
Reference shall be made to the following codes and standards unless otherwise specified.
1. The Egyptian code for soil mechanics and design and execution of foundations.(ECP 202-
2001)
2. ASTM: Standards
a) ASTM D 698: Test Method for Laboratory Compaction Characterizes.
b) ASTM D 1557: Laboratory Compaction Characterizes of Soil using Modified Effort.
c) ASTM D 1586: Sampling of Soil
d) ASTM D 2049: Relative Density of Cohesion less Soil
e) ASTM D 4253: Standard Test Methods for Maximum Index Density and Unit Weight of Soils
using a
Vibratory Table.
f) ASTM D 4254: Standard Test Method for Min Index Density and Unit Weight of Soils and
Calculation of Relative Density
Chemical analysis:
1. Technical analysis of ground water (if any).

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2. Percent of chlorides, sulphates and organic matter in soil.

3. Tests for swelling soil.
2.1.3 SUBMITTALS
The Contractor shall submit to the Engineer before commencement of work, the following
documents for approval:
1. Shop drawings indicating actual limits and depth of excavation.
2. Method of excavation, removal to disposal areas, filling materials and compaction tests.
3. Available laboratory equipment for measurement of compaction.
4. Compaction curves for fill and backfill materials.
2.1.4 PROTECTION
1. All adjacent areas not specifically excavated shall be fully protected against possible damages
caused in the execution of the work under this Contract.
2. Sloped and graded surfaces damaged or disturbed as a result of the works shall be restored
to the conditions existing at the start of work.
3. Special care shall be taken to protect the existing trees, planned to remain, from being
damaged during construction operations.
4. Hazardous and dangerous conditions shall be prevented and safety of personnel shall be
maintained.
5. Scaffoldings shall be carefully designed to maintain the safety of personnel.
6. Care shall be taken during placing of fill and compacting of same around structure or under
floor slab so as not to damage concrete surfaces, waterproofing membranes joints or coatings
that have been applied to concrete surface.
7. Carefully maintain all bench marks, monuments and other reference points and replace if
disturbed or destroyed.
8. Protect active utilities from damage, remove or relocate only as approved by Engineer.

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2.2 MATERIALS
2.2.1. Sand for fill shall be of Ø = 35° materials clean, free from clay lumps and organic
Structural Specifications meters. Sand shall be brought from quarries approved by Engineer.
2.2.2. Replacement soil shall consist of graded stones and sand within percentages (2: 1) or as
approved by Engineer.

2.3. EXECUTION
2.3.1. EXCAVATION – GENERAL
1. Do not perform blasting on the site. Materials to be removed are unclassified and include
rock if any.
2. Excavate to dimensions and elevations indicated, allowing additional space as required for
construction operations and inspection of foundations.
3. Remove old foundations, building construction, and other materials concealed beneath
present grade, where required to execute work, and as indicated.
4. Properly level off bottom of Engineer
5. Conduct necessary dewatering and shoring as required in accordance with related sections
approvals of the Engineer.
6. Do not carry excavations lower than indicated, except when directed by the Engineer.
Unauthorized excavations carried below indicated level shall be filled with concrete of the same
strength as construction, at no extra cost or with replacement soil as directed by the Engineer.
7. Transport all excavated materials not used for filling to disposal areas approved by the Cairo
or Giza governorate. Do not make heaps at site.
2.3.2. FILLING
Structural Specifications
1. Remove all rocks, lumps, soft or wet materials, vegetation, and other foreign materials upon
which fill is to be placed
2. Scarify top 300 mm. of earth and compact to 95 percent of maximum dry density

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3. Excavated soil can be used for fill provided that the soil to be used is approved by the
Engineer and tested to prove that the soil is free of organic matter, swelling soil, chlorides and
sulphates. Tests are to be performed for every 500 cubic meter of fill.
4. Place sand fill in 150 mm. lifts and compact each li�to average relative density of 75% with
no individual test less than 70% percent of maximum density in accordance with ASTM D4253
and D4254.
5. For soil other than sand place fill in 150 mm to 200 mm thick and compact to 95%. Of
maximum dry density in accordance with ASTM D 1557 & ASTM D698.
6. Maintain between 3 percent below and 3 percent above optimum moisture content during
compaction.
7. Compact the fill using suitable mechanical tamping equipment to obtain specified density.
Compact sand using vibratory methods. Before placing fill on subgrade, obtain approval of
Engineer.
8. Correct and/or re-compact compacted materials not meeting specified compaction
requirements. Continue corrective measures until required compaction has been attained.
9. Do not fill against foundations, walls, curbs, footings, and other area until concrete forms
have been removed, masonry work has been pointed and protected, and concrete finishing,
damp proofing, and waterproofing have been completed and approved.
2.3.3 TESTING
Perform compaction test for every 100 m3 of fill at locations designated by the Engineer.

END OF SECTION

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SECTION (3)
CONCRETE WORKS
3.1 GENERAL
3.1.1 This section of specifications covers the concrete works for the project
3.1.2 Unless otherwise specified in this section reference shall be made to the specification of
concrete works enforced Egypt "The Egyptian Code for Reinforced Concrete Construction
2012".
3.1.3 Special care shall be exercised to the design of concrete mixes and quality control
procedures described in this section. All required tests shall be performed in a regular manner
according to the rates mentioned hereunder.
3.1.4 Inspection and quality control procedures conducted before, during and after placement
of concrete Shall conform to the aforementioned reference specifications stipulations as well as
the conditions specified in this section.
3.1.5 The Contractor shall submit to the Engineer, prior to start of work the following
documentations for approval:
a. Sources and characteristics of concrete materials comprising cement, steel reinforcement,
coarse and fine aggregates, water and admixtures.
b. Methods of concrete mixing, transportation, placing, compaction and cunng.
c. Details of bat ching plant.
d. Quality control procedures comprising methods of sampling and testing as well as site
laboratory equipment and experience records and number of quality control technicians.
The approval of the Engineer on the aforementioned documents shall not reduce the
Contractors responsibility of work.

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3.2 MATERIALS
3.2.1 CEMENT
3.2.1.1 Cement shall be delivered from approved sources and shall conform to one of the
following Specifications:
a) Egyptian Standards 4756‐1/2012
b) Egyptian Standards (ES 583) /2012
c) British Standards (BS‐12)
3.2.1.2 Cement shall be delivered in the original sealed, sound secured bags. All bags shall be
stored on a raised wooden floor in properly constructed sound, dry, weatherproof covered
place. Any cement affected by damp or otherwise imperfect shall be removed from site.
3.2.2 STEEL REINFORCEMENT
3.2.2.1 Steel reinforcement shall conform to the Egyptian Standards 262 (steel bars for concrete
reinforcement) with the following characteristics:

Yield Tensile stress Minimum

Stress Kg/mm2 Elongation
kg/mm2
24 35 20
- Steel 24/35 (Normal Mild Steel)

36 52 12
- Steel 36/52 (Ribbed High Tensile Steel)

40 60 10
- Steel 40/60 (Ribbed High Tensile Steel)

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3.2.2.2 Manufacturer certificates indicating mechanical and chemical properties of the steel
shall be submitted to the Engineer for approval prior to placing order. All reinforcement shall be
of production of one manufacturer unless otherwise approved by the Engineer.
3.2.2.3 Steel reinforcement shall be stored on shaped concrete floors, 15 permission will be
given for storing steel reinforcement on soil. Bars of each size shall be stored separately.
3.2.3 AGGREGATES
3.2.3.1 Aggregates for concrete shall be materials from natural sources and shall conform to
E.S.I109/2002 (concrete aggregates from natural sources).
3.2.4 LIGHT WEIGHT AGGREGATES
Light weight aggregates shall of types suitable for concrete as leca (light expanded clay
aggregates) produced by National Cement Company or similar. The specific weight of
aggregates shall not exceed 0.8 gm/cm3
3.2.5 WATER
Mixing water shall be potable water, clean and free from harmful matter. Where doubt exist
water shall be tested in accordance with the requirement of BS 3148. The content of salts and
impurities shall not exceed the limits stated in item 2.2.3 of the Egyptian Code.
3.2.6 ADMIXTURES
3.2.6.1 Suitable admixtures may be used to modify certain properties of concrete.
However, as they may at the same time adversely affect other important properties of
concrete, it is essential to carry out preliminary tests with the concrete to which they are
added.
Admixtures containing chlorides must not be used for reinforced concrete.
3.2.6.2 Admixtures shall conform to one of the following standards:
I. Egyptian Standards
2. German Standards
3. American Standards
4. British Standards

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3.2.6.3 Admixtures shall be used according to manufacturer directions and preliminary tests'
results.
Catalogues of products and results of tests on concrete to which the admixtures have been
added shall be submitted to the Engineer for approval before delivery to the site.
3.2.7 CEMENTITIOUS GROUT
Cementious grout as "Master Flow 524M ‐ Master Builder" or similar of the following
characteristics.
Compressive strength (ASTMC‐I 09)
1 day 39 N/mm‐
3 days 43 /mm2
28 days 58 N/mm‐
Flexural strength (BS 6319 Part 3)
28 days 6.95 N/mm2
Tensile strength (BS 6319 Part 7)
28 days 4.04 N/mm‐
Water absorption 01 Part 5: Nil
3.2.8 EPOXY GROUT
Epoxy resin castable grout as "Sikadur 42 ‐ Sika" or similar of the following characterestics
according to E 150 norms (4x4x 16cm prism)
‐ Compressive strength 70‐85 N/mm‐
‐ Flexural strength 30‐35 N/mm2
‐ Tensile strength 15‐20 N/mm2
‐ Bond Strength to concrete 4 N/mm‐
‐ Bond strength to steel (DIN 53232) 15‐20 N/mm‐
‐ Modulus of elasticity (Static) 1400 N/mm2
‐ Coefficient of thermal expansion 43x I 0‐6 (temp to 60°C)

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3.3 DESIGN OF MIX AND CONCRETE PROPORTIONS

3.3.1 Proportion of ingredients for concrete shall be established to provide:
a. Conformance with the strength test requirements
b. Adequate workability and proper consistency to permit the concrete to be worked readily
into the forms and around reinforcement under the conditions of placement to be employed
without excessive segregations.
3.3.2 All mixes shall be designed in approved well known laboratories. The designed laboratory
mixes shall indicate higher strength than the required strength by margins indicated in the
reference specifications (item 2‐6).
3.3.3 The following are the concrete mixes used in the project and the corresponding minimum
cement requirements:
Minimum (N/mm2) Minimum
Strength (Kg/cm2) Cement
Cube -28 days Requirement (kg/m3)
Mix A 30 400
Mix B 35 450
Mix C (lean concrete) 20 250
Light weight Concrete 12 200(light weight
aggregates)
3.3.4 The workability should be controlled by direct measures of water content making
allowance for any water in fine or coarse aggregates. The slump shall be kept as low as possible
consistent with the proper handling and thorough compaction. In no case shall the slump of
concrete be more than 10 cm. The water cement ratio shall be within 0.55, except for water
reservoirs where the ratio shall not exceed 0.45.

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3.4 BATCHING, MIXING AND PLACING OF CONCRETE

3.4.1 Concrete materials shall be measured and batched in modern up‐to‐date calibrated plants
with all necessary scales, bins and mix concrete materials. The plants shall be approved by the
Engineer.
3.4.2 The quantities of cement, fine aggregates and the various sizes of coarse aggregate shall
be measured by weight. The quantity of water shall be measured and monitored for every
batch. Admixtures shall be precisely measured by weight (if solid) or per liter if liquid. All
measuring equipment shall be maintained in a clean serviceable condition. Equipment accuracy
shall be checked before commencement of work and maintained periodically thereafter. The
accuracy of equipment shall fall within the limits in BS 1305 batch type concrete mixers.
3.4.3 The Contractor shall provide standby mixers of suitable capacity in the site that are
capable of measuring, weighing, batching and mixing of concrete so that the placing of concrete
for anyone operation of any structure will be continued from start to finish. The Contractor
shall calibrate and furnish certificates of scales and metric devices every 3 months during
production of concrete.
3.4.4 Concrete plants and mixers manufacturers’ manuals shall be presented to the Client's
Representative to monitor all operation procedures including material weighing, mixing speed,
number of drum revolutions, mixing time ... etc.
3.4.5 Concrete ingredients shall be mixed at the drum rotation speed recommended by the
mixer manufacturers. Generally the mixing time for one cubic meter batch shall not be less than
90 seconds after all materials are in the mixers. The mixing �me shall be increased by 20
seconds for each additional cubic meter or fraction thereof. Controls shall be provided to
ensure that the batches cannot be discharged until the required mixing time has elapsed.
3.4.6 The entire contents of the mixers shall be removed from the drum before materials for
the succeeding batch are placed therein. The materials composing a batch shall be

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simultaneously mixed except that about 10% of the mixing water shall enter in advance of the
cement and aggregates.

3.4.7 When a truck mixer is used for complete mixing, 70 to 100 revolutions of the drum or
blades at the rate of rotation designated by the manufacturer as mixing speed are required to
produce the specified uniformity of concrete. Not more than 100 revolutions at mixing speed
may be used. All revolutions after 100 should be done at a rate of rotation designated by the
manufacturer as agitation speed unless otherwise specified by manufacturer. Mixing speed is to
be 8 to 12 rpm and agitating speed is 2 to 6 rpm. In all cases the concrete shall be delivered and
discharged within I 1/2 hour or before the drum has revolved 300 times after introduction of
water to the cement and aggregates or the cement to aggregates.
3.4.8 The volume of batch in the mixer or the truck agitator shall in no case be greater than the
manufacturer's rated capacity. Mixer blades shall be replaced when they lost 10% of their
original height.
3.4.9 Unless otherwise specified, ready mixed concrete shall conform to BS 8500. Copies of all
delivery notes shall be submitted to the Client's Representative in duplicate, and shall include at
least the following information.
1. Name of supplier, serial number of ticket and date.
2. Truck number.
3. Name of Contractor.
4. Name of Contract and location of office.
5. Grade of concrete.
6. Specified workability.
7. Type and source of cement.
8. Source of aggregate.
9. Nominal maximum size of aggregate.
10. Quantity of each concrete ingredient.
11. Type of admixture and quantity.

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12. Water content

13. Time of loading and departure from ready‐mix plant
14. Arrival and departure times of truck
15. Time of completion of discharge
16. Notations to indicate equipment was checked and found to be free of contaminants prior to
batching.
A copy of the delivery note shall be given to the Client's Representative's site representative for
each load.
3.4.10 Transportation, delivery and handling shall be in accordance with the requirements of
the Egyptian code.
3.4.11 Concrete shall be conveyed from the mixer to the place of final deposit by methods
which prevent the separation or loss of materials and without interruptions sufficient to permit
loss of plasticity between successive increments. Truck agitators or truck mixer operating at
agitating speed only shall be used for transportation of ready mixed concrete unless a special
permission is given for using non‐agitating trucks having proper body proportions so that
concrete is delivered without segregation. The specified time of haul shall be reduced to a
maximum of 20 minutes in case none agitating trucks are used.
3.4.12 Concrete can be pumped to places of charge within the maximum lengths allowed by
pumps manufacturers taking into consideration reductions due to curves, lifts, shapes . . etc.
Aluminum pipes must NOT be used for transporting pumped concrete due to unfavorable
reactions between aluminum and alkalis in cement for pumped concrete, the maximum size of
aggregates should not be greater than one quarter of the internal diameter of the pipe.The
slump shall be in the range 7.5 to 15 cm. Admixtures shall be used with caution to avoid
adverse effects under pumping conditions.
3.4.13 Concrete shall be carefully handled, transported and placed so that the completed work
is consistent throughout. Vertical drops (down pipes) shall be provided at the discharging points
of mixers to minimize segregation of concrete components. Chutes should be of metal or metal
lined, sufficiently large to avoid concrete overflow. Slopes of chutes shall be neither fla�er than
I to 3 nor steeper than I to 2. Vertical down pipes shall be provided at the chute end to
eliminate segregation. The length of chutes shall not exceed 3.00ms. Buckets, handled or

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transported by cranes shall be provided with controlled gates operated manually or

mechanically. Concrete should not be permitted to drop freely for more than 1.5 ms otherwise
metal chutes or pipes shall be provided.

3.4.14 before concrete is placed, forms, reinforcement and other embedded parts shall be
rigidly secured in proper position. All dirt, mud, water and debris shall be removed from the
space to be occupied by the concrete. All surfaces which may have encrusted with dried mortar
or concrete from previous placement operation shall be cleaned and the entire installation shall
be completely ready for placing concrete.

3.4.15 Concrete shall be deposited as near as practicable to its final position to avoid
segregation due to re-handling or flowing. The use of vibrators for transportation of concrete is
completely prohibited.
3.4.16 Concrete shall be deposited continuously or in layers of such thickness that no concrete
will be deposited on concrete which has hardened sufficiently to cause the formation of seems
or planes of weakness within the section. The depth of a layer shall not exceed 30 cm. Placing
shall be carried on at such a rate that the concrete which is being integrated with fresh
concrete is still plastic. Plastic concrete is defined as concrete which can be re‐vibrated at least
to the extent that an immersion type vibrator spud will penetrate the concrete at least 25 mm
by vibrating action under its own weight.
3.4.17 Concrete shall be consolidated by vibration so that the concrete is thoroughly worked
around the reinforcement, around embedded items and into corners of forms, eliminating all
air or stone pockets which may be form honeycombing pitting or planes of weakness. Internal
vibrators shall have a minimum frequency of 10000 cycles of vibra�
ons per minute and
sufficient amplitude to consolidate the concrete effectively. External vibrators (rigidly clamped
to the form work) shall be used especially in places where internal vibrators cannot be
sufficiently used. The frequency of the external vibrators shall be less than of not be less than
3000 cycles per minute. The formwork be strong and tight to disallow distortion and leakage of
grout.

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3.4.18 placing of girders and slabs shall continue from corners to center to avoid forma�on of
weak planes at highly stressed points. It is recommended to construct the forms to the levels of
the planned construction joints, over‐filling the forms by 5 cm of concrete and then removing
the excess concrete just before setting occurs.

3.4.19 Paints (or primers) applied to the structural steel parts in contact with concrete shall be
of special types not affecting the bond between concrete and steel. The paint shall be applied
according to manufacturer directions.
3.4.20 Place all sleeves, inserts, anchors, and embedded items required for adjoining work or
for its support, prior to concreting.
3.4.21 Give contactors whose work is related to concrete or supported by it ample no�
ce and
opportunity to introduce and/or furnish embedded items before concrete placement.
3.4.22 Position expansion joint material, and other embedded items accurately and support
against displacement .Fill voids in sleeves, inserts and anchor slots temporarily with readily
removable materials to prevent entry of concrete.
3.4.23 Fix weep hole pipes at places designated on drawings or approved by the Client's
Representative.

3.5 CURING OF CONCRETE

3.5.1 Concrete shall be maintained with minimal moisture loss at a relatively constant
temperature for the period necessary for hydration of cement and hardening of concrete.
Curing shall be continued for at least 10 days after placement of concrete. Curing for surfaces
placed against wooden forms or metal forms shall be done by keeping the forms wet until they
can be safely removed. For concrete surfaces not in contact with forms curing shall be made
either by continuous sprinkling or by application of sand kept continuously wet.
3.6 PLACING AND SHAPING OF REINFORCEMENT BARS
3.6.1 Before commencement of works in any of the elements, the Contractor shall submit to
the Engineer 3 copies of the detailed bending lists for approval. The lists shall indicate shape,
diameter, length, number and weight of every bar in addition to the total weight of bars in
every element.

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3.6.2. All bar reinforcement shall be bent cold, before the bars are placed in position
3.6.3 Welding of bars is not permitted unless otherwise approved by the Engineer for steel bars
satisfying welding conditions).

3.6.4 All reinforcement, at the time concrete is placed, shall be free of mud, oil, grease, loose
rust, mill scale or other materials which may adversely affect or reduce the bond. The steel
reinforcement shall be brushed with steel brushes and cleaned with air jets if required by the
Engineer.
3.6.5 All reinforcement shall be supported and fastened together to prevent displacement by
construction loads or placing of concrete. Supporting concrete blocks shall be used between the
steel reinforcement and the forms. Bare metal supports shall not be used in contact with forms
for exposed surfaces.
3.6.6 Splices, bending of steel and other details concerned with shaping of steel reinforcement
shall be done according to the Egyptian code for Reinforced Concrete Works unless otherwise
indicated on the Drawing.
3.7 FORMS
3.7.1 Forms shall be designed to produce hardened concrete having the shape, lines, levels and
dimensions indicated on the drawings. They shall be also able to withstand, without
displacement or vibrations, movement of men, weight of materials and all other loads to which
they may be subjected.
3.7.2 Formwork shall be of sound timber or other approved material and shall be substantial
and sufficiently tight to prevent leakage of mortar. They shall be properly braced or tied so that
they will maintain the required position, shape and alignment during and after placing concrete
therein. Vertical studs, internal ties and other form supports shall be of sufficient size and
number and shall be located and spaced such that all acting loads are safely resisted.
3.7.3 Internal metal ties shall be reduced to a minimum. The ties shall be of type designated for
use for exposed surfaces and shall permit their removal to a depth at least 1.5 cm from the face
of the wall without injury to the concrete. All fittings for metal ties shall be of such design that

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upon their removal the cavities which are le�will be of the smallest possible size but not
exceeding 2.5cm in diameter.

The cavities shall be filled with cement mortar (preferably with antishrink additives) and the
surfaces shall be left, sound, smooth, even and uniform. System using pipes passing through
the walls are not permitted unless otherwise approved by the Engineer. Internal ties shall not
be used for underground or water structures.
3.7.4 Forms for surfaces indicated or required to be "Fair Face Concrete" shall be of
PREFABRICATED
PLYWOOD PANEL FORMS, job built plywood forms, or forms that are lined with plywood. The
forms shall be laid out in a regular and uniform pattern with the long dimension of panels
vertical and all joints aligned. The forms shall produce finished surfaces that are free from
offsets ridges, waves, and concave or convex areas. The maximum deviation from a true plane
shall not exceed (3 mm) in (J 80 cm). Plywood and fiberboard shall be new when it is brought to
the construction site and shall be properly stored, protected and maintained throughout its
use.
3.7.5 Forms shall not be re‐used unless they are well maintained and repaired so as to produce
the same surface produced by the first time use. Special attention shall be paid to the water
tightness and surface smoothness of the re‐used forms. Forms which are unsatisfactory in any
respect shall not be re‐used. Exposed surface forms shall be only treated with approved form
coatings which do not affect the surface appearance concrete characteristics or protective
coating application.
3.7.6 Forms shall be removed according to the following directions
3.7.6.1 Formwork for sides of girders and other parts not supporting the weight of concrete can
be removed after 24 hours provided that the concrete is sufficiently hard not to be injured
thereby.

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3.7.6.2 Slabs and beams soffits: according to the following formula but not less than 7days and
not more than 2 days + 2.0 times the smaller span of beams or slabs (measured in ms).
3.7.6.3 2 days + 4 times span (measure in ms.)
But not less than 7 days
3.7.6.4 Periods mentioned above commence from the last day on which concrete was placed in
the part of the structure concerned.

3.8 SURFACES FINISH

3.8.1 Exposed fair face concrete shall be finished as described in item 3.10.4
3.8.2 For formed surfaces when plaster or stucco or lining is to be applied, the concrete shall be
cast against rough faced form boards (but not very rough to disallow striking of forms). The
gradual irregulars measured by a template 1.5 m length should not exceed 5 mm.
3.8.3 For formed surfaces of foundations, depressions within the surfaces shall not exceed 10
mm if measured into a template 1.5 m length.
3.8.4 Unformed surfaces of slabs
Scratched finish, for surfaces to receive mortar topping .
Float finish, for surfaces to receive tiles (and for foundation).
3.9 CONNECTION TO OTHER WORKS
Before placing concrete all bolts, pipes or conduits or any other fixtures which are to be built in
shall be fixed in their correct positions. Cores and other devices for forming holes shall be held
fast by fixing to the formwork. Block out of polystyrene foam may be used for forming voids for
fixing base plates or other embedded items and shall be carefully installed in their proper
position. The exposed steel parts shall be painted with zinc epoxy weather resistant paint, min
60 micron dry film. Subject to the approval of the Engineer, grouting shall be either
a. By use of concrete of the same strength as the original concrete, but with aggregates of
maximum I O mm nominal size and addition of a plasticity admixture complying with ASTM
C494 type D or similar French, British or German Specifications.
b. By use of ready mixed non shrink high strength grout to reach a minimum strength
= 40 N/mm2 after one day.

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3.10 Patching formed surfaces of concrete

3.10.1 After the forms removal, all concrete surfaces shall be inspected and all poor joints,
voids, air pockets or other defective areas permitted by the Engineer to be patched, shall be
patched before the concrete is thoroughly dry. Defective areas shall be chipped to a depth of
not less than 25 mm with the patched edges perpendicular or the surface. The area to be
patched together with a space of at least 15 cm wide surrounding shall be wetted to prevent
absorption of water from the patching mortar.

3.10.2 A grout of equal parts of Portland cement and sand with sufficient water to produce a
suitable consistency shall then be well applied into the surface, followed immediately by the
patching mortar. The patch shall be made of the same material and of the same proportions as
used for the concrete, except that the coarse aggregate shall be omitted. The amount of mixing
water shall be as little as consistent with the requirements of handling and placing. The mortar
shall be retempered, to be used within a maximum of one hour, by continuous mixing. Without
the addition of water.
3.10.3 The mortar shall be thoroughly compacted into place and screeded off so as to leave the
patch slightly higher than the surrounding surface. It shall then be left undisturbed for a period
of one to two hours to permit initial shrinkage before being finally finished. The patch shall be
finished in such a manner as to match with the adjoining surface. The holes left by withdrawal
or rods shall be filled solid with mortar after first being thoroughly wetted. For holes passing
entirely through the wall, a plunger type grease or other approved device shall be used to force
the mortar through the wall.
3.12 ANCHOR VOIDS & ANCHOR BOLTS
Anchor voids shall be formed using polystyrene blocks or wooden forms. The blocks or forms
shall be carefully removed after placing and hardening concrete and the surface shall be
thoroughly prepared according to Engineers directions taking into consideration the grout
manufacturer directions. The selection of grout (either cementitious or epoxy) shall be based
on suitability of grout to sustain the acting forces and stresses (vibrations, compressive
strength, .. )

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Epoxy grout shall not be used in places of temperature exceeding its allowable working
temperatures.
3.13 QUALTY ASSURANCE AND QUALTY CONTROL
3.13.1 The Contractor shall at his own expense, perform the following tests for quality control
of concrete and steel. Tests which are not performed in the site laboratory, shall be conducted
in well recognized approved laboratories. Test shall conform to relevant Egyptian or American
or British standards.

3.13.2 CONCRETE MATERIALS TEST:

A. CEMENT:
Cement shall be tested before use and during construction to ensure its conformity with the
Specifications in a minimum rate of one test for every 80 tons delivered to the Site. The tests
shall include chemical analysis, strength requirements, setting time and all other relevant tests
required by the Specifications.
B. STEEL BARS:
Tensile tests, cold bend tests and allowable discrepancies in dimensions checks shall be
performed according to the specifications for each group of bars weighing 50 tons.
C. AGGREGATES:
Regular test shall be made for every 50 cubic meters of fine aggregates and 100 cubic meter
coarse aggregates. Tests shall include sieve analysis, moisture content, organic impurities, bulk
density and aggregate volume weight and all other tests specified in the Specifications.
3.13.3 CONCRETE TESTS
SLUMP TEST:
A slump test shall be made from each of the first three batches mixed each day. An additional
slump test shall be made for every 40 (forty) cubic meters of concrete in any day or whenever
requested by the Engineer. The slump test shall be conforming to the provisions of B.S. 1881
"Method of Testing Concrete".
B. COMPRESSIO TEST:

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Test cubes shall be prepared, cured and tested in accordance with B.S. 1881 "Method of Testing
Concrete". Two sets of compression test cubes shall be made each day when 80 cubic meters or
less of concrete are placed. Two additional sets shall be made for each additional 80 cubic
meters or major fraction thereof placed in anyone day. A set of test specimen shall consist of six
cubes all made from the same batch. Three cubes of each test shall be tested after 7 (seven)
days and other three cubes at 28 (twenty eight) days. When special types of forms are
requested to be removed at earlier periods the periods previously indicated will be adjusted
according to the Engineer's directions.

3.13.4 GROUT
Grout shall be tested periodically by conducting mechanical tests on samples selected by the
Engineer.

END OF SECTION

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Section (4)
Masonry
4.1 General
4.1.1 This Section Covers the Specifications of masonry work for the Project.
4.1.2 Reference shall be made to the Egyptian code for the design and code or the design and
code for design and construction of Masonry Works, ECP-204-2005.
4.2 Materials
4.2.1 CEMENT:
Cement shall conform to the Egyptian Specifications ES 371 Ordinary Portland cement and
Rapid
Hardening Cement.
4.2.2 LIME
Quick and hydrated lime conform to ES 584. Tests shall be made in accordance with ES 597
(methods of testing limes).
4.2.3 Sand shall be delivered from approved sources and shall conform to ES1108 "Sand for
Building Mortars".
4.2.4 WATER:
Only clean fresh water from mains or other sources approved by the Engineer shall be used.
When doubt exists, water shall be tested in approved labs.
4.2.5 HOLLOW CONCRETE BLOCKS:

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Hollow concrete blocks shall be obtained from an approved manufacturer and shall conform
to ES 1292. Ordinary Portland cement or Portland Blast furnace should be used in manufacture
together with approved type of aggregates conforming to ES I 109.Approved admixtures may
be used to improve certain properties (as setting time) on condition that no harmful effect
occurs to the other concrete properties. Allowance in dimensions shall be +3 mm and ‐5mm in
length and height and + 3mm in depth. The minimum average compressive strength for 10 units
shall not be less than 70Kg\cm2. The minimum strength for one unit shall not be less than 56
kg/ cm2. The thickness of block walls, top and webs shall not be less than 25 mm. The volume of
voids should not exceed 50% of the total volume of block. Steam curing is preferable to the
normal

water curing to speed up the works. In all cases the blocks shall not be used before attaining
70% of the minimum required strength.
4.2.6 SOLID CONCRETE BRICKS
Solid concrete bricks shall conform to ES 1292. The percent of voids shall not exceed 25%. The
average compression stress shall not be less than 70 Kg/ cm2 (per 10 units) and 56 Kg/ cm2 for
one unit.
4.2.7 CLAY BRICKS (TAFLl)
Clay bricks shall be mechanically manufactured and obtained from approved manufacturer.
The bricks shall be of regular dimensions with sharp well defined arrises. The average
compressive strength shall not be less than 50 Kg/cm2. The average water absorption by weight
‐ when determined by the five hour's boiling test ‐ shall not be greater than 15%
(Fifteen percent) by weight. Allowance in dimensions shall not exceed 5 mm for length and 3
mm for thickness and width.
4.2.8 SAND LIME BRICKS
Sand lime bricks shall conform to ES 42/1980. The bricks compressive strength shall not less
than 150 kg/cm2 and the absorption shall not exceed 10%. Tolerances in dimensions shall not
exceed ± 3mm for length and ± 2mm for width and thickness.
4.2.9 FIRE BRICKS

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Fire bricks shall be product of specialized manufacturer as "Sornage‐Egypt" or similar. Unless

otherwise specified the fire bricks shall be of the following properties
1. Alumina percent 38/40%
2. Density 2.0gm/cm3
3. Apparent porosity 20‐25%
4. Max resistant temp 1370C
5. Crushing strength (Min) 250Kg/cm2
4.2. 10 WALL CONNECTORS
Walls connectors for connecting bricks to concrete joints shall be made of galvanized steel
as produced by Metalex ‐ Egypt or similar.

4.3 Mortars
4.3.1 Mortar for burnt clay bricks, concrete hollow blocks and concrete bricks shall consist of
300Kg cement to one cubic meter of sand. Admixtures to improve workability are to be used as
required.
4.3.2 The ingredients for cement, lime, sand shall be measured in proper gauge boxes on a
boarded platform, the ingredients being turned over twice dry and twice whilst water is added
through a hose.
Alternatively, mixing may be by means of an approved mechanical batch mixer. Mortars shall
be used within two hours of mixing.
4.4 Sample Masonry Panels
After all materials samples are approved, construct sample panels of each type of brick walls on
the site, not less than 2m x 1.5m, to be approved by the Engineer. Leave sample panels in place
until brick work has been completed and accepted.
4.5 Laying of Brick Block Work
4.5.1 All brickwork shall be set out and built to the respective dimensions, thickness and heights
shown on the Drawings.
4.5.2 In dry weather, all clay bricks and concrete blocks shall be well soaked before being used
and the tops of walls left off shall be wetted before work is commenced.

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4.5.3 All bricks and blocks shall be well buttered with mortar before being laid and all joints
shall be thoroughly flushed up as the work proceeds.
4.5.4 Brick work shall be carried up in a uniform manner, no one portion being raised more than
1.00 meter above another at one �
me. All perpends, quoins, ... etc. shall be kept strictly true
and square and the whole properly bonded together and leveled round each floor.
4.5.5 Generally, brick works, including facing shall be built in Flemish bond or other approved
types of bonds. Half brick walls, blocks and casings to cavity walls, shall, unless otherwise
directed by the Engineer be built in stretcher bond. Alternatively, half‐brick walls in facing shall
be built with snap headers to match bond of solid walls. All concrete block units shall be laid in
running bond with vertical joints of one course over the center of the unit in the preceding
course.

4.5.6 No Four Courses Shall rise more than 4 (Four cm) above the same laid dry.
4.5.7 Joints in masonry walls that are to receive plaster shall be racked out to a depth of 1.5 cm
to form a key with plaster. Joints in facing bricks or exposed walls shall be formed with steel bar
and tooled to a smooth concave configuration. Exposed joints shall be pointed with rich cement
mortar cement (450 kg/m3 of sand if required).
4.5.8 Brick and block layers shall be sprayed thoroughly with water two times a day for the next
three days following the day of their laying.
4.5.9 The brick walls shall be bonded to the concrete columns with galvanized steel connectors
conforming to item 3.2.11. The connectors shall be fixed at distances not exceeding 50 cm.
4.5.10 Cover all joints between walls and concrete columns and beams with galvanized steel
metal lath. 40 cm width. The lath shall be fixed to walls and concrete elements using rails and
shall receive a scratch coat according to the stipulations stated in plaster.
4.5.11 Brick and block work shall be sprayed with water twice a day for a minimum of seven
days.
4.5.12 Provide reinforced concrete horizontal intermediate ties for walls exceeding 4 ms height
as well as on top of walls not ended with beams or ceilings. Also vertical reinforced concrete

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posts shall be provided where walls areas exceed 20m2. The concrete and steel reinforcement
shall be considered as included in masonry prices.
4.5.13 Fire brick walls shall be built using special fire resistant mortar supplied by the brick
manufacturer.
4.6 QUALITY CONTOL
Tests to check bricks conformance to the specifications, mainly compression tests, water
absorption and tolerance dimensions, shall be conducted at the Contractor's expense in
approved laboratories for every 2000 concrete blocks and 500 bricks.

END OF SECTION

ACE Project Management I-City Project