TECHNICAL

SPECIFICATION
FOR

CAST-IN-PLACE CONCRETE

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 TABLE OF CONTENTS
1.0 GENERAL
1.1 DESCRIPTION
1.1.1 Scope
1.2 QUALITY ASSURANCE
1.2.1 Codes and Standards
1.2.2 Reinforcement
1.2.3 Design of Formwork
1.2.4 Qualification of Installers
1.3 SUBMITTALS
1.3.1 Product Data
1.3.2 Samples
1.4 PRODUCT HANDLING
1.4.1 Protection
1.4.2 Delivery
1.4.3 Storage
1.4.4 Replacements
1.4.5 Rejection
2.0 PRODUCTS
2.1 MATERIALS
2.1.1 Cement
2.1.2 Aggregates
2.1.3 Water
2.1.4 Admixtures
2.1.5 Curing Materials
2.1.6 Other Concreting Materials
2.1.7 Batching, Mixing, and Delivery of Concrete
2.1.8 Reinforcement
2.1.9 Formwork
2.1.10 Formwork Ties
2.1.11 Formwork Coatings
3.0 EXECUTION
3.1 GENERAL
3.2 CONCRETE PLACEMENT
3.2.1 General
3.2.2 Placement Schedule
3.2.3 Concrete Placement and Procedures
3.3 CONSOLIDATION
3.3.1 General
3.3.2 Procedures
3.3.3 Maintenance of Vibrators

3.4 CONSTRUCTION JOINTS

3.4.1 General
3.4.2 Isolating Joints in Slabs

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 3.5 CURING
3.5.1 General

3.6 CONCRETE FINISHING

3.6.1 General
3.6.2 Finish of Formed Surfaces
3.6.3 Monolithic Slab Finishes

3.7 REMEDIAL WORK TO CONCRETE

3.7.1 General

3.8 INSTALLATION OF REINFORCEMENT

3.8.1 General
3.8.2 Fixing Reinforcement

3.9 FORMWORK
3.9.1 General
3.9.2 Fabrication
3.9.3 Assembly and Inspection
3.9.4 Support Work
3.9.5 Chamfers
3.9.6 Formwork Coatings
3.9.7 Installation of Embedded Items
3.9.8 Removal of Formwork
3.9.9 Re-use of Formwork

3.10 ANCHOR BOLTS

3.10.1 General
3.10.2 Setting of Anchor Bolts

3.11 MARKING

3.12 TOLERANCES
3.12.1 Tolerances of Form
3.12.2 Tolerance of Embedded Items

3.13 INSPECTION
3.13.1 General
3.13.2 Concreting Check Items

1.0 GENERAL

1.1 DESCRIPTION

1.1.1 Scope

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 In accordance with the provisions of this section and the drawings,
provide:

(1) Cast-in-place concrete, complete, in place, and properly

installed.

(2) All steel, complete, and in place, required for reinforcement of

cast-in-place concrete.

(3) Formwork for all cast-in-place concrete.

1.2 QUALITY ASSURANCE

1.2.1 Codes and Standards

(1) Applicable Standards

Comply with standards specified in this specification.

(2) Particular Standards

ASTM American Society of Testing and Materials

ACI American Concrete Institute

1.2.2 Reinforcement

Reinforcement shall be free from defect, corrosion, or other deleterious

coatings.

1.2.3 Design of Formwork

Design of formwork is the contractor’s full responsibility.

1.2.4 Qualification of Installers

(1) Throughout the progress of installation of the work of this

section, provide at least one person who shall be thoroughly
familiar with the specified requirements, completely trained
and experienced in the necessary skills, and who shall be
present at the site and shall direct all work performed under this
section.

(2) In actual installation of the work of this section, use adequate

numbers of skilled workmen to ensure installation in strict
accordance with the approved design.

(3) In acceptance or rejection of work performed under this

section, the Owner will make no allowance for lack of skill on
the part of workmen.

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 (i) Verification of Site Condition

The contractor, before commencing any work, shall

verify the grade conditions of all ground surfaces and
any other conditions at the site and other areas which
may affect his work and shall notify the Project
Manager in writing of any discrepancies between
conditions as actually existing and as shown on the
design drawings.

(ii) Quality Control

(1) Testing Arrangements

Prior to all work under this section, make all

necessary arrangements with the testing
laboratory regarding timely implementation of
testing procedures and quality control for
concrete and concrete related materials.

(2) Trial Mixes and Strength Tests

(a) At least four weeks prior to

commencement of concrete placing, trial
mixes shall be made for each class of
concrete.

(b) The contractor shall submit a detailed

execution plan for the trial mixes for
approval by the Project Manager before
commencing the work.

(c) Samples for strength tests of each class

of concrete placed each day shall be
taken not less than once a day nor less
than once for each volume stated below.
Total Concrete Volume No. of Samples to
be
(cubic meters) per day taken

0 - 50 One sample
51 - 200 One for each 75 CM
201 - 400 One for each 100 CM
401 or over One for each 150
CM

(1) Changes in Materials and Mix Proportions

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 Neither the mix proportions nor the source of
material supply to the jobsite shall be altered.
However, adjustments can be made in the
proportions of the mix as required to take
account of permitted variations in the materials.
In this case, trial mixes and strength tests shall
be carried out.

(2) Failure to Meet Requirements

If the 28-day test results are found to be below

the specified strength, cylindrical core
specimens shall be cut from the hardened
concrete at appropriate locations. Where the
strength of the specimens is less than the
specified strength at 28 days, the concrete
structure or part of it shall be removed and
replaced.

(3) Records

Records shall be kept of the positions in the

works of all batches of concrete, of their grade
and of all tests or other specimens taken from
them.

1.3 SUBMITTALS

1.3.1 Product Data

Submit the following within 30 days after award of the contract.

(1) Complete material list of all items proposed to be furnished and

installed under this section.

(2) Sufficient data to demonstrate compliance with the specified

requirements.

(3) Complete information on cement source of supply, physical

and chemical characteristics, transportation, and intermediate
terminating procedures for mill-to-site handling, and site
storage procedures.

(4) Complete information on aggregate procurement, processing

and storage.

(5) Complete information on proposed batching and mixing

equipment and procedures, including water chilling or other
devices or systems to reduce mix temperatures.

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 (6) Complete information on concrete handling equipment
proposed to be used, including capacities for chutes, pumps,
buckets, and all other equipment.

(7) Complete information on proposed consolidation equipment.

(8) Complete description of proposed curing methods.

(9) Steel producers certificates of mill analysis, plus tensile and

bend tests for reinforcing steel.

(10) Manufacturers data and installation instructions for proprietary

formwork materials including form coatings, ties and
accessories, and manufactured form systems if used.

1.3.2 Samples

Submit to the Project Manager samples of the following:

(1) Concrete constituents, including admixtures.

(2) Formwork ties and spreaders.

(3) Formwork release agent

(4) Remolded joint filler

(5) Vapor barriers

(6) Waterstops

(7) Wedge inserts, and;

(8) Expansion bolts

1.4 PRODUCT HANDLING

1.4.1 Protection

Use all means necessary to protect the materials of this section before,
during, and after installation and to protect the work and materials of
all other trades.

1.4.2 Delivery

Deliver reinforcement to the jobsite bundled, tagged, and marked. Use

metal tags indicating bar size, lengths, and other information
corresponding to markings shown on placement diagrams.

1.4.3 Storage

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 (1) Cement

All cement shall be delivered in sound and properly secured

bags and shall be stored in a dry weatherproof shed with a
raised wooden floor, or other facilities approved by the Project
manager.

Each consignment shall be kept separate and distinct, and shall

be used in the sequence in which it is delivered to the site. Any
cement that has become seriously affected by damp or other
causes shall be removed from the site immediately.

(2) Aggregates

Aggregates shall be stored so that intermixing of different

grading shall not occur. Stockpile aggregates in a manner that
will prevent contamination from the ground with undesirable
material.

(3) Reinforcement

Store reinforcement at the job site in a manner as to prevent

damage and accumulation of dirt and rust.

1.4.4 Replacements

In the event of damage to materials of this section, immediately make

all repairs and replacements necessary to the approval of the Project
manager.

1.4.5 Rejection

Any consignment or part of a consignment that does not comply with

the specification shall not be used in the work and shall be removed
from the site.

2.0 PRODUCTS

2.1 MATERIALS

2.1.1 Cement

(1) Portland Cement

Portland Cement shall conform to Type 1 or equivalent and

shall be applied to all concrete grades. Different brands of

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 cement shall not be mixed. Preferably, use only one brand of
cement for the entire work.

(2) Certificate

The manufacturer’s complying with the above specification

shall certify cement and a copy of the manufacturers test
certificates shall accompany each consignment.

2.1.2 Aggregates

(1) General

For the concrete of this section, all fine and coarse aggregate
shall preferably come from only one source.

(2) Testing

Certified copies of satisfactory tests by a testing laboratory

approved by the Project Manager shall be accepted for
aggregate quality requirements.

2.1.3 Water

Water for mixing concrete shall be fresh and clean, and free from
injurious amounts of oil, acid, alkali, salt, or organic materials

2.1.4 Admixtures

Admixtures shall be subject to prior approval of the Project Manager,

if they are to be used.

2.1.5 Curing Materials

(1) Liquid Curing

Liquid curing and sealing compound shall be clear or
translucent without dye.
(2) Sheet Materials
Sheet materials in sheet form used for covering the surfaces of
concrete to inhibit moisture loss during the curing period like
curing paper, polyethylene film, and white burlap polyethylene
sheet.

(3) Burlap cloth

For moist curing burlap cloth made from jute or kenaf and
weighing approximately 305 grams per sq. m. and shall be used
in two layers.

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 2.1.6 Other Concreting Materials

(1) Pre-formed Expansion Joint

Expansion joint filler material shall be bituminous fiber type.

(2) Waterstops

Water stops shall be extruded from new stock polyvinyl

chloride, ribbed, expandable center bulb, or other approved
type. The minimum width shall be 150 mm and minimum
thickness shall be 6.4 mm.

(3) Vapor Barriers

Vapor barriers shall be polyethylene sheets having a thickness

of 0.2 mm minimum.

2.1.7 Batching, Mixing, and Delivery of Concrete

Use transit-mixed concrete from the approved batching and mixing

plant.

2.1.8 Reinforcement

(1) Reinforcing Bars

Reinforcing bars shall be deformed bars of grade 60 steel
(10mm dia. and larger, grade 60 smaller than 10mm).

(2) Steel Wire

Double strands Ga. 16 tie wires for fixing and tying

reinforcements. For big diameter bars, use Ga. 14.

(3) Supports for Reinforcements

Bolsters, chairs, spacers, and other devices of or spacing,

supporting, and fastening reinforcement in place.

(a) Use wire bar type supports, unless otherwise indicated.

Do not use wood, brick, and other unacceptable
materials.

(b) For slabs on grade, use supports with sand plates or

horizontal runners where abase material will not support
chair leg.

(c) For exposed-to-view concrete surfaces, where legs of

supports are in contact with forms, provide supports
with either hot-dip galvanized or plastic protected legs.

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 (1) Compliance

All bars, wires, and mesh reinforcement shall be certified by

the manufacturer as complying with the above specification and
a copy of the manufacturers test certificate shall accompany
each consignment.

(2) Bending and Cutting

(a) Reinforcing bars shall conform to required shapes and

dimensions, with bending and cutting tolerances. In
case of errors, do not re-bend or straighten
reinforcement in a manner that will injure or weaken the
material. Reinforcing bars shall be sized and shaped at
ambient temperature.

(b) Reinforcement with any of the following defects will

not be permitted in the work:

(i) Bar lengths, depths, and bends exceeding

specified fabrication tolerances.

(ii) Bends or kinks not indicated on the final shop

drawings.

(iii) Bars with reduced cross-section due to rusting or

other cause.

(c) Bars shall be cropped to length and flame cutting will

not be permitted unless with the approval of the Project
Manager.

2.1.9 Formwork

(1) Exposed Surfaces

Formwork material for faces of exposed concrete surfaces shall be

smooth faced undamaged plywood, metal or other panel type
materials acceptable to the Project Manager, to provide straight,
smooth, as-cast surfaces that have no discoloration.

(2) Unexposed Surfaces

Formwork material for faces of concrete surfaces concealed from

view or to be covered with plaster are to be timber/plywood of
sufficiently sound grade, or be of metal or other type panel
material. In whichever case the quality or condition of the materials
used shall be acceptable to the Project Manager.

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 The face of concrete where plaster is to be applied shall have
sufficient mechanical bond produced by the formwork.

(3) Material Strength

Provide formwork face material with sufficient thickness to

withstand the pressure of newly placed concrete without excessive
and objectionable bow or deflection.

2.1.10 Formwork Ties

(1) Provide factory-fabricated, adjustable-length, removable or

snap-off metal form ties, designed to prevent deflection and
spilling concrete surfaces upon removal.

(2) Provide ties so that the portion remaining within the concrete
after removal of exterior parts is at least 3.8 cm from the outer
concrete surface.

(3) Provide form ties that will not leave a hole larger than 2.5 cm
diameter in the concrete surface.

2.1.11 Formwork Coatings

Provide commercial formulation form-coating compounds that will not

bond with stain, nor adversely affect concrete surfaces requiring bond
or adhesion, nor impede the wetting of surfaces to be cured with water
or curing compounds.

3.0 EXECUTION

3.1 GENERAL

Concrete for reinforced concrete structure is classified into grade, quality and
slump. The class of concrete shall be specified on the drawings, denoted by
minimum 28 days compressive strength, based on 15 cm diameter x 30 cm
height.

Table 1 - Concrete Grade

Concrete Grade Maximum Size of Coarse

Aggregate
Pile & Pile Cap – 34.5 MPa (5000 psi) 25 mm.
Susp. Slabs, Columns – 27.6MPa (4000psi) 25mm
Beams, Girders – 27.6 MPa (4000 psi) 25mm
Slab-On-Grade – 27.6 Mpa (4000 psi) 25mm
Parapet Walls – 27.6 MPa (4000 psi) 25mm

Table 2 - Slump Values for Concrete Work

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 Placement of Concrete in: Slump (cm)

Foundation with reinforcement

And foundation footings 7.5 +/- 2.5

Slabs, beams, columns, and

Walls 10.0 +/- 2.5

3.2 CONCRETE PLACEMENT

3.2.1 General

Place concrete in compliance with practices and recommendations as

herein specified.

3.2.2 Placement Schedule

Prior to starting work procedure, a schedule of the planned concreting

activities that include preparation, method of pouring and equipment to
be used. No concreting work shall commence before the Project
Manager has approved this schedule.

3.2.3 Concrete Placement and Procedures

(1) Deposit concrete, continuously or in layers of such thickness

that no concrete will be placed on concrete which has hardened
sufficiently to cause the formation of seams or planes of
weakness within the section.

(2) If a section cannot be placed continuously, provide construction

joints as approved by the Project Manager.

(3) Perform concrete placing at such a rate that concrete, which is

being integrated, with fresh concrete is still flowing.

(4) Deposit concrete as neatly as practicable in its final location to

avoid segregation due to re-handling and flowing.

(5) Do not subject concrete to any procedure that will cause

segregation.

(6) Do not use concrete which becomes ”non-plastic” and

unworkable, or does not meet the required quality control
limits, or which has been contaminated by foreign materials.

(7) Remove rejected concrete from the site and dispose of it in a

location approved by the Project Manager for that purpose.

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 (8) Use chutes for pouring concrete where a drop of more than 2.0
meters is required.

Chute arrangement:

(a) Chutes shall be of steel or PVC and the cross section

shape shall be v-type. The gradient of chutes shall be
4/10 to 7/10 to avoid material segregation.

(b) In cases where concrete must be chuted from a high

elevation, vertical flexible chutes shall be used.

(1) Pumps may be used only if they can pump the design mix. Do
not add fine aggregate or water to the mix to satisfy needs of a
pumping device.

(2) Concrete pumps and related piping shall be lubricated by using

mortar just before starting the work.

(3) The operation of concrete pumps shall not be suspended longer

than 30 minutes when the pumps are filled with concrete.

(4) Concrete mix should be poured within 1 hour after water has
been added to dry mix.

(5) If the quality of concrete is damaged by rain, necessary steps

shall be taken as instructed by the Project Manager. If concrete
is too placed when it is raining, full protective measures should
be taken during pouring. When there is heavy rain, pouring of
concrete shall be discontinued.

(6) No concrete that has partially hardened or has been

contaminated by foreign matter shall be placed in formwork or
in any other part of the permanent work.

(7) Concrete shall not be “freshened up” with water or re-tempered

in any way.

(8) Placing concrete in formwork:

(a) Deposit concrete in formwork in even horizontal layers

not deeper than 60cm.

(b) Where placement consists of several layers, place each

layer while the preceding layer is still plastic and
thereby avoid cold joints.

(c) Remove temporary spreaders in formwork when

concrete placing has reached the elevation of such
spreaders.

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 (d) Only place concrete in supporting elements (e.g., walls,
and columns) after the concrete of previously placed
lifts is no longer “Plastic”.

(1) Placing concrete slabs:

(a) Deposit and consolidate concrete slabs in a continuous

operation, within the limits of construction joints,
and/or until the placing of a panel or section is
completed.

(b) Consolidate concrete during placement by the use of

approved equipment.

(c) Coarse aggregate should not be visible on the surface of

finished concrete slabs.

(d) Limit the time of vibrating consolidation to prevent

bringing an excess of fine aggregate to the surface.

(e) Bring slab surfaces to the correct level with a straight

edge and produce a finish free from bumps and hollows.

(f) Do not sprinkle water on the “plastic” surface, and do

not disturb surfaces prior to the start of finishing
operations.

(1) Concrete conveying

Handle concrete from the point of delivery and transfer to the

concrete conveying equipment and to the locations of final
deposit, as rapidly as practicable and by methods, which will
prevent segregation and loss of concrete mix materials. Keep
interior surfaces of conveying equipment, including chutes and
pump piping, free from hardened concrete, debris, water, and
other deleterious materials.

(2) Concrete without formwork

Concrete may be poured without formwork subject to the

Project Manager’s approval. In this case, the minimum cover of
concrete to rebar shall be 7.5 cm.

(2) Cold water placing (Not Applicable)

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 (4) Hot weather placing

When hot weather conditions exist this would seriously impair

the quality and strength of concrete, place the concrete as
follows:

(a) Maintain concrete temperature at time of placement

below 32 degrees Celsius (90 degrees Fahrenheit). Use
chilled mixing water or chopped ice to control concrete
temperature, provided the water equivalent of the ice is
calculated to the total amount of water.

(b) Cover reinforcing steel with water-soaked burlap cloth

if the steel becomes too hot. Steel temperature shall not
exceed the ambient air temperature immediately prior to
placement of concrete.

(c) Wet forms thoroughly prior to placement of concrete.

(d) Use set-control admixtures in the concrete mix.

3.3 CONSOLIDATION

3.3.1 General

(1) Consolidate all concrete in accordance with provisions of these

specifications.

(2) Concrete should be thoroughly compacted during the operation

of pouring and carefully worked around the reinforcement,
embedded fixtures and into all corners of the formwork.

(3) The concrete shall be compacted by the use of mechanical

vibrators. Spare vibrators shall be provided. Vibrators shall not
be used after there is no apparent decrease in the volume of
concrete and under no circumstances should they be allowed to
cause segregation.

(4) In tamping, the height of a layer is to be less than 30 cm. For

monolithic construction, each concrete layer shall be poured
while the underlying layer is still responsive to vibration.

(5) During an operation of concrete placement, a frequency of

vibration shall not be less that 7,000 per minute per internal
vibrator or otherwise specified by the Project Manager.

(6) Do not vibrate forms or reinforcement.

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 (7) Vibration shall be applied only at the point of placing freshly
deposited concrete.

3.3.2 Procedures

(1) Limit duration of vibration to the time necessary to produce

satisfactory consolidation without causing segregation of
aggregates.

(2) Insert the vibrator so as to penetrate the lift immediately below

the one being placed, and manipulate to blend the two lifts.

(3) Do not insert the vibrator into lower courses that have begun to
set.

(4) Use the vibrator to melt down the concrete as it is being placed,
and uses the vibrator to consolidate the mass of concrete.

(5) In the case of wall construction, assign at least one vibrator and
vibrator-operator to melting down the mix; and assign at least
one other vibrator and vibrator-operator to consolidating the
mass of concrete.

(6) Spacing between insertions of the vibrator, which is used to

consolidate, shall not exceed twice the radius of action.

(7) Under no circumstances shall the points of insertions during the

consolidation phase be more than 45 cm. Apart.

(8) Vibration shall not be continued at any one point to the extent
that localized areas of grout are formed. Vibrators shall not
touch reinforcement.

(9) Vibrators shall be inserted and withdrawn out of concrete pours

slowly.

3.3.3 Maintenance of Vibrators

Initiate a maintenance program for the vibrators to assure that they are
operating at peak efficiency at all times, and to facilitate effective
consolidation of the concrete.

3.4 CONSTRUCTION JOINTS

3.4.1 General

(1) The contractor shall ensure that all construction joints are
arranged to minimize the effects of shrinkage. The position and
arrangement of construction joints shall be according to the

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 drawings, or otherwise that contractor shall show them in
complete detail on drawings submitted to the Project Manager
for approval.

(2) In cases where the use of construction joints is unavoidable,

parting strips shall be provided along the concrete edges to
prevent flow-out of cement paste.

(3) Construction joints shall be horizontal or vertical. If required in

beams and slabs, they shall be located at the area where the
stress is minimum.

(4) The surfaces of construction joints shall be cleaned of laitance

and shall be roughened. Before pouring fresh concrete, the
surface shall be thoroughly wetted.

(5) At points where layer concrete strength is specifically required,

cement paste or rich-mix concrete shall be used. Concrete shall
be placed immediately.

3.4.2 Isolating Joints in Slabs

Provide isolation joints in slabs at points of contact between slabs and

vertical surfaces where indicated on the drawings. Seal joints with
caulking material approved by the Project Manager.

3.5 CURING

3.5.1 General

(1) For five days after pouring, concrete surfaces shall be kept
constantly wet and protected from sunlight and rapid drying.
This is to be achieved by spraying water directly on to the
concrete surface or over previously laid curing membrane or
material.

(2) Two days curing shall be applied for miscellaneous concrete

work. The contractor shall submit his proposed methods of
curing for approval by the Project Manager.
(3) For twenty-four hours after pouring, no person shall be allowed
to walk on the surface of the concrete, even after that period
has elapsed; no shock or vibration shall be applied to the
concrete while it is in a state of hardening.

3.6 CONCRETE FINISHING

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 3.6.1 General

(1) The following surface conditions and finishing methods shall

apply unless otherwise specified on drawings. After removal of
formwork, no defective areas shall be repaired without prior
approval from the Project Manager.

(2) Unless otherwise agreed with the Project Manager, noticeable

bulges or projections shall be removed by chipping or tooling at
an acceptable finish.

(3) Large honeycombs or other defective areas shall be chipped out

to behind the reinforcing bars. The edges shall be cut straight
from the surface on a slight undercut, to provide a key. These
areas shall then be thoroughly wetted and filled with a cement
mortar of the same color as the cement used in the concrete.

3.6.2 Finish of Formed Surfaces

(1) Rough form finish

(a) Provide as-cast rough form finish to formed concrete

surfaces that are to be concealed by finish work or by
any other construction.

(b) Standard rough form finish shall be the concrete surface

having the texture imparted by the form facing material
used, with tie holes and defective areas repaired and
patched, and all fins and other projections exceeding 6
mm in the height rubbed down or chipped off.

(2) Smooth form finish

(a) Provide as-cast smooth form finish for formed concrete

surfaces that are to be exposed to view, or that are to be
covered with a coating material other than cement
plaster applied directly to the concrete.

(b) Produce smooth form finish by selecting form material

to impart a smooth, hard, uniform texture and arranging
them orderly and symmetrically with a minimum of
seams.

(c) Repair and patch defective areas with all fins and other
projections completely removed and smoothed.
(3) Related unformed surfaces

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 At top of walls, horizontal offsets, and similar unformed
surfaces occurring adjacent to formed surfaces, strike off
smooth and finish with a smooth toweled finish.

3.6.3 Monolithic Slab Finishes

(1) Scratch finish

(a) Apply scratch finish to monolithic slab surfaces that are

to receive concrete floor topping or mortar setting beds
for terrazzo tile and other bonded applied cementations-
finish flooring material.

(b) After placing slabs, form the surface to tolerance not

exceeding 6 mm in 60cm when tested by a straightedge.

(c) Uniformly slope surfaces to drains where required.

(d) After leveling, roughen the surface before the final set
using stiff broom brush, or rake.

(2) Float finish

(a) Apply float finish to monolithic slab surface that are to

receive trowel finish and other finishes hereinafter
specified, and to slab surfaces which are to be covered
with insulation, and as otherwise shown on the
drawings or in the schedules.

(b) After placing concrete slabs, do not work the surface

further until ready for floating.

(c) Begin floating when the surface water has disappeared

and when the concrete has stiffened sufficiently to
permit operation of a power-driven float, or both.

(d) Consolidate the surface with power-driven floats, or by

hand floating if area is small or inaccessible to power
units.

(e) Check and level the surface plane to a tolerance not

exceeding 7 mm in 3 meters when tested with a 3 meter
straightedge placed on the surface at not less than two
different angles.

(f) Cut down high spots and fill low spots.

(g) Uniformly slope surfaces to drains where required.

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 (h) Immediately after leveling, re-float the surface to a
uniform, smooth, and granular texture.

(3) Trowel finish

(a) Apply trowel finish to monolithic slab surfaces that are

to be exposed to view, unless otherwise shown, and to
slab surfaces that are to be covered by resilient flooring,
carpeting, paint, or other thin film finish coating system.

(b) After floating, begin the first trowel finish operation

using a power-driven trowel. Begin final troweling
when the surface produces a ringing sound as the trowel
is moved over the surface.

(c) Consolidate the concrete surface by the final hand

troweling operation, free from trowel marks, uniform in
texture and appearance, and with a surface plane
tolerance not exceeding 7 mm in 3meters when tested
with a 3-meter straightedge placed on the surface at not
less than two different angles.

(d) Grind smoothly those surface defects, which would

show through applied floor covering system

(4) Non-slip broom finish

(a) Apply non-slip broom finish to exterior concrete

platforms, steps, and ramps, and elsewhere as shown on
the drawings or in the schedules.

(b) Immediately after trowel finishing, slightly roughen the

concrete surface by brooming in the direction
perpendicular to the main traffic route. Use a fiber
bristle broom.

(c) Coordinate the required finish with the Project Manager

prior to application.

3.7 REMEDIAL WORK TO CONCRETE

3.7.1 General

Reinforce or replace deficient work as directed by the Project Manager

3.8 INSTALLATION OF REINFORCEMENT

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 3.8.1 General

Comply with specified standards and for details and methods of fixing
reinforcement and supports, and as herein specified.

3.8.2 Fixing Reinforcement

(1) Clean reinforcement to remove loose rust and mill scale, earth,
and other materials that reduce or destroy bonding with
concrete.

(2) Position, support, and secure reinforcement against being

displaced by formwork, construction, or concrete pouring
operations. Locate and support reinforcing by metal chairs,
runners, bolsters, spacers, and hangers, as required.

(3) Place reinforcement to obtain the minimum coverage for

concrete protection. Arrange, space, and securely tie bars and
bar supports together with 16 gage wire to hold reinforcement
accurately in position during concrete pouring. Set wire ties so
that twisted ends are directed away from exposed concrete
surfaces.

(4) Install welded mesh reinforcement in as long lengths as

practicable. Lap adjoining pieces at least one full mesh.

(5) Cover blocks are to be made of properly cured mortar.

(6) Provide sufficient number of supports and of strength to carry

reinforcement. Do not place reinforcing bars more than 5 cm
beyond the last leg of any continuous bar support. Do not use
supports as bases for runways for concrete conveying
equipment and similar construction loads.

(7) Splicing shall be carried out by lapping ends, placing bars in

contact, and tight wire tying.

(8) Unless otherwise stated on the drawings, the following

minimum concrete cover of reinforcement shall apply:

Cover to Reinforcing Bar Minimum Cover

Concrete exposed to earth
Pouring with formwork d< or = 16 mm 5 cm
d> or = 19 mm 6 cm
Pouring without formwork 7.5 cm

Concrete not Exposed to Earth

Slabs, walls, joist 2 cm

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 Beams, columns 4 cm

Where d = diameter of bars

The minimum concrete cover shall not be less than the diameter of the
bars.

3.9 FORMWORK

3.9.1 General

(1) Construct forms complying to the exact size, shape lines, and
dimensions shown, and as required to obtain accurate
alignment, location, grade, level, and plumb work in finish
structures.

(2) Forms shall not be connected to such temporary facilities as

scaffolds, etc.

(3) All rubbish, shavings, saw dust, wire clipping, loose concrete
and any other refuse shall be removed from the inner face of
the forms before placing concrete.

(4) Washout holes shall be provided where necessary to provide

access for cleaning.

3.9.2 Fabrication

(1) Formwork shall be substantial and rigid construction to

withstand concrete weights and other working loads without
detrimental amounts of deformation.

(2) Fabricate formwork for easy removal wherever possible.

(3) Provide top form for inclined surfaces where the slope is too
steep to place concrete with bottom form only.

3.9.3 Assembly and Inspection

(1) Prior to assembling formwork components or modules for

major concrete structures, it shall be marked for location and
elevation to enable the Project Manager to inspect, checks, and
approve.

(2) All formwork shall be inspected by the Project manager prior to

concrete pouring.

3.9.4 Support Work

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 (1) Erect support work, on brace, and maintain it to safely hold
vertical, lateral, and symmetrical loads applied until such loads
can be supported by in-place construction. Construct support
work so that adjustments can be made for take-up and
settlement.

(2) Provide wedges, jacks, or camber strips to facilitate vertical

adjustments. Carefully inspect support work and formwork
during and after concrete placement operations to determine
abnormal deflection or signs of failure; make necessary
adjustments to produce work of required dimensions.

3.9.5 Chamfers

All exposed edges of concrete above ground shall be chamfered 25

mm with the exception of:

(1) The tope of piers supporting equipment.

(2) Concrete edges providing direct support for flooring, or to

which steel will be attached for flooring support; and,

(3) Architectural requirements as indicated on the drawings.

3.9.6 Formwork Coatings

(1) Contact surface of forms shall be thoroughly cleaned and

coated with form oil compound before reinforcement is placed.
Do not allow excess form oil to accumulate in the formwork or
to come into contact with surfaces that will be bonded to fresh
concrete. Apply in compliance with manufacturers instructions.

(2) Form oil shall be approved by the Project Manager prior to use.

3.9.7 Installation of Embedded Items

Set and build into the work anchorage devices, piping, boxes, sleeves
and other embedded items required for other work that is attached to,
or supported by, cast-I-place concrete. Items are to be set firm and
rigid so that no movement occurs when concrete is being poured.

3.9.8 Removal of Formwork

(1) Formwork shall not be removed without prior approval from

the Project Manager

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 (2) Unless otherwise instructed by the Project Manager, forms and
support work shall be left in position for the periods stated in
Table 3.

Table 3 - Minimum Forming Frame Retention Period

Type of Formwork Minimum Period Before

Removal

Vertical formwork to columns,

Walls, large beams, footings,
And foundations 3 days

Soffit formwork to suspend

Slabs and beams 7 days

Props and supports to slabs and

Beams 14 days

(3) Do not hammer or pry against concrete surfaces, provide crush

plates or wrecking plates where stripping may damage cast
concrete surfaces.

3.9.9 Re-use of Formwork

Clean and repair surfaces of forms to be re-used ion the work. Split,
frayed, delaminated or otherwise damaged form facing material will
not be acceptable. Apply new form coating compound material to
concrete contact surfaces as specified for new formwork. When forms
are used for successive concrete placement, thoroughly clean surfaces,
remove fins, and laitance, and tighten forms to close all joints. Align
and secure joints to avoid offsets.

3.10 ANCHOR BOLTS

3.10.1 General

(1) Deformed bolts shall not be used.

(2) Prior to setting anchor bolts, they shall be cleaned of loose rust,
oil, grease, dust, and other foreign matter, which may reduce
concrete bonding.

(3) Prior to concrete pouring, anchor bolts secured in place shall be

inspected by the Project Manager, with reference to their
positions, directions, perpendicularity, projection lengths, etc.

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 (4) The tolerance for anchor bolts embedment shall comply with
provisions as shown in Table 4.

(5) Grease shall be applied sufficiently to the portions of anchor

bolts which are not to be embedded, nuts shall be screwed on,
and proper protection such as vinyl or cloth covers shall be
provided to prevent concrete from adhering to the bolts.

(6) While pouring concrete, care shall be taken so that the anchor
bolts held in place do not move, or any other interference is
caused.

(7) Protect anchor bolts from interference by other concrete related

activities or by other trades.

(8) Immediately after formwork has been removed, the alignment

of the anchor bolts shall be checked and shall be subjected to
inspection by the Project Manager.

(9) Generally, the changing of anchor bolt positions shall not be

permissible. If corrections are necessary, they will be subject to
the Project Manager’s approval.

(10) Bolts extending from foundations shall be protected from being

bent and their threads from being damaged, until corresponding
equipment or structures are installed.

3.10.2 Setting of Anchor Bolts

For setting of anchor bolts, the following two methods shall be applied
in conjunction with relevant drawings and/or instructions given by the
Project Manager. If other special methods are to be used the contractor
will be informed by the Project Manager accordingly.

(1) Method of anchor bolt embedment using jig plates

(a) Jig plates shall be secured in place by using support

structures approved by the Project Manager.

(b) The above-mentioned support structures shall be of

sturdy construction so that they can withstand shocks
and impacts due to concrete placement, etc., without
moving. Details of these structures shall be drawn up by
the contractor and shall be subject to approval by the
Project Manager before fabrication.

(c) After jig plates have been inspected and approved by

the Project Manager, they shall be secured accurately in
position horizontally, and in elevation. Setting jig plates
shall be subject to inspection.

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 (d) Seven days or more after concrete pouring, jig plates
shall be removed with the approval of the Project
Manager.

(2) Method of anchor bolt embedment using wooden or metal

bolthole forms

(a) Bolt hole forms shall be fabricated by the contractor,

unless otherwise instructed.

(b) Bolt hole forms shall be accurately sized and positioned

and shall be subject to inspection by the Project
manager.

(c) Unless otherwise instructed, bolthole forms shall be

carefully removed shortly after the concrete has begun
to set.

(d) After the concrete has hardened all protruding bolts

shall be thoroughly cleaned of foreign matter.
3.11 MARKING

After the concrete has hardened, the centerline of foundations shall be clearly
marked on the top surface. Also a horizontal line at a level 100 mm below the
underside of the structure to be installed (e.g. bottom of base plate) shall be
marked on all the side surfaces of foundations.

3.12 TOLERANCES

3.12.1 Tolerances of Form

(1) Variations from the plumb

A deviation in the line and surface of columns, walls, piers, and

in arises:

(a) In any 3m of vertical distance +/- 6

mm

(b) Maximum for entire vertical distance +/- 2.5 mm

(2) Variations from the level

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 Deviations from the level or from grades indicated on the
drawings:

(a) In any 3 m horizontal distance +/- 6

mm

(b) In any bay or in any 6 m horizontal distance +/- 10

mm

(c) Maximum for entire horizontal distance +/- 20

mm

(3) Variations of span distance between walls,

Columns, and beams +/- 10
mm

(4) Variations in cross-sectional dimensions of columns

And beams and in the thickness of slabs and
Walls -6mm +
10mm

(5) Footings variation of dimension “in plan” -6mm +

10mm

3.12.2 Tolerance of Embedded Items

(1) Offset +/- 5

mm

(2) Elevations +/- 5

mm

(3) Inclination from true in any direction +/- 10

mm
(Vertical elements only)

(4) The tolerance for anchor bolt embedment is as given in Table 4

hereunder:

Table 4 - Tolerance of Anchor Bolt Embedment

Bolt Size Deviations from Projected Perpendicularity

Position at top of Length
Bolt

Anchor bolts +/- 2.0 mm + 5.0 mm 1/200

Under 1 inch - 3.0 mm

Anchor bolts +/- 2.5 mm + 10.0 mm 1/200

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 1 inch and over + 5.0 mm

Distances between
Center of grouped
Anchor bolt +/- 3.0 mm

Note: when stiffener type jigs are used, Table 4 need not be followed with the
exception of projected length

3.13 INSPECTION

3.13.1 General

The contractor shall prepare and submit an inspection sheet to the

Project manager for approval.

The above sheet shall be presented to the Project Manager shortly

before the contractor is ready to commence concreting to allow
inspection approval.

3.13.2 Concreting Check Items

(1) Before concreting, check that,

(a) Excavation, formwork, placement of embedded items

and reinforcement are completed;

(b) Protection has been provided if placing during rain;

(c) All water is removed from formwork;

(d) The ambient temperature is within allowable limits

prior to concreting;

(e) Materials are handled and stored as specified; and,

(f) Material samples have been submitted (if required) or

that manufacturers material certificates have been
submitted.

(2) During concreting, check that,

(a) Batching, mixing, delivering, sampling, and testing

concrete is following correct procedure;

(b) Concrete is mixed only in amounts of immediate use;

(c) Set concrete is not used orre-tamped;

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 (d) Concrete is placed without segregation or loss of
material;

(e) Concrete is plastic when placed;

(f) Concrete in each lift or section is placed continuously;

(g) Concrete is consolidated by vibrations without

overworking;

(h) Vibrators are not used to transport freshly poured

concrete;

(i) Laitance has been removed from construction joints,

and that joint surfaces have been slushed with grout
before new concrete is placed;

(j) Cast concrete tops and slab work is struck too required
level and floated-off on the disappearance of water
sheen;

(k) Finished surfaces are scratched, toweled or broomed as

specified; and,

(l) Placing is finished within the time specified.

(3) After concreting, check that,

(a) Concrete is cured for the required time and maintained

within the allowable temperature range;

(b) Concrete is protected against mechanical disturbances,

water flow, loafing, shock, and vibration during curing;
and,

(c) On removal of forms, defects and tie holes are patched,

and that fins are removed.

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