Spec for Concrete Supply

ENGINEERING SPECIFICATIONS Project No.: Master

ADCO DOC. NO. 30-99-75-3205

CONCRETE SUPPLY REV. A DATE :14 April 2013

PAGE 2 OF 33

Table of Content

1 GENERAL ................................................................................................................................................... 3

2 CODES AND STANDARDS .......................................................................................................................... 4

3 REFERENCE DOCUMENTS ...................................................................................................................... 10

4 DOCUMENT PRECEDENCE ...................................................................................................................... 10

5 SPECIFICATION DEVIATION/CONCESSION CONTROL ........................................................................... 10

6 QUALITY ASSURANCE/QUALITY CONTROL ............................................................................................ 11

7 DOCUMENTATION .................................................................................................................................. 12

8 SUBCONTRACTORS/VENDORS ............................................................................................................... 12

9 HANDLING ............................................................................................................................................... 13

10 CONCRETE TESTING ............................................................................................................................ 13

11 CONCRETE CONSTRUCTION ............................................................................................................... 14

12 MATERIALS .......................................................................................................................................... 14

13 CONCRETE MIX DESIGN ....................................................................................................................... 19

14 CONCRETE ACCEPTANCE - DURABILITY, STRENGTH AND CHEMICAL LIMITS .................................. 23

15 MATERIAL STORAGE AND HANDLING ............................................................................................... 26

16 ON-SITE BATCH PLANT ....................................................................................................................... 28

17 CONCRETE TRUCKS ............................................................................................................................. 31

18 CLEANUP ............................................................................................................................................. 32


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1 GENERAL

The CONTRACTOR shall provide the services required for the concrete supply,

concrete mix design and the furnishing of the on-site batch plant.

1.1. DISTRIBUTION, INTENDED USE AND REGULARETY CONSIDERATIONS

This document is intended for use in all ADCO areas, including production facilities, accommodation, BAB 13, industrial and tank farm area.

1.2. DEFINITIONS

Where used in this specification, the following terms shall have the meanings indicated

below unless otherwise clearly indicated by context of their use.

COMPANY ABU DHABI COMPANY FOR ONSHORE OIL OPERATIONS

(ADCO)

CONTRACTOR The party, which carries out all or part of the design

engineering, procurement, construction and commissioning or

management of the project.

SUBCONTRACTOR An organisation providing specific services to the

CONTRACTOR.

MANUFACTURER The service organisation, which actually manufactures the

material/product in question.

PROJECT

MANAGEMENT

TEAM (COMPANY)

The COMPANY authorised party responsible for the overall

day-to-day execution of the Project. PMT (Project

Management Team) is to serve as a Liaison between

COMPANY and the CONTRACTOR(S) on the Project.

SHALL Indicates a mandatory requirement

SUPPLIER The organisation, which supplies the material/product to the

CONTRACTOR/SUBCONTRACTOR.


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CONCESSION

REQUEST

A deviation requested by the CONTRACTOR or VENDOR,

usually after receiving the contract package or purchase

order. Often, it refers to an authorisation to use, repair,

recondition, reclaim, or release materials, components or

equipment already in progress or completely manufactured

but which does not meet or comply with ADNOC

requirements. A CONCESSION REQUEST is subject to

COMPANY approval.

DESIGNER The Engineering Division of the CONTRACTOR or

the Consultant, which performs the design of the

element in question.

2 CODES AND STANDARDS

The following Codes, Standards and Specifications apply to this Specification. When an

edition date is not indicated for a Code or Standard, the latest edition and addendums in force at time of purchase shall apply. Material and equipment shall be as specified or an

equal approved by the COMPANY. Where there are conflicts between the

requirements of different Codes and Standards the most stringent criteria shall apply.

Alternate standards and codes meeting the requirements of the referenced standards

and codes may be used with approval of the COMPANY.

BRITISH STANDARDS INSTITUTION (BSI)

BS 12 Ordinary Portland Cement

BS 146 Specification for blastfurnace cements with strength properties

outside the scope of BS EN 197-1

BS 812 Testing of Aggregate

BS 882 Aggregates from Natural Sources for Concrete

BS 1377 Tests for Soils

BS 1881 Testing Concrete (including non-destructive tests methods)


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BS 3148 Tests for Water for Making Concrete

BS 3797 Lightweight Aggregates for Masonry Units and Structural

Concrete.

BS 4246 High Slag Blast Furnace Cement

BS 5075 Concrete Admixtures

BS 5328 Concrete

BS 6699 Specification for Ground Granulated Blast Furnace Slag for use

with Portland Cement

BS 8007 Design of Concrete Structures for Retaining Aqueous Liquids

BS 8110 Structural use of Concrete

BS 812-105.2 Testing aggregates. Methods for determination of particle shape.

Elongation index of coarse aggregate

BS 812-111 Testing aggregates. Methods for determination of ten per cent

fines value (TFV)

BS 1881-122 Testing concrete. Method for determination of water absorption

BS 1881-124 Testing concrete. Methods for analysis of hardened concrete

BS 1881-201 Testing concrete. Guide to the use of non-destructive methods of

test for hardened concrete

BS 8500-1 Concrete. Complementary British Standard to BS EN 206-1.

Method of specifying and guidance for the specifier

BS 8500-2 Concrete. Complementary British Standard to BS EN 206-1.

Specification for constituent materials and concrete


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BS EN 197-1 Cement. Composition, specifications and conformity criteria for

common cements

BS EN 206-1 Concrete. Specification, performance, production and conformity

BS EN 480-4 Admixtures for concrete, mortar and grout. Test methods.

Determination of bleeding of concrete

BS EN 932-1 Tests for general properties of aggregates. Methods for sampling

BS EN 932-3 Tests for general properties of aggregates. Procedure and

terminology for simplified petrographic description

BS EN 933-1 Tests for geometrical properties of aggregates. Determination of

particle size distribution. Sieving method

BS EN 933-3 Tests for geometrical properties of aggregates. Determination of

particle shape. Flakiness index

BS EN 934-2 Admixtures for concrete, mortar and grout. Concrete

admixtures. Definitions, requirements, conformity, marking and

labelling

BS EN 934-6 Admixtures for concrete, mortar and grout. Sampling, conformity

control and evaluation of conformity

BS EN 1008 Mixing water for concrete. Specification for sampling, testing

and assessing the suitability of water, including water recovered from

processes in the concrete industry, as mixing water for concrete

BS EN 1097-3 Tests for mechanical and physical properties of aggregates.

Determination of loose bulk density and voids

BS EN 1097-6 Tests for mechanical and physical properties of aggregates.

Determination of particle density and water absorption

BS EN 1367-2 Tests for thermal and weathering properties of aggregates.

Magnesium sulfate test

BS EN 1367-4 Tests for thermal and weathering properties of aggregates.

Determination of drying shrinkage

BS EN 1744-1 Tests for chemical properties of aggregates. Chemical analysis

BS EN 12350-1 Testing fresh concrete. Sampling

BS EN 12350-2 Testing fresh concrete. Slump test

BS EN 12390-1 Testing hardened concrete. Shape, dimensions and other

requirements for test specimens and moulds

BS EN 12390-2 Testing hardened concrete. Making and curing specimens for

strength tests


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BS EN 12390-3 Testing hardened concrete. Compressive strength of test

specimens

BS EN 12390-7 Testing hardened concrete. Density of hardened concrete

BS EN 12390-8 Testing hardened concrete. Depth of penetration of water under

pressure

BS EN 12504-1 Testing concrete in structures. Cored specimens. Taking,

examining and testing in compression

BS EN 12620 Aggregate for concrete

BS EN 12878 Pigments for the colouring of building materials based on

cement and/or lime. Specifications and methods of test

BS EN 13055-1 Lightweight aggregates. Lightweight aggregates for concrete,

mortar and grout

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM C31 Practice for making and curing concrete tests specimens in the field

ASTM C33 Specification for Concrete Aggregates

ASTM C88 Test Method for Soundness of Aggregates by use of Sodium

Sulphate or Magnesium Sulphate

ASTM C94C94M Specification for Ready Mixed Concrete

ASTM C127 Test Method for Specific Gravity and Absorption of Coarse

Aggregate

ASTM C131 Test Method for Resistance to Degradation of Small Size

Coarse Aggregates by Abrasion and Impact in the Los Angeles

machine

ASTM C150 Specification for Portland cement

ASTM C142 Test Method for Clay Lumps and friable Particles in Aggregates


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ASTM C143 Test Method for Slump of Hydraulic Cement Concrete

ASTM C227 Test Method for Potential Alkali Reactivity of Cement -

Aggregates Combinations (Mortar Bar Method)

ASTM C232 Test Methods for Bleeding Concrete

ASTM C260 Specification for Air-Entraining Admixtures for Concrete

ASTM C289 Test Method for Potential Alkali-silca Reactivity of Aggregates

(Chemical Method)

ASTM C494 Specification for Chemical Admixtures for Concrete

ASTM C535 Test Method for Resistance to Degradation of Large-Size

Coarse Aggregate by Abrasion and Impact in the Los Angeles

Machine

ASTM 979 Specification for Pigments for Integrally Colored Concrete

ASTM C1078 Test method for determining cement content for freshly mixed

concrete

ASTM C1079 Test method for determining water content for freshly mixed

concrete

ASTM C1017 Specification for Chemical Admixtures for Use in Producing

Flowing Concrete

ASTM C1116 Specification for Fiber-Reinforced Concrete and Shotcrete

ASTM C1202 Test method for electrical indication of concretes ability to

resist chloride ion penetration

ASTM C1260 Test Method for Potential Alkali Reactivity of Aggregates

(Mortar-Bar Method)

ADDITIONAL STANDARDS


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DIN 1048 Water Impermeability/Testing of Fresh Concrete

RILEM CPC 11.3 Water Absorption by Immersion

AASHTO T26 Quality of Water to be used in Concrete

AASHTO T277 Papid Determination of the Chloride Permeability of Concrete

ACI 318/318RM Building Code Requirements for Structural Concrete

ACI 212-3R-91 Chemical Admixtures for Concrete

ACI 211.1-91 Standard Practice for Selecting Proportions for Normal, Heavy

Weight and Mass Concrete

ACI 226-IR-87 Ground Granulated Blast - Furnace Slag as a Cementitious

Constituent in Concrete

NRMCA

CPMB100M-00

Concrete Plant Standards (Concrete Plant Manufacturers

Bureau)

GERMAN NATIONAL STANDARD FOR BATHCHING PLANT.

INTERNATIONAL STANDARDS ORGANISATION

ISO 9001:2000 Quality Management Systems - Requirements


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3 REFERENCE DOCUMENTS

DESIGN GENERAL SPECIFICATIONS:

30-99-75-0066 Specification for Concrete Construction

30-99-75-3212 Specification for On-Site Testing Laboratory

30-99-75-3228 Specification for Grouting

4 DOCUMENT PRECEDENCE

It shall be the CONTRACTORS responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this

specification, the related data sheets, the Codes and Standards and any other specifications

noted herein. Resolution and/or interpretation precedence shall be obtained from the

COMPANY in writing before proceeding with the design/manufacture.

In case of conflict, the order of precedence shall be:

Purchase Order or Contract Design Drawings

Design General Specifications and Standards

Industry Codes and Standards

5 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Purchase Order and its attachments including, but not limited to, the

Design General Specifications shall be sought by the CONTRACTOR only through

CONCESSION REQUEST format. CONCESSION REQUESTS require COMPANYs review/approval, prior to the proposed technical changes being implemented. Technical

changes implemented prior to COMPANY approval are subject to rejection.


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6 QUALITY ASSURANCE/QUALITY CONTROL

Quality Management Systems shall comply with the applicable requirements of ISO

9001:2000 Quality Management Systems- Requirements.

The CONTRACTOR shall ensure that the MANUFACTURER/VENDOR shall have in effect at all

times, a QA programme, which clearly establishes the authority and responsibilities of those

responsible for the quality system. Persons performing quality functions shall have sufficient and

well-defined authority to enforce quality requirements that they initiate or identify and to

recommend and provide solutions for quality problems and thereafter verify the effectiveness of

the corrective action.

Quality System and Quality Control requirements shall be identified and included in the

CONTRACTORs Purchase documentation. Based on these requirements, the MANUFACTURER/VENDOR will develop a QA/QC programme, which shall be submitted

to the CONTRACTOR for review and concurrence. The

MANUFACTURER/VENDORs QA/QC programme shall extend to SUBVENDORs.

The QA/QC programe shall cover all aspects related to production/execution requirements, such

as performance of tests, trial mixes, avialability of certificates/ data sheets, sources of cement/

aggregates/water/sand, workmanship, batch plant(s), storage, transport, handling etc. Trial

concrete mixes shall be proven to perform under local conditions and with the equipement to be

used during execution.

The contractor shall prepare an Inspection & Test Plan (ITP) identifying the tests, frequencies,

rejection criteria and responsibilities. A reporting system of quality records shall be part of the

QA/QC programe. The reporting system shall record all the results obtained during testing,

transporting, production, supplying, placing/ pouring, finishing, curing, striking etc.

After completion, rebound and/or ultrasonic measuerments should be taken to control and verify

the concrete quality against compliance tests and required concrete quality, If there is any doubt

about the above records. The results should be recorded. Any deviation shall be reported,

including the measurements to be taken.

COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship standards

at all stages of manufacture and to witness any or all tests. The MANUFACTURER/VENDOR, 30

days after award but prior to the pre-inspection meeting, shall provide the CONTRACTOR

with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory

COMPANY/CONTRACTOR witness or hold points.


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7 DOCUMENTATION

7.1 MATERIAL SOURCES

7.1.1 All material sources shall be approved by COMPANY. All materials must be selected from the

approved sources.

7.1.2 The CONTRACTOR shall submit full details of each proposed material a minimum of two weeks

prior to establishing the mix designs to allow detailed COMPANY review.

Submittals shall include the following:

MANUFACTURERS details.

Fully detailed data sheets showing all chemical and physical information.

Recent test results (not more than 3 months old).

Detailed technical assessment, which confirms that all materials meet the

requirements of this Specification.

Details of MANUFACTURERS Quality Assurance System.

Details of MANUFACTURERS Quality Control Procedures.

The CONTRACTOR shall submit an Compliance Certificate before beginning construction. The certificate shall confirm that all material meets the requirements of this Specification.

8 SUBCONTRACTORS/VENDORS

The CONTRACTOR shall assume unit responsibility and overall guarantee for the

concrete supply.

It is the CONTRACTORS responsibility to enforce all Purchase Order and Design General Specification requirements on its SUBCONTRACTORS/VENDORS.

The CONTRACTOR shall submit all relevant SUBCONTRACTORS/VENDORS


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Engineering data to the COMPANY.

The CONTRACTOR s h a l l obtain and transmit a l l SUBCONTRACTORS/VENDORS

Warranties to the COMPANY.

9 HANDLING

(NOT APPLICABLE)

10 CONCRETE TESTING

10.1 On-site testing, unless noted otherwise, will be in accordance with the Design General

10.2 Specification For On-Site Testing Laboratory, 30-99-75-3212.

10.3 All testing work in conjunction with establishing the project mix designs shall be the

responsibility of the CONTRACTOR.

10.4 The CONTRACTOR shal l provide all samples for verification of sources of materials

after commencement of concrete work for the permanent plant to the On-Site Testing

Laboratory and shall co-operate fully with the On-Site Testing Laboratory for the testing

requirements on-site.

10.5 The CONTRACTOR shall be responsible for testing of all materials prior to

commencement of concrete work for the permanent plant.

COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship standards

at all stages of manufacture and to witness any or all tests. The MANUFACTURER/VENDOR, 30

d a ys a f t e r a w a r d b u t p r i o r t o t h e p r e -inspection

meeting, shall provide the CONTRACTOR with a copy of its Manufacturing and

Inspection Plan for review and inclusion of any mandatory COMPANY/CONTRACTOR

Witness or hold points.


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11 CONCRETE CONSTRUCTION

Concrete construction will be in accordance with the Design General Specification For

Concrete Construction, 30-99-75-0066.

12 MATERIALS

12.1 CEMENT:

Rapid hardening Cement shall not be sued. Cement shall be one of the following:

Blast furnace cement Type BIIIB-42.5L to BS 146 or Combination Type CIIIB-42.5L to

Tables 1 and A.1 of BS 8500-2 with 70% ggbs to BS 6699 and 30% BS EN 197-1-CEM I-

42.5 cement. For this type of cement, ggbs with alumina content greater than 14% should be

used only with Portland cement having a tricalcium aluminate (C3A) content not exceeding

10%. (For general applications)

Blast furnace cement Type BIIIA-42.5L to BS 146 or Combination Type CIIIA-42.5L to

Tables 1 and A.1 of BS 8500-2 with 55% ggbs to BS 6699 and 45% BS EN 197-1-CEM I-42.5

cement.(For foundation/ structures in contact with soil or exposed to weather)

Moderately sulfate resisting cement (MSRC) in accordance with ASTM C150 typeII. (for

foundation/ structures in contact with soil or exposed to weather)

12.1.1 The source of High Slag blast furnace cement shall be subject to approval of COMPANY.

Once a source is approved alternative slag shall not be used without further approval of the

COMPANY.

12.1.2 Slag cement shall be supplied from a source that has a well-established proven record for

consistent supply of quality material (minimum of two years production). References will be required

to be submitted.

12.1.3 Cement shall be of recent manufacture and shall be used within a period of 3 months from

production. Blast Furnace Slag age from granulation to blending shall not be more than six (6)

months.

12.1.4 The amount of cement replacement shall be finalized in accordance with the manufactures

recommendations and based on the trial mixes to achieve the specified durability and strength

requirements.

12.1.5 A manufactures test certificate, indicating the particular batch number and fabrication date etc, shall

be submitted by the supplier before or during the delivery of the cement. The manufactures test


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certificates should confirm that cement delivered to the site has been tested and found to comply

with the requirement of appropriate standard and this document. If subsequent tests on any

consignment of cement show it does not comply with standard requirements, then the whole

consignment shall be removed immediately from the site notwithstanding the manufactures

certificate results.

12.1.6 Access to the cement store shall be provided during working hours for the purpose of sampling the

cement for further testing. Tests on the GGBS shall be carried out for each shipment to confirm

compliance with BS6699.

12.1.7 Pre-cast elements: The CONTRACTOR will DETERMINE (if necessary) the replacement

percentage of blast furnace slag taking into account the types of elements to be precasted.

12.1.8 Blending or batch mixing at blending plant other than cement factory mill shall not be acceptable.

12.1.9 Before or after delivery the COMPANY shall have the right to check any cement and/or associated

documentation. COMPANY may reject the cement if it does not comply with this specification.

12.1.10 The COMPANY reserves the right to take samples and order any additional tests. The

12.1.11 CONTRACTOR shall remove all rejected cement from the site immediately.

12.2 AGGREGATES

12.2.1 All aggregates shall comply in every respect with BS EN 12620 (aggregates for concrete

in general) and comply with the further restrictions indicated in this section. They shall be

well graded, clean, hard, and free from undesirable material and obtained from an approved

source.

12.2.2 Coarse and fine aggregates shall be limestone crushed rock to BS EN 12620 or ASTM

C33 from Ras Al-Khaimah (R.A.K) or equivalent (not accepted for Al Ain dune sand).


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12.2.3 Aggregates shall consist of fine aggregates (those passing a 4mm sieve), and coarse

aggregates (those retained on a 4 mm sieve) batched separately which, when combined

together, shall meet the requirements of BS EN 12620 on aggregate grading.

12.2.4 All aggregates shall be obtained from the same source (approved at the

commencement of the works), throughout the contract. Aggregates shall be obtained from the

source and tested to ensure only aggregates conforming to this specification arrive at the batch

plant.

12.2.5 During excavation at a particular source of aggregate care shall be taken to ensure the

excavation does not get too close to the high water mark where there may be a high

concentration of salts due to the evaporation of water.

12.2.6 At all times, the aggregates shall be free from impurities and if not, the aggregates shall be

washed mechanically with water to remove clay, silt and fine dust.

12.2.7 All fine and coarse aggregates shall be within the limits laid down in Table 1:


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TABLE 1 - LIMITS and STANDARDS FOR NORMAL WEIGHT AGGREGATES

Property Method of Test & Standards Maximum Limit (% by weight)

Clay, Silt and

Dust Wet Sieving through 63 m sieve

(BS EN 933-1) Coarse Aggregates

Crushed rock Fine

Aggregates Natural

dune sand Crushed

rock

3%

3%

5% Clay Lumps and

friable particles ASTM C 142, ASTM C 33 Coarse Aggregates

Fine Aggregates 1%

1% Organic

Impurities BS EN 1744-1 Clause 15 Stiffening time difference <

30min.

Compressive strength

difference < 10%

Chlorides as Cl Analysis following acid* extraction

(BS EN 1744-1 Clause 7)

Coarse Aggregates

Fine Aggregates 0.03%

*

0.06%

* Sulphates as

SO3 Analysis following acid extraction

(BS EN 1744-1 Clause 12) Coarse Aggregates

Fine Aggregates 0.4%

0.4% Alkali Reactivity ASTM C 289 (Chemical

method) Innocuous

ASTM C 1260 (Mortar bar

method) Less than 0.10%

Equivalent

Alkalis BS 1881, part 124, Method 10.4 a) Less than 0.5 % by

weight of total

aggregate

If this limit is exceeded then the

Alkali in the cement shall be limited

such that the total alkalis in the

concrete is less than 3

kg/m3

Cement -

Aggregate

Combination

ASTM C 227 (Mortar bar

method)

Note: If the result of ASTM C 289 is

potentially deleterious or the ASTM

C 1260 is > 0.10 %, then this test is

to be carried out.

6 month expansion 0.1%

maximum

Grading BS EN 933-1 (Sieve analysis) Surface texture Descriptive (BS EN 932-3) Limit not applicable

Particle density (SSD)

BS EN 1097-6 Mid range of 2.5 and 2.8

Water

absorption BS EN 1097-6 Coarse

Fine 2%

2% Soundness Sulphate resistance (BS EN

1367-2) Loss after 5 cycles in sulphate solution with MgSO4

15% Drying BS EN 1367-4 Shrinkage < 0.05% of dry


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Strict control shall be exercised to ensure that the maximum chloride content

indicated i s not exceeded a t any time. Any violations s h a l l be cause enough

for rejection at any stage of the construction

12.2.8 When aggregates have been approved, the entire supply of each type shall be secured

from the approved sources. Testing shall be carried out frequency specified below to

ensure the same quality and grading of the material is being maintained.

12.2.9 tests shall be carried out as per the following frequency:

- tests for clay, silt and dust, moisture content and sieve analysis shall be carried out on every 20 tons of fine aggregates and 40 tons of coarse aggregates delivered to the site.

- chemical analysis shall be carried out on every 100 tons delivered to the site.

shrinkage

length Flakiness index

Elongation

index

BS EN 933-3

BS 812 Part 105.2 Maximum

Maximum 25%

25%

Mechanical

Properties 10% Fines value (BS 812-111)

Los Angeles abrasion test (ASTM

C-131 and C-535)

For wearing surfaces >100kN

Elsewhere >75kN

For wearing surfaces

Elsewhere

30%

35%


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12.3 WATER

12.3.1 All water, including but not limited to, mixing, ice production, cooling aggregates, washing

aggregates and concrete curing shall be obtained from an approved source and shall be clean

and free of acids, oils, vegetable, and deleterious matter which may have an effect on the

strength and appearance of the hardened concrete by discoloration or efflorescence.

12.3.2 The water shall comply in all respects with the requirements of BSEN 1008. Testing shall be

done at source (trucked) or at site (piped to holding tank), for chlorides and sulphates.

12.3.3 The pH value of water shall be within the range of 6.5-9 and the maximum

concentration of inorganic contamination shall be as follows:

PPM %

Dissolved solids including those listed below 2000 0.20

Sulphates 500 0.05

Alkali carbonates or bicarbonates 500 0.05

Chlorides 200 0.02

Suspended solids 2000 0.20

12.3.4 Suitable means shall be provided to ensure that the temperature of the concrete when deposited

does not exceed 30 degrees C. Mixing water shall be refrigerated, or have flake ice added.


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12.4 ADMIXTURES AND ADDITIVES

12.4.1 General

12.4.1.1 Admixtures and additives shall be used only with the prior approval of the COMPANY.

Test certificates shall be provided by manufacturer for every batch or shipment. Strict control

shall be maintained to ensure that the correct quantity of admixture/ additions is used at all

times. The equipment to be used for dispensing and method of incorporating the admixture in

the concrete shall be subject to company approval. The dispensing unit shall be translucent so

that the operator can see the discharge of the admixture. The use of admixture/ additions shall

be in accordance with manufacturers recommendations.

12.4.1.2 Admixtures/Additive shall:

Be compatible with the cement. Have no adverse effect on the durability, shrinkage and water tightness properties of

finished concrete. Shall contain no chlorides.

12.4.1.3 The CONTRACTOR shall advise of the following:

The long and short term effects of the admixture on the concrete. The effects of under and over dosage. Whether or not the admixture entrains air or has an effect on air content. Safety precautions in handling. Storage Life and Conditions. Affect on use of other admixtures used in the mix. The water content of the admixture. The necessity for agitation prior to use.

12.4.2 Retarding Admixtures

Retarding admixtures shall be in accordance with BS EN 934-2 & 934-6 or ASTM C 494/C 494M.

The admixture shall not affect long-term strength of the concrete. CONTRACTOR to be aware that such admixture may increase the time for adequate

curing and protection.

12.4.3 Plasticizer Admixtures (Accelerating, Workability...)

Shall be in accordance with BS EN 934-2 & 934-6 or ASTM C 494/C 494M. Hydroxy-Carboxylic acid based plasticizers may be used, subject to site tests and COMPANY

approval.


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12.4.4 Super-Plasticizer Admixtures (High Range Water Reducing Agent - HRWRA)

Shall be in accordance with BS EN 934-2 and 934-6 or ASTM C 1017.

For blast furnace slag cement concrete melamine-formaldehyde based super plasticizers may be used.

12.4.5 Corrosion Inhibitor

Calcium Nitrate shall be added to the concrete at the rate of 10 liters per cubic. Calcium Nitrate shall comply to the requirements of ASTM C494 and ASTM G109 and shall be added as an aqueous solution which contains 30+3 percent of Calcium Nitrate by weight.

The corrosion inhibitor should be incorporated into the mixing water for the purpose of determining the water cement ratio of the concrete and has to be added for all reinforced concrete works.

Concrete Mix shall maintain at manufacture recommended dosage (1.0 litre/m3 for MCI 2005 and 5 Litre/m3 for RHEOCRETE 222+) at the plant regardless of Chloride concentration.

During the construction course, the supplier should be advised to be present and carry out the necessary quality control.

12.5 FIBRE REINFORCING

12.5.1 All large areas of concrete which are externally exposed (such as paving including ditches,

slabs and walls) shall contain polypropylene fibres at a dosage of 0.6 to 0.9 Kg/m3

of

concrete volume, depending on the cement content and the fibre manufacturer's

recommendations. Fibrillated fibres shall be used where a broom finish is required and

monofilament fibres shall be used were a troweled finish is required. Fibres shall be

accordance with ASTM C-1116.

12.5.2 Fibres shall not be considered as substitute for all or part of the steel reinforcement.

12.5.3 During mixing the fibres shall be uniformly and rapidly dispersed without balling or

agglomeration.

12.6 The CONTRACTOR shall be responsible for performing reviews, inspections, audits and/or

witnessing tests at the SUPPLIER's facility as appropriate to ensure quality of procured items. The

CONTRACTOR shall provide access to COMPANY to perform similar activities if the need is

established.


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13 CONCRETE MIX DESIGN

13.1 GRADES OF CONCRETE

13.1.1 Concrete shall be as shown in Table 2 of this Specification. The criteria given in the table are

designed to produce concrete of the required durability and strength. HRWRA shall be used in

the concrete mixes.

13.1.2 Concrete shall comply with BS 8110 except where BS 8007 or this Specification differs. Sampling for

test purposes shall comply with BS EN 12350-1 and BS EN 12390-1 and making and curing of

specimens shall comply with BS EN 12390-2.

13.1.3 Before concrete placement the CONTRACTOR shall obtain approval by PMT of the mixes

proposed for each class of concrete. The mixes shall be designed to achieve the minimum

workability for the placement and compacting the concrete with the equipment proposed

for use.

TABLE 2

CONCRETE GRADES AND 28 DAYS CUBE/CYLINDER STRENGTH

NOMINAL GRADE (2) (3) (4)

STRENGTH APPLICATION MAXIMUM FREE WATER/

CEMENTITIOUS

RATIO

CEMENTITIOUS

CONTENT

KG/M3

CUBE MPa

MPa Maximum Maximum (mm)

Minimum (kg/ m3)

20 20 Blinding, Electrical Duct banks, Screed

0.50 250

40

40

Equipment Foundations,

Structures, Footings, Pipe Sleepers,

Pits,Basins

0.40

380


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Notes:

1- All concrete mixes to be designed for pumping. 2- Grade is included only to provide a strength basis for design. It is not intended to identify durability

level. 3- All concrete mixes to contain corrosion inhibitor.

13.2 The CONTRACTOR shall submit for COMPANY approval his anticipated slump for each mix design.

The use of a flow table may be adopted in place of slump tests for slumps greater than 150mm.

13.3 The mix design shall produce the minimum of bleeding and segregation.

13.4 Total cementitious contents shall be limited to those required for durability to avoid excessive

risk of thermal and shrinkage cracking. The proportioning of mixes for durability will be primarily

controlled through the specified limits on free w/c ratio. The w/c ratio shall be equal to or less than

the values shown in Table 2 above. Appropriate use shall be made of approved admixtures to

simultaneously meet the requirements for w/c ratio and workability.

13.5 Maximum aggregate size shall be 20 mm except as noted above.

13.6 TRIAL MIXES

Trial mixes shall be performed both in a laboratory and in the field.

13.6.1 Laboratory Trials

13.6.1.1 After the basic materials for concrete are approved by the COMPANY, the

CONTRACTOR shall carry out preliminary laboratory tests to determine the mixes using the

approved materials to satisfy the requirements of this Specification.

13.6.1.2 Trial mixes shall be tested to determine the following properties for initial field tests:-

Durability parameters at trial mix stage to be in accordance with clause 13.6.2.6.

Bleeding in accordance with BS EN 480-4.

Workability in accordance with BS EN 12350-2.

Density in accordance with BS EN 12390-7

Crushing strength in accordance with BS EN 12390-3


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Admixtures, super plasticizer or retarding super plasticizer with ASTM C494.

If the values obtained are unacceptable, the mix shall be re-designed until satisfactory results are

obtained.

13.6.1.3 Laboratory trial mixes of structural concrete shall be tested for durability at an age of 28 days after

casting. Samples shall consist of:

a. 6N 150 mm cubes for water penetration testing to BS EN 12390-8

b. 8N 150 mm cubes from which 1 N 100 mm diameter x 75 mm long core shall be taken

from each cube and trimmed for 50 mm length for rapid chloride permeability

testing to ASTM C.1202.

13.6.1.3.1 Curing of the samples shall be:

a. One half of each number to be fully water cured for 28 days in accordance with the

Standard Test Method.

b. The other half of each number to be water cured for 14 days and then exposed to the

external environment until tested, so as to replicate site conditions.

13.6.2 Field Trials

13.6.2.1 Field trial mixes shall be prepared and cured under full-scale site conditions and utilizing

the actual batch plant and materials provided for the project, and tested in accordance with

BS EN 12350 and BS EN 12390 or ACI 318M/318RM.

13.6.2.2 Note that field trial mixes are to be performed early enough to obtain 28 days durability test

results.

13.6.2.3 Mixes shall be made on three different days.

13.6.2.4 Testing for Durability

13.6.2.4.1 The CONTRACTOR shall prepare trial panel for each structural mix design from which the

following samples shall be prepared for testing after 28 days:

a. 3 N cores, 75 mm dia. x 75 mm long for water absorption testing in accordance with BS 1881, Part 122.


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b. 3 N cores, 150 mm dia. x 75 mm long for porosity testing in accordance with RILEM. CPC11.1

c. 4 N cores, 100 mm dia. x 75 mm long for RCP testing in accordance with ASTM

C.1202. These cores will be saw cut to a specimen thickness of 50 mm.

d. Testing of all specimens shall be at 28 days after casting.

13.6.2.4.2 Additionally, 150 mm cubes shall be cast from the same batches of concrete used to cast the

panels, as follows:

a) 6 N for water penetration testing to BS EN 12390-8.

b) 2 N from which 1 N x 75 mm dia. X 75 mm long core shall be taken from each

for water absorption testing to BS 1881, Part 122.

c) 2 N from which from 1 N x 150 mm dia. X 75 mm long core shall be taken from

each for porosity testing to RILEM CPC 11.1. ,

d) 4 N from which 1 N x 100 mm dia. X 75 mm long core shall be taken from each

and trimmed to 50 mm length for rapid chloride permeability testing to ASTM

C.1202.

Curing of the samples shall be as described in Clause 13.6.1.3. Testing of all

specimens shall be at 28 days after casting.

13.6.2.4.3 Curing the Trial Panel shall be as close to the future site practice as possible.

13.6.2.4.4 Further trials/mixes shall be made and tested if any test result falls below the specified value by

more than 10%.

13.6.2.5 Testing for Strength

13.6.2.5.1.1 Twelve (12) x 150 mm cubes shall be taken from each mix design. Test 2 N at 3 days, 3 N at

7 days, 2 N at 14 days and 4 N at 28 days for compressive strength.

13.6.2.5.1.2 Further trials/mixes shall be made and tested if the average of the eleven cubes at any of the

above ages is less than the target mean strength (the twelfth cube is a spare).

Standard deviation and required average strength shall be calculated. The mix proportions shall then be selected to produce the required average strength in accordance with BS EN 206-1 Tables 14 and 15 and BS 8500-1 and 8500-2.


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13.6.2.6 Durability Criteria

13.6.2.6.1 The Criteria for the approval of the mix designs for grades 40, 40F and 50 for samples cured in

accordance with Clause 13.6.1.3.1 (a) shall be as follows:

a) Water Absorption (BS 1881, Part 122) < 2.0%

b) Porosity (RILEM CPC 11.1) < 10.0%

c) Rapid Chloride Permeability (ASTM C.1202) < 1,500 coulombs

d) Water Penetration (BS EN 12390-8) < 10 mm

13.7 The CONTRACTOR shall not be entitled to any additional cost or time expended during the approval

process of the design mix.

14 CONCRETE ACCEPTANCE - DURABILITY, STRENGTH AND CHEMICAL LIMITS

Only individual materials and concrete fully meeting the requirements of this

specification shall be presented to COMPANY for acceptance.

Only concrete from approved SUPPLIERS with a proven record shall be used after satisfying

all the requirements of this specification.

The CONTRACTORs Batch Plant Manager shall be responsible for the control of quality of all batch plant operations.

14.1 DURABILITY REQUIREMENTS

14.1.1 For the first three months of concreting, the On-Site Testing Laboratory will each month prepare

a trial panel from each structural mix from which the following samples shall be prepared for

testing after 28 days:

a. 3 N cores, 75 mm dia. x 75 mm long for water absorption testing in accordance

with BS 1881, Part 122.

b) 3 N cores, 150 mm dia. x 75 mm long for porosity testing in accordance with


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RILEM. CPC 11.1.

c) 4 N cores, 100 mm dia. x 75 mm long for RCP testing in accordance with ASTM

C 1202. These cores will be saw cut to a specimen thickness of 50 mm.

d) Testing of all specimens shall be at 28 days after casting.

14.1.2 The CONTRACTOR shall also make 3No, 150 mm cubes for testing at 28 days in accordance

with BS EN 12390-8. Curing of these samples shall be in accordance with the requirements of

BS EN 12390-8.

14.1.3 Curing of the Trial Panel will be as close to the current site practice as possible.

14.1.4 Individual test results done at 28 days will be compared with the field trials 28 day results but

results should not be more than the figures stated in 14.1.2 plus a margin of 10%.

14.1.5 The On-Site Testing Laboratory will test the prepared panels and cubes.

14.1.6 The On-Site Testing Laboratory will repeat the above trial panels and cubes for durability

testing every 3 months.

14.1.7 The durability acceptance criteria for grades 40, 40F and 50 during routine QC testing shall be

the average value of each of the parameters obtained from the tests made on cores and cubes

at the field trial stage plus an allowance of 10 % in accordance with Clause 14.1.1.4.

14.1.8 In the event that the acceptance criteria in Section 14.1.2 is not achieved,

CONTRACTOR shall immediately inform COMPANY and stop further concreting on works

where that particular concrete mix is being used. CONTRACTOR shall identify all areas where

durability constraints have not been met.

14.1.9 For each area where the concrete has been identified as of questionable durability, the

CONTRACTOR shall take 4 N cores, 100 mm dia. X 70 mm long for Rapid Chloride

Permeability testing to ASTM C.1202. The cores shall be saw-cut to a 50 mm test length. Care

must be taken to avoid contact with rebar during coring and a covermeter shall be used. The

average value of the 4 N RCP measurements shall not be less than the current average value

of all RCP measurements obtained to date from routine QC trial panels plus an allowance of 10

% of that value.

14.1.10 In areas where taking cores is impracticable or is structurally unacceptable to

COMPANY, then, the CONTRACTOR carry out in situ air permeability tests (as


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developed by the British Cement Association) or such alternative non destructive test as may be

approved by COMPANY.

14.1.11 The CONTRACTOR shall demonstrate a satisfactory correlation between the insitu air

permeability test or alternative non-destructive test with the rapid chloride permeability value.

Subject to COMPANY approval, such method may be used in lieu of coring in other areas.

14.1.12 For areas which are confirmed as not meeting COMPANY durability criteria the

CONTRACTOR shall take the following actions:-

14.1.13 Identify and implement further protective methods in order to guarantee the design life of the

structure where durability parameters have not been met, at no cost to COMPANY.

14.1.14 Revise the mix design, materials control and/or construction method to meet durability

requirements.

14.2 STRENGTH REQUIREMENTS

14.2.1 One (1) set of three (3) cubes will be taken at the point of placement by the On Site Testing

Laboratory on each day of concrete pours for every 100m3 or fraction thereof.Two (2) cubes

shall be tested at 28 days and one (1) cube at 7 days.

14.2.2 Acceptance criteria is defined as:

14.2.2.1 The average of each set of two cubes (tested at 28 days) constitutes a test result.

14.2.2.2 The average of any 4 consecutive test results shall exceed the specified characteristic strength

by at least 3 N/mm2.

14.2.2.3 No individual test result shall be less than the specified characteristic strength minus3N/mm2.

14.2.2.4 Remedy in the event of strength cube failure.


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14.2.3 In the event that the acceptance criteria in Section 14.2.2 is not achieved, the

COMPANY will decide whether the concrete in the work represented by those cubes can be

accepted or not. Failing acceptance, the CONTRACTOR shall carry out one or more of the

following actions at his own expense to prove the concrete used in the works is within

acceptable limits:

14.2.3.1 Drilling and testing of cored cylinders in accordance with the procedures laid down in BS EN

12504-1 and BS 1881: Part 124.

14.2.3.2 Carrying out load tests, or other non-destructive tests as referred to in BS 1881: Parts 201 to

2010.

14.2.3.3 The course of action to be taken, types and number of tests, the size and location of cores for

testing and interpretation will be decided by the COMPANY who will also approve the

testing authority and laboratory. If the COMPANY after these secondary testing procedures

have been completed, still considers that the concrete used is not acceptable, the

CONTRACTOR shall remove all sections of the works containing the defective concrete and

replace it with approved concrete at his own expense.

14.3 CHEMICAL LIMITS

14.3.1 Chloride Content: The total chloride content of concrete shall not exceed 0.20%

expressed as % of chloride ion by weight of cementitious material for normal reinforced

concrete.

14.3.1.1 The method of assessment and test shall be in accordance with BS1881-124.

14.3.1.2 Sulphate Content: The total sulphate content of concrete (including sulphate ions in

cement and slag) shall not exceed 4.0%, expressed as % of SO3 by weight of

cementitious material.

15 MATERIAL STORAGE AND HANDLING

15.1 CEMENTS STORAGE


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15.1.1 Cement storage shall afford easy access for inspection and identification of each

shipment in accordance with test reports. It shall be used in the order in which it is delivered to

the site.

15.1.2 cement in bulk is to be used it shall be stored in approved purpose made silos large enough to

allow continuity of work.

15.1.3 Cement stored in bulk silos shall not exceed 75o C. No cement shall be stored on site for more

than 3 months.

15.1.4 Bagged cement shall be delivered to site in the manufacturer's original sealed bags or

containers and shall be stored in a dry, weather tight, properly ventilated covered

structure, with adequate provisions for preventing the absorption of moisture and raised at least

150 mm off the ground to prevent deterioration. The storage shall be large enough to allow

sufficient cement to be kept to allow continuity of work. Not more than

15.1.5 10 small bags or 3 'Big Bags' shall be piled one on top of the other while storing at site. Suitable

shading shall be provided to limit the temperature to 40o C.

15.1.6 Cement shall be stored in white colored insulated silos or sheds.

15.2 AGGREGATE STORAGE

15.2.1 The concrete plant shall at all times maintain sufficient quantities of each type of

aggregate to be sufficient to ensure continuity of work.

15.2.2 Each type and grade of aggregate shall be stored separately in bins, in such a manner that

segregation of the various size particles shall not occur. The floors of the bins shall be of

concrete or other approved material having sufficient slope to ensure adequate drainage of

aggregates before being used for concreting. Storage bins shall be emptied and cleaned at

regular intervals.

15.2.3 Strict precautions shall be taken to avoid contamination of aggregates by windblown dust,

chlorides etc.


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15.2.4 Suitable means shall be provided to ensure that the temperature of the concrete when deposited

does not exceed 30 degrees C. Aggregate stockpiles shall be shielded from direct sunshine.

15.2.5 Suitable shading shall be provided to control the temperature and any contaminations especially

chlorides.

16 ON-SITE BATCH PLANT

16.1 All concrete shall be produced from a controlled fully automatic on-site computerized central plant.

The central plant shall be provided by CONTRACTOR or subcontracted by CONTRACTOR to a

COMPANY approved Ready Mix Concrete SUPPLIER. The plant shall have a minimum capacity

of 0.5 cubic meters per batch and a minimum rated capacity of 100 cubic meters per hour.

16.2 Mixing at a central plant shall conform to the applicable requirements of the Standard

Specification for Ready-Mixed Concrete of ASTM C 94/C 94M, this Specification and Concrete

Plant Standards NRMCA CPMB100M-00 of the Concrete Plant Manufacturers Bureau.

16.3 The Batch Plant shall include the following:

Full computerization

Full segregation of materials

Materials to be shaded and covered to prevent contamination by air borne

chlorides, dust and other contaminants.

Automatic compensation for moisture in fine aggregate

Adequate ice and chilled water plants

Adequate capacity

Fully automated

Calibration every 3 months for aggregate

Calibration every 6 weeks for water, cement and admixtures

Print out of mix design together with actual mix

Calculation and print out of actual water/cementitious ratio


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16.4 The mixing machines (scales/meters, etc.) capacity shall be selected to ensure the required

maximum production can be comfortably achieved.

16.5 The mixing machines (scales/meters, etc.) Shall be tested and calibrated for their accuracy by a

specialist at regular intervals of at most three months or such periods as required by COMPANY.

Test certificates shall be provided before the commencement of works and after each test.

16.5.1 The mixing machines shall be tested in accordance with the appropriate British Standard

or equivalent (DIN, ASTM, etc...)

16.5.2 The accuracy of the measuring equipment shall be within 3 %. The measuring equipment

shall be maintained in a clean, serviceable condition.

16.5.3 The quantities of all materials for concrete shall be charged to the pan by weight.

16.5.3.1 The weights of fine and coarse aggregates shall be automatically adjusted to allow for any free

water contained in them. Accordingly the amount of water to be added shall be reduced by this

amount of free water contained in the aggregates.

16.5.3.2 Admixtures that have been approved as part of the design mix shall be added by approved

automatic dosing equipment.

16.6 Mixing shall insure a uniform distribution of materials and a uniformity of consistency and colour.

The mixing shall be continued until the mix is homogeneous. The time required to produce a

homogeneous mix shall be determined by satisfying the requirement of ASTM C 94/C 94M

Annex A1.

16.7 The CONTRACTOR shall ensure that the materials used for each batch in the mixerdo not

exceed the manufacturer's rated capacity for the machine.


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16.8 The machine shall be kept clean, free from any residual material after depositing each batch of

concrete and the mixer pan drum shall be washed and cleaned out immediately following

the completion of each concreting operation or when changing to a mix using a different type of

cement.

16.9 Hand mixed concrete shall not be used.

16.10 The batch plant shall be able to provide a computer printout of the following for each truck:

Grade of concrete

Cement type

Admixture types

Actual measurement of all components of water in the mix

Actual batched weights of cement, aggregates (separately), water and admixtures

Date and Time of batching

Calculation of the actual water/cement ratio.

16.11 Prior to commencement of the work the CONTRACTOR shall furnish the following details

to the COMPANY.

Name and qualification of SUPPLIER(s).

Certificate of quality assurance.

Quality control facilities/procedures.

Certificate and test reports on concrete production and products.

Source(s) of aggregates, cement, etc.

Quality of water, aggregates and cement.

Production capacities.


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Description of Plant Equipment and Facilities.

SUPPLIERs test certificate giving results of tests on aggregates for durability, strength and chloride content shall be submitted by the CONTRACTOR to the

COMPANY at weekly intervals.

Any other relevant data such as workability of concrete, admixtures, etc..

Qualifications o f personnel e a r -marked f o r the Project, (approved

pe rsonne l shall not be changed without prior approval of COMPANY).

16.12 The CONTRACTORs Batch Plant Manager will be responsible for the control of the quality of all

batch plant operations.

16.12.1 The arrangements for inspection, testing, reporting and verification shall be approved by the

COMPANY. As a minimum, the controls system implemented shall address the following:

Liaison with the site laboratory so as to ensure that the test status of materials

is known.

Supervision and recording of receipt, storage, handling and protection of materials.

Supervision and recording of batching and mixing, including verification of

batch computer print-outs before trucks are released.

Control of moisture adjustments.

Initial and routine batch plant calibration and maintenance procedure.

Regular reporting formats.

The COMPANY will verify that the control system is being implemented and verify the

documentation raised, in accordance with an approved system.

17 CONCRETE TRUCKS


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17.1 Concrete trucks and their manner of operation shall conform to the applicable requirements

of ASTM C94/C 94M.

17.2 Concrete trucks shall be of a size, design, and required number to accommodate the anticipated

placement rates.

17.3 Truck mixers shall be of the revolving drum type, watertight, and so constructed that the concrete

can be conveyed and discharged at the site maintaining the uniform distribution of materials

throughout the mass.

17.4 The drum shall be painted white and kept clean to ensure maximum reflectivity.

17.5 The maximum size of batch in truck mixers shall not exceed the maximum rated capacity

of the mixer as stated by the manufacturer and stamped in metal on the mixer.

17.6 On no account shall water from the concrete truck be used in the mix.

17.7 Each and every delivery to site shall be accompanied with a computer printout containing

the information listed in Section 16.10 of this Specification.

17.8 Concrete, after being discharged from the plant, shall be transported as rapidly as possible

to its final position in the works and shall prevent adulteration, segregation, loss or contamination

of the ingredients. Scheduling and dispatching of trucks shall be such that they arrive at the work

site just before the concrete is required.

17.9 Equipment shall be cleaned at the end of each operation or workday.

18 CLEANUP

18.1 Upon completion, leave project site clear of debris and surplus material resulting from work of this

contract. All debris and surplus material shall be disposed off project limits in a manner meeting

all local authority requirements.


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Calibration every 6 weeks for water, cement and admixtures

Print out of mix design together with actual mix

Calculation and print out of actual water/cementitious ratio.

Spec for Concrete Supply

Documents

concrete supply

concrete testing

concrete construction

concrete trucks

concrete mix design

master adco

adco areas

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