SPECIFICATION FOR CIVIL

ENGINEERING WORKS

Series 4050: Tunnelling – In-situ

Concreting and Formwork
Document Number: HS2-HS2-CV-SPE-000-014050

This document contains proprietary information. No part of this document may be reproduced without prior written consent from the Chief
Executive Officer, HS2 Ltd.
SECURITY CLASSIFICATION: OFFICIAL
Contents
1 Introduction 1
1.1 General 1
2 Performance requirements 1
2.1 In-situ concrete 1
3 Submittals 1
3.1 General 1
3.2 Contractor’s specifications 2
3.3 Method statements 3
4 Concrete requirements 4
4.1 General 4
4.2 Pre-construction trials 6
5 Conformity and identity testing 6
5.1 General 6
5.2 Identity testing 7
6 Concrete production 7
6.1 Production control 7
6.2 Consistence at delivery 7
7 Concrete construction general 8
7.1 Transporting, placing and compacting 8
7.2 Concreting in inclement weather 9
7.3 Concreting in cold weather 9
7.4 Concreting in hot weather 10
7.5 Concrete temperature 10
7.6 Curing 10
7.7 Records of concreting 11
8 Formwork 12
8.1 Construction of formwork 12
8.2 Tunnel formwork 13
8.3 Cleaning and treatment of forms 14
8.4 Striking of formwork 14
8.5 Sloping formwork 15
8.6 Tie bolts for formwork 15
9 Reinforcement 15
9.1 Cutting and bending of reinforcement 15
9.2 Fixing of reinforcement 16
9.3 Surface condition of reinforcement 17
 9.4 Laps and joints 17
9.5 Welding of reinforcement 18
9.6 Fibre reinforced concrete 18
9.7 Built-in items 18
10 Joints 19
10.1 Construction joints 19
10.2 Movement joints 20
11 Concrete surface finish 20
11.1 Trial panels of concrete 20
11.2 Surface finishes produced without formwork 21
11.3 Surface finishes produced with formwork 21
11.4 Wearing screeds 21
12 Inspection and testing of concrete elements 21
12.1 General 21
12.2 Remedial action 22
12.3 Concrete repairs 23
13 Geometrical tolerances 23
13.1 General 23

List of Tables
Table 1: Examples of pre-construction concrete testing 4
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1 Introduction
1.1 General
1.1.1 This section of the Works Information defines the Employer’s minimum performance
requirements for in-situ concreting and formwork, for tunnels, underground works and cut
and cover tunnels and buildings associated with tunnels but excludes sprayed concrete.

1.1.2 For all other applications of in-situ concrete refer to Employer’s Specification Series 1700.

2 Performance requirements
2.1 In-situ concrete
2.1.1 In-situ concrete works are in accordance with the performance requirements for the works
which includes:

a. structural performance;

b. durability;

c. water tightness; and

d. aesthetics.

2.1.2 The works reflect the Employer’s environmental and health, safety and welfare ambitions for
the Project.

3 Submittals
3.1 General
3.1.1 At least 16 weeks prior to the commencement of concrete construction, the Contractor
provides the following to the Project Manager:

a. an organisation chart and documentation to demonstrate that all Working Area staff,
including the quality management and laboratory staff have the required competence;

b. comprehensive specifications, Method Statements and Inspection and Testing Plans (ITPs)
for checking and assuring the quality of the works consistent with the recommendations of
the Contractor’s Durability Assessment Report (see Technical Standard Hs2-Hs2-CV-STD-
000-000003);

c. Evidence that the proposed material sources comply with the specified requirements and
are able to consistently produce the quantities and quality of Plant and Materials required
by the Project; and

d. Concrete mix details (sources of materials, test data for the individual constituents, mix
design and laboratory and Working Area trial data) demonstrating acceptable performance
and compatibility of the proposed material combinations. Sufficient information is
provided for proprietary mixes to demonstrate sustainability and durability.
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3.2 Contractor’s specifications

3.2.1 The Contractor’s detailed specifications includes detailed proposals relating to all aspects of
concrete production including, transportation, placement, compaction, finishing and curing.
This includes specific reference to particular fresh and hardened concrete requirements for the
proposed construction methods. In each case, the Contractor considers and provides
information on specific issues and/ or programme, timing and other constraints related to
each proposed method of construction. The information provided:

a. includes a performance specification for the concrete

b. is sufficiently detailed to allow for detailed review of all aspects;

c. identifies the specific tests that are carried out to demonstrate each design mix is
suitable for the proposed placement method;

d. includes details on how each concrete property is controlled during production within
the proposed programme and timing constraints; and

3.2.2 includes detailed cross reference to the Contractor’s detailed specifications, including the
Numbered Appendices, e.g. Appendix 17/1, containing contract specific information and
requirements in accordance with the Employer’s Specification Series 1700.

3.2.3 Durability considerations are incorporated into the Contractor’s detailed specifications in
accordance with Technical Standard – Materials and Durability (HS2-HS2-CV-STD-000-
000003). The summary requirements include:

a. maximum permitted water/ cement ratio (w/c);

b. minimum permitted total cement content;

c. cement combination and replacement level;

d. permitted aggregate type(s);

e. minimum cover to reinforcement and reinforcement fixing tolerances;

f. durability testing requirements and limits (e.g. chloride diffusion chloride diffusion
and water permeability); and

g. any additional protective measures (e.g. sacrificial cover and coatings).

3.2.4 The Contractor’s detailed specifications include a series of detailed ITPs for concrete and
associated works.

3.2.5 The Contractor’s ITP clearly sets out the Quality Assurance (QA) and Quality Controls (QC) to
be applied to the concrete works, and acknowledge the particular requirements and
constraints of each construction method.

3.2.6 No concrete production commences until the proposals have been accepted by the Project
Manager.

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3.3 Method Statements

3.3.1 Method Statements prepared for the following construction activities:

a. preconstruction trials;

b. curing and protection;

c. cold weather concreting;

d. hot weather concreting;

e. early-age thermal cracking;

f. batching and mixing;

g. transport, handling and compaction;

h. large and/ or complex pours;

i. joints;

j. reinforcement storage, fixing and coupling;

k. sequencing of the works;

l. formwork/ falsework construction and striking;

m. post-tensioned construction;

n. inspection and testing;

o. repairs; and

p. emergency responses.

3.3.2 Method statements contain full details of the methods of working for the matters detailed in
this specification, including the following:

a. intended Plant and Equipment, including stand-by provision;

b. hold-points for inspection and testing;

c. response to non-conformities and emergencies;

d. references to Health and Safety Plan, Environmental Plan and Quality Assurance
procedures; and

e. Compliance with the Works Information including (Sustainability and Environmental

Minimum Requirements) WI 600 (Quality management) and WI 1100 (Health and
safety).

3.3.3 The Contractor provides a table showing the following parameters for each element of the
works:

a. construction/ transport/ placement method;

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b. maximum time from mixing to placement (hours);

c. maximum time from mixing to compaction and initial finishing (hours); and

d. maximum delay during placement (hours).

3.3.4 The Contractor undertakes trials to confirm the timings compatible with the concrete
properties, methods and Equipment including any time required for special finishes and
provides this to the Project Manager.

4 Concrete requirements
4.1 General
4.1.1 The Contractor undertakes the necessary initial testing and pre-construction trials to confirm
that the concrete is appropriate and meets the Contractor’s Design, detailed specifications,
construction methods, performance and durability requirements.

4.1.2 All concrete mixes are tested to determine compliance under statistical evaluation as required
by BS EN 206.

4.1.3 Examples of pre-construction testing are given below. The scope of testing should be
developed by the Contractor to encompass the intended methods and expected conditions.
Table 1: Examples of pre-construction concrete testing

Required concrete Example of Comment Required tests

properties possible
construction/
placement
method
High flow, Flowability and Bored piles, internal Placed into Slump-flow T500 time
potentially flow rate shaft liner stabilising fluid
L-box test
slightly extended (bentonite) or water
placement times
Viscosity and Underwater
Workability loss over
filling ability concrete Not possible to
the placement period
provide mechanical
compaction
Passing ability
High flow and Diaphragm walls Additional visual ASTM C1712 Rapid
moderately inspection needed Assessment of Static
extended at the top 3m after Segregation
Segregation
placement times hardening and Resistance
resistance
excavation
Bleed to ASTM C232
High flow and Internal tunnel liner Some mechanical
very extended Reduced bleed compaction may be
placement times possible via Washout and
vibrators mounted segregation to BS EN
Reduced washout externally on forms 8443 annex A and C
respectively
Low strength Early age strength Secant piles 1,3,7 and 14 day
soft/ female piles development compressive strength

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at time of boring development to BS

for hard/ male EN 12390-3
piles
Fibre reinforced Placing, Secondary liner Fibre dispersal, Consistence (and
concrete compaction, placed by pump content and residual retention)
finishing and flexural strength to compressive and
strength BS EN 14845-2 flexural strength
Architectural Placing, Edge beam, wing Finish may vary Consistence (and
concrete compaction and walls under different retention) bleed
finishing ambient conditions compressive strength
Colour
AACM Concrete Placing, Mass concrete PAS 8820, Sections Consistence (and
compaction and 5 and 6 provides retention) and
handling guidance compressive strength
characteristics

4.1.4 For concrete placed underwater and/or into ground support fluid, as a minimum, the pre-
construction tests, mix design, methods and the Equipment and ITPs follow the requirements
of BS EN 206.

4.1.5 Testing replicates the range of expected placement conditions, and be designed and executed
to provide confidence that the proposed construction method(s) and associated timings are
achievable, and that the appropriate in-situ concrete properties are achieved. The following
variables are considered and appropriate sensitivity analyses included in the pre-construction
testing accordingly.

a. temperature;

b. reinforcement density;

c. minimum dimensions;

d. mixing regime;

e. transport method and duration;

f. placement method and duration;

g. finishing and curing methods; and

h. batching tolerances on water content.

4.1.6 The tests and trials are repeated if any of the following conditions arise:

a. change in process, Plant and Materials (source, nature, content exceeding ± 5%),
timings, placement conditions;

b. placement problems; and

c. Defects.

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4.1.7 During production, testing and pre-construction trials are carried out in adequate time before
any planned changes are made in the sources of materials or in the proportions of the
materials to be used.

4.1.8 A representative number of samples of appropriate type for each period of testing are taken
for testing to check the modulus of elasticity and the coefficient of thermal expansion, if
needed by the design.

4.2 Pre-construction trials

4.2.1 The Contractor demonstrates by pre-construction trials that the proposed mixes are
compatible with the proposed construction methods and Equipment and specified
performance. The pre-construction trials involve full-scale production batches and testing of
each structural concrete mix on three separate days from the primary and standby plants.
Where necessary to achieve and demonstrate compliance, additional testing and limits are
adopted as part of the ITPs and provided to the Project Manager.

4.2.2 The pre-construction trials are considered together with the planning and design of the
various construction methods for the various elements. Each series of tests are designed to
replicate the particular placement method and the expected worst case delays + 30 minutes.
The outcome of the testing feeds into the Contractor’s construction program, detailed
specifications and ITP requirements.

4.2.3 Pre-construction trials may be combined with production of trial panels in accordance with
section 11.1.

5 Conformity and identity testing

5.1 General
5.1.1 Conformity of fresh and hardened concrete is as specified in BS EN 206. All sampling, curing
and testing of fresh or hardened concrete is carried out in accordance with BS EN 12350, BS
EN 12390 and BS 1881 (where current).

5.1.2 The Contractor or Supervisor may, before placement, reject any concrete which does not
conform with the approved mix design or is unsatisfactory in any respect or, in the case of
concrete mixed off-site, for which a delivery docket containing the full information as
specified is not immediately available. The Contractor may propose testing at earlier ages to
give a prediction of the 28 day strengths. Early age testing does not relieve the Contractor of
his obligation to carry out testing in accordance with this specification.

5.1.3 Other tests for compliance may be proposed by the Contractor where the properties are
needed by the Contractor’s detailed design.

5.1.4 A regime of accelerated curing and early testing of samples which is capable of predicting the
28 day strength may be used, subject to adequate calibration as demonstrated by correlation
of predicted values with cube tests, and accepted by the Supervisor.

5.1.5 The Contractor provides the Supervisor with details of the party responsible for undertaking
each inspection and test in the ITP. These details include names of specialist laboratories and
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relevant UKAS certification and staff CVs for the tests undertaken by the Working Area
laboratory.

5.2 Identity testing

5.2.1 The Contractor undertakes identity testing in accordance with contract specific Appendix 1/5
and/ or Appendix 1/6 in the Series NG 100 of the Employer’s specification.

5.2.2 A fully staffed and equipped Working Area laboratory is provided and maintained for those
tests which are not carried out by specialist laboratories. Unless otherwise accepted by the
Project Manager, the Working Area laboratory is UKAS accredited for the specific test
methods carried out as part of the works.

5.2.3 The consistence of every load is determined immediately before any concrete from that load
is used in the works. If the test indicates that the workability lies outside the permitted range
the load is remixed (after an addition of water or admixture as appropriate) and the tests
repeated. If the result of the retest is still unsatisfactory then that load is not used in the works.

5.2.4 For Classes of concrete where air entrainment is specified, the target total air content is within
the limits specified in BS 8500-1, BS 8500-2 and BS EN 206-1. The total air content is checked
at regular intervals at the point of placement as described in BS EN12350-7. On each occasion
that air content is checked, a set of test cubes for compressive strength is made.

6 Concrete production
6.1 Production control
6.1.1 The Contractor measures the free moisture content of representative samples of all aggregate
size fractions prior to batching, at regular intervals and not less than once per day. The
moisture content and water absorption of the aggregate is allowed for in the quantity of water
to be added to the concrete.

6.1.2 All trial and production concrete is mixed in a forced action pan mixer or truck mixer unless
concrete uniformity for the proposed alternative batching and mixing method and Plant has
been established in accordance with ASTM C94. The quantity of concrete lies within the
recommended range for the pan or mixer truck.

6.1.3 The mixing blades are maintained within the tolerances specified by the manufacturer of the
mixer and the blades are replaced when it is no longer possible to maintain the tolerances by
adjustment.

6.1.4 No remixing of partially hardened concrete is allowed.

6.1.5 The Contractor supplies appropriate Equipment for automated accurate dosage and even
dispersal of fibres into the mix. The process includes means of monitoring and avoiding fibre
clumps.

6.2 Consistence at delivery

6.2.1 No water or admixture is added to any concrete unless at the production facility or under the
responsibility of the concrete producer. Water or admixture is only added through calibrated
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measuring Equipment. The amount of water or admixture added is recorded on the delivery
ticket. The maximum total designed free water/ cement ratio or admixture dosage is not
exceeded.

7 Concrete construction general

7.1 Transporting, placing and compacting
7.1.1 Transportation, placement and compaction of concrete is in accordance with clause 1710(3) of
the Employer’s specification.

7.1.2 Placing is not commenced until the fixing and condition of reinforcement and items to be
embedded and the condition of the containing surfaces including formwork and existing
concrete have been accepted by the Supervisor.

7.1.3 Blinding concrete, formwork or other agreed separating layer is used to prevent any
reinforced concrete, except piling and diaphragm wall concrete, from being placed directly
against the ground.

7.1.4 The prepared surfaces of the existing concrete to receive fresh concrete are, subject to the
acceptance of the Supervisor, pre-wetted with potable water for up to four hours prior to
placing the new concrete. The extent of wetting depends on the age and moisture condition
of the surface of the existing concrete and its accessibility. All areas in which concrete is to be
placed are kept clean and free from standing water immediately before and during the placing
of the concrete and loose concrete and other materials removed

7.1.5 The Contractor’s method of transporting concrete prevent contamination, segregation or loss
of ingredients, and are placed and finished within the proposed Contractor programme and
timings.

7.1.6 Concrete is placed directly in its final position without displacement of the reinforcement,
embedded items and formwork.

7.1.7 For pumping and pneumatic transport of concrete the details, layout and method of operation
of the Equipment which is to be used is included in the Method Statement. Concrete is not
pumped or discharged through aluminium or alloy conduits.

7.1.8 The size and sequence of pours is arranged in such a manner as to minimise internal and
external restraint and associated thermal and shrinkage cracking. Detailed measures to
mitigate the risk of early-age cracking are set out by the Contractor in his Method Statements.

7.1.9 The Contractor casts concrete bays sequentially and avoids infill panels, unless the Contractor’s
design takes account of the impact of construction in bays. The Contractor provides sufficient
labour and Equipment including standby Equipment available on the Worksite to ensure the
placing in each unit or section of work is continuous between construction joints. All measures
are taken to avoid the formation of cold joints in the concrete. If the Contractor’s maximum
timings are exceeded, then the Contractor erects vertical stop ends and form a construction
joint or remove the concrete already placed and restart after the cause(s) of the original failure
have been remedied and accepted by the Supervisor. Competent steel fixers and shuttering
joiners are in attendance during the whole of the concreting operations to ensure that the
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falsework, formwork and reinforcement remain in the required position during placing and
compaction and finishing of the concrete.

7.1.10 Unless self-compacting concrete is accepted by the Supervisor, concrete is placed as close as
possible to its final position and in continuous, near level layers between construction joints.
The depth of the layers does not exceed 500mm and each layer is compacted by appropriate
means before succeeding layers are placed. The layers are placed evenly to maintain balanced
pressure on the formwork.

7.1.11 Concrete is placed in a manner that minimises the risk of entrapping air or leaving voids,
particularly in the invert and crown of in-situ tunnel linings.

7.1.12 No fresh concrete is allowed to free fall more than 2m into the placement.

7.1.13 Vibration is not applied by way of the reinforcement. Where vibrators of the immersion type
are used, contact with reinforcement and all inserts are avoided as far as is practicable.
Internal vibrators operate at not less than 10,000 cycles per minute and external vibrators at
not less than 3,000 cycles per minute. External vibrators are only used when set out in the
Method Statements.

7.1.14 Vibration is not applied directly or indirectly to concrete after the initial set has taken place,
nor is it used to make concrete flow in formwork.

7.2 Concreting in inclement weather

7.2.1 Unprotected concrete placing does not take place in the open during storms, heavy rain or
snow. If such weather conditions are likely to have an adverse effect on concreting, the
Contractor provides protection for the Plant and Materials, and to Equipment so that the works
may proceed. If strong winds are prevalent, adequate protection from driving rain and dust is
to be provided..

7.3 Concreting in cold weather

7.3.1 Precautions are taken when concreting in cold weather in accordance with clause 1710(6) of
the Employer’s specification.

7.3.2 Heated constituents, insulating blankets or heated enclosures may be used to achieve
compliance.

7.3.3 Heated enclosures are adequately ventilated and hot air jets not be allowed to play directly
onto any concrete or formwork surfaces.

7.3.4 The Contractor takes precautions to minimise thermal stresses due to cold air temperatures in
cold weather.

7.3.5 Any concrete which has been damaged by frost is removed from the works.

7.3.6 Concrete samples for testing are stored in accordance with the appropriate standards and are
protected from the effect of cold weather.

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7.4 Concreting in hot weather

7.4.1 Precautions are taken during hot weather in accordance with clause 1710(7) of the Employer’s
specification.

7.4.2 The Contractor takes precautions to limit the temperature of the fresh concrete in accordance
with the guidance in ACI 305.

7.4.3 The temperature of mixing water for concrete should not be less than 5°C nor more than 60°C.
Water may be cooled by the gradual addition of chilled water or flaked ice where this is the
case no ice particles are present when the water is added to the mix. The ice to be used is the
product of water which complies with the above acceptance criteria.

7.4.4 The Contractor submits proposed measures to prevent plastic shrinkage cracking of newly
formed exposed concrete surfaces, such as shading and application of aliphatic alcohols, to
the Supervisor at least 16 weeks prior to construction in accordance with the Schedule of
Contractor’s Deliverables. The measures take account of the ambient conditions and the mix
design, including the inclusion of silica fume, polymer microfibers or other additions.

7.5 Concrete temperature

7.5.1 Precautions to control concrete temperature and the risk of delayed ettringite formation and
early-age cracking in sections greater than 500mm minimum thickness are taken in
accordance with clause 1710 (3) of the Employer’s specification.

7.5.2 The temperature of the concrete at the point of delivery to the works does not exceed 30°C
when measured in accordance with BS 8500-2, unless additional measures such as adoption of
cementitious types containing at least 40% GGBS or 20% fly ash are adopted. The Contractor
uses a lower maximum temperature where this is necessary to minimize the risk of early age
thermal cracking.

7.5.3 Precautions are taken to protect the concrete against early age thermal cracking in
accordance with CIRIA Report C660. At least 16 weeks prior to construction, a detailed
Method Statement to mitigate the risk of early age thermal cracking is submitted by the
Contractor to the Supervisor for acceptance in accordance with the Schedule of Contractor’s
Deliverables.

7.5.4 The peak concrete temperature during curing does not exceed 70°C unless the Contractor’s
Durability Assessment Report indicates otherwise. .

7.6 Curing
7.6.1 The Contractor is responsible for curing concrete to achieve the design life taking account of
his durability assessment requirements and Technical Standard – Materials and Durability
(HS2-HS2-CV-STD-000-000003).

7.6.2 The minimum curing requirements is in accordance with clause 1710(5) of the Employer’s
specification and the Curing Class to BS EN 13670.

7.6.3 In cold weather, when the concrete temperature is below 5°C during the initial curing period,
the temperature of the water used for wet curing is maintained above 5°C.
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7.6.4 During the entire curing period effective measures are taken to prevent the loss of moisture
and to minimise thermal stresses caused by the difference in temperature between the
surface of the concrete and the core of the concrete mass, and to promote sustained
hydration of the concrete.

7.6.5 Curing methods are in accordance with the guidance in Appendix F of BS EN 13670.

7.6.6 Curing compounds are 90% efficient. Applications of a curing compound are within one hour
of removal of temporary curing. Application is at least the minimum coverage per square
metre of concrete surface as recommended by the manufacturer. Unless otherwise accepted
by the Supervisor, curing compounds are not used on surfaces to which concrete is
subsequently to be bonded, such as surfaces of construction joints, or where any bonded
protection or finish is to be applied.

7.6.7 Where the Contractor proposes alternative curing and protection methods, such as internal
curing agents, the Contractor undertakes Working Area trials to demonstrate the effectiveness
of the curing methodology in providing the concrete properties required by the Contractor’s
Design.

7.6.8 Where the Contractor proposes a curing enclosure it is designed to withstand the working
conditions and maintained in an operational condition. Any damaged temporary seals or
other aspects that prevent it working are repaired prior to the next pour.

7.7 Records of concreting

7.7.1 Records held on the Working Area available for inspection include, but not be limited to, the
following:

a. co-ordinated records of docket numbers, sample references and fresh and hardened
concrete test data;

b. autographic records of batch masses, showing aggregate free moisture content and
added water (at plant and Working Area);

c. concrete placing temperature;

d. ambient temperature and relative humidity;

e. concrete temperature (if monitored) during curing;

f. timing and nature of measures applied to mitigate the risk of early-age cracking;

g. location of batch within the works;

h. non-conformities and remedial actions; and

i. checks undertaken on the section of the works.

7.7.2 Records held at the batching plant available for inspection include, but not be limited to, the
following:

a. calibration records for batching Equipment (including aggregate moisture

measurement);

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b. ambient temperature; and

c. moisture and water absorption of each aggregate size fraction.

8 Formwork
8.1 Construction of formwork
8.1.1 All edges have a minimum 25mm chamfer or 30mm radius. The cover depth is not less than
the specified minimum cover at the chamfer or radius.

8.1.2 Formwork panels have true edges for accurate alignment and are fixed with either vertical or
horizontal joints. Where chamfers are required the fillets are formed to provide an even line.
Joints do not permit leakage of grout, nor steps and ridges in exposed finished surfaces. Due
allowance is made for deflection of formwork during concrete placement in relation to
prevention of loss of grout and the finished tolerances.

8.1.3 Wrought formwork comprise steel panels, GRP, plywood or other suitable materials to
produce the required finish as represented by the accepted trial panels.

8.1.4 Rough formwork consists of sawn boards, sheet metal or any other suitable material which
prevent loss of grout when the concrete is vibrated and produce an acceptable concrete.

8.1.5 The Contractor takes every precaution in the selection and use of forms and in removing the
forms and curing the concrete to prevent rapid temperature variations in the concrete, in
accordance with this specification.

8.1.6 Falsework is designed in accordance with the recommendations of BS 5975.

8.1.7 For above ground exposed concrete, the finished appearance of the entire elevation of the
structure and adjacent structures is considered when planning the pattern of joint lines caused
by formwork and by construction joints to ensure continuity of horizontal and vertical lines. All
horizontal and vertical formwork joints are so arranged that the joint lines form a consistent
uniform pattern on the face of the concrete.

8.1.8 Faces of formwork in contact with concrete are free from adhering foreign matter, projecting
nails and the like, splits and other Defects. All formwork are clean and free from standing
water, dirt, shavings, chippings and other foreign matter. Formwork joints are sufficiently
watertight to prevent the escape of grout or the formation of blow holes or other blemishes
on the face of the concrete.

8.1.9 Openings are provided in formwork, as necessary, for preparing the formwork and
compaction of concrete. These are securely closed in sequence in accordance with the
Contractor’s Method Statement as the work proceeds.

8.1.10 Where holes are needed in forms to accommodate projecting reinforcement or fixing devices,
or any other embedded items, the Contractor ensures there is no loss of grout when
concreting or damage when removing the formwork.

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8.1.11 Formers for all chases, grooves, recesses, chamfers etc. are securely fixed as part of the
formwork. No part of the concrete work is cut away for any such item or for any other reason
unless detailed in the Method Statements.

8.1.12 Formwork is designed in accordance with HS2 Temporary Works Technical Standard (HS2-
HS2-CV-STD-000-000005), Temporary Works Procedure (HS2-HS2-CV-PRO-000-000005) and
Technical Standard – Spatial Arrangements (HS2- HS2-CV-STD-000-000001).

8.1.13 Permanent formwork or special formwork complies with contract specific Appendix 17/4 in the
Series NG 1700 of the Employer’s specification, completed by the Contractor and accepted by
the Supervisor.

8.2 Tunnel formwork

8.2.1 The tunnel formwork shall be sized to accommodate the spatial requirements detailed in the
Employer’s Technical Standard – Spatial Arrangements (HS2-HS2-CV-STD-000-000001).

8.2.2 Formwork for the intrados of bored tunnels and for the cut and cover tunnels with the same
profile as the bored tunnels is new at the commencement of the work, and of steel
construction with substantial framing sections and with a skin plate sized to provide a rigid,
true to shape curved surface free from dimpling or quilting. The length of formwork does not
exceed 15m and is selected to suit the method of construction, the placing of concrete,
traversing tunnel curves and preventing cracking that could cause the tunnel to breach the
water resistance requirements detailed in Technical Standard (HS2-HS2-TN-STD-000-
000001). The surface finish is as specified in section 11.

8.2.3 Tunnel lining curved in the longitudinal direction on plan or in elevation may be formed as a
series of straight chords provided the minimum thickness and the required internal
dimensions of the lining are maintained. The chord length suits the radius of curvature of the
tunnel and be such that the formwork does not deviate by more than 36mm from the
theoretical required surface. The design of the formwork is such that the intrados of the lining
at the ends of chords forms a continuous smooth surface, free from steps and fins.

8.2.4 The Contractor confirms the formwork dimensional tolerances for inclusion in the ITPs for
acceptance by the Supervisor such that the completed works meet the requirements of this
specification and the Contractor’s Design.

8.2.5 The Contractor’s method of placing concrete avoids trapping air or water pockets in the tunnel
lining by the provision of sufficient ports in the tunnel formwork to ensure an even distribution
of concrete around the tunnel former. The method of placing and/or mix design is varied
where the Contractor’s inspection and testing identifies voidage in trial pours or during
production.

8.2.6 Tunnel forms and forms for deep pours are provided with openings for cleaning, inspection
and for placing concrete, spaced at not more than 2.5m centres longitudinally and
circumferentially. Openings in the crown are staggered alternatively on each side of the tunnel
centreline. All openings are fitted with grout tight hinged doors which fit flush with the
intrados face of the finished lining when closed. The openings are not smaller than 0.5m x
0.5m and allow placement and compaction of the concrete and inspection within the form
using suitable lighting.
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8.2.7 Holes are provided in the formwork so that embedded grout and vent pipes may be inserted in
a regular fixed pattern. The formwork around the holes are adequately reinforced and
provided with suitable threaded bosses to accept couplers for locating and fixing the grout or
vent pipes. When not in use the holes are closed with grout tight plugs fitting flush with the
finished surface of the concrete.

8.2.8 The design of formwork and travelling tunnel shutters provide safe working areas, access and
walkways needed for the operation and maintenance of the formwork.

8.3 Cleaning and treatment of forms

8.3.1 Formwork is cleaned and prepared in accordance with clause 1710(2) of the Employer’s
specification. All foreign matter, including tie wire and standing water, is removed from the
forms prior to placing the concrete.

8.3.2 The Supervisor will give four hours’ notice of any inspections for acceptance.

8.3.3 The Contractor ensures that the selection and application of release agent is appropriate to
achieve the surface finish required for each concrete element and/ or form of construction,
without affecting the bond of concrete to reinforcement or the surface finish adversely. The
formwork release agents are compatible with any waterproofing or coating systems that
may be required to be applied to the finished concrete surfaces. Working Area trials are
carried out to demonstrate that adhesion of primers to the concrete surface is not reduced
and that the performance of the coating systems are not impaired.

8.3.4 Formwork which is to be used repeatedly is maintained in good condition as to accuracy of

shape, strength, rigidity, water/grout tightness and smoothness of surface. The formwork is
thoroughly cleaned and any repairs required are carried out after each use. All faces of the
formwork which come in contact with the concrete are coated with a suitable release agent to
facilitate stripping immediately prior to concreting. Damaged or distorted formwork, which is
unsatisfactory in any respect is not used and, if the Defects cannot be rectified, are removed
from the Working Area.

8.4 Striking of formwork

8.4.1 Prior to construction, the Contractor proposes the criteria for formwork striking for each
element and form of construction and a minimum notice period for the Supervisor’s
acceptance of his intention to strike formwork. The minimum formwork striking period is in
accordance with clause 1710(4) of the Employer’s specification or the Contractor’s Design.

8.4.2 Where the timing for removal of formwork is based on in-situ concrete strength this is
determined for each specific element, in accordance with CIRIA Report 136, using one or more
of the following:

a. maturity calculated from temperature measurements using an appropriate maturity

(temperature and time) calculation function. Relationships between in-situ strength
and maturity are generated for the specific concrete mix using at least six data points
over the range of values expected to be encountered during the works. Estimates of
in-situ strength incorporate appropriate factors of safety in accordance with CIRIA
Report 136;
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b. non-destructive or partially destructive testing, e.g. pull-out tests. Rebound hammer

measurements are not to be used as a means of assessing strength prior to formwork
stripping; and

c. samples stored alongside the formwork or subject to temperature matched curing in

accordance with BS 1881-130.

8.4.3 Formwork, falsework and centring are not removed, or loads applied to concrete until the
Contractor has demonstrated that the concrete has gained sufficient strength to withstand the
stresses induced.

8.4.4 Forms are removed with care, without hammering and wedging, and in a manner which do
not damage the concrete or disturb the remaining supports. Centres are lowered gradually
and uniformly in such a manner as to avoid unnecessary stress to any parts of the structure.

8.4.5 Formwork is not removed where it could lead to excessive thermal or shrinkage stresses and
an associated risk of cracking.

8.5 Sloping formwork

8.5.1 Formwork is provided for the top surfaces of sloping work where the slope exceeds 1:2½ and
is anchored to enable the concrete to be properly compacted and to prevent flotation, care
being taken to prevent air being trapped.

8.5.2 The use of sloping formwork includes measures to prevent entrapment of air and water at the
form surface.

8.6 Tie bolts for formwork

8.6.1 Tie bolts do not embed any permanent metal parts within 50mm of the concrete surface for
bar or steel fibre reinforced concrete, or within 150mm of the concrete surface for
unreinforced concrete.

8.6.2 Metal ties or anchors within the formwork are so constructed or sleeved so as to permit either
their complete removal or their removal to a depth of at least the minimum specified cover
from the face without damage to the concrete. All fittings for removable metal ties are of such
design that, upon removal, the cavities left are of the smallest possible size.

8.6.3 Ties for use in structures designed to retain an aqueous liquid incorporate a diaphragm not
less than 75mm diameter and not less than 4mm thick welded to the mid-point of the tie to
prevent water passing along the tie.

8.6.4 The cavities due to either partial or complete removal of ties are roughened to provide an
exposed aggregate finish and filled using suitable materials and methods.

9 Reinforcement
9.1 Cutting and bending of reinforcement
9.1.1 Cutting and bending of reinforcement are in accordance with clause 1713 of the Employer’s
specification.

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9.1.2 The Contractor to arrange for independent laboratory testing of reinforcement bars of each
diameter in use and three different shape codes when requested by the Supervisor and for test
certificates indicating the following:

a. chemical composition;

b. tensile strength;

c. elongation; and

d. bend test values.

9.2 Fixing of reinforcement

9.2.1 Fixing of reinforcement is in accordance with clause 1714 of the Employer’s specification.

9.2.2 Nominal concrete cover to reinforcement is defined as the minimum cover plus fixing
tolerance Δc of at least:

a. for pre-cast concrete elements produced under factory conditions = 5mm;

b. for precast concrete elements not produced under factory conditions = 10mm;

c. for in-situ concrete cast against formwork = 15mm; and

d. for concrete cast directly against the ground = 50mm.

9.2.3 The Contractor proposes higher fixing tolerances for acceptance by the Supervisor, where the
construction method may lead to increased risks of achieving low cover in-situ, e.g.
diaphragm walls.

9.2.4 The achievement of these fixing tolerances is confirmed by cover meter measurement on trial
panels and all exposed faces of the completed works in accordance with clause 1714 of the
Employer’s specification and the Contractor’s ITPs. Additional independent verification of
cover is undertaken across at least 20% of the works.

9.2.5 Minimum concrete cover to reinforcement is not less than the minimum cover required by the
structural design and durability design (as defined by the Contractor’s Durability Assessment
Report).

9.2.6 Reinforcement is firmly fixed and held in position during the placing of concrete by use of
tying wire and distance pieces, spacers or other methods in accordance with BS 7973.

9.2.7 For Consequence Class 3 structures, no corrodible metal part of any device used for
connecting bars or for maintaining reinforcement in the correct position remains
permanently within the specified minimum concrete cover to the reinforcement.

9.2.8 Concrete spacers are used of similar concrete grade to the parent concrete. The spacers
comply with the specified requirements for water absorption. All spacers are properly fixed in
their required position.

9.2.9 The capacity of spacers to hold the reinforcement securely in position during preparation and
concreting without detriment to concrete placement, compaction, durability or any surface

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finish required by the contract are fully demonstrated for acceptance by the Designer before
their use in the works.

9.2.10 Links are taut so that bars are braced and the inside of their curved parts are in contact with
the bars being connected.

9.2.11 Measures are taken to provide electrical continuity to the reinforcement in locations the
Contractor’s design identifies that they are affected by stray currents or requiring future
cathodic protection. Testing of electrical continuity is undertaken in accordance with the ITPs
using high impedance meters prior to the commencement of pours and visual checks are
conducted to identify and secure any loose reinforcement.

9.3 Surface condition of reinforcement

9.3.1 Steel reinforcement condition is in accordance with clause 1715 of the Employer’s
specification.

9.3.2 Steel reinforcing bars and fabric reinforcement are kept clean and are free from pitting, loose
rust, mill scale, oil, grease, earth, paint, chlorides or any other material which may impair the
bond between the concrete and the reinforcement.

9.3.3 Any reinforcement exposed to contamination, including by chlorides, release agent,

groundwater or surface water, is thoroughly washed with clean, fresh water prior to fixing and
if necessary before concreting.

9.3.4 Where reinforcement becomes corroded or contaminated to the point where the bond may be
affected, the Contractor either replaces the reinforcement or cleans the bars surface by grit
blasting or other means accepted by the Supervisor.

9.3.5 Projecting reinforcement is protected, to prevent undue corrosion and to prevent staining of
finished surfaces by runoff water from corroded bars.

9.3.6 Reinforcement is not dropped from a height greater than 0.5m at any time and is not stacked
in positions where water running off causes staining to any of the works.

9.4 Laps and joints

9.4.1 Laps and joints are in accordance with clause 1716 of the Employer’s specification.

9.4.2 Unless otherwise specified the minimum lap lengths and effective anchorage lengths for bars
under stress are full tension lap lengths in accordance with BS EN 1992-1-1.

9.4.3 Overlaps in fabric reinforcement are a minimum of two rectangles in one or two directions.

9.4.4 Laps in adjacent bars are staggered where practicable.

9.4.5 Lap lengths for bars in sections formed under support fluid take account of potentially
reduced bond conditions.

9.4.6 The use of mechanical couplers are in accordance with the manufacturer’s recommendations
and evidence is available to demonstrate that adequate coupling of bars can be carried out in

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the field conditions to obtain full bar strength at coupling. The specified minimum cover to
reinforcement are maintained at all locations.

9.4.7 Couplers in adjacent bars are staggered by at least 1.5 times the coupler length.

9.5 Welding of reinforcement

9.5.1 Welding of reinforcement is in accordance with clause 1717 of the Employer’s Specification.

9.5.2 Reinforcement is not welded at the Worksite and welded reinforcement is not incorporated
into the works without the written agreement of the Supervisor and his acceptance of the
Contractor’s Method Statement outlining the proposed welding procedures and personnel
proposed for executing the works.

9.6 Fibre reinforced concrete

9.6.1 Fibre reinforced concrete is subject to testing to establish the properties of the concrete in
accordance with the Contractor’s Design and the ITPs. This includes testing consistence, fibre
dispersal and residual flexural strength characteristics to BS EN 14845-2.

9.6.2 The sample moulds are filled by direct discharge from the truck and compacted such that the
orientation and distribution of the fibres is representative of the concrete being sampled. All
fibre reinforced concrete test specimens are compacted by vibrating table and not by
rodding/tamping or internal poker vibrators.

9.6.3 The Contractor carries out checks on fibre content and distribution as detailed below. The
frequency of these checks is in accordance with the Contractor’s ITP.

9.6.4 The concrete is tested by collecting the fibres from randomly selected 10 litre samples of fresh
concrete. The mix is washed to clean all the cement from the fibres until all cement has been
washed out. The flow-out of any other material than cement and fines of that size are
prevented by using appropriate sieves.

9.6.5 Polymer fibres have a lower density than that of water and therefore float on the surface of
the wash from which they can be collected. They are air dried and their volume is compared to
that specified for the mix. The volume is not less than 80% of the design volume. Other
methods to test the homogeneity of the polymer fibre concrete may be used subject to
acceptance by the Supervisor.

9.6.6 Steel fibre content is assessed in accordance with BS EN 14488-7, Method B. The fibres are
collected, oven dried and weighed. The fibre content is deemed acceptable if no individual
sample has a fibre content less than 80% of the Contractor’s Design fibre content.

9.7 Built-in items

9.7.1 The Contractor submits proposals for the design and installation of instrumentation and
monitoring Equipment. The monitoring system is described in the Contractor’s Durability
Assessment Report and be designed to ensure there is no path for water, air or aggressive
agents into or through the concrete.

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10 Joints
10.1 Construction joints
10.1.1 Construction joints are in accordance with clause 1710(1) of the Employer’s specification.

10.1.2 The Contractor proposes the positions, including tolerances, and details of all construction
joints on drawings and in contact specific Appendix 17/4 of the Employer’s specification for
acceptance by the Supervisor at least 28 days prior to construction in accordance with the
Schedule of Contractor’s Deliverables.

10.1.3 The Contractor ensures before casting, that the joints are properly prepared with
waterproofing details in accordance with the Contractor’s Design. Any water stops or similar
details are in position and adequately fixed so as to avoid displacement during concreting.

10.1.4 Concrete placing is not interrupted except where joints are installed. Planning and sequencing
of pours is designed to allow adequate time to complete the works within the permitted
working hours.

10.1.5 Construction joints are located to avoid aggressive exposure conditions and to minimise
shrinkage and thermal strains to the concrete.

10.1.6 Upon removal of the formwork the joint face is inspected, and if the soundness of the concrete
is not in accordance with the specification the Contractor to investigate and remedy Defects.

10.1.7 Projecting portions of water stops are adequately protected from damage to the satisfaction
of the Supervisor.

10.1.8 The removal of laitance is achieved by the use of air/ water jets while the concrete is still green
where required by the Contractor’s design. Surface retarding agents are not used. The use of
abrasive blasting or mechanically operated percussive tools after the concrete has hardened
should be avoided wherever possible. Where percussive methods are used to prepare the joint
surfaces for subsequent concrete, the Contractor ensures that all loose and/or fractured
material including aggregate is removed.

10.1.9 Where new concrete is to be jointed to existing concrete by grouted or chemically anchored
reinforcing bars, holes are drilled to the required depth, blown clean, prepared and filled with
an accepted material in accordance with the manufacturer’s recommendations. Bars are
immediately inserted and left undisturbed until the grout or chemical anchor has achieved
adequate strength.

10.1.10 Where required by the Contractor’s Design, water stops are included in the joints in trial
panels.

10.1.11 The water stop is fully continuous when laid. Working Area joints are made by electrical fusion
in accordance with manufacture’s recommendations.

10.1.12 Transverse joints are arranged to stagger by at least 300mm where they intersect longitudinal
joints.

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10.1.13 In-situ concreting up to precast units are not permitted until a sufficient number of units are
built up ahead of the in-situ work to prevent the transmission of excessive movement or
stresses in the completed works.

10.2 Movement joints

10.2.1 The Contractor’s design specifies the positions and details of movement joints in accordance
with the guidance in CIRIA Report 146 and to meet the Employer’s requirements..

10.2.2 Movement joints are positioned at locations accepted by the Designer. The Contractor
submits details of movement joints to the Supervisor for acceptance prior to incorporating in
the works.

10.2.3 Proprietary movement joint materials are stored, handled, and installed in accordance with
the manufacturer’s recommendations.

10.2.4 Where movement joints are incorporated into the works, dowel bars, where required, are
made from plain, round steel bars with accurately sawn ends to maintain a circular cross-
section, located and aligned as required by the Contractor’s Design. Bond between concrete
and dowel bars is broken on one side of the joint by the use of proprietary sleeving or other
suitable means.

10.2.5 Contraction joints are formed or induced at locations required by the Contractor’s Design.

10.2.6 Where crack inducers are used, grooves in the secondary lining left by the removal of crack
inducers are filled with an appropriate accepted non-flammable compressible material.

10.2.7 The joint filler is installed in accordance with the manufacturer’s recommendations.

10.2.8 Joint fillers are cut to the exact dimensions of the joint to be filled and have edges neatly and
accurately trimmed. The joint filler is secured so as to provide a firm base for the joint sealer
and to avoid leakage of grout or sealant. Where the depth of joint between the concrete
surface and the water stop does not exceed 500mm the filler is placed in single depth sections.
If more than one strip is used within a joint the ends are butted tightly and taped together to
prevent grout leakage.

11 Concrete surface finish

11.1 Trial panels of concrete
11.1.1 Trial panels for the main concrete elements and architectural finishes are in accordance with
clause 1708 of the Employer’s specification.

11.1.2 The Contractor produces trial panels of finished concrete for acceptance by the Supervisor at
least 35 days in advance of the works and submits details in accordance with WI 300
(Contractor’s Design). These are formed using the proposed construction methods and include
the intended finish and typical details, such as joints.

11.1.3 The trial panels are subject to cover meter and visual and other checks in accordance with the
ITPs and are part of the basis for assessing the acceptability of the works concrete.

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11.2 Surface finishes produced without formwork

11.2.1 Unformed concrete surface finishes are in accordance with clause 1708 of the Employer’s
specification and the Contractor’s Design and, consistent with the durability and other
performance requirements.

11.2.2 For areas where pedestrian and other traffic may require access, the Contractor propose
methods and materials in order to provide adequate skid and/or slip resistance under the in
service conditions. The skid/slip resistance are subject to testing in accordance with the ITPs.

11.2.3 Slip resistant surfaces are finished to U3 in accordance with clause 1708(4) of the Employer’s
specification. Slip resistant granules are trowelled into the surface of the concrete in
accordance with the manufacturer’s recommendations. Alternatively, the slip resistance are
achieved by floating and trowelling in accordance with BS8204-2. The slip resistance for a wet
test in accordance with BS 7976-2 is ≥ PTV 40.

11.2.4 Following construction and finishing, all surfaces are adequately protected from construction
traffic and all other potential sources of damage. Surfaces exposed in the works are also
protected from disfigurement.

11.3 Surface finishes produced with formwork

11.3.1 Formed concrete surfaces surface finishes are in accordance with the clause 1708 of the
Employer’s specification and Contractor’s Design and consistent with the durability and other
performance requirements and the accepted trial panel(s).

11.3.2 Following construction and finishing, all surfaces are adequately protected from construction
traffic and all other potential sources of damage. Surfaces exposed in the works are also
protected from disfigurement.

11.4 Wearing screeds

11.4.1 Wearing screeds are in accordance with clause 2607 of the Employer’s specification.

11.4.2 The Contractor demonstrates a successful track record for laying wearing screeds using the
staff proposed for the works.

12 Inspection and testing of concrete

elements
12.1 General
12.1.1 Inspection and testing of structures and components are in accordance with clause 1727 of the
Employer’s specification.

12.1.2 Fire testing to be undertaken in accordance with Series 4055 Employer’s works specification –
fire testing for tunnel linings and underground structures.

12.1.3 Hardened concrete surfaces are subject to inspection, dimensional checks and testing in
accordance with the accepted ITPs. The findings of the inspection are documented and any

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Defects potentially requiring remedial work reported to the Supervisor within 24 hours. No
treatment of any kind is applied to the concrete unless accepted by the Supervisor.

12.1.4 The Contractor arranges for full inspection of both sides of the top of the first six panels of
each type of diaphragm wall panel to a depth of at least 3m. Adequate time is provided by the
Contractor to allow the inspection to be witnessed by the Supervisor. The inspection includes,
but not be limited to, the following:

a. global walkover visual inspection;

b. cover meter survey; and

c. any notable features are recorded, photographed, and marked on the structure.
Where Defects are recorded, the Contractor submits proposals for repair and/or
replacement and future avoidance, for acceptance by the Supervisor.

12.1.5 The Contractor should include regular inspection to diaphragm walls as excavation proceeds,
to ensure the entire excavated area is inspected for Defects.

12.2 Remedial action

12.2.1 Remedial action is undertaken by the Contractor in the event of a failure to comply with the
specified requirements, including, but is not limited to the following aspects:

a. characteristic strength;

b. dimensional tolerances;

c. surface appearance; and

d. curing and cracking.

12.2.2 The Contractor’s Durability Assessment Report and Method Statements include proposed
remedial actions in the event of non-compliance. The remedial actions are in accordance with
the Contractor’s Design and consistent with the required durability and other performance
requirements for the works.

12.2.3 The proposed remedial actions are subject to acceptance by the Supervisor before being
undertaken.

12.2.4 The potential remedial actions include, but not limited to:

a. changing the mix and Improving quality control to prevent repeated non-compliance;

b. non-destructive testing and cutting and testing cores;

c. load testing;

d. repairing the concrete;

e. removal and recasting of the concrete; and

f. application of cathodic protection.

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12.3 Concrete repairs

12.3.1 All repairs to new and existing structures and elements are designed and executed in
accordance with BS EN 1504.

12.3.2 The Contractor submits detailed proposals to the Supervisor for acceptance to cover all
proposed repair methods and materials. The Contractor’s Durability Assessment Report
indicates how the required design life is achieved in the repaired area.

12.3.3 Trial repairs are undertaken to demonstrate the suitability of the proposed methods and
materials to achieve the appearance, strength, durability and other performance
requirements.

12.3.4 The principal repair methods include:

a. resin injection of cracks;

b. patch repair using polymer modified proprietary repair mortars; and

c. application of protective coatings as an additional measure.

12.3.5 All repairs are in accordance with the manufacturer’s instructions and, documented and
photographed. A record of the repairs undertaken is included in the Durability Verification
Report in accordance with (HS2-HS2-CV-STD-000-000003) Technical Standard – Materials
and Durability.

12.3.6 If the amount of Defects requiring repair is unacceptably high compared to the trial panels, the
Contractor reviews his casting procedures and submit proposals to reduce the extent of such
damage.

13 Geometrical tolerances
13.1 General
13.1.1 The geometrical tolerances are in accordance with clause 1728 of the Employer’s Specification
unless stated otherwise in the Works Information or, proposed by the Contractor and accepted
by the Project Manager.

13.1.2 The Contractor ensures that the fixing of reinforcement includes sufficient tolerances that the
minimum cover are consistently achieved in the completed works.

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