Q. Civil Work Particular Technical Specification

Cerro del Águila Hydropower Project - EPC Contract
Q. Civil Works Particular Technical

Specification
EXHIBIT A - Technical Specifications. Volume VI

Cerro del Águila Hydropower Project - EPC Contract Page 2 of 101
Table of Contents
Page
1. Civil Works Particular Technical Specifications 5
1.1 Surface Excavation 5
1.1.1 Scope of work 5
1.1.2 Submittals 5
1.1.3 Lines and grades 6
1.1.4 Slopes, slides, geological overbreak and unsuitable
foundations 8
1.1.5 Execution 9
1.2 Underground Excavation 16
1.2.1 General 16
1.2.2 Excavation lines, tolerances and minimum technical
requirements 19
1.2.3 Tunnel alignment control 20
1.2.4 Auxiliary underground works 20
1.2.5 Support classes 20
1.2.6 Quality control testing and reporting 21
1.2.7 Blasting 21
1.2.8 Mapping 22
1.2.9 Excavated material disposal 22
1.2.10 Underground excavation by Drilling and Blasting (D&B) 23
1.2.11 Rock mechanics testing and tunnel mapping 24
1.2.12 Evacuation of water 26
1.2.13 Illumination and electricity supplying 27
1.2.14 Ventilation and control of dust, silica and noxious gases 27
1.2.15 Safety and environmental control 27
1.3 Drilling and Grouting 28
1.3.1 Definitions 28
1.3.2 General 30
1.3.3 Minimum technical requirements 30
1.3.4 Materials 33
EXHIBIT A - Technical Specifications. Volume VII

1.3.5 Equipment 33
1.3.6 Drilling 34
1.3.7 Water testing 34
1.3.8 Structure foundation areas 35
1.3.9 Cavity and contact grouting 36
1.3.10 Repair and clean-up 37
1.3.11 Records and progress assessment 37
1.4 Rock Stabilization and Support 38
1.4.1 Scope of work 38
1.4.2 General 38
1.4.3 Submittals 39
1.4.4 Rockbolts and grouted anchor bars 40
1.4.5 Wire Mesh 51
1.4.6 Structural steel supports 52
1.5 Backfills 55
1.5.1 Scope 55
1.5.2 Definitions 55
1.5.3 Minimum technical requirements 55
1.5.4 Material 56
1.6 Instrumentation 56
1.6.1 General 56
1.6.2 Surface measuring points 57
1.6.3 Piezometers 57
1.7 Concrete 57
1.7.1 Concrete materials 57
1.7.2 Concrete mixes 61
1.7.3 Transportation of concrete 64
1.7.4 Placing of concrete 65
1.7.5 Compaction and vibration 69
1.7.6 Protection 69
1.7.7 Joints 69
1.7.8 Construction and movement joints 69
1.7.9 Protection and Curing 70
1.7.10 Watertight concrete 73
1.7.11 Defects 73
1.7.12 Records 73

1.7.13 Quality control testing 74

1.8 Ancillaries to Concrete 74
1.8.1 Reinforcement 74
1.8.2 Built-in items 76
1.8.3 Formwork 77
1.8.4 Surface finishes obtained from formwork 79
1.8.5 Unformed surface finishes 81
1.8.6 Tolerances 82
1.8.7 Specialized concrete techniques 83
1.9 Metalwork 94
1.9.1 General 94
1.9.2 Materials 95
1.9.3 Fabrication 96
1.9.4 Marking 96
1.9.5 Connections 96
1.9.6 Erection 98
1.9.7 Types of metal work 100

Cerro del Águila Hydropower Project - EPC Contract Page
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1. Civil Works Particular Technical Specifications
1.1 Surface Excavation
1.1.1 Scope of work
The work shall include the design and preparation of Construction Drawings and the
execution of all surface excavation work to be performed under this Contract, which
shall consist of removing all existing material of whatever nature to the lines and grades
shown on the Construction Drawings or as otherwise required to meet the requirements
of the Contract.
This work shall include but not be limited to
1. the excavation, loading, hauling of unclassified material for incorporation in the

Permanent Works or for disposal in an environmentally friendly manner in designated
spoil or stockpile areas
2. the drilling and blasting, loading, hauling of rock for incorporation in the
Permanent Works or for disposal in an environmentally friendly manner in designated
spoil or stockpile areas,
All as shown on the Construction Drawings and/or as required to meet the requirements
of the Contract.
The Contractor shall also be responsible for excavation which is not specifically required
for the construction of Permanent Works, but incidental to the installation of temporary
facilities such as Site roads, office buildings, campsite, construction plants, etc.
Slope protection and stabilization measures, which may be needed in conjunction with
surface excavation work, are covered in other Sections of these Specifications.
1.1.2 Submittals
Prior to the commencement of any surface excavation, the Contractor shall submit to
the Employer as part of the Contractor‟s Documents details of the proposed excavation
methods and sequences, including necessary Site drainage, safety precautions, etc.
The excavation data for permanent structures shall include the following:
 Location and area of blasting.

 Diameter, spacing, depth, pattern and orientation of blast holes.
 Type, strength, amount, column load and distribution of explosives to be used per
hole, per delay and per blast.
 The type of detonators, powder factor, and sequence and pattern of delays to be
used per blast.
 Description and purpose of any special method to be adopted by the Contractor.

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The plans and data shall be in conformity with detailed requirements for excavation
sequencing, for blasting, and for precautions in proximity to concrete and grouting
operations.
Prior to dumping or stockpiling any material, the Contractor shall submit the layout of
spoil or stockpile areas to the Employer; these will be within the areas designated in the
Construction Drawings. All pertinent data of working methods and provisions for the
security, stability and temporary and permanent drainage of the areas shall be included.
Details of volumes, material types, heights and grades shall be provided.
1.1.2.1.1 Mapping
Mapping shall be performed according to the satisfaction of the client, to the state of the
art and the national requirements.
Soil Description
American Society for Testing and Materials, "Standard Practice for Description and
Identification of Soils (Visual-Manual Method), ASTM
Rock Description
International Society for Rock Mechanics, "Suggested Method for Quantitative
Description of Discontinuities in Rock Masses",
Details of rock support and drainage including location, type, length and tension of rock
bolts/anchors, location of drain holes, and extent of shotcrete shall be indicated on
geological maps or on drawings to the same scale.
The use of good-quality color digital photographs for mapping is encouraged; however,
photographs shall not be used to replace maps.
All mapping and other records shall remain available for review by Engineer over the
duration of the Contract. On completion of the Work, one set of digital as-built drawings
plus hardcopy and two completed sets of photographs labeled with the date, location
(preferably with approximate coordinates) and geological map cross references shall be
provided to Employer. All maps shall show the site grid or survey references on each
sheet.
1.1.3 Lines and grades

The Contractor shall set out all the structures and slopes as shown in the Construction
Drawings.
The final excavation grades shall in general be in rock of specified quality. However,
where the final excavation grades are defined by line and grade, the Contractor shall
take every precaution, and use the most appropriate method of excavation, to avoid the
loosening of material or the breaking of rock beyond the lines and grades shown in the
Construction Drawings.

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The bottoms of all excavations shall be trimmed to line and grade. If necessary the final
20 cm of any loose geological formation in excavations where concrete is to be placed,
shall be excavated by hand to avoid disturbance of the bottom.
If, for any reason, excavation is carried out beyond the lines and grades shown on the
Construction Drawings, the Contractor shall remove the excess material and take the
necessary measures to restore the required lines and grades with approved backfill or
concrete.
1.1.3.1 Unwatering and dewatering

Unwatering shall mean the complete removal of water from within a cofferdam area and
the maintenance of the area in a dry state.
Dewatering shall mean the control and removal of surface or groundwater from the
working areas such that they are maintained in a dry state.
In addition to initial removal of water from within a cofferdam area, unwatering shall
include the design, installation and operation of wells and/or the deployment and
operation of surface pumps for the removal of water and control of inflow into a
cofferdam area for the duration of river diversion. When appropriate, Contractor shall
install, monitor and record water levels in piezometers to confirm the effectiveness of
unwatering systems.
Dewatering shall include the design, installation and operation of wells or well-points for
the stabilization of slopes and inverts of temporary excavations. Contractor shall install,
monitor and record water levels in piezometers located adjacent to or within excavations
to establish that groundwater levels have been lowered sufficiently to safely proceed
with excavation.
1.1.3.2 Open-cut excavation: Overburden
1.1.3.2.1 Definitions
Overburden materials shall be defined as all materials other than solid masses of rock
and shall include wet materials, soil, stumps, roots, peat and other organic debris, as
well as individual rock fragments, boulder and detached rock blocks having a volume of
1.5 m³ or less.
The removal of rock fragments, boulders and detached rock blocks encountered in the
unclassified excavation which are larger than 1.5 m3 is covered under rock excavation.
The distinction between intact, in situ overburden and rock for the purposes of
classification of excavation shall be based on seismic compression wave velocities (Vp).
Material with in situ Vp exceeding 1500 m/s shall be classified as rock. All other material
shall be classified as overburden. The method of excavation shall not be used to
classify excavation.

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1.1.3.3 Open-cut excavation: Rock
Rock excavation is defined as the removal and disposal of boulders in excess of 1.5 m³
in volume, in situ bedrock, and any material with an in situ compression wave velocity,
Vp, in excess of 1500 m/s.
Dental excavation consists of the removal and disposal of unsuitable material found in
excavated rock surfaces, generally in confined spaces outside the lines and grades
shown on the drawings, requiring the use of light equipment and considerable manual
labor.
Controlled perimeter blasting includes, but is not limited to, presplitting (also known as
preshearing), cushion blasting and line drilling; in all cases, special drilling and blasting
methods shall be employed to produce smooth rock faces conforming to the prescribed
neat lines and to minimize any overbreak and blasting-induced fractures in the rock
faces outside the excavation lines.
Presplitting consists of drilling a single row of closely spaced holes, loading all or
selected holes lightly and continuously, and firing them simultaneously before any
adjoining main excavation area is blasted to produce a crack along the line of presplit
holes to which a subsequent primary blast can break. Completion of the blasting
techniques required to remove the adjoining rock requires a suitable burden/spacing
ratio, a reduced explosive charge in the line of holes nearest the presplit line and a limit
on the distance between the presplit line and the nearest line of primary blast holes.
Cushion blasting consists of drilling a single row of closely spaced holes with a suitable
burden spacing ratio, loading all the holes lightly and continuously with a uniform
continuous charge of small-diameters explosive, and firing them simultaneously as the
last delay period in the round.
Line drilling consists of drilling a single row of very closely spaced holes; not loading the
holes except for the possible use of special explosive to split the rock webs between
adjacent holes; having a suitable burden/spacing ratio and a reduced explosive charge
in the line of holes nearest the line drilled holes and a limit on the distance between the
line drilled holes and the nearest line of primary blast holes.
A `Lift' is defined as a single cycle of drilling loading and blasting to excavate rock,
including scaling, mucking and moving equipment in and out open-cut excavations.
Overbreak consists of the volume of rock removed during excavation operations beyond
the neat lines of open-cut excavation.
1.1.4 Slopes, slides, geological overbreak and unsuitable foundations

If geological conditions during the performance of the work do not permit excavation of
slopes as shown on the Construction Drawings, or where the material is unsuited to
form a firm foundation for the structures, the Contractor will modify the Construction

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Drawings accordingly or issue direct order to change the slopes and grades. Such
modified Construction Drawings shall be submitted to the Employer in good time as part
of the Contractor‟s Documents.
If over break in rock excavation or slides or rock falls occur, which are due to improper
working methods or negligence by the Contractor or otherwise, and the effective
excavated surfaces are beyond the excavation lines shown on the Construction
Drawings, the Contractor shall remove all excessive material and place suitable backfill
in the excavated voids.
If, during the course of construction and in the Contractor's opinion the slopes as shown
on the reviewed Construction Drawings are unsafe or otherwise objectionable, and in
his opinion should be changed, he shall modify the excavation accordingly.
Materials used in refilling the voids created by over break, or in additional excavation,
shall be compacted whenever it is practicable. In such case the foundations shall be
prepared, and material placed, moistened and compacted.
1.1.5 Execution
1.1.5.1 General
The surface excavation shall be performed by any appropriate method using any
excavating and hauling equipment suitable for the work in accordance with the
submitted detailed plans and time schedule, or modifications thereof which are
consistent with the Contract.
The work areas shall be properly drained. When underwater excavation is to be

performed, suitable equipment shall be used. The Contractor shall carry out periodic
cleaning to ensure that no hazardous accumulation of loose material occurs on the
slopes or on any berms or ledges forming part of the excavation profile.
Excavation for structure foundations shall be performed in reasonably dry conditions.

Final surfaces shall be protected against damage by erosion and travel of the
construction equipment. Any damage caused shall be repaired by the Contractor.
Rock surfaces at sensitive locations, at structures and tunnel portals, shall be carefully
excavated and preserved during construction. Line-drilling or smooth blasting
techniques shall be used as appropriate. Rock supports shall be installed where
indicated on the Construction Drawings, or as necessary to suit the actual geologic
conditions encountered.
The Contractor shall exercise particular care when excavating in the vicinity of existing
structures or those under construction. He shall be liable for any damage to structures
or equipment caused by his operations. Acceleration due to the blasting shall be
monitored as specified hereinafter.
The Contractor shall protect the subsoil and particularly the ground water and not to
contaminate as for example by fuel or oil from his equipment.
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The Contractor shall document the geological conditions of all excavated surfaces
(including galleries, shafts, etc.) in detailed maps.
1.1.5.2 Clearing and grubbing

Clearing means the removal, transport and disposal of all trees, brush, stumps,
fences, existing structures, debris and other obstructions in the areas to be occupied
by Permanent Works, surfaces of borrow and quarry areas, spoil and stockpile areas,
and where interfering with the prosecution or functioning of the work.
No trees shall be cut outside of the clearing limits without prior agreement by the
Employer. All trees designated by the Employer to be left intact shall be protected from
damage by the Contractor's operations.
The clearing limits, with exception of reservoir area clearing, shall extend 5m beyond
the limits of excavation, toes of embankments and spoil tips except where otherwise
indicated on the Construction Drawings or otherwise directed by the Employer.
Grubbing means the removal, transport and disposal of all roots, buried logs,
foundations of structures and other materials foreign to the natural topsoil in the areas
to be occupied by Permanent Works and surfaces of borrow and quarry areas.
No grubbing will be required in spoil and stockpile areas.
Clearing and grubbing work shall be performed either manually or with mechanical
equipment. The Contractor shall make every reasonable effort to salvage such
material which may be put to beneficial use.
All materials from clearing and grubbing work shall be disposed of in an acceptable
manner.
Materials to be burnt shall be piled neatly in such a manner and in such locations as to
not cause any fire risk or any inconvenience to the local population from smoke, and
shall be burnt completely so that all material is reduced to ashes.
The Contractor shall have suitable equipment and supplies for fighting fire during the
burning of material and shall take all necessary precautions to prevent fire from
spreading.
The specifications regarding clearing shall be prepared by Contractor and made

available for review by Employer
1.1.5.3 Stripping and unclassified (loose) excavation

Stripping consists of removing all rubbish, humus, vegetable material and all or part of
the organic topsoil in the areas and to the depth as indicated on the Construction
Drawings or as otherwise directed by the Employer.

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Unclassified (Loose) Excavation means general excavation of material such as

organic topsoil, clay, silt, sand, gravel, and boulders of up to 0.75 m³ in volume and
soft or disintegrated rock, which can be removed by common earth moving equipment
without ripping or blasting.
Stripping and Loose Excavation shall be accomplished by proper excavation and

hauling equipment suitable for the work which allows for an efficient work progress
adapted to the soil conditions encountered.
When the bottom of excavation as indicated on the Construction Drawings is not rock
and the natural foundation material is disturbed or loosened, for any reason, the
Contractor shall improve it by compaction or replace it with suitable fill and compact so
as to achieve satisfactory foundation conditions.
Excavations shall always be conducted in such a manner that the disturbance or
damage to materials lying outside the designated lines and grades is maintained at a
minimum.
1.1.5.4 Rock excavation by ripping, pre-splitting and blasting

In order to preserve the structural integrity of the excavated openings, it is the intent of
these specifications that Contractor's rock excavation methods be such as to produce
smooth and sound rock surfaces with a minimum of fracturing of the rock outside the
excavation. All necessary precautions shall be taken to achieve this result.
Contractor shall develop, by trial, controlled perimeter drilling and blasting techniques
which will result in a minimum of over-break and a minimum of fracturing of the rock
beyond the excavation lines thereby producing sound and reasonably uniform
surfaces to the completed excavations. For this purpose, Contractor shall perform trial
controlled perimeter blasting in the open-cut excavations, varying the burden, drill hole
pattern, hole depth, explosive type and quantity, blasting sequence and delay pattern.
Ripable material is defined as rock which can be loosened or broken down by a

bulldozer capable of developing 220 kW (300 Hp) of continuous power equipped with
a single shank rear-mounted, heavy-duty rock ripper, operating in low gear.
Material which in the opinion of the Contractor should be removed by ripping shall be
exposed, and the Employer notified before proceeding further. The top of the rock
surface shall be surveyed by the Contractor.
Ripping shall be performed in such manner that the ripper tooth does not damage the
material laying beyond the final excavation lines. Any material remaining to the final
excavation lines shall be removed by wedging, barring, broaching, or other suitable
methods.
Particle velocities for blasting shall generally not exceed the following limits:
1. For concrete and grout in place more than 60 hours, the maximum particle
velocities shall not exceed 50 mm/s measured at the concrete surface.
2. For concrete or grout in place less than 60 hours, the maximum particle velocities
shall not exceed 10 mm/s measured at the concrete surface unless otherwise
authorized by Engineer.
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3. For existing structures including structures not forming part of this Contract
adjacent to excavation areas, the maximum particle velocities shall not exceed 50
mm/s measured at these structures.
1.1.5.5 Support and pressure relief for excavations and natural slopes
Support shall mean the provision of external support measures such as dowels, rock
bolts, or rock anchors, shotcrete, wire mesh and steel anchors or girders to maintain
the stability slopes and underground openings.
Pressure relief shall consist of drilling and washing of pressure relief holes, the
installation of permanent liners and maintenance of holes over the duration of the
contract.
Dowels are un-tensioned bars inserted into a drill hole and generally grouted along
their entire length. Dowels may or may not be provided with a nut and face plate at the
rock surface and the exposed end may be straight or hooked.
Rock bolts are tensioned reinforcing elements with an ultimate capacity of up to 300
kN. Except for temporary usage, bolts are generally fully grouted after tensioning and
may be single or double corrosion protected.
Rock anchors are tensioned reinforcing elements with an ultimate capacity in excess
of 300 kN. Due to the relatively high capacity and corresponding grades of steel,
anchors require more stringent testing procedures and corrosion protection provisions.
Anchors with a working life in excess of 1 year shall be provided with double corrosion
protection.
Anchorages shall mean either rock bolts or rock anchors.
Shotcrete shall mean a mixture of cement, water, fine and coarse aggregate, fiber
reinforcing and additives applied by pneumatically projecting the mixture through a
nozzle onto a surface. Shotcrete may be produced by either a wet-mix or dry-mix
process.
Wire mesh for reinforcement of shotcrete shall consist of welded or wound wire mesh
that will remain stable under the impact of shotcrete application.
Steel arches for tunnel support shall consist of structural steel members preshaped to
the tunnel profile. The term 'steel arches' shall include all invert struts and temporary
blocking and lagging.
Lattice girders shall consist of members of a welded, lightweight space-frame

construction, preshaped to the tunnel profile that are incorporated into shotcrete and
act in concert with the shotcrete to resist rock loads.
Support and pressure relief shall be installed in portions of the Work in excavations
where the stability of the excavated surfaces will not be maintained naturally.
Steel for dowels, rock bolts and rock anchors shall conform with the requirements of
ASTM 615 or the equivalent Peruvian standards.
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The use of rock dowels shall be restricted to cases where the relatively large rock
movements required to mobilize tension in dowels can be sustained without adversely
affecting the Works.
Adequate corrosion protection shall be provided for all permanent rock bolts and for all
rock anchors with a design life in excess of 1 year, consistent with function. Double
corrosion protection of critical rock anchors shall be used where necessary.
Rock that is likely to deteriorate significantly on exposure in permanent excavations

shall be shotcreted as soon as practicable. Prior to shotcreting, all loose or
deteriorated material shall be removed to achieve good bond. The requirements for
washing of surfaces detailed in Vol. 2 Foundation Preparation and Treatment, prior to
shot-crating may be relaxed for slaking rock. High-pressure compressed air jets may
be used for cleaning rock surfaces in this case.
Dowels, rock bolts and rock anchors shall be installed in accordance with Post-
Tensioning Institute (1986) "Recommendations for Prestressed Rock and Soil
Anchors", Second Edition, Post-Tensioning Institute, 301 W. Osborn, Suite 3500,
Phoenix, Arizona, 85013, USA, 1986.
The Contractor shall carry out and document mill tests to demonstrate that the bolts or
anchors and couplers are capable of developing 95% of the guaranteed ultimate
tensile strength.
Testing of installed rock bolts or rock anchors shall be carried out in accordance with
International Society of Rock Mechanics “Suggested Method for Rock Anchorage
Testing”:
The specified maximum testing limit (SMTL) for simplified design tests at the lower of
133% of the working load (1.33 PW) or the guaranteed yield strength of the bar. The
proof test SMTL shall be set at 125% of the working load (1.25 PW).
Simplified design tests shall be carried out on the first three to five rock bolts and rock
anchors and on a minimum of 2% of production rock bolts and rock anchors. The
actual percentage of these tests may be increased depending on field conditions and
the results of previous testing.
Acceptance criteria for testing shall be in accordance with the ISRM Suggested
Method.
Steel for steel ribs, invert struts and lattice girders shall conform within the
requirements Vol.2 Metalwork.
Ribs and girders shall be pre-formed into the required tunnel profile. Adjustments of
the rib or girder shape to match the actual tunnel profile in the field shall not be by a
method, such as bending after heating that may cause deterioration of the steel.

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Blocking for steel ribs shall consist of steel wedges or blocks that may be firmly
wedged against the rock surface. Wooden wedges, or blocks shall not be incorporated
into the permanent Works, and shall only be used a temporary support.
Steel ribs and lattice girders shall be provided with steel sole plates, welded to the
ends of the ribs or girders and seated firmly on the invert of the excavation.
Lattice girders shall be braced against adjacent girders by means of bracing bars in
accordance with the manufacturer's instructions.
Shotcrete testing data, including trial mix tests, field preproduction tests and
production tests. Failures of shotcrete, including cracking and delamination, shall be
documented, photographed and evaluated.
1.1.5.6 Foundation Preparation and Treatment

Foundation shaping shall entail excavation or backfilling of relatively large scale
irregularities in the foundation surface, which may, by their presence, lead to
differential movements or stress concentrations in the overlying structures.
Dental excavation and concreting shall entail excavation or soft, loose permeable or
erodible material from karst cavities, joints, seams, shear zones, or other features
within the foundation and the subsequent backfilling of the excavation or natural
opening with concrete.
Slush grout shall mean a mixture of water, cement and sand in the form of slurry that
can be introduced into surface joints or cracks, which are too fine to accept dental
concrete by the use of brooms.
Rock surfaces against which concrete or shotcrete is to be placed shall be clean, solid,
and free from oil, mud, loose, semidetached or unsound fragments of rock,
objectionable coatings and debris, and shall be sufficiently rough to assure satisfactory
bond with the concrete or shotcrete.
Rock surfaces shall be prepared immediately before placement of concrete or

shotcrete and the methods employed shall include the use of high-velocity air/water
jets, or air jets, wet sand blasting, stiff wire brooms, picks or other effective means.
The rock surfaces shall be washed or blown to remove all loose material. All pools of
water shall be removed from depressions to ensure proper bonding of the fresh
concrete or shotcrete to the rock surfaces.
Where water flows from rock or other source against which concrete or shotcrete is to
be placed and that water cannot be sealed off by concreting or application of shotcrete
alone, the water shall be excluded from the area by caulking or diverted by pipes, pans
or other means in such a manner that the concrete or shotcrete will be unaffected by
action of the water through percolation by hydrostatic pressure or erosion.
The rock surface shall be kept moist for a continuous period of at least 2 hours prior to
placement of concrete or shotcrete unless the rock is likely to deteriorate significantly
by the application of water.
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Final foundation surfaces for concrete structures in rock that is likely to deteriorate on
exposure to air or water shall be covered with a layer of protective shotcrete as soon
as practicable after excavation, cleaning and mapping.
Limits on blasting vibrations (particle velocities) for blasting for foundation shaping or
dental treatment shall be in accordance with the requirements of the chapter Open-cut
Excavation: Rock.
Controlled perimeter blasting techniques shall be used for all blasting for foundation
shaping to maintain the integrity of the rock outside the final excavation line.
The depth and extent of foundation shaping and dental treatment shall be determined
by Contractor as discussed in this specification.
Dental concrete shall be of the same quality and specifications as the concrete in any
immediately adjacent structure.
The rock-concrete contact for all concrete placed for foundation shaping or dental
concreting shall be contact grouted in accordance with the requirements of the chapter
Drilling, Grouting and Drainage.
The rock around the full perimeter of concrete-lined underground openings shall be
consolidation grouted to a specified depth in accordance with the requirements of the
chapter Drilling, Grouting and Drainage.
Overburden foundations for structures shall be drained and cleaned of loose or wetted
materials, debris, weak and unsuitable materials prior to placement of fill or concrete.
The final surface shall be thoroughly compacted prior to placement of fill or concrete.
1.1.5.7 Borrow areas and quarries
Borrow areas involve exploitation of overburden or similar materials as defined under
the chapter Excavation: Overburden.
The term quarry is restricted to areas where rock materials are exploited as defined
under the chapter Open-cut Excavation: Rock
1.1.5.7.2 General
Contractor shall be responsible for exploiting borrow areas and quarries in such a
manner as to yield the maximum of usable material. Exploitation methods shall ensure
that borrow materials are not adversely affected by prolonged exposure before final
exploitation. Contractor shall carry out trial blasts in quarries to establish blasting
procedures to maximize the yield of acceptable material.

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1.2 Underground Excavation
1.2.1 General
1.2.1.1 Scope of work

The work will include the calculation, design and preparation of Construction Drawings
and the construction of all underground excavations to be executed under this Contract.
The Contractor will use full face drilling and blasting method base on the rock mass
behavior control. The work described herein includes loading, transporting and
disposing of excavated materials to spoil or stockpile areas, as well as the removal of all
loose materials by scaling and cleaning of the excavated surfaces, all in accordance
with the requirements of the Contract.
1.2.1.2 Definitions
For the sake of clarity, the following terms will be used in connection with the Works as
defined herein:
1. Excavation by drilling and blasting: Excavation of tunnels and caverns applying

drilling and blasting (D&B).
2. Heading face: The advance end of a tunnel or other excavation at which the work is
progressing.
3. Heading zone: The section of the D&B tunnels, ascending or descending, or vertical
or inclined D&B shafts with upward heading, are extending from the heading face over
the previous three round lengths.
4. Bottom range zone: Refers to the sinking or top-down enlargement of vertical or
sub-vertical shafts and is defined as the space between the newly established floor and
the length of the previous round above it plus 1 m, regardless of shaft diameter.
5. Rear zone: Refers to the entire tunnel or shaft section extending respectively from
the heading zone, or bottom range zone to the portal.
6. Pull: The advance of the heading face in a D&B excavation from one blasting round
to the next (equivalent to round length).
7. Working day (wd): This is a calendar day on which work is performed. When
working days are mentioned in writing, these will be shown with additional indices such
as: wdl, wd2 or wd3, indicating the number of working shifts on that day.
8. A „round‟ is defined as a single cycle of drilling, loading and blasting to excavate
rock, including scaling, mucking and moving equipment in and out of underground
excavations.
9. „Heading excavation‟ is defined as the crown portion of tunnel excavations which is
undertaken as the first blast in each round.
10. „Bench excavation‟ is defined as excavation subsequent to the heading excavation,
either as a single blast or a series of blasts, to enlarge the excavation to its final profile.
„Pilot tunnel‟ is defined as an advance excavation of smaller cross section than the final
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excavated cross section, located as required anywhere within the proposed

underground excavations.
11. Excavation by raise boring: Continuous excavation of shafts by means of an Alimak
Raise Climber machine (ARC).
1.2.1.3 Analytical design

The Contractor will prepare detailed numerical calculations in order to define stress and
strain, i.e. stability calculations, in the underground due to the intended excavations;
these calculations will be made prior to any excavation work and will be compared,
during and at the end of the works to the prevailing stress and strain situation.
Appropriate computerized numerical calculation programs (e.g. “UNWEDGE”
“EXAMINE” “PHASE”, “FLACK” “UDEC”) for all different situations will be employed.
The Contractor will implement the necessary instruments and carry out geological and
geomechanical mapping, monitoring and tests before and during the excavation, as
required by the specifications and consistent with sound engineering practice.
1.2.1.4 Rock mass designation
Q system (Barton, 2002) will be used to classify the encountered rock mass during
excavation. The rock mass behavior will be predicted by combined analysis of GSI,
UCS of excavated rocks, the intrinsic characteristics of the rock mas
will be mapped by experienced geologists. Systematic tunnel monitoring

(convergences) will permit to evaluate the efficiency of the designed “excavation and
support profile types” Rock burst phenomena will be managed with the application of
specific bolting supports. Daily advancements will be always anticipated by face drilling
with an electronic controlled Jumbo, equipped with advancement data logger. The
recorded data will permit to predict daily front face excavations and the expected rock
mass designations.
1.2.1.5 Classification of underground excavation

Underground excavation will be divided into different rock and support classes in order
to differentiate the level of effort and advance rates due to the varying properties and
structure of the material encountered.
Shown support classes on the drawings will be reconfirmed based on the mentioned
numerical stability calculations prepared by the contractor.
Class of support defined in relation to the rock and typical rock support systems will be
shown on the Construction Drawings.
Subsequent or supplementary installation of support in the rear zone will have no

influence on the determination of the support class.

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The assignment of an individual support class will always apply to the whole of the
excavation cross section as defined by the "A"-line, even if the partial excavation
method (e.g. top heading and benching) is being used.
1.2.1.6 Liability
The approval given by the Employer‟s Representative to the Contractor‟s methods and
equipment does not relieve the Contractor of his full responsibility for the proper and
safe execution of underground excavations; he will assume all liability for injuries to
persons or fatal accidents resulting from his work methods; and he will always fulfill all
of his obligations under this Contract.
1.2.1.7 Submittals
No less than 45 days prior to the commencement of any permanent underground
excavation, the Contractor will submit to the Employer as part of the Contractor‟s
Documents all relevant details and data pertinent to the underground excavation,
including the mentioned numeric stability calculations for underground excavations, with
description of staged excavations.
He will further indicate the proposed equipment, drilling and blasting patterns,
ventilation, dewatering, details of safety measures, methods of drilling pilot holes, types
and quality of initial support and rock reinforcement, e.g. sprayed concrete, concrete
lining, rockbolts, rock anchors, grouting details, together with the pertinent
manufacturer‟s specifications, instructions and certificates, installation procedures and
testing.
A detailed work schedule for the underground excavations will accompany the above
information.
1.2.1.8 Excavation general planning

The Contractor will, no less than 30 days prior to the commencement of excavation,
submit to the Employer, as part of the Contractor‟s Documents, plans of excavations
beyond design lines, which the Contractor considers necessary for the proper execution
of the Works, such as excavations for pumping and drainage, communication and
access facilities, transformer bays, passing bays, workshops etc.
1.2.1.9 Daily reports

During the advance of underground excavations, the Contractor will, unless otherwise
agreed, submit to the Employer daily, regardless of progress, the following information
on the progress of the excavation (regardless of excavation method):
1) Length excavated and theoretical volume of solid material excavated according to

the support classes;
2) Amount, location, spacing and type of steel ribs, lagging and spilling installed;

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3) Volume and location of sprayed concrete, with and without fibres, amount of fibres
and wire mesh installed;
4) Number, lengths, types and location of rockbolts/rock anchors installed;
5) Rock-falls, zones of instability and logs of pilot holes;
6) Water inflow at the headings and the rate of discharge of water from the de-
watering systems, along with the temperature of the water;
7) Personnel employed during the various stages of operation;
8) Unusual occurrences including all delays and the reasons for these;
9) Horizontal and vertical alignments with respect to the designed alignment.
The Contractor will record the results of all rock mechanics tests performed by him and
submit these documents to the Employer within 2 days.
The Client may require any additional information deemed necessary to be included in
the submitted documents and to ensure the quality and accuracy of the Works. He will
give his comments on the submitted documents not later than 14 days prior
commencement of the works.
1.2.1.10 Definitions and related requirements
1.2.2 Excavation lines, tolerances and minimum technical requirements

Typical cross sections, excavation lines and dimensions of excavations will be shown
on the Construction Drawings.
An “A”-line will be defined indicating the minimum excavation line within which no rock
material will be permitted to remain.
All necessary precautions will be taken in order to preserve the structural integrity of the
excavated openings.
Contractor will develop, by trial, controlled perimeter drilling and blasting techniques
which will result in a minimum of over-break and a minimum of fracturing of the rock
beyond the excavation lines thereby producing sound and reasonably uniform surfaces
to the completed excavations.
For this purpose, Contractor will perform trial controlled perimeter blasting in the
underground excavations, varying the round length, burn cut location and geometry, drill
hole pattern, explosive type and quantity, blasting sequence and delay pattern.
Over-breaks generated by unfavorable joint sets (so called geological over – break) if
existing, will daily signaled to the Engineer in order to anticipate possible claims.
Systematic over-break in the inverted, related to unexpected and unforeseen geological

conditions, that could require a significant amount and not quoted concreting, will be
object of specific discussions between the Employer and the Contractor.

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1.2.2.1 Excavation surface

Excavation will everywhere extend to the design lines, grades and dimensions shown in
the Construction Drawings or as otherwise required meeting the requirements of the
Contract.
1.2.3 Tunnel alignment control
Immediately behind the heading face, the Contractor will measure the excavated profile
by means of a profile template or another method satisfactory to the Employer.
Average deviation of the tunnel center line from the design center line, along a 100 m
length of any tunnel section, will not exceed 150 mm.
Deviations of shafts excavated by shaft-sinking, from the design center line, will not
exceed 0.2 m at the shaft bottom. The maximum allowed deviation at breakthrough
includes all inaccuracies relating to the surveying grid, to surveying carried, out by the
Contractor and to setting-out.
If deviations in tunnels or in shafts excavated by shaft-sinking exceed the specified

tolerance, the Contractor will be required to adapt his working methods so that the
specified tolerances are achieved.
If the maximum allowed deviation of tunnels or shafts at breakthroughs is surpassed,

the Contractor will be required to adapt the tunnel or shaft alignment to accommodate
and to smooth out the actual deviation, including additional excavation and/or lining
concrete, as directed by the Employer.
1.2.4 Auxiliary underground works
Excavation not shown on the Construction Drawings as Permanent Works, but which
the Contractor considers necessary for his own convenience, such as excavation for
mucking pits, pump sumps, drain ditches other than those shown on the Construction
Drawings, additional adits, spaces for mechanical or electrical facilities, may only be
carried out with prior consent by the Employer.
The locations of tunnel portals shown on the Construction Drawings are approximate.
The actual position will depend on the conditions encountered and will be determined by
the Contractor, and reviewed by the Engineer, in the preliminary geological investigation
campaign.
1.2.5 Support classes

In order to manage with the variety of rock conditions expected to be encountered in the
tunnels, adits and shafts, typical primary rock support classes has been previously
defined for drill and blast excavation, and it will be reconfirmed by analytical
calculations, based on new geomechanical data provided by the planned geological and
borehole investigation campaign.

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Any variation of intact rock or rock mass properties, from those provided in geological
documents for geological units and lithologies along tunnel alignments, will be
considered in order to review the determination of the applicable support class only if it
will depend from unforeseen conditions from those presented in the geomechanical
profile of the Contract.
This variation, as well as the unforeseen conditions that require a support review will
have to be supported by monitoring, testing and numerical calculations and will have be
agreed between the Contractor and the Engineer..
1.2.6 Quality control testing and reporting

Contractor will prepare and submit to Engineer, its overall plan of proposed methods
and sequence of excavation for underground excavation, including location and
treatment of disposal areas.
1.2.7 Blasting
Different blasting patterns pull lengths and support schemes will be prepared, with
respect to the expected rock condition and different design profile types, and submitted
with the above information.
The drilling pattern design will be defined in order to minimize over break and
disturbance of the rock mass surrounding the underground works. The submitted
description of drilling and blasting procedures will include the following:
• Diameter, spacing, depth, pattern and orientation of blast holes;
• Type, strength, amount, column load, and distribution of explosives to be used per
hole, per delay, and per blast;
• Type of detonators and sequence and pattern of delays to be used per blast;
 Excavation sequences (e.g. details of top heading and benching in excavation for
tunnels, staged excavation for shafts).
The Employer may order blasting tests to be undertaken to substantiate presumed

performance and suitability of the proposed materials, methods and equipment.
1.2.7.1 Blasting recording

The plan will include the sequence of excavation for each round, location, depth and
area of blast holes; the type, strength, amount, column load and distribution of explosive
to be used per hole, per delay and per blast; the sequence and pattern of delays and
the description and purpose of any special methods to be adopted by Contractor. The
plan will also state how these methods are to be varied to suit differing rock conditions.
Blast proposals will be prepared for each blast with all of the information relating to
blasting in its overall plan included and will remain accessible for review by Engineer for
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the duration of the contract. Should the results of this blast monitoring indicate that
Contractor's blasting methods endanger either completed excavation, completed
grouting, concrete work or adjacent structures, Contractor will be required to alter its
blasting methods to prevent such damages.
1.2.8 Mapping
Contractor will carry out detailed engineering geological mapping of underground
excavations at a scale of 1:50, or larger, in accordance with the methods detailed in the
following documents.
Mapping will be performed according to the satisfaction of the client, to the state of the
art and the national requirements.
 Soil Description (if any)
 Rock Description (Q-system)
 Details of rock support and drainage, including location, type, length and tension of
rock bolts/anchors, steel ribs or lattice girders and extent of shotcrete, will be indicated
on geological mapping or on drawings to the same scale.
 Exhaustive photographic documentation of front face, crown, walls, and – when

possible – crown, will be taken.
All mapping and other records will remain available for review by Engineer over the
duration of Contract.
On completion of the Work, one set of reproducible as-built drawings and photographs
labeled with the date, location (preferably with approximate coordinates) and geological
map cross references will be provided to Employer as softcopy. All maps will show the
site grid or survey reference lines on each sheet.
1.2.9 Excavated material disposal

At least 30 days prior to dumping or stockpiling any material, the Contractor will submit
the layout of the spoil and stockpile areas, which will be within the areas so designated
by the Contractor and approved by the Engineer. All pertinent data regarding working
methods and provisions for the security, stability and temporary and permanent
drainage of the areas will be included, and details of volumes, material types, heights
and grades provided.
Suitable materials from required excavations will be utilized in the Works to the
maximum extent practicable. Excavation techniques will, as far as possible without
interfering with the quality of the Works, maximize the yield of suitable construction
materials. All materials from underground excavation suitable for use as fill, concrete
aggregates or for other purposes will be stockpiled on the Site if the immediate
placement in the final location in Permanent Works is impractical.

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Excavated materials, not suitable for or in excess of the construction requirements, will
be disposed of in spoil areas so designated. The spoil areas will be finished to a neat
and orderly appearance, graded for self drainage, blending in with the surrounding
topography.
The Contractor will provide adequate diversion of existing and intermittent water
courses and the proper drainage in the spoil areas and will be liable for any damage to
the Works, or to the property of third parties, caused by insufficient drainage in the spoil
or stockpile areas.
1.2.10 Underground excavation by Drilling and Blasting (D&B)

The Contractor will use drilling and blasting techniques (smooth blasting) which will
produce a smooth final profile, a minimum of over break and a minimum of fracturing of
the rock beyond the required excavation lines.
Smooth blasting will consist of drilling closely spaced holes along the final excavation
perimeter (0.40 – 0.60 m, depending on geological conditions), and blasting them with
light charges in the same blasting cycle as the main blast.
The techniques used will at all times be subject to mutual agreement with the Employer,
who may order a series of blasting tests to optimize the drilling and blasting procedure.
Time, location and arrangement of blasting tests will be subject to prior mutual
agreement between the Parties.
In order to achieve a smooth excavation surface, the angular deviation for drilling of the
perimeter holes (smooth blast holes) will be limited, so as to result in a blasted contour
which should not deviate from the tolerances shown on the Construction Drawings,
excepting from those cases were unfavorable joint set conditions generate unstable
wedges over the excavation line.
The length of a new round will never exceed that shown on the Construction Drawings.
Where required, spacing of holes or even the pull of the rounds may have to be reduced
in order to acquire the desired surface smoothness.
A reduced round length will be required in some sections of tunnels and shafts,
depending on geological conditions.
After excavating, the Contractor will adequately protect the invert surface from damage
caused by construction traffic, e.g. by the timely placement of a layer of blinding
concrete or by placement of invert concrete.
Scaling and cleaning of excavated surfaces
Scaling will be systematically performed in all underground excavations, prior to

applying any rock reinforcement and support. Scaling in this context refers to the
removal of loose material, fragments and debris from the excavation surface.
After each blasted round and possibly prior to the removal of the bulk of the material
loosened by the blast, the Contractor will scale the newly exposed surface of loose
fragments and debris, taking care to not cause further or unnecessary fracturing of the
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Scaling will be done by using an appropriate hydraulic rock hammer on excavator,

taking care to not damaging the rock counter.
1.2.10.1 Tunnel invert for D&B

In those sections of tunnels which will be fully lined with concrete, all tunnel muck will be
removed prior to placement of invert blinding concrete. No vehicular traffic will be
permitted over the tunnel invert after removal of the muck prior to placement of invert
blinding concrete.
1.2.11 Rock mechanics testing and tunnel mapping
1.2.11.1 Tests and investigations

The Contractor will provide profile and cross section surveys for the complete lengths of
all tunnels, adits and shafts. The Contractor will make provision in his planned
excavation activities to enable water pressure and any rock mechanics testing to be
carried out concurrently with the underground excavation.
All sampling of rock or soils will be performed by the Contractor who will invite the
Employer to witness them. Similar procedure applies to the selection of locations for in-
situ testing.
Lugeon water pressure testing‟s hall be performed by the Contractor and will be
witnessed by the Employer.
In particular adverse and unforeseen geological conditions, independently or instructed

by the Employer, the Contractor will carry out exploratory drillings with core recovery,
water test, and whatever needed to determine front face conditions.
In particularly unfavorable conditions, the use of a preventer to manage high pressure

water inflows could be required.
1.2.11.2 Convergence measurements
Convergence measurement will be performed in underground excavations to

determine the absolute displacement of measuring points placed around the
excavation perimeter. The measurement will be performed by the Contractor and the
data and analysis will be presented to the Employer within 8 working hours.
Comparison to the initial numeric calculations will be made and will be accompanying
the measurements.
The measuring points will consist of topographic reflectors, mounted on a threaded bar
grouted into predrilled holes.
The absolute position of the reflectors will be measured in 3-dimensional space by an

electronic coaxial theodolite equipped with distance measuring facility and data
logging. Accuracy of the distance measurement will be +1 mm and the directional
measurement +1 mgon.

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The convergence bolts will be installed directly behind the face within the heading
zone immediately after the installation of supports. Five bolts per measurement cross
section will be installed at a spacing of 25 m or as directed by the Employer. At the
beginning, the measurement will be carried out daily. Later, weekly readings will be
taken for several months up to cessation of convergence. Final lining cannot be placed
till convergence has ceased.
The measurements may be logged directly into a suitable data module and stored on
a suitable computer station and evaluated by the Contractor with appropriate software.
The Contractor will supply the Employer free of charge with the required hardware and
software to enable him to independently check the data.
1.2.11.3 Mapping of permanent underground excavations (documentation)

Concurrently with excavation, the geological conditions along all permanent
underground structures will be mapped by the Contractor. Mapping will be preformed
after every D&B round. The mapping, which also permit to define the Q value of the
front face, will normally contain the following:
 Geological unit
 Intact rock:
 rock type and lithologic description;
 weathering, alteration degree;
 compressive strength (from point load tests and UCT).
 Rock mass:
 jointing degree;
 geometry of discontinuities;
 properties of discontinuities surfaces;
 face conditions;
 rock classes according to definition in the geological report;
 water inflow;
 over breaks (geologic, non-geologic);
 ground response;
 suspected pervious zones.
 Support classes
The Contractor will make available to the Employer all geological data in his
possession regarding the underground excavations. The Contractor will strictly follow
the nomenclatures of the geological report (units, lithologic types, rock classes etc.) in
any geological documents he may produce or be required to submit.
In case that unexpected lithologic types are encountered, new nomenclatures will be
defined in agreement with the Engineer. The Contractor will provide adequate lighting,
ventilation, and access for tunnel mapping.
A summary of the surveyed geological conditions will be reported and signed after
every mapping in a “geological report book” located at the portal of the tunnel

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The Contractor will weekly make a copy of the geological report book and will
distribute it by mail to the Engineer and the Employer.
The geological conditions and support classes encountered and mapped will be jointly
agreed upon by the Employer and the Contractor at least weekly throughout the
execution of the underground work.
In case of heterogeneous front face the rock conditions will be determined by the worst
case, except in whose cases were the unfavorable conditions are very limited (les the
10% of the whole front face and located close to the invert.
1.2.11.4 Extensometers
Simple and multiple extensometers will be installed in control sections in the
underground cavern excavations (powerhouse, transformers, upper drop shaft cavern.
The number of extensometers will be defined by the Contractor and agreed by the
Employer, based on the mentioned numeric stability calculations and on “in situ” tests.
The borehole extensometer will consist of steel or fiberglass rods in protective plastic
sleeves with five groutable anchors and a reference head and protective cap. The
reference head will be designed to allow reading with a depth micrometer to 0.5 mm
resolution. The extensometers will be supplied by a recognized international
manufacturer.
Reading frequency will be defined by the Contractor but will initially be at least every
day.
1.2.12 Evacuation of water

The Contractor will carry out all work required to capture rain and service water and
infiltrated groundwater during construction. Water from underground dewatering will
be measured:
 15 meters from the front face, in order to quantify the amount of water inflowing in
the working area and strongly affecting the advancement rate
 at the tunnel portal, in order to quantify the total amount of drainage water along
the entire tunnel.
Water will be measured with the help of a “debimeter” (flow measurement instrument)
or of an appropriate water flow measurement structure.
Water within the tunnel will be canalized (excavation upstream) or pumped and
appropriate pipes (excavation downstream).
Water will be appropriately treated at the portal, as required by the national laws,
before having reintroduced in the natural drainage.

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1.2.13 Illumination and electricity supplying

The Contractor will install an adequate illumination system in all underground works.
The front face will be equipped with additional lightning as well as all the other
intermediate working areas (tunnel crossing, niches, etc).
An appropriate electrical system will be design and executed in order to supply

ventilation, pumping systems and auxiliary equipments. The system will have to
respect the national requirements and the international standards.
1.2.14 Ventilation and control of dust, silica and noxious gases
The Contractor will install and operate equipment and carry out all works required for
the ventilation and control of dust, silica and noxious gases.
In the tailrace tunnel particular attention will be keep for potential toxic natural gases
like CO, CO2, SO, SO4, that could be introduced in case of water inflows. Gas
detectors, ventilation procedures and evacuation procedures will be developed by the
Contractor and presented to the Employer in order to manage this dangerous gas risk.
1.2.15 Safety and environmental control
Contractor will assume full and sole responsibility for the safety of all excavations
performed under the Contract until final acceptance of the Work. The Work under this
Contract will be in accordance with the latest versions of all Peruvian (government)
laws and regulations or equivalent internationally accepted standards.
Contractor will regularly inspect all sloping, overhead and vertical faces in the
excavations made under this Contract, and will forthwith remove and dispose of or
support any rock deemed loose, unsound or disintegrated, or in any way unsafe.
Safety precautions such as grounding of electric equipment used underground and

preventing interference between power circuits used for detonators and other
equipment will be fully incorporated in the technical specifications prepared by
Contractor.
Effective communication facilities from the tunnel portal areas to working faces will be
provided and maintained by Contractor. Specific arrangements will be made for
transmitting warnings of approaching electrical storms. No loading operations will be
carried on while an electrical storm is active in the immediate area.
Contractor will light the underground works in accordance with Peruvian (government)
laws and regulations or equivalent internationally accepted standards. In addition, the
degree of illumination in the tunnels will not be less than that provided by a string of
100-W lamps hanging on one wall of the tunnel at 10-m intervals, 2.5 m above the
roadbed, working level or tunnel grade.
Contractor will ventilate the underground works in accordance with Peruvian

(government) laws and regulations or equivalent internationally accepted standards.

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The fresh air supply for the tunnels will not be loss than:
 that of required to produce a linear velocity of 10m/min on the average, throughout

the tunnel cross sections
 5.5 m3/min at the face of the tunnel for each man underground plus 2 m3/min break
horsepower for all diesel units operating in the tunnel.
Notwithstanding the requirements given above, the maximum amounts of noxious

gases permissible at any location in the underground atmosphere will not exceed the
following concentrations/levels:
 Carbon monoxide - 0.10% in exhaust gases of equipment or 0.005% in the

underground atmosphere
 Nitrogen dioxide - 0.0005% in the underground atmosphere
 Aldehydes - 0.0005% in the underground atmosphere
 Methane - 50% of the lower explosive limit (LEL)
 Oxygen - not less than 19% in the underground atmosphere.
Drilling, blasting and mucking operations will be so conducted that the concentration of
respirable siliceous dust measured near the face of the workmen will not exceed 0.1
mg respirable quartz per cubic meter of air.
The free silicon dioxide content of dust will be determined from collected samples
representative of the dust from the various work areas. Contractor will provide the
apparatus for checking the concentration of airborne respirable dust containing silicon
dioxide.
Analysis of collected dust samples must be done by a qualified laboratory using an

approved analytical procedure for the X-ray diffraction determination of silica in dust.
Contractor will, in the design and operation of the tunnel ventilation systems, take all
necessary measures to limit the generation of fog, to remove fog accumulations and to
maintain adequate visibility for safe and efficient operation at all times when Work is in
progress. The air intake for tunnel ventilation will be so located that the exhaust air is
not reused.
1.3 Drilling and Grouting
1.3.1 Definitions
The following terms whenever used in this Section shall have the following meanings:
“Depth” means the distance measured from the start of the hole regardless of
direction.
“Stage” means a partial or complete length of hole in which grouting is performed.

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“Grouting in descending stages” means drilling to a limited depth, setting a packer

and grouting the hole, permitting the grout injected around the hole to set sufficiently to
prevent its entering the hole when the hole is cleaned, cleaning out the hole, drilling to
a deeper stage, setting a packer at the bottom of the previously grouted stage,
grouting the new stage; and thus continuing in as many cycles of drilling and grouting
as are required.
“Grouting in ascending stages” means drilling a hole to the full depth in one
operation and grouting from the end of the hole towards the surface in successive
stages by setting the packers at predetermined depths.
“Split-spacing” means the system of locating an additional grout hole approximately

midway between two grout holes which have previously been drilled and grouted.
“Curtain grouting” means grouting of rock in one or more lines of holes spaced to
form a curtain barrier.
“Blanket grouting” means drilling and grouting of rock with a pattern of holes spaced,
drilled and grouted as directed in order to achieve grout saturation throughout the rock
contained in the volume treated.
“Primary holes” are initial grout holes drilled at suitable spacing before any grouting
has taken place.
“Secondary holes” are holes drilled midway between primary holes and parallel
thereto.
“Tertiary holes” are grout holes drilled midway between adjacent primary and
secondary holes and parallel thereto.
“Consolidation grouting” means drilling and grouting holes in a regularly spaced

array over an area to specified depths to improve bedrock strength, deformability and
permeability.
“Cavity grouting” means grouting to fill any voids at rock/concrete interfaces around
structures.
“Contact grouting” means drilling and grouting holes to any specified depth
intersecting an existing rock/concrete or concrete/steel interface to produce an
impervious contact. Contact grouting shall also mean grouting the void remaining
between concrete lining and rock in a tunnel.
“Grouting pressure” means the pressure of grout as measured at the header while
grout is being pumped into the hole.
“Effective pressure” means the pressure of grout, while being pumped at the point of
absorption in the hole, as calculated from the measured grouting pressure at the
header and allowing for the pressure head of grout in the hole.

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“Multiple row grouting” means the procedure of drilling and grouting additional rows
of holes parallel and on both sides of the main grout curtain to achieve greater water
tightness in any particular zone. Multiple row grouting can be carried out by grouting
outer rows and subsequently grouting inner rows or by drilling cells of holes in all rows
and installing packers at the same depth in all holes in the same cell while grouting
from only one hole.
“Grout take” is the quantity of materials injected in a length of hole expressed in units
of kilograms of grout material or total volume of grout.
1.3.2 General
The following relates to certain methods of geotechnical ground treatment. Where the
ground treatment proposed by the Contractor relates to a method not specifically
referred to in these Specifications, precise details of all materials and methods shall be
provided in a Supplementary Technical Specification to be prepared by the Contractor
as part of the Contractor‟s Documents.
Wash water and waste grout resulting from all grouting operations shall not be allowed
to contaminate any fill, backfill, steel lining or other Permanent Works, and such water
or grout shall not be allowed to flow into any watercourse until it has passed through
settling ponds or tanks.
Where hazardous materials are used in grouting operation, the Contractor shall
demonstrate, with appropriate testing, that these materials are not escaping to the
surface or entering water courses.
In hot climates precautions shall be taken to reduce the possibility of premature setting
of grout through overheating. The consistency and temperature of the grout shall be
checked using flow cones and thermometers.
1.3.3 Minimum technical requirements
Contractor shall prepare and submit to Engineer a detailed method statement

regarding drilling, grouting and drainage. This shall detail all relevant field procedures
for grouting including drilling methods, whole washing methods, proposed grout plant,
flow and pressure measurement devices, communication systems, grouting and water
pressure testing procedures, grout materials, additives, and proposed mixes. The
method statement shall also detail all relevant field procedures for drilling and
completing the dam and spillway drainage curtain including drilling and washing
methods and details of hole liners and permanent collar standpipes.
Contractor's method statement shall also include the type, size, location of grouting
and drainage galleries including the proposed method of excavation and temporary
and permanent support systems.
Contractor shall prepare, for use by field personnel, a detailed grouting manual
including grout whole locations, orientations, mixes, allowable pressures, pumping
rates, mix thickening and refusal criteria and water pressure testing procedures. The

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manual shall also detail methods of recording drilling, water pressure testing and
grouting data.
Contractor shall employ competent and experienced drilling and grouting supervisors
for field direction and supervision.
Methods and technicques to be applied:
• Jet grouting
• Diaphragma walls
• Foundation grouting using GIN method
• Cement-Betonite Slurry Trench Cutoff
• Soil-Bentonite Slurry Trench Cutoff
Automatic pressure relief valves shall be provided at the collar of the hole to ensure
that design pressures are not exceeded.
Contractor shall carry out laboratory trials on field mixed grouts to determine flow
properties (viscosity, cohesion) sedimentation and strength for various mixes.
All grout holes and drainage holes shall have a diameter in excess of 50 mm, and may
be drilled by rotary or percussion techniques using water flush. Air flush or air-water
flush shall not be used for drilling grout and drainage holes.
Water pressure tests consisting of injection of clear water or a cement grout with a
water cement ratio greater than 5:1 by weight shall be carried out for each packer
setting in each grout hole. Tests shall be continued long enough to obtain a stabilized
flow reading.
For cement grouts, grout mixers shall be of the high-speed colloidal type. For other
grouts, appropriate batching and mixing equipment shall be used.
Grouting stage lengths shall not be greater than 10 m.
Grouting shall not be carried within 25 m of a concrete structure where the foundation
is less than 7 days old. Grout holes shall not be drilled, water pressure tested or
grouted less than 12 m from a hole which is being grouted or which was grouted less
than 24 hours previously.
Foundation grouting from surface shall not be carried out closer than 25 m from the
edge of an area where foundation preparation is fully completed.
Cooling of grout constituents may be required if ambient temperatures are high.
Foundation drain holes shall not be drilled until consolidation, curtain and contact
grouting have been completed.
Contractor shall ensure that all grout holes are backfilled with an appropriate material
on completion of grouting. Completed grout holes shall be marked by a painted metal
peg and a metal tag indicating the hole number.

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Grouting and drainage galleries shall be constructed and supported in accordance with
the requirements of Underground Excavation: Rock, and Support and Pressure Relief
for Excavations and Natural Slopes.
Contact grouting for structures shall be carried out at preset pressures based on the
capacity of the structure to withstand grouting loads. In general, during contact
grouting adjacent grout holes shall remain uncapped to permit venting of thin grout
mixes until the thickest practicable mix is attained. Contact grouting shall be carried
out for tunnel concrete and steel linings, dam foundation, spillway foundation, tunnel
plugs, dental and foundation shaping concrete fill.
Consolidation grout holes shall be drilled and grouted on a regular grid over structure
foundations, however, additional consolidation grout holes at different orientations may
be required to intercept and grout specific features identified from geological mapping
or visual observations. Consolidation grouting shall be carried out over the dam and
spill way foundations, and investigative consolidation grouting around pressure tunnel
concrete lining and tunnel plugs. It may also be required for improving foundation
properties for other structures such as the powerhouse.
Curtain grouting shall be carried out for the gravity dam and spillway foundations and
abutments and around the diversion tunnels and power tunnels. Curtain grouting shall
be carried out in single or multiple lines. Provisions shall be made for additional curtain
grouting under the gravity dam after impounding the reservoir to full supply level.
Foundation drainage holes shall be drilled downstream from the grout curtain to the
same depth as the grout curtain. Drain holes shall be provided with slotted liners,
filters or other inserts as necessary to prevent clogging. Holes shall be designed to
remain easily accessible for periodic purging, flushing or acidization. Holes shall be
provided with a suitable protective standpipe at the point of discharge. The standpipe
for every fourth drain hole shall be designed so that the hole can be capped and a
pressure gauge attached to measure water pressure in the drain. Drainage galleries
shall be provided with appropriate concrete lined channels for conveying drainage
water and, if necessary, pumps and standby pumps for draining the galleries.
Measurement weirs shall be provided at the outlet of each drainage gallery.
A number of exploratory holes which have not been backfilled exist in the project area,
which shall be backfilled by Contractor with a thick sand-cement grout.
After completion of curtain grouting in a given section, exploratory drilling shall be

carried out to confirm the effectiveness of grouting. Exploratory drilling shall be carried
out using standard water flush rotary diamond drilling, using, as a minimum double
tube core barrels. The core diameter shall be `N' sized or greater. The spacing of
exploratory grout holes shall be no greater than four times the spacing of primary
holes and holes shall extend to a depth of at least 20 m below the bottom of the
deepest grout hole in its vicinity. In general, exploratory holes shall have the same
orientation as adjacent grout holes, however, every fourth exploratory hole shall be
given a different orientation within the plane of the grout curtain to confirm that
grouting effectiveness has not been affected by hole orientation. Core recovered from
holes shall be carefully stored in labeled wooden core boxes and it shall be logged for
both lithology and structural data including a detailed discontinuity log. As soon as
practicable, the core shall be photographed, both in a wet and dry state. Core boxes

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shall be stored in a permanent shed built for that purpose at a location selected by
Engineer. All exploratory grout holes shall be water pressure tested in 3 m stages
using a double packer arrangement. Tests shall be carried out at the same pressure
as the grout pressures used in adjacent holes at the same depth.
1.3.4 Materials
Grout for injection under pressure into rock shall consist of cement, water and, where
required, sand, pozzolan, bentonite or other additives.
Cement for grouting shall be micro cement with Blaine values greater then 450 m²/kg.
Water for grouting shall be as specified for concrete. Sand for grouting shall be as
specified for fine aggregate for concrete except that all particles shall be finer than 1
mm.
When bentonite is used for grouting it will normally be used in the range 2-7 per cent
by weight of cement. Bentonite for grouting work shall be the sodium montmorillonite
type and shall be as specified by the American Petroleum Institute. Bentonite must be
mixed thoroughly with clean water before cement is added to form the grout. It will be
necessary to have a special mixer when bentonite is used to avoid difficulty in mixing
this exceedingly fine-grained material.
1.3.5 Equipment
1.3.5.1 Drilling equipment
Drill-holes may be drilled with either rotary type diamond drills or percussion type drills
provided that, where holes satisfactory for subsequent grouting cannot be drilled by
rotary type diamond drills, percussion type drills shall be used.
The drilling equipment shall be capable of drilling at any angle, of being set up to an
accuracy of 1° and of drilling to an accuracy of 3°.
1.3.5.2 Grouting equipment
Grouting equipment shall be capable of effectively batching, mixing and maintaining

grout mixtures in suspension as specified, and of delivering and pumping grout into the
grout holes and concrete joints through grout connections in a continuous
uninterrupted flow at any constant pressure up to the limiting pressure required.
The arrangement of the grouting equipment shall be such as to provide a continuous

circulation of grout of uniform consistency throughout the grouting system and to
permit accurate pressure and flow control at the collar of the hole being grouted at all
rates of grout acceptance.

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1.3.6 Drilling
1.3.6.1 General
Holes shall be drilled from within 150 mm of the stipulated locations in the
Construction Drawings and grouted in stages. Casing of the hole is to be provided as
necessary to support a hole when drilling through loose overburden or difficult ground.
In cases where water loss occurs during drilling, or for other reasons, holes may be
grouted in descending stages.
Lubricants or other additives to drilling water shall not be permitted as an aid to drilling
grout holes or check holes except as a combined air/water flush for deep holes.
Where packers are to be used in any hole for grouting or water testing, every
precaution shall be taken to maintain a smooth wall in the hole in order that packers
can be set at any location and seal the hole in the required fashion.
1.3.6.2 Holes in structures
Where holes are required through concrete these shall be preformed, through which
the rock behind can be drilled. If, however, holes are drilled through concrete and steel
reinforcement is encountered drilling shall be discontinued immediately and new holes
shall be drilled nearby. Holes shall be backfilled with concrete or mortar and the
surface repaired. No drilling shall be carried out in concrete less than 7 days old.
1.3.6.3 Cored check holes
Cored check holes to check the effectiveness of grouting operations shall be drilled
within the range of the adjacent grout holes.
1.3.6.4 Core drilling
When diamond core drilling is being carried out, best practice techniques such as triple
tube core barrels, face discharge bits and foam flush shall be used where appropriate.
The rods shall be withdrawn and the core removed as often as is necessary to recover
the maximum amount of core. Samples obtained from the drilling shall be recovered
and stored, which shall be done as far as possible from each linear metre of the drill-
hole. The cores from such holes shall be packed in sequence in boxes. The boxes and
their contents shall be adequately labeled to identify the hole location. Soils should be
sealed where appropriate.
1.3.7 Water testing
In conjunction with the drilling and grouting operations, Lugeon water tests shall be
carried out in grout holes and check holes to determine the permeability of the rock
and the effectiveness of the grouting operations. Simple, i.e. one stage, water
pressure tests may be used where applicable. Water tests shall be conducted
immediately after drilling each stage has been completed in all curtain grout holes,
cored check holes and in holes for cavity grouting.
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Unless otherwise requested by the Employer‟s Representative, the pumps shall have
a capacity of 100 l/min at a pressure of 25 bar and shall be capable of exerting a
pressure of at least 50 bar. The pumping system shall be capable of maintaining any
desired pressure without fluctuation and the pressure and discharge must be
continuously adjustable.
Water pressure shall be measured by means of a pressure gauge with an accuracy of

0.5 bar and a range of 50 bar. Discharge shall be measured with an accuracy of 2%.
The water meter shall measure the discharge from 0.5 l/min. Water meters as well as
all pipes, hoses and couplings shall be designed to resist a pressure of 60 bar.
Water meters and pressure gauges shall be calibrated and certified by an independent
laboratory prior to installation at the Site and shall be subject to periodic verification. If
requested, one pressure gauge and one water meter shall, after independent
checking, remain at the disposal of the Employer‟s Representative for further checking
purposes.
The Contractor may be requested to establish, by way of tests, correction graphs for
pressure losses occurring in the pipes. Pressure gauges shall be installed directly at
the collar of the drillhole.
Packers shall consist of mechanically expanded rings or pneumatically expanded

sleeves of rubber or other suitable material, which can be set tightly in a drillhole at
any depth required. Packers shall be capable of withstanding pressures of up to 100
bar without leakage. The Contractor shall keep at the Site an adequate supply of
single packers, as well as double packers spaced 6m apart to allow to isolate a section
of a hole, and of sizes to suit the various hole diameters.
For water level measurements, electrical probes with an accuracy of 10mm shall be
used. They shall be provided with measuring tapes marked with centimetre gradations.
1.3.8 Structure foundation areas
1.3.8.1 General
Drilling and grouting in dam foundation areas will not be permitted:
a. until excavation for structures and foundations has been completed over and for
30 m beyond the area of the grouting operations;
b. within 20 m horizontally from any concrete structure until it is complete to +5m
above ground level unless otherwise specified; or
c. at any location within a distance of 30 m horizontally from concrete surface
preparation operations.
In foundation areas blanket grouting – if any – shall precede curtain grouting.
Primary holes shall be grouted first. If in primary holes it is considered that water
losses during drilling or water testing are high or that subsequent grout acceptances

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are high, then secondary holes (and tertiary holes if necessary) shall be drilled and
grouted on a split-spacing pattern.
Angles of holes shall be decided depending on the dip of the rock formations.
The sequence of drilling shall take account of the following:
• in no case may a primary hole be drilled before the previously drilled primary hole
adjacent to it has been grouted;
• in no case may a secondary hole be drilled before the primary holes surrounding it
have been grouted; and
• in no case may a tertiary hole be drilled before the secondary and primary holes
surrounding it have been grouted.
1.3.8.2 Blanket grouting
Holes for blanket grouting – if any – shall be drilled and grouted in either ascending or
descending stages. The sequence for drilling and grouting for blankets shall be as
follows:
 primary grout holes shall be drilled and grouted;

 if required, secondary lines (and tertiary lines if necessary) shall be drilled and
grouted between, and parallel to, the primary lines of a split spacing pattern.
1.3.8.3 Curtain grouting
Holes for curtain grouting shall be drilled and grouted in either ascending or
descending stages.
Where several lines of curtain grouting are required the outer lines shall normally be
grouted before work begins on the main inner curtain. Holes for the main line of
grouting shall be located along the centre line of the core foundation zone. Where
required, secondary and tertiary holes shall be drilled and grouted on individual lines
on a split spacing pattern.
1.3.9 Cavity and contact grouting
1.3.9.1 Contact grouting
During all grouting around steel linings, hydraulic gate frames etc., grouting pressures
shall be controlled and the internal surface of the lining continuously monitored so that
grouting can be stopped if any localized pressure causes the steel to deflect.
Following installation and encasement of any steel lining, a low pressure grouting
operation will be required over the full length of the lining, or lesser length depending
on void sounding tests, to seal any voids at the steel/concrete interface. No drilling will
be required for this operation but grout nipples will be required to suit and protect the
grout sockets.

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Grout sockets in steel linings will generally be arranged so that it should be possible
for grout to flow from one socket to another behind the lining.
Sockets shall be grouted at low pressure with adjacent holes being capped after the
emerging grout has displaced any water from behind the lining and the pressure has
been brought up to the required value.
Grouting will start with a water test to gauge the size of the cavity and lubricate the
concrete/steel interface; and will proceed starting with a thin mix which will be
thickened once interconnections between sockets have been established.
Where sounding tests indicate that there are still voids behind the steel despite grout
refusal at an adjacent socket, the lining shall be drilled and further grout sockets
installed and grouted.
If a pipe has been cast into the concrete to facilitate future cavity grouting, the pipe
shall be plugged during the contact grouting. The plug shall be removed and the pipe
flushed out as soon as the contact grout has taken up its initial set.
1.3.9.2 Cavity grouting
The rock/concrete interfaces around concrete surface structures shall be grouted from
within. Normally, it will be required to drill 300 mm into the rock prior to grouting.
In the case of areas faced with steel, cavity grouting will normally be carried out after
contact grouting of the steel/concrete interface, if not specified otherwise. Packers
shall be used to prevent grout pressure being applied to the steel lining.
1.3.10 Repair and clean-up
Concrete surfaces and foundation surfaces over which grout has flowed shall be
cleaned and restored to their original condition. Upon completion of the grouting and
checking of any area, the holes shall be washed and then backfilled with a thick grout
mix.
On completion of grouting in areas of concrete with a steel lining which is to be

painted, the steel surface shall be cleaned to a condition suitable to receive paint when
dry. In order to minimize damage to earlier protective coatings, this cleaning work will
normally be carried out by the supplier of the steel lining.
1.3.11 Records and progress assessment
Records of the drilling, grouting and water pressure tests, pressures, flow rates, the
quantities used in the grouting operations and any other general records shall be kept.
These will be required for the control of the grouting operation and shall therefore be
available for inspection by the Employer at any time. The Contractor shall detail the
procedures which will be undertaken in order to record and assess the progress of the
grouting works in the Quality Plan.

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1.4 Rock Stabilization and Support
1.4.1 Scope of work

The work will include the design and preparation of Construction Drawings and the
supply of all labor, materials, tests, equipment and services required to protect,
stabilize, or support rock masses uncovered in the course of surface and underground
excavation works, as well as anchoring of the concrete structures into surrounding or
underlying rock. This Section covers the following items:
 Rockbolts and grouted anchor bars

 Post-tensioned rock anchors
 Wire mesh
 Lattice Girders
 Structural steel supports
 Self drilling anchors
Principle works required under this Contract are as follows:
 Stabilizing of surface excavation slope and cuts. The support measures required will
be determined by the actual rock conditions encountered, but may consist of individual
or pattern rock bolting, post-tensioned anchors, sprayed concrete, wire mesh, and
dental works;
 Underground rock supports in tunnels, adits, shafts and caverns. The support
measures required will be determined by the actual rock conditions encountered, but
may consist of individual or pattern rock bolting, sprayed concrete, wire mesh, steel
ribs with or without lagging, lattice girders and/or post-tensioned rock anchors;
 Systematic anchorage of concrete structure into rock by means of grouted anchor
bars.
1.4.2 General
Rock stabilization and supporting measures to be undertaken during or after the
course of excavation work will be determined in a general manner in advance based
on the numeric stability calculations.
This rock stabilization and the ground improvement related to the linear underground
works (tunnels and shafts) have already been preliminary defined e presented in 9
different support profile types, related, each of them related to a specific rock mass
behavior. The finally placed rock stabilization and supporting measures will be
determined in the process of advancing excavation works and depending on the
material encountered.
Double corrosion protection will be applied to all permanently required rock

stabilization and supporting measures. This means that double corrosion protected
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structures will be implemented where the numeric stability calculations demonstrates

their permanent functioning. Double corrosion protected structures will not be required
in temporary rock stabilization and supporting measures.
The installation of the rock support will follow closely the excavation heading and they
will be installed before the next round of excavation advance. The Contractor is
responsible for the timely and proper installation of the rock supports and for checking
and maintaining it up and until the final lining or structure is placed.
An adequate quantity of rock support materials and equipment will be stored by the
Contractor at the excavation sites and be kept ready for immediate use during the
whole construction period.
1.4.3 Submittals
Within a reasonable time after the Commencement Date, but before procuring or
shipping the Materials to the Site, the Contractor will submit to the Employer as part of
the Contractor‟s Documents the following:
a) All pertinent information regarding the type and quality of rockbolts proposed to be
used together with manufacturer's instructions and certificates, methods of installation
and testing the suitability, testing equipment, and, for grouted rockbolts and anchor
bars, the grouting system.
b) Complete details concerning type and materials of the post-tensioned rock anchors
proposed to be used together with manufacturer's instructions and certifications,
methods of installation, corrosion protection, stressing equipment, grouting method
and equipment, proposal for anchor testing, stressing tests and equipment.
c) Design, calculations and fabrication details of steel ribs and lagging including size,
steel quality, accessories and methods of installation together with certified copies of
manufacturers' reports.
Prior to ordering any of the above materials, the Contractor will submit to the Employer
his proposed materials delivery schedule. Any major amendments to the delivery
schedule, proposed by the Contractor as the work proceeds, will also have to be
submitted to the Employer.
The Contractor's shop drawings of structural steel supports will be submitted to the
Employer prior to their installation.
The Contractor will record the results of all tests performed on the rockbolts and post-
tensioned anchors prior, during and after their installation and submit these results to
the Employer.

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1.4.4 Rockbolts and grouted anchor bars
1.4.4.1 General
The Contractor will furnish, install, test and maintain rockbolts and grouted anchor bars
as specified herein. The reinforcement element consists of a single steel bar of
selected length, shown on the Construction Drawings. The required diameter of the
rock bolt, which is pushed into a drilled hole, is to be defined according to the
structural analysis, performed by the Contractor.
The terms used in this Section are defined as follows:
Reinforcing Element is a general term for rockbolts, rock anchors and post-tensioned
rock anchors (specified separately).
 Rockbolt is a stressed (or tensioned) reinforcement element consisting of a rod, a

mechanical, resin or cement anchorage, and a plate and a nut for stressing by
torquing the nut or for retaining tension applied by direct pull. It is synonymous with
"active rock anchor". Rockbolt may be grouted or ungrouted.
 Rock Anchor is an untensioned reinforcement element consisting of a rod
embedded in a cement mortar filled hole. It is synonymous with "passive rock anchor"
and "rock dowel".
 Grouted Anchor Bar is a reinforcing element consisting of a reinforcing bar
embedded in cement mortar filled hole in rock and in structural concrete to provide
anchorage of concrete structures.
Individual Bolting refers to the installation of reinforcement elements in localized areas
of instability or weakness as determined during excavation. It is synonymous with
"spot bolting".
Pattern Bolting refers to the installation of reinforcement elements in a regular pattern

over the excavation surface.
The following types of reinforcing elements will be used:
a) "Perfo" type or similar
b) Expansion-shell type, ungrouted
c) Expansion-shell type, cement grouted
d) Resin-grouted type, limited to temporary work for safety
e) Swellex-type or similar
f) Grouted anchor bars
g) Self drilling anchors

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The type length, diameter, inclination and pattern of the rockbolts will be defined by the
Contractor. Rockbolts will be furnished complete with all accessories and other
materials necessary for their installation, stressing and grouting.
All surfaces of the bearing plates, nuts, washers and wedges, and threads on the
projecting ends of rockbolts will be protected and lubricated with rust preventive
compound (2 base layers and 2 final epoxy layer).
When rockbolts are used in conjunction with wire mesh, the mesh will be connected
firmly to the bolts by means of extra steel plates and nuts. Wire mesh will not be
placed between rock and the bearing plate for the rockbolt.
1.4.4.2 Testing and monitoring of rockbolts

The Contractor will furnish at least two sets of testing equipment including hydraulic
jacks, fixing device, hydraulic pump with manometer, extensiometer, and all necessary
accessories. The testing equipment will be capable of stressing the largest diameter
rockbolt to the yield stress of the bolt.
Prior to the installation of rockbolts in the Works, a series of pull-out tests will be
carried out, following the Norm ASTM D4435-08, in different rock types and which will
be representative of the rock expected to be encountered during the excavation, to
prove the suitability of the rockbolts proposed by the Contractor.
The pull-out tests will be carried out sufficiently in advance of the installation of the
rockbolts in the Works so that, in the event that the rockbolts proposed by the
Contractor do not meet load-strain requirements, the Contractor will have time to
furnish and test rockbolts of a different type.
The Contractor will maintain detailed records of the pull-out tests, the result of which
will be used to established relationships between rock quality and type of rockbolts
and tensioning.
During the progress of the work, the Contractor will perform pull-out tests, in the
presence of the Employer, on at least 1 per 100 rockbolts installed. The Employer, in
consultation with the Contractor, will determine the bolts to be tested.
Grouted expansion-shell type rockbolts will be tested before grouting. Other type of
rockbolts will be tested after the mortar has achieved the design strength.
1.4.4.3 Drilling holes and preparation for installation
The diameter of each hole will be in accordance with manufacturer's recommendations

except for grouted anchor bars where the hole diameter will be at least 1.5 times that
of the rod specified for that hole.
The length of drillhole will be such as to receive the specified rockbolt and to provide
for its satisfactory anchorage. The downward holes will extend 15 to 20 cm beyond the
length of the rockbolt.
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After drilling, each hole in rock will be washed out with clean water and cleaned by
blowing out all drill cuttings and debris with compressed air.
1.4.4.4 Friction-type Rock Bolts

Friction-type, or friction-anchored, rock bolts represent the most recent development in
rock reinforcement techniques. Two friction anchored rock bolts are available, the Split
Set and the Swellex. For both types of rock bolt system, the frictional resistance to
sliding, (for the Swellex combined with interlocking) is generated by a radial force
against the borehole wall over the whole length of the bolt.
Friction anchored rock bolts are the only type of bolts where the load of the rock is
transferred to the reinforcing element directly without any necessary auxiliary such as
mechanical locking devices or grouting agents
1.4.4.5 Split Sets
Split Sets, sometimes called Split Set friction rock stabilizers, have only two parts – a
tube and a bearing plate. The high-strength steel tube has a slot along its length; one
end is tapered for easy insertion, and the other has a welded ring flange to hold the
plate.
With the bearing plate in place, the tube is driven into a slightly small hole, using the
same standard percussion drill when made the hole. As the tube slides into place, its
full-length slot narrows; the tube exerts radial pressure against the rock over its full
contact length. Plate loading is generated immediately. The result is a tight grip, which
actually grows stronger with time and ground movement
In addition to its easy and fast installation (it usually takes less than a minute) and
giving immediate support after installation, Split Set also has the following advantages:
a) no special equipment needed, b) no mixing of grout, thus no waiting for grout to set,
c) low labor and material cost, d) no need of torquing or retorquing, thus no
maintenance cost.
1.4.4.6 Swellex Bolts
The Swellex rock bolting system has gained worldwide acceptance since its
introduction about twenty years ago. Today, the Swellex bolts are in use at mines and
construction sites worldwide.
The Swellex bolt system consists of rock bolts made from circular steel tube, which
has been folded to reduce its diameter, and a high pressure water pump. The Swellex
rock bolts are placed in a drilled hole and expanded by high-pressure water. During
the expansion process, the Swellex bolt compacts the material surrounding the hole
and adapts its shape to fit the irregularities of the borehole.
A combination of frictional and mechanical interlock is generated throughout the entire

bolt length, reinforcing and increasing the load-bearing strength of the rock

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surrounding the drill hole. The load of the rock is transferred to the Swellex bolt directly
without any necessary auxiliaries such as mechanical locking devices or grouting
agents, the quality of which is difficult to control.
The installation procedure of Swellex bolt is easy and acts as a quality assurance
control: first, put the bushing head of the bolt into the chuck and insert the bolt in the
borehole. Then, start pumping the water into the tube through a connection at the
lower sleeve. This causes the tube to swell in the hole. When the preset pressure has
been reached the mechanical interlock with the rock is established and the pump
stops automatically.
The Swellex bolts have almost the same advantages as those of Split Sets due to the
similar friction mechanism and tubing configuration.
Furthermore, the Swellex bolts have additional advantages, which are:
 Borehole condition and dimension are not crucial for installation so it can be used
in a variety of ground condition
 The holding capacity is 20 metric tons for Super Swellex.
 The stainless steel tube is protected to corrosion and it has a life time of 100 years
1.4.4.7 “Perfo” type or similar
The "Perfo" type consists of two perforated half round sections of sheet metal, which
will be filled with mortar, wired together and installed in a hole. A steel reinforcing bar
is inserted, manually or with a compressed air hammer, into the tube causing the
mortar to squeeze through the perforations and bond to the sides of the drillhole.
The sheet metal will have a minimum wall thickness of 1 mm.
The deformed steel bars will be 20, 26 or 30 mm diameter, as shown on the

Construction Drawings or as directed, of Grade 400 with a yield strength of not less
than 400 N/mm2 which will conform to ASTM Specification A 615 M or equivalent. The
bars will taper at one-end over a length of 50 mm to a point and will be threaded at the
other.
The mortar for filling the "Perfo" tube will consist of Portland cement Type I, water, and
washed sand with a maximum size equivalent to that passing a U.S. Standard Sieve
No.8 (2.36 mm). The cement to sand ratio will be 1:1. The mix proportion, the method
of mixing, and accelerator admixtures, if used, will be agreed with the Employer.
The following drill-hole/tube/bar diameter relationships will be maintained if not

otherwise recommended by the manufacturer:
Drill-hole Tube Internal Bar

Diameter Diameter Diameter
_______________________________________________

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32 mm 27 mm 20 mm
38 mm 32 mm 26 mm
45 mm 36 mm 30 mm
"Perfo" type may be used as active as well as passive rock reinforcement. Should
stressing of the bar be required, it will be performed according to manufacturer's
instructions.
1.4.4.8 Expansion-shell type
Expansion-shell (or mechanical-anchor) type rockbolts will be 22 mm diameter as

manufactured by Dyckerhoff & Widmann AG (Dywidag) of Germany, or similar as
agreed with the Employer. They will be supplied complete with all accessories required
for installation, stressing and grouting.
Rockbolts installed as a permanent support for open cuts or anchoring of concrete

structures will be grouted.
The method and equipment used for installation, to effectively seat, and to stress the
expansion-shell rockbolts will be in accordance with the manufacturer's instructions
and subject to the agreement of the Employer.
Unless otherwise specified the rockbolts will be stressed, immediately after installation
in the hole, by torquing or jacking, by means of an approved and regularly calibrated
stressing device, to two-thirds (67%) of their yield point stress, on the basis of values
established during pull-out tests.
After initial installation, the Contractor will ensure that the rockbolts continue to act as
effective supports by periodically testing the rockbolts and, if necessary, retightening to
the directed torque or tension.
Grouting, if required, of the expansion-shell rockbolts will be performed without

destressing the bolt. Grouting will be performed as soon as practicable after, but in any
case within 21 days, of rockbolt installation. The bearing plate will he caulked around
its perimeter and grout will be introduced into the hole through a plastic tube fixed to
the shaft and extended to outside through a hole provided in the bearing plate, at a
pressure sufficient- to fill completely the space around each bolt for the full length
without any air-pockets remaining inside the hole.
Cracks and fissures adjacent to the rockbolt which the grout is found to be flowing
from, during the grouting operation, will be plugged or caulked.
If no accelerator had been used in the grouting of the expansion shell anchors, no
blasting may be performed within 15 m of a grouted rockbolt until 5 days after grouting.

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1.4.4.9 Post-tensioned cement-bonded type

For post-tensioned cement-bonded type rockbolts the "GD-TOPAC" cartridges
containing accelerator as supplied by ALIVA AG, Postbox 8967 Widen,
SWITZERLAND or equivalent will be used in agreement with the Employer.
The deformed steel bars will be 20, 26 and 30 mm diameter of Grade 400 with a yield
strength of not less than 400 N/mm².
In the first step the anchorage zone in the deepest portion of the drillhole will be filled
with plastic mortar on the length of GD-TOPAC cartridge, or cartridges if more than
one is used and the cartridge inserted into it. The rest of the drillhole will be filled with
mortar prior to inserting the steel rod into the hole. The rod consisting of a reinforcing
steel bar with one end tapered will be inserted with a compressed air hammer. The
tapered end of the bar will tear the cartridge open and allow mixing of the accelerator
with the mortar.
Stressing of the bar will be carried out after 1 to 3 hours depending on the required
stressing load and according to the manufacturer's recommendations.
The following drill-hole/bar diameter relationships will be maintained if not otherwise

recommended by the manufacturer:
Drill-hole Bar
Diameter Diameter
28 mm 20 mm
36 mm 26 mm
45 mm 30 mm
1. Resin-grouted type
For resin-grouted type rockbolts the "TITAN" resin cartridges as developed by the
Societe des Explosifs Titanite and supplied by ALIVA AG, Postbox 8967 Widen,
SWITZERLAND or equivalent will be used in agreement with the Employer.
Manufacturer's directives concerning the time restrictions for utilization of resin

cartridges will be strictly observed. The resin package which shows signs of hardness
or other indications of deterioration will not be used. Resin-grouted bolts will only be
acceptable for temporary safety measures.
The cartridge consists of cylindrical charge made up of a double walled tube of

impermeable paper closed at each end. A catalyst is spread uniformly between the
two walls and the resin mixed with a mineral is enclosed in the internal envelope.

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The cartridges will be pushed into the drill-hole for the full length of the hole. The rod
consisting of reinforcing steel bar with one end tapered will be inserted with a
compressed air chamber at the velocity of approx. 1 m per 20 seconds. By rotating the
bar the cartridge will be torn and the catalyst mixed with the resin.
The rapidity of the polymerization and hardening of the resin will be such that the steel
bar will not fall out of the upward hole due to its own weight by the time the tapered
end of the bar has reached the end of the hole. The bar will be able to sustain in dry
ground the tractive force equal to its yield point strength 15 minutes after inserting the
bar into the hole.
Resin-grouted type can be used as active as well as passive rock reinforcement.

Should stressing be required, a cartridge containing fast-setting resin for anchoring the
bar will be pushed into the deepest portion of the hole. The rest of the hole will be filled
with cartridges containing slow-setting resin grout which allows the stressing of the
bar.
The following drill-hole/bar diameter relationships will be maintained if not otherwise

recommended by the manufacturer:
Drill-hole Bar
Diameter Diameter
25 mm 18 mm
30 mm 22 mm
1.4.4.10 Grouted anchor bars (dowels)
The grouted anchor bars will not be stressed. The rods will be fully grouted with
cement mortar grout. The rods will be deformed reinforcing steel bars with the yield
strength of not less than 400 N/mm². The diameter of anchor bars will be 20 and 26
mm and the length and position as required.
The surface of the anchor bars will be clean of rust, scale, dirt or other foreign matter.
Holes drilled for anchor bars will be kept plugged until just prior to commencement of
grouting operations. Before grouting, each hole will be thoroughly flushed with water
and cleaned with compressed air.
Where possible, water will be removed from the hole before grouting. If the hole
cannot be kept dry during grouting, the grout will be introduced into the end of the hole
through a pipe, which will be gradually withdrawn as the hole is filled.
Portland cement Type I will be used for the grout mixture. Grout will have a water to
cement ratio of between 0.4 and 0.55 by weight, and a sand to cement ratio of 1:1 by
weight, unless otherwise specified. Admixtures will be determined in agreement with
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the Employer. The minimal compressive strength of grout will be not less than 25
N/mm².
The anchor bar will be forced into the grout-filled hole before the initial set of the grout.
The bar will be vibrated or tapped in order to ensure good contact between the steel
surface and the grout.
Bar ends to be embedded in the concrete structure will be provided with hooks welded
to the bar to provide a good anchorage. In order to facilitate the inserting of the bar
into the hole the bar end will overlap the hook by at least 4 cm.
Anchors bars will be protected after installation in such a manner as to prevent any
movement until the grout has hardened. The Contractor will replace any bars found to
be loose after the grout has set.
The depth of holes indicated on the Construction Drawings will be measured from the
effective excavation surface. Should the anchor bars be connected to the
reinforcement steel of the concrete structure to be anchored, longer bars will be
provided in case of over excavation, to maintain the required position in the structure.
1.4.4.11 Self drilling anchors

Self drilling anchors, type IBO, as supplied by the Alwag Company or approved
equivalent may be used in extremely poor ground conditions, both on the surface or in
underground works.
1.4.4.12 Post-tensioned rock anchors (tendons)
a. General
Post-tensioned rock anchors (or tendons) are tensioned reinforcement elements,

generally of higher capacity than the rockbolts, consisting of a high strength steel
tendon (made up of one or more wires, strands or bars) fitted with a stressing
anchorage at one end and a means permitting force transfer to the grout and rock at
the other end.
The Contractor will furnish and install post-tensioned rock anchors in areas and to the
extent shown on the Construction Drawings or in agreement with the Employer. The
work, if required, will be executed in stages, in step with the progress of the
excavation.
Installation of post-tensioned rock anchors includes excavation for concrete bases,

placing of concrete bases, drilling of anchor holes, furnishing of anchors with all
accessories including permanent (i.e. double) corrosion protection of all elements of
the anchor, primary grouting, stressing, re-stressing, secondary grouting, and testing.

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b. Testing
Prior to the installation of post-tensioned rock anchors, the Contractor will carry out
anchor tests to examine the behavior of the anchor type he proposed to use, and to
establish values for maximum permissible working loads for different types of rock
encountered.
An accurate drilling and grouting record will be kept for each test to allow a
comparison of the test anchors with other anchors which have not undergone any
tests. If too large deviations occur during the installation of anchors, a new series of
tests will be performed.
The number of tests anchors will correspond to 2 % of the total anchors to be installed,
but at least 3 anchors. They will be supplied for testing purpose and not used again.
The test load to which anchors will be submitted during the various tests will in a first
phase be 95% of the yield load capacity and in a second phase up to yield.
During the anchor test the axial movement of the anchor head, the movements of the
anchor plate and the anchor force in the tendon will be measured.
After installation and stressing of all anchors, the Contractor will perform stressing
tests to assess the work. All anchors will be checked by means of simple stressing test
and at least 5 % of the total number of anchors installed will undergo the
comprehensive stressing tests.
During the simple stressing test the behavior of the anchor at the test load and the
deformation will be observed for a certain time. During the comprehensive stressing
test the anchor will be tensioned in steps. The behavior of the anchor will be observed
during the intermediate steps, the unloading periods, and at the test load. The
load/deformation curve will be recorded until the test load is reached.
The value measured during the preliminary anchor test and during the simple and
comprehensive stressing tests will be plotted in stressing records. All tests will be
carried out in the presence of the Employer.
c. Drilling of holes and water-pressure testing
Holes will be drilled as specified herein at the locations and to the depths and
inclinations shown in the Construction Drawings or in agreement with the Employer.
The drilling method will be suited to the type of ground and the necessary drill-hole
diameter.
Diameter of the holes will be such as required by the manufacturer, but not less than
98 mm. Depth of the holes will exceed the total anchor length (including anchorage
length) by 30 to 40 cm.

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Use of bentonite, rod grease or other lubricators on drill rods will not be permitted.
Core drilling will be performed for exploratory purposes where required, and the cores
will be stored in core boxes and kept in a secure place.
Each drill-hole in rock will be checked for water-tightness by means of water-pressure

tests before the anchor is installed. The water loss will be measured at a suitable test
pressure and may not exceed 1 Lug eon unit. If the water loss exceeds this value the
drill-hole will be grouted, redrilled, and subject to a second water-pressure test.
The drill-hole will also be grouted and redrilled if groundwater is entering the drill-hole,
or if during execution of the water-pressure tests water entry into neighboring drill-
holes can be observed.
After completion of the drilling in rock the hole will be washed out with clean water at a
rate of not less than 25 1/min until the returning water is clear, but at least for 10
minutes.
Upon completion, the drill-hole will be tightly plugged in a suitable manner to prevent
contamination by foreign matter and again washed and blown out immediately prior to
inserting the anchor. In loose material the walls of the drill-hole will be supported by
casing until the anchor has been installed. In earth or rock liable to swell the anchors
will be installed and grouted immediately.
Any hole that becomes clogged or otherwise obstructed before the completion of
anchoring operation will be cleaned out or another hole will be provided by the
Contractor.
d. Materials
The anchor tendon will be composed of a number of seven-wire type high strength
strands as used in the post-tensioned concrete with a minimum ultimate tensile
strength of 1,860 N/mm².
The strands will be continuous without splices or couplers and will be free of dirt, oil,
rust and without mechanical damage. Strands will be delivered in coils of at least 1.5
m in diameter, properly protected against abrasion and corrosion by a factory applied
method.
The anchor head will consists of a steel bearing plate with a central hole and
peripheral holes for the strands and will permit stressing of each strand or all strands
simultaneously as well as grouting. The structural failure load of the anchor head will
not be less than the sum of the rupture loads for the strands.
The stressing mechanism will be such that the load can be reliably applied to the
tendon, will permit de-stressing and reapplication of the load, and will be such that the
measurement of the loads and deformations is guaranteed during stressing tests.
The anchorage will be made of carbon steel or other approved material.

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It will include a packer to separate the free stressing length from the anchorage zone
and prevent the grout from flowing into the free stressing zone. The limit load of the
anchorage will be greater than or at least equal to the failure load of the tendon.
Sheathing material will be durable, rust and corrosion proof, flexible and watertight.
Grout tube will be made of PVC and will be perforated at regular intervals with holes
covered with rubber sleeves.
e. Execution
A reinforced concrete anchor base will be constructed on the prepared excavated

ground. Concrete will be of Class C 25/30 or fibre reinforced shotcrete.
The tendon will be slowly inserted into the hole in such a manner as to prevent
damage and tangling of the individual strands.
After being inserted, the anchor will be fixed in position so that no displacement can
occur during the grouting work. The tendon will be centered in the hole so that
adequate covering of the steel with the grouting material is ensured.
Immediately following installation of the anchor into the hole, the primary grouting of
the anchorage zone and outside of sheathing will be carried out.
Grout mixture, use of admixtures, mixing, grouting pressure and grouting equipment
will be subject to consent by the Employer. The grouting equipment must permit grout
pressure up to 20 bars.
Stressing of the anchors will not be performed until the grout has achieved a cylinder
strength of 25 N/mm². The minimum time between grouting of anchorage zone or
concreting the anchor base and stressing will be established during the anchor tests.
The stressing will follow a program drawn up in agreement with the Employer, which
will include the sequence in which the anchors are to be stressed, the test loads, the
stressing loads, any eventual stressing modifications to be made subsequently, and
tests to be carried out.
Stressing will be made by applying a jack. The stressing of the anchor will be carried
out up to the design load plus an allowance of 10 % relaxation.
All the important conditions and observations during the stressing procedure, the loads
applied and the elongation of the tendon at each load increment will be recorded by
the Contractor in a stressing record.
After the anchor has been tensioned, the stressing will not be relaxed for any purpose,
unless in agreement with the Employer.
One month after the first stressing the load in the anchors will be checked and if
necessary re-stressed.

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As soon as possible after stressing or re-stressing have been completed, the

secondary grouting inside of the sheathing will be performed to encase completely the
strands for the full length of the hole.
The recess left in the concrete anchor base for accommodating the anchor head will
be filled with concrete if not otherwise required for testing or re-stressing.
10% of the post-tensioned rock anchors will be equipped with permanent load cells
with remote recording.
1.4.5 Wire Mesh
1.4.5.1 Chain Link Fabric
Chain link fabric will be installed in surface or underground construction sites generally
without sprayed concrete, to protect surfaces from which loose pieces of rock or
cobbles may fall.
Chain link fabric will conform to the requirements of ASTM Specifications A 392 for
Zinc-coated Steel Chain- Link Fence Fabric or equivalent. The fabric will have a mesh
size of approximately 50 x 50 mm, and a wire diameter of approximately 3 mm.
The fabric will be clean of mud, grease, oil or other foreign matter if sprayed concrete
is to be applied.
The fabric will be placed against excavated surfaces and fastened to rockbolts, if
present, with extra steel plates of minimum size 100 mm x 100 mm x 5 mm and nuts.
The fabric will be securely fastened to the rock at intermediate points between the
rockbolts with steel pins. Sufficient pins will be provided to ensure that the fabric is
held tightly to the rock surface.
The installation of chain link fabric as reinforcement of sprayed concrete will be

permitted only when the excavated surface is so uneven and rough that placing of
welded wire fabric is impractical.
1.4.5.2 Welded Wire Fabric
Welded wire fabric will be installed in surface and underground excavation as

reinforcement for sprayed concrete usually in combination with rockbolts. It may also
be used with steel ribs, when it will be laid over the outer flange of the rib and pinned
or fixed to the excavated surface between the ribs where necessary.
Welded wire fabric will conform to the requirements of ASTM Specifications A 185 or
equivalent. The fabric will have a square mesh of 100 to 120 mm spacing made of
wires having a yield strength not less than 275 N/mm². The diameter of the wires will
be between 3 and 5mm.

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Where possible, the welded wire fabric will be placed at the same time as rockbolts
are installed. It will not be placed between the rock surface and bearing plates of
rockbolts, but will be placed over the heads of rockbolts and fastened to them by
separate plates and nuts. Sufficient intermediate anchors such as steel expansion
bolts or dowels, or additional rockbolts, will be placed to ensure that the fabric is drawn
close to the excavated surface so that when sprayed concrete is applied subsequently,
the mesh neither sag nor vibrate excessively and impair the effectiveness of the
sprayed concrete
Usage of wooden pegs or pins for fastening of the wire mesh to the rock surface will
not be permitted.
Welded wire fabric will be firmly stretched between the rockbolts. Care will be taken to
ensure that air pockets are not formed behind the wire mesh when used as
reinforcement for spayed concrete.
Overlap of wire fabric will be at least 3 times the mesh spacing with the clearance
between parallel bars but not less than 30 cm.
1.4.6 Structural steel supports
1.4.6.1 General
Structural steel supports will be installed either as complementary measures to the

previously installed rockbolts and spayed concrete when those prove to be insufficient
to stabilize the excavated profile, or as immediate supporting after excavation in the
heading zone when the material encountered in the process of excavation requires
such measures.
Steel ribs will be furnished complete with bracing, bolts, nuts, washers, plates, tie rods,
and other accessories necessary for installation of the supports. Horizontal or bent
steel bracing in the invert may be required.
Steel lagging will be furnished separately from steel ribs.
1.4.6.2 Steel ribs
Steel ribs will be made from steel conforming to ASTM Specification A 36. They will be
made of wide flange I-beams, channels.
The ratio between the moments of inertia for the two principal axes of the wide flange
I-¬beams will not be less than Ix/ly = 1/3 and the height of the steel section will not
exceed 300 mm.
Rib splices will be welded or made of bolted plates in such a manner as not to reduce
the section moment of resistance.

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Only one section size of steel rib profile will be used for each portion of the
underground works and the structural requirements due to rock conditions
encountered will be met by varying the spacing of the ribs.
1.4.6.3 Steel lagging

Lagging are the longitudinal supporting members placed behind the steel ribs
necessary to support the walls and crown of the excavation.
Steel lagging will be made of the same material as steel ribs. Two different types
of steel lagging are envisioned: approx 2 to 3 mm to be used behind the steel ribs in
profiles already excavated; and approx 4 to 5 mm when they are to be pressed or
hammered ahead of the heading face for protection (“Marciavanti”).
The Contractor may propose the use of precast reinforced concrete panels to be used
as lagging instead of the steel profiles, but such proposal will be agreed to with the
Owner before the Contractor starts with the manufacture thereof.
The Contractor may also propose the use of reinforced wire mesh or pressed steel
lagging instead of the steel profiles, but such proposal will be agreed to with the Owner
before the Contractor starts with the manufacture thereof.
1.4.6.4 Execution
Steel ribs will be bent with an allowance of approx 1% of the radius to the shape of the
theoretical excavation profile. Reshaping of the bent ribs at the place of installation
may only be undertaken if necessary and if the material properties would not be
impaired.
Excavation of the tunnel profile will be completed true to the "A"-line before installation
of steel ribs. Steel ribs will be placed as near as possible to the excavated surface.
Concrete blocks or steel profiles will generally be provided as footings for the steel
ribs. The foot plates will be of sufficient size and rigidity. If required, the legs of the ribs
will be anchored to the rock by rockbolts. Where invert bracing is required, it will be
bolted securely to the lower legs of the rib in such a way that buckling is not induced in
the steel rib by a presence of such bracing.
Immediately after placing the ribs in a correct position, they will be interconnected and
braced by means of steel rods or beams in order to prevent any displacement and to
maintain spacing.
The space remaining between the outer flange of the steel ribs and the rock surface
will be backfilled immediately after the rib has been placed with sprayed concrete over
the entire circumference of the steel rib in order to provide uniform load distribution. In
over excavation, the bulk of the void space may be filled with concrete blocks, followed
by the sprayed concrete. If required, sprayed concrete will be applied also between the

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steel ribs and encasing them to form an arched bracing in the direction of tunnel
centerline.
The Contractor will survey and record the position of all steel ribs installed in order to
facilitate drilling operations. Their position will be marked the finished concrete lining
surface.
Blocking and wedges used to set the steel ribs may be steel, or concrete blocks.
Any steel rib installed improperly or damaged by the Contractor's operations will be
adjusted, repaired or replaced as appropriate by the Contractor without delay after
notification by the Employer.
Lagging will be placed behind the steel ribs where necessary to support the roof or the
sides of the underground excavations. Where conditions require, it may be supported
on the last steel rib by pressing and/or hammering it into the ground and provide a
temporary overhead protection while installing the next steel rib.
The space between the rock surface and the lagging will be backfilled with concrete.
1.4.6.5 Lattice girders
Steel for lattice girders will be made from steel conforming to ASTM Specification A
36. Circumferential bars of lattice arches will have a minimum strength of 400 MPa.
Fully detailed fabrication drawings and specifications for all components of the lattice
girders will be submitted to the Employer as part of the Contractor‟s Documents before
commencing manufacture.
1.4.6.6 Temporary supports

Temporary supports may be used to support sections of excavation not completed to
final lines and grades or to facilitate installation of the permanent support.
All such temporary supports, lagging, or blocking which do not comply with
requirements for primary support will be removed by the Contractor prior to
placement of in-situ or sprayed concrete or backfilling, as appropriate.
1.4.6.7 Traffic in tunnels

The Contractor will install and operate an adequate transport system in and out of the
underground works.
1.4.6.8 Communication system

The Contractor will install and operate the communication system between each
heading face and entrance to all adits, tunnels, shafts and powerhouse.

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1.5 Backfills
1.5.1 Scope
This clause deals with the construction of backfills wherever required on the works as
shown in the Construction Drawings or as directed by the Engineer.
1.5.2 Definitions
In comprises all works necessary for placement of impervious, granular fill, rock fill or
riprap for earth structures including temporary structures such as cofferdams, structure
backfilling and slope protection
Rock fill is a graded mix of rock fragments which is placed in horizontal layers or lifts.
Riprap is a graded mix of rock fragments usually placed on slopes by mechanical

means to act as erosion protection for the slope surface.
1.5.3 Minimum technical requirements

Fill materials shall consist of clean, sound and durable mineral particles, free of roots,
topsoil, organic matter or other debris.
Impervious fill shall be well graded natural materials with at least 15% of the material
finer than the 0.075 mm sieve.
Granular fill for backfilling structures shall be natural or processed free draining well
graded, granular materials free of clay or rock fines.
Rock fill and riprap shall be excavated and processed well graded rock fragments
which are hard, dense, durable and free from seams and cracks. These materials shall
be free of excessive sand, clay or rock fines. Rock fragments shall be equidimensional
and not flat or elongated.
Fills shall be dumped, spread and compacted in layers not exceeding two time the
maximum particle dimension in thickness prior to compacting. The dumping and
spreading operation shall be conducted so that no segregation of materials occurs.
Compacting of impervious fill shall be by means of rubber tired or pad foot rollers, but
not vibratory smooth steel drum rollers. Compacting of granular and rock fills shall be
by means of vibratory smooth steel drum rollers.
Contractor shall maintain or vary the moisture content of fills to optimum moisture
content as defined by standard Proctor compacting or vibratory maximum density
tests. Backfill shall be compacted to at least 90% standard Proctor in accordance with
ASTM Test Method D 698.
Contractor shall take all necessary steps to ensure good bonding between successive
lifts and homogeneity between lifts and or lift boundaries.
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1.5.4 Material
Backfill material shall consist of well graded, cohesion-less, free draining material such
as sand, gravel or rock fragments or a mix of all of them. The material shall be
produced in the quarries of the reservoirs or may be gained from excavations for
Works.
The fine grained material shall be free of organic soil or matter and shall be sufficiently
compacted. Water should be added if necessary before compaction to achieve
satisfying densities.
Care should be given to structures and units adjacent and/or inside the backfill to
prevent damage.
1.6 Instrumentation
1.6.1 General
All excavation, installation, testing and backfilling and operation procedures for
instruments shall be in accordance with manufacturer‟s instructions.
It shall be carried out by crews skilled and experienced in such work and installations
shall only proceed during the hours of daylight.
To prevent foreign matter entering tubes and casings during installation, the open
ends of all incomplete lines of tubing and casing shall be kept sealed.
Backup readout units shall be provided where appropriate.
The following types of instruments shall be installed in accordance with the Client:
 Standpipe piezometer
 Settlement gauges
 Threaded brass inserts for mounting survey instruments on surface settlement
monuments
 Rockmeters
 Pressure cells
 Seisometers
 „V‟ notch weirs and other flow measuring devices
 Directed and inverted pendulums
 Inclinometers
 Extensometers
 Joint movement gauges
 Total stress and temperature gauges

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1.6.2 Surface measuring points

Surface measuring points (X, Y, Z) shall be installed in different locations as shown in
the drawings. The base of the surface measuring points consist of concrete elements
(precast or cast in situ); they will be placed either on concrete structures or whenever
possible in rocky terrain. A steel base plate is on top of each concrete element
allowing positioning of (i) a measuring unit (total station) or (ii) a measuring point.
The distance between the surface measuring points shall be short, i.e. shall allow
independent and exact deformation measurements in 3-dimensional space.
1.6.3 Piezometers
Piezometers shall be installed in different locations as shown in the drawings.
Piezometers shall be implemented in vertical boreholes.
Mechanically operated piezometers shall be used.
Some boreholes will be equipped with multiple piezometers; there the intermediate
sections of the boreholes shall be sealed.
1.7 Concrete
1.7.1 Concrete materials
1.7.1.1 General
The Contractor shall operate a quality assurance system to ISO 9001 which prescribes
procedures of supervision, inspection, testing, maintenance and calibration to ensure
the specified characteristics of the concrete will be achieved. Concrete mixes shall be
specified, produced, transported and tested for compliance in accordance with
Peruvian Standards or ACI and comply with any additional criteria described herein.
1.7.1.2 Mass and reinforced concrete
The work to be performed under this section shall comprise the supply of all labor,
construction plant and materials, transportation, unloading, and storage and
performing all work necessary for:
 testing, evaluation, reporting, proportioning, quality control and supply of concrete

including the supply of all cement, aggregates, water, pozzolans and admixtures

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 batching, mixing, transportation, placing, finishing, curing, heating and cooling of

concrete and/or aggregate and/or water for concrete and cleaning and preparing
construction joints
 supply, transportation, storage, cutting, bending, cleaning and fastening of
reinforcing steel
 supply and installation of all waterstops, joint-sealers, contraction joints and
expansion joints
 Design, checking, drafting reporting, quality control and supply, fabrication,
installation, placement of structural supports, temporary stores and bracing and
stripping of all form-work required for construction of concrete elements.
 Former work design shall conform to ACI-347 recommendation
1.7.1.3 Durability
General
The concrete must perform satisfactorily in the working environment during its
anticipated service life. The materials and mix proportions specified and used should
be such to maintain its integrity and protect any embedded metal and reinforcement
from corrosion. Among the inter-related factors affecting durability, the environmental
conditions to which the concrete will be exposed, the structural form, strength grade,
cover to steel and possibly cement type will be defined by the Contractor in his design.
The quality of concrete shall comply with the durability requirements of the Peruvian
standard or ACI 318.
The quality of construction workmanship, levels of control and inspection of

construction shall comply with the required Peruvian standards and ACI 318.
A design life of 100 years may be anticipated by compliance with this specification.
Where an extended design life is required consideration should be given to increasing
the cement content (i.e. concrete glass), increasing reinforcement cover or using
special reinforcement.
Chloride Content of Mixed Concrete

The mix design shall comply with Peruvian standard or ACI 318. The acceptable
maximum chloride content limit shall be 0.2 per cent.
Alkali-silica Reaction
Precautions to prevent alkali-silica reaction shall be taken in accordance with Peruvian
standard or ACI 318 and USBR MERLREPORT -09-23, August 2009. ASTM C 1260,
ASTM C 1293 and ASTM 15 have to be take into consideration. In addition, opal,
tridymite and cristobalite will not be accepted in aggregates. Quartz aggregate shall
not contain quartzite, nor more than 30 per cent by weight of highly strained quartz
(defined as giving an average undulatory extinction of more than 250 mm thin
sections). The amount of equivalent sodium oxide in mixed concrete shall not exceed
3 kg/m3.
The possibility of alkali-silica reaction will be reduced if ingress of water into the body
of the concrete is itself minimized. Therefore, good practice shall always be used so as
to produce uniformly-compacted concrete with a dense surface and (on flat slabs)
minimum laitance.
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Mica and Muscovite content

Mica and Muscovite can be detrimental to concrete. Therefore only material, which
has less than the max. allowable limit of mica or muscovite shall be used as concrete
aggregates and sand.
1.7.1.4 Materials
General
The contractor shall select and use only those materials that will provide superior
performance to the completed works. Engineer reserves the right to request alternate
material types or specifications should the proposed material or specification be
considered unsatisfactory.
Contractor shall select suitable aggregate sources and shall manufacture adequate
fine and coarse aggregate supplies and perform all necessary tests to ensure the
adequacy of the aggregates.
Aggregates shall conform to Peruvian standard or ASTM C33.
Cement
The Contractor shall supply ordinary Portland cement Type I conforming to Peruvian
standard or ASTM Specification C 150. The use of other cements shall be subject to
the agreement of the Employer‟s Representative and they shall be stored separately.
The alkali content of the cement shall not exceed 1% by weight.
Each consignment of cement delivered to the Site shall be accompanied by a test

certificate issued by the manufacturer in quadruplicate. The Employer‟s
Representative will have the right to attend the sampling and testing at the
manufacturer's plant at any time. If delivery is not directly from the manufacturer, the
intermediate storage and delivery arrangements shall be subject to the scrutiny of the
Employer‟s Representative.
Cement which does not comply with ASTM Specification C 150 or is damaged in
consignment, handling or storage shall be promptly removed from the Site.
Bulk cement shall be transported from the port or mill to the Site in adequately
designed weatherproof tankers, or by other means where the cement will be protected
from exposure to moisture. Immediately upon arrival at the Site, the cement shall be
stored in a dry, weatherproof and properly ventilated structure with adequate
provisions for the prevention of absorption of moisture, and constructed in such a way
that there will be no dead storage. The vents of the bins and silos shall be equipped
with dust collectors to reduce loss of cement during handling and inconvenience to the
personnel.
Cement bags shall be stored in weatherproof buildings with a raised, well ventilated
wooden floor, and placed so that each consignment can be segregated if required and
used in order of its age. Bags shall not be stacked more than 1.5m high. Cement shall
not be stored outdoors, except for immediate use, and in such event shall be protected

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during storage and handling by waterproof covers and a raised floor. Unused cement
shall be returned to the storage buildings.
Cement shall be used in the same sequence in which it has been received at the Site.
Storage of cement shall be limited to 90 days in bags and 150 days in bulk. Cement
that has been in storage for longer than these periods or which may have absorbed
moisture shall not be used unless it has been retested by the Contractor to the
Employer‟s Representative‟s satisfaction. Cement that has become lumpy shall not be
used.
Cements from different mills or of different makes shall be stored separately.

The temperature of cement upon arrival to the Site shall not exceed 70°C.
The maximum heat of hydration for Portland cement Type I shall not exceed 80 and 90
calories per gram at ages 7 and 28 days respectively, and Portland cement Type II
shall not exceed 70 and 80 calories per gram at the same ages.
The Contractor shall keep and make available to the Employer‟s Representative
records of the date, amount, and storage location of each delivery of cement and of
the part of the Works in which it was used and shall provide facilities for checking the
stock of cement.
Aggregates
Fly ash, if used, shall conform to ASTMC618. Coarse aggregate and sand shall be
from natural sources or crushed stone and shall conform to Peruvian standard ASTM
C33 or ACI 318, with the exception that the flakiness index of any type of coarse
aggregate shall not exceed 35. The suitability of particular aggregates shall comply
with Peruvian standard or ACI 318. Aggregates for concrete shall be well graded. All
sand shall be washed if necessary, especially to remove unacceptable levels of clay
particles.
Aggregate of 80 mm maximum size are acceptable for unreinforced concrete pours of

minimum thickness 250 mm. Larger aggregates will be acceptable in hearting concrete
remote from formed surfaces and construction joints.
Water
Water used for concrete manufacture shall be clean and free from harmful amounts of
acids, alkalis, organic matter or other substances which will impair the strength or
durability of the concrete. Any testing of water to determine its suitability shall be in
accordance with Peruvian standard ASTMC1602M or ACI 318.
If it is intended to utilize river water arrangements shall be provided to ensure that the
content of impurities (organic, inorganic) is within acceptable limits.
Admixtures
Generally admixtures shall conform to Peruvian standard or ACI 318 and their use
shall comply with the recommendations of that standard.
Storage of Materials

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Storage and handling of cement, cementitious materials, aggregates, admixtures and

water shall comply with Peruvian standard or ACI 318.
1.7.2 Concrete mixes

Concrete mix types shall be either “designed” or “standard” as defined by Peruvian
standard or ACI 318. Designed mixes are specified by their required performance in
terms of strength grade, subject to any restriction on materials, minimum or maximum
cement content, maximum free water/cement ratio and any other properties required.
The designs of all mixes shall be based on the particular type and brand of cement to
be used on the Site. The type of cement, aggregates and mix proportions shall be
selected in accordance with Peruvian standard or ACI 318 and for water retaining
structures Peruvian standard or ACI 318 to achieve a durable concrete for the
exposure conditions it will encounter in its particular working environment.
Standard mixes are selected from the restricted range given in Peruvian standard or
ACI 318. They may be used in non structural or minor structural applications in
accordance with Peruvian standard or ACI 318.
The required concrete mixes shall be identified in the Construction Drawings for each
structure. For designed mixes concrete will be identified by class comprising the
compressive strength grade, the maximum aggregate size, and a numeric mix
number; e.g. C35/40/1 where the cylinders fc.= 35 MPa the maximum aggregate size
is 40mm and the mix number is MIX9. Full details of materials and mix proportions for
all classes of designed mixes for use in the Works shall appear on one key drawing.
The constituents of concrete, i.e. cements, aggregates, water, admixtures and

pozzolans or slag (if used) shall be combined to create a product adequate to meet
design requirements, be durable, sound, free from deleterious effects and watertight.
Concrete trial mixes shall be made generally following the relevant procedures of ACI.
Concrete mix designs shall be adjusted during the course of construction to

consistently meet design requirements, as demonstrated by statistical analysis of test
results.
1.7.2.1 Assessing compliances of concrete mixes

Trial Mixes
Before any designed concrete mix is provided for inclusion in the Permanent Works
the suitability of the proposed mix proportions to meet specified strength and
workability requirements shall be determined by trial mixes in accordance with
Peruvian standard or ACI 318. Trial mixes shall be made at least 35 days in advance
of intended use.
For each proposed mix two batches of concrete shall be made, from each batch
seven cylinders of e.g. 150mm x 300mm nominal size shall be made, three for
testing at 7 days and three for testing at 28 days one as a spare. Furthermore the
individual strengths of cylinders in sets of 3 tested at 28 days shall not vary by more
than 20 per cent of the strength of the weakest cylinder of the set. Should it vary by

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more than 20 per cent the spare cylinders can be tested and used instead in
assessing compliance to this clause. Actually since 2008 ACI requires only the
results of 2 cylinders of Ø 150mm x 300mm. (It is still 3 cylinders Ø 100mm x 200mm
samples are used). Test result of 1 cylinder is if Δ > 35. Test result of 1 cylinder
ACI 2/4R-02§ 5.3 Remaining cylinder should be tested at 90 days. A test value is the
average result of two Ø 150mm x 300mm cylinders or at least three Ø 100mm x 200mm
cylinders. ACI 318M.08 § 5,6,2,4
Surface Finish Trials

Where the surface finish of concrete is permanently exposed to view and its
appearance is aesthetically important practical surface finish tests shall be made
using trial formwork or surface finishing processes. In these tests all equipment and
formwork shall be exactly as intended for use in the Permanent Works and the
samples shall be retained for future reference until the relevant work is completed.
Modifications of Mix Proportions

The proportions of mix ingredients including water content for each class of concrete,
once used in the Permanent Works, shall not be varied unless the mix design class
fails to meet the specified requirements.
Conformity Testing of Works Concrete

For designed mixes compressive strength testing shall form an essential part of the
assessment of conformity to the specification. Sampling, testing and compliance
requirements shall be in accordance with the requirements of Peruvian standard or
ACI 318.
The quantity of concrete represented by strength test results shall be as stated in

Peruvian standard or ACI 318, consequently the rate of sampling determines the
maximum quantity of concrete at risk. As a minimum one sample shall be taken each
week for each class of designed mix concrete used that week. Moreover one sample
shall be taken each day on which more than 6 m3 of the particular mix is placed and
thereafter at a rate of one sample per 40 m 3 as per ACI 214 R-02§5.2 of in situ
concrete and one sample per 20 m3 of precast concrete.
Four test cylinders of 150mm x 300mm nominal size shall be prepared from each
sample, two from each set shall be tested at 7 days and the remaining two at 28
days. The mean strength of the two cube results at 28 days shall be taken as the test
result. Results at ages less than 28 days will be used as an early indicator of
potential non-conformity.
Action to be taken in the Event of Non-conformity

Remedial action to be taken in the event of non-conformity shall be determined after
consideration of the location and quantity of concrete involved and the possible
consequences of any reduction in concrete quality and strength on the durability and
structural performance of the Works.
The structural requirements of the concrete in the Works will be satisfied provided
that (i) no 28-day test result is less than 85 per cent of the specified characteristic
strength and (ii) no individual 28-day cylinder strength is less than 70 per cent of the
specified characteristic strength.

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If either of (i) or (ii) is not satisfied, the volume of concrete represented by the sample
shall be considered structurally suspect. Where structural performance is critical
further actions shall include one or more of the following:
a. Cores shall be drilled from the suspect portions of the structure to determine
whether the equivalent cylinder strength of the in situ concrete satisfies the strength
required for the particular part of the structure. Diameter of the cores shall be 100mm
preferably but 76mm are acceptable. 50mm shall not be used.
b. Non-destructive testing, e.g. ultrasonic examination, of the suspect portions may
be carried out to assess the equivalent cube strength of the in situ concrete.
c. Full scale load tests.
d. If load tests are impracticable, or if a tested portion of the structure fails to pass
the tests, the Contractor shall either replace or strengthen each section that failed or
which contains concrete that failed, as relevant.
e. The work shall be demolished and reconstructed.
1.7.2.2 Batching
General
Batching by weight of concrete constituents shall be in accordance with Peruvian
Concrete shall be batched with suitable equipment with adequate capacity and
batching accuracy. Batching and mixing shall be in accordance with ACI 318, Chapter
5.8.
Concrete shall be conveyed and placed and consolidated in accordance with ACI 318
and accepted practice. Mass concrete shall be placed in successive layers. Maximum
layer height shall be specified in relation to method of vibration and maximum
aggregate size and expected temperature increase within the concrete. Layers shall
be carried forward in a stair-step fashion in the block by means of successive
discharges such that there is a 1.5 m setback between forward edges of successive
layers. Placement shall be in such a manner as to minimize surface exposure. This
procedure shall be used to complete the lift from one end of the block to the other.
Usually one tries to vibrate one lift into the others. Under no circumstances shall
mortar be brushed onto the joints or at the rock/concrete interface.
Concrete lifts shall generally not exceed 3 m or 750 mm against rock foundation for
the gravity dam.
Concrete shall be cured in accordance with ACI 301 and 318. Curing by water is to be
the preferable method and shall be used on all lift construction joints. The use of
curing agents shall be excluded from lift joints or from areas in which their use may
detract from the appearance of the cured concrete and which will be exposed to view
following completion of construction.

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1.7.2.3 Mixing
Preparation
Coarse aggregate shall reach the point of mixing in a saturated, surface-dry condition.
Coarse aggregate should be cooled if necessary. The temperature of cement at the
time of mixing shall not exceed 60°C.
Before the start of each period of mixing, the inner surface of the mixer shall be
cleaned and all hardened concrete shall be removed. An initial charge of 1:2
cement/sand slurry of sufficient quantity to coat the entire drum shall be mixed and
discharged.
Procedure
Mixing shall be in accordance with Peruvian standard or ACI 318. Adequate stand-by
mixing capacity shall be available at all times.
The mixing time shall be sufficient to ensure that a thoroughly blended, homogeneous
mixture is produced. The minimum mixing times shall be not less than 1 ½ minutes for
a drum mixer and 1 minute for a pan mixer. The period of mixing shall be measured
from the time when all the materials are in the mixer to the commencement of
discharge. During this period the mixer shall be rotated at the speed recommended by
the manufacturer.
The maximum mixing times shall be 20 minutes for drum mixers and 10 minutes for
pan mixers.
The discharge of concrete shall be carried out such that there is no segregation.
Delays
In the event of delay in the concreting operations, the concrete may be retained in the
mixer for the period the concrete remains adequately workable but not exceeding 60
minutes provided that during this time the mixer is restarted for short periods of 2-3
minutes at intervals of 10-15 minutes.
1.7.3 Transportation of concrete

Concrete shall be transported from the mixers to the place where it is required in such
a manner that segregation, loss of ingredients and adulteration are prevented and that
the batch is uniform and of the required workability at the point and time of placing.
All equipment shall be of suitable size and proven design and maintained in first-class
working order. Adequate stand-by equipment shall be available at all times.
Where agitator trucks are used, the drum shall rotate continuously during the journey
and shall be run at maximum speed for 30 seconds immediately before discharge.
Each delivery of concrete shall be accompanied by a delivery ticket (giving concrete

class and mix number) issued at the batching plant and collected at the point of
discharge.

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1.7.4 Placing of concrete
1.7.4.1 General
The concrete shall be placed in its final position and fully compacted before loss of
workability occurs. In no case shall concrete be placed in the Permanent Works more
than 20 minutes after discharge from the mixer unless it is carried in agitator trucks,
operating continuously, in which case the placing time shall be within 60 minutes of the
introduction into the agitator trucks.
Concrete shall not be re-tempered by the addition of water or other material (except
admixtures that are approved by the engineer). All contact surfaces including any
previously placed concrete, shall be left damp but no free water shall be permitted to
remain on these surfaces. Hardened sentences shall be soughened by green cutting.
The concrete shall be placed in such a manner that the exposed area of fresh
concrete against which further concrete is to be placed is kept to a minimum. When
concreting closed circuits, therefore, work shall proceed from one or more points on
the periphery in both directions at the same time so that closing junctions are always
made between newly cast faces.
When layers of concrete are used in large areas such as thick slabs and foundations,
the compacted layer thickness shall not exceed 0.75 m (see § 1.7.2.2).
1.7.4.2 Prevention of segregation
Concrete shall be handled and deposited using approved equipment in such a manner
as to prevent segregation. Particular attention shall be paid to the following points:
 Precautions shall be taken at all points of discharge of concrete. For example,

suitable spouts or baffles shall be provided at the ends of chutes;
 Concrete shall drop vertically into the container which receives it in a position
close to its final position. The moving of concrete laterally by vibrators is not allowed;
 Falling concrete should be closely confined in a downpipe of the proper size to

within 1 m of the place of deposition in the forms or other container, and the final drop
shall be vertical. The maximum distance through which concrete may be dropped
without downpipes is 2 m;
 Concrete shall not be dropped through reinforcing steel or into any deep form,
whether reinforcement is present or not, in such a manner as to cause separation by
repeated impacts on the reinforcing bars or the sides of the form. For placing in such
conditions hoppers, vertical ducts or other means shall be used to prevent the
concrete from either reaching the final place of deposition in a state of segregation, or
coating the reinforcing steel and the forms with mortar which will dry out before it can
be covered with concrete;

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Use of external vibrators acting outside the formwork shall generally be avoided.
Where unavoidable the formwork must be designed specifically for their use.
In general it cannot be assumed that segregation occurring in handling will be

eliminated in the course of other operations. Segregation shall be prevented and if it
occurs remedial measures shall be taken.
1.7.4.3 Hot Weather Concreting
1.7.4.3.1 General
Where required to control thermal shrinkage, concrete cooling by one or all of the
following methods shall be employed:
 Cooling the aggregates

 Pre-cooling concrete by inclusion of finely chopped ice in place of mixing water
 shading aggregates from direct sunlight
 steel form-work
 water cooling and shading of placed concrete
 embedded pipe cooling.
Contraction and construction joints of dams shall be placed where appropriate to

control thermal shrinkage and/or expansion and where applicable shall be grouted to
create a monolithic structure. Grouting of contraction joints shall be performed
consistent with design assumptions. Grouting of any one portion of contraction joint
shall be performed while the grout initially injected remains in a fluid state. Additional
post-grouting or regrouting shall be performed as required to ensure a monolithic
structure. Grouting shall only commence once an adequate gap at the joints of dams
is available. Contraction joints shall be thoroughly flushed prior to grouting.
On completion, cooling pipes shall be fully grouted
1.7.4.3.2 Temperature of concrete

The maximum permitted temperature rise in concrete and temperature distribution
after placement will be determined from laboratory tests performed prior to the start of
concreting work using the actual cement and concrete mix proportions for the concrete
under consideration.
The maximum temperature developed after placement should not be higher than 60°C
and the temperature difference within the pour or lining should not exceed 20°C.
For linings of pressure tunnels and shafts the heat of hydration shall be limited to 55°C
for maximum heat of hydration, and the temperature gradient in any section of the
lining shall not exceed 10°C.
Hot weather concreting shall be deemed to apply when the average daily shaded air
temperature of concrete when being placed in hot weather shall be as follows, unless
otherwise assessed by the Engineer:

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a) Mass concrete - TAvg, air >25°C.

b) Structural and tunnel lining - TAvg, air >25°C
c) All other concrete, TAvg, air >27°C
whereas TAvg, air = (T6:00 AM + 2T12:00 AM + T6:00 PM + T12:00 PM)/5.
and the concrete placing temperature is higher than the air TAvg by 5°C (see table
2.1.5 of ACI 305-99). Hot weather conditions shall also be considered to be in effect
whenever the day temperature is above 32°C and is expected to exceed this value
over a prolonged period.
The Contractor shall supply and install thermocouples within the fresh concrete in the
structures and shall perform temperature measurement.
1.7.4.3.3 Hot Weather Precautions

The Contractor shall furnish, install, operate, and maintain equipment and make the
necessary provisions in order to maintain the temperature of concrete, when being
placed, below the maximum temperatures specified above.
The following means may be employed to attain the specified concrete temperatures:
a) Pre-cooling of coarse aggregate by sprinkling, immersion in cold water or with

cold air blast, or cooling silos.
b) Refrigerating the mixing water or adding chip or flake ice as a portion of the
mixing water.
c) Insulating the water tanks and water supply lines, cement silos, mixer drums,
exposed pipelines for pumped concrete and sheltering the aggregates.
d) Mixing and placing the concrete at night Ice, when used for mixing water, shall be
completely melted before mixing is completed.
The temperature of concrete at the mixing plant shall normally be 3°C lower than the
placing temperature specified above during the day and 2°C during the night.
The Contractor's concreting operations shall be in accordance with the

recommendations contained in the Peruvian standard or inACI 305 R-99 "Hot Weather
Concreting".
1.7.4.4 Concreting in wet weather

Concrete shall not be placed during periods of heavy rainfall. Suitable precautions
shall be taken to protect concrete which has been placed and has not hardened
sufficiently to resist damage from rainfall.

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1.7.4.5 Concreting in wet ground

Concrete shall be placed in the dry except where this is impracticable. In locations
susceptible to flooding, concrete shall not be placed in any excavation until a
dewatering pump of adequate capacity to deal with maximum probable rates of inflow
of water is installed and available for immediate operation, together with a standby
pump of equal capacity and all necessary ancillary equipment. Pumps connected in
parallel shall have a control valve on the discharge side.
During and after concreting in wet ground, pumping or dewatering operations in the
immediate vicinity shall be suspended if there is any danger that they will extract
cement or otherwise interfere with the newly-placed concrete before it has set and
gained adequate strength.
1.7.4.6 Placing concrete under water

No concrete shall be placed in flowing water and concrete placed under water shall not
be vibrated.
Before placing concrete under water, measures shall be taken to ensure that there is
no accumulation of mud, silt or other deleterious materials. Concrete to be placed
under water shall be placed by tremie and shall not be discharged freely into the
water. Pumping of concrete is acceptable where appropriate. The end of the tremie
shall not be lifted out of the concrete liquid mass while planning “tremie” concrete.
The cement content of the mix shall be increased by 20 per cent over and above that
required for an equivalent grade of concrete placed in dry conditions and for such a
case it will be permissible to exceed the maximum cement contents for designed
mixes.
If necessary, the mix shall be re-designed with increased sand content and higher
slump to ensure that it will flow satisfactorily. The concrete shall be a rich coherent mix
of high workability, with a slump of 150 mm or more but ≤ 250 mm, placed in such a
manner that segregation does not occur.
The concrete shall contain 1% AWA (Anti Washout Admixture).
The hopper and pipe of the tremie shall be clean and watertight throughout. At the
commencement of concrete placing the pipe shall extend to the base of the pour and a
sliding plug or barrier shall be placed in the pipe to prevent direct contact between the
first charge of concrete in the tremie pipe and the water. The pipe shall at all times
penetrate the concrete which has previously been placed and shall not be withdrawn
from the concrete until completion of concreting. A sufficient quantity of concrete shall
be maintained within the pipe to ensure that the pressure from it exceeds that from the
water. The internal diameter of the tremie pipe shall be not less than 150 mm for
concrete made with 20 mm aggregate and not less than 200 mm for concrete made
with 40 mm aggregate. It shall be so designed that external projections are minimized,
allowing the tremie to pass within any reinforcement without causing damage.
The internal face of the pipe of the tremie shall be free from projections.
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1.7.4.7 Pumped and pneumatically-placed concrete

Pumped and pneumatically-placed concrete shall comply with the requirements of
these Specifications except that a maximum slump limit of 100 mm will apply.
Admixtures are permissible.
1.7.5 Compaction and vibration
1.7.5.1 General
Compaction of concrete shall comply with Peruvian standard or ACI 318.
1.7.5.2 Slabs of large area

Concrete in slabs of large area and road slabs shall be vibrated initially by poker
vibrators but when using poker vibrators it is essential to avoid displacing
reinforcement. The surface shall then be struck off above the side forms and finally
compacted using a steel-shod hardwood or metal tamping beam not less than 75 mm
wide and 225 mm long.
1.7.6 Protection
All newly-placed concrete shall be adequately protected from anything likely to
interfere with the process of setting, such as vibrations from nearby machinery and/or
due to explosions. After the removal of formwork no load of any kind shall be imposed
on any reinforced concrete member until the concrete has attained ~ 70% of its design
strength, unless permitted by the Engineer.
Formwork removal requires approval of the Engineer (see also § 1.8.3.5).
1.7.7 Joints
1.7.8 Construction and movement joints

Construction joints and movement joints shall comply with Peruvian standard or ACI
318.
Joint fillers and sealants and expansion joints shall be adequate for service conditions
and resist all anticipated movements without damage or degradation.
1.7.8.1 Emergency construction joints

In the event of a failure of the concrete supply lasting longer than 1 hour all concrete
surfaces on which fresh concrete has still to be placed shall be covered from the direct
heat of the sun. Wherever practicable on exposed faces, a timber of the same
thickness as the cover to reinforcement shall be inserted between the formwork and
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the reinforcement and removed before further concreting, to form a neat straight joint
conforming with the existing joint pattern. (Dowels shall be placed. DB25 at 0.45 m c/c
1 m into the existing concrete in extension for the concrete still to be placed at the
center of bulkhead.
If the initial set has commenced before the concrete supply is restored the pour shall
be terminated. The surface of the concrete left in place shall be prepared as a normal
construction joint to receive future concrete, with the additional requirement that
concreting shall not be recommencing until 24 hours after the termination.
1.7.9 Protection and Curing
1.7.9.1 Protection
The Contractor shall protect all concrete against damage from excessive heat, lack of
moisture, overstress, or any other cause until final acceptance.
Fresh concrete shall be protected from damage such as that due to drying, sunshine, rain
and traffic. The Contractor shall provide such protection while the concrete is still plastic
and whenever such precipitation, either periodic or sustaining, is imminent or occurring.
Care shall be taken not to disturb the concrete by loading or striking forms until it has
hardened sufficiently.
Construction loads shall not be allowed on beams, decks or slabs until the concrete has
attained its design strength, nor shall the Contractor impose loads exceeding the design
loading.
All fresh concrete surfaces shall be protected until the concrete has hardened. Surfaces
which have received U2 or U3 finishes shall be protected by covering with protective mats,
plywood, or other effective means agreed by the Employer‟s Representative.
1.7.9.2 Curing
1.7.9.2.1 General
All concrete shall be moist cured for a period of not less than 14 consecutive days by an
approved method or combination of methods applicable to local conditions. The
Contractor shall have on hand, and ready to install, all equipment needed for adequate
curing of concrete before actual concrete placement of each pour begins. The curing
medium and method, or the combination of mediums and methods, will be subject to
agreement of the Employer‟s Representative.
Concrete poured in tunnels to form tunnel linings shall be cured by membrane curing, as
described hereafter. Curing compounds used in tunnels shall not contain solvents which
may create hazardous conditions.

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1.7.9.3 Water curing

Water used for curing shall meet the requirements of mixing water, free of deleterious
materials and substances that will stain or discolour the concrete.
Water curing shall start as soon as the concrete has hardened sufficiently to prevent
damage by erosion and shall continue for the duration of the entire curing period or
until covered with fresh concrete. All surfaces shall be kept continuously wet during
curing.
Water curing shall be carried out by one of the following methods:
a) Spraying or sprinkling by a system of perforated pipes, lawn sprinklers, soaking

hoses or by other approved methods. Intermittent sprinkling will not be acceptable
b) Covering the concrete surfaces with burlap, cotton mats, or rugs which will hold
water on the surface either horizontal or vertical. The covering materials shall be kept
continuously water-saturated during the curing period
c) Covering the horizontal construction joints and finished surfaces with a minimum
thickness of 50mm of sand which shall be kept uniformly distributed and continuously
saturated during the curing period
1.7.9.4 Membrane Curing by Sealing Compound

Sealing compounds shall be used for concrete curing only if agreed by the Employer‟s
Representative. Sealing compounds will generally be accepted on the manufacturer's
certification of compliance with the Specification, but such acceptance shall in no way
relieve the Contractor of the responsibility for furnishing a compound which meets the
requirements of the Specification. Sealing compounds will be subject to sampling and
testing.
The liquid membrane-forming sealing compounds for curing concrete shall conform to
the requirements of ASTM Specification C 309. The compounds shall be of uniform
consistency and quality within each container and from shipment to shipment.
Membrane curing shall be performed by application of the sealing compound onto the
surfaces of concrete. The sealing compound shall be white-pigmented.
Sealing compound shall not be used on concrete surfaces to which additional

concrete, paint or tiles are to be bonded, unless the Contractor has demonstrated that
the membrane can be satisfactorily removed before subsequent application or can
serve satisfactorily as a base for these applications.
When sealing compounds are used on unformed concrete surfaces, application of the
compounds shall commence immediately after finishing operations are completed.
When sealing compounds are to be used on formed concrete surfaces, the surfaces
shall be moistened with a light spray of water immediately after the forms are removed
and shall be kept wet until the surfaces will not absorb more moisture. As soon as the

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surface film of moisture disappears but while the surface still has a damp appearance,
the sealing compound shall be applied.
Special care shall be taken to ensure ample coverage with the compound at edges,
corners, and rough spots of formed surfaces. After application of the sealing
compound has been completed and the coating is dry to touch, any required repair of
concrete surfaces shall be performed. Each repair, after being finished, shall be
moistened and coated with sealing compound in accordance with the foregoing
requirements.
Equipment for applying sealing compounds and the method of application shall be to
the agreement of the Employer‟s Representative. Traffic and other operations by the
Contractor shall be such as to avoid damage to coatings of sealing compounds for a
period of not less than 14 days. Any sealing membrane that is damaged or that peels
from concrete surfaces within 28 days after application shall be repaired without delay.
Sealing compounds used for surfaces exposed to view shall degrade completely when
exposed to air for more than 3 months. They shall remain at least 80% impermeable
for 1 month after application.
1.7.9.5 Particular cases

Columns
In the case of columns, close wrapping with an impervious material such as polythene
sheeting immediately after removal of the forms will be deemed to be equivalent to
retaining the forms in position insofar as curing is concerned.
Slabs etc.
Water curing of surfaces not cast against formwork shall be commenced as soon as
possible after final set and shall normally be carried out by ponding or by covering the
surfaces with sand, jute, or similar material kept in a saturated condition. Sloping
surfaces will require continuous application of water.
Walls etc.
Water curing of surfaces other than horizontal top surfaces of concrete shall be carried
out by laying out a perforated waterpipe along the top of the pour where possible or
spraying at sufficiently frequent intervals to ensure that the surfaces are always
maintained in a moist condition.
If climatic conditions are such that drying out would occur at night, the Contractor shall
arrange for spraying to be carried out at night as well as during the day.
Prolonged Curing
In cases where the concrete may be subject to attack due to atmospheric pollution or
aggressive groundwater, where the concrete may be subject to abrasion or where the
concrete is required to be impervious to gases or fluids other than water, the curing
period may have to be increased up to twice that specified above.
Effect on Appearance

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Precautions shall be taken to ensure that the concrete is not permanently stained,
marked, contaminated or otherwise damaged as a result of the curing operations and
shall scrub down surfaces so affected if they will be visible on completion.
1.7.10 Watertight concrete
1.7.10.1 General
Construction Drawings shall indicate those parts of the Works where watertight
concrete occurs and the following provisions shall apply:
 No metal ties in formwork unless the watertight concrete requirements under

“Formwork: Ties ” are met;
 Expanded metal is not permitted in construction joints unless removed afterwards;
 Particular attention shall be paid to vibration, especially near construction joints.
1.7.11 Defects
The concrete shall be free from honeycombing and planes of weakness. It shall have
the required standard of surface finish and shall be watertight where required.
1.7.12 Records
A daily record shall be kept of all concreting operations, which shall include, inter alia,
records of:
a. Each section of the work in which concrete has been cast, and the grade and
quantity of concrete placed;
b. All test cylinders made during each day, allowing space for later entry of the
cylinders crushing strengths, which shall be recorded in the appropriate space as soon
as they become available;
c. The daily maximum and minimum temperatures in the shade at the particular
site;
d. Any events which may affect the quality of the concrete, e.g. the occurrence of
rain, high wind, breakdowns in weigh-batchers, mixers, cranes or other concreting
plant etc.;
e. Any emergency construction joints formed as a consequence of a breakdown in
the supply of concrete.
f. In addition records shall be kept of calibration tests as carried out periodically on
weigh-batching plant.
The records shall be available at all times during the progress of the work for
inspection.

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1.7.13 Quality control testing

Concrete shall be adequately tested and reported during the course of construction.
Reports shall be submitted to Engineer. Sampling and testing shall conform to ACI
318, Chapter 5 with the following additional tests being required.
Concrete pour release forms shall be prepared and signed off by Contractor's
supervisory staff (inspector) for each concrete pour. The forms shall be retained for
inspection by the Engineer.
Signing of this form indicates that the work complies with "Approved for Construction
Drawings."
1.8 Ancillaries to Concrete
1.8.1 Reinforcement
1.8.1.1 General
The Contractor shall furnish, fabricate, and install all reinforcement steel as shown on
his Drawings. The work shall further include the provision and installation of all tie
wires, clips, supports, chairs, spacers, and other appurtenances necessary to fulfill the
requirements of the Specification and to produce finished concrete structures.
All reinforcing bars shown on the detailed reinforcement drawings shall be identified on
the bar lists and all bars shall be defined and dimensioned in clear and unambiguous
way. All bar lists shall be referenced to the relevant reinforcement placement
drawings. The Contractor shall be responsible for the correctness of the reinforcement
placement drawings and bar lists.
The Contractor shall submit to the Employer‟s Representative the main reinforcement
drawings.
1.8.1.2 Quality requirements

Reinforcing bars shall be deformed or where shown on the Drawings plain, billet-steel
bars conforming to ASTM Specification A 615 M. The minimum yield strength of the
bars shall be as follows:
 Grade 400M, 400N/mm² (4,077kg/cm²)
Wire for tying reinforcement shall be smooth wire conforming to ASTM Specification A
82. Welded wire fabric for in-situ or sprayed concrete reinforcement shall be made
from electrically welded smooth wire and shall conform to the requirements of ASTM
Specification A 185.
Pre-stressing steel shall be strands of seven-wire type conforming to ASTM

Specification A 416, Grade 1860 (see ACI 318-08 Appendix E) with minimum ultimate
tensile strength 1,860 N/mm2.

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1.8.1.3 Storage
Reinforcement shall be stored at the Site and separate into the various sizes in such a
manner that it is not contaminated with deleterious matter. Reinforcement coming from
different manufacturers shall be stored separately. Reinforcement fabric supplied in
rolls shall be straightened into flat sheets before being placed.
1.8.1.4 Cutting and bending
Steel bars shall be accurately cut and bent to the dimensions and shapes as shown on
the placement drawings and bar lists.
The bars shall be bent cold at temperature greater than 5°C. Bending below that
temperature or warm-bending will only be permitted when adequate precautions are
taken to comply with the corresponding direction issued by the steel manufacturer for
such bending.
Temporary bending and subsequent straightening of bars partially embedded in

concrete shall not be permitted, except when shown on the Drawings or by agreement
with the Employer‟s Representative.
Should welding of reinforcement be necessary and be agreed by the Employer‟s

Representative, the provisions of the American Welding Society "Reinforcing Steel
Welding Code" (AWS D1.4) shall be followed. Welding of reinforcing steel shall only be
acceptable for wieldable grade rebars conforming to A 706 M unless special
precautions as per AWS D1.4 and certified welders are used.
1.8.1.5 Splicing
Reinforcement bars, other than tie bars, shall not be spliced at points other than those
shown on the Drawings without the consent of the Employer‟s Representative. On
occasions when it becomes necessary to alter the position of such splices, the new
position and the type of splice shall be subject to the written agreement of the
1.8.1.6 Placing
Reinforcing steel, before being positioned, shall be free from loose mill and rust scale,
and from any coating that may destroy or reduce the bond between the steel and
concrete. As a rule, the same type of reinforcement from the same source shall be
used in any one part of the structure.
Reinforcing steel shall be accurately positioned and secured against displacement by
using ties made of annealed iron wire of not less than American Wire Gauge No.16
(1.3 mm) or suitable clips at intersections.
The metal chairs, bar spacers and similar reinforcement support devices that touch the
forms shall be galvanized or shall have plastic tips at the point where the support
device touches the forms.

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The bottom layer of reinforcing steel in slabs on the ground shall be supported by
means of precast concrete spacer blocks. The spacer blocks shall have a 100 mm x
70 mm horizontal surface and be of concrete quality at least equivalent to that which is
to be placed. The upper layer of reinforcement in ground slabs and all other slabs and
in beams shall be supported by means of steel chairs. In all cases, sufficient supports
for horizontal reinforcement shall be used so that there will be no sagging of the bars.
1.8.1.7 Concrete cover of the reinforcement

The cover to the reinforcement shall be as indicated below or as shown on the
Drawings:
In-situ concrete:
 Bottom of foundations and footings 100 mm exposed to flowing waters

 Concrete cast directly against soil or rock 75 mm
 Formed concrete permanently exposed to backfill or water 70 mm
 Outside exposure 50 mm
 Inside exposure 40 mm
Precast concrete:
 Outside exposure 40 mm
 Inside exposure 30 mm
Reinforcement closest to the concrete surface where water can flow shall be
positioned approx. parallel to the flow direction.
1.8.2 Built-in items
1.8.2.1 General
Construction Placement Drawings shall indicate all embedded items from any source,
identifying each type of embedment and/or inserts, and giving their location, the
accuracy of positioning required and any special workmanship requirements. In all
cases built-in parts shall be within 5 mm of the position indicated on the Construction
Drawings.
1.8.2.2 Blockouts, recesses and 2nd concrete stage

Construction Placement Drawings shall clearly indicate all block-outs and recesses.
Moreover, areas where second stage concrete shall be carefully detailed with respect
to lines and grades and to the necessity of starter-bars and/or connecting anchors.
Should expanded metal latz be used as temporary formwork it shall be removed and
the surface chipped to good concrete and then applying the surface treatment (which
may consist of just damping the fresh surface, or using an approved boarding agent)

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before placing the 2nd stage concrete. Note that in non-sensitive areas the Engineer
may decide not to remove the extended metal.
Built-in items shall be securely fastened into position to resist forces which will be
imposed by the concreting activities. Large items of electro-mechanical plant for
example may require restrictions on pour heights to keep flotation or other forces
acting on restraints during concreting within designed limits.
Proprietary built-in items shall be assembled and installed strictly in accordance with
the manufacturers‟ instructions, using appropriate tools, ancillaries and consumables
supplied by or as recommended by the manufacturer.
Any built-in item which cannot subsequently be examined or replaced easily shall have
a design life in its working environment not less than the anticipated lifetime of the
structure it is built into.
Built-in items shall be protected as necessary to prevent damage, deterioration or loss

of serviceability.
Pipes shall not be built-in unless they are connected to the remainder of the pipework
system, properly aligned, and complete with valves supports; or unless there is
adequate flexibility in the pipework system not yet in place to accept all probable
misalignments and positional errors. Otherwise box-outs shall be left in the concrete.
The surfaces of box-outs shall be prepared as construction joints.
1.8.3 Formwork
1.8.3.1 General
The Contractor shall design, supply and fix all necessary formwork, together with its
attendant falsework, scaffolding, timbering, shoring, strutting, diagonal bracing, etc,
required for the placing of concrete. The design construction and treatment of
formwork shall be in accordance with Peruvian standard or ACI 318 except where
specified otherwise below.
Form-work shall be maintained rigidly in position and shall be designed to be adequate

for all imposed construction loadings including superimposed equipment, wind load or
earthquake loading expected during construction (10 year and 20 year return period,
respectively).
Forms to be used in water-passages, and for concrete which will ultimately be

exposed to view, shall be faced with plywood or steel and shall be free of all defects
which may be reproduced as blemishes on the finished concrete surface.
1.8.3.2 Ties
Where internal metal ties are used, they or their removable parts shall be extracted
without damage to the concrete and the remaining holes filled with a suitable mortar.

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No permanently embedded metal part of a tie shall have less than 40 mm cover to the
finished concrete surface.
Where the concrete is to be watertight, internal metal ties of any sort shall not be used
unless they are in two parts, each screwed into a central metal or other block which
remains in the concrete and in which the screwed lengths do not penetrate through the
block. The void left after removal of the tie shall be filled by a mortar having the lowest
practicable water/cement ratio.
Where tie bolts are used in concrete which is to pass high-velocity water flow, a
proprietary system shall be used which enables the tie bolt to be completely removed,
the void effectively plugged and the surface made flush with neither projection,
depression nor feathered edge. One possible system is a non-ferrous tube with a
threaded end. After removal of the bolt the tube is filled with grout and a non-ferrous
threaded plug is screwed in and ground off flush with the surface.
For other areas prominently and permanently visible on completion, ties shall be
aligned in a regular symmetrical pattern and preformed cones shall be used at the
ends. The cones shall be removed after striking the formwork and the resultant
recesses filled to 10 mm back from the general surface with a smoothed mortar of
water/cement ratio less than that of the concrete.
In areas which will not be visible after completion, the cones may be filled flush with
the concrete.
1.8.3.3 Exposed corners

All exposed concrete shall have external angles chamfered 25 mm x 25 mm by means
of moulding strips fixed to the formwork.
1.8.3.4 Erection of formwork

Formwork shall conform to ACI 347-04.
The height of concrete lifts shall not exceed the Contractor‟s designed capacity of the
formwork unless noted otherwise on the drawings.
The formwork for successive vertical lifts must make good contact with the concrete in
the preceding lift such that there will be no excrescences, bulges, tears and other
outward signs of a faulty junction, e.g. significant grout leakage. Compressible grout
strips or timber strips shall be used to ensure that such untidy irregularities at junctions
between lifts are avoided.
The forms must be fixed in perfect alignment and securely braced in order to
withstand, without displacement or deflection, the movement of men, materials and
plant, and the pressure of the wet concrete whilst it is being cast.
Particular care shall also be taken with the fixing of stop ends to form construction
joints so as to ensure that there will be no unacceptable leakage of mortar.

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1.8.3.5 Removal of formwork

Removal of formwork shall comply with Peruvian standard ACI 347-04 Section 3.7, or
ACI 318, but not before the concrete has attained sufficient structure. Nevertheless,
formworks shall not be removed before approval by the Engineer.
1.8.4 Surface finishes obtained from formwork
Concrete finishes shall follow procedures outlined in ACI 301. All concrete shall be
finished even and uniform in texture and color. All honeycombing, unsightly bulges and
ridges shall be repaired and ground smooth. All exposed corners shall be chamfered.
Repair of surface blemishes to concrete shall follow procedures outlined in ACI 301.
The surface of the spillways from the beginning of the upstream curvature of the
rollway to the downstream end of the flip bucket (or stilling basin), the surfaces of the
spillway piers and walls and water passages of the draft tubes, shall be grounded and
thoroughly cleaned, where necessary, to provide smooth boundaries offsets shall not
exceed 1 mm. At construction joints transverse to the water flow the upstream part
shall be chamfured 15 mm at 1:1 and the downstream part at 1:8.
The classification of formed surface finishes shall be in the following categories. Finish
classifications shall be indicated on the Construction Drawings.
1.8.4.1 Class F1
Usually for areas which will not be visible in the completed works:
Unwrought timber may be used.
1.8.4.2 Class F2
Usually for areas, except high velocity waterways, which will be visible in the
completed Works.
Normal fair finish for exposed work, obtained from the use of steel shutters or forms
lined with plywood, formboard, blockboard or hardboard of approved manufacture or
other approved material. Upon removal of the formwork all fins and joint irregularities
shall be ground smooth. Air cavities shall be made good with mortar of the same color
as the concrete.
Wherever possible on large surface areas, large panels (generally 2.4 m x 1.2 m
approx.) of 5 or more ply timber shutter panels with a minimum number of joints
between panels shall be used.
In areas prominently and permanently visible on completion, particular attention shall

be given to the arrangement of joints and bolts (where used), so as to achieve a
symmetrical pattern in the finished concrete surfaces. In general, panel and bolt lines
shall be vertical, horizontal or parallel to the overall lines of the structure.

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The finished face of concrete resulting from the use of Class F2 formwork shall be of
an even light color without significant color variations between panels. Defects in
finished surfaces shall be rectified.
1.8.4.3 Class F3
Special shuttered surfaces, including those for waterways subject to high velocity
water flow:
As F2 but the formwork is to be lined with materials of the highest quality and heavily
strutted to ensure a particularly accurate line of finish within the given tolerances in
which no filling of blemishes will be necessary. The only allowable remedial work will
be grinding off to obtain required tolerances but even this work will not be considered
to be the norm.
1.8.4.4 Class F4
Exposed aggregate finish for architectural purposes:
As F2 but additionally an exposed aggregate finish shall be produced by coating the

relevant areas of the forms with an approved retarding agent, followed by brushing the
concrete surfaces immediately after the formwork has been struck. Formwork treated
with a retarding agent shall be struck within 60 hours of casting the concrete. In order
to achieve uniformity of finish, construction joints shall be kept to a minimum where the
concrete aggregate is to be exposed and due allowance shall be made for
temperature variations when estimating the time between casting and brushing the
concrete surfaces to expose the aggregate.
The type of formwork used and care in placing concrete for areas which are to have an
exposed aggregate finish shall be consistent with the need to produce a uniform finish
in each area of exposed aggregate.
In order to obtain a uniform color for the exposed aggregate, crushed rock sand shall
be used.
Before forming any exposed aggregate surface, sample panels of 4 m² minimum area
shall be cast to establish a mix with the desired appearance, uniformity and depth of
aggregate exposure. The time lapse between casting and brushing the concrete
surfaces, the method of brushing, types of brush used, temperature effects etc. shall
be established at this time and will then be used for all exposed aggregate surfaces.
Sample panels shall be manufactured at least 3 months before any such permanent
surfaces are intended to be formed, and must be allowed to weather for 2 months
before selection.

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1.8.5 Unformed surface finishes
1.8.5.1 General
Exposed surfaces of concrete not finished against formwork, such as horizontal slabs
or slightly sloping surfaces, shall be brought up to a uniform surface and worked with
screeds or other suitable tools to a smooth finish within the required tolerances.
If the concrete surface of any section of work is unsatisfactory and does not conform to
the specified finish, such surfaces shall be rubbed down while still green or
alternatively grind them down with carborundum or other methods when hard in order
to give a smooth clean finish. Honeycombed surfaces shall be cut back and re-cast to
the specified finish.
1.8.5.2 Classification of surface finishes

The classification of surface finishes for concrete not cast against formwork shall be in
the following categories. Surface finish classifications shall be indicated on
Construction Drawings.
1.8.5.3 Class U1: Tamped finish

Exposed surfaces of concrete not finished against formwork such as horizontal or
slightly sloping surfaces shall be brought up to a uniform surface and worked to exact
line and level using screeding boards or other suitable tools to a uniform finish without
excessive laitance. Where these surfaces are to receive a secondary or finished
screed or layer the concrete surface shall be sprayed with a water jet after the initial
concrete set has taken place so as to loosen and remove the surface mortar and
expose clean particles of the coarse aggregate.
This is the normal finish for ordinary work and construction joints. Additional measures
for slabs of large area have been described under “Compaction and Vibration”.
1.8.5.4 Class U2: Wood float finish

As U1 but after the concrete has hardened sufficiently the surface shall be floated by a
wooden float to produce a uniform surface free from screed marks.
1.8.5.5 Class U3: Steel float finish

As U2 but using a steel float with great care to produce a particularly hard and smooth
surface while avoiding the development of excessive laitance. This is for high quality
work.
1.8.5.6 Class U4: Specially required quality

Specially-Required Quality in the topmost layers or at the surface of the fresh
concrete.

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When a particular treatment is to be applied to concrete before hardening it will be

designated as follows and shown in the Construction Placement Drawings:
 U4.1: Small chippings applied to plastic concrete.

 U4.2: Applied chemical hardener.
 U4.3: Applied chemical sealer.
 U4.4: Power floating.
 U4.5: Vacuum process.
Various specialized treatments are available for differing requirements, mostly utilizing
proprietary equipment or products. The supplier‟s recommendations shall be strictly
followed and the work shall be carried out only by personnel experienced in the type of
work concerned.
1.8.6 Tolerances
1.8.6.1 General
Tolerances shall be in accordance with ISO 7737 except in critical areas where plant
or other service requirements are more demanding.
1.8.6.2 Local deviations in planar surfaces

Local tolerances for slabs, walls and other flat surfaces will be designated as S1, S2 or
S3 and indicated on the Construction Drawings. These categories are defined as
follows:
a. When a 2 m straight edge is laid on the surface the maximum deviation (valley)
measured below the straight edge shall not exceed:
 For S1: 3 mm;
 For S2: 5 mm;
 For S3: 10 mm.
b. The local slope computed as the depth of a “valley ” divided by its distance from
the nearest “crest ” (point where the straight edge touches) shall not be steeper than:
 For S 1 : 1 in 200;
 For S2 : 1 in 120;
 For S3 : 1 in 60.
c. Steps at joints shall not exceed:

 For S1: 1 mm;
 For S2: 2 mm;
 For S3: 2 mm.
Slabs which are to receive a screed as part of the finishing work shall be to S3 unless
otherwise stated. Category S3 shall be assumed where no tolerance is stated.
Remedial work by grinding of protrusions will always be preferred to filling of hollows.

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1.8.6.3 External slabs and road slabs

Road slabs shall be to S2 both longitudinally and transversely. All external slabs
across which storm-water will flow and other slabs laid to falls shall always be able to
shed water effectively even if this suggests a tighter tolerance.
1.8.6.4 High-velocity water conduits
Abrupt protrusions, steps and hollows in conduits which will carry water at high velocity
are likely to lead to cavitation immediately downstream of the defect, with potentially
very serious consequences. Accordingly, concrete surfaces in such conduits shall be
to S1 parallel to the flow and S2 transversely, except that at joints transverse to the
flow no projection at all of the downstream edge into the flow will be accepted.
1.8.6.5 Openings/areas for hydraulic steel structures

Openings/areas in concrete in which hydraulic steel structures will be implemented
shall be made in considering the tolerances of the hydraulic steel structures.
1.8.7 Specialized concrete techniques
1.8.7.1 Repair of defective concrete
1.8.7.1.1 General
Concrete which is damaged or which may have been originally defective or which
becomes defective at any time prior to the final acceptance of the completed work, or
concrete which departs from the established position, line or grade, or concrete which
for any other reason does not conform to this Specification, shall be satisfactorily
repaired, or removed and replaced with acceptable concrete by the Contractor.
The Contractor shall correct all imperfections on the concrete surfaces as necessary to
produce the specified finishes within the following times:
a) Minor formed surface repairs that require surface working or grinding shall be
completed within 2 hours after form removal
b) Concrete replacement less than 250mm thick that require repair by mortar or
drypack mortar shall be completed within 7 days after the original concrete placement
c) Concrete replacement more than 250mm thick that require repair by epoxy-resin
bonding, and all other repairs shall be completed after 7 days, but before 56 days after
the original placement All repair work shall be finished to the same standard as the
surrounding concrete, and shall be adequately cured. Plastering or rendering of
surfaces to produce a smooth surface finish shall not be permitted.
No repair work shall be carried out before the Employer‟s Representative has
inspected the defective area and given consent for remedial work to begin.

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Concrete requiring F1, U1, F2 or U2 finish that is honeycombed or fractured, or that

contains surface depressions which exceed the allowable tolerance specified in this
Section or that is otherwise defective shall be cut back to a minimum depth of 25mm
into sound concrete in all directions, and the edges undercut. The area to be removed
shall be outlined to a depth of 15mm with a diamond saw prior to removing the
defective concrete. The fresh concrete surface shall then be roughened, cleaned,
washed down and thoroughly soaked with water until the concrete becomes saturated.
The concrete surface shall be damp, (not wet). Repairs to the surface shall then be
carried out using the materials and methods described hereafter.
For bonding new concrete to older one, a bonding agent, formulated for this purpose,
shall be used in accordance with the manufacturer's instructions. Alternatively, a neat
cement paste may be used. A paste of Portland cement and water mixed to a thick
cream consistency shall be applied to damp, clean concrete. The concrete shall have
no free water on its surface.
Concrete requiring F3, F4, U3 or U4 finish that is honeycombed or fractured, or that

contains surface depressions which exceed the allowable tolerances specified in this
Section or that is otherwise defective shall be repaired as follows:
a) Minor areas of defective concrete
The Contractor shall drill a hole of such diameter in the defective area into sound
concrete, that the defective concrete is completely removed. The minimum diameter of
such a hole shall be 40mm, the minimum depth shall be equal to the diameter of the
hole drilled and the maximum depth shall be 70mm. The hole shall then be reamed out
such that the diameter at the bottom of the hole is at least 20mm larger than the hole
at the surface. Finally, the hole shall be cleaned and washed out, the surplus water
removed, and then filled with concrete incorporating a non-shrink agent agreed by the
b) Large areas of defective concrete
Concrete which contains defective areas too large to be repaired as described above
shall be cut to within 10 mm of the face of surface reinforcement or further if necessary
to 25 mm pass the face of the surface reinforcement to remove all the defective
material, and then the edges undercut to key in the repair concrete. The fresh concrete
surface shall then be cleaned, washed down and thoroughly soaked with water until
the concrete becomes saturated. The concrete surface should be damp but not wet.
Finally the hole shall be filled with concrete which may incorporate a non-shrink agent
agreed by the Employer‟s Representative.
Concrete which will be exposed to public view shall be repaired in a manner which will
result in a concrete surface with a uniform appearance.
1.8.7.1.2 Dry-pack mortar

The dry-pack mortar shall consist of 1 part cement to 2.5 part of sand, by volume that will
pass the US Standard Sieve No.16 (1.18 mm). Only enough water shall be used to

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produce a mortar which will stick together when moulded into a ball by a slight pressure of
the hands and will not exude water but will leave the dry-pack in thin layers.
Dry-pack mortar shall be placed and packed in layers. Each layer shall be solidly
compacted over its surface by use of a hardwood stick and hammer.
Dry-pack mortar shall be used for filling holes having at least one surface dimension less
than the hole depth, for narrow slots cut for repair of cracks, for redrilled grout holes and
grout pipe recesses, and for tie-rod fastener recesses.
Dry-pack mortar shall not be used for filling behind reinforcement or for filling holes that
extend completely through the concrete section.
1.8.7.1.3 Mortar filling

Mortar to be used for repair work shall have the same sand, cement and air
proportions as in the mix of the concrete to be repaired. The Contractor shall place
mortar filling with a mortar gun or by hand.
Mortar filling shall be used to repair defects which are too wide for dry-pack filling and
too shallow for concrete filling and no deeper than the far side of the reinforcement
that is nearest the surface.
Mortar filling in concrete surfaces destined to be in contact with flowing water shall be
used only together with the application of bonding agents using a procedure agreed by
the Employer‟s Representative.
1.8.7.1.4 Concrete filling

Concrete filling shall be used for holes extending entirely through concrete sections,
for holes in which no reinforcement is encountered and which are greater in area than
0.1 m2 and deeper than 100 mm, and for holes in reinforced concrete which are
greater in area than 0.05 m2. Holes in reinforced concrete which extend beyond the
reinforcement shall be enlarged as necessary to permit satisfactory filling of the hole
with concrete.
Concrete filling shall be tightly packed and completely bonded to the surfaces of the
hole. The mix proportions of the filling materials shall be such as to provide a strong,
dense repair which will avoid color variations in surfaces exposed to view.
On surfaces permanently exposed to view, the Contractor shall supply white cement in
sufficient amount, as determined by trial, which when blended with normal cement will
produce a finish of similar appearance to the adjacent concrete.
A non-shrink agent shall be used where a watertight joint is required. The surface of
patches shall be smooth and flush with the surrounding concrete.

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1.8.7.1.5 Epoxy-resin bonding

Any repairs made after 7 days after the original concrete placement for thicknesses
less than 250mm thick shall utilize a bonding agent system. The locations where
bonding agent will be used will be agreed with the Employer‟s Representative, who will
approve the type and brand to be used. In areas where there is no flowing water an
epoxy-resin may be used for the repair if approved by the Engineer.
The method of repair shall be as recommended by the manufacturer. The product

used shall not contain toxic elements. The concrete surfaces repaired with epoxy-resin
bonded system shall be lightly ground to eliminate gloss of the finished epoxy mortar
surface and to produce a surface color and texture that closely matches the
surrounding concrete.
1.8.7.1.6 Stains and discolorations

Stains or discoloration of exposed concrete surfaces shall be removed. The procedure
or method or removing the stains and/or discoloration will be subject to approval. The
removal of stains or discoloration shall not be started until the work that originally
caused the stains or discoloration is completed.
1.8.7.2 Precast concrete
Scope
This Section applies to all concrete cast away from its position in the Permanent
Works, whether reinforced or pre-stressed. It also applies if the pre-casting is carried
out within the main limits of the work site or at a factory.
Marking
Every precast unit shall be marked with a unique identifying number and the date of
casting. The marking shall be made with indelible paint on a surface which will not be
visible on completion.
Handling
Precast concrete units shall be lifted and supported during manufacture, transport and
erection only at specific lifting or supporting points and these shall be clearly identified
on drawings and marked on the units. Transportation, site handling and erection shall
be carried out only by experienced personnel using methods and equipment which will
not overstress the units.
Where precast units are stored on the ground, the supporting area shall be
strengthened as required to avoid settlement which could adversely affect the precast
units.
Erection will include the placing, precise alignment and leveling of members in final
position in the structure. The correctness of line and level shall be ensured before
erection by careful leveling and preparation of the bearing details. Joints between
precast elements shall be fastened, grouted, pointed, glued or caulked as required.

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Bearings
Bearings other than steel details shall be proprietary items obtained from a
manufacturer specializing in this type of equipment.
Bearings shall be set to the exact detail shown on the Construction Drawings to the
designated tolerance using the manufacturer‟s recommended fixing and seating
arrangement, shims and special grouts as required.
1.8.7.3 Pre-stressed concrete

Scope
This Section relates to in situ and precast pre-stressed concrete. For pre-cast work the
requirements given for precast concrete shall apply in addition.
It is assumed herein that post-tensioning will be used. The use of pre-tensioning

however is not excluded.
General
Pre-stressing operations shall be carried out only under the direction of an
experienced and competent supervisor and all personnel operating the stressing
equipment shall have been properly trained in its use. Special precautions shall be
taken when working with or near tendons which have been tensioned or are in the
process of being tensioned.
Formwork which will be in place during stressing shall be designed to allow for the
horizontal and hogging movements which will take place during stressing.
Tendons, anchorages and stressing equipment shall all be compatible. Under no

circumstances shall apparatus designed for use with one system of pre-stressing be
used in conjunction with apparatus designed for use with another system.
Pre-stressing Tendons
The specification and workmanship for pre-stressing tendons including materials,
handling, tendon arrangement, anchorage, the tensioning apparatus and the
tensioning procedure shall comply with Peruvian standard or ACI 318.
Full records shall be kept of all tensioning operations including the measured
extensions, pressure gauge or load cell readings and the amount of pull-in at each
anchorage. Copies of these records shall be supplied to the Employer.
Grouting of Ducts
Ducts shall be grouted with cement grout as soon as practicable after the tendons
have been stressed. Grout for prestressing tendons shall comply with Peruvian
Prestressed beams shall be load tested selecting 1 in 10 for the first 50 of a particular
type of unit and 1 in 25 thereafter.

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The test load shall exceed the maximum design load (unfactored) but will not be such
as to exceed either 40 per cent of the specified cube strength in compression or 10 per
cent of the required cube strength at transfer in tension.
Units intended for composite construction may have to have a temporary top slab of
reinforced concrete for purposes of the test. This will be deboned from the pre-
stressed concrete.
Loads shall be measured to an accuracy of 2 per cent (or 0.05t if greater) and
deflections to 0.5 mm. Loading jacks and gauges shall be calibrated together.
Loads for beams and like items shall be applied equally to the third points of the span.
For other structural units the load shall be applied at the centre of the span. Loads
shall be increased in 10 stages, held for 15 minutes at each stage and released in 5
stages.
The initial hog shall be measured together with the load/deflection curve during the
test. At least 85 per cent of the maximum deflection shall be recovered on completion
of the test.
Any pre-tensioned unit which fails the test shall be rejected. Other units cast in the
same line shall also be rejected unless tested and found to be satisfactory.
Full records shall be supplied to the Employer of the test showing age of unit, initial
hog, loads, deflections and calculated value of Young‟s Modulus of Elasticity.
1.8.7.4 No-fines concrete

No-fines concrete will be used where required to produce a stable porous foundation
or for other applications.
The aggregate shall be gap-graded such that all particles pass a 37.5 mm sieve but
not more than 10 per cent pass a 20 mm sieve; alternatively, all particles shall pass a
20 mm sieve but not more than 5 per cent shall pass a 10 mm sieve. The
aggregate/cement ratio shall be between 6 and 9.
The water/cement ratio shall not exceed 0.45 and shall be a minimum such that each
particle of aggregate is completely coated with a smooth grout paste, but at the same
time the paste shall be sufficiently wet that the mortar coatings run together at the
point of contact (without filling the interstices between the particles) to form a fillet
which will bond the particles together.
Trial mixes shall be carried out to establish optimum mix proportions before any no-
fines concrete is used in the Permanent Works.
The aggregate shall be thoroughly saturated immediately before batching.

No-fines concrete shall not be moved from its point of deposition other than to strike
off to the correct level.

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Where no-fines concrete is to be covered by normal concrete a layer of building

plastic, or preferably mortar, shall be placed over the surface of the no-fines concrete
to prevent mortar of the concrete from filling the interstices of the no-fines concrete.
1.8.7.5 Superplacticized concrete

It is envisaged that superplasticized concrete may be required in areas where
reinforcement is very congested and access is very difficult.
Superplasticized concrete is a normal concrete to which a superplasticizing admixture

has been added as a workability agent to increase the workability considerably during
the first 30-60 minutes after mixing without adversely affecting the required properties
of the hardened concrete.
Trial mixes shall be carried out to verify the extent of the increase in workability and to
prove that it is not accompanied by excessive bleeding or segregation. It may be
necessary to increase the sand content from the equivalent grade of unplasticized mix
in order to meet these requirements. The flow table spread of the mix before addition
of superplasticizer shall not exceed 44 cm.
In the production of concrete the superplasticizer shall be added by a calibrated

gravity-feed dispenser and mixing shall continue for 2-5 minutes thereafter. If there is a
delay such that the effect of the plasticizer wears off significantly, the concrete shall be
used elsewhere or discarded; a second dosing shall not be permitted.
It shall be assumed that vibration will still be necessary, unless assessed otherwise by
the Engineer.
1.8.7.6 Sprayed concrete
Minimum technical requirements
The final acceptance of proposed mix designs shall be based on field trials involving
test application to rock surfaces, coring and testing of in-place shotcrete.
Contractor shall demonstrate, by compiling precedent data, that any additives for use
in sprayed concrete mixes will not impair the final quality and durability of the
shotcrete.
Additives may include accelerators, super-plasticizers, air entraining agents,

microsilica and deformed steel fibers. Polypropylene or other fibers than deformed
steel fibers shall not be used.
Scope
The term “gunite ” will be used for sprayed concrete where the maximum aggregate
size is less than 10 mm and the term “shotcrete ” where the maximum aggregate size
is 10 mm or greater. The use of gunite may be expected to be restricted mostly for
work of a cosmetic nature of which the visual appearance is important.

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This Section is applicable to sprayed concrete applied in both open cut and
underground excavations.
The dry mix process in which water is added at or adjacent to the nozzle shall be used
unless the Contractor can demonstrate that he has successfully used the wet mix
process in comparable conditions elsewhere.
Any aspects of sprayed concrete work not covered by the Specification shall be in
accordance with the relevant clauses of ACI 506R-05.
General
Areas to which sprayed concrete is to be applied and the thicknesses to be applied
shall be identified on the Construction Drawings and supported by structural
calculations as part of the Contractor‟s Documents submitted in good time before work
on a particular area commences.
The primary use of sprayed concrete will be as a means of preventing disintegration of

a rock mass during the first few hours after its exposure following excavation. In such
cases the first layer of the sprayed concrete shall therefore usually contain an
accelerating admixture and will normally be applied after blasting but before removal of
spoil. This layer may be expected to have a nominal thickness of at least 50 mm.
Temperature restrictions on concrete placing shall apply also to sprayed concrete.
Preparation of Surfaces
Depending on the tunnel excavation class of support; after stabilizing the excavation
header with suitable dowel-anchors, if required, the surfaces to which sprayed
concrete is to be applied are to be barred down and descaled of all large loose
material and cleaned down with a mixture of water and air applied at high pressure.
Where the inflow of groundwater renders the surface too wet for the normal application
of sprayed concrete, the water shall be previously suitably drained so that the surface
is free of running water or grouting may be necessary to reduce water inflow to
acceptable limits.
All surfaces to receive sprayed concrete shall be moist but free of dirt, oil, rebound or
other deleterious material. Where sprayed concrete is to be placed over a previous
layer, that layer shall be first allowed to reach its initial set and then cleaned of all
laitance, rebound or other loose material by brooming or sluicing.
Pins at suitable spacings shall be inserted into the surface to receive sprayed concrete
to facilitate the verification of the applied thickness.
Reinforcement
Where required, steel mesh reinforcement or non-metallic fibres shall be incorporated
in sprayed concrete. Minimum reinforcement shall comprise a single layer of welded
steel fy ≥ 400 MPa mesh fabric of 5 mm wires at 150 mm centers or 4 mm wires at
100 mm on centers. Where heavier reinforcement is required, a built up system made
from steel reinforcing bars shall be used.

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In areas where mesh is to be used, a first application of sprayed concrete shall be

made before fixing the mesh fabric with the object of filling fissures and pockets to
form a more uniform surface against which the mesh can be placed satisfactorily.
The steel mesh shall be securely fixed at maximum centers 800 mm both ways at the
optimum distance from the surface for the application process such as to minimize
rebound and prevent voids. The minimum cover between the reinforcement and the
exposed face of the sprayed concrete shall be 30 mm. Laps shall be 250 mm
minimum for mesh and 50 diameters for steel bars.
If two layers of reinforcement are required, each layer of reinforcement shall be

contained in a separately-applied layer of sprayed concrete.
Equipment
Equipment used for the application of sprayed concrete shall comprise compatible
components of established design and in proper working order. Water needed for the
process shall be supplied at a steady pressure of 3-6 bar. Air for the equipment is to
be clean, dry and oil free and should be provided at the equipment within the pressure
range of 4 to 6 bar.
The nozzle shall produce a conical discharge stream of uniform appearance
throughout.
Experience of Operators
Nozzlemen employed on the Works shall have experience of similar work on previous
projects. Supervisors shall have adequate background specialist experience.
Protection of Personnel
Sprayed concrete generates considerable dust and this is particularly aggravated
when powdered additives or admixtures are used. The situation is made more severe
when the additive is siliceous. Personnel other than the spraying operators must be
suitably warned and protected if need be. Nozzlemen and assistants must be issued
with adequate protective clothing to prevent excessive dust entering ears, nose and
mouth; respirators shall be used if necessary. Hands must also be protected against
prolonged contact with cement.
Materials
Water and reinforcement shall be as specified. Cement shall be Ordinary Portland
Cement as specified in the Concrete Section. Uniformly fine-grained cement is
preferable.
Where an accelerating admixture is necessary in order to apply the sprayed concrete

successfully or to maintain safe conditions, the amount used shall be within limits
recommended by the manufacturer but within the range 2-7 per cent by weight of
cement. In the case of cement containing a pozzolan, the advice of the manufacturer
of the additive (and of the cement if necessary) shall be sought to determine the
suitability of the combination.
The objective in adding such an admixture should be to obtain high early strengths
appropriate to the conditions.

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Depending on the materials available on Site, it may be possible to use 10 mm and 20

mm aggregates as used for ordinary concrete works. Aggregates with a high
proportion of flaky particles may prove to be unsatisfactory. Suitable tests shall be
carried out to determine the optimum type and grading of aggregate.
Sieve Size (mm) Percentage Passing

10 100
5 95-100
2.4 80-95
1.18 50-85
0.6 25-60
0.3 10-30
0.15 0-10
0.075
0-2 (mandatory)
There are quite wide variations in 10 mm aggregate gradings which appear

satisfactory for gunite. It is to be expected that a grading within and parallel to the
following band will be satisfactory, but the exact grading used is likely to be subject to
trial and error and will vary depending on whether crushed rock or naturally occurring
materials are used.
In the case of the combined grading of 20 mm aggregate for shotcrete there appears
to be reasonably close agreement on practicable gradings and it is suggested that a
grading within and parallel to the following band is likely to be satisfactory:
Sieve Size (mm) Percentage Passing

20 100
12 95-100
10 90-100
5 70-85
1.18 35-55
0.6 20-30
0.3 8-20
0.15 2-10
0.075 < 2% (mandatory)

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Mixes and Properties

There shall be sufficient over-design strength to allow for rebound, variation in
workmanship and other relevant factors.
The mixes as sprayed shall lie within the following limits unless otherwise agreed:
Cement content (kg/m3) 300-450
Aggregate/cement ratio for gunite 1.0-3.0
Aggregate/cement ratio for shotcrete 3.0-5.0
Water/cement ratio 0.35-0.45
In determining the water/cement ratio, account shall be taken of the water content of
the aggregate, which should normally be in the range 3-6 per cent. Water shall be
added in sufficient quantities to minimize rebound while simultaneously avoiding any
slumping of the layer of sprayed concrete during.
The specified 28-day compressive strength of 100 mm diameter cores 100 mm long
shall be 30 N/mm².
When the mix incorporates an accelerator the following properties shall be the
objective:
 Maximum time of Initial Set: 3 minutes

 Maximum time of Final Set: 12 minutes
 Core strength at 8 hours: 3 N/mm²
 Core strength at 72 hours: 12 N/mm²
Test panels
At least 2 weeks before any sprayed concrete is expected to be produced not less
than 3 test panels for each mix for testing shall be prepared. Sets of test panels shall
comprise one shot downwards on to a horizontal surface, one shot on to a vertical
surface and one shot on to an overhead horizontal surface.
The panels shall be obtained by securely attaching 760mm x 760mm x 90mm deep
timber boxes to appropriately aligned surfaces and applying sprayed concrete to the
areas contained in the boxes using the same mixing and placing equipment to be used
in the Works.
All the panels shall be a minimum thickness of 75mm. When the final set has taken
place the test panels shall be transported to the laboratory where the crushing strength
will be determined by testing cylindrical cores cut from the panels. No trial core
strength, after adjustment for length of core, shall fall below the minimum specified.
During sprayed concrete operations, routine test panels shall be prepared beside the
application zones for the purpose of quality control. Three panels shall be supplied for
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approximately each 25 m3 of sprayed concrete and shall be tested as described

above but at least once per day.
The quality of the sprayed concrete will be considered satisfactory if every test result is
at least 80 per cent of the specified strength and if at least 80 per cent of all results
exceed the specified strength.
Batching
Materials shall be batched by weight and cement shall not be added more than 1 hour
before the anticipated time of placing the sprayed concrete.
Placing
Unless trials have demonstrated otherwise, the nozzle shall discharge 1-1.5m from the
surface. There shall be no significant inclusion of rebound in the finished work, no
hollow areas. These shall be good adherence to the rock and a reasonably smooth
surface finish. Rebound shall be kept clear of sprayed concrete being placed and an
air jet shall be provided for this purpose.
Sprayed concrete should be available for application immediately following the scaling
of the excavation.
The thickness of sprayed concrete applied in one pass shall be at least 25 mm but no
more than 50 mm. In general an initial layer sufficient to stabilize the rock immediately
after excavation is to be expected, followed by any reminder at some convenient later
time. It is not intended that the finished exposed surface will present the same
appearance as a concrete lining placed behind formwork; large radius irregularities will
be permitted, but local roughness and re-entrant angles are to be avoided.
Construction joints in the layer shall be formed at 45° to the face and precautions shall
be taken to prevent weak and unsightly edges at construction joints. If necessary,
timber strips may be temporarily fixed in place to give a neat, strong edge. Before
placing the adjoining work the edge shall be cleaned and thoroughly wetted.
The sprayed concrete after completion is not to be touched up, trowel led, smoothed
off or worked in any way, but left undisturbed. Before a succeeding layer is placed the
existing work shall be checked for hollow or non-adhering areas and these shall be cut
out and replaced.
Curing
The sprayed concrete shall be kept moist continuously for 7 days. Spraying with a fine
mist of water is to be anticipated at intervals not exceeding 4 hours unless the area of
application is one of high humidity.
1.9 Metalwork
1.9.1 General
In accordance with the specifications contained in this section and as shown on the
Drawings, the Contractor shall detail, furnish, install, test, paint or galvanize

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miscellaneous metal works, complete with anchors, bolts and fastenings ,including but
not limited to the following:
1. Structural steel for precast concrete covers; structural steel frames, covers and
gratings,
2. Metal ladders, steel stairs, steel stairways, ring ladders, platforms and welded
gratings with frames,
3. Structural steel supporting frames for partition doors, watertight mandoors,
4. Steel safety chains,
5. Steel chain-link fences (or similar) and gates.
The Engineer's drawings will be of general arrangement and details of connections

etc. showing the assembled work and relevant structural requirements.
The Contractor shall at his own cost prepare all necessary supplementary works top
drawings in respect of the various pieces.
If the Contractor produces any drawings beyond workshop drawings, they shall be
submitted for approval of the Engineer before fabrication is commenced. The
Contractor's drawings shall be of standard A1 size.
The Contractor shall bear the costs of any alteration of the work because of any
discrepancies, errors or omissions in any drawings or after particulars supplied by him,
which are not in accordance with the given data, whether or not such drawings or
particulars have been approved by the Engineer.
1.9.2 Materials
All material shall conform to relevant Peruvian standards with respect to structural
steel sections, plates and steel products (bolts, units screws and other for fastenings,
chains, pipes etc.). Structural steel shall be of ST37, or corresponding to higher quality
if so directed by the Engineer.
All material shall be cold straightened at the mills and all plates, bars and sections
shall be flattened and straightened by rolling or pressure and not by hammering, and
made true and free from twist before and after being drilled. No straightening will be
allowed after a built-up member has been assembled.
The Contractor shall make certain that all sections are free from piping, laminations,
blisters, scale, loose rust or other defects.
The Contractor may suggest, for approval, the use of rolled steel sections other than
those indicated on the Drawings, but no liability for delay to progress will arise as a
result of either the time taken by the Engineer to examine the proposals or the
Engineer being unable to accept the proposals.

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1.9.3 Fabrication
1.9.3.1 General
The work shall be carefully and accurately laid out in the shop and all holes shall be
drilled. All butting ends of sections shall be planed or trimmed so as to bring surfaces
in contact metal to metal when the parts are assembled. All columns or struts shall be
milled or sawn at each end to the axis of the column or strut. Stanchions or struts,
whether rolled sections or built up, must be perfectly straight. All girders and beams
must be true and without twist. They shall have such camber as may be specified or
may be required to allow for loading due to subsequent work such as concrete in
composite construction.
All holes shall wherever possible be drilled in position, i.e. through the assembled
parts at one time and to the full diameter required. If this is not possible, the holes
must be drilled and afterwards reamed. After drilling, the edges of the holes on the
outside faces shall be de-burred.
Drifting of holes not in alignment will not be allowed. Drift pins will be permitted only to
bring parts together and shall not be used in such a manner as to distort the material.
No burning in, remedial welding, filling or plugging up of defective members will be
permitted.
All steelwork bolted or welded together must be absolutely in contact over the whole of
the mating surfaces, including the faces of both flat and tapered washers. Except
where high strength friction grip bolts are used, surfaces to be bolted together shall be
painted beforehand.
Parts shall be made interchangeable wherever possible.
1.9.4 Marking
Each individual piece of steelwork shall be clearly marked in compatible paint with the
order number and appropriate erection mark.
1.9.4.1 Inspection and testing

The Engineer shall be advised as soon as the fabrication of steelwork is in hand so
that he may inspect and examine the materials and workmanship during fabrication.
The Engineer or his duly authorized representative shall have access to the place of
fabrication at all reasonable times for the purposes of inspection.
1.9.5 Connections
1.9.5.1 Bolted connections

Groups of nuts and bolts shall be tightened in a staggered pattern and, where there
are more than four in any one joint, they shall be tightened from the center outwards.

97 of 101
The bolts shall be drawn up tight by a hand spanner over the whole group before
applying any power tool. Bolts must not be loosened and then re-tightened.
On completion of bolting, all bolt holes shall contain bolts and no gaps shall exist
between members being fixed. All bolts shall be of the correct length such that the
threaded end of the bolt shall project between 2 mm and 10 mm through the nut when
pulled up tight.
Where fitted bolts are specified the holes shall be reamed to the correct size. No
drifting of holes will be allowed. On rolled sections, each bolt shall have a flat washer
on each side and a beveled washer where necessary.
Where, due to its location or duty, a bolted joint might show a tendency to work loose
due to vibration or other causes, the nuts at such joints shall be locked in position by
an approved locking device.
No permanent bolting shall be carried out until proper alignment has been obtained.
1.9.5.2 Welded connections

The Contractor shall submit for approval full details of his proposed welding
procedures and the provisions of relevant Peruvian Standards shall apply to the
approval thereof. Approval of the welding procedure shall not relieve the Contractor of
his responsibility for correct welding and for the minimizing of distortion in the finished
structure. Fusion faces, angles of bevel, root radius, etc., shall be properly prepared
to give the approved weld forms. The fusion faces shall be carefully aligned and the
correct gap and alignment maintained during the welding operation. All fusion faces
shall be prepared by prepared by machining or, where approved by the use of special
flame cutting apparatus. Prepared faces shall be protected from accidental damage
and kept clean throughout.
All main butt welds shall have complete penetration and shall wherever practicable be
welded from both sides. The back of the first run shall be suitably gouged out.
The electric current used in making welds shall be within the range defined by the
manufacturer of the electrodes and the deposition of the weld metal shall ensure
uniformity, continuity and complete penetration of the weld. The weld surface shall
have an even contour and regular finish indicating proper fusing with the parent metal.
Welds showing cavities, slag inclusions, porosity or other defects shall be cut out and
rewarded. Under-cutting will not be permitted.
All slag shall be removed after making each run, and for this purpose light hammering
followed by wire brushing is to be adopted.
The Contractor shall employ sufficient competent welding supervisors to ensure that
all welding plant and equipment is maintained in efficient working order and that the
welding is carried out in accordance with this Specification.
The Contractor shall when directed carry out radiographic examination or other non-
destructive examination of any welding. The radiographs shall be given to the
98 of 101
Engineer for examination. The decision of the Engineer as to acceptance or rejection

of any weld as a result of the examination of the radiograph or other test result shall be
final.
1.9.6 Erection
1.9.6.1 General
Only approved, competent artisans, carefully supervised by a qualified erector, will be
permitted to carry out erection work on the Site. During erection the work will be
inspected by the Engineer. Particular attention will be paid to the accurate plumbing,
levelling, setting and alignment of the various parts, which must be satisfactory before
permanent connections are made.
1.9.6.2 Procedures
The Contractor shall allow for the provision of all necessary cranes, tackle etc., for the
unloading and erection of the steelwork.
The positioning and levelling of all steelwork and placing of every part of the structure
shall be carried out accurately to the requirements shown on the Drawings and to the
satisfaction of the Engineer.
During erection the work shall be securely bolted or otherwise fastened and, if
necessary, temporarily braced to make adequate provision for all erection stresses
and conditions, including those due to erection equipment and its operation. No
permanent bolting shall be carried out until proper alignment has been obtained.
The use of a gas cutting torch in the field shall be limited to the correction of fabrication
or erection errors. Permission of the Engineer in writing must be obtained before such
use.
Drift pins may only be used to bring together the several parts and they shall not be
used in such a manner as to distort the material.
1.9.6.3 Safety
The Contractor shall comply with all conventional and locally applicable precautions
and regulations in the interests of safety during erection. The Engineer reserves the
right to prohibit any practice or operation by the Contractor which the Engineer
considers to be dangerous in any way. Any instructions given by the Engineer in the
interests of safety shall be complied with before erection is allowed to proceed further.
1.9.6.4 Temporary works

The Contractor shall be solely responsible for the sufficiency, stability and safety of all
temporary works in his care. No temporary works shall be erected without prior
approval by the Engineer and the Contractor shall, when requested, supply drawings,
99 of 101
details and calculations to establish the stability of the temporary works. No approval
of same by the Engineer will relieve the Contractor of any of his contractual
obligations.
1.9.6.5 Tolerances
The following limits are the maximum acceptable variations from perfectly lined
levelled and plumbed steelwork:
Vertical plane: 1 in 1500

Horizontal plane: Beams at connection points shall be within 10 mm of the theoretical
level.
Plan: In plan view all columns, floors beams and connections shall be exactly
square to each other, (i.e. at right angles), unless otherwise shown on the relevant
drawings.
1.9.6.6 Painting
All steel surfaces shall be painted. The quality of paint and the painting process shall
conform to the provisions of section Painting of these Specifications.
Unless otherwise specified, zinc galvanized surfaces and parts embedded in concrete
shall not be painted.
The colour of paint shall be determined by the Engineer.
1.9.6.7 Galvanizing
Steel material, including all minor parts such as washers, bolts screws and nuts shall
be hot-dip galvanized if indicated on the Drawings or otherwise specified.
Hot-dip galvanizing shall conform to the provision of ASTM: A 123, A 153, A 385 and A
386.
All material to be galvanized shall be cleaned carefully of rust, loose scale, dirt oil,
grease and other foreign substances. Particularly, slag shall be removed from welded
areas.
The material(s) shall be galvanized after the conclusion of all machine operations at
the factory. Material which cannot be straightened out without damaging the
galvanizing shall be rejected.
Unless otherwise specified the weight of the zinc coat shall be as follows:
 For screws, nuts, washers, etc. 380 g/m²

 For steel plate (under 5 mm thickness) 469 g/m²
 For steel plate (5 mm and over) 610 g/m²

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When required by the Engineer, test of the weight of zinc coat shall be performed (in
accordance with the test methods specified in ASTM: A90).
Damaged galvanized finishes shall be repaired on site as specified by the

manufacturer and approved by the Engineer.
1.9.7 Types of metal work
1.9.7.1 Steel handrail, parts and safety chain

The Contractor shall supply and install steel pipe handrails parts and safety chains,
where shown on the drawings and shall furnish all pipe, fitting bolts, drive pins, flanges
and other accessories required for the complete installation.
Steel handrail type A shall be 80 mm in diameter and shall be installed outdoor. Steel
handrail type B shall be 50 mm in diameter and shall be installed indoor. If required,
steel handrail shall be made removable. Steel parts and safety chains to be furnished
around hatches shall be removable.
Recess shall be left as holes drilled in the concrete for the anchorage of handrails to
be assembles and grouted in position later on. Unless otherwise specified on the
drawings, they shall not be required to be galvanized.
Steel handrail type C shall be 50 mm dia.
1.9.7.2 Steel ladder

Steel ladder with steel landing columns, handrails, safety cages, anchor bolts, and all
accessories required for the installation shall be supplied completely fabricated in
sections convenient for handling and transportation.
Field assembly shall be by bolting or welding.
Anchors and anchor bolts shall be embedded in the concrete at the proper locations
while the concrete is placed, or recesses shall be left for grouting in place.
Unless otherwise specified in the Drawings, steel ladder shall not be required to be
galvanized.
1.9.7.3 Steel stairway

The Contractor shall supply and install straight flight stairways indicated on the
Drawings, and shall furnish all anchor, anchor bolts and all other accessories required
for the complete installation of the stairway.
Steps of stairways to be furnished shall be made of checkered steel plate.
Unless otherwise specified in the Drawings, steel stairway shall not be required to be
galvanized.

101 of 101
Steel handrails to be furnished along the stairs shall be covered by paragraph

"Handrails" of these Specifications.
Steel Hatch Covers

Steel hatch covers including checkered steel covers, frames and embedded frames
and anchors shall be supplied and installed as shown on the Drawings.
Cover plates shall be made of checkered steel plate with welded reinforcing steel
amples or channels. The cover plate shall be provided with lifting slots, and laid in
position the clearance between the cover plate and the frame shall not exceed 5 mm
at each side.
Steel frames shall be anchored to the concrete with steel bolts or straps spaced at a
maximum of 50 cm.
Steel hatch covers design load shall be the same as for the adjoining structural
elements.
Unless otherwise specified in the Drawings, steel hatch covers shall not be required to
be galvanized.
1.9.7.4 Steel grating

Steel grating of an approved type shall be supplied complete with steel amples frames
and installed as shown on the Drawings.
Steel frames shall be anchored to the concrete with steel bolts or straps spaced at a
maximum of 50 cm.
Both steel gratings and frames shall be galvanized.
1.9.7.5 Frames for precast concrete hatch covers

Steel frames to be embedded in the floor openings and steel frames for the matching
hatch covers, shall be supplied and installed according to the Drawings.
Both frames shall be provided with the necessary anchorage sockets, for removable
posts, devices for crane lifting.
1.9.7.6 Steel fences and gates

Steel fences, including steel gates shall be supplied and installed as shown on the
Drawings (around switchyard and the transformers).
Excavation, reinforced concrete foundations and other incidental work shall be

included in this work.

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Cerro del Águila Hydropower Project - EPC Contract

Q. Civil Works Particular Technical

EXHIBIT A - Technical Specifications. Volume VI

EXHIBIT A - Technical Specifications. Volume VII

EXHIBIT A - Technical Specifications. Volume VII

1.7.13 Quality control testing 74

EXHIBIT A - Technical Specifications. Volume VII

1. Civil Works Particular Technical Specifications

1.1 Surface Excavation

1.1.1 Scope of work

This work shall include but not be limited to

1. the excavation, loading, hauling of unclassified material for incorporation in the

 Location and area of blasting.

EXHIBIT A - Technical Specifications. Volume VI

1.1.3 Lines and grades

EXHIBIT A - Technical Specifications. Volume VI

1.1.3.1 Unwatering and dewatering

1.1.3.2 Open-cut excavation: Overburden

EXHIBIT A - Technical Specifications. Volume VI

1.1.3.3 Open-cut excavation: Rock

1.1.4 Slopes, slides, geological overbreak and unsuitable foundations

EXHIBIT A - Technical Specifications. Volume VI

The work areas shall be properly drained. When underwater excavation is to be

Excavation for structure foundations shall be performed in reasonably dry conditions.

1.1.5.2 Clearing and grubbing

No grubbing will be required in spoil and stockpile areas.

The specifications regarding clearing shall be prepared by Contractor and made

1.1.5.3 Stripping and unclassified (loose) excavation

EXHIBIT A - Technical Specifications. Volume VI

Unclassified (Loose) Excavation means general excavation of material such as

Stripping and Loose Excavation shall be accomplished by proper excavation and

1.1.5.4 Rock excavation by ripping, pre-splitting and blasting

Ripable material is defined as rock which can be loosened or broken down by a

Anchorages shall mean either rock bolts or rock anchors.

Lattice girders shall consist of members of a welded, lightweight space-frame

Rock that is likely to deteriorate significantly on exposure in permanent excavations

EXHIBIT A - Technical Specifications. Volume VI

1.1.5.6 Foundation Preparation and Treatment

Rock surfaces shall be prepared immediately before placement of concrete or

1.1.5.7 Borrow areas and quarries

EXHIBIT A - Technical Specifications. Volume VI

1.2 Underground Excavation

1.2.1.1 Scope of work

1. Excavation by drilling and blasting: Excavation of tunnels and caverns applying

excavated cross section, located as required anywhere within the proposed

1.2.1.3 Analytical design

1.2.1.4 Rock mass designation

will be mapped by experienced geologists. Systematic tunnel monitoring

1.2.1.5 Classification of underground excavation

Subsequent or supplementary installation of support in the rear zone will have no

EXHIBIT A - Technical Specifications. Volume VI

1.2.1.8 Excavation general planning

1.2.1.9 Daily reports

1) Length excavated and theoretical volume of solid material excavated according to

EXHIBIT A - Technical Specifications. Volume VI

1.2.1.10 Definitions and related requirements

1.2.2 Excavation lines, tolerances and minimum technical requirements

Systematic over-break in the inverted, related to unexpected and unforeseen geological