Sepa15014 MFSTD CV 00 SPC 002 Concrete Works Rev 0

CONCRETE WORKS
PROJECT CODE: SEPA15014
UTAPATE TERMINAL
CONCRETE WORKS
DOCUMENT NO.: SEPA15014-MFSTD-CV-00-SPC-002
Transmittal No: UTAPATE TERMINAL/DET/PTSPL/TR-0743
0 07 Dec 2022 ISSUED FOR APPROVAL KA CN ASK
REV. DATE PURPOSE BY. CHECKED APPROVED

UTAPATE TERMINAL
NNPC E&P LTD, NOSL & BADUGO
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CONCRETE WORKS Rev No. : 0
REVISION DESCRIPTION SHEET
Rev.
Paragraph Reference Revision Description Date
No.
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Table of Contents
Contents
1. INTRODUCTION ............................................................................................................................. 7
1.1. PURPOSE ....................................................................................................................................... 7
1.2. SCOPE ............................................................................................................................................ 7
1.3. ABBREVIATIONS ........................................................................................................................... 7

2. CODES & STANDARDS................................................................................................................. 8
Table 2.1 – Concrete Codes and Standards (American codes) ............................................................. 8
2.1. CONFLICTING REQUIREMENTS ................................................................................................ 11
2.2. ORDER OF PRECEDENCE.......................................................................................................... 11

3. UNIT OF MEASUREMENT ........................................................................................................... 11
3.1 MATERIAL SOURCES .................................................................................................................. 11
3.2 SUB CONTRACTORS/VENDORS................................................................................................ 12
3.3 EXISTING SERVICES AND FACILITIES ...................................................................................... 12
4. PREPARATORY WORK............................................................................................................... 13
4.1 SETTING OUT .............................................................................................................................. 13
4.2 SITE PREPARATION, EXCAVATION, BACKFILL AND TEMPORARY DRAINAGE ................... 13
5. MATERIALS.................................................................................................................................. 13
5.1 CEMENT ....................................................................................................................................... 13
5.1.1 Test certificate ............................................................................................................................. 14
5.1.2 Cement Transport ...................................................................................................................... 14
5.1.3 Cement Storage .......................................................................................................................... 14

5.2 AGGREGATES ............................................................................................................................. 15
5.2.1 Aggregate grading ..................................................................................................................... 16
5.2.2 Sampling and Testing of Aggregates ..................................................................................... 16
5.2.3 Aggregate Transportation ........................................................................................................ 16
5.2.4 Storage of Aggregates .............................................................................................................. 17

5.3 REINFORCING STEEL ................................................................................................................ 17
5.3.1 General ........................................................................................................................................ 17
5.3.2 Fabric reinforcing ....................................................................................................................... 17
5.3.3 Spacers ........................................................................................................................................ 17

5.4 WATER.......................................................................................................................................... 18
5.5 ADMIXTURES AND ADDITIVES ................................................................................................. 19
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5.5.1 Admixtures .................................................................................................................................. 19
5.5.2 Additives...................................................................................................................................... 20
5.6 GROUTING ................................................................................................................................... 20
5.7 ANCHOR BOLTS .......................................................................................................................... 21
5.8 WATER STOPS ............................................................................................................................ 21
5.9 EMBEDMENTS ............................................................................................................................. 21
5.10 JOINT FILLER .............................................................................................................................. 21
5.11 CONCRETE MIX DESIGN ........................................................................................................... 21
5.11.1 Grades of Concrete ................................................................................................................... 21
TABLE 5.2 CONCRETE GRADES .............................................................................................................. 22

6. FORMWORK................................................................................................................................. 23
6.1 GENERAL ..................................................................................................................................... 23
6.1.1 Ties and Spacers ....................................................................................................................... 24
6.1.2 Permanent Form work ............................................................................................................... 24
6.1.3 Form work for Externally Vibrated Concrete ......................................................................... 24
6.1.4 Cleaning and Treatment of Forms .......................................................................................... 24
6.1.5 Removal ....................................................................................................................................... 25
6.1.6 Tolerances for Formed surfaces ............................................................................................. 26

7. PLACING REINFORCEMENT ...................................................................................................... 26
7.1 CUTTING, BENDING AND WELDING .......................................................................................... 26
7.2 PLACING ...................................................................................................................................... 26
7.3 HANDLING, STORAGE AND CLEANING .................................................................................... 27
7.4 SPLICING ...................................................................................................................................... 28
8. CONCRETE MEASURING, MIXING, PRODUCTION, TRANSPORTING AND WEATHER
PROVISIONS ................................................................................................................................ 28
8.1 MEASURING, MIXING, PRODUCTION AND TRANSPORTING ................................................. 28
8.1.1 Measuring .................................................................................................................................... 28
8.1.2 Mixing........................................................................................................................................... 29
8.1.3 Transporting ............................................................................................................................... 31

8.2 EXTREME WEATHER PROVISIONS ........................................................................................ 31
8.2.1 Heat of Hydration ....................................................................................................................... 31

8.3 READY MIX CONCRETE ............................................................................................................. 32
8.3.1 Use of Ready-mix concrete ...................................................................................................... 33
8.3.2 Transport and Delivery of Ready-Mix Concrete .................................................................... 33

9. CONCRETE PLACING ................................................................................................................. 34
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9.1 GENERAL ..................................................................................................................................... 34

9.2 PLACING AND COMPACTING OF CONCRETE .......................................................................... 36
9.3 PLACING BY A PUMPING METHOD ........................................................................................... 36
9.4 CONCRETE PLACED IN UNDERWATER STRUCTURES .......................................................... 36
10. JOINTS.......................................................................................................................................... 36
10.1 CONSTRUCTION JOINTS ............................................................................................................ 36
10.2 EXPANSION JOINTS .................................................................................................................... 37
10.3 CONTRACTION JOINTS .............................................................................................................. 37
11. FINISHING AND REPAIR ............................................................................................................. 38
11.1 FINISHING .................................................................................................................................... 38
11.1.1 Formed Surfaces – Classes of Finish..................................................................................... 38
11.1.2 Unformed Surfaces – Classes of Finish................................................................................. 38

11.2 REPAIR ......................................................................................................................................... 39
12. SETTING ....................................................................................................................................... 39
12.1 INITIAL SETTING TIME ................................................................................................................ 39
13. CURING OF CONCRETE ............................................................................................................. 40
13.1 GENERAL ..................................................................................................................................... 40
13.2 HORIZONTAL SURFACES ......................................................................................................... 40
13.3 VERTICAL SURFACES .............................................................................................................. 40
13.4 LARGE FOUNDATIONS / SECTIONS (MACHINERY) ............................................................. 40
13.5 CONTROL OF CURING .............................................................................................................. 41
13.6 TESTING OF CONCRETE .......................................................................................................... 41
13.6.1 Testing ......................................................................................................................................... 41
13.6.2 Compliance ................................................................................................................................. 42
13.6.3 Unsatisfactory Concrete ........................................................................................................... 42
13.6.4 Standard Deviation .................................................................................................................... 42
13.6.5 7-Day Tests ................................................................................................................................. 43
13.6.6 Crushing strength tests for blinding concrete ..................................................................... 43
13.6.7 Measurement of concrete temperature .................................................................................. 43
13.6.8 Cement content and water/ cement ratio ............................................................................... 43
13.6.9 Salt content ................................................................................................................................. 43

13.7 PROTECTION OF CONCRETE SURFACES ............................................................................ 44
13.7.1 General ........................................................................................................................................ 44
13.7.2 Blinding Concrete ...................................................................................................................... 44
13.7.3 Impervious Membrane .............................................................................................................. 44

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13.7.4 Surfaces below Ground Level ................................................................................................. 45
13.7.5 Exposed External Surfaces at Ground Level and above..................................................... 45

14. LIQUID RETAINING CONSTRUCTION ........................................................................................ 45
14.1 GENERAL ..................................................................................................................................... 45
14.2 JOINTS .......................................................................................................................................... 45
15. PRECAST CONCRETE ................................................................................................................ 46
15.1 GENERAL ..................................................................................................................................... 46
15.2 PRECASTING YARD ................................................................................................................... 46
15.3 MOULDS FOR PRECAST CONCRETE ....................................................................................... 46
15.4 MARKING ...................................................................................................................................... 46
15.5 CURING, MATURING AND STACKING ....................................................................................... 46
15.6 CEMENT/SAND MORTAR ............................................................................................................ 47
16. CHEMICAL-RESISTANT STRUCTURES .................................................................................... 47
17. QUALITY PLAN ............................................................................................................................ 47
17.1 GENERAL ..................................................................................................................................... 47
17.2 TEST FOR WATER ..................................................................................................................... 47
17.3 TEST FOR CEMENT ................................................................................................................... 48
17.4 TEST FOR AGGREGATES ........................................................................................................ 48
17.5 TEST FOR REINFORCEMENT .................................................................................................. 50
17.6 TEST FOR ADMIXTURES .......................................................................................................... 51
17.7 TEST FOR FRESHLY MADE CONCRETE ............................................................................... 51
17.8 TEST FOR HARDENED CONCRETE ........................................................................................ 52
CLEAN UP 52
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1. INTRODUCTION
1.1. PURPOSE
Purpose of this document is to provide the requirements for the concrete works to be
performed for MFS Tank Farm Projects at Akwa Ibom, Nigeria.
1.2. SCOPE
The Main Flow station facility (MFS) is a centralized facility handling the production from
various reservoirs and surrounding Satellite fields. Both will be developed in a phased
manner. The total design capacity of the Main Flow Station is to handle 100,000 BLPD of
well fluids in two trains (2 x 50%) in phase 1 with a provision in piping and layout to add 4
x 50,000 BLPD for phase 2 and 250 MMSCFD of associated & non-associated gas and
150,000 BWPD of formation / injection water in phase 1.
Oil will be separated, stabilized, stored, pumped and metered prior to entering the sub-sea
export pipeline for further offshore transport. Gas will be separated, compressed,
dehydrated dew point controlled and re-compressed prior to entering the pipeline
delivering to LPG extraction/Petrochemical plant. Water will be separated, treated and
stored prior to inject in selected reservoirs to maintain reservoir pressure or help in
enhanced oil recovery.
The Tank Farm shall consist of seven (07) Nos. each of 0.5 MB storage tank in Phase
1 and a space provision of five (05) Nos. each of 0.5 MB storage tank in Phase 2.
1.3. ABBREVIATIONS
SHORT NAME DESCRIPTION

MFS Main Flow Station
NNPC Nigerian National Petroleum Corporation
NNPC E&P Nigerian National Petroleum Corporation Exploration and Production
BS British Standards
ACI American Concrete Institute
HSE Health, Safety, Environment
OSHA Occupational Safety and Health Administration
ASTM American Society for Testing and Materials
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2. CODES & STANDARDS
All material specifications shall conform to the requirements of the following latest Codes,
Standards, and Specifications including applicable supplements and revisions, unless
noted otherwise in this specification and / or Project Specifications.
All the works shall be performed and tested in accordance with the latest ACI / ASTM
relevant codes and standards from the regulatory agencies and institutes.
Table 2.1 – Concrete Codes and Standards (American codes)
Reference Title Description
Specifications for tolerances for concrete construction and

ACI 117
materials
ACI 318-14 Building code requirements for structural concrete
ACI 305R Guide to Hot weather concreting
ACI 347R Guide to Formwork for concrete
Guide for measuring, mixing, transporting, and placing

ACI 304R
concrete
Guide to Placing concrete by pumping methods
ACI 304.2R
ACI 309R Guide for consolidation of concrete
ACI SP-66 ACI Detailing Manual
Standard specification for deformed and plain carbon-

ASTM A615/A615M
steel bars for concrete reinforcement
ASTM A996/A996M Specification for Rail-Steel and Axle-Steel Deformed Bars
for Concrete Reinforcement
ASTM Standard specification for Carbon Steel Wire and Welded

A1064/A1064M Wire Reinforcement, Plain and Deformed, for Concrete
ASTM C33/C33M Standard specification for concrete aggregates
Standard test method for compressive strength of

ASTM C39/C39M
cylindrical concrete specimens
Standard test method for organic impurities in fine
ASTM C40/C40M
aggregates for concrete
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Standard test method for effect of organic impurities in

ASTM C87/C87M
fine aggregate on strength of mortar
ASTM C88 Standard test method for soundness of aggregates by
use of sodium sulfate or magnesium sulfate
ASTM C94/C94M Standard specification for ready-mixed concrete
Standard test method for compressive strength of

ASTM C109/C109M hydraulic cement mortars (using
2-in. or [50 mm] cube specimens)
ASTM C114 Standard test methods for chemical analysis of hydraulic

cement
ASTM C117 Standard test method for materials finer than 75-μm (No.
200) sieve in mineral aggregates by washing
Standard test method for lightweight particles in
ASTM C123/C123M
aggregate
Standard test method for relative density (specific gravity)
ASTM C127
and absorption of coarse aggregate
Standard test method for relative density (specific gravity)
ASTM C128
and absorption of fine aggregate
Standard test method for resistance to degradation of
ASTM C131/C131M small-size coarse aggregate by abrasion and impact in
the Los Angeles Machine
Standard test method for sieve analysis of fine and

ASTM C136/C136M
coarse aggregates
Standard test method for density (unit weight), yield, and

ASTM C138/C138M
air content (gravimetric) of concrete
Standard test method for clay lumps and friable particles
ASTM C142/C142M
in aggregates
ASTM C143/C143M Standard test method for slump of hydraulic-cement
concrete
ASTM C150/C150M Standard specification for Portland cement
Standard test method for autoclave expansion of

ASTM C151/C151M
Hydraulic cement
Standard Specification for Sheet Materials for Curing
ASTM C171
Concrete
Standard Test Method for Heat of Hydration for Hydraulic
ASTM C186
Cement
ASTM C188 Standard test method for density of hydraulic cement

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Standard test methods for time of setting of hydraulic

ASTM C191
cement by Vicat needle
Standard test methods for fineness of hydraulic cement

ASTM C204
by air-permeability apparatus
Standard test method for potential alkali reactivity of
ASTM C227
cement-aggregate combinations (mortar-bar method)
ASTM C232/C232M Standard test methods for bleeding of concrete
Standard guide for petrographic examination of

ASTM C295/C295M
aggregates for concrete
Standard specification for liquid membrane forming
ASTM C309
compounds for curing concrete
Standard specification for chemical admixtures for
ASTM C494/C494M
concrete
Standard test method for resistance to degradation of
ASTM C535 large-size coarse aggregate by abrasion and impact in
the Los Angeles machine
Standard test method for total evaporable moisture

ASTM C566
content of aggregate by drying

ASTM C586 carbonate rocks for concrete aggregates (rock cylinder
method)
ASTM C595/C595M Standard specification for blended hydraulic cements
Standard specification for coal fly ash and raw or calcined

ASTM C618
natural pozzolan for use in concrete
Standard specification for slag cement for use in concrete
ASTM C989/C989M
and mortars
Standard test method for acid-soluble chloride in mortar
ASTM C1152
and concrete
Standard test method for electrical indication of concrete's
ASTM C1202
ability to resist chloride ion penetration
Standard test method for water-soluble chloride in mortar

ASTM C1218
and concrete

ASTM C1260
aggregates (mortar-bar method)
Standard test method for determination of length change
ASTM C1293
of concrete due to alkali-silica reaction
Standard specification for mixing water used in the
ASTM C1602
production of hydraulic cement concrete
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ASTM C1603 Standard test method for measurement of solids in water
AASHTO American Association of State Highways and

Transportation Official Standard Specifications for
Highway Bridges
2.1. CONFLICTING REQUIREMENTS
In case a conflicting requirement is mentioned between individual documents, the conflict

shall be reviewed, discussed, analysed and design basis shall be developed by for
company’s approval in a technical query format based on precedence of documents as
mentioned in clause no. 2.2 as below with sound engineering practices. In all such cases
of conflict COMPANY’s decision shall be final.
2.2. ORDER OF PRECEDENCE
In case of conflict between the requirements of this specifications and the reference codes,
standards and specifications, the following precedence shall apply:
1. The Laws, Standards and Regulations of Nigeria.
2. Process Industry Practices (PIP)
3. Project Standard and Specifications.
4. International oil and gas industry Codes, Standards and Recommended
Practices (all where specified in the above or, where none of the above is
applicable, as proposed by CONTRACTOR and Approved by COMPANY.
5. Internationally recognized oil and gas industry sound practices.
3. UNIT OF MEASUREMENT
All dimensions, quantities and units of measurement used in drawings and calculations
may be given in MKS (Meter Kilogram Second) units
3.1 MATERIAL SOURCES
All material sources shall be approved by COMPANY. All materials must be selected
from the approved sources.
The CONTRACTOR shall submit full details of each proposed material a minimum of
two weeks prior to establishing the mix designs to allow detailed review by
COMPANY.
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Submittals shall include the following:
 MANUFACTURER’S details.
 Fully detailed data sheets showing all chemical and physical information.
 Recent test results (not more than 3 months old).
 Detailed technical assessment, which confirms that all materials meet the
requirements of this specification.
 Details of MANUFACTURER’S Quality Assurance System.
 Details of MANUFACTURER’S Quality Control Procedures.
The CONTRACTOR shall submit an “Compliance Certificate” before beginning

construction. The certificate shall confirm that all material meets the requirements of
this specification.
3.2 SUB CONTRACTORS/VENDORS
The CONTRACTOR shall take the responsibility and overall guarantee for the concrete
supply and construction.
It is the CONTRACTOR’S responsibility to enforce all Purchase Order and Design

General Specification requirements on its SUB CONTRACTORS / VENDORS.
The CONTRACTOR shall submit all relevant SUB CONTRACTORS / VENDORS

technical data to the COMPANY.
The CONTRACTOR shall obtain and transmit all SUB CONTRACTORS /

VENDORS warranties to the COMPANY.
3.3 EXISTING SERVICES AND FACILITIES
Before beginning work, the CONTRACTOR shall ascertain the nature and location of
all existing above and underground services and facilities on site and in adjacent
areas by inspecting available plans or, if necessary, by hand excavation. COMPANY
will make available, for review, any existing layout drawings which cover the area of
work. CONTRACTOR will be responsible for confirmation, or otherwise, of any such
information given.
The CONTRACTOR shall take every precaution including providing temporary

supports, bridging, shoring, and safety barriers to protect the existing services and
facilities from damage or interference during construction. The CONTRACTOR’S
precautions shall be subject to approval by COMPANY.
The stability of supports, bridging, shoring, etc, shall be proven by calculation based
on realistic and available data.
The CONTRACTOR shall notify COMPANY in writing if any previously unrecorded

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services or other objects are discovered before or during construction. The

CONTRACTOR shall record and give to COMPANY accurate description,
dimensions, location, and elevations related to reference datum and other relevant
details of such services.
A certificate or permit shall be obtained from COMPANY, indicating that services

have been cut off and made safe and specifying any services or other facilities
adjacent to site including related safety aspects and measures which must be
maintained during the execution of the work. The CONTRACTOR shall confirm
independently that service have in fact been cut off and made safe.
When the CONTRCTOR needs to block drainage paths during construction, they
shall provide temporary or permanent alternate routing during construction and
restore the drainage to the satisfaction of COMPANY when construction is complete.
When the CONTRACTOR accidentally damages existing structures or facilities, they

shall repair or replace them at no cost and to the satisfaction of COMPANY.
Suitable temporary roads shall be laid to provide access for all construction activities
and should preferably coincide with permanent routes.
4. PREPARATORY WORK
4.1 SETTING OUT
Setting out of work and foundation earthworks including grade preparation, excavation
and backfilling shall be in accordance with Document No SEPA15014-MFSTF-CV-00-
SPC-0001. “Specification for site preparation and earthworks”.
All work shall be set out accurately from datum and benchmarks. During execution
the correct position, level and alignment of all parts of the work shall be ensured at
all times.
Setting out shall meet the requirements of ACI 117.
4.2 SITE PREPARATION, EXCAVATION, BACKFILL AND TEMPORARY DRAINAGE
Site preparation, excavation, back fill and temporary drainage shall be in accordance
with Document No. SEPA15014-MFSTF-CV-00-SPC-0001, “Specification for site
preparation and earthworks.
5. MATERIALS
5.1 CEMENT
All information regarding the cement, such as certificates, concrete mix trials, test
results, etc. shall be made available to COMPANY.
.
For general applications, Portland cement shall conform to ASTM C150 Type I,
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which shall be used in all areas (above and below ground, pavement, and slabs on
grade).
All selected cement shall conform to the recommendations of the geotechnical

investigation report.
5.1.1 Test certificate
A Manufacturer's test certificate, indicating the particular batch number or production

date, etc. shall be submitted by the Supplier before or during the delivery of the
cement.
Manufacturer certificates should confirm that cement delivered to the site has been
tested and found to comply with the requirements of the appropriate standard and
this section. The certificate shall be delivered to site prior to dispatch of each
consignment. If subsequent tests on any consignment of cement show it does not
comply with specification requirements, then the whole consignment shall be
removed immediately from the Site notwithstanding the manufacturer's certificate
results.
Access to the cement store shall be provided during working hours for the purpose
of sampling the cement for further testing.
Testing of cement shall be as per clause 17.3 of this specification.
Blending or batch mixing at blending plant other than cement factory mill shall not be
acceptable.
Before or after delivery COMPANY shall have the right to check any cement and/or
associated documentation. COMPANY may reject the cement if it does not comply
with this specification.
COMPANY reserves the right to take samples and order any additional tests.
5.1.2 Cement Transport
The cement shall be delivered to the site in ply bags or in bulk carriers. Bags
transported by sea shall be packed in plastic. The name and brand of the
manufacturer, including batch number or fabrication date, shall be plainly marked on
the bags.
Cement delivered hot from the factory shall not be used until its temperature is below 35oC.
5.1.3 Cement Storage
Cement storage shall afford easy access for inspection and identification of each
shipment in accordance with test reports.
The bulk cement shall be stored in a silo. The silo shall comply with the following:
 In hot climates the silo shall be painted in a reflective white color;

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 In all areas the temperature shall not exceed 40 °C.
The cement shall be suitably protected during storage to avoid deterioration in quality.
Cement which has been in storage for more than 3 months from the date of
manufacture shall be tested to verify that its quality is still in accordance with the
standards referred to in 5.1.1 or 5.1.2.
Sufficient cement for continuous execution of works (one week's consumption as a

minimum) shall be always available. If cement in bulk is to be used, prior approval
shall be obtained.
The presence of lumps will lead to rejection of the cement. Cement older than 6
months shall not be used.
The cement shall be stored in such a way that the date of manufacturing is clearly
visible so that it is used in sequence by the date of manufacture, oldest first.
Bagged cement shall be delivered to site in the manufacturer's original sealed bags
or containers and shall be stored in a dry, weather tight, properly ventilated covered
structure, with adequate provisions for preventing the absorption of moisture and
raised at least 150 mm off the ground to prevent deterioration. Not more than 10
small bags or 3 'Big Bags' shall be piled one on top of the other while storing at site.
Cement storage area shall be provided with the following:
 concrete floor;
 waterproof walls and roof;
 ventilation in the building to prevent condensation;
 adequate drainage system;
5.2 AGGREGATES
All aggregates shall be from approved sources.
Coarse and fine aggregates shall comply with ASTM C33 or approved equivalent.
The content of water-soluble chlorides (expressed as Cl), in combination with the

chloride content from the other constituent materials, shall not exceed the limits
according to BS EN 206-1 or approved equivalent
The content of acid-soluble sulphates (expressed as calculated SO3 equivalent) shall

not exceed 0.4 % by weight of fine aggregates and 0.4 % by weight of coarse
aggregates.
The aggregates shall be examined in accordance with ASTM C295 to determine

presence of alkali-reactive constituents or other deleterious reactivity.
At all times, the aggregates shall be free of impurities and if not, the aggregates shall
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be washed mechanically with water (with properties as specified in Clause 8.4) to

remove clay, silt and fine dust.
Note: Some aggregates can be reactive to alkalis. Every effort shall be made to select
non- reactive aggregates and make use where possible of proven reliable sources.
This also applies to aggregates with lower chloride diffusion resistance.
Aggregates shall consist of fine aggregates (those passing a 4mm sieve), and
coarse aggregates (those retained on a 4 mm sieve) batched separately which, when
combined, shall meet the requirements of ASTM C33 on aggregate grading.
5.2.1 Aggregate grading
Coarse aggregates shall consist of crushed or uncrushed gravel or crushed stones

and shall be selected, re-crushed, finish screened and washed with water. Fine
aggregates shall consist of crushed gravel; crushed stone or natural sand with
rounded or surrounded particles and shall be washed as necessary. Coarse
aggregate shall meet the grading requirements of Table 2 of ASTM C33 and fine
aggregate grading shall be as per Clause 6 of ASTM C33. Coarse aggregates shall
be limited to 20mm nominal size for all grades of concrete.
Strict control shall be exercised to ensure that the maximum chloride content
indicated is not exceeded at any time. Any violations shall be cause enough for
rejection at any stage of the construction
When aggregates have been approved, the entire supply of each type shall be
secured from the approved sources. Testing shall be carried out frequency specified
below to ensure the same quality and grading of the material is being maintained.
Tests shall be carried out as per the following frequency:
 Tests for clay, silt and dust, moisture content and sieve analysis shall be carried
out on every 20 tons of fine aggregates and 40 tons of coarse aggregates delivered
to the site.
 Chemical analysis shall be carried out on every 100 tons delivered to the site.
Coarse and fine aggregates shall be limestone crushed rock to ASTM C33 or
equivalent.
Aggregates shall be clean, hard, durable, chemically inert and impermeable. They
shall be free from adherent coatings, laminated particles or materials likely to be
deleterious to the concrete.
Beach sand shall not be used for fine aggregate.
5.2.2 Sampling and Testing of Aggregates
Test requirement, test method & frequency shall be as per clause 17.4 of this specification.
5.2.3 Aggregate Transportation
During transportation to the site, all aggregates are to be protected from windborne
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contaminates. Should these contaminates be present at the time of delivery to Site,

then the aggregates shall be washed with water meeting the requirements specified
hereinafter under "Water" section 5.3. Transport vehicles shall be cleaned from
possible contamination due to previous use.
5.2.4 Storage of Aggregates
Sufficient quantities of each type of aggregate shall be maintained on site at all times
to ensure continuity of work.
Each type and grading of aggregate shall be stored separately in bins, in such a
manner that mixing of the various size particles shall not occur. The floors of the bins
shall be of concrete or other approved material and shall be sloped sufficiently to
ensure adequate drainage of surplus water.
Strict precautions shall be taken to avoid contamination of aggregates by windblown

dust, chlorides etc. Aggregate stockpiles shall be shielded from direct sunshine and
sprayed with water.
5.3 REINFORCING STEEL
5.3.1 General
Reinforcement for general concrete work shall be hot rolled high yield deformed bars.
Steel for main and secondary reinforcement shall be deformed bars and shall conform to
ASTM A615 grade 60 (yield strength = 420 MPa).
5.3.2 Fabric reinforcing
Fabric reinforcement shall be an approved type to ASTM A185.
Manufacturer's test certificates giving the results of mechanical and chemical tests
shall be submitted for approval. Bond performance tests shall be carried out on
coated bars.
5.3.3 Spacers
Concrete spacer blocks shall conform to the requirements of this specification. Non-
concrete spacer blocks shall only be permitted provided they do not adversely affect
the strength and durability of the concrete.
Unless otherwise specified by COMPANY reinforcing bars shall be placed within the
tolerance requirement. reinforcing bars shall be moved as necessary to clear pipes,
seal, recesses, embedded metal works and conduits except in areas where
reinforcing bars is congested. In the latter case, relocating of the embedded material
must be considered. In no case should tension bar be bent with sharp offset.
Reinforcing bars shall be placed to maintain a clear distance of at least 30mm between
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the reinforcing bars and anchor bolts or other embedded metalwork at right angles to
bars. Unless otherwise approved by COMPANY, bars support shall be;
 Precast concrete blocks when concrete is cast on grade.
 CRSI (Concrete Reinforcing Steel Institute) class 3 - bright basic wire bar
supports, which provides no protection against rusting, and are used where they
will not come in contact with the exposed concrete surface unless otherwise
noted on the drawing.
 CRSI (Concrete Reinforcing Steel Institute) class 1 - plastic-protected wire bar

supports provide maximum protection against corrosion or severe exposure,
unless noted on the drawing
Reinforcing spacers between reinforcing layers shall consist of steel reinforcing cut
and bent to ensure the tolerance as specified in ACI SP-66 – Detailing Manual
5.4 WATER
All water, including but not limited to, mixing, ice production, cooling aggregates,
washing aggregates and concrete curing shall be obtained from an approved source
and shall be clean and free of acids, oils, vegetable, and deleterious matter which
may influence the strength and appearance of the hardened concrete by
discoloration or efflorescence.
The water shall comply in all respects with the requirements of ASTM C1602.
Testing shall be done at source (trucked) or at site (piped to holding tank), for
chlorides and sulphates.
The water shall comply in all respects with the requirements of BS EN 1008 or
equivalent, with the following additional requirements for pH, dissolved solids and
contamination:
 The pH value of water shall be in the range of 6.5 to 9
 Total dissolved solids 2000 mg/kg
 Total Sulphates 500 mg/kg
 Total Chlorides 500 mg/kg
 Alkali (expressed as equivalent sodium oxide) 500 mg/kg
 Suspended solids 200 mg/kg
 Water used for curing of concrete shall be free of dirt, organic materials and litter
in suspension and shall comply with BS 5328 and BS 3148 or equivalent.
Suitable means shall be provided to ensure that the temperature of the concrete
when deposited does not exceed 30oC. Mixing water shall be refrigerated, or have
flake ice added.
Testing of water shall be as per clause 20.2 of this specification.

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5.5 ADMIXTURES AND ADDITIVES
Strict control shall be maintained to ensure that the correct quantity of admixture /
additives is used at all times. The equipment to be used for dispensing and method of
incorporating the admixture in the concrete shall be subject to approval. The
dispensing unit shall be translucent so that the operator can see the discharge of the
admixture. The use of admixtures /additives shall be in strict accordance with
manufacturer’s recommendations / instructions.
5.5.1 Admixtures
An admixture is defined as a product which is added in quantities generally not more

than 5 % by mass of the cement before or during mixing or during an additional mixing
operation, causing the required modifications to the normal properties.
Admixtures shall comply with ASTM C494 or equivalent.
All admixtures used to modify one or more characteristics of concrete shall be

accompanied by a certificate from an approved institute, stating:
 exact range and method of application;
 physical and chemical composition;
 positive and negative side effects;
 a recommendation on the maximum allowable quantities (as a percentage of the

mass of the cement) to achieve the particular requirement;
 proportioning and mixing.
The admixtures shall contain no chlorides. If a retarder and plasticizer are required
only a dual-purpose additive should be used.
The classification of admixtures shall comply with ASTM C494.
The CONTRACTOR shall be responsible for any defective concrete that may result
from the use of such admixtures. All information regarding the admixture(s), such as
certificates, concrete mix trials, test results, etc. shall be made available to
COMPANY.
No air-entraining agent shall be used.
 Superplasticizers
If necessary, and only if approved by COMPANY, a naphthalene sulphonate

retarding superplasticizer shall be used to increase workability of the concrete
and retard the initial set. It shall comply with ASTM C494 Type G.
Acceptable Manufacturers are “Fosroc”, ”Master Builders”, “Grace”, “Sika”, or

equal approved.
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5.5.2 Additives
An additive is defined as a finely divided material that is added to the concrete in

order to improve certain properties or to achieve special properties. Examples of
additives are:
 fly-ash in accordance with BS EN 450-1 (pozzolanic material, used to reduce

heat caused by hydration in mass concrete) or equivalent.
 silica fume (pozzolanic material used for high strength concrete) BS EN 13263 or
equivalent;
 polymers (used for liquid tight floors and rapid repairs).
All additives used to modify or improve one or more characteristics of concrete shall
be accompanied by a certificate from an approved institute, stating:
 exact range and method of application,
 physical and chemical composition,
 positive and negative side effects,
 a recommendation on the maximum allowable quantities (as a percentage of the

mass of the cement) to achieve the particular requirement,
 proportioning and mixing.
The additives shall contain no chlorides. Trial mixing shall be executed to check their
effectiveness. The CONTRACTOR shall be responsible for any defective concrete that
may result from the use of such additives. All information regarding the additive(s),
such as certificates, concrete mix trials, test results, etc. shall be made available to
COMPANY.
 Polypropylene Fibers
Fibers shall be monofilament polypropylene fibers and manufactured from

polypropylene complying with BS 5139 classification code AH-3.0-L-B29 or ASTM
C1116. The fibers shall be added to the concrete at the rate of 0.91 Kg per cubic
meter of concrete either during mixing at the batch plant or to the truck mixer.
The polypropylene fibers shall be used for slabs on grades only.
5.6 GROUTING
Grouting refers to all work to be carried out to properly fill the spaces between
concrete surfaces and base plates of equipment, steel structures or prefabricated
concrete elements with mortar in order to achieve adequate transfer of horizontal and
vertical forces.
For all the grouting work, the finished concrete support surface shall be such that it
does not accumulate water.
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For grouting details refer Document No. SEPA15014-MFSTF-CV-00-SPC-004,

“Specification for Grouting Equipment and Structural Supports”.
5.7 ANCHOR BOLTS
The design of the anchoring length of the anchor bolts shall be checked for maximum
pull- out force. Anchor bolts, pipe sleeves, anchor rails, inserts, bolts, etc. shall be
positioned accurately, and be firmly attached to the formwork before the concrete is
poured.
If slight adjustment in the position of anchor (holding-down) bolts is required, this

shall be indicated on the base plate drawing supplied with the loading information,
and it shall also be clearly indicated on the detail foundation drawing with the
method(s) to be applied.
Installed anchor bolts, etc., shall be properly protected against damage and corrosion
until the equipment/structure is permanently installed. The minimum concrete cover
shall be 75 mm.
For Anchor bolt details refer Drawing No. SEPA15014-MFSTF-CV-00-STD-020,

“Standard Detail Of Anchor Bolts”.
5.8 WATER STOPS
Water stops shall be factory preformed ribbed type 10 mm minimum thickness in

accordance with BS 2571 for PVC or ASTM D395 and ASTM D2240 for rubber as and
shall be done in accordance with manufacture’s instruction.
Minimum width of water stop shall be 230mm for concrete section greater than
200mm wide and 150mm for concrete section less than 200mm.
5.9 EMBEDMENTS
Embedment material shall be in accordance with BS EN 10025 S275 or ASTM A36/A36M.
Embedment shall be hot-dipped galvanized in accordance with ASTM A123/A123M or

BS EN ISO 1461 with approval from the company.
5.10 JOINT FILLER
Joint filler shall be pre-molded asphalt impregnated fiberboard per ASTM D994, or
pre- molded non-extruding type material per ASTM D1751.
5.11 CONCRETE MIX DESIGN
5.11.1 Grades of Concrete
The concrete mix design shall take into account the type of foundations, structures,
elements etc. for which it is intended.
To verify whether the mix design meets the specified quality requirements, trial mixes
shall be produced (unless otherwise specified) preferably on site. For each trial mix
tests shall be performed.
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Special attention shall be paid to possible bleeding after placing. Trial tests, including
a bleeding test in accordance with ASTM C232, shall be performed especially for
large/thick concrete elements (e.g. horizontal slabs, columns).
Special admixtures may be considered if bleeding cannot be controlled sufficiently
by means of a standard mix design. In general a low slump in combination with proper
grading and/or the use of an air entrained may prevent bleeding. BS EN 206-1 shall
apply.
The required concrete mixes shall be designed in accordance with BS EN 1992 and
BS EN 206-1, or approved equivalent, with a designation of nominal maximum size
of aggregate and workability.
Furthermore, the concrete mix shall be designed for durability taking full account of
the environment to which it will be subjected.
The maximum total content of water-soluble chlorides (expressed as Cl) shall not
exceed the limits according to BS EN 206-1.
The maximum total mass fraction of acid-soluble sulphates in cement shall not exceed 4.0
%.
The grades of concrete for the various works shall be as noted on the Drawings and
as specified in Table 5.2. The criteria given in the table are designed to produce
concrete of the required durability and strength.
The water/cement ratio shall be continuously checked at the mixer with due
allowance being made for water (if any) contained in the aggregates. Under no
circumstances is additional water to be added between the mixer and the place of
concrete placement.
Concrete in exposed parts of the Works shall be made from the same brand and
batch of cement to ensure that surfaces have a consistent tint or shading.
Concrete shall comply with ACI-318 or this Specification differs. Sampling for test
purposes shall comply with American Code equivalent to BS EN 12350-1 and BS EN
12390-1 and making and curing of specimens shall comply with American Code
equivalent to BS EN 12390-2.
Before concrete placement the CONTRACTOR shall obtain approval of COMPANY for
the mixes proposed for each class of concrete. The mixes shall be designed to
achieve the minimum workability for the placement and compacting the concrete with
the equipment proposed for use.
TABLE 5.2 CONCRETE GRADES
Min. 28
Cement days
Max.
Cement Content Cylinder /
Grade Position in Work W/C
Type in kg/m3 Cube
Ratio
(Minimum) Strength
in N/mm2
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All foundations (including

ASTM C150, Type-I
pre-cast foundations),
Ground/ Tie Beams, Pipe
sleepers, Pits, Concrete 325 0.4 25 / 30
kerbs, Footing for fencing,
floor slabs and all work in
A contact with ground and
Super structures exposed
to weather
Super structures not

B exposed to weather ASTM C150, Type-I
325 0.4 25 / 30
Blinding, Bedding, Screed,

ASTM C150, Type-I
C Mass concrete, Bollard 280 0.5 12/15
foundation, and Signboard
foundation
Notes:
1. All concrete mixes to be designed for pumping.

2. Actual cement content shall be based on approved mix design.
3. Grade is included only to provide a strength basis for design. It is not

intended to identify durability level.
The CONTRACTOR shall submit for COMPANY approval his anticipated slump for
each mix design. The use of a flow table may be adopted in place of slump tests for
slumps greater than 150mm.
The mix design shall produce the minimum of bleeding and segregation.
Total cementitious contents shall be limited to those required for durability to avoid
excessive risk of thermal and shrinkage cracking. The proportioning of mixes for
durability will be primarily controlled through the specified limits on free w/c ratio.
Appropriate use shall be made of approved admixtures to simultaneously meet the
requirements for w/c ratio and workability.
Maximum aggregate size shall be 20 mm except as noted above.
6. FORMWORK
6.1 GENERAL
Forms shall be of wood or steel, provided that where plywood is used for exposed
surfaces, it is of type (plastic coated marine plywood, etc) to achieve the specified
finish. The number of uses of any particular form work shall be such that the quality
of the specified finish is maintained and where the concrete has subsequently to be
coated, that coating can be effectively applied.
Forms shall be designed as outlined in ACI 347 and constructed to maintain rigidly
throughout the placing, ramming, vibration and setting of the concrete to the required
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shape, position, and level and specified class of finish within the allowable
tolerances specified under item 5.1.
All joints shall be sufficiently tight to prevent leakage of grout. If movement or

deflection of the formwork or loss of grout occurs, the damaged concrete supported
by such form work shall be removed and the concrete re-cast to the required finish.
Form work and its supports should be designed to withstand the worst combination of
self-weight, reinforcement and wet concrete weights, concrete pressure, construction
and wind loads. The form work shall be precambered by an amount equal to the
expected maximum deflection of the member.
The forms shall be faced to give the specified class of finish for the structures. The
form surfaces for exposed concrete shall be smooth, true and free from all
irregularities.
For below ground concrete except against existing structures, rough form work may
be used, which may be block work, brickwork, steel pans, etc., provided all joints
prevent the loss of grout.
Form work shall be provided to the top face of sloping work where the slope exceeds
15º from horizontal.
All exposed finished edges of concrete shall be chamfered by chamfers cut from
nominal 25mm x 25mm timber unless special architectural finishes are specified.
6.1.1 Ties and Spacers
Where it is required to use internal ties and spacers, their type, spacing and use
shall be approved. No part of any such tie or spacer remaining permanently
embedded in the concrete shall be nearer than specified cover to the finished surface
of concrete. Wire ties projecting through the concrete face shall not be permitted.
6.1.2 Permanent Form work
Permanent form work for elevated concrete floors in steel structures shall be profiled
steel sheet (metal decking). The sheet shall be of sufficient thickness to sustain all
construction loads plus the weight of fresh concrete between supporting beams
without excessive deflection.
6.1.3 Form work for Externally Vibrated Concrete
If external vibrators are to be used for concrete compaction, the type of vibrator,
design of the form work and the method of fixing the vibrator shall be approved by
COMPANY.
6.1.4 Cleaning and Treatment of Forms
Before concreting is commenced the forms and previously cast concrete shall be
thoroughly cleaned and freed from all sawdust, tie wire, shavings, dust, direct and
other debris. Temporary openings shall be provided where necessary to drain away
water and remove rubbish.
Release agents should be applied before reinforcement is placed and should be

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compatible with the class of finish. Care shall be taken not to allow form coating to
accumulate in forms and not to contact or contaminate the reinforcement.
6.1.5 Removal
The formwork shall be removed in accordance with American Code equivalent to

BS EN 1992-1-1:2004 Clause 3.1.2.5.
A striking plan shall be produced, which anticipates climatic conditions, heat of

hydration, strength development, load conditions and relevant curing methods.
All formworks shall be removed after concrete has attained sufficient strength and
without damage to the concrete including removal without shock to prevent impact
load on the partially hardened concrete. Materials and plant should not be placed on
any new construction until concrete has achieved the required strength to take the
additional construction loads required.
Soffit forms shall not be struck until the concrete has reached as a minimum at least
double the strength required to carry its own weight plus any other temporary loads
which may be applied, whichever is the greater. The concrete strength shall be
assessed from tests on cubes cured under similar conditions to the concrete in the
structure.
Where cube test results are not available, the times given in American Code
equivalent to BS EN 1992-1-1 may be used as a guide for the removal of formwork
when ordinary portland cement is used. Temperatures given in this code shall apply
to the surface of the concrete but air temperatures may be used where the surface
temperature cannot be conveniently measured.
After removal of the formwork, all fins and projecting edges shall be cleaned from the
concrete faces which are to be exposed in the permanent works and if the surfaces
require dressing it shall be as described in the relevant standard. Curing procedures
shall be initiated immediately after removal of formwork.
The following time span shall apply before formwork is removed:
Part Time span
Bottom of beams 10 days
Side of beams 3 days
Part Time span
Removal of props to beams 21 days
Bottom of slabs 7 days
Removal for prop for slabs 10 days

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Side of slabs 3 days
Construction joints 24 hours
Vertical formwork of columns(unloaded) and beams 3 days
Tank walls 3 days
6.1.6 Tolerances for Formed surfaces
Formwork shall be constructed so that the concrete surfaces will conform to the
tolerances of ACI 301, ACI 117, and limits listed in the table below:
Sl. Item Distance Permitted
No. Tolerances
1 Variation from the plumb In 2.50 m +/- 5 mm
2 In the lines and surfaces of In any story or 5.00 m +/- 5 mm
columns, piers, walls and arises In any 25.00 m +/- 50 mm
3 Variation from the level or from In any 3.00 m +/- 5 mm

the grades indicated on the In any bay +/- 5 mm
drawings. In any 6.00 m +/- 10 mm
Note: - Sufficient slope shall cover the tolerance to avoid water pounding
4 Variation in the thickness of +/- 6 mm
slabs and walls
5 Misplacement or eccentricity +/- 10 mm
Tolerances apply to concrete dimensions only and not to the positioning of vertical
reinforcing steel, dowels or embedded items.
7. PLACING REINFORCEMENT
7.1 CUTTING, BENDING AND WELDING
Reinforcing steel shall be cut, bent and welded in accordance with ACI SP-66.
All cutting and bending of the steel reinforcement shall be complete before final
positioning prior to concrete placement and shall be carried out at a specially
commissioned bar bending shop established at the site under control of
CONTRACTOR for production and quality. Welding of reinforced steel should be
avoided but if this is necessary the relevant welding standards shall be adopted,
especially regarding welder qualifications and the recommendations of the
reinforcement Manufacturer. Welding shall be included in the quality plan.
Re-bending or straightening of bars shall not be permitted.
7.2 PLACING
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Black annealed steel binding wire of approximately 1.5 mm thickness shall be used
for fixing the reinforcing material. The ends of the binding wire shall be tucked in to
prevent corrosion spots in the concrete.
The reinforcing bars, ties, links, stirrups and all other reinforcing shall be positioned
and rigidly fixed exactly as shown on the Drawings. Corner bars in columns and
beams shall be cranked from the entire length of the lap such that the minimum cover
requirements are achieved and the true alignment of the reinforcement is maintained.
Splices in reinforcements shall be made at design locations shown on the Drawing.

Lap lengths for splices shall be in accordance with BS EN 1992-1-1 or
ACI318/318M.
Fabric reinforcement shall be fixed on bar supports spaced to minimize sagging and
shall have a minimum lap of at least one full mesh but not less than 300 mm tied as
above. Where two layers of fabric reinforcement are required both layers shall be fixed
with spacer bars before concreting.
All reinforcement shall be washed clean, using water suitable for producing concrete,
prior to placement of concrete.
After installation all reinforcement exposed for more than 7 days shall be protected
from contamination before and between pours by wrapping the formwork with suitable
sheeting.
7.3 HANDLING, STORAGE AND CLEANING
When handling coated bars, care shall be taken to avoid bundle to bundle abrasion, or
bar to bar abrasion resulting from sagging bundles. This may require lifting
equipment with a spreader beam to sling from multiple pick-up points.
All lifting equipment shall use either nylon or padded slings. Coated bars shall be off-
loaded as close as possible to their fixing area to minimize rehandling. The steel shall
not be soiled with any grease, oil, paint or preservative or any substance likely to
inhibit the bond with concrete.
All reinforcing bars and fabric reinforcement shall be stored on the Site on supports
suitably spaced and at sufficient height to keep the steel clear off the ground. Coated
bars shall be placed on timber planks and timbers placed between bundles when
stacking is necessary.
All reinforcement shall be covered with impermeable sheets during storage. Long
term storage shall be minimized. On site storage shall not exceed 6 months.
When the extent of coating damage exceeds 1% of the surface area of the coated
bar in any one meter length, the coated bar shall be discarded.
Fabric reinforcement shall have all scale and rust removed and after such treatment
the steel shall remain within the limits of over and underweight as specified. The steel
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shall not be coated with any grease, oil, paint or any other substance likely to inhibit
the bond with concrete.
7.4 SPLICING
Splices in reinforcements shall be made at design locations shown on the design

drawing. Lap lengths for splices shall be in accordance with ACI318/318M.
8. CONCRETE MEASURING, MIXING, PRODUCTION, TRANSPORTING AND

WEATHER PROVISIONS
8.1 MEASURING, MIXING, PRODUCTION AND TRANSPORTING
The measuring, mixing, production and transporting of concrete shall be in accordance

with BS EN 1992 and BS EN 206-1. Concrete shall not be hand-mixed or re-
tempered.
The CONTRACTOR shall provide full details of the fully automated concrete mixing
plant(s) and devices, and shall produce trial mixes before the permanent placing of
concrete is started, to prove that the specified concrete grade can be obtained.
The temperature of the fresh concrete can be reduced by cooling the water (by adding
ice) and by storing the aggregate under shade.
The amount of water shall be in compliance with the approved mix design. No
additional water shall be added to the mix at any time.
8.1.1 Measuring
Materials used in concrete shall be proportioned by weight, by means of an approved

weigh batching machine. Due allowance shall be made for the water content of the
aggregates when determining the amount of mixing water to meet the specified
water/cement ratio for the mix.
Cement when contained in bags, shall be used in such a way that each batch of
concrete requires a number of whole bags. If the cement is stored in bulk, the
measuring device shall be approved before use and calibrated at regular intervals. A
separate weighing device shall be provided for cement.
Coarse and fine aggregates shall be proportioned separately by weight in an

approved weigh batching machine.
The water/cement ratio shall be continuously checked at the mixer with the allowance
being made for water (if any) contained in the aggregates. Under no circumstances
shall water be added in the interval between the mixer and the place of concrete
placement.
All measuring devices shall be accurate to within + 2.5% and shall be satisfactorily
tested and approved before any concrete is mixed (considering that the minus is
more important for cement). The measuring equipment shall be maintained in a
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clean, serviceable condition.
8.1.2 Mixing
All concrete shall be mixed in a batch mixer of approved design to comply with BS
ISO 18650 where applicable, with an automatic water measuring device and
maintained in good order. The mixer and mixing platform shall be suitably protected
from the wind to prevent loss of cement. The mixer shall be fitted with the
manufacturer's plate, stating the rate capacity and the recommended number of
revolutions per minute. Batching of cement and aggregate shall be by weight. The
mixer shall be fitted with an approved accurate mechanism for weighing separately
the cement, fine aggregate and coarse aggregate. Water shall be measured by
volume or by weight, but in either case the delivery shall be predetermined amount
to ensure the design water/cement ratio. Periodic checks shall be made to confirm
the accuracy of the weighing equipment. The mixing shall be done for the period
recommended by the mixer manufacturer, or until the concrete is of uniform color
and consistency, whichever period is longer. The entire batch is to be discharged
before recharging.
Whenever there is a change in the type of cement in use or mixing is stopped for more
than half an hour, the churn of the mixer must be thoroughly washed out with clean
water. A competent operator shall be in continuous control of the mixer.
Retempering shall not be allowed.
The total time required for mixing, transportation and pouring of the concrete should
in general not exceed 60 min when not agitated and 120 min when agitated. During this
period
the segregation of aggregates shall be prevented, and the workability shall be
maintained. A mixing, transportation and pouring schedule shall be produced.
All concrete shall be produced from a controlled fully automatic computerized central
plant. The central plant shall be provided by CONTRACTOR or subcontracted by
CONTRACTOR to a COMPANY approved Ready Mix Concrete SUPPLIER. The
plant shall have a minimum capacity of 0.5 cubic meters per batch and a minimum
rated capacity of 100 cubic meters per hour.
Mixing at a central plant shall conform to the applicable requirements of the

Standard Specification for Ready-Mixed Concrete of ASTM C 94/C 94M.
The Batch Plant shall include the following:
 Full computerization
 Full segregation of materials
 Materials to be shaded and covered to prevent contamination by air borne

chlorides, dust and other contaminants.
 Automatic compensation for moisture in fine aggregate
 Adequate ice and chilled water plants
 Adequate capacity
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 Fully automated
 Calibration every 3 months for aggregate
 Calibration every 6 weeks for water, cement and admixtures
 Print out of mix design together with actual mix
 Calculation and print out of actual water/cementitious ratio
The mixing machines (scales/meters, etc.) capacity shall be selected to ensure the
required maximum production can be comfortably achieved.
The mixing machines (scales/meters, etc.) Shall be tested and calibrated for their
accuracy by a specialist at regular intervals of at most three months or such periods
as required by COMPANY. Test certificates shall be provided before the
commencement of works and after each test.
The mixing machines shall be tested in accordance with the appropriate British
Standard or equivalent (DIN, ASTM, etc...)
Admixtures that have been approved as part of the design mix shall be added by
approved automatic dosing equipment.
Mixing shall insure a uniform distribution of materials and a uniformity of consistency

and colour. The mixing shall be continued until the mix is homogeneous. The time
required to produce a homogeneous mix shall be determined by satisfying the
requirement of ASTM C 94/C 94M Annex A1.
The CONTRACTOR shall ensure that the materials used for each batch in the mixer
do not exceed the manufacturer's rated capacity for the machine.
The machine shall be kept clean, free from any residual material after depositing
each batch of concrete and the mixer pan drum shall be washed and cleaned out
immediately following the completion of each concreting operation or when changing
to a mix using a different type of cement.
Hand mixed concrete shall not be used.
The batch plant shall be able to provide a computer printout of the following for each truck:
 Grade of concrete
 Cement type
 Admixture types
 Actual measurement of all components of water in the mix
 Actual batched weights of cement, aggregates (separately), water and admixtures
 Date and Time of batching

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 Calculation of the actual water/cement ratio.
8.1.3 Transporting
Concrete, after being discharged from the mixer shall be transported as rapidly as
possible to its final position by approved means which shall prevent adulteration,
segregation, loss of workability or contamination of the ingredients. The containers
that convey the concrete shall at all times be kept clean and free from hardened or
partially hardened concrete.
The addition of water at the point of discharge is prohibited. The use of chutes,
spouts, skips and pumps shall be permitted if approved by COMPANY. The use of
any aluminum pipe to be in contact with fresh concrete or other conveying equipment
containing aluminum is prohibited.
8.2 EXTREME WEATHER PROVISIONS
Provisions for pouring concrete in extreme weather conditions shall be made with
reference to the following standards:
For hot weather:
 ACI 305R;
 BS EN 1992-1-1; and
In hot weather suitable means shall be provided to ensure that the temperature of
the concrete when deposited in the forms does not exceed 30°C. Mixing water shall
be protected from direct sunlight by sheltering the storage tanks with shades painted
White on the outside. Chilled water or flaked ice shall be used to reduce the
temperature of the mix. Aggregate stockpiles shall be shielded from direct sun and
sprayed with water, especially when evaporation rates are high. All formwork and
reinforcement shall be shielded from direct sunshine and sprayed with water when
necessary to keep temperature below 30°C before concrete is placed. Water used for
mixing and spraying shall be as specified under "Water" clause 5.3.
Any concrete with a temperature in excess of 30°C at time of placement shall not be used.
Concrete placing shall be completed as quickly and efficiently as possible and

exposed surfaces immediately covered to minimize the evaporation of water from
the concrete.
8.2.1 Heat of Hydration
Mass Concrete should be poured in accordance with ACI 207.1R.
If the temperature gradient is more than 20°C between the inside and outside faces of
the concrete, adequate measures shall be developed and proposed to reduce the
thermal gradient. The proposal shall be submitted to CONTRACTOR for approval
and proven through site trials.
Where Mass Concrete is specified, the heat of hydration shall be monitored in trials
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to demonstrate excessive thermal gradients shall not be present during the works. A
formal method statement shall be developed and submitted when heat of hydration
issues exist.
For each mix design for slabs and walls over 600 mm (24 inches) thick and sections
which are required to be liquid retaining or liquid tight, the following shall be
performed and a method statement developed accordingly:
 Computer model simulations shall be performed to confirm that the heat of

hydration will not cause a temperature differential between the interior of the
concrete and any outside face greater than 20 °C.
 The performance of trial mixes / trial pour with special attention to the heat of
hydration and workability:
o Full size (scale 1:1) test pieces shall be cast and tested representing the
actual pouring conditions;
o Temperature monitoring using thermocouples;
o Strength development versus time;
o Observation of bleeding and general condition of the concrete during the pour;
o Guidance and supervision by authorized personnel;
o Protective measurements and curing to avoid crack formation;
o The size and sequence of pours, concrete temperature-monitoring

system of pours, formwork type and removal time, and calculations for
temperature and
strain development at internal and surface locations, taking into account heat of
hydration, ambient radiation and temperature, and physical restraints;
o After removal of formwork a check on crack formation, supported by taking cores.
The following shall be taken into consideration for cold climates:
 The precautions to be considered for reducing the heat of hydration shall include
the use of heating measures, plywood formwork, the insulation of surfaces,
protection of newly cast surfaces from solar radiation and the avoidance of cold
water curing leading to thermal shock and/or by applying low-heat cement,
retarder, pozzolanic material.
The following shall be taken into consideration for hot climates:
 The precautions to be considered for reducing the heat of hydration shall include
the use of cooling measures, plywood formwork, the insulation of surfaces,
protection of newly cast surfaces from solar radiation and the avoidance of
evaporation leading to thermal shock and/or by applying low-heat cement,
retarder, pozzolanic material.
8.3 READY MIX CONCRETE

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8.3.1 Use of Ready-mix concrete
The use of ready mixed concrete shall be permitted and shall meet the requirements of
this Section.
The name and works address of the supplier shall be submitted to COMPANY for
approval and shall be obtained prior to placing an order.
Arrangements shall be made for the supplier's works to be inspected. A Record Book
shall be kept on the Site readily available for inspection and shall contain the
following information:
Before discharging the concrete at the point of delivery, the CONTRACTOR shall
provide COMPANY with a delivery ticket for each batch of concrete on which is
printed, stamped or written the following minimum information.
Name of ready-mixed concrete batch

plant Serial number of ticket
Date
Truck number
Project name
Grade or mix description of concrete, including minimum cement content
Specified workability
Type of cement
Nominal maximum size of aggregate
Type and name of admixture, if
included
Quantity of concrete in the truck in cubic
meters Time of loading/adding water to the
dry materials
NOTE: Space shall be provided for any additional items that have been specified
and for the following to be completed on Site:
 position where concrete is placed
 whether test cubes were taken from the delivery
 arrival and departure times of the truck
 times of start and completion of discharge
8.3.2 Transport and Delivery of Ready-Mix Concrete
Transport of concrete: Concrete shall be transported in a truck mixer complying with

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the requirements of BS ISO 18650.
Delivery time: Concrete shall be discharged from the delivery vehicle within 1 hour after
the time of loading, when concrete is transported in truck mixers or agitators. The
time of loading, defined as the time of contact between cement and aggregates or,
when these are surface dry, between cement and added water, shall be recorded on
the delivery ticket.
On completion of delivery of the concrete the truck mixer may be washed down on
Site only at location designated. The wash down from the internal of the truck mixer
shall not be discharged on Site but shall be returned to the ready mix plant for
disposal.
Concrete trucks and their manner of operation shall conform to the applicable
requirements of ASTM C94/C 94M.
Concrete trucks shall be of a size, design, and required number to accommodate the
anticipated placement rates.
Truck mixers shall be of the revolving drum type, watertight, and so constructed that
the concrete can be conveyed and discharged at the site maintaining the uniform
distribution of materials throughout the mass.
The drum shall be painted white and kept clean to ensure maximum reflectivity.
The maximum size of batch in truck mixers shall not exceed the maximum rated
capacity of the mixer as stated by the manufacturer and stamped in metal on the
mixer.
On no account shall water from the concrete truck be used in the mix.
Concrete, after being discharged from the plant, shall be transported as rapidly as
possible to its final position in the works and shall prevent adulteration, segregation,
loss or contamination of the ingredients. Scheduling and dispatching of trucks shall
be such that they arrive at the work site just before the concrete is required.
Equipment shall be cleaned at the end of each operation or workday.
9. CONCRETE PLACING
9.1 GENERAL
The placing of concrete shall be in accordance with the appropriate clauses of BS EN

1992 with the following pre-concreting operations:
1. A concreting and inspection test plan including all actions to be dealt with
relevant to the execution.
2. The initial testing of concreting by trial casting, documented before the start
of execution.
3. Completion of all preparation works, inspected and documented.
4. If concrete is placed directly against rock or ground, the fresh concrete shall
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be protected against intermixing and water suction (blinding concrete, building

paper) according to section 16.7.2 and 16.7.3.
5. Ground, rock, formwork or structural parts in contact with the section to be cast
shall have a temperature which does not result in freezing of the concrete
before it has sufficient strength to resist the effects of freezing (in general > 5
N/mm²).
6. If the ambient temperature is expected to be high (hot weather concreting) at
the time of casting or in the curing period, precautions shall be taken to
protect the concrete against damaging effects (e.g. drying out or excessive
shrinkage)
Concrete shall not be placed unless the positioning, fixing and condition of the
reinforcement and any other embedded items, the cleanliness, alignment and
suitability of the containing surfaces have all been previously examined and
approved. Adequate time shall be allowed for inspection when scheduling concrete
pours.
Forms shall be well soaked with water, but no standing water shall be present inside
forms when concreting.
The concrete shall be placed in the positions at sequence shown on the Drawings
and be deposited as near as possible to its final position in such a manner as to avoid
segregation of the concrete, or displacement of the reinforcement or form work. It
shall be deposited in regular courses or layer not exceeding 200 mm in thickness
when compacted by hand and
400 mm thickness when mechanically compacted unless otherwise directed. Every
precaution shall be taken to prevent the form work and reinforcement moving during
the placing or setting of the concrete and any remedial work that is necessary shall be
executed promptly.
The work shall be organized so that the placing of concrete is efficient and
continuous between specified or approved construction joints. In horizontal sections
if approved by COMPANY, when the placing of concrete has been interrupted and
delayed and concrete has gained its initial set and cannot be adequately worked or
compacted, the surface of the unfinished concrete shall be thoroughly cleaned,
preferably by air and water jetting, to expose the aggregate and washed with cement
grout immediately before fresh concrete is added. The first layer of new concrete
place shall not exceed 150 mm in depth and particular care shall be taken with the
compaction of this layer to ensure a good bond.
When the construction of vertical columns is interrupted the unfinished concrete shall
be cleaned and left for 12 hours to set before any further concrete is placed. The
surface shall be thoroughly cleaned of all loose, foreign matter and all laitance before
casting the remaining concrete. Such cleaning may require temporary removal of all or
part of the form
work. Casting of thin sections such as floor slabs in two layers shall not be permitted.
Great care shall be taken to prevent foreign matter from being introduced into the
concrete from any source. Concrete shall not be freely dropped from more than 1.5m
height without the use of terns.
Structural concreting against open excavations will not be permitted.

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9.2 PLACING AND COMPACTING OF CONCRETE
Full compaction of the concrete shall be achieved throughout the entire depth of the layer.
It shall be thoroughly worked against the form work and around the reinforcement,
successive layers shall be thoroughly bonded together. Air bubbles formed during
the mixing and casting shall be expelled; particular care shall be taken where sloping
soffits occur.
Transportation of concrete through forms by vibrator shall not be permitted.
Unless directed otherwise, approved power-driven poker vibrators shall be inserted

vertically at such distances apart or applied in such a manner that will ensure that
the concrete is satisfactorily and uniformly compacted. Immersion vibrators shall
penetrate the full depth of the layer, and when the underlying layer is fresh concrete,
vibrators shall enter and re-vibrate that layer to ensure that successive layers are
bonded together. Over vibration causing segregation, surface laitance or leakage
through form work shall be avoided. Immersion vibrators shall be withdrawn slowly to
prevent the formation of voids. Vibrators shall not be used to work the concrete along
the forms, or in such a way as to segregate the mix, damage form work, or displace
the reinforcement. External vibrators shall not be used without obtaining approval for
the form work design and the configuration of the vibrators.
9.3 PLACING BY A PUMPING METHOD
A back up plan (including facilities) shall be in place to ensure the continuity of

concrete placing in case the pump should fail.
9.4 CONCRETE PLACED IN UNDERWATER STRUCTURES
Special precautions are required when concrete is placed in underwater structures.

A concrete placing plan shall be submitted by the construction CONTRACTOR, for
approval by COMPANY, based on trials which demonstrate that the required quality
and consistency of the concrete mix can be achieved.
10. JOINTS
10.1 CONSTRUCTION JOINTS
Construction joints shall comply with BS EN 1992-1-1Clause 12.9.2 and kickers shall
be cast monolithically with beams/slabs/foundations.
Proper bonding of the joint is required in order to transfer tensile or shear stresses,
and to prevent any passage of liquids. Therefore, the surface shall be roughened to
increase the bond strength and to provide aggregate interlock. This can be achieved
by mechanical means or by spraying the joint with a retarder immediately after
placing of the concrete. After approximately 16 hour the thin cement layer can be
removed by cleaning using high water pressure methods resulting in exposed
aggregates. By roughening the surface of the concrete in an approved manner, the
aggregate will be exposed uniformly and no laitance, loosened particles of aggregate
or damaged concrete at the surface will be produced.
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The number of construction joints shall be kept to a minimum. Their location shall be
carefully considered and approved by COMPANY in writing before concrete is
placed.
The position of the joints shall generally be at points of low shear stress and at right
angles to the main rebar in the member. Stop ends for vertical joints shall be removed
as soon as it is practical without damaging the concrete face. The joint surface shall
be roughened without disturbing the coarse aggregate by spraying with air and water.
Care shall be taken to ensure that the joint is clean and coated with a neat cement
grout freshly mixed and placed immediately prior to placing fresh concrete. The new
concrete shall be well worked against the old face to ensure a good joint.
Proper concrete bonding agent duly approved by COMPANY shall be applied at

construction joints, just before casting new concrete against it.
10.2 EXPANSION JOINTS
Expansion joints and joints around columns in concrete slab on grade shall be formed
with an approved bitumen impregnated fiberboard. The upper 25mm shall be sealed
with an approved two-part, poly sulphide, oil resistant sealant, applied strictly in
accordance with the manufacturer's instructions.
The joint filler shall be fixed firmly to the first placed concrete before the adjoining
concrete is placed. The concrete must be thoroughly compacted on both sides of the
joint.
The location of expansion joints shall be as shown on the Drawings where required
by design.
10.3 CONTRACTION JOINTS
Contraction joints (either complete or partial) shall be located at as indicated on shop

drawings approved by COMPANY and formed with a building paper membrane
interface, or equivalent separating membrane and the upper 25 mm depth sealed as
described herein before under “Expansion Joints”. The steel reinforcement shall be
continuous through partial contraction joints. The use of contraction joints shall be
kept to a minimum compatible with freedom from cracking. Contraction joints for slab
on grades shall be spaced at 4m in both directions unless otherwise mentioned on
the drawings.
Joint sealant shall conform to ASTM C920, TYPE S, two parts poly-sulphide oil
resistant sealant. Pour grade for horizontal joints and non-sag, gun grade for vertical
or overhead joints.
Concrete edges that are to receive joint sealant shall be placed against non-oiled
forms. the non-oiled portion shall extend a minimum of 64mm from the edge to be
sealed.
Joints receiving sealant shall first be coated with primer if required by the sealant
manufacturer. Joint preparation and application of primer and sealant shall be in
accordance with manufacturer's instructions
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Backing rod shall meet the requirement of ASTM D5249, TYPE 1.
11. FINISHING AND REPAIR
11.1 FINISHING
Top surfaces of concrete in walls, beams, buttresses and floors shall be finished to
the proper level and, if specified, to the required slopes according to BS EN 1992-1-
1 . No holes or rough patches shall remain. Surfaces requiring subsequent plastering or
tiling shall be rough-finished to provide a proper key for the finishing layer.
11.1.1 Formed Surfaces – Classes of Finish
Class F.1: This finish is for surfaces against which backfill or further concrete will be
placed. Form work shall be sawn boards, sheet metal or any other
suitable material which will prevent loss of grout when concrete is
vibrated.
Class F.2: This finish is for surfaces that will be permanently exposed to view. Form
work shall be faced with wrought boards with square edges arranged in
uniform pattern. Alternatively plywood or metal panels may be used if they
are free from defects likely to detract from the general appearance of the
finished surface.
Joints between boards and panels shall be horizontal and vertical unless
otherwise directed. The finish shall be such as to require no filling of
surface pitting, but fins, surface discoloration and other minor defects shall
be remedied by approved methods.
Rendering of defective concrete as a means of making good will not be

permitted. As an exception, in the case of minor porosity on the surface,
approval may be given for the surface to be treated by rubbing down with
a cement mortar of the same fine aggregate/cement ratio as the concrete.
The treatment shall occur immediately after removing the form work. Both
cement and aggregate shall be from the same source as the concrete
materials. Concrete containing honeycombing, major air holes or similar
defects shall be cut out and replaced as directed.
11.1.2 Unformed Surfaces – Classes of Finish
Unless shown otherwise on the drawings, the following finishes shall be used:
Class U1: This is a finish for surfaces of roads, subsequent stages of construction
bonded concrete topping or cement mortar bed to receive paving. The
concrete shall be uniformly leveled and tamped.
Class U2: This is a broom finish for reinforced concrete ramps and sidewalks.
Class U3: This is a hard smooth steel trowelled finish for tops of buried foundations
(as they have to subsequently to be coated), surfaces of concrete paving,
tops of walls, coping and other members exposed to weathering. It also
applies to surfaces of bed and slabs to receive thin flexible sheet and tile
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paving bedded in adhesives. This finish shall be steel trowelled by hand or

machine to produce a dense, smooth uniform surface free from trowel
marks.
11.2 REPAIR
Before starting any concrete work, a repair method statement shall be developed
and submitted to COMPANY for review and comment. The method statement shall
address the following criteria and include the repair materials based on cement
types. The cured mortar colour shall be approximate to the cured mother material.
Tie holes, sand pockets, honeycombs, excessive fanning, and other concrete
surface defects shall be repaired promptly after form removal at a time and in a
manner that shall not delay, interfere with, or impair the proper curing of the fresh
concrete.
Touching up of concrete surfaces after the removal of formwork is not permitted until
they have been inspected and released in accordance with the quality procedures.
The repair method, including materials and the extent of the repair works to remedy
the imperfections of the concrete, shall be specified and approved for each repair
case and comply with the design requirements of the structure concerned.
If the defect is greater than either of the following sizes, an individual repair method
statement shall be submitted to COMPANY for review and comment:
a. Depth is 75 mm at the maximum point and surface area is greater

than 100,000 square mm.
b. Depth is greater than 1/4 the thickness of the member and greater
than 150 mm in any other direction.
Critical slab areas, identified in the drawings and/or specifications shall be replaced if
out- of-tolerance. A demolition and replacement plan for the slab areas shall be
submitted to COMPANY before proceeding.
Cracks in liquid retaining structures, structural cracks and other cracks that are
judged COMPANY to be potentially deleterious to the integrity of the structure shall
be repaired.
12. SETTING
After initial setting of the concrete, any disturbance thereon (e.g. from walking,
wheeling- over or vibration of the formwork) shall be prevented until the concrete has
sufficiently hardened.
Reinforcement, anchor bolts etc. projecting from the concrete shall not be disturbed
during hardening of the concrete.
12.1 INITIAL SETTING TIME
The initial setting time shall be not less than 1 hour after the production concrete is
discharged into the forms, and with a maximum time between mixing and placing
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concrete not to exceed 1 hour, the total time between mixing and initial set shall be a
minimum of 2 hours. There shall be a maximum setting time of 6 hours.
When trial mixes are made to determine the workability of the concrete, as described
under "Trial Mixes" clauses, the initial setting time of the cement paste shall be
determined using the method defined in ASTM C191. The maximum allowable
temperature (30°C), the same proportions of pozzolan (if any) and retarding
superplasticizer shall be used.
13. CURING OF CONCRETE
13.1 GENERAL
Proper curing is essential for the durability of the concrete. Curing shall be carried
out to avoid premature drying of the concrete and to provide the cement paste in the
concrete with sufficient water in order to achieve a high degree of hydration.
Curing shall be carried out in accordance with BS EN 1992-1-1 and the following
requirements.
The principal methods of curing are listed below in order of preference:
 keeping formwork in place;
 sprinkling with water (at ambient temperatures above freezing);
 placing of wet hessian, covered with plastic sheet;
 applying curing compounds.
Curing of concrete shall proceed for seven days min. and for 14 days when a
pozzolan is used.
All water used for curing shall be of the same quality as that specified for mixing
concrete under "Water" Section 8.4.
13.2 HORIZONTAL SURFACES
Horizontal surface shall be saturated with water as soon as practical after the concrete
has been placed. The surface shall then be bonded and flooded with water or draped
with wet hessian (of weight not less than 0.29kg/m2), covered with white impervious
(1000 gauge polythene) sheeting and kept continuously wet for the curing period.
13.3 VERTICAL SURFACES
Vertical timber form work shall be draped with wet hessian as soon as concrete is
placed. Vertical surfaces shall be draped with wet hessian as soon as form work is
removed, and kept continuously wet for the length of the curing period.
13.4 LARGE FOUNDATIONS / SECTIONS (MACHINERY)
Particular attention shall be given to the curing of large foundations / sections,

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typically those for compressors and other heavy machinery that extend above
ground level.
At the point of placement the fresh concrete shall be protected from drying winds and
solar radiation by the provision of a PVC or similar tented shelter which shall remain
in place throughout the curing period. The tent shall cover the entire foundation and
shall be constructed such that finishing operations can be carried out whilst it is in
place.
To prevent early drying and cracking, the relative humidity shall be kept high and the
concrete surfaces kept moist by spraying with clean water and covered with wet
hessian.
13.5 CONTROL OF CURING
Monitoring to ensure that curing is continuous & effective throughout the curing period
shall be properly scheduled and supervised.
Curing compounds shall not be used unless approved by COMPANY and shall
comply with the requirements of ASTM C309. Curing compounds shall be white;
water based wax emulsion for concrete above ground that will not be coated otherwise
the curing compound shall be compatible with the coating. Curing compounds shall
be of a type that causes no adverse effect on the bond between protective coatings
and concrete surfaces.
13.6 TESTING OF CONCRETE
13.6.1 Testing
Sampling, curing and testing shall be carried out to American Code equivalent to BS 1881.
All testing work along with establishing the project mix designs shall be the
responsibility of the CONTRACTOR.
COMPANY reserves the right to inspect materials and workmanship standards at all
stages of manufacture and to witness any or all tests.
Samples for production concrete cube tests shall be taken at the average rate of two
per 60 m3 of placed concrete, with a minimum of two samples of each mix every day
used. A sample consists of three cubes.
Samples shall be taken at the point of placement. A sample consists of three cubes
150 mm each. Cubes shall be made one for testing at 7 days after casting and two
for testing at 28 days.
All samples shall be clearly marked with their identification and accurate records
shall be submitted to COMPANY including the following data:
 Identification of test cube
 Date and time of pour and sampling
 Mix designation
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 Location of sampled batched after placing
 Ambient temperature and humidity
 Cement type manufacture and quantity
 Volume of pour
 Concrete temperature (in position)
 Aggregate type source and proportions
 Admixture details
 Water/cement ratio
 Method of compaction
 Date of testing
 Results of test
 Weight of sample in grams
 Density in kg/m3
 Crushing load in Newton
 Crushing strength N/mm2
 Signature of person preparing cube
 Signature of person crushing cube.
13.6.2 Compliance
The concrete will be deemed to comply with the specified design strength provided
the following conditions are met:
 The average strength determined from all sets of three consecutive tests is at
least equal to the specified design strength.
 No individual strength test falls below the specified design by more than 3.5 N/mm2.
13.6.3 Unsatisfactory Concrete
If any test results fail to comply with the above, then the quantity of concrete poured
with this result shall be at risk and may be required to be removed and replaced.
13.6.4 Standard Deviation
The 28 days cube crushing results shall be grouped consecutively in groups of 40 and
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each group shall have standard deviation less than 4.0 N/mm2.
If the standard deviation is greater than this, the concrete production shall be reviewed.
13.6.5 7-Day Tests
Tests, which are carried out at 7 days, establish a relationship between the 7-day and
28- day strengths. The relationship shall be used to interpret further test results in
order to predict the probable value of the corresponding 28 days strengths.
Notice shall be given without delay of any 7 days test result which indicates that the
corresponding 28 day test results are likely to fail to meet the specified strength,
necessary action can be taken to minimize the effect of such possible failure.
13.6.6 Crushing strength tests for blinding concrete
There shall be no production tests on blinding concrete.
13.6.7 Measurement of concrete temperature
The temperature of the concrete at the point of and prior to placement shall be
measured 50 mm below the surface and recorded on the pour card for each pour.
The temperature of the concrete shall not exceed 30°C otherwise concreting shall
cease until the requirements can be met.
13.6.8 Cement content and water/ cement ratio
A sample of freshly mixed concrete shall be selected by COMPANY at random once

per week from the structural grade and determination made of cement content and
water/cement ratio in accordance with BS 1881. If the cement content is less than
90% or the water/cement ratio greater than 110% of the requirements specified herein
before, then there shall be an investigation to establish the cause and prevent its
recurrence. The cast concrete from which the samples were taken may be rejected
subject to the sole judgement of COMPANY. No analysis of freshly mixed concrete
shall be required for blinding concrete.
13.6.9 Salt content
The total concentration of sulphates and chlorides in fresh concrete shall be

measured at least once per week for all structural grades of concrete. Tests shall be in
accordance with BS 1881. Concentrations of either ions shall not exceed the following
respective limits:
 The total chloride content of the concrete shall not exceed 0.2 % expressed as %
of chloride ion by weight of cementitious material.
 The total sulphate content of the concrete (including sulphate ions in cement and
slag) shall not exceed 4.0 % expressed as % of SO3 by weight of cementitious
material.
Should these limits be exceeded, further tests shall be required on concrete cast during
the week to determine the total extent of the problem and decisions made as to how
the situation shall be remedied.
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13.7 PROTECTION OF CONCRETE SURFACES
13.7.1 General
All concrete surfaces shall be investigated, provided that any small holes formed by
air bubbles caught against form work shall be filled with a filler compatible with the
coating to be applied.
13.7.2 Blinding Concrete
Unless otherwise specified, all foundations shall be placed on 50mm thick blinding
concrete. Prior to placing this concrete, the subsoil shall be well compacted and free
from loose material.
The extent of the blinding concrete shall be minimum 50 mm from the edge of
foundation/paving or such that all member protective coating can be applied in
accordance with the MANUFACTURER’S recommendations.
Concrete for blinding shall be a designed mix with specified design strength of 12
N/mm2.
13.7.3 Impervious Membrane
Concrete shall be cast onto polythene sheeting 1000 gauge laid under the concrete
blinding immediately after excavation. Overlap shall be 150 mm and the sheeting
shall extend 150 mm beyond the edge of all foundations.
The Polyethylene sheet shall have following property:
Property Standard Limit

Elongation, Film ASTM D638 170%
Tensile Strength, Film ASTM D638, 6.3 N/mm²
BS EN ISO 527-3:1996 4.8 N/mm²
Longitudinal
Transverse
Adhesion ASTM D1000 >1.8 N/mm²
Adhesion to primed concrete >1.8 N/mm²
Adhesion to self (Lap Adhesion)
Puncture Resistance ASTM E154 225 N (min)
Moisture ASTM E96 < 0.3g/m² /24hrs
Vapor Transmission
Peel Strength ASTM D903 500 N/m
Tear resistance ASTM D4073, ASTM D624 270 N/mm
Longitudinal 270 N/mm
Transverse
Crack bridging ASTM C836 1.5mm
Adhesive softening point ASTM D36 >1000oC
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13.7.4 Surfaces below Ground Level
Surface below ground level shall be coated with 2 coats of bituminous paint to give a
total dry film coating thickness of 400 microns.
13.7.5 Exposed External Surfaces at Ground Level and above
Protective Coating for Concrete surfaces above ground level and exposed external
surfaces is not envisaged.
14. LIQUID RETAINING CONSTRUCTION
14.1 GENERAL
All liquid retaining construction shall comply with this specification and ACI 318.
Where concrete is designated on drawings as water retaining, the finished structures

shall be free from penetration of dampness. Any leaks or signs of dampness
appearing during construction, testing and maintenance periods of the contract shall be
made completely dry and shall remain dry during testing after remedial work without
further attention for a period equal to the contract maintenance period.
The method proposed for dealing with shrinkage cracks, leaks, dampness, or other
defective work shall be approved prior to commencement of the work.
Special attention shall be directed during the construction phase to the elimination of
cracking. In this connection consideration should be given to the following:
The form work should be struck as soon as practicable to ensure

curing is not delayed.
Good compaction to all joints ensuring the correct location of water bars.
The addition of plasticizers, chemical or other waterproofing compounds to the

concrete, may be used providing details are supplied for approval prior to concrete
work starting.
All concrete in water retaining construction shall be compacted by mechanical

vibration of a type to be approved.
Any bolts or fastenings for formwork involving fixings embedded in or passing through
the concrete shall be as not to impair the water tightness of the structure and shall be
approved. The use of bolts necessitating through holes is strictly prohibited.
14.2 JOINTS
The preparation of horizontal and vertical joint surfaces to receive fresh concrete
shall be given particular attention.
An air and water jet shall be used to remove laitance and expose coarse aggregate
while the concrete is “green”. The formwork to vertical joints may be treated with an
approved retarder to facilitate this operation. The fresh concrete shall be cast against
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the joint surfaces without the addition of grout.
External type PVC water bars, Minimum width of water stop shall be 230mm for
concrete section greater than 200mm wide and 150mm for concrete section less than
200mm, are preferred and shall be incorporated where suitable in all construction and
expansion joints as shown on the drawings. Intersection pieces shall be factory
made. Only butt jointing of identical sections shall be carried out on site, strictly in
accordance with the manufacturer’s recommended methods. Care shall be taken at
all times to ensure that water bars are not perforated or damaged in any way, and
concrete shall be carefully placed and compacted to ensure dense impervious
concrete. Particular attention shall be paid to the placing and vibration of the concrete
to ensure well-compacted concrete around the ribs of the waterbars. At all joints the
concrete shall be placed up to the centerline of the waterbar.
15. PRECAST CONCRETE
15.1 GENERAL
The requirements relating to concrete and reinforcement shall be observed so far as

they are applicable to reinforced concrete. In addition to the following requirements
specifically relating to precast work should be met.
15.2 PRECASTING YARD
The yard in which pre-casting work is to be undertaken shall be clean and shall have
firm level beds, preferably of concrete, with drainage channels between the beds.
The beds shall have a surface of suitable quality to give the precast units the required
class of finish.
Where precast units have projecting reinforcement, the moulds shall, if necessary, be
raised on stools above the general level of the pre-casting yard.
15.3 MOULDS FOR PRECAST CONCRETE
The moulds shall be strongly constructed, closely jointed and true to the required
shape with edges, corners and surfaces which comply with the relevant class of
finish. Moulds are to be so designed that they can be readily taken apart and
reassembled.
15.4 MARKING
All units shall be marked on a face which will not be exposed in the permanent works,
with the date of manufacture and such distinguishing letters or numbers required for
erection identification.
15.5 CURING, MATURING AND STACKING
The production schedules shall allow for proper curing and maturing of precast
concrete and shall be carried out as approved. The sides of the moulds may be
removed after not less than 12 hours provided that the concrete has thoroughly set.
All concrete surfaces shall be kept covered with thoroughly wetted hessian for at
least ten days.
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Slinging transporting and stacking may take place when designed handling stresses
have been attained, but building or setting in the works shall not be permitted until
the 28 days cube strength has been reached.
The time periods required for gain of strength of concrete may be reduced where
approved special techniques are adopted such as vacuum or pressed concrete, steam
curing or when a rapid hardening cement is used. No methods of accelerated curing
shall be used without prior approval.
15.6 CEMENT/SAND MORTAR
Cement/sand mortar for bedding and jointing precast members shall be of equivalent
strength, quality and color to that of the concrete member being added or jointed.
Cement/sand mortar shall be mixed in small quantities and used immediately.
Particular attention shall be paid to compacting the cement/sand mortar to prevent
the formation of voids and air pockets. The mortar mix shall be determined from
tests following the recommendations of appendix A of BS EN 1996, alternatively
grouting may be considered.
16. CHEMICAL-RESISTANT STRUCTURES
Protection against chemicals, even very dilute solutions, shall be provided either by
suitable chemical resistant bricks or tiles.
17. QUALITY PLAN
17.1 GENERAL
The CONTRACTOR shall submit a quality plan which shall comply with the BS EN
1992 (Eurocode 2) and shall be based on BS EN ISO 9001 quality system
requirements, DEP 30.99.97.0006 and BS EN 206-1. The quality plan shall cover
quality assurance and control and shall be divided into detailed design and
production/execution plan. The quality plan shall be subject to audit by COMPANY.
CONTRACTOR should submit a ITP inspection and test plan to all activities and get
it approved by COMPANY.
Inspection & Test Plans (ITPs) identifying the tests, frequencies, rejection criteria
and responsibilities shall be prepared as part of the quality plan.
The CONTRACTOR shall perform the following concrete and concrete material
related tests at the frequency shown below:
17.2 TEST FOR WATER

Test
Test method Test frequency
requirement
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MFSTD-CV-00-SPC-002
Chlorides BS 1427 - Method 4.3 or Every truck delivery or once a week if

Quantab Test Strips for tests piped from a water public supply or
on truck deliveries an reverse Osmosis Plant
Sulfates BS 1427 - Method 4.6 or Every truck delivery or once a week if
Quantab Test Strips for piped from a water public supply or a
tests on truck deliveries reverse Osmosis Plant
PH BS 1427 - Method 5.3 Every truck delivery or once a week if
piped from a water public supply or a
reverse Osmosis Plant
Total Dissolved BS 1427 - Method 5.4 Weekly
Solids
Alkali BS 1427 - Method 4.1 Weekly
Carbonates
Bicarbonates BS 1427 - Method 4.1 Weekly
17.3 TEST FOR CEMENT

Test requirement Test method Test frequency
Physical and chemical Standards: Receipt and review of
properties for Ground BS EN 15167-1, Manufacturer’s Test Certificate
Granulated Blast BS EN 15167-2, for each delivery of cement to the
Furnace Slag Cement BS EN 196 site
Physical and chemical Standards: BS EN Receipt and review of
properties for Portland 197-1, Manufacturer’s Test Certificate
and High Slag blast BS EN 196 for each delivery of cement to the
furnace cements site
17.4 TEST FOR AGGREGATES
AGGREGATES Each Single Size Each Fine

Coarse Aggregate (2 Aggregate (2 Nos)
Nos.)
Sampling BS 812-101, As required by As required by

BS 812-102, individual test individual test
BS EN 932-1,
BS EN 932-6 or
ASTM D75/D75M
Clay, silt and BS 812-103.2 Each 2 weeks or Each 1 week or
dust 2,000 M3 of concrete, 1,000 M3 of
whichever is the concrete, whichever
more frequent is the more
(Class 2) frequent.
(Class 1)
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Clay Lumps and ASTM Each 4 weeks or (Test not applicable

friable particles C142/C142M 5,000M3 of concrete, to fine aggregate)
whichever is more
frequent (Class 3)
Organic ASTM C40/C40M (Test not applicable Each 4 weeks or
Impurities to coarse aggregate) 5,000 M3 of
concrete, whichever
is the more frequent
(Class 3)
Chlorides as Cl BS EN 1744-1. Each 1 week or Each 1 week or
1,000 M3 of concrete, 1,000 M3 of
whichever is the concrete,
more frequent. whichever
(Class 1) is the more
frequent.
(Class 1)
Sulphates as BS 812, Part 118 Each 1 week or Each 1 week or
SO3 Method 6, 1,000 M3 of concrete, 1,000 M3 of
BS EN 1744-1 whichever is the concrete,
frequent.
(Class 1)
Alkali Reactivity ASTM C1260 At the start of the project and whenever
there is a change in the source of supply
Alkali Reactivity ASTM C227 At the start of the project and whenever
there is a change in the source of supply, as
necessary depending on the result of
ASTM C1260 above
Grading BS 812-103.2, Each 4 weeks or Each 2 weeks or
BS EN 933-1 or 5,000 M3 of concrete, 2,000 M3 of
ASTM C136 whichever is the concrete,
frequent.
(Class 2)
Relative BS 812, Part 2 Each 4 weeks or Each 4 weeks or
density (S.S.D) Method 5.4, 5,000 M3 of concrete, 5,000 M3 of
BS EN1097-3 whichever is the concrete,
frequent.
(Class 3)
Water BS 812, Part 2 Each 2 weeks or Each 2 weeks or
absorption Method 5.5, 2,000 M3 of concrete, 2,000 M3 of
BS EN1097-6 whichever is the concrete,
frequent.
(Class 2)
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MFSTD-CV-00-SPC-002
Soundness ASTM C88 Each 8 weeks or (See below for fine

(19 to 9.5) mm 10,000 M3 of aggregate)
and concrete, whichever
(9.5 to 4.75) mm. is the more frequent.
(5 cycles: Sodium (Class 4)
Sulphate) or
BS 812 - 121,
BS EN 1367-2
Soundness ASTM C88 (See above for Each 8 weeks or
(9.5 to 0.3) mm. coarse aggregate) 10,000 M3 of
(5 cycles: Sodium concrete,
Sulphate) or whichever
BS 812- 121, BS is the more
EN 1367-2 frequent.
(Class 4)
Flakiness index BS 812, Each 4 weeks or (Test not applicable
Part 105.1 5,000 M3 of concrete, to fine aggregate)
(combined 20mm whichever is the
to 6.3mm) more frequent.
(20/10) : (10/5) = (Class 3)
70 : 30 and
BS EN 933-3
Elongation index BS 812, Each 4 weeks or (Test not applicable
Part 105.2 5,000 M3 of concrete, to fine aggregate)
(combined 20mm whichever is the
to 6.3mm) more frequent.
(20/10) : (10/5) = (Class 3)
70: 30
10% Fines value BS 812, Part 111 Each 8 weeks or (Test not applicable
(Standard test 10,000 M3 of to fine aggregate)
size), concrete, whichever
BS EN 1097-2 is the more frequent.
(Class 4)
Los Angeles ASTM C131 Each 8 weeks or (Test not applicable
Abrasion (standard grading 10,000 M3 of to fine aggregate)
B and C), concrete, whichever
ASTM C535 is the more frequent.
(Class 4)
17.5 TEST FOR REINFORCEMENT

Test Test method Test frequency
requirement
Standard Standards: Receipt and review of
physical and BS 4449, Manufacturer’s Test Certificates for
chemical BS 4482, each delivery of rebar or fabric to
properties of BS 4483 Site.
reinforcing bars
and steel fabric
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Mechanical Methods as Specified One test for (a) Tensile Strength /

testing in the relevant code Elongation and ( b) Be n d /Re-bend
EN ISO 15630-1 / on each 500 Tonnes of each
ASTM E488 diameter of rebar.
Chemical Methods as One test for
testing Specified in the (a) Carbon, Phosphorous and
relevant BS Sulphur per 500Tonnes of each
Standard diameter of rebar and
(b) Carbon Equivalent per 100
Tonnes of each diameter of rebar
for all rebar to be welded on site.
17.6 TEST FOR ADMIXTURES

requirement
Standard Standard: Receipt and review of Manufacturer’s
physical and ASTM C494/C494M Test Certificates for each delivery of
chemical admixture to Site.
properties of
admixtures
17.7 TEST FOR FRESHLY MADE CONCRETE

requirement
Sampling BS EN 12350-1 As required by individual test.
Slump BS EN 12350-2 The first two (2) truck loads in each
pour and then every 3 truckloads.
Not more than 1 test / truck load but
additional test if any truck (whether
tested or not) is unduly delayed.
Temperature BS 8500-1, The first two (2) truck loads in each
BS 8500-2, pour and then every 3 truckloads.
BS EN 206 -1 Not more than 1 test / truck load but
(not greater than additional test if any truck (whether
30oC) tested or not) is unduly delayed.
Cement content BS 1881 PT 128 Every 300 M3 of concrete.
Note: COMPANY may request
test, to check calibration of batch
plant controls
Water content BS 1881 PT 128 Every 300 M³ of concrete.
Note: COMPANY may request test,
to check calibration of batch
plant controls
Chlorides BS EN 14629 As for Chlorides in Hardened
Method B.3 Concrete. Sample to be taken from
the same batch as will be used for
the test on the hardened concrete.
No analysis of freshly mixed concrete shall be required for blinding concrete
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MFSTD-CV-00-SPC-002
17.8 TEST FOR HARDENED CONCRETE

requirement
Sampling BS EN 12350-1 As per individual test.
Strength (cubes) Manufactured and cured to 2 cubes for every 60 M³ Min.
BS EN 12390 Parts 1 and or 1 set (3 Nos.) per day that
2, tested to BS EN 12390 concrete is placed, one
Part 3, Density determined to tested at
BS EN 12390 Part 7. 7 days and two tested at 28
days.
Strength (drilled BS EN 12504-1 As required if cube tests do
cores) not meet acceptance criteria.
Water DIN 1048 150mm cubes Cured Three tests every month for the
penetration a) 28 days water. first three months of production
(cubes) b) 14 days water then 14 then every three months.
days air.
Porosity RILEM CPC 11.3. Three tests every month for the
150mm dia x 75mm long first three months of production
cores from a) trial panel then every three months.
at 28 days and b) cubes
water cured for 28 days.
Chloride AASHTO T 259 Three tests every month for the
permeability 100mm dia x 50mm long first three months of production
cores from a) trial panel then every three months.
at 28 days and b) cubes
Water BS 1881, Part 122. Three tests every month for the
absorption 75mm dia x 75mm long first three months of production
cores from a) trial panel at then every three months.
28 days and b) cubes
Total chlorides BS 1881, Part 124 Three tests every month for the
Method 10.2 first three months of production
then every three months.
Total sulfates BS 1881, Part 124 Three tests every month for the
Method 10.3 first three months of production
then every three months.
Air voids ASTM C457/C457M Three tests every month for the
first three months of production then
every three months.
Note: This Test is applicable
to Air Entrained Concrete only.
CLEAN UP
1. Upon completion, leave project site clear of debris and surplus material
resulting from work of this contract. All debris and surplus material shall be
disposed off project limits in a manner meeting all local authority
requirements.

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CONCRETE WORKS

PROJECT CODE: SEPA15014

DOCUMENT NO.: SEPA15014-MFSTD-CV-00-SPC-002

Transmittal No: UTAPATE TERMINAL/DET/PTSPL/TR-0743

0 07 Dec 2022 ISSUED FOR APPROVAL KA CN ASK

REV. DATE PURPOSE BY. CHECKED APPROVED

Doc No.: SEPA15014-

REVISION DESCRIPTION SHEET

Doc No.: SEPA15014-

1.1. PURPOSE ....................................................................................................................................... 7

1.2. SCOPE ............................................................................................................................................ 7

1.3. ABBREVIATIONS ........................................................................................................................... 7

Table 2.1 – Concrete Codes and Standards (American codes) ............................................................. 8

2.1. CONFLICTING REQUIREMENTS ................................................................................................ 11

2.2. ORDER OF PRECEDENCE.......................................................................................................... 11

5.1.1 Test certificate ............................................................................................................................. 14

5.1.2 Cement Transport ...................................................................................................................... 14

5.1.3 Cement Storage .......................................................................................................................... 14

5.2.1 Aggregate grading ..................................................................................................................... 16

5.2.2 Sampling and Testing of Aggregates ..................................................................................... 16

5.2.3 Aggregate Transportation ........................................................................................................ 16

5.2.4 Storage of Aggregates .............................................................................................................. 17

5.3.1 General ........................................................................................................................................ 17

5.3.2 Fabric reinforcing ....................................................................................................................... 17

5.3.3 Spacers ........................................................................................................................................ 17

Doc No.: SEPA15014-

5.5.1 Admixtures .................................................................................................................................. 19

5.11.1 Grades of Concrete ................................................................................................................... 21

TABLE 5.2 CONCRETE GRADES .............................................................................................................. 22

6.1.1 Ties and Spacers ....................................................................................................................... 24

6.1.2 Permanent Form work ............................................................................................................... 24

6.1.3 Form work for Externally Vibrated Concrete ......................................................................... 24

6.1.4 Cleaning and Treatment of Forms .......................................................................................... 24

6.1.5 Removal ....................................................................................................................................... 25

6.1.6 Tolerances for Formed surfaces ............................................................................................. 26

8.1.1 Measuring .................................................................................................................................... 28

8.1.3 Transporting ............................................................................................................................... 31

8.2.1 Heat of Hydration ....................................................................................................................... 31

8.3.1 Use of Ready-mix concrete ...................................................................................................... 33

8.3.2 Transport and Delivery of Ready-Mix Concrete .................................................................... 33

Doc No.: SEPA15014-

9.1 GENERAL ..................................................................................................................................... 34

11.1.1 Formed Surfaces – Classes of Finish..................................................................................... 38

11.1.2 Unformed Surfaces – Classes of Finish................................................................................. 38

13.6.1 Testing ......................................................................................................................................... 41

13.6.2 Compliance ................................................................................................................................. 42

13.6.3 Unsatisfactory Concrete ........................................................................................................... 42

13.6.4 Standard Deviation .................................................................................................................... 42

13.6.5 7-Day Tests ................................................................................................................................. 43

13.6.6 Crushing strength tests for blinding concrete ..................................................................... 43

13.6.7 Measurement of concrete temperature .................................................................................. 43

13.6.8 Cement content and water/ cement ratio ............................................................................... 43

13.6.9 Salt content ................................................................................................................................. 43

13.7.1 General ........................................................................................................................................ 44

13.7.2 Blinding Concrete ...................................................................................................................... 44

13.7.3 Impervious Membrane .............................................................................................................. 44

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13.7.4 Surfaces below Ground Level ................................................................................................. 45

13.7.5 Exposed External Surfaces at Ground Level and above..................................................... 45

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SHORT NAME DESCRIPTION

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