WOQOD PETROL STATION

AT AL MARKHIYA EXTENSION

SPECIFICATIONS - PART B

INDEX
SECTION 5 CONCRETE
SECTION 16 STRUCTURAL STEEL WORKS
WOQOD PETROL STATION
AT AL MARKHIYA EXTENSION

Section 5 CONCRETE

Part 1 General
Part 2 Aggregates
Part 3 Cement
Part 4 Water
Part 5 Admixtures
Part 6 Property Requirements
Part 7 Batching and Mixing
Part 8 Transportation and Placing of Concrete
Part 9 Formwork
Part 10 Curing
Part 11 Reinforcement
Part 12 Joints
Part 13 Inspection and Testing of Hardened Concrete
Part 14 Protective Treatments for Concrete
Part 15 Hot Weather Concreting
Part 16 Miscellaneous
Part 17 Not used
Part 18 Not used
Part 19 Not used
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WOQOD PETROL STATION Section 5 Part 1 General Page 1

1. GENERAL
1.1 INTRODUCTION

1.1.1 Scope
1.1.2 References
1.1.3 Definitions

1.2 PRODUCTS

1.2.1 Approved Products

1.3 IMPLEMENTATION
1.3.1 Approved Installers
1.3.2 Field Quality Control
1.3.3 Rejected materials
1.3.4 Records
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WOQOD PETROL STATION Section 5 Part 1 General Page 2

1. GENERAL

1.1 INTRODUCTION

1.1.1 Scope

1 This Section includes the requirements for concrete work for pipelines, roadworks, runways,
structures, water retaining structures, foundations and bases for structures and equipment.

2 This Part includes relevant standards, definitions, abbreviations, and requirements for testing
facilities, rejected materials, and record keeping.

3 Related Sections are as follows:

Section 1, General
Section 2, Demolition and Alteration
Section 4, Piling,
Section 6, Roadworks
Section 8, Sewerage
Section 9, Mechanical and Electrical Equipment
This Section:
Part 2, Aggregates
Part 3, Cement
Part 4, Water
Part 5, Admixtures
Part 6, Property requirements
Part 7, Batching and mixing
Part 8, Transportation and placing of concrete
Part 9, Formwork
Part 10, Curing
Part 11, Reinforcement
Part 12, Construction joints
Part 13, Inspection and testing of hardened concrete
Part 14, Protective coatings to concrete
Part 15, Hot weather concrete
Part 16, Miscellaneous

1.1.2 References

1 The following standard is referred to in this Part:

BS 6100, Glossary of Building and civil engineering terms.
BS EN 12390-1, Shape, dimensions and other requirements for specimens and moulds
BS EN 12350-1, Method of sampling fresh concrete in site
BS EN 12390-2, Making and curing specimens for strength tests

GS 939, Preparation of concrete specimen for compressive strength test

1.1.3 Definitions

1 Definitions used in this Section follow the requirements of BS 6100.

The following are terms and abbreviations used:

°C degree Celsius
cal calorie
cm centimetre
d day
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WOQOD PETROL STATION Section 5 Part 1 General Page 3

fcu characteristic cube strength of concrete

GGBFS ground granulated blast furnace slag
GUTS guaranteed ultimate tensile strength
h hour
kg kilogram
kJ kilojoule
kN kilonewton
l litre
m metre
m2 square metre
m3 cubic metre
mg milligram
min minute
mm millimetre
mm2 square millimetre
months months
MPa megapascal
MSRPC moderately sulphate resisting Portland cement
OPC ordinary Portland cement
PFA pulverised fuel ash
PVC polyvinylchloride
s second
SRPC sulphate resisting Portland cement
ton 1000 kg

2 Reference to a technical society, institution, association or governmental authority is made in

accordance with the following abbreviations.

AASHTO American Society of State Highway and Transportation Officials

ACI American Concrete Institute
ASTM American Society for Testing and Materials
AWS American Welding Society
BS British Standard
BSCP British Standard Code of Practice
BSI British Standards Institution
C & CA Cement and Concrete Association
CIRIA Construction Industry Research and Information Association
CRSI Concrete Reinforcing Steel Institute
CS Concrete Society
DIN Deutsches Institut fur Normung e.V.
EN Euro Norm
FHWA Federal Highway Authority
ICE Institution of Civil Engineers
ISO International Organisation for Standardisation
PCI Prestressed Concrete Institute
UK DOT United Kingdom Department of Transport

1.2 PRODUCTS

1.2.1 Approved Products

1 The contract specific documentation may identify approved products and approved or
prequalified manufacturers and suppliers of products used in concrete work.
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WOQOD PETROL STATION Section 5 Part 1 General Page 4

1.3 IMPLEMENTATION

1.3.1 Approved Installers

1 The contract specific documentation may identify approved or prequalified providers of

concrete construction services.

1.3.2 Field Quality Control

1 CONTRACTOR shall carry out the test procedures required by this Section and any other
tests and test procedures as directed by WOQOD Representative from time to time. The test
procedures shall be carried out using the facilities of an approved independent testing
laboratory.

2 Supply, storage, sampling and testing of materials shall be the responsibility of the
Contractor, unless the Contract specifies others.

3 WOQOD Representative may also require CONTRACTOR to take samples of materials and
deliver them to the Central Materials Laboratory for additional tests to be carried out by the
Employer. Sampling procedures and sample sizes shall conform to the requirements shown
in Table 1.1.

4 The minimum equipment required for testing on Site is given in Table 1.2. This equipment
shall be maintained on Site at all times during concreting operations together with the
necessary scoops, buckets, sample containers, and other items required for sampling. The
cube curing tank shall be located in an air-conditioned area.

1.3.3 Rejected materials

1 Any material rejected by WOQOD Representative, in particular cement which has

deteriorated or aggregates which have segregated or become contaminated, shall be
immediately removed from the Site.

1.3.4 Records

1 CONTRACTOR shall maintain on the Site full records of all work carried out accurately
related to the location of the work on site, which shall include:

(a) the time and date when all concrete was poured, formwork removed and when
formwork props were fully removed
(b) all cubes and other tests
(c) daily maximum and minimum temperatures.

2 One copy of all test results shall be sent to WOQOD Representative immediately upon
completion of the tests
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WOQOD PETROL STATION Section 5 Part 1 General Page 5

Table 1.1

Sampling Procedure and

Minimum Sample Sizes for Central Materials Laboratory

Material Test Sample Size

Cement Full range of tests Composite sample of 7 kg taken from at least 12 bags
Aggregate Full range of tests 200 kg
Sieve analysis 50 kg
Chemical analysis
Soundness test
Specific gravity
Water absorption
Bulk density
Flakiness index
Dust content
Abrasion value
Aggregate crushing value 25 kg
Ten percent fines 25 kg
Immersed rotational test 100 kg
Reinforcement Tensile test 500 mm
Bend test 300 mm
Water Full range of tests 5 litres

Table 1.2
Minimum Testing Equipment for Each Site
Test Equipment to be Provided Number Required
Slump test Slump cone with base plate 1
BS 1881 Tamping rod 1
Part 2 Trowel 1
300 mm rule 1
Small scoop 1
Cube 150 mm cube moulds and base plate 6
making 1.8 kg Tamping bar 380 mm long with
BS 1881 25 mm square ramming face 1
Part 3 Set of tools for assembling and stripping
moulds 1
Trowel as for slump test -
Scoop as for slump test -
Mould oil in closed container with brush 1

Cube curing Hessian or sacking, impervious sheet lot

BS 1881 Maximum/minimum thermometer 1
Part 3 Waterproof marking crayon/paint or
equivalent 1
Curing tank (in air conditioned room) 1
Supply of packing materials for sending
cubes to commercial laboratory lot
Concrete Concrete thermometer 1 1
temperature

Note: The use of 100 mm cube moulds is not permitted.

END OF PART
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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 1

2. AGGREGATES

2.1 GENERAL

2.1.1 Scope
2.1.2 References
2.1.3 Source Approval
2.1.4 Sampling

2.2 QUALITY AND TESTING

2.3 STORAGE

2.4 FINE AGGREGATE FOR CONCRETE AND MORTAR

2.5 COARSE AGGREGATE FOR CONCRETE

2.6 COMBINED AGGREGATE FOR CONCRETE

2.7 WASHING AND PROCESSING

2.8 AGGREGATES FOR WATER RETAINING STRUCTURES

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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 2

2. AGGREGATES

2.1 GENERAL

2.1.1 Scope

1 This part covers the requirements of aggregates for use in structural concrete.

2 Related Sections and Parts are as follows:

This Section
Part 3, Cement
Part 4, Water
Part 6, Property Requirements
Part 7, Batching and Mixing
Part 8, Transportation and Planning of Concrete
Part 15, Hot weather Concreting

2.1.2 References
QS 25/2007 Aggregates for Asphalt Mixtures and Concrete Mixtures
QS 997 Natural Construction Sand

GS 1455 Testing Aggregates – Determination of Aggregate Size and Particle Shape

Part2: Determination of Sand Equivalent
GS 1456 Testing Aggregates – Determination of Aggregate Size and Particle Shape
Part3: Method of Determination of Flakiness Index
GS 1457 Testing Aggregates – Determination of Aggregate Size and Particle Shape
Part4: Elongation Index and Angularity Number
GS 1458 Physical Tests for Aggregates Part1: Specific Gravity and Absorption of
Water for Fine Aggregate
GS 1459 Physical Methods of Tests for Aggregates Part2: Specific Gravity and
Absorption of Water for Coarse Aggregate
GS 1460 Physical Tests for Aggregates Part3: Unit Weight and Voids in Aggregate
GS 1461 Physical Tests for Aggregates Part4: Method of Determination of Shell
Content in Coarse Aggregate
GS 1462 Mechanical Tests for Aggregates Part3: Determination of the Required
Crushing Value to Produce 10% Fine Materials
GS 1463 Mechanical Tests for Aggregates Part4: Determination of the Crushing Value
for Coarse Aggregates

BS 812, Testing aggregates

BS EN 12620 Aggregates for Concrete
BS EN 1744-1 Tests for chemical properties of aggregates, Chemical analysis
BS EN 1367-4 Determination of Drying Shrinkage

ASTM C40, Test Method for Organic Impurities in Fine Aggregates for Concrete
ASTM C88, Test Method for Soundness of Aggregates by Use of Sodium Sulphate or
Magnesium Sulphate
ASTM C123, Test Method for Lightweight Pieces in Aggregate
ASTM C127, Test Method for Specific Gravity and Absorption of Coarse Aggregate
ASTM C128, Test Method for Specific Gravity and Absorption of Fine Aggregate
ASTM C131, Test Method for Resistance to Degradation of Small-Size Coarse Aggregate
by Abrasion and Impact in the Los Angeles Machine
ASTM C142, Test Method for Clay Lumps and Friable Particles in Aggregates.
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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 3

ASTM C227, Test Method for Potential Alkali Reactivity of Cement-Aggregate

Combinations (Mortar-Bar Method)
ASTM C289, Test Method for Potential Alkali-Silica Reactivity of Aggregates (Chemical
Method)
ASTM C535, Test Method for Resistance to Degradation of Large-Size Coarse Aggregate
by Abrasion and Impact in the Los Angeles Machine

2.1.3 Source Approval

1 CONTRACTOR shall submit to WOQOD Representative for approval full details of the
proposed sources of aggregate. These sources of aggregate supply shall be regularly and
thoroughly investigated to ensure that the quality of the material supply is satisfactory and
that it does not deteriorate during the performance of the project.

2.1.4 Sampling

1 CONTRACTOR shall provide samples of both fine and course aggregate to WOQOD
Representative, in accordance with the requirements of BS 812 Part 101, Guide to Sampling
and Testing Aggregates, for testing at least two weeks before beginning deliveries to the Site.

2 All samples shall be taken in the presence of WOQOD Representative.

2.2 QUALITY AND TESTING

1 Aggregates shall consist of tough, hard, durable and uncoated particles containing no harmful
material in quantities sufficient to adversely affect the concrete or reinforcing steel,
and shall contain no materials likely to cause staining or otherwise disfigure the concrete
surface.

2 Aggregates which shall be obtained from a source approved by WOQOD Representative,

shall comply with the requirements of QS 25/2007 and QS 997 as minimum requirements
and BS EN 12620 except as modified here under. If required by WOQOD Representative,
and in order to comply with these requirements the aggregates shall be washed clean with
potable water.

3 CONTRACTOR shall provide all data as specified in BS EN 12620.

4 CONTRACTOR shall satisfy WOQOD Representative that aggregates to be supplied will not
give rise to alkali aggregate reaction with the cement.

5 Sampling of the aggregates shall be carried out in accordance with the requirements of BS
812 and BS EN 12620.

6 Fine aggregates shall be natural sand or manufactured crushed rock sand. Crushed rock
sand shall be the direct product of a manufacturing process, not the by-product of coarse
aggregate production.

7 Beach sand shall not be permitted for use in concrete mixes.

8 The use of clean Dune Sand, blended with coarser sand, may be permitted providing it can
be shown that the sand is free from contaminants.
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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 4

9 Aggregates shall meet the requirements of Table 2.1

10 Frequency of routine testing shall meet the requirements of Table 2.2

11 Mineralogical tests are to be carried out as instructed by WOQOD Representative.

12 No aggregate deliveries shall be made to the Site until WOQOD Representative has
approved the samples as complying with this specification.

13 Samples of aggregates shall be tested in accordance with the requirements of table 2.2.

2.3 STORAGE

1 CONTRACTOR shall provide a means of storing aggregate at each point where concrete is
made such that
(a) each nominal size of coarse aggregate and the fine aggregate shall be kept
separated at all times
(b) contamination of the aggregates by the ground or other foreign matter shall be
effectively prevented at all times
(c) each heap of aggregate shall be capable of draining freely
(d) storage shall be such as to prevent segregation
(e) stockpiles shall be on hard and clean surfaces with not more than 5 % slope
(f) stockpiles shall be protected from direct sunlight

2 CONTRACTOR shall maintain the stockpiles of coarse aggregate in separate gradings.

3 The preparation, location and size of any stockpiles, and the methods of segregation shall be
to the approval of WOQOD Representative.

Table 2.1

Limits for Physical, Chemical and Mechanical

Properties of Aggregates for Concrete

Item Test Methods Permissible Limits

No. Requirement BS 812 ASTM GS Fines Coarse
1. Grading Part 103 Standard Standard
(dry)
2. Material finer than 0.075 mm. Part 103
Natural, uncrushed/ Crushed (wet) 3% max 2% max
Crushed rock 5% max 2% max
3. Clay lumps and friable particles C142 3% max 2% max
4. Lightweight pieces C123 0.5% max 0.5% max
5. Organic impurities C40 Colour standard not darker
than Plate No. 3
6. Water absorption (saturated Part 2 C128/ 1458/ 2.3% max 2.0% max
surface dried) C127 1459
7. Specific gravity (apparent) Part 2 C128/ 2.6 min 2.6 min
C127
8. Shell content: Part 106 3 % max 3 % max
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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 5

9. Particle shape:
Flakiness index Part 1456 30 % max
Elongation index 105.1 35 % max
Part 1457
105.2
10. Acid soluble chlorides : Part 117
A. Reinforced concrete with
SRPC 0.06 % max 0.03% max
OPC and MSRPC 0.06 % max 0.03% max
B. Mass Concrete with
SRPC 0.06 % max 0.03% max
OPC/MSRPC 0.06 % max 0.03% max
C. Prestressed Concrete and
Steam cured structural
Concrete 0.01 % max 0.01% max
11. Acid soluble sulphate Part 118 0.4% max 0.3% max
12. Loss by Magnesium Sulphate C88 15 % max 15 % max
Soundness (5 cycles)
13. Mechanical strength :
10 % fines value (dry condition) Part 111 150 kN min
Aggregate Impact value Part 112 25 % max
Loss by Los Angeles abrasion C131/ 30 % max
C535
14. Drying shrinkage Part 120 0.05 % max
15. Potential reactivity :
 Of aggregates: C289 Not reactive
Alkali-silica Reaction C586
Alkali-carbonation reaction
 Of cement aggregate C227 6 month expansion 0.10 %
combination Max.

Table 2.2

Frequency Of Tests On Aggregates

Item Requirement Test Method Test Frequency

1. Grading BS 812: Part 103 Every 2 weeks or per 100m3
whichever is more frequent
2. Material finer than 0.075 mm BS 812 : Part 103 Every 2 weeks or per 100m3
whichever is more frequent
3. Clay lumps and friable particles ASTM C142 Every 2 weeks or per 100m3
whichever is more frequent
4. Organic impurities ASTM C40 Each month or per 200 m3,
whichever is more frequent
5. Water absorption ASTM C128/C127 Every 2 weeks or per 100m3
whichever is more frequent
6. Specific gravity ASTM C128/C127 Every 2 weeks or per 100m3
whichever is more frequent
7. Shell content BS 812 : Part 106 Each month or per 100 m3,
whichever is more frequent
8. Particle shape BS 812 : Part 105 Every 2 weeks or per 100m3
whichever is more frequent
9. Acid soluble chlorides BS EN 1744-1:1998 Every 2 weeks or per 100m3
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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 6

whichever is more frequent

10. Acid soluble sulphates BS EN 1744-1: 1998 Every 2 weeks or per 100m3
whichever is more frequent
11. Loss by Magnesium Sulphate ASTM C88 Each month
Soundness
12. Mechanical strength
10% fines or aggregate impact BS 812 : Parts 111/112 Every 2 weeks or per 100m3
value whichever is more frequent

Los Angeles abrasion ASTM C131/C535 Each Month

13. Moisture variation in sand Twice daily

(moisture meter)
14. Drying shrinkage BS EN 1367-4 At the start of the project and
whenever there is a change
in the source of supply
15. Potential reactivity :
 Of aggregates:
- Alkali-silica Reaction ASTM C289
- Alkali-carbonation reaction ASTM C586 As directed by the WOQOD
Representative
 Of cement-aggregate ASTM C227
combination

Note : Frequency ; m3 means per volume of concrete produced.

2.4 FINE AGGREGATE FOR CONCRETE AND MORTAR

1 Fine aggregate shall consist of natural clean sand, stone screenings or artificial sand or a
combination thereof, confirming to the requirements of grading and physical properties
complying with QS 997, QS 25/2007 and subject to WOQOD Representative’s acceptance

2 The gradation of fine aggregate for concrete and mortar shall be in accordance with the
gradation designations in QS 997 and as shown in Table 2.3

3 For mortar where joints thicker than 12.5 mm are employed, the grading of aggregate shall
comply with that of zone 2 or zone 3 of table 2.3. In the case where joints up to a maximum of
12.5 mm are employed the grading of aggregate shall comply with tale 2.3A

Table 2.3
Fine Aggregate Grading
BS 410 Percentage Weight Passing BS Sieves
Test Grading Grading Grading
Sieve Zone 1 Zone 2 Zone 3
mm
10.00 100 100 100
5.00 90-100 90-100 90-100
2.36 60-95 75-100 85-100
1.18 30-70 55-90 75-100

µm
600 15-34 35-59 60-79
300 5-20 8-30 12-40
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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 7

150 0-10 0-10 0-10

75 (a) 0-3 0-3 0-3
75 (b) 0-5 0-5 0-5

(a) natural sands

(b) crushed rock

Table 2.3A

Grading of Aggregate for mortar where Joints are up to a Maximum of 12.5 mm

Sieve Size Percent Passing

(mm)
4.75 100
2.36 95-100
1.18 70-100
0.600 40-75
0.300 10-35
0.150 2-15
0.075 0-5

4 Each batch of aggregate delivered to the Site shall be kept separate from previous batches,
and shall be stored for at least three working days before use to allow for inspection and tests
to be carried out.

5 The aggregate used shall be clean, sharp, natural or crushed sand or a uniform mixture of
both.

6 CONTRACTOR shall mechanically wash the aggregate to remove salts and other impurities
in order to meet the specified requirements.

7 The storage area for clean washed sand shall be shaded from the direct rays of the sun and
shall be screened for protection from dust. The area in the neighbourhood of stockpile/ mixing
plant shall be watered as necessary, to reduce as far as possible the rising of dust.

2.5 COARSE AGGREGATE FOR CONCRETE

1 The coarse aggregate shall consist of clean crushed rock and free from deleterious matter,
conforming to the requirements of grading and physical properties requirements complying
with QS25/2007 as a minimum requirements and subject to WOQOD Representative’s
acceptance with in BS EN 12620 and as shown un Table 2.4

2 Aggregates that are deleteriously reactive with the alkalis in cement shall not be used.

3 CONTRACTOR shall mechanically wash the aggregates to remove salts and other impurities
in order to meet the requirements specified.
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WOQOD PETROL STATION Section 5 Part 2 Aggregates Page 8

Table 2.4

Coarse Aggregate Grading

BS Percentage by Weight Passing BS Sieves for normal sizes

Sieve Graded Aggregate Single Sized Aggregate
Size 40 mm 20 mm 14 mm 40 mm 20 mm 14 mm 10 mm 5 mm
(mm) to 5 mm to 5 mm to 5 mm @

50.0 100 - - 100 - - - *

37.5 90-100 100 - 85-100 100 - - -
20.0 35-70 90-100 100 0-25 85-100 100 - -
14.0 25-55 40-80 90-100 - 0-70 85-100 100 -
10.0 10-40 30-60 50-85 0-5 0-25 0-50 85-100 100
5.0 0-5 0-10 0-10 - 0-5 0-10 0-25 45-100
2.36 - - - - - - 0-5 0-30

@ Used mainly in precast concrete products

2.6 COMBINED AGGREGATE FOR CONCRETE

1 The material passing the 0.075 mm sieve shall not exceed 3% of the combined aggregate (by
weight)

2 Combined aggregate gradation used in the work shall be as specified, except when otherwise
approved or directed by WOQOD Representative.

4 Changes in the approved gradation shall not be made during the progress of the works
unless approved or directed by WOQOD Representative.

2.7 WASHING AND PROCESSING

1 Where aggregates have been washed shortly before delivery to the Site, or if stockpiles have
been sprayed to cool them samples of the aggregate shall be taken frequently to determine
the correct amount of water to add to the mix.

2.8 AGGREGATES FOR WATER RETAINING STRUCTURES

1 Aggregates for use in water retaining structures shall comply with the requirements of BS EN
12620.

2 Water absorption, as measured in accordance with BS 812: Part 2 shall not be greater than
2%.

END OF PART
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WOQOD PETROL STATION Section 5 Part 3 Cement Page 1

3. CEMENT

3.1 GENERAL

3.1.1 Scope
3.1.2 References

3.2 SOURCE APPROVAL

3.3 SAMPLING

3.4 QUALITY AND TESTING

3.4.1 WHITE CEMENT

3.5 DELIVERY, STORAGE AND HANDLING

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WOQOD PETROL STATION Section 5 Part 3 Cement Page 2

3. CEMENT

3.1 GENERAL

3.1.1 Scope

1 This Part covers the requirements for the testing and use of cement in structural concrete.

2 Related Sections and Parts are as follows:

Part 6, Property Requirements

3.1.2 References

1 The following standards are referred to in this part

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

cements
BS 146, Portland-blast furnace cement
BS 1370, Low heat Portland cement
BS 4027, Sulphate-resisting Portland cement
BS 4550, Methods of testing cement
ASTM C 150, Standards specification for Portland cement.

3.2 SOURCE APPROVAL

1 CONTRACTOR shall submit to WOQOD Representative for approval full details of the
proposed source of cement. These sources of cement supply shall be regularly and
thoroughly investigated to ensure that the quality of the material supply is satisfactory and
that it does not deteriorate during the performance of the project. The cement source shall
not be changed without the WOQOD Representative’s acceptance.

2 CONTRACTOR shall supply WOQOD Representative with the manufacturer’s test sheets for
each consignment of cement, certifying that the cement is in compliance with the relevant
standards.

3 CONTRACTOR shall submit to WOQOD Representative the date of manufacture and proof
that the specifications have been complied with, certified by an independent agency in the
country of origin.

3.3 SAMPLING

1 The methods of obtaining samples of cement for testing shall be carried out as described in
BS 4550 Part 1

2 Each delivery of cement to the Site shall be accompanied by the manufacturer’s test
certificates. If such certificates are not available, the CONTRACTOR shall take representative
samples from different bags or containers of each consignment, or as required by the
WOQOD Representative. The samples shall be packed, labelled and sent for testing to an
accepted testing laboratory. Fourteen days shall be allowed for the WOQOD
Representative’s review of these samples.
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WOQOD PETROL STATION Section 5 Part 3 Cement Page 3

3.4 QUALITY AND TESTING

1 The specification requirements for ASTM cement types I, II, III, IV and V and ordinary
Portland cement, rapid hardening Portland cement, sulphate resisting Portland cement and
low heat cement are given in Tables 3.1 and 3.2.

2 Ordinary Portland cement and rapid hardening Portland cement shall meet the requirements
of BS EN 197-1. Low heat Portland cement shall conform to the requirements of BS 1370.
Sulphate resisting Portland cement shall conform to the requirements of BS 4027. Portland
blast-furnace cement and low heat blast-furnace cement shall conform to the requirements of
BS 146.

3 ASTM cement types I, II, III, IV and V shall meet the requirements of ASTM C 150.

4 The testing of cement shall be carried out in accordance with the provisions of BS 4550 Parts
2 and 3.

Table 3.1

Specification Requirements for the Chemical Composition of Portland Cements Made to BS and
ASTM Standard Specifications

Compound/ Property ASTM C 150 BS EN 197-1 BS BS 1370

I II III IV V OPC RHP 4027 low heat
SRPC
Silica, (SiO2), % > - 20.0 - - - - - - -
Alumina, (Al2O3), % < - 6.0 - - - - - - -
Ferric Oxide, Fe2O3), % < - 6.0 - 6.5 - - - - -
Magnesia (MgO), % < 5.0 5.0 5.0 5.0 5.0 5.0** 4.0 5.0** 4.0
Sulphur trioxide (SO3),%:
when tricalcium
aluminate < 8.0% < 3.0 3.0 3.5 2.3 2.3 - - - -
when tricalcium
aluminate > 8.0% < 3.5 - 4.5 - - - - - -
when tricalcium
aluminate < 5.0% < - - - - - - 3.0 - 2.5
when tricalcium
aluminate > 5.0% < - - - - - - 3.5 - 3.0
Loss on ignition, % < 3.0 3.0 3.0 2.3 3.0 3.0 4.0 3.0 4.0
Insoluble residue, % < 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5
Tricalcium silicate (C3S),% < - - - 35.0* - - - - -
Dicalcium silicate (C2S),% > - - - 40.0* - - - - -
C3S + C2S, % - - - - - 66.7** - 66.7** -
CaO/SiO2, - - - - - 2.0** - 2.0** -
Tricalcium aluminate (C3A),% < - 8.0 15.0 7.0* 5.0^ - - 3.5 -
Tetracalcium aluminoferrite plus
twice the tricalcium aluminate - - - - 25.0^ - - - -
(C4AF+2(C3A)),% <
C3A for moderate sulphate
Resistance , % < - - 8.0 - - - - - -
C3A for high sulphate
Resistance,% < - - 5.0 - - - - - -
C3S+C3A for moderate heat
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WOQOD PETROL STATION Section 5 Part 3 Cement Page 4

of hydration,% < - 58.0 - - - - - - -

Equivalent Alkalis
(Na2O+0.658K2O) 0.6 0.6 0.6 0.6 0.6 - - 0.60
for low alkali cement,% <
Chloride, % < - - - - - 0.10 0.10 0.10 -

* Does not apply when heat of hydration option is specified

^ Does not apply when sulphate resistance limit is specified
@ Low-alkali cement may be produced
** Applies to the klinker rather than to the cement itself.

Table 3.2

Specification Requirements for Physical and Other Properties of Portland Cements Made to BS and
ASTM Standard Specifications
ASTM C 150 BS EN 197-1 BS 4027 BS 1370
I II III IV V OPC RHPC SRPC low heat
Property
Air entrained in mortar***, % of
volume < 12 12 12 12 12
Setting Time (min)
 Vicat Test
Initial (min) > 45 45 45 45 45 60 45 60 60
Final (h) < 6.25 6.25 6.25 6.25 6.25 - 10 - 10
 Gillmore test
Initial (min) > 60 60 60 60 60 - - - -
Final (h) < 10 10 10 10 10 - - - -
Fineness
 Air Permeability (m2/kg) > 280 280 - 280 280 - 350 - 275
 Turbidimeter (m2/kg) > 160 160 - 160 160 - - - -
Soundness
 Autoclave expansion (%) < 0.8 0.8 0.8 0.8 0.8 - - - -
 Le Chatelier (mm) < - - - - - 10 10 10 10
Compressive strength (MPa) >
 Mortar Cubes
1d - - 12.0 - - - - - -
2d - - - - - 20 - 20 -
3d 12.0 10.0^ 24.0 - 8.0 - 29 - 10
7d 19.0 17.0a - 7.0 15.0 - - - -
28 d 28 28 - 17.0 21.0 42.5* 46** 42.5* 28**
 Concrete Cubes
2d - - - - - - 15 - -
3d - - - - - - - - 5
28 d - - - - - - 38 - 19**
Heat of Hydration (kJ/kg) <
7d - 290aa - 250aa - - - - 250
28 d - - - 290aa - - - - 290
^ Becomes 7.0 if the heat of hydration option or C3S+C3A chemical limit is specified
a Becomes 12.0 if the heat of hydration option or C3S+C3A chemical limit is specified
* And not exceeding 62.5
** And higher than the compressive strength at 3 days
*** shall not be the same percent in concrete mix
aa Optional
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 3 Cement Page 5

3.4.1 White Cement

1 Where white cement is required for architectural purposes the typical compound composition
for white Portland Cement shall be as shown on Table 3.3

2 The manufacturing process used for the production of white Portland cement shall ensure
that the impurities which can affect the finished product are excluded. In particular coal ash
shall not be used in kiln fuel, iron shall not be used on flux in clinkering and grinding shall not
be carried out by ball grinding,

Table 3.3

Typical Compound Composition of White Portland Cement

Compound Content, percent

Tricalcium Silicate (C3S) 51
Dicalcium Silicate (C2S) 26
Tricalcium Alumina (C3A) 11
Tetracalcium Alumina Ferrite (C4AF) 1
Sulphur trioxide (SO3) 2.6
Alkalis 0.25

3.5 DELIVERY, STORAGE AND HANDLING

1 Cement shall be delivered to the Site in sealed and branded bags, or in the manufacturer’s
containers, bearing the manufacturer’s name, cement type and date of manufacture, in
batches not exceeding 100 tons.

2 Cement shall be stored at the site in such a manner, as to prevent its deterioration, intrusion
of moisture and foreign matter. It must be kept dry at all times. Immediately upon arrival at
the Site CONTRACTOR shall store the cement in

(a) silos designed for the purpose, or

(b) dry, weather tight and properly ventilated structures with floors raised a minimum of
450 mm above the ground with adequate provision to prevent absorption of moisture.

3 All storage facilities shall be subject to the approval of WOQOD Representative, and shall be
such as to permit easy access for inspection and identification. Prolonged storage of cement
at site is to be avoided.

4 Each consignment of cement shall be kept separately, and CONTRACTOR shall use the
consignments in the order in which they are received. The CONTRACTOR shall keep records
of the various consignments of cement in store, giving quantities received and used, and the
sections of the work in which the cement has been used, on a daily basis and weekly return
to the WOQOD representative accordingly. Cement used in the Works shall be free flowing
and free from lumps.

5 In no case shall bagged cement be stored in stacks more than eight bags high.

6 A free passage of at least 1 m shall be left between the cement and the side walls of the
structure.
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 3 Cement Page 6

7 Different types of cement shall be kept in clearly marked separate storage facilities.

8 Cement delivered to Site in drums or bags by the supplier or manufacturer shall be stored in
the drums or bags until used in the Works.

9 Any cement in drums or bags which have been opened shall be used immediately.

10 Cement that has partially of fully caked in storage will not be permitted in work and shall be
immediately removed from the storage area. Any bag or package or sample of cement which
has been damaged, or rebagged or in any way has deteriorated shall be rejected either as an
individual bag or package or as the whole consignment in which such bag, package or
sample is contained, as advised by the WOQOD representative.

11 Where Site limitations preclude the storage of cement of Site, cement shall be stored at a
central location and shall be delivered daily as required to specific job sites.

12 CONTRACTOR shall provide weighing machines which shall be kept permanently in each
shed for checking the weight of the bags or barrels of cement. The weighing machines shall
be calibrated by an independent agency. WOQOD Representative shall have access at all
times to the cement storage sheds.

13 During transport and storage the cement shall be fully protected from all weather elements.

14 Any consignment of cement not used within two months from the date of manufacture and
cement which in the opinion of WOQOD Representative is of doubtful quality shall not be
used in the Works until it has been retested and test result sheets showing that it complies in
all respects with the specification and relevant standards have been delivered to WOQOD
Representative.

15 Cement stored for longer than 28 days shall be tested for “loss on ignition” prior to use to
check for deterioration, and any cement which fails the test shall not be used in the works.

END OF PART
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 4 Water Page 1

4. WATER

4.1 GENERAL

4.1.1 Scope
4.1.2 References

4.2 QUALITY OF WATER

4.2.1 General
4.2.2 pH of Water
4.2.3 Permissible Temperatures
4.2.4 Supply and Storage

4.3 TESTING AND SAMPLING

___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 4 Water Page 2

4. WATER

4.1 GENERAL

4.1.1 Scope

1 This Part includes water used for concrete mixes, washing of aggregates and equipment,
wetting of surfaces or ponding during curing or for wetting formwork and washing
reinforcement.

2 Related Sections and Parts are as follows:

This Section
Part 2, Aggregates
Part 6, Property Requirements
Part 9, Formwork
Part 10, Curing
Part 11, Reinforcement

4.1.2 References

1 The following standards are referred to in this Part:

BS EN 196-1, determination of strength

BS EN 196-3, Determination of setting time and soundness
BS EN IAO 9963-1, Determination of total and composite alkalinity
BS EN ISO 9963-2, Determination of carbonate alkalinity
BS 1377, Methods of test for soils for civil engineering purposes.
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 2690, Methods of testing water used in industry
BS 6068, Water quality
BS 4550, Test for setting timer

ASTM C109, test Method for Compressive Strength of Hydraulic Cement Mortars (using 2-in
or 50 mm Cube Specimens)

4.2 QUALITY OF WATER

4.2.1 General

1 The water shall be clean, fresh and free from oil, organic matter and other deleterious
substances.

2 Water to be used for making and curing concrete shall be potable and shall comply with the
requirements of BS 3148 except as modified below.

4.2.2 pH of Water

1 The pH of water used in concrete works shall be as shown in Table 4.2.

___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 4 Water Page 3

4.2.3 Permissible Temperatures

1 Temperature of water for concrete shall not be less than 5 °C and not more than 25 °C

2 Water may be cooled to not less than 5 °C by the gradual addition of chilled water or ice as
follows:
(a) no ice particles shall be present in the mix
(b) alternatively, flaked ice may be used
(c) ice to be used shall be crushed and shall be a product of frozen water which
complies with the acceptance criteria of Tables 4.1 and 4.2.

3 Every effort should be made to protect water pipes and tanks from the sun; e.g., burying,
shading, insulation or painting white.

4.2.4 Supply and Storage

1 CONTRACTOR shall make his own arrangements and obtain the approval of WOQOD
Representative for the supply of water.

3 Storage of water should be such that contamination is prevented from occurring. Any
measures taken to avoid contamination of the water shall be to the approval of WOQOD
Representative.

4.3 TESTING AND SAMPLING

1 Whenever required to do so by WOQOD Representative CONTRACTOR shall take samples

of the water being used, or which it is proposed to use, for mixing concrete and test them for
quality.

2 Samples of water of not less than 5 l shall be taken, sealed and sent for testing at an
approved independent laboratory, prior to the approval of any water source, and whenever
the sources of water is changed periodically during the continuance of its use.

3 Water of questionable quality should comply with the physical tests of Table 4.1 and chemical
limitations listed in Table 4.2.

4 No source of water shall be used until the required tests have demonstrated its suitability for
concreting.

5 The use of water from a municipal or government supply does not preclude the requirement
for testing.

Table 4.1

Acceptance Criteria and Physical Tests for Mixing Water

Test Method Limits

Compressive strength, min % BS EN 196-1 90%

control at 7 d
Setting time, deviation from
control, h:min BS EN 196-3 from 1:00 early to
1:30 later
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 4 Water Page 4

Table 4.2

Chemical Limitations for Mixing Water

Max. Concentration Test Method Maximum Limit,

mg/l
(a) Chloride (as CI) BS 1377 : Part 3 500
(b) Sulphates (as S03) BS 1377 : Part 3 1000
(c) Alkali carbonates and BS 6068-2.51 500
bicarbonates BS EN ISO 9963-1
BS EN ISO 9963-2

(d) Total dissolved ions, BS 1377 : Part 3 2000

including a, b and c
above
(e) pH BS 6068-2.50 6.5 - 9.0

END OF PART
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 5 Admixtures Page 1

5. ADMIXTURES

5.1 GENERAL

5.1.1 Scope
5.1.2 References
5.1.3 Definitions
5.1.4 Submittals

5.2 USE OF ADMIXTURES

5.2.1 General
5.2.2 Trials
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 5 Admixtures Page 2

5. ADMIXTURES

5.1 GENERAL

5.1.1 Scope

1 This Part includes materials added to the concrete materials during mixing.

2 Related Sections and Parts are as follows:

This Section
Part 1, General
Part 6, Property Requirements
Part 7, Batching and Mixing
Part 16, Miscellaneous

5.1.2 References

1 The following standards and other documents are referred to in this Part:
BS EN 197-1, Cement, Composition, specifications and conformity criteria for common
cements
BS 3892-1, Specification for pulverised fuel ash for use with Portland cement
BS 5075, Concrete admixtures
BS EN 480, Admixtures for concrete, mortar and grout. Test Methods (Parts: 1, 2, 4, 5, 6, 8,
10, 11, and 12)
BS EN 934, Admixtures for concrete, mortar and grout (Parts: 2, 6)
BS 6699, Specification for ground granulated blastfurnace slag for use with Portland
cement.
EN 196, Methods of testing cement

ASTM C494, Standard Specification for Chemical Admixtures for Concrete

ASTM G61, Test Method for Conducting Cyclic Potentiodynamic Polarization
Measurements for Localized Corrosion Susceptibility of Iron, Nickel, or Cobalt Based
Alloys
ASTM G109, Test Method for Determining the Effects of Chemical Admixtures on the
Corrosion of Embedded Steel Reinforcement in Concrete Exposed to
Chloride Environments

ACI 302, Guide for Concrete Floor and Slab Construction

ACI 305, Hot Weather Concreting
ACI 308, Standard Practice for Curing Concrete

FHWA/RD-83/012, Time-to-Corrosion of Reinforcing Steel in Concrete

5.1.3 Definitions

Admixtures shall mean materials added to the concrete materials during mixing for the
purpose of altering the properties of the concrete mix.

5.1.4 Submittals

1 In addition to the specified general requirements for approval of materials, approval of

admixtures shall be subject to extensive trials to demonstrate the suitability, adequacy of
dosing arrangements and performance.
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 5 Admixtures Page 3

2 The Concrete supplier shall furnish a series of at least ten trial mixes which clearly indicate
that the use of the admixture has consistently exhibited the specified absorption, permeability
and poring values. The trial mix should be verified by an approved independent laboratory.
The Concrete supplier shall also conduct (with the aforementioned) a trial showing that a
control mix without the admixture does not exhibit a greater density than that incorporating
the admixture.

5.2 USE OF ADMIXTURES

5.2.1 General

1 Admixtures shall mean materials added to the concrete materials during mixing for the
purpose of altering the properties of the mix.

2 Where approved and or directed by WOQOD Representative, admixtures shall be used as a

means of:
(a) enhancing concrete durability
(b) increasing workability of the concrete without increasing the water:cement ratio
(c) controlling and limiting retardation and setting.

3 Admixtures shall comply with the following requirements:

(a) water reducing admixture : ASTM C494, Type A
(b) retarding admixtures : ASTM C494, Type B
(c) water reducing, high range ASTM C494, Type F
(d) retarding admixtures: ASTM C494, Type G

4 The methods of use and the quantities of admixture used shall be in accordance with the
manufacturer’s instruction and subject to WOQOD Representative’s approval after evaluation
in trial mixes and shall in no way limit CONTRACTOR’s obligations under the Contract to
produce concrete with the specified strength, workability and durability.

5 The effects of accidental overdose of the admixture and measure to be taken if an overdose
occurs shall be provided by CONTRACTOR to WOQOD Representative.

6 No admixtures containing chlorides shall be used. In particular, the use of acceleration

admixtures containing calcium chloride shall not be used.

7 The use of the admixtures shall be controlled; i.e., strict quality control to ensure correct
dosages as prescribed by the manufacturer and justified by trial mixes to be used. A
calibrated dispenser or flowmeter shall be used to for the addition of the admixture.

5.2.2 Trials

1 In addition to the standard requirements for the approval of materials, approval of admixtures
shall be subject to extensive trials to demonstrate the suitability, adequacy of dosing
arrangements and performance, when a proven history of performance can be provided to
the satisfaction of WOQOD Representative.

2 The concrete supplier shall furnish a series of at least ten trial mixes which clearly indicate
that the use of the admixture has consistently exhibited the specified absorption, permeability
and porosity values. These are to be verified by an approved independent laboratory. The
concrete supplier shall also conduct (with the aforementioned) a trial showing that a control
mix without the admixture does not exhibit a greater density than that incorporating the
admixture.
END OF PART
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page1

6. PROPERTY REQUIREMENTS

6.1 GENERAL

6.1.1 Scope
6.1.2 References
6.1.3 Submittals

6.2 GRADES OF CONCRETE

6.2.1 General
6.2.2 Design of Concrete Mixes
6.2.3 Portland Cement Concrete
6.2.5 Blinding Concrete
6.2.6 Fiber-Reinforced Concrete
6.2.7 No-fine concrete

6.3 TRIAL MIXES

6.4 QUALITY AND TESTING

6.4.1 General
6.4.2 Tests

6.5 PRELIMINARY TEST (TRIAL TESTS).

6.5.1 Target Mean Strength

6.5.2 Change of Current Margin

6.6 WORKS TEST CUBES

6.7 WORKABILITY

6.7.1 General
6.7.2 Slump Tests
6.7.3 Vebe and Compaction Factor

6.8 PERMEABILITY

6.8.1 General
6.8.2 Testing

6.9 DRYING SHRINKAGE

6.9.1 Aggregate Shrinkage

6.9.2 Concrete Shrinkage

6.10 REJECTION OF CONCRETE MIXES

6.10.1 Rejection of Concrete Mixes
6.10.2 Unsatisfactory Concrete Works
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page2

6. PROPERTY REQUIREMENTS

6.1 GENERAL

6.1.1 Scope

1 This Part includes Grades 15, 20 and 35 of concrete to be used in the Works, and the
requirements for workability, permeability, and drying shrinkage.

2 Related Sections and Parts are as follows:

This Section
Part 2, Aggregates
Part 3, Cement
Part 4, Water
Part 5, Admixtures
Part 7, Batching and Mixing
Part 8, Transportation and Placing of Concrete
Part 9, Formwork
Part 13, Inspection and Testing of Hardened Concrete

6.1.2 References

1 The following standards are referred to in this Part:

GS 505, Testing Concrete Method for Determination of Compacting Factor

GS 506, Testing Concrete Method for Determination of Vebe Time
GS 507, Testing Concrete Method for Determination of Density of Compacted Fresh
Concrete
GS 508, Testing Concrete Method for Determination of Air Content for Fresh Concrete
GS 939, Preparation of Concrete Specimens for Compressive Strength Test
GS 940, Determination of the Compressive Strength of Concrete Specimens

BS EN 12350, Testing fresh concrete

BS EN 12390, Testing hardened concrete
BS 812, Testing aggregates
BS EN 12620, Aggregate for concrete
BS 1881, Methods of testing concrete
BS 4027, Specification for Sulphate-resisting Portland cement
BS 8500, Concrete
BS EN – 206-1, Concrete, Specification, performance , production and conformity
BS EN 1744, Tests for chemical properties of aggregates
BS 6073, Precast concrete masonry units
BS 8007, Design of concrete structures for retaining aqueous liquids
BS 8110, Structural use of concrete

Concrete Society Report No. 31

RILEM CPC 11.3 Absorption of water by immersion under vacuum
AASHTO T227-83

ASTM C150, Specification for Portland Cement

ASTM C232, Test Methods for Bleeding of Concrete

DIN 1048, Test methods for concrete.

___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page3

6.1.3 Submittals

1 CONTRACTOR shall submit details of mix designs to WOQOD Representative for approval.

6.2 GRADES OF CONCRETE

6.2.1 General

1 Grades of concrete to be used in the Works shall in general be as shown in Table 6.1. Where
different grades of concrete are required the design of the mix shall follow the requirements
of this specification.

2 Where adequate workability is difficult to obtain at the maximum water:cement ratio allowed,
the use of plasticizers or water reducing admixtures may be considered. Alternatively an
increase in cement content may be considered at the discretion of WOQOD Representative
where this will not adversely affect the durability of the concrete.
3 Cement contents in excess of 400 kg/m3 shall not be used unless special consideration has
been given to reduce thermal stress in the concrete, and approval has been obtained from
WOQOD Representative.

6.2.2 Design of Concrete Mixes

1 At the start of the construction period, CONTRACTOR shall design a mix for each grade of
concrete listed in Table 6.1 that is required to be built into the Works.

2 Each mix design shall be such that:

(a) the aggregate shall comprise fine aggregate and coarse aggregate no greater than
the maximum size specified in Table 6.1
(b) the combined aggregate grading shall be continuous
(c) the aggregate quantity shall be calculated by weight
(d) the mixes shall be designed to produce a concrete cube strength at twenty-eight
days after manufacture of not less than the cube strength specified in Table 6.1.

3 For concrete using other than moderately sulphate resisting Portland cement (ASTM Type II)
or incorporating admixtures, the strengths shall not be less than those specified in Table 6.1,
but the mix designs shall be revised and agreed with WOQOD Representative.

Table 6.1

Grades of Concrete

Concrete Max. Size Min. Cement Max. Free Cube Crushing at 28 d

Grade Aggregate Content kg/m3 Water:Cement Trial Mix Works
mm Type of Ratio Test Test
Cement MPa MPa

35 20 350/MSRPC 0.4-0.45 45 35

20 20 310/MSRPC 0.55 30 20

15 20 280/MSRPC 0.55 25 15
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page4

6.2.3 Portland Cement Concrete

1 Portland cement concrete shall consist of a mixture of Portland cement, fine aggregate,
coarse aggregate, water, and additives (when required).

2 The maximum cement content shall not exceed 450 kg/m 3

2 The proportioning, mixing and placing of the mixture shall be in accordance with Parts 7 and
8 of this Section

6.2.5 Blinding Concrete

1 Blinding concrete shall be to be Grade 20 made with sulphate resisting cement unless
otherwise specified.

2 The thickness of the blinding concrete shall be as shown on the Drawings, but shall in no
instance be less than 75 mm.

3 The surface finish to blinding concrete shall be Class U2 as specified in Clause 9.3.1 of Part
9 of this Section or as directed by WOQOD Representative.

6.2.6 Fiber-Reinforced Concrete

1 Fiber-Reinforced concrete shall comprise of Type III Synthetic Fiber-Reinforced Concrete

containing synthetic fibers for which documentary evidence can be produced confirming their
long-term resistance to deterioration when in contact with the moisture and alkalis present in
cement paste and the substances present in admixtures and shall conform to BS EN 14889-2

2 Fibers for concrete shall be macro synthetic grade fibrillated fibers (100% virgin
polypropylene fibers manufactured to ISO 1873-PP-H classification code FN 28-02-045 and
containing no reprocessed olefin materials) conforming to BS EN 14889-2:2006 Class II and
specifically engineered & manufactured in an ISO 9001-2000 certified facility. The fiber
manufacturer must document evidence of a minimum of 5 years satisfactory performance
history.

3 Fibers must deliver Re3 minimum of 42% according to ASTM C1609/C1609m or Fr1 of 1.88
MPa and Fr4 of 1.72 MPa according to EN14651.

4 Provide fibers for concrete reinforcing capable of achieving a two hour fire resistance rating
when tested under ASTM E 119. Fire tests must be certified.

5 Fibers must be CE certified for structural use in concrete according to BS EN 14889-2.

6 Fibers shall be measured by mass. When the fibers are to be measured by mass, bags,
boxes, or like containers are acceptable provided that such like containers are sealed by the
fiber manufacturer and have the mass contained therein clearly marked. No fraction of a
container delivered unsealed, or left over from previous work, shall be used unless weighed.

7 Prepackaged, dry, combined materials, including fibers, shall comply with the packaging and
marking requirements of Specification ASTM C 387 or C 1480 and shall be accepted for use
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page5

provided that after addition of water, the resulting fiber reinforced concrete meets the
performance requirements of this specification.

8 Batching plant used for the preparation of continuously mixed fiber-reinforced concrete shall
comply with the applicable requirements of NRMCA. Fibers shall be added to the feed belt of
the aggregate in a batch mixing plant at the time of batching in amounts in accord with
approved submittals for each type of concrete required. The stream of fibers added to mixer
shall be at a nearly uniform rate while the mixer is mixing the materials. The batching plant
mixer shall separate the fibers using mechanical agitation to ensure full separation. The
correct dosage will be recorded at batching and shown on all required documents. Mix
concrete in strict accord with fiber-reinforced concrete manufacturer, instructions and
recommendations

9 The fibers shall be supplied in small pucks wrapped in soluble PVC to aid uniformed
dispersal and to prevent balling and clumping.

10 The manufacturer of the fiber-reinforced concrete shall furnish to the purchaser a delivery
ticket or statement of particulars on which is printed, stamped, or written, information with
details of the type, brand, and amount of fibers used.

11 The contractor shall afford the inspector all reasonable access, without charge, for the
procurement of samples of freshly mixed fiber-reinforced concrete at the time of placement to
determine compliance with the requirements of this specification.

12 The wash out test to determine the homogeneity or dispersion of fiber in FRC shall be
performed as described below.

a) Each concrete sample shall consist of at least number of three specimens, each with a
volume of concrete contained in a bucket of 10 liters capacity. Each fresh concrete
sample will be placed over a 5 mm sieve and washed with water to remove the fine
contents. From the remaining mass of aggregates and fibers, the fibers are to be
separated manually, dried and weighed. The average weight of fibers obtained is used
to determine the nominal fiber dosage, which shall not be less than 90% of the
specified fiber dosage.

b) Samples shall be taken at the average rate of the following:

i. One sample every truck, if the pour is less than or equal to 10 m3.
ii. One sample every 20 m3, if the pour is less than or equal to 90 m3.
iii. One sample every 100 m3, if the pour is greater than 90m3 and equal to or less
than 2000 m3

13 The amount of fibers shall be added at a maximum dosage of 4kg/m3 and the slump of the
FRC when delivered at site shall not exceed 180 ± 10 mm for pumped concrete.

14 If the measured slumps, time of flow, or air content fall outside the limits permitted by this
specification, make a check test immediately on another portion of the same sample. If the
results again fall outside the permitted limits, the material represented by the sample fails to
meet the requirements of this specification

15 Finishability - Pre-project trials shall be utilized to determine acceptable surface finishability

by the Engineer. The manufacturer shall provide the services of a qualified technician to
instruct the concrete supplier in proper batching and mixing of materials to be provided.
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page6

6.2.7 No-Fines Concrete

1 No-fines concrete shall be made using a coarse natural aggregate conforming to BS EN

12620 and moderately Sulphate resisting Portland cement (ASTM Type II) to ASTM C150
subject to the following requirements:
(a) no-fine aggregate shall be used in the mix
(b) grading of the coarse aggregate
(i) not less than 95 % by weight passing a 20 mm BS sieve
(ii) not more than 5 % by weight passing a 10 mm BS sieve.

2 Proportion of aggregate, cement and water shall be determined by trial mixes by

CONTRACTOR starting with a cement-aggregate ratio of one to eight by volume.

3 All the aggregate particles are to be coated with a film of cement grout.

4 The water content shall be just adequate to ensure that the cement paste completely coats
the aggregate.

5 No-fines concrete when placed shall contain no layers of laitance.

6 No-fines concrete shall not be mixed by hand.

7 Vibration shall not be used to compact no-fines concrete.

8 Three test cubes of no-fines concrete shall be made of each preliminary mix.

9 Minimum crushing strength of the chosen mix shall be 15 MPa at 28 days.

10 The porosity of no-fines concrete shall be such that water will pass through a slab 300 mm
thick at the rate of not less than 7 l/m2 • s of slab with a constant 100 mm depth of water on
the slab.

11 Where a slab incorporating vertical weep holes or drain holes is cast above a layer of nofines
concrete any polyethylene sheeting shall be pierced below the pipes forming such drain holes
and the edges of the sheeting sealed to the lower end of the pipe to prevent the ingress of
grout and fine particles from the slab concrete into the no-fines concrete.

6.3 TRIAL MIXES

1 As soon as WOQOD Representative has approved the concrete mix design for each grade of
concrete and during or following the carrying out of the preliminary tests, CONTRACTOR
shall prepare a trial mix of each grade in the presence of WOQOD Representative at least 35
days before commencement of concreting. Trial mixes shall be mixed for the same time and
handled by means of the same plant which CONTRACTOR proposes to use in the Works.
Each trial mix shall comprise not less than 0.5 m3 of concrete.

2 Where ready mix concrete is being used, the above requirement may be waived at the
discretion of WOQOD Representative if CONTRACTOR has documented previous
experience of a particular mix design with test results available.

3 The proportions of cement, aggregate and water shall be carefully determined by weight in
accordance with the CONTRACTOR's approved mix design (or modified mix design after
preliminary tests), and sieve analyses shall be made, by the method described in BS 812 and
BS EN 12620, of the fine aggregate and of each nominal size of coarse aggregate used.
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page7

4 The compacting factor of each batch of each trial mix shall be measured immediately after
mixing by the method described in GS 505 or BS 1881 and shall not be less than 0.85 nor
greater than 0.92. Slump test measurements shall also be taken immediately after mixing.

5 CONTRACTOR shall make three separate batches for each trial mix and six 150 mm
compression test cubes shall be made from each batch in the presence of WOQOD
Representative. Three cubes shall be tested at 7 d and 3 at 28 d and one to be tested at the
discretion of the WOQOD representative, after manufacture in accordance with the method
described in GS 507 or BS EN 12350-1. If either or both the average value of the strength of
the nine cubes tested at 28 d is less than the trial mix strength given in Table 6.1, or the
difference between the greatest and the least strengths is more than 20 % of the average
strengths, CONTRACTOR shall:
(a) remove from site materials from which the trial mix was prepared
(b) provide new materials and prepare and test further trial mixes until specified
requirements are achieved.

Additionally, CONTRACTOR shall measure the temperature, workability and density of

concrete in each batch

6 A full scale test of the workability of each trial mix of each grade of concrete shall be made by
CONTRACTOR in the presence of WOQOD Representative. The trial mix of each grade of
concrete shall be batched, mixed and then transported a representative distance in the
manner that the CONTRACTOR proposes to batch, mix and transport the concrete to be
placed in the Works. After discarding the first batch so made, the concrete from later batches
shall be placed and compacted in trial moulds both for reinforced and mass concrete with
dimensions typical of the Works. The sides of the moulds shall be capable of being stripped
without undue disturbance of the concrete placed therein. The sides of the moulds shall be
stripped after the concrete has set and the workability judged on the compaction obtained. If
the workability test shows that the workability required is not attained for any trial mix for any
class of concrete, the trial mix shall be redesigned by the CONTRACTOR and a further full
scale workability test shall be undertaken for that trial mix of concrete.

7 Redesign of the concrete mixes and the making and testing of preliminary and trial mixes of
concrete shall be repeated for each grade of concrete until trial mixes of concrete meeting the
requirements of the Table 6.1 and having the workability required to place it in the Works, as
demonstrated in the full scale workability test described above, have been established.

8 CONTRACTOR shall use only the approved mix of each grade of concrete in the Works. If at
any time during the construction of the Works the source of cement or aggregate is changed
or the grading of the aggregate alters to such an extent that the fraction of aggregate retained
on any sieve cannot be maintained within two percent of the total quantity of fine and coarse
aggregate when adjusted in accordance with this Clause, then further trial mixes of concrete
shall be made, tested and approved for use.

9 Preliminary laboratory tests shall be carried out to determine the mixes to satisfy the
specification with the approved materials. Trial mixes shall be tested to determine the
following properties of mixes proposed for initial field tests:
(a) bleeding in accordance with ASTM C232 (non-vibrating) shall not exceed 0.5 %
(b) drying shrinkage in accordance with BS 1881 or BS 6073 Part 1, Appendix D
(c) air content to GS 508 or BS EN 12350-7
(d) free water:cement ratio
(e) workability to BS EN 12350-2
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WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page8

(f) fresh and hardened concrete densities to BS EN 12350-6 and BS EN 12390-7,

respectively
(g) compressive strength to GS 940 or BS EN 12390-3
(h) water permeability for concrete of Grade 30 and over to DIN 1048 for constant
pressure for 3 d
(i) maximum 10 mm at 7 d
(ii) maximum 15 mm at 28 d
(iii) if the values obtained are unacceptable, the mixes shall be redesigned.

10 Approval of the job-mix proportions by WOQOD Representative or his assistance to

CONTRACTOR in establishing those proportions, in no way relieves CONTRACTOR of the
responsibility of producing concrete which meets the requirements of this Specification.

11 WOQOD Representative may also require practical tests to be made on the Site by filling trial
moulds to confirm the suitability of:
(a) mix for the works
(b) type of plant used for mixing
(c) face intended for use in the works
(e) type of form oil
(f) type of protective coatings.

12 All costs connected with the preparations of trial mixes and the design of the job mixes shall
be borne by CONTRACTOR.

13 Whenever a change of brand or source for any of the concrete ingredients occurs, additional
“preliminary tests” will be required.

14 The CONTRACTOR shall declare any change in the source of the material and any changes
in the cement content consumption greater than 20.0 kg/m 3 from that used in the trial mixes.

6.4 QUALITY AND TESTING

6.4.1 General

1 In order to ensure that the quality of materials and mix proportions are maintained throughout
concreting operations, sampling and testing shall be carried out using the relevant
procedures set out in BS 812, BS EN 12650, BS EN 12350 and BS 1881 and all other
relevant codes quoted in this specification in accordance with a routine testing program that
shall be agreed with WOQOD Representative before the start of concrete work.

2 The CONTRACTOR shall supply all necessary moulds for tests, shall cast all cubes, strip and
store them in water. He shall also arrange for the transport of cubes to the place of testing
and shall supply the WOQOD representative with duplicate copies of all test certificates.

6.4.2 Tests

1 Unless WOQOD Representative directs otherwise, the program shall include at least the
tests specified below.

2 Tests on aggregates shall be as described in Part 2 of this Section.

3 Slump tests shall be carried out at the rate of one test per load of concrete delivered to the
site, or one test per 10 m3 whichever is the lesser. The maximum slump, measured at the
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WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page9

point of placing the concrete shall not be less than 75mm – 15/ ±35 mm for general concrete
work and not less than 100 mm -20/+40 mm for pumped concrete. The use of either or both
admixtures or additives to meet these requirements will not be permitted unless approved by
WOQOD Representative. Any variations from these slumps necessitated by the use of super
plactisers or other admixtures or additives shall be approved by WOQOD Representative.

4 Samples for works cubes tests shall be taken at the average rate of one sample every other
load, or one test per 15 m3 whichever is less, of concrete of a particular grade placed, with a
minimum of one sample taken every day that the mix is used. A sample consists of nine
cubes, three to be tested at 7 d, three at 28 d and three to be tested at the discretion of
WOQOD Representative. Additional cubes may be taken as directed by WOQOD
Representative.

5 Test reports for strength shall contain the tests required above and the information listed
below:-
(a) Name of the CONTRACTOR
(b) Identification of mixer or ready mix supplier and department
(c) Grade of Concrete
(d) Type of Cement
(e) Section of work represented by sample
(f) Density of cube (kg/m 3).

6.5 PRELIMINARY TEST (TRIAL TESTS)

6.5.1 Target Mean Strength

1 The concrete mix shall have at least the required minimum cement content and mean
strength greater than the required characteristic strength by at least the current margin.

2 The current margin shall be taken as the lesser of:

(a) 1.64 times the standard deviation of cube tests on at least 100 separate batches of
concrete of nominally similar proportions of similar materials and produced over a
period not exceeding 12 months by the same plant and under similar supervision, but
not less than one-sixth of the characteristic strength for concrete of Grade 15 or not
less than 3.75 MPa for concrete of Grade 20 or above
(b) 1.64 times the standard deviation of cube tests on at least 40 separate batches of
concrete of nominally similar proportions of similar materials and produced over a
period exceeding 5 days but not exceeding 6 months by the same plant under similar
supervision, but not less than one-third of the characteristic strength for concrete of
Grade 15 or not less than 7.5 MPa for concrete of Grade 20 or above
(c) if enough data is not available to satisfy the requirements of either (a) or (b) above,
the margin shall be taken as two-thirds of the characteristic strength for concrete of
grade 15 or 10 MPa for concrete of grade 20 or above.

3 CONTRACTOR shall declare any change in source of material and any change in cement
content, nature and source of each material, full details of tests on trial mixes, proposed
quantities of each ingredient per cubic metre of fully compacted concrete.

4 To establish the suitability of any material used in the concrete work, unless specified
otherwise, CONTRACTOR shall make preliminary tests and prepare design mixes, in
accordance with BS 8500 u=in addition to BS EN 206-1, in a design laboratory acceptable to
WOQOD Representative.
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WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page10

5 As part of the routine testing program CONTRACTOR shall verify that the total chloride ion
(Cl) content and the total sulphate (SO3) content of each mix is within the specified limits.
(a) CONTRACTOR shall perform Chloride tests in accordance with BS EN 1744-1.
(b) CONTRACTOR shall perform sulphate (SO3) tests in accordance with BS EN 1744-1

6 Chloride and sulphate levels in the concrete mix shall comply with the requirements of Table
6.2.

Table 6.2

Chloride and Sulphate Limits

Type of Concrete % by wt. of Cement

Chlorides Sulphates
as Cl as S03
For reinforced concrete
if made with OPC/MSRPC max. 0.30 max. 3.70
if made with SRPC max. 0.15 max. 3.70

Prestressed concrete and heat-cured max. 0.10 max. 3.70

reinforced concrete

For mass concrete

if made with OPC/MSRPC max. 0.60 max. 3.70
if made with SRPC max. 0.15 max. 3.70

Notes:
(a) OPC and MSRPC cements can also contain chlorides, the relevant standard BS EN
197-1 allows up to 0.1 % of chloride ion
(b) any chloride content present in the cement has to be taken into account while
computing total chloride ion in the mix.

6.5.2 Change of Current Margin

1 When the results of a sufficiently large number of tests show that the previously established
margin is significantly too large or too small, a change in the current margin used for judging
compliance with the specified characteristic strength may be appropriate.

2 Recalculation of the margin shall be carried out as before, but the adoption of recalculated
value will not generally be justified if the two values differ by less than:
(a) 18 %, when based on tests on 40 separate batches
(b) 11 %, when based on tests on 100 separate batches
(c) 5 %, when based on tests on 500 separate batches.

3 This recalculated margin, if adopted, becomes the current margin for the judgement of
compliance with the specified characteristic strength of concrete.

6.6 WORKS TEST CUBES

1 Test cubes shall be taken as specified from fresh mixed concrete which is being used in the
Works and which has been prepared in the normal way.
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WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page11

2 Cubes shall be numbered consequently and marked with the date, section of work from
which they are taken and any other relevant information.

3 A minimum of six cubes for each sampling shall be made, testing three cubes at 7 d and
three cubes at 28 d.

4 The strength of cubes shall be not less than the minimum strength requirements for each
type of concrete given in Table 6.1.

5 If the average strength of the three works test cubes at 7 d indicate that the required strength
at 28 d will not be achieved CONTRACTOR shall immediately:
(a) stop all concreting until checks are made on material and equipment
(b) rectify any defect which has become apparent as the result of checking.

At CONTRACTOR’s option, defective concrete may be removed and replaced without

awaiting the 28 d test results.

6 If works test cubes fail at 28 days CONTRACTOR shall suspend concreting operations and
shall not proceed further without approval. CONTRACTOR shall carry out in situ testing of the
suspect concrete in accordance with Part 13 of this Section, in the presence of WOQOD
Representative. All defective work shall be replaced and retested to the satisfaction of
WOQOD Representative.

6.7 WORKABILITY

6.7.1 General

1 The workability of fresh concrete shall be suitable for the conditions of handling and placing
so that after compaction concrete surrounds all the reinforcement, tendons, ducts and
completely fills the formwork without voids or honeycombing. The design slump range of the
concrete shall be the minimum necessary to ensure the correct placement and compaction of
the mix.

2 For each concrete mix design prepared, CONTRACTOR shall state the nominal design
workability value expressed as the 'slump' in accordance with the BS EN 12350-2.

6.7.2 Slump Tests

1 The design slump range shall be between 50 mm and 100 mm. For intricate difficult
placements with congested reinforcement WOQOD Representative may permit the
formulation of a mix design with a design slump up to 150 mm. Such permission shall be in
writing and shall identify the specific placing conditions.

2 The slump test shall be carried out in accordance with BS EN 12350-2. Sampling of concrete
for the slump test shall be carried out in accordance with clause 4.2 of BS EN 12350-2 when
sampling from a mixer truck.

3 The limits of acceptance on the slump shall include a tolerance on the design value of
(-10/+35) mm for a design slump of 50 mm, (-15/+35) mm for design slumps of 75 mm and (-
20/+40) mm for a design slump of 100 and over.

4 For each trial mix, a plant production trial shall be carried out and the slump of the concrete
checked immediately after discharge from the mixer and thereafter at 15 min intervals up to
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WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page12

the maximum time period envisaged for delivery and standing on site. Based on this trial the
mix design shall identify any adjustments to the range of plasticiser for acceptable workability
for different times after batching.

5 The slump of the concrete shall be checked from each mixer truck produced. Slump values
shall be written on the delivery ticket with the time taken.

6 CONTRACTOR shall arrange for the concrete to be tested for slump just prior to placing at
the site. The first truck of the pour shall be tested to verify the workability and thereafter for
every hour of production or every 30 m3. Slump values shall be written on the delivery ticket
with the time taken.
7 In the event of high variability of slump values, WOQOD Representative may instruct that
each truck of concrete is checked for slump at the plant. CONTRACTOR shall carry out an
investigation to establish the cause of the high variation in slump and shall take any
necessary corrective action.

6.7.3 Vebe and Compaction Factor

1 For very wet mix designs or very dry stiff mix designs WOQOD Representative may permit
the use of the flow table with vebe time or the compaction factor test. These tests shall be
carried out in accordance with:

(a) GS 505 or BS EN 12350-4, method for determination of compacting factor

(b) GS 506 or BS EN 12350-3, method for determination of vebe time.

6.8 PERMEABILITY

6.8.1 General

1 All concrete shall be designed to be dense, durable and have a high impermeability to water.

2 Where mix design suffixes I (impermeable) and HI (highly impermeable) are specified then
the concrete shall be tested for permeability to water at frequencies and locations as directed
by WOQOD Representative and specimens shall meet the criteria given in Table 6.3 at an
age of 28 d.

6.8.2 Testing

1 The tests listed in Table 6.3 shall be carried out on a trial mix of the proposed mix design
using all the envisaged constituent materials and aggregates. WOQOD Representative shall
be given the opportunity to witness all the stages of the trial mixes. All testing shall be carried
out by an approved laboratory. In all cases more than one specimen shall be prepared and
tested to provide an indication of the precision of the test method. The testing laboratory shall
prepare a full report detailing the procedures used in the test. WOQOD Representative may
require concrete to be tested in accordance with other test procedures which shall include,
but shall not be limited to:

(a) porosity as per RILEM CPC 11.3

(b) initial surface absorption of concrete (ISAT) to BS 1881, Max. flow at times of
10, 30, 60 & 120 minutes
(d) BS 1881 Part 122 method of determination for water absorption.
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WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page13

Table 6.3

Permeability Testing
HI ( Highly
Test Method I ( Impermeable ) Impermeable )
Maximum Maximum
a) Water Penetration to DIN 1048 Part 1 20 mm 10 mm
b) Rapid determination of the chloride 1000 C 500 C
permeability of concrete as per AASHTO
T277-83.
c) Capillary Rise to Concrete Society Report 10 mm 5 mm
No. 31 1987 Section 4.2.2 (Taywood
Sorption Test) - Max. rise in 4 h

6.9 DRYING SHRINKAGE

6.9.1 Aggregate Shrinkage

1 If requested by WOQOD Representative CONTRACTOR shall carry out tests on the

proposed aggregate combination in accordance with. BS EN 1367-4, Method for testing and
classifying drying shrinkage of aggregates in concrete.

2 Aggregate combinations with a drying shrinkage up to and including 0.05 % are suitable for
all concreting purposes subject to the confirmation of the particular design in accordance with
BS EN 1992-1-1 – Eurocode 2, Design of Concrete Structures. General rules and rules for
buildings. Where the aggregate drying shrinkage is greater than 0.05 % the aggregates shall
be deemed suitable for:
(a) locations where complete drying out never occurs
(b) mass concrete surface with air entrained concrete
(c) members symmetrically and heavily reinforced not exposed to the weather.

3 For aggregates sources where the drying shrinkage is greater than 0.05 % the test shall be
performed annually , where the drying shrinkage is less than 0.05 % the test shall be carried
out once every five years provided the essential character of the material as determined by
WOQOD Representative does not change.

6.9.2 Concrete Shrinkage

1 The proposed aggregate sources and rock types shall be checked to identify if the particular
rock types have a history of shrinkage.
2 Where instructed by WOQOD Representative CONTRACTOR shall arrange for drying
shrinkage tests to be carried out on the proposed concrete mix design in accordance with BS
1881 for Determination of changes in length on drying and wetting. Tests shall establish
the following:
(a) initial drying shrinkage: the difference between the length and the prism moulded and
cured and its length when subsequently dried as specified in the test standard
(b) drying shrinkage: the difference between the length of the prism of matured concrete
after immersion in water and its length when subsequently dried or under specified
conditions.
(c) wetting expansion: the difference between the length of the prism when dry and its
length when subsequently immersed in water all under specified conditions.

3 The initial drying shrinkage shall not exceed 0.05 %.

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WOQOD PETROL STATION Section 5 Part 6 Property Requirements Page14

6.8 REJECTION OF CONCRETE MIXES

6.10.1 Rejection of Concrete Mixes:

1 Concrete mixes shall be rejected if they fail to meet one or more requirements, which cannot
be brought into compliance of visually unsatisfactory as related to any of the following:

(a) Improper class of concrete

(b) Improper workability
(c) Overmixing
(d) Air Content, slump or temperature not within specific limits
(e) Oversized Aggregate
(f) Maximum water-cement ratio is exceeded

6.10.2 Unsatisfactory Concrete Works

1 Should any of the test results be unsatisfactory, the WOQOD representative may order the
work to be stopped pending his further instructions, Executed work for which test results are
unsatisfactory shall be liable for rejection and if so advised the work shall be rebuilt at the
CONTRACTOR’s expense.

2 In the case of 7-day works cube tests proving unsatisfactory, the work may be stopped but
shall not be liable to rejection pending the result of the 28-day test. If the test results fail to
comply with the requirements the work shall be immediately liable for rejection. The
CONTRACTOR may however be given the option of cutting three acceptable specimens from
the completed work and preparing from them test cubes or cores which shall be tested as for
WORKS test cubes. Should the average strength of these specimens attain the maximum 28
day strength the work will be accepted but otherwise the work will remain liable to rejection as
above.

3 The cost of such cuttings, preparation of specimens, transportation and testing, and of
making good the portions of the structure affected shall be borne by the CONTRACTOR.

4 Regardless of satisfactory test cube results, any concrete work which, in the WOQOD
representative’s opinion, is excessively honeycombed or in any other way is defective, shall
be liable to rejection. Minor defects apparent on stripping the formwork must be made good
at the CONTRACTOR’s expense. No such repair work shall be carried out until after
inspection by the WOQOD representative and his acceptance of the proposed treatment has
been given. Work which has not been previously inspected but which shows signs of such
treatment shall be liable to rejection as defective work.

5 The cost of all delays on site due to faulty concrete work shall be met by the CONTRACTOR.

END OF PART
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WOQOD PETROL STATION Section 5 Part 7 Batching and Mixing Page 1

7. BATCHING AND MIXING

7.1 GENERAL
7.1.1 Scope
7.1.2 References

7.2 BATCHING

7.2.1 General
7.2.2 Plant Type
7.2.3 Bins and Weight Batchers
7.2.4 Tolerances of Measuring Equipment
7.2.5 Batching Tolerances
7.2.6 Charging the Mixer

7.3 MIXING

7.3.1 Charging Concrete Materials

7.3.2 Charging Admixtures
7.3.3 Mixing Time for Stationary Mixers
7.3.4 Mixing
7.3.5 Limitation of Water:Cement Ratio

7.4 READY-MIXED CONCRETE

7.4.1 General
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WOQOD PETROL STATION Section 5 Part 7 Batching and Mixing Page 2

7. BATCHING AND MIXING

7.1 GENERAL

7.1.1 Scope

1 This Part covers batching and mixing of concrete and ready-mixed concrete.

2 Related Sections and Parts are as follows:

This Section
Part 1, General
Part 2, Aggregates
Part 3, Cement
Part 4, Water
Part 5, Admixtures
Part 6, Property Requirements
Part 8, Transporting and Placing of Concrete
Part 15, Hot Weather Concreting
Part 16, Miscellaneous.

7.1.2 References

GS 585, Ready – Mixed Concrete

BS 1881, Testing concrete
BS EN 12350, Testing fresh concrete
BS 8500, Concrete
BS EN 206-1, Concrete, Specification, performance, production and conformity

7.2 BATCHING

7.2.1 General

1 During measurement operations, aggregates shall be handled in a manner to maintain their

desired grading, and all materials shall be weighed to the tolerances required for the desired
reproducibility of the selected concrete mix.

2 Sequencing and blending of the ingredients during charging of the mixers shall be carried out
in such a way as to obtain uniformity and homogeneity in the concrete produced as indicated
by such physical properties as unit weight, slump, air content, strength and air-free mortar
content in successive batches of the same mix proportions.

3 The mix recipe for the mixes to be produced shall be readily available to the mixer operator.
Only authorised personnel shall be allowed to make changes to the mix design.

7.2.2 Plant Type

1 Manual control batching. Manual plants are acceptable for small jobs having low batching
rate requirements, generally for jobs up to a total concrete quantity of 1000 m3 and 10 m3/h.

2 Semi-automatic control batching. In this system, aggregate bin gates for charging batchers
are opened by manually operated push buttons or switches. Gates are closed automatically
when the designated weight of material has been delivered.
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WOQOD PETROL STATION Section 5 Part 7 Batching and Mixing Page 3

3 Automatic control batching. Automatic batching of all materials is electrically activated by a

single starter switch. However, interlocks shall interrupt the batching cycle when the scale

7.2.5 of this Part are exceeded.

7.2.3 Bins and Weight Batchers

4 Batch plant bins shall be of sufficient size to effectively accommodate the production capacity
of the plant. Compartments in bins separate the various concrete materials, and the shape
and arrangement of aggregate bins shall prevent aggregate segregation and leakage.

5 Weight batchers shall be charged with easy-operating clam shells or undercut radial-type bin
gates.

6 Gates used to charge semi-automatic and fully automatic batchers shall be power operated
and equipped with a suitable in flight correction to obtain the desired weighing accuracy.
They shall be calibrated by the plant supplier for the types of aggregate used at the standard
range of moisture contents.

7 Weigh batchers shall be accessible for obtaining representative samples, and they shall be
arranged to obtain the proper sequencing and blending of aggregates during charging of the
mixer.

8 The amount of concrete mixed in any one batch shall not exceed the rated capacity of the
mixer.

9 On cessation of work, including all stoppages exceeding 20 min, the mixers and all handling
plant shall be washed with clean water.

10 All mixing and batching plants shall be maintained free of set concrete or cement and shall be
clean before commencing mixing.

11 For each different type of cement at use at the plant a separate silo shall be provided.

7.2.4 Tolerances of Measuring Equipment

1 Scales for weighing concrete ingredients s

% for additives. Standard test weights shall be available to permit the checking of scale
accuracy.

2 Testing of the weighers shall be at three-month intervals. If water is dispensed by flow meter
the frequency of testing shall be at three-month intervals. Such testing shall be undertaken by
a calibration company approved by the Central Materials Laboratory.

3 Test certificates shall be displayed in the plant in prominent positions.

7.2.5 Batching Tolerances

1 Operation of batching equipment shall be such that the concrete ingredients are consistently
measured within the following tolerances. The plant shall have the ability to flag values that
are outside these limits. The operator shall make manual adjustments to the batching and the
final weights shall be within the given limits. Any adjustments shall be displayed on the batch
weight printouts.
Cement ±1 %
Water ±1 %
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WOQOD PETROL STATION Section 5 Part 7 Batching and Mixing Page 4

Aggregates ±
Admixtures ±

2 Cement supplied in bags shall be placed directly from the bag into the intake of the mixing
plant and each batch must contain one or more complete bags of cement. No mixer having a
rated capacity of less than one-bag batch shall be used and the mixer shall not be charged in
excess of its rated capacity

7.2.6 Charging the Mixer

1 Each batch shall be so charged into the mixer that some of the water will enter in advance of
the cement and aggregates. Controls shall be provided to prevent batched ingredients from
entering the mixer before the previous batch has been completely discharged.

2 The first batch of concrete through the mixer shall contain an excess of cement to allow for
coating of the inside of the mixing drum without reducing the required mortar content of the
mix.

3 Mixing plant that has been out of action for more than 30 minutes shall be thoroughly cleaned
before any fresh concrete is mixed in it.

4 When a change of mix is made to one using a different type of cement, the mixing plant shall
be thoroughly cleaned of all traces of the previously used cement, whatever is the time
interval between successive mixes.

7.3 MIXING

7.3.1 Charging Concrete Materials

1 Water shall enter the mixer first with continuous flow while other ingredients are entering the
mixer. Water charging pipes must be of the proper design and of sufficient size so that water
enters at a point well inside the mixer and charging is completed within the first 25 % of the
mixing time.

7.3.2 Charging Admixtures

1 Admixtures shall be charged to the mixer in accordance with the instructions of the
manufacturer.

2 Automatic dispensers shall be used.

7.3.3 Mixing Time for Stationary Mixers

1 The mixing time required shall be based upon the ability of the mixer to produce uniform,
homogeneous, consistent mixture throughout the batch and from batch to batch.

2 Final mixing times shall be based on the results of mixer performance tests made at the start
of the project and the time fixed unless a change is authorized by WOQOD Representative.
The time shall however not be less than 90 sec..

3 The mixing time shall be measured from the time all ingredients are in the mixer.

4 Batch mixers with audible indicators used in combination with interlocks which prevent mixer
discharge prior to completion of a preset mixing time shall be provided on automatic plants
and are also desirable on manual plants.
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WOQOD PETROL STATION Section 5 Part 7 Batching and Mixing Page 5

5 The mixer shall be designed for starting and stopping under full load.

7.3.4 Mixing

1 All structural concrete to be placed in situ shall be manufactured in a computer controlled

batching plant of the types described in Clause 7.2.2 of this Part.

2 The plant shall be complete with suitable water chilling or ice making facilities, or both, to
ensure concrete temperatures are maintained as specified in Part 15 of this Section.

3 Concrete shall be mixed in batches in plant capable of combining the aggregates, cement
and water (including admixtures, if any) into a mixture of uniform colour and consistency and
of discharging the mixture without segregation.

4 Automatic moisture content probes, set in the hoppers shall be used to continuously
determine the moisture content of the aggregates.

5 CONTRACTOR shall make due allowance for the water contained in the aggregates when
determining the quantity of water to be added to each mix.

6 The amount of water added to each mix shall be adjusted to maintain the constant approved
water:cement ratio of the mixed concrete.
7.3.5 Limitation of Water:Cement Ratio

1 No concrete shall exceed the water:cement ratio as given in Table 6.1 of Part 6 of this
Section.

2 The quantity of water used in mixing shall be the least amount that will produce a workable
homogeneous plastic mixture which can be worked into the forms and around the
reinforcement.

3 Excess water over the maximum allowed by the mix design shall not be permitted and any
batch containing such excess will be rejected.

7.4 READY-MIXED CONCRETE

7.4.1 General

1 The manufacture of readymix concrete for use in government projects may only be carried
out in batching plants that have an approval certificate issued by the Central Materials
Laboratory. In addition, the use of readymix concrete in any part of the work shall require the
WOQOD representative’s written approval.

2 CONTRACTOR shall satisfy the WOQOD Representative on the following:

(a) materials used in ready-mixed concrete comply with the specification in all respects
(b) manufacturing and delivery resources of the proposed supplier are adequate to
ensure proper and timely completion.

3 The specified requirements as to the sampling, trial mixing, testing and quality of concrete, of
various grades as described in Part 6 of this Section, shall apply equally to ready-mixed
concrete.
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WOQOD PETROL STATION Section 5 Part 7 Batching and Mixing Page 6

4 Every additional facility, including but not limited to testing equipment, labour, laboratory
facilities and transport, which the WOQOD Representative or persons authorised by him may
require for the supervision and inspection of the batching, mixing, testing and transporting to
Site of readymixed concrete shall be provided by the Contractor at no extra cost.

5 Copies of all delivery notes shall be submitted to the WOQOD Representative in duplicate, on
computer generated forms and shall include at least the following information.
(a) name of supplier, serial number of ticket and date
(b) truck number
(c) name of Contractor
(d) name of Contract and location of office
(e) grade of concrete
(f) specified workability
(g) type and source of cement
(h) source of aggregate
(i) nominal maximum size of aggregate
(j) quantity of each concrete ingredient
(k) type of admixture and quantity
(l) water content
(m) time of loading and departure from ready-mix plant
(n) arrival and departure times of truck
(o) time of completion of discharge
(p) notations to indicate equipment was checked and found to be free of contaminants
prior to batching.

6 A copy of the delivery note shall be given to the WOQOD Representative's site representative
for each load.

7 Unless approved otherwise in advance of batching all concrete of single design mix for any
one day's pour shall be from a single batch plant of a single supplier.

8 Ready-mix concrete shall conform to GS 585 or BS 8500 in addition to BS EN 206-1, except

materials, testing and mix design shall be as specified in this Section.

9 Transit mixers equipped with automatic devices for recording the number of revolutions of the
drum shall be used.

10 Excess water over the maximum allowed by the mix design shall not be added.

11 Each mixer truck shall arrive at the job site with its water container full.

12 In the event that a container is not full or concrete tests give a greater slump than acceptable,
the load shall be rejected.

13 Shade temperature and concrete temperature shall be recorded at the point of discharge of
the mixer and at placement for each load of concrete delivered to site.

14 Maximum and minimum temperatures and wet bulb temperatures shall be recorded daily.

15 Slump tests shall be performed in accordance with BS EN 12350 at the point of placement for
each load delivered to the Site.

16 No water shall be added at the Site.

END OF PART
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WOQOD PETROL STATION Section 5 Part 8 Transportation & Placing of Concrete Page 1

8 TRANSPORTATION AND PLACING OF CONCRETE

8.1 GENERAL

8.1.1 Scope of Work

8.1.2 References
8.1.3 Submittals

8.2 TRANSPORTATION

8.2.1 General
8.2.2 Pumped Concrete
8.2.3 Records

8.3 PLACING CONCRETE

8.3.1 General
8.3.2 Preparation
8.3.3 Placing
8.3.4 Compaction
8.3.5 Continuity of Concrete Work
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WOQOD PETROL STATION Section 5 Part 8 Transportation & Placing of Concrete Page 2

8. TRANSPORTATION AND PLACING OF CONCRETE

8.1 GENERAL

8.1.1 Scope of Work

1 This part deals with the transportation, placing and compaction of concrete

2 Related Parts are as follows:

This Section
Part 1, General
Part 7, Batching and Mixing
Part 9, Formwork
Part 15, Hot Weather Concreting
Part 16, Miscellaneous.

8.1.2 References

BS 8500, Concrete
BS EN 206-1, Concrete. Specification, performance, production and conformity

8.1.3 Submittals

1 Should CONTRACTOR propose to use concrete pumps for the transportation and placing of concrete, he
shall submit details of the equipment and operating techniques he proposes to use for the approval of
WOQOD Representative.

2 A method statement shall be submitted for approval for major concrete placements, which shall address
(a) the planned rate of placing
(b) number of batching plants
(c) number of trucks
(d) number and positioning of pumps
(e) pour sequence
(f) quality control measures
(g) spare equipment
(h) any other factors that might affect the placing of concrete.

The method statement should be submitted at least three days in advance of the planned pour. If required
by WOQOD Representative, or any other concerned party a prepour planning meeting may be arranged
with representatives from the ready-mix supplier, CONTRACTOR and WOQOD Representative.

3 CONTRACTOR shall submit to WOQOD Representative for approval details of his proposed operations
and standby equipment.

8.2 TRANSPORTATION

8.2.1 General

1 Transportation delivery and handling shall be in accordance with the requirements of BS 8500 and BS EN
206-1.

2 Concrete shall be conveyed from the mixer to its place in the Works as rapidly as possible by methods
which will prevent segregation or drying out and ensure that the concrete is of the required workability at
the point and time of placing.
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WOQOD PETROL STATION Section 5 Part 8 Transportation & Placing of Concrete Page 3

3 Should segregation occur in the concrete then the materials shall be remixed to the satisfaction of
WOQOD Representative or discarded. Furthermore the cause of the segregation shall be determined and
further occurrences prevented.

4 CONTRACTOR shall ensure that the time between placing of different lifts or layers of concrete is short
enough to prevent the formation of cold joints. CONTRACTOR shall ensure that there is a back up plant
that can be used in the event of a breakdown, and that adequate provision has been made for the number
of delivery trucks.

5 The concrete shall be transported to the site in an approved type of truck mixer or agitator truck which
apart from the cab and chassis shall be painted white and kept clean at all times. The discharge chute and
other dirty areas shall be washed down after delivery to prevent spillage on the roads.

6 The insides of concrete mix trucks shall be inspected periodically, and any build up of concrete removed
that may impair the efficiency of the mixing action.

7 Concrete shall be handled from the place of mixing to its place in the Works within 60 min unless retarders
have been incorporated in the mix that have satisfactorily demonstrated that workability and other
properties can be retained, and that approval is obtained in writing from WOQOD Representative.

8.2.2 Pumped Concrete

1 Access for the pump shall be checked prior to the pour. If access cannot be assured, CONTRACTOR shall
not continue with concreting operations.

2 If approval is obtained for pumped concrete, CONTRACTOR shall ensure that shock is not transferred
from the pipeline to the formwork and previously laid concrete.

3 During placing concrete by pumping the end hose must never reach into the concrete. All measures shall
be taken to avoid blockage of the delivery hose system. The Compaction of concrete shall be carried out
as per standard practice procedures.

4 Grout shall be pumped through the concrete pump to provide initial lubrication. The initial discharge of any
pumped concrete shall not be incorporated in the permanent works.

5 Where concrete is conveyed by chuting or pumping the plant shall be of a size and design to ensure
continuous flow in the chute or pipe. The slope of the chute or the pressure of the pump shall allow the
concrete to flow without the use of any water additional to that approved by WOQOD Representative to
produce the required consistency and without segregation of the ingredients. The delivery end of the chute
or pipe shall be thoroughly flushed with water before and after each working period and kept clean. The
water used for this purpose shall be discharged outside and away from any permanent works.

8.2.3 Records

Within 24 h of delivery, CONTRACTOR shall provide WOQOD Representative with delivery notes giving
the information required under Paragraph 7.4.1.5 of this Section.

8.3 PLACING CONCRETE

8.3.1 General

1 CONTRACTOR shall obtain the approval of WOQOD Representative to his proposed arrangements before
beginning concreting.
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WOQOD PETROL STATION Section 5 Part 8 Transportation & Placing of Concrete Page 4

2 All placing and compacting of concrete shall be carried out under the direct supervision of a competent
member of CONTRACTOR’s staff with a minimum of five years of experience in
concreting works, and in a manner to produce a watertight concrete of maximum density and strength.

3 For night concreting operations, CONTRACTOR shall arrange adequate suitable lighting.

4 CONTRACTOR shall provide safe secure access for all personnel on concreting operations.

5 Where the thickness of the concrete section exceeds 600 mm CONTRACTOR shall adopt special
precautions, to be approved by WOQOD Representative , to avoid thermal cracking due to external and
core temperature differentials.

6 Concrete shall not be placed in adverse weather conditions such as dust storms or heavy rain.

8.3.2 Preparation

1 No concrete shall be placed until WOQOD Representative has inspected and approved in writing the
surfaces upon which the concrete is to be placed, the formwork, and reinforcing steel. CONTRACTOR
shall give WOQOD Representative at least 24 hours notice to enable this inspection to be carried out. If
concrete is not placed within 24 hours of approval being given, approval shall be obtained again before
concreting. An inspection shall be made immediately prior to concreting to check the cleanliness of the
forms.

2 Wood forms, unless lined, shall be oiled or wetted with water in advance of placing concrete so that joints
will tighten and prevent seepage of cement grout from the mix.

3 The reinforcement shall be sprayed with a small amount of water prior to starting the pour. Reinforcement
shall be secured in position, inspected, and accepted by the WOQOD Representative before placing the
concrete.

4 All inserts, anchor bolts, sleeves and other embedded items shall be accurately located, using templates
where appropriate, and held securely to prevent displacement during the placing of the concrete.
Aluminium items shall be completely covered and protected when embedded in the concrete.

5 Except where shown on the drawings, no fixtures shall be attached to the concrete by shot fixing or drilling
without acceptance by the WOQOD Representative. Notwithstanding any such authorisation, the
Contractor shall be responsible for all damage so caused to the concrete and make good at his own
expense.

6 Water shall be removed from excavations before concrete is deposited. Any flow of water shall be diverted
through proper side drains and shall be removed without washing over freshly deposited concrete. All
dewatering works shall be continued as long as required. Hardened concrete, debris, and foreign materials
shall be removed from interior of forms and from inner surfaces of mixing and conveying equipment.

7 Runways or other means accepted by the WOQOD Representative shall be provided for wheeled
equipment to convey the concrete to the points of deposit. Equipment used to deposit concrete shall not
be wheeled over reinforcement nor shall runways be supported on reinforcement.

8 Before depositing new concrete on or against concrete that has set, existing surfaces shall be thoroughly
roughened and cleaned of laitance, foreign matter and loose particles. Forms shall be re-tightened and
existing surfaces slushed with a grout coat of mortar consisting of cement and fine aggregate in the same
proportion in the mix, but not leaner than one (1) part cement to two (2) parts fine aggregate, after the
existing surface has been moistened. New concrete shall be placed before the grout has attained initial
____________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 8 Transportation & Placing of Concrete Page 5

set. Horizontal construction joints shall be given a brush coat of grout consisting of cement and fine
aggregate in the same proportion as concrete to be placed, followed by approximately 75mm of concrete
of regular mix, except that the proportion of coarse aggregate shall be reduced 50%.

9 High strength grout for precision support of machine base and soleplates, including equipment subject to
thermal movement, tanks, column base plates, bridge seats, anchor bolts and dowels, etc., shall be a non-
shrink, ready-to-use, fluid precision grout material, proportioned, premixed and packaged at the factory,
delivered to the job site to be placed with only the addition of water, formwork, and curing shall be as
specified.

8.3.3 Placing

1 Concrete shall be placed in its final position before initial set has commenced and shall not be
subsequently disturbed. All concrete shall be placed within 15 min of mixing unless carried in purpose
made agitators.

2 Concrete shall be carefully placed in horizontal layers which shall be kept at an even height throughout the
work. The depth of layers and time between placement of layers shall be such that each layer can be
properly merged into the preceding layer before initial set takes place, the depth of layer shall be
determined from the type of plant CONTRACTOR proposes to use.

3 Concrete shall be allowed to slide or flow down sloping surfaces directly into its final position from skips,
down pipes or other placing machines or devices or, if this is not practical, it should be shovelled into
position, care being taken to avoid separation of the constituent materials.

4 Concrete placed in horizontal slabs from barrows or other tipping vehicles shall be tipped into the face of
the previously placed concrete.

5 Concrete dropped into place shall be dropped vertically. It shall not strike the formwork between the point
of its discharge and its final place in the Work, and except by approval of WOQOD Representative it shall
not be dropped freely through a height greater than 1.5 m. Chutes and conveyor belts shall be also
designed so that there is no segregation or loss of mortar and shall be provided with a vertical tapered
down pipe, or other device, to ensure that concrete is discharged vertically into place.

6 Concrete shall not be placed in standing water in the formwork.

7 Concrete that has attained its initial set or has contained its water content for more than 1.5 hours or 300
drum revolutions, whichever comes first, shall not be deposited in the work.

8 Cold weather concreting shall be in accordance with BS 8110 or CIRIA Report 67.

9 Hot weather concreting shall be in accordance with Part 15 of this section.

10 Special care shall be taken to protect new concrete from the harmful effects of drying winds.

11 During wet weather, the concrete shall be adequately protected as soon as it is in position.

12 No concreting shall be carried out during periods of continuous heavy rain unless it is completely covered
during mixing, transporting and placing.

13 No concrete shall be carried out during dust storms.

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WOQOD PETROL STATION Section 5 Part 8 Transportation & Placing of Concrete Page 6

14 Underwater placing of concrete is allowed only for unreinforced components, the placing being effected
exclusively with stationary tremies or with a bottom-opening watertight boxes and shall be in accordance
with the requirements of DIN 1045 or equivalent as accepted.

15 Underwater concrete is to be placed continuously without interruption. For water depths up to 1 m the
concrete may be placed without tremie. In the case of water depths exceeding 1 m the concrete is to be
placed in such a way that it does not fall freely through the water. The tremies must at all times dip
sufficiently far into the freshly placed concrete to ensure that the concrete emerging from the tremie does
not come into contact with the water.

16 All work connected with the placing of concrete under water shall be designed, directed and inspected with
due regard to local circumstances and purposes. Work shall not proceed until all phases and methods to
be used in the placing operations have been accepted by the WOQOD Representative.

17 Stops in concrete, at the end of a period of work, shall be made only at construction joint locations shown
on the drawings and/or positions accepted. Where the positions of construction joints are not indicated on
the drawings, these may be assumed, for estimating purposes, to occur at 5 metre intervals in foundations
and retaining walls and at one-third to one-quarter of span in slabs and beams subject to a maximum
spacing of approximately 9 metres.

18 At construction joint location the surface of the completed concrete shall be prepared by spraying, wire
brushing or chipping so that it is free from all laitance, scum and loose material and shows a slightly
roughened texture and tips of the coarse aggregate exposed. Before continuing concreting the exposed
concrete face shall be thoroughly wetted.

19 In the ground floor slab (where ground bearing), construction joints, crack inducer joints, contraction joints
and expansion joints shall be incorporated into the work as appropriate. The slab shall be cast in strips not
more than 4.0 metres wide, in alternating sequence, across the width of the building. A minimum of 3 days
shall elapse between the casting of adjacent strips. Within each strip, crack induced joints shall be
provided at not more than 5.0 metre spacing, and contraction joints shall be provided at not more than
15.0m spacing.

20 Construction joints shall be provided between adjacent strips with contraction joints at every 4th joint.

21 Wherever necessary and as required by the WOQOD Representative, waterstops of a type acceptable to
the WOQOD Representative shall be embedded in the concrete. The waterstop should be made of a high
quality material, which must retain its resilience through the service life of the structure for the double
function of movement and sealing. The surface of waterstops should be carefully rounded to ensure
tightness of the joint even under heavy water pressure. To ensure a good tightness with or without
movement of the joints, the waterstop should be provided with anchor parts. The cross-section of the
waterstops should be determined in accordance with the presumed maximum water pressure and joint
movements. The complete works of fixed and welded connections must be carried out strictly in
accordance with the manufacturer’s instructions.

22 WOQOD Representative’s acceptance shall be obtained by the Contractor, prior to start of work, on the
casting sequence and the layout of joints.

8.3.4 Compaction

1 Concrete shall be thoroughly compacted by vibration during the operation of placing and thoroughly
worked around the reinforcement, around embedded fixtures and into corners or the formwork to form a
solid mass free from voids.
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WOQOD PETROL STATION Section 5 Part 8 Transportation & Placing of Concrete Page 7

2 When vibrators are used to compact the concrete, vibration shall be applied continuously during the
placing of each batch of concrete until the expulsion of air has practically ceased and in a manner that
does not promote segregation of the constituents of the concrete.

3 Immersion type vibrators shall be capable of producing not less than 10 000 cycles per minute, and
external vibrators not less than 3000 cycles per minute.

4 A sufficient number of vibrators in serviceable condition shall be on site to ensure that spare equipment is
always available in the event of breakdown.

5 Immersion type vibrators shall be inserted into the uncompacted concrete vertically and at regular
intervals. Where the uncompacted concrete is in a layer above freshly compacted concrete the vibrator
shall penetrate vertically for about 100 mm into the previous layer. Vibrators shall not come into contact
with the reinforcement or the formwork. They shall be drawn back slowly from the mass concrete so as to
leave no voids. Internal type vibrators shall not be placed in the concrete in a random or haphazard
manner nor shall concrete be moved from one part of the work to another by means of the vibrators.

6 Operators shall be trained in the use of vibrators. Foremen shall have a minimum of five years of
experience in the supervision of placing concrete

7 Vibration of the concrete shall not be applied by way of the reinforcement.

8 Compaction shall commence as soon as there is sufficient concrete to immerse the vibrator and continue
during the placing operations so that at no time shall there be a large volume of uncompacted concrete in
the formwork.

9 The duration of vibration shall be limited to that required to produce satisfactory compaction without
causing segregation. Vibration shall on no account be continued after water or excess grout has appeared
on the surface.

10 During the placing of all reinforced concrete, a competent steel fixer and a competent carpenter shall be in
attendance on each concreting gang. They shall ensure the reinforcement embedded fittings and forms
are kept in position as work proceeds.

8.3.5 Continuity of Concrete Work

1 Whenever instructed by WOQOD Representative, CONTRACTOR shall carry out the work in such a
manner that the placing of the concrete in any particular section of the structure shall be executed without
any interruption whatsoever from the beginning to the end of the operation.

2 Casting of concrete shall not begin until a sufficient quantity of approved material is at hand to ensure
continuity of operation, nor shall work begin until there is sufficient equipment in reserve in case of
breakdown.

END OF PART
__________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 9 Formwork Page 1

9. FORMWORK

9.1 GENERAL

9.1.1 Scope
9.1.2 References
9.1.3 Submittals
9.1.4 Quality Assurance

9.2 FORMWORK MATERIALS

9.2.1 General

9.3 CLASS OF FINISH AND MATERIALS:

9.3.1 Unformed surfaces

9.3.2 Surface Finish Classifications
9.3.3 Formwork Materials
9.3.4 Exposed Concrete Surface Finishes
9.3.5 Form Ties
9.3.6 Coating and Accessories

9.4 FORMWORK EXECUTION

9.4.1 General
9.4.2 Trial Panels
9.4.3 Formwork Face in Contact with Concrete
9.4.4 Sloping Surfaces
9.4.5 Temporary Openings
9.4.6 Form Windows
9.4.7 Co-ordination
9.4.8 Conduits
9.4.9 Ties and Bolts
9.4.10 Chamfers
9.4.11 Cambers
9.4.12 Exterior Angles
9.4.13 Surface Retarders
9.4.14 Detection of Movement During Concrete Placement
9.4.15 Building in Pipes

9.5 REMOVAL OF FORMWORK

9.5.1 General
9.5.2 Stripping of Formwork
9.5.3 Holes to be Filled
9.5.4 Repair to Damaged Concrete Surfaces
9.6 DELIVERY AND STORAGE

9.6.1 Delivery
9.6.2 Storage

9.7 TOLERANCES

9.8 EARLY LOADING

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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 2

9. FORMWORK

9.1 GENERAL

9.1.1 Scope

1 This Part includes permanent forms, temporary formwork, and falsework for structural and
architectural cast-in-place concrete including form liners, coatings, and accessories.

2 Related Sections and Parts are as follows:

This Section
Part 8, Transportation and Placing of Concrete
Part 10, Curing
Part 17, Structural Precast Concrete.

9.1.2 References

1 The following standards and other document are referred to in this Part:

BS 8500, Concrete
BS EN 206-1, Concrete. Specification, performance, production and conformity
BS 5975, Code of practice for falsework
BS EN 12812, Falsework. Performance requirements and general design
BS 8110, The structural use of concrete

Concrete Society Technical Report No. 13

9.1.3 Submittals

1 Shop drawings shall include plans and sections, giving the following minimum information for
each level:
(a) details of individual panels
(b) position, size and spacing of adjustable steel shores
(c) position, size and spacing of joists, soldiers, ties
(d) details of formwork for columns, beams, parapets, slab and kickers
(e) details of construction joints and movement joints
(f) details of retaining walls and deep beams showing the position and size of ties,
joints, soldiers and sheeting, together with detailed information on erection and
casting sequences and construction joints
(g) general assembly details
(h) full calculation sheets
(i) proposals at all penetrations through the concrete
(j) proposed sequence of shoring and reshoring beams and slabs for different spans
and floor heights and number of floors shored, and the stripping time for supported
and suspended structural elements, clearly identifying the supported element and
suspended element.

2 Scales of shop drawings shall be as follows:

(a) details: 1:1, 1:5, 1:10, 1:20

(b) construction: 1:50, 1:100
(c) layout and Site Plan: 1:100 or 1:200
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 3

3 CONTRACTOR shall submit samples of all proposed formwork materials and samples of ties
proposed for use in general situations above the water table and for fair faced concrete.

4 CONTRACTOR shall allow 14 days for WOQOD Representative’s review of submittals or

samples.

5 Supply and delivery of built-in pipework should be clearly shown on the detailed construction
program to be submitted by CONTRACTOR.

9.1.4 Quality Assurance

1 Formwork shall comply with the requirements of BS 5975 and BS 8110

2 The erection of formwork and associated falsework shall be executed and supervised by fully
qualified personnel having a minimum of five years experience.

3 CONTRACTOR shall obtain approval to load any particular section of the works from
WOQOD Representative

4 Formwork design shall be carried out in accordance with the Concrete Society Technical
Report No. 13.

5 The erected formwork shall be watertight from the ingress of external liquids and the egress
of internal liquids. Adjustable steel supports and shores shall allow formboards and
framework to be accurately adjusted to line and level. CONTRACTOR shall ensure that
adequate ground support for falsework is available, and if not shall take measures to make
them suitable.

6 Formwork shall be designed to be sufficiently rigid to maintain the correct position, shape and
profile so that the final concrete structure is within the dimensional tolerances specified
Subpart 9.7 of this Part.

7 Formwork shall be designed to be demountable without causing shock, disturbance or

damage to the concrete.

8 Soffit formwork, properly supported on shores only, shall be capable of being retained in
position during the concrete maturing period.

9 The design shall allow free movement and accessibility under the formwork.

10 Shores for abnormal ceiling heights shall be specially designed.

11 The forms shall be designed to incorporate 20 mm chamfers on exposed corners of columns,

walls and beams.

12 The design of formwork shall take into account the following :

(a) height and rate of pour
(b) thickness of the member
(c) concrete slump and density
(d) placing temperature
(e) texture of finish
(f) construction joints
(g) wind load
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 4

(h) on soffit forms (in addition to concrete weight)

(i) an additional live load of 2.5 kPa, or
(ii) if a motorised cart is used, an additional live load of 3.75 kPa
(i) minimum design load for combined dead and live load
(i) 6.50 kPa
(ii) if a motorised cart is used, 7.75 kPa
(j) the worst combination of:
(i) self-weight
(ii) formwork forces
(iii) reinforcement weight
(iv) wet concrete weight
(v) construction loads
(vi) wind loads, based on a design wind speed of 45 m/s
(vii) incidental dynamic effects caused by placing, vibrating and compacting
concrete
(viii) the use of externally applied vibrators

(k) method of concrete discharge

(l) access for concrete placement and vibration.

13 Before beginning related formwork operations CONTRACTOR shall erect a job mock-up, to
a reasonable size including all items such as sheeting, stiffeners, soldiers, ties etc. (and
including release agents, where used) for the following types of formwork, and shall obtain
the approval WQOD Representative before proceeding:
(a) columns
(b) slabs and beams
(c) staircases
(d) fair-faced concrete (show method used to conceal tie holes) cove ties not required.

14 Upon prior consultation, agreement of location and approval, the job mock-ups may remain
as part of the finished work.

9.2 FORMWORK MATERIALS

9.2.1 General

1 Forms shall be of wood; metal or other material acceptable to the WOQOD Representative.

2 The design of formwork shall be the responsibility of CONTRACTOR.

3 Formwork shall conform to the requirements of BS 8110

4 Form oil and form sealer shall be of quality as acceptable to the WOQOD Representative.

9.3 CLASS OF FINISH AND MATERIALS:

9.3.1 Unformed surfaces

1 Unformed surfaces shall be classified as either:

(a) U4, timber trowel finish
(b) U3, steel trowel finish
(c) U2, brush finished
(d) U1 other finish designated by WOQOD Representative, such as.
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 5

(i) Screeded Finish - Where the floor slab is to receive a screeded finish, the slab shall
be laid to the slopes and levels shown on the drawings and the top surface shall be
tamped whilst unset, to produce a suitable keyed surface for the receipt of the
appropriate finishing materials.
(ii) Floated Finish - Where a floated finish is required to the floor slabs the top surface
shall be leveled and floated whilst unset to an uniform finish to the slopes and levels
shown on the drawings. The floating shall be done in such a manner as not to bring
an excess of mortar to the surface.
(iii) Dustproof Finish - Where concrete surfaces are required to provide a dustproof finish
these shall be treated with two coats of accepted material. Each coat shall be applied
with a soft brush on a clean and dry surface in accordance with the manufacturer's
printed instructions.
(iv) Non-slip Finish - Concrete surfaces described on the drawings as having a nonslip
finish shall be treated with carborundum dust, evenly sprinkled on whilst the concrete
is still green, at a rate of 1½ kg/m² and lightly trowelled in before final finishing.
Alternatively, the carborundum dust may be incorporated into the finish by means of
a mechanical power float.
(v) Hardened Finish - Where a hardened finish is required to the floor slabs these shall
be treated with three coats of accepted material. Each coat shall be applied with a
soft brush on a clean and dry surface in accordance with the manufacturer's printed
instructions.
(vi) Finishing Unformed Surfaces - Finishing unformed surfaces shall be tamped,
floated, trowelled or brushed as defined below and shown on the drawings.
(a) Type T - Tamped surfaces shall be formed by levelling and tamping the concrete
to produce a uniform plain or ridged surface, surplus concrete being struck off by
a straight edge immediately after compaction. It is also the first stage of the
following finish.
(b) Type F - Floated surfaces shall be uniform surface which has been worked no
more than is necessary to remove screed marks by hand with a wood float or by
power float of a type acceptable to the WOQOD Representative. The surface shall
not be floated until the concrete has hardened sufficiently.
(c) Type ST - Steel trowelled shall be a hard, smooth finish, free from trowel marks
and formed with a steel trowel under firm pressure. Trowelling shall not
commence until the moisture film has disappeared and the concrete has hardened
sufficiently to prevent excess laitance from being worked to the surface. If laitance
is brought to the surface it shall be removed.
(d) Type BR - Brushed shall be formed before the concrete has hardened by drawing
a wire broom over the concrete surface at right angles to the traffic flow to give an
average texture depth of 1mm.
(e) For ground slab concrete shall be treated with sodium silicate or a similar dust
preventive coating. This must be applied in accordance with the manufacturer's
instructions.
2 The type of finish will be specified on the drawings or as directed by WOQOD
Representative. Before beginning any concrete pour with unformed surfaces, CONTRACTOR
shall obtain confirmation of the type of finish required from WOQOD Representative.

3 Initial finishing of unformed surfaces shall commence immediately after the placing and
compaction have taken place.

4 Suitable access boards or platforms shall be provided to allow access to all parts of unformed
surfaces to be finished.
__________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 9 Formwork Page 6

5 Where a protective treatment or topping layer is to be applied to the concrete the

manufacturers and suppliers recommendations shall be followed concerning the required
finish.

6 Brush to finish shall be obtained by carrying out a steel trial finish and then using a suitable
stiff nylon brush dragged lightly across the surface.

7 The addition of small quantities of water to the finishing trowel will be permitted to aid
finishing.

9.3.2 Surface Finish Classifications

1 Finishes to formed surfaces of concrete shall be classified as F1, F2 and F3, or such other
special finish as may be designated.

2 Where the class of finish is not designated:

(a) all internal concrete shall be finished to Class F3
(b) external concrete below ground shall be finished to Class F1
(c) where surfaces are to be tanked by covering with paint or sheeting, the formwork
shall be capable of achieving a finish suitable for the proposed tanking as directed by
WOQOD Representative.

9.3.3 Formwork Materials

1 Formwork for Class F3 finish shall be lined with as large panels as possible of non-staining
material with a smooth unblemished surface such as sanded plywood or hard compressed
fibre board, arranged in a uniform approved pattern and fixed to back formwork by oval nails.
(a) the same type of lining shall be used throughout any one structure
(b) unfaced wrought boarding or standard steel panels shall not be permitted.

2 Formwork for Class F2 finish shall be faced with wrought tongued and grooved boards or
plywood arranged in a uniform approved pattern free from defects likely to detract from the
appearance of the surface.

3 Formwork for Class F1 finish shall be constructed of timber, or of any suitable materials
which will prevent loss of grout when the concrete is vibrated.

9.3.4 Exposed Concrete Surface Finishes

1 Exposed concrete surfaces shall have a Class F3 finish.

2 Care shall be taken to ensure that the finish to the exposed concrete on the external and
internal surfaces are of the highest quality to produce a smooth concrete surface of uniform
texture and appearance without visible imprint of grains, steppings or ridges.

3 The resulting concreting shall be free from honeycombing, stains, fins, lipping, nail and screw
marks, raised grain marks or any other imperfections and shall be of a uniform surface
texture and colour. Only very minor surface blemishes caused by entrapped air or water will
be accepted provided that they do not exceed 0.5% by area of each square metre considered
separately and in addition they shall not be concentrated in a manner such that they are
noticeable.

4 Formwork to the wetted surfaces of water retaining structures shall be Class F3.
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 7

5 All exposed concrete corners and edges shall have 20 mm by 20 mm chamfers.

6 Grooves in exposed concrete shall be formed by attaching tapered planed timber battens
accurately aligned to the face of formwork.

9.3.5 Form Ties

1 Form ties shall conform to the following requirements:

(a) factory-fabricated
(b) adjustable in length
(c) use removable or snap-off metal form ties
(d) designed to prevent formwork deflection and to prevent spalling concrete surfaces on
removal
(e) no metal shall be left closer than the applicable level of cover to the surface of the
concrete
(f) holes larger than 10 mm diameter in the concrete surface, when using snap ties shall
not be permitted
(g) form ties shall have a factor of safety not less than 1.5.

9.3.6 Coating and Accessories

1 Form coatings shall be 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, shall be used. The use of form coatings shall be strictly in
accordance with the manufacturer instructions.

2 Formwork in contact with the concrete shall be treated with a suitable non-staining mould oil
to prevent adherence of the concrete.

3 Forms for exposed surfaces shall be coated with oil before reinforcement is placed. Forms for
unexposed surfaces may be thoroughly wetted with water in lieu of oiling, immediately before
placing of concrete except during freezing weather.

4 Excessive oiling of the forms shall not be permitted in order to prevent discoloration of the
cement plaster. Where concrete surface is to be painted, the form-oil must not affect the bond
between concrete and paint.

5 Care shall be taken to prevent the oil from coming in contact with reinforcement or with
concrete at construction joints. Any oil on reinforcing steel shall be removed.

6 Release agents shall not be used where concrete surfaces receive special finishes or applied
coatings which may be affected by the agent, unless approved by WOQOD Representative.

7 Fillet and chamfer strips shall be PVC or timber to the approval of WOQOD Representative.

8 Tapes to be used to seal joints of formwork panels for smooth finish concrete shall be plastic
faced adhesive tape to the approval of WOQOD Representative.

9 Precast concrete moulds shall be rigid steel, wood or fibreglass moulds.

10 Flashing reglets shall be galvanised steel of the longest possible length.

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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 8

9.4 FORMWORK EXECUTION

9.4.1 General

1 Where formwork to external faces will be permanently exposed, all horizontal and vertical
formwork joints shall be so arranged that joint lines will form a uniform pattern on the face of
the concrete.

2 Where CONTRACTOR proposes to make up the formwork from standard sized

manufactured formwork panels, the size of such panels shall be approved by WOQOD
Representative before they are used in the construction of the Works.

3 The finished appearance of the entire elevation of the structure and adjoining structures shall
be considered when planning the pattern of joint lines caused by the formwork and by the
construction joints to ensure continuity of horizontal and vertical lines.

4 Masonry nails or similar items shall not be used to fix formwork of the like to permanent
concrete works.

9.4.2 Trial Panels

1 The trial panels shall comprise surfaces that have unformed surfaces and formed surfaces
F1, F2 and F3.

2 The concrete cast from the job mock-up shall be used to assess the acceptability of the
CONTRACTOR’s workmanship for finishing.

3 If the finishing is deemed unacceptable by WOQOD Representative, CONTRACTOR shall

prepare a further mock-up with a particular class of finish.

4 The job mock-ups shall be retained during the course of the works to allow comparative
inspection, with production concreting and finishing and for the purpose of colour comparison
to ensure colour consistency.

9.4.3 Formwork Face in Contact with Concrete

1 Faces of formwork in contact with concrete shall be free from adhering foreign matter,
projecting nails and the like, splits or other defects, and all formwork shall be clean and free
from standing water, dirt, shavings, chippings or other deleterious matter.

2 Joints between forms and tie holes shall be watertight to prevent the escape of mortar or the
formation of fins or other blemishes on the face of the concrete.

3 CONTRACTOR shall verify lines, levels and measurement before proceeding with formwork
erection.

9.4.4 Sloping Surfaces

1 Formwork shall be provided for the top surfaces of sloping work where the slope exceeds 15

2 The formwork shall be anchored to enable the concrete to be properly compacted and to
prevent flotation.
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 9

3 Care shall be taken to prevent air being trapped under the sloping formwork.

9.4.5 Temporary Openings

1 CONTRACTOR shall provide temporary openings for inspection of the inside of the formwork
and for the removal of water used for washing down. The openings shall be formed as to be
easily closed before placing concrete.

9.4.6 Form Windows

1 CONTRACTOR shall provide windows in forms wherever directed by WOQOD

Representative or necessary for access for concrete placement and vibration.

2 The windows shall be of a size adequate for tremies and vibrators spaced at maximum 1.8 m
centres horizontally.

3 Any windows shall be tightly closed and sealed before proceeding to place concrete at a
higher level.

9.4.7 Co-ordination

1 CONTRACTOR shall ensure that the work of other trades in forming and setting openings,
slots recesses, chases, sleeves, bolts, anchors and other inserts is fully co-ordinated.

9.4.8 Conduits

1 Conduits or pipes shall be located so as not to reduce the strength of the construction.

2 In no case shall pipes other than conduits be placed in a slab 125 mm or less in thickness.

3 Conduits embedded in a concrete slab shall not have an outside diameter greater than one-
third the thickness of the slab nor be placed below the bottom reinforcing steel or over the top
reinforcing steel.

4 Conduits may be embedded in walls provided they are not larger in outside diameter than
one-third the thickness of the wall, are not spaced closer than three diameters on centre, and
do not impair the strength of the structure.

5 Embedded pipes and conduits shall be supported independently from reinforcing steel in a
manner to prevent metallic contact and thereby prevent electrolytic deterioration.

6 Pipes and conduits where embedded shall be placed as nearly as possible to the centre line
of the concrete section.

7 Conduits, piping, and other wall penetrations or reinforcements shall be subject to the
WOQOD Representative’s review and approval.

9.4.9 Ties and Bolts

1 The position of ties passing through concrete shall be subject to the approval of WOQOD
Representative.
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 10

2 Ties, bolts or other devices shall not be built into the concrete for the purpose of supporting
formwork without the prior approval of WOQOD Representative. The whole or part of any
such supports shall be capable of removal so that no part remaining embedded in the
concrete shall be nearer to the surface than the cover required for reinforcement.

9.4.10 Chamfers

1 Chamfer moulding strips shall be positioned on the exposed corners of columns and beams.

9.4.11 Cambers

1 If required, cambers shall be as shown on the Drawings.

2 The depth of beams at all points in the span, where cambers are used, shall be as shown on
the Drawings.

3 Allowance shall be made for compression and settlement of the formwork on line and level.

9.4.12 Exterior Angles

1 All exterior angles to concrete exposed to view in the completed structure shall be cast to the
true angles evenly throughout the length.

2 Care shall be taken to ensure that no waviness occurs along the angle and that no spalling
occurs to the concrete on removal of the formwork.

9.4.13 Surface Retarders

1 Surface retarders shall not be used on any formwork surface in contact with concrete unless
expressly authorised by WOQOD Representative.

9.4.14 Detection of Movement During Concrete Placement

1 Devices of telltale type shall be installed on supported forms and elsewhere as required to
detect formwork movements and deflection during concrete placement.

2 Where required slab and beam cambers shall be checked and correctly maintained as
concrete loads are applied on forms.

3 Workmen shall be assigned to check forms during concrete placement and to promptly seal
all mortar leaks.

9.4.15 Building in Pipes

1 Pipes and pipe specials through concrete walls and floors shall as far as possible be
positioned and built in during construction. They shall be located exactly in the positions
shown on the Drawings and shall be true to line and level.

2 CONTRACTOR shall take particular care to ensure that fully compacted concrete is in
contact with the pipe at all points.

3 Where it is not practicable to cast pipes and specials in the concrete, boxholes shall be
formed in the shuttering.
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 11

4 The box shall have six or eight sides, depending on the pipe diameter, and shall be no larger
in size than will give adequate clearance for the subsequent positioning and grouting in of the
pipe. The sides of the boxhole shall be provided with a tapered central annular recess to
provide a positive key. The boxhole shall be provided with a grout hole and, at the top of the
central annular recess, a vent hole. The boxhole shall be stripped with the main shuttering
and the concrete surface thoroughly cleaned and roughened.

5 When the pipe is later fixed, the remaining hole shall be reshuttered and filled with non-shrink
epoxy grout or non-shrink concrete. In the case of water retaining structures, CONTRACTOR
shall ensure that the measures adopted shall provide a finished joint which is resistant
against and free from leakage.

9.5 REMOVAL OF FORMWORK

9.5.1 General

1 WOQOD Representative shall be notified in writing before the removal of any formwork.

2 The Contractor, under no circumstances, shall strike the formwork until the concrete has
attained adequate strength to resist damage, in particular to arises and features.

3 Concrete shall be thoroughly wetted as soon as the forms are first loosened and shall be kept
wet during the removal operations and until the curing media is applied.

4 A potable water supply with hoses having fine fog spray attachments shall be ready at each
removal location before operations are commenced.

9.5.2 Stripping of Formwork

1 The period of time elapsing between the placing of the concrete and the striking of the
formwork shall be approved by WOQOD Representative after consideration of the loads likely
to be imposed on the concrete and shall in any case be not less than the periods shown in
Table 9.1

2 Stripping of the formwork within the time limits listed above does not relieve CONTRACTOR
from successfully crushing test cubes and achieving the specified compressive strength
results.

3 Notwithstanding the foregoing CONTRACTOR shall be held responsible for any damage
arising from removal of formwork before the structure is capable of carrying its own weight
and any incidental loading.

4 Where finished surfaces have re-entrant angles, the formwork shall be removed as early as
possible, within the time limits set above, to avoid shrinkage cracks.

5 The formwork shall be carefully stripped to avoid sudden shocks from the removal of wedges,
or vibration which might cause damage to the concrete.
6 Reshoring to beams and slabs shall be placed immediately after stripping formwork.
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 12

Table 9.1

Stripping Times of Formworks

Type Of Formwork Minimum Period Before Stripping

(Times Are From Concrete
Placement)

Beam sides, walls and column 1d

Soffits of slabs (props left under) 4d
Soffits of beams, joists and girders(props 10 d
left under)
Props to slabs 11 d
Props to beams 15 d

9.5.3 Holes to be Filled

1 Holes formed in concrete surfaces by formwork supports or the like shall be filled neatly with
non-shrink grout.

2 CONTRACTOR shall clean and scarify any hole that is to be filled with non-shrink grout.

9.5.4 Repair to Damaged Concrete Surfaces

1 Where the concrete surface has been damaged, CONTRACTOR shall break out any loose,
broken or cracked concrete or aggregate.

2 The concrete surrounding the hole shall be then be thoroughly soaked after which the surface
shall be dried so as to leave a small amount of free water on the surface. The surface shall
then be dusted with ordinary Portland cement by means of a small dry brush until the whole
surface that will come into contact with the dry-pack mortar has been covered and darkened
by absorption of the free water by the cement. Any dry cement in the hole shall be removed

3 Dry-pack material shall then be placed and packed in layers having a compacted thickness in
accordance with the manufacturer’s instructions. Compaction shall be carried out by the use
of a hardwood stick and a hammer and shall extend over the full area of the layer, particular
care being taken to compact the dry-pack against the side of the hole. After compaction the
surface of each layer shall be scratched before further loose material is added

4 The hole shall not be over-filled and the surface shall be finished by layering a hardwood
block against the dry-pack fill and striking the block several times. Steel finishing tools shall
not be used and water shall not be added to facilitate finishing.

5 The surface of the concrete shall be rubbed down smooth with carborundum and water in an
approved manner within three days of removing the formwork. Holes left after removal of
such supports shall be neatly filled with non-shrink grout of a suitable consistency and
matching colour.

9.6 DELIVERY AND STORAGE

9.6.1 Delivery

1 The delivery of formwork materials shall be done in such a manner that damage can be
prevented.
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WOQOD PETROL STATION Section 5 Part 9 Formwork Page 13

9.6.2 Storage

1 Formwork should be stored, after cleaning and preparing for reuse if used before, in such a
manner that access to all different materials is available.

2 Materials which can be affected by weathering shall be stored in appropriate buildings or

under cover.

9.7 TOLERANCES

1 The concrete work shall be constructed to an accuracy which shall permit the proper
assembly of components and installations and shall be compatible with the finish. The
accuracy of the work shall be within the tolerances shown on the Drawings or specified
elsewhere and, in the absence of any other requirements, shall comply with the following:

All laying out dimensions

Sections of concrete members
Surface of foundations against ground
Top surfaces of foundations, bases and piers
Surface level of floor slabs (5m straight edge)
Surface level of floor slabs to datum
Plumb of columns and walls in storey height
Plumb of columns and walls in full building height
Inside faces of elevator shafts in storey height
Inside faces of elevator shafts in full building height

9.8 EARLY LOADING

1 The Contractor should note that the loading from the falsework and wet concrete, during the
construction of a floor, will not exceed the permissible loading on the floor immediately below.
Consequently two of the floors immediately below the one being constructed will need to be
used, to share the loading.

2 While propping through two floors, the Contractor shall ensure, that the props beneath the
floor last constructed are released over its full extent as soon as the concrete has achieved
sufficient strength to support itself plus any superimposed loading, but not sooner than the
periods given in Table 9.1. The props shall then be re-tightened so that these may be used to
share the construction loading from the floor above.

3 Not withstanding the requirements of this Section for the removal times for formwork, the
following provisions shall apply to early loading of concrete.

4 Concrete shall at no time be subject to loading including its own weight which will induce a
compressive stress in excess of 0.33 of the actual compressive strength of the concrete at
the time of loading or 0.33 of the specified 28 d characteristic strength whichever is the lower.
For the purpose of this clause the assessment of the strength of the concrete and the stress
produced by the loads shall be subject to the agreement of WOQOD Representative.

5 If, due to his method of construction, CONTRACTOR wishes to place an imposed load on the
structure, he shall arrange for additional cubes to be cast at the point of the structure to be
loaded and these cubes will be crushed to monitor the compressive strength in accordance
with BS EN 12390-3 Compressive strength of test specimens. CONTRACTOR shall submit
__________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 9 Formwork Page 14

calculations showing the stresses induced by any proposed temporary loads to be placed on
the structure.

4 No superstructure load shall be placed upon finished piers or abutments until WOQOD
Representative has given his approval in writing and in no case shall any load be placed until
the curing period is complete.

5 Deck slabs of bridges shall only be opened to traffic or construction equipment and plant
when authorised by WOQOD Representative and in no case until the curing period is
complete.

END OF PART
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 10 Curing Page 1

10. CURING

10.1 GENERAL
10.1.1 Scope
10.1.2 References
10.1.3 Submittals
10.1.4 Quality Assurance
10.1.5 Storage

10.2 CURING

10.2.1 General
10.2.2 Water for Curing
10.2.3 General Requirements
10.2.4 Curing of Formed Surfaces
10.2.5 Curing of Unformed Surfaces
10.2.6 Moisture Curing
10.2.7 Moisture Retaining Cover Curing
10.2.8 Liquid Membrane Curing
10.2.9 Steam Curing
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WOQOD PETROL STATION Section 5 Part 10 Curing Page 2

10. CURING

10.1 GENERAL

10.1.1 Scope

1 This part covers the requirements for the curing of concrete.

2 Related Sections and Parts are as follows:

This Section
Part 1, General
Part 4, Water
Part 6, Property Requirements
Part 15, Hot Weather Concreting
Part 16, Miscellaneous.

10.1.2 References

BS 7542, Method of test for curing compounds for concrete.

ASTM C 309, Specification for Liquid Membrane-forming Compounds for Curing Concrete
AASHTO M 148.74, Liquid Membrane Curing
ISO 9000, Quality management and quality assurance standards
ISO 9001, Quality systems - Model for quality assurance in design, development,
production, installation and servicing

10.1.3 Submittals

1 CONTRACTOR shall submit to WOQOD Representative the proposed method of curing for
approval.

10.1.4 Quality Assurance

1 CONTRACTOR shall submit to WOQOD Representative for approval the details of proposed
curing media, if any. Details shall include chemical tests for the product in accordance with
BS 7542 and details of quality assurance procedures, including ISO 9000 certificates if held.

10.1.5 Storage

1 Chemical curing compounds shall be stored in accordance with manufacturer's

recommendations.

10.2 CURING

10.2.1 General

1 CONTRACTOR shall ensure that curing is provided for 24 hours per day including holidays
and that all related necessary plant and labour resources are also available.

2 Special attention shall be given to the curing of vertical and overhanging surfaces to ensure
satisfactory curing.

3 CONTRACTOR shall adopt curing measures that preclude the possibility of thermal shock to
the concrete during curing. This may be achieved by ensuring that the temperature of the
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 10 Curing Page 3

10.2.2 Water for Curing

1 Water used for any curing purposes shall conform to the requirements of Part 4 of this
Section.

10.2.3 General Requirements

1 Freshly placed concrete shall be protected from sun, wind, exposure and excessive drying
out.

2 All concrete shall be cured for a period of time required to obtain the full specified strength,
but not less than seven consecutive days. The method of curing shall be by water for the first
seven days and by water or membrane until the concrete has reached the full specified
strength.

3 Exposed surfaces shall be protected from air blown contamination until 28 d after the
concrete is placed.

4 The method of curing shall ensure that sufficient moisture is present to complete the
hydration of the cement, and shall be to the approval of WOQOD Representative. The
method of curing shall not :
(a) disfigure permanently exposed surfaces
(b) affect bonding of subsequent coatings
(c) increase the temperature of the concrete.

5 During the curing period, exposed concrete surface shall be protected from the direct rays of
the sun.

10.2.4 Curing of Formed Surfaces

1 Formed surfaces, including the underside of beams, girders, supported slabs and the like, by
moist curing with the forms in place for the full curing period, or until the forms are removed.

2 When the forms are stripped, curing shall continue by any approved method.

10.2.5 Curing of Unformed Surfaces

1 Unformed surfaces shall be protected as soon as possible after the concrete has been placed
by polythene sheeting. When sufficiently hard, hessian or other absorbent material shall be
placed on the concrete surface and shall be kept wet for the required period. The hessian
shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of water.
Alternatively a curing method approved by WOQOD Representativemay be used.

10.2.6 Moisture Curing

1 Moisture curing shall be performed by :

(a) covering the surface of the concrete with water and keeping it continuously wet
(b) continuous use of fine fog water sprays
(c) covering the surface with a saturated absorptive cover and keeping it continuously
wet.

2 Where method (a) is employed, the bunds used shall not be made from fill from excavations
or any other areas where there is the possibility of chloride contamination.
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WOQOD PETROL STATION Section 5 Part 10 Curing Page 4

10.2.7 Moisture Retaining Cover Curing

1 The concrete surface shall be covered with a suitable absorptive covering, such as hessian.

2 The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.

3 The cover shall be in the widest practical widths and shall have 200 mm side and end laps.

4 The laps shall be sealed with adhesive tape.

5 Any penetrations or tear in the covering shall be shall be repaired with the same material and
waterproof tape.

10.2.8 Liquid Membrane Curing

1 Liquid membrane curing shall be in accordance with the requirements of ASTM C 309 or
AASHTO M 148.74.

2 Membrane forming curing compounds shall be applied in accordance with the manufacturer's
recommendations immediately after any water sheen which may develop after finishing has
disappeared from the surface and within 2 h of stripping formwork on formed surfaces.

3 Membrane forming curing compounds shall not be used on surfaces against which additional
concrete or other material is to be bonded unless:
(a) it is proven that the curing compound will not prevent bond, or
(b) positive measures are taken to remove it completely from those areas which are to
receive bonded applications
(c) on fair faced concrete surfaces.

10.2.9 Steam Curing

1 An enclosure shall be formed around the concrete using tarpaulin or other suitable means.

2 Application of steam shall not be commenced until at least 2 h after final placement of
concrete.

4 Excessive rates of heating and cooling shall be prevented during steam curing and
temperatures in the enclosure shall not be allowed to increase or decrease by more than 22

5 The maximum steam temperature shall be maintained in the enclosure until concrete has
reached its specified strength.

END OF PART
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 1

11. REINFORCEMENT

11.1 GENERAL

11.1.1 Scope
11.1.2 References
11.1.3 Submittals
11.1.4 Quality Assurance
11.1.5 Delivery Storage and Handling

11.2 REINFORCING MATERIALS

11.2.1 Reinforcing Bars

11.2.2 Welded Steel Wire Fabric
11.2.3 Tie Wire

11.3 INSPECTION, SAMPLING AND TESTING

11.3.1 Sampling
11.3.2 Testing

11.4 CUTTING AND BENDING OF REINFORCEMENT

11.5 FIXING OF REINFORCEMENT

11.5.1 General
11.5.2 Welding
11.5.3 Mechanical Splices
11.5.4 Bundling and Splicing of Bundled Bars
11.5.5 Examination
11.5.6 Electrolytic Action
11.5.7 Cover
11.5.8 Spacers, Chairs and Other Supports
11.5.9 Reinforcement
11.5.10 Forms and Linings
11.5.11 Tanking
11.5.12 Adjustment and Cleaning

11.6 Not used

___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 2

11. REINFORCEMENT

11.1 GENERAL

11.1.1 Scope

1 This Part includes tension, compression, and temperature reinforcing steel, including welded
wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and
placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric, ties,
and supports.

2 Related Sections and Parts are as follows:

This Section
Part 16, Miscellaneous

Section 6, Blockwork.

11.1.2 References

QS 1705, Non-Weldable Reinforcing Steel

BS 4449, Specification for Carbon steel bars for the reinforcement of concrete
BS 8666, Specification for scheduling, dimensioning, bending and cutting of steel
reinforcement for concrete
BS EN ISO 4066, Construction drawings. Bar scheduling
BS 4482, Specification for Cold reduced steel wire for the reinforcement of concrete
BS 4483, Steel fabric for the reinforcement of concrete
BS EN 1011, Welding. Recommendation for welding of metallic materials
BS ISO14654, Epoxy- coated steel for the reinforcement of concrete
BS ISO 14656, Epoxy powder and sealing material for the coating of steel for the
reinforcement of concrete
BS 5135, Specification for the process of welding of carbon and carbon manganese steels
BS 8110, Structural use of concrete

ASTM A706, Specification for Low-allow Steel Deformed Bars for Concrete Reinforcement

ISO 9000, Quality management and quality assurance standards

11.1.3 Submittals

1 Product data including the manufacturer’s specification and installation instructions for
proprietary materials and reinforcement accessories shall be provided.

2 CONTRACTOR shall submit, the manufacturer’s records of chemical and physical properties
of each batch of billet steel bars and a certificate that the respective material furnished meets
the requirements for the steel reinforcement specified. The manufacturer’s records shall
include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.

3 Three copies of the steel test report shall be furnished with each consignment of steel
reinforcement. The steel shall be tagged and cross-referenced with mill certificates.

11.1.4 Quality Assurance

1 CONTRACTOR shall submit to WOQOD Representative for source approval details of the
proposed source of supply of the reinforcement. Details shall include chemical and physical
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 3

tests for the past six months production and any independent test results for this period.
Details of quality assurance procedures, including ISO 9000 certificate if held, shall also be
given.

2 CONTRACTOR shall furnish WOQOD Representative with a certificate of compliance for

each shipment of epoxy coated bars. The certificate of compliance shall state that
representative samples of the epoxy coated bars have been tested and that the test results
comply with the requirements herein specified. Test results shall be retained by
CONTRACTOR for seven years. A complete set of test results shall also be handed to the
client at the completion of reinforcement works, and shall be made available to WOQOD
Representative upon request.
11.1.5 Delivery Storage and Handling

1 On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show
the manufacturer’s test number and lot number and other applicable data that will identify the
material with the certificate issued for that lot of steel. The fabricator shall furnish three copies
of a certification which shows the batch number or numbers from which each size of bar in
the shipment was fabricated.

2 Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the

ground surface to prevent damage and accumulation of dirt, rust and other deleterious
matter. Storage facilities shall be such as to permit easy access for inspection and
identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark
reference.

3 The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock
loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free
from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may
impair the bond between the concrete and the reinforcement. The reinforcement shall be
covered to ensure protection from wind blown dust, condensation and other deleterious
materials.

11.2 REINFORCING MATERIALS

11.2.1 Reinforcing Bars

1 Reinforcement shall be from an acceptable source. All steel reinforcement shall comply with
the requirements of QS 1705 as a minimum and BS 4449 Grades 260 and 420 Type 2 (hot
rolled bars) and BS 4461 Grade 460/425 Type 2 cold worked steel or similar acceptable
International Standards.

2 Weldable reinforcing steel bars shall conform to the requirements of BS 4449: 1997.

3 Non-weldable reinforcing steel bars shall conform to the requirements of QS 1705.

3 If in the opinion of WOQOD Representative the steel has excessive surface rust, dust or
other deleterious material then the steel shall be sand blasted. Sand for blasting shall not
contain materials deleterious to the durability of the reinforcement or concrete. Dune sand
shall not be used for the sandblasting of reinforcement.

4 All reinforcement shall be pressure washed with fresh water after erection and immediately
before placing concrete.
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WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 4

11.2.2 Welded Steel Wire Fabric

1 Steel fabric reinforcement shall comply with the requirements of BS 4483 or similar
acceptable International Standards and shall be delivered to Site in flat mats.

2 Welded intersections shall not be spaced more than:

(a) 310 mm for plain round bars
(b) 400 mm apart for deformed high yield bars in direction of calculated stress except
when used as stirrups.

11.2.3 Tie Wire

1 Tie wire shall conform to the requirements of BS 4482.

2 1.6 mm. black annealed mild steel shall be used for tie wire.

3 No wires smaller than size D-4 shall be used.

11.3 INSPECTION, SAMPLING AND TESTING

1 Inspection of reinforcing steel and the installation thereof will be conducted by WOQOD
Representative.

2 CONTRACTOR shall give 24 hour notice to WOQOD Representative before closing forms or
placing concrete.

3 WOQOD Representative may instruct CONTRACTOR to break out and remove completely
all sections of the work already constructed under any of the following circumstances:
(a) reinforcing steel sample under test fails to meet the specification requirements at any
time
(b) WOQOD Representative considers that samples which were presented to him for
test were not truly representative
(c) it becomes apparent that reinforcing steel which has not been approved has been
used on the Works.

11.3.1 Sampling

1 Representative samples of all reinforcing steel that CONTRACTOR proposes to use in the
Works must be submitted, before work is commenced, to WOQOD Representative for his
written approval.

2 Manufacturer's certificates stating clearly for each sample:

(a) place of manufacture
(b) expected date and size of deliveries to site
(c) all relevant details of composition, manufacture, strengths and other qualities of the
steel.

3 WOQOD Representative reserves the right to sample and inspect all reinforcement steel
upon its arrival at the work site.

4 CONTRACTOR shall provide a certificate confirming that samples taken from the bars
delivered to the works pass the rebend test.

5 Frequency of sampling and the method of quality control shall be in accordance with
Appendix C of BS 4449.
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WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 5

6 Where epoxy coated steel is used 0.3 kg samples of the coating, material from each batch
be supplied in an airtight container and identified by the batch number.

7 Allow 14 days for WOQOD Representative’s review of samples.

11.3.2 Testing

1 Tests shall be carried out when directed by WOQOD Representative.

2 Tests shall be carried out in accordance with BS 4449.

3 Tensile tests providing information on following will be required from each delivery of
reinforcement:
(a) elastic limit
(b) ultimate strength
(c) stress/strain curve
(d) cross-sectional area
(e) deformation/bond characteristics of deformed bars.

4 The Contractor is to allow for dimensions and weight measurements, tensile, bend and/ or
rebend tests at his own cost, for each size of bar to be used in the concrete construction.

5 The Contractor is to allow for chemical analysis at his own cost if producer certificate is not
existed. Producer certificate shall be sufficient for chemical analysis.

6 Test results for each bar size shall be submitted to WOQOD Representative three weeks
before concrete work commences on Site.

7 Full testing shall be required if the source of supply of reinforcement changes, in which case
the cost of such extra testing will be borne by CONTRACTOR.

8 When any test results do not conform to the relevant standard the reinforcement steel shall
be removed from the Site and all costs resulting therefrom shall be borne by CONTRACTOR.

11.4 CUTTING AND BENDING OF REINFORCEMENT

1 Cutting and bending of reinforcement shall be in accordance with ISO 4066 and shall be
done without the application of heat. Bends shall have a substantially constant curvature. For
epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply.

2 Shall the Contractor decide to use pre-bent steel reinforcement from his supplier as an
alternative to site bent steel, he shall provide a hand-bender and a small site stock of each
size and type of unbent reinforcement.

2 Reinforcement shall not be straightened or rebent without the approval of WOQOD

Representative. If permission is given to bend projecting reinforcement care shall be taken
not to damage the concrete and to ensure that the radius is not less than the minimum
specified in BS 4466.
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WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 6

11.5 FIXING OF REINFORCEMENT

11.5.1 General

1 All reinforcement shall be securely and accurately fixed in positions shown on the Drawings
to ensure that the reinforcement steel framework as a whole shall retain its shape. The
framework shall be so temporarily supported as to retain its correct position in the forms
during the process of placing and consolidating the concrete.

2 The ends of all tying wires shall be turned into the main body of the concrete and not allowed
to project towards the surface.

3 No part of the reinforcement shall be used to support access ways, working platform or for
the conducting of an electric current.

4 CONTRACTOR’s specific attention is drawn to the following general requirements:

(a) lapped joints shall be as indicated on the Drawings and/or in accordance with the
requirements of BS 8110
(b) hooks shall be semicircular with a straight length of at least:
(i) four bar diameters for mild steel
(ii) six bar diameters for high yield steel.

11.5.2 Welding

1 Welding shall not be used unless authorised by WOQOD Representative and recommended
by the reinforcement manufacturer.

2 Where welding is approved it shall be executed under controlled conditions in a factory or

workshop.

3 Welding shall not take place on site without the approval of WOQOD Representative and
unless suitable safeguards and techniques are employed and the types of steel employed
have the required welding properties.

4 Welding if approved, may be used for:

(a) fixing crossing or lapping reinforcement in position
(b) fixing bars to other steel members
(c) structural welds involving transfer of loads between reinforcement or between bars
and other steel members.
5 The length of run deposited in a single pass shall not exceed five times the bar diameter. If a
longer welded length is required, the weld shall be divided into sections with the space
between runs made not less than five times the bar diameter.

6 Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be
approved, subject to their satisfactory performance in trial joints.

7 Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for
lapped joints.

8 Flash butt welding shall be executed with the correct combination of flashing, heating,
upsetting and annealing, using only machines which automatically control this cycle of
operations.
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WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 7

9 Metal-arc welding shall comply with BS EN 1011 and the recommendations of the
reinforcement manufacturer.

10 Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of
principle reinforcement shall be staggered, unless otherwise approved. The distance between
staggered joints shall be not less than the end anchorage length joints.

11 Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.

11.5.3 Mechanical Splices

1 Mechanical splices shall comply with BS 8110, and shall be used as and where indicated on
the Drawings.

2 Details of mechanical splices shall be submitted to WOQOD Representative for approval.

11.5.4 Bundling and Splicing of Bundled Bars

1 Bundling and splicing of bundled bars shall be in accordance with BS 8110.

2 Splicing, except where indicated on the Drawings or approved shop drawings, will not be
permitted without the approval of WOQOD Representative.

11.5.5 Examination

1 CONTRACTOR shall notify WOQOD Representative at least 24 hours before commencing

the fixing of reinforcement in order to facilitate the inspection of formwork.

2 CONTRACTOR shall ensure that areas to receive reinforcement are cleaned before fixing.

11.5.6 Electrolytic Action

1 Reinforcement shall not be fixed or placed in contact with non-ferrous metals.

11.5.7 Cover

1 Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer
pieces.

2 The cover shall not be less than as given below, according to the type of structural member
and the placing and exposure conditions as follows.
Condition 1 : Concrete placed in forms and not to be exposed later to the weather,
groundwater, fresh water, or to any combination of these.
Condition 2 : Concrete placed in forms but later to be exposed to the weather, groundwater,
fresh water, or to any combination of these.
Condition 3 : Concrete placed directly in contact with the ground.
Condition 4 : Concrete to be exposed to corrosive vapours, corrosive groundwater, sea
water or sea spray. Sufficient protection to the reinforcement shall be
provided by : adopting the minimum cover for exposure condition 3 and
applying a protective coating or membrane on the concrete surface. The
method of protection shall be in accordance with the provisions of the
specification and to the approval of WOQOD Representative.
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WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 8

Table 11.1

Minimum Cover to Reinforcement

Minimum Cover (mm) for Placing of
Reinforcement for Exposure Condition
Structural Member Condition 1 Condition 2 Condition 3
Pad footings and Pile Caps - 65 75
Strip footings - 50 65
Bored or Cast Piles - 50 75
Columns of all types 30 40 75
Walls, including retaining walls 25 30 75
Beams 30 40 65
Slabs, including concrete joist and
hollow block construction 5 30 65
Cover to embedded pipes 25 30 65
Reinforcement adjacent to blocks in
hollow block slab construction which
are integral with the structure 10 - -

11.5.8 Spacers, Chairs and Other Supports

1 Spacers, chairs and other supports shall be provided as necessary to maintain the
reinforcement in its correct position.

2 In a member where the nominal cover is dimensioned to the links, spacers between the links
and formwork shall be the same dimension as the nominal cover.

3 Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in
diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars
are detailed.

4 Spacers, chairs and other supports shall be made of concrete, plastic or other material to the
approval of WOQOD Representative. Where supports are made of concrete they shall have
at least the same cube strength as the concrete in the host member.

11.5.9 Reinforcement

1 Placing of all reinforcement steel bars will be checked by WOQOD Representative and in no
case is concrete to be placed around any reinforcement steel that has not been approved by
WOQOD Representative. Insertion of bars into or the removal of bars from concrete already
placed will not be permitted.

2 Reinforcement steel temporarily left projecting from the concrete at the joints shall not be
bent without the prior approval of WOQOD Representative.

11.5.10 Forms and Linings

1 Damage to forms and linings shall be avoided.

11.5.11 Tanking

1 Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.
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WOQOD PETROL STATION Section 5 Part 11 Reinforcement Page 9

11.5.12 Adjustment and Cleaning

1 Check position of reinforcement before and during placing concrete:

(a) pay particular attention to the position of top reinforcement in cantilever sections
(b) ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose
mill scale, oil and other substances which may adversely affect reinforcement,
concrete, or the bond between the two.

2 Protect projecting reinforcement from the weather where rust staining of exposed concrete
surfaces may occur.

3 At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and
freed from all mud, oil or any other coatings that might destroy or reduce the bond:

(a) clean all set or partially set concrete which may have been deposited thereon during
the placing of a previous lift of concrete
(b) all uncoated rust bars shall be again sand blasted and pressure washed.

4 Immediately before concrete placing the reinforcing steel shall be washed thoroughly with
high pressure potable water jets to remove any deposited salts.

END OF PART
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 12 Joints Page 1

12. JOINTS

12.1 GENERAL

12.1.1 Scope
12.1.2 References
12.1.3 Submittals
12.1.4 Quality Assurance
12.1.5 Definitions

12.2 CONSTRUCTION JOINTS

12.2.1 General

12.3 MOVEMENT JOINTS

12.3.1 General
12.3.2 Joint Filler
12.3.3 Joint Sealants

12.4 Not used

12.5 WATERSTOPS

12.5.1 General
12.5.2 Waterstops
12.5.3 Butyl Rubber Waterstops
12.5.4 Water Swelling Gaskets
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 12 Joints Page 2

12. JOINTS

12.1 GENERAL

12.1.1 Scope

1 This part deals with movement and construction joints, slip bearings, waterstops and
associated sealants and filler materials.

2 Related Sections and Parts are as follows:

This Section
Part 1, General
Part 10, Curing
Part 15, Hot Weather Concreting
Part 16, Miscellaneous

12.1.2 References
BS 2571, General purpose flexible PVC compounds for moulding and extrusion
BS 2782, Methods of testing plastics
BS 6093, Design of joints and joining in building construction
BS 7164, Chemical test for raw and vulcanized rubber
ISO 9001, Quality systems - Model for quality assurance in design, development,
production, installation and servicing
ISO 9002, Model for quality assurance in production, installation and servicing.

12.1.3 Submittals

1 CONTRACTOR shall submit for approval by the WOQOD Representative as soon as

practicable after acceptance of his Tender and not less than three weeks before
commencement of concreting, drawings showing his proposals for the position of
construction joints having due regard to any that may be shown on the Contract Drawings.

2 For slide bearings CONTRACTOR shall provide at least three samples of the proposed
material, together with the manufacturer's technical specifications and recommendations in
respect of application and performance.

3 For slip joints CONTRACTOR shall provide at least three samples of materials proposed,
together with manufacturer's technical specifications and recommendations in respect of
application and performance.

4 For waterstops CONTRACTOR shall provide at least three samples of proposed types,
including prefabricated joints and junctions, if applicable. If joints are to be made up on site,
provide worked samples, including samples for each make of waterstop, where samplesfrom
different manufacturers are provided.

5 CONTRACTOR must supply a certificate of compliance for the joint sealant, stating that it
meets the requirements of the specification. CONTRACTOR shall also supply the
Manufacturer’s technical and installation data for the proposed material. CONTRACTOR shall
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 12 Joints Page 3

provide details of previous installations of the product, with the client name, structure name,
type of joint and value of contract.

6 CONTRACTOR shall prepare shop drawings that show the layout of the waterstops, specials
and joints.

12.1.4 Quality Assurance

1 The joint sealant, including primers and debonding materials shall be compatible with each
other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality
Assurance Scheme.

12.1.5 Definitions

1 Construction Joint: The surface where two successive placements of concrete meet, across
which it is desirable to develop and maintain bond between the two concrete placements, and
through which any reinforcement which may be present is not interrupted.

2 Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a

weakened plane and regulate the location of cracking resulting from the dimensional change
of different parts of the structure. (See also Isolation Joint.)

3 Expansion Joint: A separation between adjoining parts of a concrete structure which is

provided to allow small relative movements such as those caused by thermal changes to
occur independently.

4 Isolation Joint: A separation between adjoining parts of a concrete structure provided to

isolate and element and thus allow independent movement.

5 Joints Fillers: Materials that are used to fill space within movement joints during construction.
They may provide support to a sealant applied subsequently.

12.2 CONSTRUCTION JOINTS

12.2.1 General

1 Where construction joints are required in slabs or beams they shall be located within the
middle third of their spans. Where slabs are supported by beams then the beams and slabs
shall be constructed in one operation.

2 In all cases vertical stop boards of a form to be approved by WOQOD Representative shall
be provided by at the end of each section of work which is to be concreted in one operation
and the concrete shall be thoroughly compacted against these stop boards.

3 Where slabs, beams and walls incorporate construction joints, panels shall generally be
constructed consecutively. Where this is not possible a gap not exceeding one metre shall be
formed between adjacent panels. This gap shall not be concreted until a minimum interval of
7 d has expired since the casting of the most recent panel.

4 The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but
in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with
nominal reinforcement.
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WOQOD PETROL STATION Section 5 Part 12 Joints Page 4

5 Horizontal construction joints in walls will only be permitted when the wall is continuous with
the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls
meeting the soffits of suspended members.

6 Construction joints in monolithic structures shall be aligned with each other whenever
practicable.

7 Before placing new concrete against concrete which has already set the latter shall be
treated to expose the aggregate over the full section and leave a sound irregular surface.
This shall be done while the concrete is still fresh by means of water spray and light brushing
or other means approved by WOQOD Representative.

8 Immediately before the new concrete is placed all foreign matter shall be cleaned away and
the surface moistened.

9 If during the course of the Contract it should become apparent that CONTRACTOR’s
methods of forming construction joints are not proving effective WOQOD Representative may
order CONTRACTOR to execute at CONTRACTOR’s expense such preventative measures
as WOQOD Representative may consider necessary to ensure the watertightness of the
construction joints in further work.

12.3 MOVEMENT JOINTS

12.3.1 General

1 Movement joints for expansion and contraction shall be constructed in accordance with the
details and to the dimension shown on the Drawings or where otherwise ordered by WOQOD
Representative and shall be formed of the elements specified.

2 CONTRACTOR shall pay particular attention to the effects of climatic extremes on any
material which he may desire to use on any movement joint and shall submit for approval by
WOQOD Representative his proposals for the proper storage, handling and use of the said
materials having due regard for any recommendations made by the manufacturer in this
connection.

12.3.2 Joint Filler

1 Joint fillers shall conform to the requirements of BS 6093.

2 The joint filler shall be fixed to the required dimensions of the joint cross-section and shall
provide a firm base for the joint sealer.

12.3.3 Joint Sealants

1 All joints to be sealed shall be formed and the groove grit blasted to remove all traces of
deleterious materials such as form oil or curing compounds and also to remove any surface
laitance from the sides of the joint. The joint shall be dry prior the application of priming.
Where the use of grit blasting is not possible CONTRACTOR may propose alternative
methods subject to the approval of WOQOD Representative.

2 The back of the joint shall receive a debonding tape or polyethylene foam backer cord in
order to provide the correct depth to width ratio and prevent three sided adhesion.

3 The areas adjacent to the joint shall be protected using masking tape.
___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 12 Joints Page 5

4 The sides of the joint shall be primed with the relevant primer as recommended by the
sealant manufacturer and the sealant material applied in accordance with the manufacturers
instructions.

5 The sealant material shall be a non-biodegradable multicomponent pitch polyurethane

elastomeric joint sealant, carefully selected as appropriate for the specific climatic and
environmental exposure conditions expected. Alternative types of sealant will be considered,
including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the
specification and the approval of WOQOD Representative.

6 Sealants shall exhibit the following properties:

Movement accommodation factor 25 %
Shore ‘A’ hardness 20 - 25
Solids content 100 %
Service temperature range 0 oC to 90 oC
Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis
Width to depth ratio 2:1

7 Where shown on the Drawings sealants shall also be suitable for use with potable water.

8 All surface preparation, priming, mixing and application shall be carried out in strict
accordance with the manufacturer’s instructions.

9 The sealant shall have a proven track record of no less than ten years under similar local
conditions.

12.5 WATERSTOPS

12.5.1 General

1 Waterstops and associated materials shall be by a manufacturer with a minimum of ten years
experience in the field of engineering waterproof products.

2 PVC waterstops shall be suitable for storage, handling, installation and service within a range
of 150C to 650C.

12.5.2 Waterstops

1 The waterstop shall be a high performance system forming a continuous network as shown
on the Drawings.

2 Site jointing is to be limited to butt joints and shall be performed strictly in accordance with
the manufacturer’s instructions.

3 Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web
sections.

4 Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The
water bar used at the location of expansion joints shall have a bulb in the centre to
accommodate the movements.

5 Waterstops shall have a minimum thickness of 5 mm.

___________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 12 Joints Page 6

6 The minimum test performance data for PVC waterstops shall be as follows:
Tensile strength >12 MPa
Elongation at break 300 %
Hardness Shore ‘A’ 80 to 90

7 The materials shall tested in accordance with BS 2571 or BS 2782.

12.5.3 Butyl Rubber Waterstops

1 Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in
accordance with BS 903.

Table 12.1

Properties Requirements of Butyl Rubber Waterstops

BS 903 Property Requirements

Part A1 Density 1100 kg/m3 (± 5 %)
Part A26 Handness 60-70 IRHD
Part A2 Tensile Strength Not less than 17.5 N/mm2
Part A2 Elongation at break point Not less than 450 %
Part A/6 Water Absorption (48 hours immersion) Not exceeding 5 %

2 Butyl rubber waterstops shall be suitable for storage, handling, installation and service within
a temperature of 0°C to 40 °C

12.5.4 Water Swelling Gaskets

1 Where active sealing is required for critical areas, waterstops shall be replaced with vinyl
ester gaskets such as masterflex 610E. The gasket shall conform to the following properties:

(i) Water pressure resistance : 5 Bar (50 mtr)

(ii) Expansion in contact with water : 2 x original SRE
(iii) : Reversible
(iv) Application Temperatures : - 30 -+ 50 °C
(v) Resistance to Micro Organisms : 6000
(vi) Freeze/Thaw Resistance : 6000
(vii) Dimensions : 25 x 20 mm

The selected gasket shall be available for three exposures:

(i) Type W : Black (Fresh + Potable Water)

(ii) Type E : Red (Seawater + Blackish Water)
(iii) Type C : Yellow (Chemicals, OK, Grease Solvents etc.)

The supplier shall furnish references upon request of the WOQOD Representative

END OF PART
________________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 1

13. INSPECTION AND TESTING OF HARDENED CONCRETE

13.1 GENERAL

13.1.1 Scope
13.1.2 References
13.1.3 Submittals
13.1.4 Quality Assurance
13.1.5 Non-Compliance of Work
13.1.6 General Fieldwork Requirements

13.2 CONCRETE CORES

13.2.1 General
13.2.2 Drilling Cores
13.2.3 Testing for Strength
13.2.4 Assessment of Strength

13.3 REINFORCEMENT COVER MEASUREMENTS

13.4 ULTRASONIC PULSE MEASUREMENTS

13.4.1 General
13.4.2 Selection of Test Locations
13.4.3 Execution of Tests
13.4.4 Estimated In Situ Cube Strength

13.5 RADIOGRAPHY OF CONCRETE

13.6 SURFACE HARDNESS

13.6.1 General
13.6.2 Method of Test
13.6.3 Equipment
13.6.4 Reporting

13.7 CHEMICAL CONTENT

13.7.1 Sampling
13.7.2 Laboratory Testing
________________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 2

13. INSPECTION AND TESTING OF HARDENED CONCRETE

13.1 GENERAL

13.1.1 Scope

1 This Part of the specification covers the inspection, sampling and testing of hardened concrete.

2 Related Section and Parts are as follows:

This Section
Part 6, Property Requirements

13.1.2 References

1 The following standards are referred to in this part of the specification :

BS 1881, Methods of testing concrete
BS EN 12350 Testing fresh concrete
BS 4408, Recommendations for non-destructive methods of test for concrete
BS EN 12504-2, Non-destructive testing. Determination of rebound number
BS EN 12504-4, Determination of ultrasonic pulse velocity
BS EN 1367, Test Thermal and weathering properties of aggregates
BS 6089, Guide to assessment of concrete strength in existing structures
BS EN 12504-4, Determination of ultrasonic pulse velocity

Concrete Society Report No. 11.

13.1.3 Submittals

1 CONTRACTOR shall submit to WOQOD Representative his quality assurance procedures for the particular
parts of the testing work that will be carried out.

2 CONTRACTOR shall submit for WOQOD Representative’s approval the curriculum vitae (CV) of the supervisor
proposed for the work.

3 CONTRACTOR shall prepare a factual report that identifies the test methods used and the test results. The
report shall also identify any unusual results or pertinent information relating to the testing. The report shall
comply with the following requirements;
(a) all test positions shall be uniquely referenced to allow their location of the structure to be identified. This
shall be by a sketch plan or detailed description
(b) CONTRACTOR shall supply one unbound master copy of the report in A4 size and two bound copies of
the report
(c) CONTRACTOR shall also supply one 3.5 inch floppy disk containing the computer word processing and
spreadsheet files that form the report ( IBM compatible )
(d) the master copy of the report and the two bound copies shall include colour prints of the concrete cores.

4 For each of the test results CONTRACTOR shall identify the precision or repeatability of the particular sampling
and testing method. This shall be as given from experience of the particular test by the laboratory or as
expected from information in the particular test standard.

13.1.4 Quality Assurance

1 All field and laboratory testing of concrete shall be carried out by an independent laboratory approved by
WOQOD Representative.
________________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 3

13.1.5 Non-Compliance of Work

1 If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum criteria, WOQOD
Representative may direct CONTRACTOR to carry out in-situ drilling and testing to obtain concrete core results.

2 The parts or elements of the structure made from the defective batch or batches of concrete as represented by
the works test cubes shall be identified by WOQOD Representative and
based on this information WOQOD Representative shall instruct CONTRACTOR on the position of required
number and concrete cores.

3 WOQOD Representative shall review the concrete core test results in conjunction with BS 6089 and Concrete
Society Report No. 11.

4 Based on this assessment WOQOD Representative shall decide the acceptability of the concrete in the
structural element and may either:
(a) accept the concrete
(b) instruct that certain remedial works are carried out
(c) instruct that the element is replaced.

13.1.6 General Fieldwork Requirements

1 CONTRACTOR shall make all arrangements to provide safe stable access to testing locations.

2 When gaining access to testing locations and whilst testing CONTRACTOR shall take care not to damage the
structure or leave it in an untidy or unclean state.

3 CONTRACTOR shall take precautions to ensure that cooling water from concrete coring/other operations is
discharged such as not to cause a mess or damage the interior or exterior parts of the structure.

4 CONTRACTOR shall be responsible for arranging the water supply required for testing.

5 CONTRACTOR shall arrange for a suitable power supplies. Where testing is being carried out on an occupied
structure a power supply from the building services may not available and CONTRACTOR shall make
arrangements for power supply and extension leads of adequate length.

6 CONTRACTOR shall appoint a qualified field supervisor to co-ordinate and manage the field work. The
supervisor shall have not less than five years experience of such work.

7 Before starting the work, WOQOD Representative with CONTRACTOR’s supervisor will mark the positions
where field testing is to be carried out. A unique referencing system to identify each sample or testing location
will be adopted, and this will either be referenced on sketch plans or drawings or by a detailed description used
throughout the report to identify test locations.

8 If testing is being carried out on an occupied structure CONTRACTOR shall co-ordinate with the owner or
operator of the structure to arrange the detailed programme for the works and gain access to the various parts
of the structure .

9 As soon as laboratory test results are available these shall be submitted by hand or faxed to the WOQOD
Representative in draft form.

10 All core holes, dust sample holes and exploratory investigation areas shall be reinstated with a proprietary non
shrink cementitious repair mortar. The preparation of the hole or area before reinstatement shall be carried out
as per the recommendation of the repair mortar supplier.
________________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 4

11 Before filling any core holes, dust sample holes or exploratory investigation areas, CONTRACTOR shall allow
WOQOD Representative time to inspect these areas and obtain written confirmation from WOQOD
Representative before filling.

13.2 CONCRETE CORES

13.2.1 General

1 The drilling and testing of cores shall be carried out in accordance with BS EN 1367-4. All of the supplementary
information listed in BS EN 1367-4 shall be included in the test report with photographs of the cores.

2 WOQOD Representative will advise the required number of and locations for the cores. If the results of the
initial coring are inconclusive, WOQOD Representative may instruct that further cores be taken at certain
locations.

3 Unless otherwise directed by WOQOD Representative, CONTRACTOR shall ensure that coring does not cut
through any reinforcing steel.

4 The required diameter and depth of cores shall be as directed by WOQOD Representative.

13.2.2 Drilling Cores

1 Before beginning coring operations CONTRACTOR shall use a proprietary cover meter to identify the position
of steel reinforcing bars at the testing location.

2 WOQOD Representative may instruct that the core is taken through the concrete without hitting any
reinforcement or WOQOD Representative may instruct that the core is taken in a position where it is expected
reinforcement will be cut in order to provide a sample of the reinforcement to check its condition. The locations
of all drilling points shall be chosen so that the core contains no steel parallel to its length.

3 Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared for test the core
shall have a length at least equal to the diameter and not more than 1.2 times its diameter.

4 Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the aggregate size does not
exceed 20 mm and 40 mm respectively. Where possible 150 mm cores should be taken to reduce the variability
due to drilling and increase the reliability of the testing, unless reinforcement is congested and the use of 100
mm cores will reduce the possibility that the core will contain steel or it is necessary to restrict the sampling to a
length of less than 150 mm.

5 Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores may be used with
the permission of WOQOD Representative.

6 During drilling operations, a log of observations that may affect the interpretation of core samples shall be
prepared.

7 If instructed by WOQOD Representative, immediately after the core has been cut and removed and the
structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein poured over the
cut surface. A photograph shall be taken of the cut core with the phenolphthalein solution applied to provide a
record of the test.

8 If during the drilling of the core, the core collapses due to weak honeycombed or defective concrete,
CONTRACTOR shall stop the drilling operation and carry out testing at an adjacent location as advised by
WOQOD Representative. If when testing at the second location, the core again breaks due to honeycombed or
defective concrete the freshly cut core shall be retained for reference and a note made of the condition.
________________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 5

13.2.3 Testing for Strength

1 The compressive strength of field concrete cores shall be assessed in accordance with BS EN 1367-4.

2 The details of the concrete core in accordance with BS EN 1367-4 shall be recorded and two photographs on
either side of the core taken.

3 Where there is reinforcement in the core, the size and the type of bar shall be noted along with its cover to the
concrete surface, the condition of reinforcing bars shall be noted with a detailed description of any corrosion of
the reinforcement.

4 Before carrying out the compressive strength testing of the cores CONTRACTOR shall inform WOQOD
Representative to allow him to witness the testing if required.

5 Crushed core samples shall be retained by the laboratory and only disposed of after written approval by
WOQOD Representative.

13.2.4 Assessment of Strength

1 The estimated in-situ strength of the concrete shall be calculated from the core result using BS EN 1367-4.

2 Reference shall be made to BS 6089 and Concrete Society Report No. 11 for the interpretation and use of
strength results.

13.3 REINFORCEMENT COVER MEASUREMENTS

1 The measurement of cover to reinforcing steel and other metallic items in concrete shall be carried out in
accordance with BS 1881 Part 204 using an electromagnetic device that estimates the position depth and size
of the reinforcement.

2 The locations for checking cover and the spacing between measurements shall be advised by WOQOD
Representative based on the objective of the investigation. CONTRACTOR shall carry out calibrations of the
electric magnetic device for a particular bar size to allow the bar diameter to be measured.

3 While testing, the orientation of steel bars shall be checked.

4 The electromagnetic device shall incorporate scale or digital display range and shall be calibrated in
accordance with clause 6 of BS 1881 Part 204. When calibrated in this manner the indicated cover to steel

given by the manufacturer.

5 The cover meter shall be used in accordance with the manufacturers instructions and checks on the zero
carried out as specified.

6 The search head shall be traversed systematically across the concrete, and, where reinforcement is located,
rotated until the maximum disturbance with electromagnetic field is indicated by the meter.

7 The cover to the reinforcement shall be noted along with the axis of the reinforcement. The cover shall also be
recorded on the concrete surface with chalk or a suitable non-permanent marking pen.

8 Care should be taken to avoid interference from other metallic sources or magnetic material.

9 The cover meter checks shall be carried out by an operator with five years experience.
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WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 6

10 The test report on cover shall include the following information:

(a) date
(b) time and place of test
(c) description of the structure or component under investigation
(d) location of test areas
(e) make and type of cover meter used
(f) date of last laboratory calibration of cover meter
(g) details of site calibration of cover meter, indicated values of cover
(h) estimated accuracy of quantitative measurements
(i) configuration of steel reinforcement

13.4 ULTRASONIC PULSE MEASUREMENTS

13.4.1 General

1 The ultrasonic velocity test equipment shall be capable of measuring the transit time of a pulse vibration through
concrete. The length of the pulse part between the transducer equipment shall be measured, and the pulse
velocity calculated.

2 Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS EN 12504-4.

3 Velocities shall be measured at a number of locations around a structure and a velocity contour of the structure
established. A minimum of 40 velocities shall be measured for each structural element.

13.4.2 Selection of Test Locations

1 Wherever possible direct transmission arrangements shall be used. The transducers shall be mounted on a
specially formed moulded surface.

2 The length of the pulse path shall be a minimum of 150 mm, but the path length shall not be longer than
required to detect small regions of bad concrete.

3 Where concrete contains steel the pulse velocity shall be adjusted in accordance with the requirement of BS
EN 12504-4.

4 Locations that contain reinforcement directly along or close to the pulse paths shall be avoided.

5 Where repositioning is not possible the semi-direct transmission measurement, where transducers are placed
on adjacent faces of the concrete, may be used.

13.4.3 Execution of Tests

1 Positions chosen for the test locations shall be clearly and accurately marked on the surface of the concrete.

2 The surface of the concrete shall be shall be cleaned and free from grit and dust. Path lengths shall be
determined to an accuracy of ±1 % and a suitable couplant (such as grease) applied to each of the test points.

3 Pulse transit times shall be measured by a skilled operator, with a minimum of five years experience in the use
of the equipment.

4 Pulse velocity measurement equipment shall be in accordance with the requirements of BS EN 12504-4.

5 Test results shall be examined and any unusual readings repeated carefully for verification or amendment.
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WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 7

13.4.4 Estimated In-Situ Cube Strength

1 A correlation shall be established between the cube crushing strength of the particular mix used in the structure
and the pulse velocity.

2 Where it is not possible to obtain cubes with the same mix design as the original structure a combination of
coring and ultrasonic pulse velocity testing may be carried out at the direction of WOQOD Representative,
where the cores are used to provide the correlation information required for the interpretation of the ultrasonic
pulse velocity tests.

13.5 RADIOGRAPHY OF CONCRETE

1 Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects:
The testing shall be carried out in accordance with the requirements of BS 1881-205 or equivalent.

13.6 SURFACE HARDNESS

13.6.1 General

1 Testing of concrete surfaces for hardness using rebound hammers shall be carried out in accordance with BS
EN 12504-2.

2 The rebound hammer shall only be used for estimation of concrete strength where a specific correlation is
carried out of the concrete from the structure being tested, this shall be from works test cubes or cores taken
from the structure.

3 The correlation between concrete strength and the rebound number shall be carried out in accordance with BS
EN 12504-2. The precision of the correlation curve between the mean rebound number and strength shall be
stated and this shall be used when reporting any strength interpretations from surface hardness readings. The
use of general manufacturers correlation or calibration curve for strength shall not be used.

4 It should be noted that the rebound hammer number only provides information on a surface layer of
approximately 30 mm in depth of the concrete and that this should be quoted in the test report.

5 The rebound hammer maybe used to establish the uniformity of the finish products or similar elements in a
structure at a constant age, temperature, maturity and moisture condition.

13.6.2 Method of Test

1 A minimum of 12 readings shall be taken to establish a single surface hardness at a particular location.

2 The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not exceeding 300 mm
by 300 mm.

3 The mean of each set of readings shall be calculated including abnormally high and abnormally low results
unless there is good reason to doubt the validity of a particular reading.

4 The coefficient of variation and the standard deviation of the readings shall be reported.

13.6.3 Equipment

1 The rebound hammer shall be a proprietary type that has been used successfully and serviced for a minimum
of five years.
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WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 8

2 The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact with the surface.

3 The manufacturers literature shall identify the impact energy and contact area of the plunger for the hammer.

13.6.4 Reporting

1 The test report shall affirm that the hardness was determined in accordance with BS EN 12504-2 and shall
provide the following information:
(a) date time and place of test
(b) description of structure and location of test
(c) details of concrete
(d) type of cement
(e) cement content
(f) type of aggregate
(g) type of curing
(h) age of concrete
(i) type of compaction of concrete
(j) forming of surface
(k) moisture condition of the surface
(l) carbonation state of surface
(m) any suspected movement of the concrete under test
(n) direction of test
(o) any other factors that are considered significant in influencing the hardness readings.

2 The details of the rebound hammer correlation with strength including the mean, range, standard deviation and
coefficient and variation of each reading shall also be included.

13.7 CHEMICAL CONTENT

13.7.1 Sampling

1 WOQOD Representative shall instruct the depth increments over which the dust samples are to be taken, the
types of chemical testing to be carried out and the quantity of sample required.

2 To provide uniform samples of cement matrix and aggregate , three separate holes shall be drilled at one
location. The diameter of the holes shall be between 12 and 20 mm.

3 Care shall be taken to discard the material from any render or finish unless this is specifically required under the
investigation.

4 Care shall be taken to ensure that dust increments are accurately measured by marking the drill bit.

5 The dust samples increments shall be carefully transferred to plastic bags and sealed to avoid contamination.
Each sealed bag shall be uniquely identified by the sample identification and depth increment.

13.7.2 Laboratory Testing

1 Residual split samples of dust from the field investigation shall be retained until WOQOD Representative has
reviewed the chloride test results. WOQOD Representative may instruct that repeat tests are carried out on
certain samples.

2 Chloride testing of concrete dust samples shall be by an acid soluble method in accordance with BS 1881 Part
124. The results shall be reported to two decimal places.
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WOQOD PETROL STATION Section 5 Part 13 Inps. & Testing of Hardened Concrete Page 9

3 Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124, using an acid soluble
method.
END OF PART
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 1

14. PROTECTIVE TREATMENTS FOR CONCRETE

14.1 GENERAL
14.1.1 Scope
14.1.2 References
14.1.3 Submittals
14.1.4 Quality Assurance
14.1.5 Preinstallation and Co-ordination
14.1.6 Delivery, Storage and Handling
14.1.7 Protection
14.1.8 General Requirements for all Treatments
14.1.9 Final Inspection

14.2 EPOXY COATING

14.2.1 General

14.2.2 Surface Preparation

14.2.3 Materials
14.2.4 Application

14.3 WATERPROOF MEMBRANE

14.3.1 General
14.3.2 Materials
14.3.3 Waterproof Membrane
14.3.4 Application
14.3.5 Crystalline Waterproofing

14.4 PENETRATIVE PRIMER

14.4.1 General
14.4.2 Material
14.4.3 Surface Preparation
14.4.4 Application

14.5 PROTECTIVE COATING

14.5.1 General
14.5.2 Surface Preparation
14.5.3 Material
14.5.4 Application

14.6 PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

14.6.1 General
14.6.2 Shop Drawings and Submittals
14.6.3 Liner Material Requirements
14.6.4 Plastic Sheet Liner Strip Properties.
14.6.5 Basic Sheet Dimensions
14.6.6 Liner Details
14.6.7 Installation
14.6.8 Testing Requirements
14.6.9 Special Requirements
14.6.10 Joints in Lining for In-Situ Concrete Structures
14.6.11 Testing and repairing damaged surfaces
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 2

14. PROTECTIVE TREATMENTS FOR CONCRETE

14.1 GENERAL

14.1.1 Scope

1 This Part covers the materials and application requirements for coatings for concrete surfaces including
epoxy coatings, waterproof membranes, penetrative primers, protective coatings, and coatings and
treatments for specialist applications where there is a harsh environment.

2 Related Section and Parts are as follows:

This Section
Part 1, General

14.1.2 References

1 The following standards are referred to in this Part:

BS 1881, Testing Concrete

BS EN 12350, Testing fresh concrete

ASTM D412, Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers Tension
ASTM D543, Test Method for Resistance of Plastics to Chemical Reagents
ASTM D570, Test Method for Water Absorption of Plastics
ASTM D638, Test Method for Tensile Properties of Plastics (Metric)
ASTM D746, Test Method for Brittleness Temperature of Plastics and Elastomers by
Impact
ASTM D882, Test Methods for Tensile Properties of Thin Plastic Sheeting
ASTM D1000, Test Method for Pressure Sensitive Adhesive Coated Tapes Used for
Electrical and Electronic Applications
ASTM D1004, Test Method for Initial Tear Resistance of Plastic Film and Sheeting
ASTM D4541, Test Method for Pull Off Strength of Coatings Using Portable Adhesion
Testers
ASTM E 96, Test Methods for Water Vapor Transmission of Materials
ASTM E154, Test Methods for Water Vapor Retarders Used in Contact with Earth Under
Concrete Slabs, on Walls, or as Ground Cover

CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments.

ISO 9000, Quality management and quality assurance standards

ISO 9001, Quality systems - Model for quality assurance in design, development,
production, installation and servicing

14.1.3 Submittals

1 CONTRACTOR shall submit manufacturers' specifications, installation instructions and other data to
show compliance with the requirements of this part of the specification and the Contract Documents.

2 CONTRACTOR shall submit samples of all materials to be used in the works before delivery of material to
Site. Samples of membrane waterproofing shall be 300 mm square. Samples of liquid components shall
be a minimum of one litre.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 3

3 CONTRACTOR shall submit comprehensive test results for the protective coating system as per the tests
in the specification which shall clearly indicate whether the values are mean values measured in current
production or minimum values which the property does not fall below.
4 CONTRACTOR shall clearly state the chemical composition of the material and the process by which
protection is given to the concrete.

5 In addition to the test methods identified in this clause of this specification, WOQOD REPRESENTATIVE
may require CONTRACTOR to carry out further tests to different standards.

6 If CONTRACTOR wishes to propose a material which has been tested to alternative standards,
CONTRACTOR shall submit correlation tests showing the comparable values of the two test methods.
These test results shall be comprehensive giving full details of the sample conditioning , preparation,
method of test, criteria for assessment etc.

7 CONTRACTOR shall submit comprehensive information of previous applications of the material in similar
conditions and environments. This information shall include : project name, type/grade of material used,
quantity of material used, name of client, name of consultant, name of CONTRACTOR. If requested by
WOQOD REPRESENTATIVE, CONTRACTOR shall supply the contact details of the client, consultant or
CONTRACTOR where the material was previously installed.

8 CONTRACTOR shall submit a guaranty for the protective coating system and the workmanship. The
guaranty shall be worded to reflect the required performance of the material and shall be approved by
WOQOD REPRESENTATIVE. The guaranty shall be worded to include the phrase ‘CONTRACTOR shall,
at the convenience of the Employer, effect all repairs and replacements necessary to remedy defects all
to the complete satisfaction of WOQOD REPRESENTATIVe'. Unless stated otherwise in the contract
specific documentation, the performance guaranty shall be for a period of ten years except for the
penetrative primer which shall be for a period of five years.

9 The use of alternatives may be considered by WOQOD REPRESENTATIVE. If CONTRACTOR wishes to

propose such systems, a technical submission shall be made which shall include a comprehensive
justification giving an explanation of why the proposed system is equivalent or superior to the one
designated.

14.1.4 Quality Assurance

1 The protective coating system shall be supplied by a manufacturer who is certified to the ISO 9000 series
of quality standards. CONTRACTOR shall submit to WOQOD REPRESENTATIVE a copy of the ISO
9000 series certificate that clearly states the scope of the certification.

2 The protective coating system shall be supplied by a manufacturer who provides technical assistance on
the suitability for the application and installation for the material. For the initial use of the material on Site,
CONTRACTOR shall arrange for the technical representative of the manufacturer to be present to
demonstrate the correct use of the material.

3 The protective coating system shall be applied by a CONTRACTOR or subcontractor who is certified to
the ISO 9000 series of quality standards. CONTRACTOR shall submit to WOQOD REPRESENTATIVE a
copy of the ISO 9000 certificate that clearly states the scope of the certification. WOQOD
REPRESENTATIVE may permit the use of an applicator who is not certified to ISO 9000 if the applicator
works to a quality system that is approved by WOQOD REPRESENTATIVE.

4 The works shall be executed by an approved specialist subcontractor having a minimum of 5 years
successful experience in the installation of the specified material. Only tradesmen experienced with the
installation of the materials specified shall be used.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 4

14.1.5 Preinstallation and Co-ordination

i After approval of all materials and before installation, a prework conference with WOQOD
REPRESENTATIVE shall be held at the Site. The meeting shall be attended by representatives of
WOQOD Representative, Contractor, subcontractor, and manufacturer.
2 The parties shall:
(a) review drawings, specifications and approved materials
(b) correct conflicts, if any, between approvals and specification requirements
(c) examine Site conditions, including inspection of substrate, material labels and methods of storing
materials
(d) review installation procedures and scheduling
(e) review protection methods for finished work from other trades.

3 Before applying the coating system to the permanent works CONTRACTOR shall carry out a small trial of
the coating system for the review and approval of WOQOD REPRESENTATIVE.

14.1.6 Delivery, Storage and Handling

1 Materials shall be delivered in their original, tightly sealed containers or unopened packages, all clearly
labelled with the manufacturer's name, brand name, and number and batch number of the material where
appropriate. Materials and equipment shall be stored as directed in a neat and safe manner.

2 Storage areas shall comply with the manufacturers requirements with regard to shade, ventilation and
temperature limits and shall be located away from all sources of excess heat, sparks or open flame.
Containers of liquid material shall not be left open at any time in the storage area.

3 Materials not conforming to these requirements will be rejected by WOQOD REPRESENTATIVE and
shall be removed from the Site and replaced with approved materials.

4 CONTRACTOR shall deliver materials to Site in ample time to avoid delay in job progress
and at such times as to permit proper co-ordination of the various parts.

14.1.7 Protection

1 CONTRACTOR shall protect the protection system installation from damage during the construction
period so that it will be without any indication of abuse, defects or damage at the time of completion.

2 CONTRACTOR shall protect the building/structure from damage resulting from spillage, dripping and
dropping of materials.

3 CONTRACTOR shall prevent any materials from running into and clogging drains.

4 Materials and plant shall not be stored on any newly constructed floor without the permission of the
WOQOD Representative.

5 Impervious membranes shall be laid as protection to all concrete surfaces in contact with the soil and
shall consist of tanking or similar accepted material, based on soil investigation report.

6 All foundations shall be provided with protection such as epoxy coatings or similar other accepted
equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.

14.1.8 General Requirements for all Treatments

1 Protective treatments shall be applied where designated in the contract specific documentation.
____________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 5

2 All protective coating systems to be used shall be applied strictly in accordance with the manufacturers
recommendations.

3 CONTRACTOR shall take all necessary precautions against fire and other hazards during delivery,
storage and installation of flammable materials specified herein and comply any regulations imposed by
the Civil Defence Department of the Ministry of the Interior in respect of the storage and use of hazardous
materials required under this section.

4 WOQOD REPRESENTATIVE shall specify the required final colour of the coating and CONTRACTOR
shall submit samples showing the colour before ordering the materials.

14.1.9 Final Inspection

1 Upon completion of the installation, an inspection shall be made by a representative of the material
manufacturer in order to ascertain that the system has been properly installed.

14.2 EPOXY COATING

14.2.1 General

1 The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in two coats to
a dry film thickness

2 Where specified, special epoxy coating (Jota Armor) shall be applied as per the manufacturer’s
recommendations. The applicator shall provide a 10 year warranty for both any nonperformance of the
material or application.

14.2.2 Surface Preparation

1 The surface of the concrete shall be free from oil, grease, loose particles, decayed matter, moss or algae
growth and general curing compounds. All surface contamination and surface laitance shall be removed
by high pressure water jetting or sweep blasting.

2 Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic epoxy resin
fairing coat. The mixing and application of this coat shall be in accordance with the product
manufacturer’s recommendations.

3 Where surface cracking is apparent these cracks shall be chased, by an approved mechanical means, to
the depth of the crack. A thixotropic epoxy resin shall be applied using a trowel, scraper or filling knife
ensuring that full compaction is achieved into the chased section and providing a flush finish with the
concrete surface. A minimum period of 24 h shall be allowed before applying any subsequent protective
coating systems.

14.2.3 Materials

1 External above ground coating materials shall provide protection against chlorides and carbonation, and
be UV and abrasion resistant.

2 The above ground coating shall be applied over the below ground coating and shall continue for a
minimum of 150 mm above the ground level.

3 The epoxy coating shall be UV stable.

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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 6

5 The materials used in the coating system shall comply with the following requirements:
Solids Content > 85 %
Service temperature -20oC to 70oC
Tensile strength (DIN 53504) 4 MPa
Resistance against crack (DIN 53515) 6 MPa
Adhesion to concrete (ASTM D-4541) greater than 3.5 MPa
Compressive strength (ASTM D-695) 90 MPa (neat resin)
Tensile elongation (ASTM D-638) 6-8 % (neat resin)
Water absorption (MIL D-24613) Nil
Abrasion resistance (ASTM C-501) 50 mg
Compressive strength (ASTM C-579) 97 MPa @ 7 days
Thermal coefficient of expansion (ASTM C-531) 46.8 x 10-6 mm/mm/degree C

14.2.4 Application

1 Where required by WOQOD REPRESENTATIVE, trial areas not exposed in the finished work shall first
be treated using the selected materials.

2 The exposed concrete surfaces as defined in the documents or as agreed with WOQOD
REPRESENTATIVE shall be treated with the material.

3 The coating shall be applied by spray, roller or brush to achieve a finish acceptable to WOQOD
REPRESENTATIVE.

4 In all operations of storage, mixing and application, CONTRACTOR is to comply with the health and
safety recommendations of the manufacturer and governing authorities.

14.3 WATERPROOF MEMBRANE

14.3.1 General

1 This Subpart covers the use of waterproof membrane for general protection to buried concrete.

2 Where indicated on the Drawings or directed by WOQOD REPRESENTATIVE, concrete in contact with
the ground shall be protected by a preformed flexible torch applied bituminous type membrane.

3 The laying, lapping and sealing of the membrane shall be in accordance with the manufacturer’s
instructions.

14.3.2 Materials

1 The material shall be an externally applied waterproof membrane shall be an impervious, torch applied
flexible laminated sheet, consisting of multilayer high density cross-laminated polyethylene film with a
backing of rubber bitumen compound, protected with silicone coated release paper.

2 Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.

3 Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured from selected
aggregates, bound in modified bitumen encased between two layers of strengthened asphalt paper. The
bituminous material shall be a minimum of 1.5 mm thick and the membrane shall be capable of bridging
crack widths in the substrate up to 0.6 mm wide.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 7

14.3.3 Waterproof Membrane

1 The material shall be suitable for use in the Gulf region the compound shall be specially formulated for
hot climates and shall have proven experience in the Middle East.

2 The waterproofing material shall conform to the standards detailed in Table 14.1

Table 14.1

Waterproof Membrane Property Requirements

Property Standard Value
Elongation Film ASTM D638 Longituduial 210 %
Transverse 160 %
Tear resistance ASTM D1004 Longitudinal 340 MPa
Transverse 310 MPa
Adhesion to primed concrete ASTM D1000 1.8 MPa
Elongation compound ASTM D1000 1.8 Mpa
Puncture resistance ASTM E154 220 N over 65 mm
Water resistance ASTM D570 After 24 h. 0.14 %
After 35 d 0.95 %
Environmental resistance ASTM D543
Moisture vapour transmission rate ASTM E96 0.3g/M2 24 h
Minimum thickness 4.0 mm

14.3.4 Application

1 Waterproofing membranes placed on vertical concrete faces shall be protected by preformed asphalt
board.

2 Boards shall be bonded onto position with high quality solvent borne contact adhesive based on
polychloroprene rubber.

3 CONTRACTOR shall co-ordinate the installation of waterproofing membrane with floor drains, equipment
bases and other adjacent work and mask adjacent work to prevent soil marks.

4 Areas where waterproofing is applied shall be protected from all traffic and where necessary backfilling.
All damage to finished portions of the waterproofing membrane shall be either repaired or replaced, or
both, in an manner acceptable to WOQOD REPRESENTATIVE.

14.3.5 Crystalline Waterproofing

REFERENCES

Applicable Standards: The following standards are referenced herein.

1. American Society for Testing and Materials (ASTM)

2. Army Corps of Engineers (CRD)

3. American Concrete Institute (ACI)

4. NSF International (NSF)

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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 8

SYSTEM DESCRIPTION

Crystalline Waterproofing Additive: Concrete waterproofing system shall be of the crystalline type, defined by
the ACI 212.3R – 10 Report on Chemical Admixtures for Concrete as a “PRAH” type hydrophilic admixture. It
shall react such that it chemically controls and permanently fixes a non-soluble crystalline structure throughout the
capillary voids of the concrete. The system shall cause the concrete to become sealed against the penetration of
liquids from any direction, and shall protect the concrete from deterioration due to harsh environmental conditions.

SYSTEM PERFORMANCE REQUIREMENTS

A. BBA – Certification on Admix .

B. Must have a proven market presence at least 10 years in Qatar with at least 5 approvals in
government executed projects. .

C. Must furnish at least 5 project references of usage in substructures, and other application areas .

D. Testing Requirements: Crystalline waterproofing system shall be tested in accordance with the
following standards and conditions, and the testing results shall meet or exceed the performance
requirements as specified herein. Independent tests verifying these results shall be submitted prior to
approval.

E. Independent Laboratory: Testing shall be performed by an independent laboratory meeting the

requirements of the recognized specifying body of the country in which the testing is performed.
Testing laboratory shall obtain all concrete samples and waterproofing product samples.

F. Water Permeability: Independent testing shall be performed according to U.S. Army Corps of Engineers
CRD-C48 - Mod “Permeability of Concrete” and the European Standard EN-12390-8. Under CRD-
C48 treated concrete samples shall be pressure tested to 150 psi (350 foot head of water) or 1.05
MPa (106 m head of water). The treated samples shall exhibit no measurable leakage against
control samples which shall exhibit full saturation and measurable leakage. EN-12390-8 testing shall
show at least a 75% reduction in depth of water penetration for Admixture treated concrete as
compared to the control concrete.
G. Compressive Strength: Independent testing shall be performed according to ASTM C39 “Compressive
Strength of Cylindrical Concrete Specimens”. Concrete samples containing the crystalline
waterproofing additive shall be tested against untreated control sample. At 28 days, the treated
samples shall exhibit an increase in compressive strength over the control sample.
H. Concrete Shrinkage: Independent testing against Australian Standard AS 1012.13, ASTM C-157 or
other recognized international standard for concrete shrinkage shall show reduced shrinkage for
admixture modified concrete as compared to a control sample.
I. Petroleum Product Permeability: Independent testing shall be performed according the European EN –
12390-8. Treated samples shall show a more than an 80% reduction in depth of penetration for both
diesel and unleaded gasoline as compared to a control concrete.
J. Chloride Resistance: Independent testing shall be performed according the European Nordtest, NT
Build 443 or other chloride penetration ponding test. Treated samples shall show a 50% or greater
____________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 9

reduction in the chloride diffusion coefficient as versus the control concrete. Further, service life
modeling based in testing shall show at least a doubling in expected time to corrosion for the
reinforcing steel in the treated samples versus the control concrete.
K. Sulfate Resistance: Independent testing shall be performed against Australian
Standard AS 1141.24, US Bureau of Reclamation - Procedure for Length Change of Hardened
Concrete Exposed to Alkali Sulfates or another recognized international
standard for weight loss and length change. Samples exposed to Ammonium Sulfate solution for 25
weeks shall show a weight loss of at least 25% less than the control concrete and a length change of
- 0.01% or less than the control.
L. Acid Resistance: Independent testing shall be performed to determine “Sulfuric Acid Resistance of
Concrete Specimens”. Treated concrete samples (dosage rates of 3% of Standard Admixture) shall
be tested against untreated control samples after 40 days of curing. All samples shall be immersed in
7% sulfuric acid and weighed daily until a control sample reaches a weight loss of 50%. At this time
on final weighing the percentage weight loss of the 3% treated samples shall be 40% or lower.
M. Crystalline Formation: Crystallizing capability of waterproofing system shall be evidenced by
independent SEM (Scanning Electron Microscope) photographs showing crystalline formations within
the concrete matrix at a magnification no greater than 2000 times.
N. Potable Water Approval: Independent testing shall be performed according to NSF Standard 61, and
approved for use of waterproofing material on structures holding potable water shall be evidenced by
NSFcertification.
Middle East Water Authorities requirement is 50 degree compatibility with Potable Water -
Certification from WRAS is must for KAHARMAA in Qatar for all Potable Water Tanks.
O. Certificate of Conformity of the Factory Production Control for Surface Protection
System for Concrete – Coating Material by BSI
P. Freeze Thaw Resistance Testing: Independent testing against JUS U.M1.016, ASTM – C-666 or other
recognized international standard for durability of air entrained treated samples shall show at least a
60% improvement for treated concrete versus that of a control concrete when subjected to 250 freeze
thaw cycles.
Q. Salt Scaling Resistance: Independent testing against JUS U.M1.055, ASTM C667 or other recognized
international standard for salt scaling resistance shall show no visible scaling for treated sample
versus a control sample which shall show showing scaling to a depth of at least 0.5 mm when
samples are subjected to 25 freeze thaw cycles.
R. Fire Testing: Independent testing against a recognized international standard for fire testing shall show
negligible difference between admixture treated concrete versus control concrete when slabs are
exposed to a hydrocarbon fire.

SUBMITTALS
General: Submit listed submittals in accordance with conditions of the Contract and with Division 1 Submittal
Procedures Section.

Product Data: Submit product data, including manufacturer's specifications, installation instructions, and general
recommendations for waterproofing applications. Also include manufacturer's certification or other data
substantiating that products comply with requirements of Contract Documents.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 10

Test Reports: Submit, for acceptance, complete test reports from approved independent testing laboratories
certifying that waterproofing system conforms to performance characteristics and testing requirements specified
herein.

QUALITY ASSURANCE

Manufacturer Qualifications: Manufacturer to have no less than 10 years experience in manufacturing the
crystalline waterproofing additive for the required work, and be capable of providing field service representation
during construction phase. Manufacturers that cannot provide the performance test data specified herein will not
be considered for the project. Manufacturer to be ISO 9001 certified.

Applicator: Installer of crystalline waterproofing additive shall be approved by the manufacturer or manufacturer's
representative in writing.

Pre-Installation Conference: Prior to installation of waterproofing, conduct meeting with Architect/Engineer,

owner's representative, applicator (concrete supplier), concrete placer and waterproofing manufacturer's
representative to verify and review the following:

1. Project requirements for waterproofing as set out in Contract Document.

2. Manufacturer's product data including application instructions.

Technical Consultation: The waterproofing manufacturer's representative shall provide technical consultation on
waterproofing application.

DELIVERY, STORAGE AND HANDLING

Ordering: Comply with manufacturer's ordering instructions and lead time requirements to avoid construction
delays.

Delivery: Deliver packaged waterproofing materials to project site in original undamaged containers, with
manufacturer's labels and seals intact.

Storage: Store waterproofing materials in dry, enclosed location, at temperature and humidity conditions
recommended by manufacturer.

Manufacturer's Warranty: Manufacturer shall provide standard product warranty executed by authorized company
official.

DOSAGE AND MIXING

General: Crystalline Admixture must be added to concrete mix at time of batching.
Dosage Rate: Under normal conditions, the crystalline waterproofing powder shall be added to the concrete mix
at a rate of 1% - 1.5% by weight of Portland cement content. Minimum Dosage is 3kgs/cum and maximum
Dosage is 6kgs/cum of crystalline admixture in terms of absolute weight.
For enhanced chemical protection or meeting specific project requirements, consult with manufacturer or its
authorized representative to determine appropriate dosage rates which are compliant to the manufacturer’s
technical data sheets.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 11

Waterproofing Construction Joints and Cold Joints Between Pours: Crystalline Concentrate, single coat
crystalline waterproofing; proprietary compound of Portland cement, silica sand and active chemicals, mixed with
water at 3 parts powder to 1 part water or in proportions recommended by manufacturer to achieve full coverage
with application method used. Application rate: 1.00 kg/sqm.

Dry Pack Joint Compound: Dry pack consistency mixture of Crystalline Concentrate; proprietary compound of
Portland cement, silica sand and active chemicals; and water at 6 parts powder to 1 part water or in proportions
recommended by manufacturer.

MANUFACTURER'S INSTRUCTIONS

Compliance: Comply with manufacturer's product data regarding installation, including technical bulletins,
product catalogue, installation instructions and product packaging labels.

PROJECT CONDITIONS

Reinforcement: All reinforcement shall be rib deformed bar in accordance with applicable standards. Exposed
concrete decks (joint free) shall contain sufficient reinforcement to minimize thermal movement and control
cracking.

Setting Time and Strength: Some retardation of set may occur when using Crystalline Admix. The amount of
retardation will depend upon the concrete mix design, the dosage rate of the Admix, temperature of concrete and
climatic conditions. Concrete containing Xypex Admix may develop higher ultimate strengths than plain concrete.
Conduct trial mixes under project conditions to determine setting time and strength of the concrete.

Consult with manufacturer or manufacturer's representative regarding concrete mix design, project conditions and
proper dosage rate.

Weather Conditions: For mixing, transporting and placing concrete under conditions of high temperature or low
temperature follow concrete practices as referred to in ACI 305R-77 (Hot Weather Concreting) and ACI 306R-78
(Cold Weather Concreting).
For flatwork being placed in either hot, dry or windy conditions use of monomolecular film (evaporation retardant)
is recommended to control loss of bleed water.

APPLICATION
General: Crystalline Admix shall be added to the concrete mix at time of batching. Thorough blending of the
Crystalline Admix throughout the concrete mix is essential for correct performance of the product and, therefore,
care should be taken to ensure that a homogeneous mixture is obtained.

Concrete Batching & Mixing:

Procedures for mixing will vary according to type of batching plant operation and equipment.

Ready Mix Batch Plant - Pan Type Mixer:

Add Crystalline Admix material to the rock and sand, then mix thoroughly for 2 - 3 minutes before adding the
cement and water. The total concrete mass should be blended using standard practices.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 12

Ready Mix Truck -

Add Crystalline Admix powder to drum of ready-mix truck as per concrete volume and required dosage rate. Mix
the materials for 7-8 minutes extensively to ensure that the Admix is distributed homogeneously throughout the
mix.

All Joint Treatments:- :

One coat of Cryatlline Concentrate slurry at a rate of (1.00 kg / sq m ) is to be applied to the entire concrete
substrate surface where the existing and new concrete will interface. Allow slurry to set or dry. No curing is
required.
OR

For hydrostatic conditions please follow Project Engineers recommended alternative system in the Construction
& Structural Joint s like PVC Waterstops or Swellable Bars. Allow one coat of Xypex Concentrate slurry coat
either side of the PVC Water Stop or Swellable Bar and create a Drypac with Xypex Concentrate in tapered by
the side of the Bar to create a standing system so that no deformation of Waterstop or Swellable Bar happens
during pouring.

CURING
General: Concrete containing Crystalline Admix shall be moist cured in accordance with ACI Reference 308, “
Standard Practice for Curing Concrete”.

Curing Compounds: Curing compounds may be used in the event that project requirements or conditions prevent
moist curing. Curing compounds shall comply with ASTM C-309.

PROTECTION
Protection: Protect installed product and finished surfaces from damage during construction.

FIELD QUALITY CONTROL

Examination for Defects: Do not conceal Crystalline treated concrete before it has been observed by Engineer,
waterproofing manufacturer's representative and other designated entities. Concrete shall be examined for
structural defects such as honeycombing, rock pockets, tie holes, faulty construction joints, cold joints and cracks.
Such defects to be repaired in accordance with manufacturer's repair procedures.

INTERFACE WITH OTHER MATERIALS

Backfilling: Normal backfilling procedures may be used after concrete has been cured for at least seven days. If
backfill takes place within seven days after concrete placement, then backfill material shall be moist so as not to
draw moisture from the concrete. In no event shall backfilling take place before concrete has gained sufficient
strength to withstand the applied load.

Grout, Cement Parge Coat, Plaster or Stucco: Because concrete containing Crystalline Admix forms a relatively
smooth surface and the resulting crystalline formation fills the concrete pores thereby reducing suction
characteristics of the concrete, it may be necessary to use a suitable bonding agent for proper bonding of
cementitious systems.
Responsibility to Ensure Compatibility: Crystalline Chemical Corporation makes no representations or warranties
regarding compatibility of Crystalline treated concrete with coatings, plasters, stuccos, tiles or other surface-
applied materials. It shall be the responsibility of the installer of the surface-applied material that is to be applied
____________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 13

over the Crystalline treated concrete, to take whatever measures are necessary, including testing, to ensure
acceptance by or adhesion to the waterproofing treatment.

GENERAL

1 The crystalline shall be highly resistant to water,

2 It shall perform well even under extreme conditions such as pressure or aggressive chemicals.

3 It shall be able to seal cracks or voids up to a width of 1 mm through crystallization process.

4 The final product shall be able to resist water pressure up to 15 bars.

5 The CONTRACTOR shall also submit to WOQOD for review, the total anticipated volume of concrete
employing crystalline waterproofing and the total weight of the proposed crystalline admixture (as per
supplier’s recommendations) at the beginning of the project.

6 Site mixing of admixture to concrete trucks shall be as per manufacturer’s recommendations.

7 The CONTRACTOR at the end of concreting of all underground structure employing crystalline admixture
shall submit to WOQOD the comparison statement of the initial estimate (as per point no. 6 in this
section) vs final actual estimate of concrete poured with the admixture along with the supplier/ supplier’s
nominated applicator certified statement of admixture dispensing. This is to ensure the admixture has
been added to the mix as per the approved volume.

8 The supplier/ supplier’s approved applicator who witnesses the concreting works shall provide a
guarantee of 10 years for material as well as workmanship against any non-performance of the crystalline
waterproofing admixture, addressed to WOQOD.

14.4 PENETRATIVE PRIMER

14.4.1 General

1 The system shall be a penetrating hydrophobic treatment that protects concrete from both water and
chloride intrusion, while permitting water vapour transmission.

2 The treatment shall significantly reduce the absorption of water and water borne salts but allow the
transmission of water vapour from the substrate.

3 The treatment shall not produce any discoloration of the substrate and shall have excellent resistance to
weathering.

14.4.2 Material

1 The material shall be a low viscosity silane-siloxane system which penetrates deeply into a porous
substrate and reacts to produce a bonded hydrophobic lining to the pores.

2 The material shall be resistant to petrol, oil, and atmospheric contaminants such as car exhaust fumes
and industrial exhausts.

14.4.3 Surface Preparation

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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 14

1 The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae growth and
curing compounds.

2 If the concrete surface is newly cast and has a very smooth finish, the surface shall be roughened by
sand or grit blasting, water blasting or some mechanical means. WOQOD REPRESENTATIVE shall
decide if this means of preparation is required.

3 Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in accordance
with the manufacturer’s recommendations.

4 Concrete finishing required shall be completed before the application of the treatment.

5 Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturer’s
recommendations.

14.4.4 Application

1 Unless directed otherwise by WOQOD REPRESENTATIVE the treatment shall be applied a minimum
period of 24 h after the wet curing period, and shall be surface dry.
2 CONTRACTOR shall carry out tests to verify the depth of penetration of the material. These tests shall be
carried out on specimens of the actual mix design and shall use coloured dyes to trace the penetration of
the material.

3 Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for reinforced
concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats' of the treatment shall
be applied before the main treatment.

4 The application of the material on surfaces shall be by a low pressure spray direct from the can. Under no
circumstances should thinning of the material be carried out.

5 The rate of application shall ensure that the surface is completely saturated. The impregnated coating
shall be applied to two or more flood coats each flood coat shall be a minimum of 0.4 l/m2.

6 The material shall be applied strictly in accordance with the manufacturers instructions and as follows:
(a) the material shall be applied by a fine nozzle spray
(b) application will not be permitted when the ambient air temperature is above 35 C or in windy
conditions
(c) the surface shall be cleaned by a stiff brush or compressed air to remove all loose deposits
(d) concrete to be treated shall be surface dry for a minimum period of 24 h before impregnation
(e) membranes, joint sealers and cast in concrete ancillaries shall be masked off before treatment
(f) application shall be made by saturation flooding
(g) the interval between application shall be at least 6 h
(h) treated areas shall be protected from sea water and rain for 6 h after treatment.

14.5 PROTECTIVE COATING

14.5.1 General

1 The coating system shall be used for the protection of new or existing reinforced concrete structures
against carbonation or chloride induced corrosion.

2 The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat system to
minimise ingress of acidic gases, chlorides and water.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 15

14.5.2 Surface Preparation

1 Before application, all surfaces must be dry and free from oil, grease, loose particles, decayed matter,
moss or algae growth and general curing compounds.

2 All such contamination and laitence must be removed by the use of grit blasting, high pressure water
jetting or equivalent mechanical means.

3 Before proceeding to apply the protective coatings, all surfaces which are not to be coated but which may
be affected by the application of the coating shall be fully masked and, in particular, flora and fauna shall
be protected.

4 Blow holes and areas of pitting shall be made good with a one part modified cementitious material and
allowed to cure in accordance with the manufacturer's recommendations. In particular, the application
shall be in accordance with the manufacturer's recommendations, with respect to the maximum
application thickness.

14.5.3 Material

1 The materials are required to provide in-depth protection against carbonation and chloride penetration
whilst permitting water vapour transmission from the concrete.

2 The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a porous
substrate and reacts to produce a bonded hydrophobic lining to the pores.

3 The material employed for the coating shall comply with the following requirements:

Wet film thickness 650 microns

Dry film thickness 400 microns
Carbon Dioxide diffusion resistance R Value at 325 µ > 161 metres.
(Taywood Engineering Laboratories)
Water vapour transmission
(Taywood Engineering Laboratories)
Reduction in chloride ion penetration 94 % minimum at 28 d
(BS 1881 : Part 124)
Tear Resistance (ASTM D624) 7.3 kN/mm2
Crack bridging (BRE Method) 5.1 mm
Chloride Ion Diffusion
(Taywood Engineering Labororatories) 3.63 x 10-10 cm2/sec.

4 Where test methods are not specified, the procedure for establishing compliance with the above criteria
shall be agreed with WOQOD REPRESENTATIVE.

5 CONTRACTOR is required to adhere strictly to the manufacturer's recommendations regarding the use,
storage, application and safety rules in respect of the approved materials.

14.5.4 Application

1 Where required by WOQOD REPRESENTATIVE, trial areas not exposed in the finished work shall first
be treated using the selected materials. These trial areas shall be noted on the Drawings and shall be
carried out using the type of materials, mixing procedures and applications that will be used on the
____________________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 16

contract and shall be approved by WOQOD REPRESENTATIVE before CONTRACTOR commences with
the general work.

2 The exposed concrete surfaces as defined in the documents or as agreed with WOQOD
REPRESENTATIVE shall be conditioned by the application of a penetrating hydrophobic treatment. The
primer shall be allowed to dry in accordance with the manufacturer's requirements.

3 CONTRACTOR shall then apply two coats of pigmented topcoat in accordance with the manufacturer's
instructions. The finished coating shall be pinhole free and have a total minimum dry film thickness of 150

4 The coating shall be applied by spray, roller or brush to achieve a finish acceptable to WOQOD
REPRESENTATIVE.

5 In all operations of storage, mixing and application CONTRACTOR shall comply with the health and
safety recommendations of the manufacturer and governing authorities.

14.6 PLASTIC SHEET LINER FOR CONCRETE STRUCTURES

14.6.1 General

1 This Subpart covers the supply and installation of sheet liners in reinforced concrete structures.
2 The liner must be continuous and free of pinholes both across the joints and in the liner itself.

3 All work for and in connection with the installation of the lining in concrete pipe and structure, and the field
sealing and welding of joints, will be done in strict conformity with all applicable specifications,
instructions, and recommendations of the lining manufacturer.

14.6.2 Shop Drawings and Submittals

1 CONTRACTOR shall submit to WOQOD REPRESENTATIVE for approval the following:

(a) liner schedule

(b) material certifications
(c) test results
(d) material samples
(e) the manufacturer of the lining will submit an affidavit attesting to the successful use of its material
as a lining for sewer pipes and structures for a minimum period of five years in service conditions
recognised as corrosive or otherwise detrimental to concrete.

14.6.3 Liner Material Requirements

1 The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and other
components necessary to make a material of permanent flexibility suitable for a liner in concrete pipes
and structures in sewerage service. The weld strips and the joint strips shall be made from like material.
For PVC and PE sheet liners, the actual resin used in manufacture must constitute not less than 99 % of
the resin used in the formulation.

2 Copolymer resins will not be permitted.

3 All plastic sheets including locking extensions, all joints and welding strips shall be free of cracks,
asperities and other defects that may affect the protective properties of the material.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 17

4 The properties of PVC and PE sheet are shown in Table 14.2

Table 14.2

Properties of PVC and PE Sheet Liners

Property Test Method Requirement
PVC

Elongation at break ASTM D638/882 300 %

Tensile Strength ASTM D638/412 15 Mpa
Low Temp. Brittleness ASTM D746 0°C

PE

Elongation at break ASTM D638/882 Exceeds 600 %

Tensile Strength Low Temp. ASTM D638/412 10-20 Mpa
Brittleness ASTM D746 -75 °C

14.6.4 Plastic Sheet Liner Strip Properties.

1 Except at shop welds, all plastic sheet liners and strips shall have the properties shown in Table 14.3
when tested at 25 °C

Table 14.3

Properties of Plastic Sheet Liner Strips

Property Requirement
Tensile strength 15 Mpa
Elongation at break 200 %
Shore Durometer 1 s 50 -
35 -
Weight change

14.6.5 Basic Sheet Dimensions

1 The minimum thickness of the material shall be as shown in Table 14.4

Table 14.4

Plastic Sheet Liner Minimum Dimensions

Material Thickness Structures

Sheet with locking extensions 4.0 mm

Sheet, plain 2.3 mm
Joint strip 1.9 mm
Weld strip 2.4 mm
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 18

14.6.6 Liner Details

1 Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be integrally
extruded with the sheet.

2 Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.

3 Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using an
electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall be repaired and
retested.

14.6.7 Installation

1 Installation of the lining, including preheating of sheets in cold weather and the welding of all joints, shall
be performed in accordance with the recommendations of the manufacturer.

2 The lining to be held snugly in place against inner forms by means of steel banding straps or other means
recommended by the manufacturer.

3 Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a careful
manner to protect the lining and produce a dense, homogenous concrete, securely anchoring the locking
extensions into the concrete.

4 In removing forms care shall be taken to protect the lining from damage. In particular:
(a) sharp instruments not to be used to pry forms from lined surfaces.
(b) when forms are removed, any nails that remain in the lining to be pulled, without
tearing the lining, and the resulting holes clearly marked.
(c) form tie holes to be marked before ties are broken off and all areas of serious
abrasion or damage shall be marked.

5 All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be patched as
follows:
(a) patches made entirely with welding strip to be fused to the liner over the entire patch area
(b) larger patches may consist of smooth liner sheet applied over the damaged area with
adhesive
(c) all edges must be covered with welding strip fused to the patch and the sound lining
adjoining the damaged area.

6 Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.

7 CONTRACTOR shall take all necessary measures to prevent damage to the installed lining from
equipment and materials used in or taken through the work.

14.6.8 Testing Requirements

1 Samples taken from sheets, joints or weld strips shall be tested to determine material properties.
Determination of tensile strength and elongation shall be in accordance with ASTM D 412 using Die B.
Determination of indentation hardness shall be in accordance with ASTM D 2240 using a Type D
Durometer, except that a single thickness of material and indentation hardness shall be made on 25 mm
by 75 mm specimens. Thickness of specimens shall be the thickness of the sheet or strip.

2 The measurement of initial physical properties for tensile strength, weight, elongation and indentation
hardness shall be determined before chemical resistance tests.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 19

3 Chemical resistance tests shall be carried out to determine the physical properties of the specimens after
exposure to chemical solutions. Test specimens shall be conditioned to constant weight at 43 °C before
3 °C.

4 Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals, specimens shall be

removed from each chemical solution and tested. If any specimen fails to meet the 112 day exposure, the
material will be subject to rejection.

5 Pull test for locking extensions: Liner locking extensions embedded in concrete shall withstand a test pull
of at least 18 kN/m, applied perpendicularly to the concrete surface for a period of 1 min, without rupture
of the locking extensions or withdrawal from embedment. This test shall be made at a temperature
between 21 °C to 27 °C inclusive.

6 Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together, shall be a least
equal to the minimum requirements of the liner for thickness, corrosion resistance and impermeability.
Welds shall show no cracks or separations and shall be tested for tensile strength. Tensile strength
measured across the welded joint in accordance with ASTM D 412 using Die B shall be at least 15 MPa.
T
section shall be used.

7 Spark test: All liner shall be shop tested for holes with a spark tester set to provide from 15 000 to 20 000
V. Sheets having holes shall be satisfactorily repaired in the shop before shipment from the
manufacturer’s plant.

8 CONTRACTOR shall provide WOQOD REPRESENTATIVE with certified copies of test reports before the
shipment of the product to the Site.

Table 14.5

Chemical Resistance Tests

Chemical Solutions Concentration

Sulphuric Acid 20 %
Sodium Hydroxide 5%
Ammonium Hydroxide 5%
Nitric Acid 1%
Ferric Chloride 1%
Soap 0.1 %
Detergent (Linear alkyl benzyl 0.1 %
sulphonate or LAS)
Bacteriological BOD not less than 700 mg/l
Phosphoric Acid 50 %

14.6.9 Special Requirements

1 Liner sheets to be closely fitted and properly secured to the inner forms.
(a) sheets that are to be cut to fit curved and warped surfaces shall use a minimum number of
separate pieces
(b) a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt joints to
prevent wet concrete from flowing around the edges.
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WOQOD PETROL STATION Section 5 Part 14 Protective Treatments for Concrete Page 20

2 Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the surfaces of
contact between the concrete structure and items not of concrete and
(a) the same procedure will be followed at joints where the type of protective lining is changed or the
new work is built to join existing unlined concrete
(b) at each return, the returned liner will be sealed to the item in contact with the plastic lined
concrete with an adhesive system
(c) if the liner cannot be sealed with this adhesive because of the joint at the return being too wide or
rough or because of safety regulations, the joint space shall be densely caulked with lead wool or
other approved caulking material to a depth of 50 mm and finish with a minimum of 25 mm of an
approved corrosion resistant material.

14.6.10 Joints in Lining for In Situ Concrete Structures

1 Field Joints and Lining at joints will be free of all mortar and other foreign material and will be clean and
dry before joints are made.

2 All welding is to be in strict conformance with the specifications of the lining manufacturer.

14.6.11 Testing and repairing damaged surfaces

1 All surfaces covered with lining, including welds, will be tested with an approved electrical holiday
detector with the instrument set at 9000 V per 1.0 mm of lining minimum:
(a) all welds shall be physically tested by a non-destructive probing method
(b) all patches over holes, or repairs to the liner wherever damage has occurred.

2 Each transverse welding strip which extends to a lower edge of the liner will be tested by an approved
testing agency at the cost of CONTRACTOR.
(a) the welding strips will extend 50 mm below the liner to provide a tab.
(b) a 5 kg pull will be applied to each tab. The force will be applied normal to the face of the structure
by means of a spring balance
(c) liner adjoining the welding strip will be held against the concrete during application of the force
(d) the 5 kg pull will be maintained if a weld failure develops until no further separation occurs.
(e) defective welds will be retested after repairs have been made
(f) tabs shall be trimmed away neatly by the installer of the liner after the welding strip has passed
inspection.
(g) inspection will be made within two days after joints has been completed in order to prevent
tearing the projecting weld strip and consequent damage to the liner from equipment and
materials used in or taken through the work.

END OF PART
______________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 15 Hot Weather Concreting Page 1

15. HOT WEATHER CONCRETING

15.1 GENERAL

15.1.1 Scope
15.1.2 References
15.1.3 Definition of Hot Weather
15.1.4 System Description
15.1.5 Submittals

15.2 PLACING TEMPERATURE

15.3 PLANNING CONCRETING

15.4 MIX DESIGN

15.5 TEMPERATURE CONTROL

15.5.1 General
15.5.2 Aggregates
15.5.3 Water
15.5.4 Cement
15.5.5 Addition of Ice
15.5.6 Liquid Nitrogen

15.6 BATCHING AND MIXING

15.7 TRANSPORTATION

15.8 PLACING AND FINISHING

15.9 CURING AND PROTECTION

15.10 INSPECTION AND TESTING

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WOQOD PETROL STATION Section 5 Part 15 Hot Weather Concreting Page 2

15. HOT WEATHER CONCRETING

15.1 GENER AL

15.1.1 Scope

1 This Part covers the precautions to be taken for hot weather concreting for all structural concrete
except blinding concrete, where a minimum compressive strength is specified.

2 Related Sections and Parts are as follows:

This Section
Part 6, Property Requirements
Part 7, Batching and Mixing
Part 8, Transportation and Placing of Concrete
Part 10, Curing

15.1.2 References

BS 8110, Structural use of concrete

BS EN 1992-1-1 - Eurocode 2, Design of concrete structures. General rules and rules for
buildings
BS EN 480, Admixtures for concrete, mortar and grout. Test methods
BS EN 934, Admixtures for concrete, mortar and grout

ACI 305R-91, American Concrete Institute , Hot Weather Concreting

ASTM C1064, Measuring the Temperature of Concrete

15.1.3 Definition of Hot Weather

1 The requirements of the following clauses of the specification are applicable during the hot
weather period in Qatar.

2 The hot weather period shall be defined as starting when the maximum ambient air shade
temperature on the Site exceed

on three consecutive days.

3 CONTRACTOR shall establish a thermometer on Site that records the ambient air shade
temperature. The thermometer shall be established at a position to provide representative air
temperature for the Site conditions. If requested by WOQOD REPRESENTATIVE
CONTRACTOR shall arrange for the calibration of the Site thermometer.

4 Hot weather conditions include the existence of one or more of the following conditions:
(a) high ambient air temperature
(b) low humidity
(c) high solar radiation
(d) high wind speeds.
(e) Calculations or experiments showing that the dry bulb temperature of the placed
concrete, taking into consideration the heat of hydration of cement, exceeds 38ºC and
that the rate of water evaporation exceeds 980 g/m 2 per hour.
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WOQOD PETROL STATION Section 5 Part 15 Hot Weather Concreting Page 3

15.1.4 System Description

1 CONTRACTOR shall undertake hot weather concreting procedures that are effective in
controlling the following potential problems associated with concreting in hot weather:
(a) increased water demand of the mix
(b) increased rate of slump loss
(c) increased rate of setting
(d) increased tendency for plastic shrinkage cracking
(e) decreased long-term strength
(f) increase tendency for drying shrinkage and cracking
(g) increased tendency for differential thermal effects with consequent cracking
(h) decreased durability from cracking where there is increased permeability.

15.1.5 Submittals

1 CONTRACTOR shall prepare weekly in advance his proposed concreting programme showing
the quantities to be placed and the anticipated placing hours.

2 At least one month before the start of the hot weather period CONTRACTOR shall submit his
specific proposals for the control of the concrete temperature for the constituent materials;
cement, water aggregates.

3 Where required CONTRACTOR shall submit to WOQOD REPRESENTATIVE his proposals for
the use of liquid nitrogen for cooling which shall include details of previous project application and
the intended methods to be used and quantities of liquid nitrogen.

15.2 PLACING TEMPERATURE

1 This Subpart of the specification applies at all times of the year and at all times of the day.

2 The maximum temperature of concrete at the point of placing shall not be more than 320C.

3 Concrete shall not be placed if the shade temperature exceeds 40ºC or the concrete temperature
exceeds 32ºC.

4 The temperature of each truck of concrete shall be measured using either a glass, dial type or
electronic thermometer, just before the placing of the concrete and the temperature recorded on
the delivery ticket. The maximum temperature at placing shall apply to the entire load of concrete
in the truck or conveyer.

5 CONTRACTOR shall allow for the increase in concrete temperature in the period from dispatch
from the plant while in transportation or whilst awaiting placement on Site and take adequate
measures to ensure the maximum temperature is not exceeded.

15.3 PLANNING CONCRETING

1 During the hot weather period as defined in Clause 15.1.3 of this Part, CONTRACTOR shall plan
concreting operations such that no concreting takes place between the hours of 10:00 hours and
17:00 hours.

2 CONTRACTOR shall arrange concrete pours such that the programme of works can be achieved
without concreting during the period from 10:00 hours to 17:00 hours.
______________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 15 Hot Weather Concreting Page 4

3 CONTRACTOR shall nominate one member of his staff to be the co-ordinator for the supply of
concrete. The co-ordinator’s responsibilities shall include ensuring the batched rate matches that
of delivery and placement and the preparations needed before commencing a concrete pour.

15.4 MIX DESIGN

1 In the hot weather period, CONTRACTOR shall review all concrete mix designs to ensure that the
design slump or workability specified is achieved without increase in the mix water content.
CONTRACTOR shall make modifications to the mix design to allow for increased slump loss
during transportation in hot weather.

2 This shall be achieved by adjusting the proportion of admixture, plasticiser or super plasticiser.
The permitted range of admixture shall be clearly stated on the concrete mix design with nominal
values for cold weather and hot weather use.

3 Under no circumstances will the addition of extra water that increases the water cement ratio be
permitted during hotter weather.

4 All concrete materials and proportions used in periods of hot weather shall be those that have a
satisfactory record of use in such conditions.

15.5 TEMPERATURE CONTROL

15.5.1 General

1 CONTRACTOR’s specific proposals for the control of the concrete temperature shall include
extent and type of shading of aggregates, method of chilling mix water and procedures for
batching and mixing, transportation, placing and finishing, curing and protection.

2 These shall include calculations in accordance with ACI 305R, clause 3.1 “estimating concrete
temperature”. CONTRACTOR shall calculate the temperature of freshly produced concrete based
on the input temperatures of the constituent materials and the weights from particular mix
designs. The calculations shall make allowance for the rise in temperature between mixing and
placing due to the transportation and waiting period. The calculations shall successfully

15.5.2 Aggregates

1 All practical means shall be employed to keep the aggregates as cool as possible.

2 Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond the
edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is not
incident on the aggregates. Shades shall be constructed to allow access for mechanical shovels
or means of conveyance. Shades and stockpiles shall be constructed so as to permit the free flow
of air over the aggregates. Embedded cooling pipes may also be used to cool the aggregate.

3 Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall not
be permitted.

15.5.3 Water

1 Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.
______________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 15 Hot Weather Concreting Page 5

2 The water shall be chilled by the use of proprietary chillers or the addition of ice to the water tank.
Measures shall be taken to ensure that ice pieces are not inadvertently deposited directly into the
mixer.

3 Water shall not be chilled below a temperature of 40C.

4 Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and
painted white.

5 The mechanical refrigeration equipment and insulated water storage shall be adequate for the
anticipated hourly and daily production rates of concrete during the hot weather period.

6 Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank, such
procedures shall be to the approval of WOQOD REPRESENTATIVE.

7 Ice shall be completely melted in mixing water prior to adding water to the mixer.

15.5.4 Cement

1 The use of freshly ground cement at very high temperatures is not permitted.

2 The cement shall be kept below the temperature which there is a tendency of false set .

3
mixture.

4 CONTRACTOR shall make arrangements for storage on Site to allow cooling of freshly ground
and delivered cement.

15.5.5 Addition of Ice

1 Crushed shaved or chipped ice can be used as part of the mixing water for reducing the concrete
temperature.

2 The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted before
the completion of mixing of the concrete in the pan.

3 To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of the
batch water requirement.

4 Crushed ice shall be stored at a temperature that will prevent lumps from forming by refreezing of
particles.

5 The batching plant shall incorporate a mechanical system for correctly proportioning and
weighing the ice to be added to the mixture.

6 The quantity of ice shall be deducted from the total batch water.

7 CONTRACTOR shall ensure there are adequate quantities of ice in suitable refrigerated storage
on the Site at the plant to meet the anticipated daily and hourly production rates of concrete
during the hot weather period.
______________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 15 Hot Weather Concreting Page 6

15.5.6 Liquid Nitrogen

1 Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.

2 Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not frozen.

3 The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and injection
facility for the batching plant or one or more injection stations for truck mixers.

4 The system may be set up at the Site for injection just before placing.

5 Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.

15.6 BATCHING AND MIXING

1 The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.

2 Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with
water and the drum flushed out with cold water before batching. Care shall be taken to ensure all
water is removed from the drum before batching.

3 The temperature of the concrete shall be checked after discharge from the mixer and written on
the delivery ticket. Temperature check shall be carried out at the plant on the concrete floor for
every 50 m3 produced or every hour which ever is the minimum.

4 A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN 480

Parts 1, 2 and 4 may be used in varying proportions under different air temperature conditions.

15.7 TRANSPORTATION

1 The transportation, placing, compaction and finishing of concrete shall be at the fastest possible
rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of placement
and compaction.

15.8 PLACING AND FINISHING

1 If the temperature of the first truck of concrete of a particular pour is above the specification
maximum temperature limit then placing shall not commence.

2 If a pour is in progress and the temperature of a particular truck exceeds the maximum permitted
temperature the placing may be allowed to continue at the discretion of WOQOD
REPRESENTATIVE in order to avoid the possible development of a cold joint.

3 However, no further concreting pours shall take place until CONTRACTOR has submitted revised
calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the maximum
temperature will not be exceeded in the future. Before beginning new pours the temperature of
the concrete constituent materials shall be monitored to verify that they meet the assumptions of
the calculations.

15.9 CURING AND PROTECTION

1 Curing and protection shall conform to the requirements of Part 10 of this Section.
______________________________________________________________________________
WOQOD PETROL STATION Section 5 Part 15 Hot Weather Concreting Page 7

2 Evaporation shall be minimized, particularly during the first few hours subsequent to placing
concrete, by suitable means such as applying moisture by fog spraying or any other means
acceptable to the WOQOD Representative.

15.10 INSPECTION AND TESTING

1 All thermometers used for the measurement of concrete temperature shall be calibrated weekly
against a glass mercury thermometer. Calibration shall be carried out over the temperature range
of 100C to 1000C using a water bath with ice or heating.

2 Thermometers used to determine acceptance of temperature controlled concrete should be

calibrated in accordance with ASTM C1064.

3 All concrete test specimens for strength or other purposes shall be carefully protected and cured.

4 Specimens shall be protected from accidental damage by plant personnel or equipment on Site.

5 Specimens shall be kept moist by the addition of water or covering by suitable curing materials.

6 The exact time of preparation of the specimen on Site shall be noted and the time when it is
transferred to the laboratory. These times shall be written on the test report.

END OF PART
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 1

16. MISCELLANEOUS

16.1 GENERAL

16.1.1 Scope
16.1.2 References

16.2 PAVEMENT QUALITY CONCRETE

16.2.1 Scope
16.2.2 Mix Designs
16.2.3 Cement
16.2.4 Water
16.2.5 Aggregates
16.2.6 Admixtures
16.2.7 Air content
16.2.8 Density

16.3 Not used

16.4 Not used

16.5 CEMENTITIOUS GROUT

16.5.1 General
16.5.2 Material
16.5.3 Workmanship

16.6 SCREEDS

16.6.1 Scope
16.6.2 General

16.7 REPAIR OF CONCRETE

16.7.1 General
16.7.2 Honeycombing or Spalling
16.7.3 Crack injection

16.8 Not used

WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 2

16. MISCELLANEOUS

16.1 GENERAL

16.1.1 Scope

1 This Part deals with miscellaneous items related to concrete works including pavement
quality concrete, cementitious grout, screeds, repair of concrete.

2 Related Sections and Parts are as follows:

This Section
Part 2, Aggregate
Part 3, Cement
Part 4, Water
Part 5, Admixture
Part 6, Property Requirements
Part 7, Batching and Mixing
Part 8, Transportation and Placing of Concrete
Part 9, Formwork
Part 10, Curing
Part 15, Hot Weather Concreting.

16.1.2 References

1 The following standards are referred to in this Part:

BS EN 197-1, Cement. Composition, specifications and conformity criteria for common
cements
BS 146, Portland-blast furnace cement
BS 812, Testing aggregates
BS EN 12620, Aggregates for concrete
BS 1881, Testing concrete
BS EN 12350, Testing fresh concrete
BS 2782, Methods of testing plastics
BS 3892, Pulverised fuel ash
BS 4551, Methods of testing mortars, screeds and plasters
BS EN 998, Specification for mortar for masonry
BS 5075, Concrete admixtures
BS EN 480, Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2, 4, 5, 6
8,10, 11, and 12)
BS EN 934, Admixtures for concrete, mortar and grout (parts: 2, 6)
BS 8500, Concrete
BS EN 206-1, Concrete. Specification, performance, production and conformity
BS 6319, Testing of resin and polymer / cement compositions for use in construction
BS EN 197-1, Cement. Composition, specifications and conformity criteria for common
cements
BS 6610, Specification for pozzolanic pulverised-fuel ash cement.
BS 8203, Code of practice for installation of resilient floor coverings.
BS EN 12390-5, Flexural strength of test specimens
BS EN 1744-1, Tests for chemical properties of aggregates. Chemical analysis
EN 206-1, Concrete. Specification, performance, production and conformity
EN 1744-1, Tests for chemical properties of aggregates. Chemical analysis
EN 12350, Testing fresh concrete

ACI 506, Guide to Shotcrete

WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 3

16.2 PAVEMENT QUALITY CONCRETE

16.2.1 Scope

1 This Subpart covers the mix design for concrete used for aircraft aprons and roadworks
as surface slabs, continuously reinforced concrete roadbase, and wet lean mix except
cement bound granular material used as a roadbase or sub-base or as a backfill material
for excavations.

16.2.2 Mix Designs

1 Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1
below , in accordance, with the pavement design shown on the Drawings or as directed
by the WOQOD Representative.

2 All concrete for use in pavements shall be designed mixes or equivalent standard mixes
in accordance with the relevant clauses of BS 8500 and BS EN 206-1, except where
otherwise specified.

3 Prescribed mixes may be used for rapid construction with the approval of the WOQOD
Representative.

Table 16.1

Pavement Grades

16.2.3 Cement

1 The general term 'cement' in this Part means the materials shown below.

Cement Complying with

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

for common cements
Portland blast furnace cement BS 146
Specification for pozzolanic pulverised-fuel ash cement BS 6610
(gradesC20 or below)
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 4

2 The use of a combination of Portland cement and ground granulated blast furnace slag is
permitted subject to the approval of the WOQOD Representative. In such cases, the
WOQOD Representative will stipulate the minimum combined cementitious material
content required for the mix.

3 The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted
subject to the approval of the WOQOD Representative. In such cases, the WOQOD
Representative will stipulate the minimum combined cementitious material content
required for the mix. PFA shall be in accordance with BS 3892.

4 The use of microsilica in the mix designs will be permitted if approved by the WOQOD
Representative. In such cases the proportion of microsilica shall be 10 ± 1 % of the
Portland cement content.

5 The WOQOD Representative will stipulate the minimum combined cementitious material
content required for the mix where PFA or GGBFS are used.

6 The maximum proportion of ground granulated blast furnace slag with Portland cement
shall be not greater than 65 % of the total cement content for grades up to C30, and 50 %
for C40.

7 In combination with Portland cement, the proportion of PFA by mass to the total cement
and the minimum Portland cement content of the blend shall be advised by the WOQOD
Representative. The limit of chloride content of the concrete shall be as stated in BS
8500 and BS EN 206-1
8 In each cubic metre of fully compacted concrete the minimum cement content shall be:

BS Grade Portland Cement kg/m3

C40 320
C30 280
C20 180 max. aggregate:cement, 14:1
C15 160 max. aggregate:cement, 14:1
C10 130 max. aggregate:cement, 18:1
C7.5 120 max. aggregate:cement, 18:1

16.2.4 Water

1 Water for use in the making and curing of concrete shall conform to the requirements of
Part 4 of this Section.

2 The water content shall be the minimum required to provide the agreed workability for full
compaction of the concrete to the required density, as determined by trial mixes or other
means approved by the WOQOD Representative, and the maximum free water:cement
ratio shall be 0.45 for grades C40 and C30 and 0.60 for grades C20 and C15.
16.2.5 Aggregates

1 The requirements of Part 2 of this specification will govern, except as modified below.

2 Aggregates for all pavement concrete shall be natural material complying with BS EN
12620 or aggregate which when crushed complies with the quality and grading
requirements of BS EN 12620.
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 5

3 Alternatively coarse aggregate may be crushed air-cooled blast furnace slag complying
with BS EN 12620.

4 Once the appropriate gradings have been determined and approved they shall not be
varied without the permission of the WOQOD Representative.

5 If requested by the WOQOD Representative, the aggregate at source shall be tested in

accordance with BS 812 Part 121 and shall have a soundness value greater than 75.
Thereafter for routine testing of such aggregates, the water absorption value of the
coarse aggregate shall be determined as in BS 812 Part 2 and BS EN 1097-3. If the
absorption value of the coarse aggregate is greater than 2 %, the soundness test shall be
carried out on the material delivered to Site.

6 The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing
between longitudinal reinforcement is less than 90 mm, the nominal size of coarse
aggregate shall not exceed 20 mm.

7 The chloride ion content of the aggregate to be used in concrete with embedded metal,
determined in accordance with BS EN 1744-1, clause 7 shall satisfy the requirements of
BS EN 12620.

8 Fine aggregate containing more than 25 %, by mass of acid-soluble material as

determined in accordance with BS EN 1744-1, clause 12 in either the fraction retained
on, or the fraction passing the 600 micron BS sieve shall not be used in the top 50 mm of
surface slabs.

9 If requested by the WOQOD Representative, the Contractor shall carry out tests on the
proposed aggregate combination to check for the possibility of alkali silica reaction. Such
tests shall be carried out in accordance with the procedure laid down in Part 2 of this
Section.

16.2.6 Admixtures

1 Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS
EN 934. Admixtures containing calcium chloride shall not be used.

2 Other chloride free admixtures may be used with the approval of the WOQOD
Representative.

16.2.7 Air content

1 The total quantity of air in air-entrained concrete as a percentage of the volume of the mix
shall be 5 ± 1.5 % for mixes of nominal aggregate size 20 and be 4 ± 1.5 % for mixes of
nominal aggregate size 40.

2 The air content shall be determined at the point of delivery to the paving plant by a
pressure type air meter in accordance with BS EN 12350-7 or EN 12350-7, at the rate of
one determination per 300 m2 of slab or at least six times per day whichever is the
greater, in conjunction with tests for workability and strength. For areas less than 300 m2,
the rate shall be at least one determination to each 20 m length of slab or less
constructed at one time or at least three times per day. If the air content is outside the
specified limits, a further determination shall be made immediately on the next available
load of concrete before discharging. If the air content is still outside the limit, the
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 6

Contractor shall immediately adjust the air content of the concrete to improve its
uniformity, before further concrete is used in the Works.

3 The air-entraining agent shall be added at the mixer, by an apparatus capable of

dispensing the correct dose within the tolerance for admixtures given in BS EN 206-1 or
EN 206-1, and so as to ensure uniform distribution of the agent throughout the batch
during mixing.

16.2.8 Density

1 The density of concrete Grades C40 and C30 shall be such that without air-entrainment
the total air voids are not more than 3 %. With air entrainment, the total air voids shall be
not more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.

2 The density of concrete Grades C20,

16.5 CEMENTITIOUS GROUT

16.5.1 General

1 This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be
used to where it is necessary to eliminate shrinkage when filling the void between a base
plate and a substrate such as in the grouting of stanchion bases, anchorage fixings,
including masts, anchor bolts and fence posts.

2 The grout shall be supplied by a reputable construction chemical company as a single

pack prepackaged cement based product which is chloride free.

3 For a particular application, CONTRACTOR shall submit a method statement detailing

how the formwork will be placed and the points where the grout will be poured.

4 Before beginning work on large repetitive works, CONTRACTOR shall arrange for a site
trial of the materials and methods with the suppliers representative being present to train
CONTRACTOR’s personnel in the correct use of the material.

16.5.2 Material

1 The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free
flowing and non shrink.

2 Positive volumetric expansion shall take place while the grout is plastic by means of
gaseous expansion to avoid shrinkage and cracking.

3 The compressive strength of the grout when tested in accordance with BS EN 12390-3
shall be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.

4 The grout shall exhibit a high early strength gain yet not be subject to cracking or other
detrimental effects.

5 At ambient temperatures above 35 °C, cool water shall be used for mixing the grout
before placing.

16.5.3 Workmanship
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 7

1 The storage handling and pouring of the grout shall be in strict accordance with the
manufacturer’s instructions.

2 The substrate surface shall be free from oil grease or loose or partially bonded material.

3 If the concrete surface is defective or has laitance it shall be cut back to a sound base.

4 Bolt holes and fixing pockets shall be blown clean of dirt or debris.

5 The substrate shall be soaked with fresh potable water before grouting, although
immediately before grouting, free water shall be removed and blown out of bolt holes or
pockets.

6 Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m
wide. For larger base plates or flow areas the manufacturers instructions shall be
followed.

7 Base plates and metallic items shall be clean and free from oil, grease, or scale.

8 Vent holes shall be provided to allow the release of air from isolated spots.

9 Formwork shall be made leak proof by the use of form rubber strip or mastic sealant
between the constructive formwork and joints. Formwork shall extend above the required
pour height and if necessary shall be extended to allow a hydrostatic head to aid
placement.

10 The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear
mixer.

11 The quantity of water to be added to the preweighed bags shall be enough to give the
desirable consistency as trowelable or flowable.

12 Mixing shall take place for a minimum of 5 min.

13 The grout shall be placed within the time limit specified by the manufacturer depending
on the actual application temperature.

14 Grout shall be poured from one side and it shall be verified that the grout has flowed
under all of the base plate with no voids. Pouring from several sides shall not be
permitted.

15 Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this
Section.

16.6 SCREEDS

16.6.1 Scope

1 This Subpart covers screeds that provide by means of a layer of mortar a level surface in
flooring applications and to provide falls on flat concrete roofs.

16.6.2 General

1 Screeds shall be suitable for application onto a concrete substrate.

WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 8

2 The screeds shall be suitable for receiving surface finishes which may arrange from thin
flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing
surface.

3 Screed mortars shall generally comprise sand and cement modified by additives or
substituted by other materials such as polymers in order to provide specific performance
requirements.

4 For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion

of 10 mm aggregate.

5 Aggregates used for screeds shall not contain deleterious materials such as coal or iron
particles which may affect the finish the surface of the screed.

6 Admixtures for mortar screeds shall assist workability or alter rates of setting and
hardening and shall comply with the appropriate part of BS EN 480 and BS EN 934.

7 Polymer based additives may be used to improve adhesion and strength of thin or
featured screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber
(SPR) or acrylic polymers.

8 Ready to use sand cement screeds shall comply with the material requirements BS EN
998.

9 Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be
used strictly in accordance with the manufacturers instructions.
10 The interface of the screed in the concrete substrate shall be specified as one of the
following options by WOQOD REPRESENTATIVE:
(a) Monolithic with the concrete base: The screed shall be applied within 3 hours of
placing the concrete base.
(b) Bonded to the concrete base: Screed shall be laid onto a concrete base which is
hardened and is subsequently been prepared to receive the screed, the minimum
thickness of the screed shall be 25 mm and the maximum thickness 40 mm.
(c) As an unbonded screed: The screed shall be laid on a separating layer.
(d) As a floating screed: The screed shall be laid on an insulating material.

10 The cement and sand screed mix shall have the minimum amount of water added to give
sufficient workability and allow the material to be thoroughly compacted.

11 Pan type mixes shall be used to ensure efficient mixing of materials, the cement to
aggregate ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand
cement, water and admixtures shall ensure a thorough homogeneous mixture with no
balling up of the cement.

12 Screeds shall be laid either between carefully levelled and trued batons or between strips
of screed laid and compacted to a finished level.

13 For bonded screed where a high degree of bond is required the surface laitance of the
concrete base shall be mechanically removed to expose the coarse aggregate. A thin
layer of neat cement grout shall be applied to the prewetted or dampened concrete and
the screed applied and compacted while the grout is wet.
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 9

14 Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at
joints around the perimeter shall be particularly well compacted to avoid breaking out and
curling.

15 Screeds thicker than 50 mm shall be laid in two approximately equal layers, screed shall
be kept protected by waterproof sheeting for at least 7 days after laying.
16 Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and
necessary strength achieved.

17 If requested by WOQOD REPRESENTATIVE CONTRACTOR shall carry out a

soundness and impact test in accordance with BS 8203.

18 Screeds shall be laid in bays of a size to minimise thermal moisture contraction.

Contraction or movement joints shall be provided as appropriate, where shown on the
drawings or as directed by WOQOD REPRESENTATIVE. Bays shall be laid alternatively.

19 Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm
thick screed.

16.7 REPAIR OF CONCRETE

16.7.1 General

1 The extent and nature of the defects in concrete shall be established in accordance with
Part 15 of this Section. Based on these results WOQOD REPRESENTATIVE shall
confirm the acceptability of the work and whether remedial works are required.

2 If remedial works are required CONTRACTOR shall submit a detailed method statement
identifying the specific materials to be used and the sequence of activities for the repair.

3 Only proprietary proven materials that form part of a standard repair system shall be
used.

16.7.2 Honeycombing or Spalling

1 Where there is honeycombed concrete or concrete damaged by physical forces such as

impact that has caused spalling, the concrete shall be replaced using a high strength free
flowing cementitious micro-concrete.

2 The areas of repair shall be marked out and agreed with WOQOD REPRESENTATIVE.

3 All honeycombed, loose, cracked or friable concrete in these areas shall be removed until
sound concrete is reached. Due account shall be taken of propping or other instructions
given by WOQOD REPRESENTATIVE regarding sequences of removal and repair.

4 The equipment and methods used to break out the concrete shall be such that no
reinforcing steel or other embedded items such as conduits, lifting sockets, or other
inserts are loosened or damaged unless so directed by WOQOD REPRESENTATIVE.

5 Where the removal of concrete by mechanical means is difficult due to reinforcement

congestion, then the use of high pressure water jetting shall be considered and
necessary provisions for protecting the rest of the structure shall be made.
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 10

6 The prepared void shall be profiled so that entrapment of air is avoided during the repair
process using fluid micro-concrete.

7 The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be
repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not
be accepted.

8 The prepared concrete surface shall be sound and clean and free of loose particles, dust
and debris.

9 Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and

loose millscale.

10 Reinforcement damaged during the removal of concrete or the preparation process shall,
if required by WOQOD REPRESENTATIVE, be repaired or replaced.

11 Adequate formwork shall be provided in accordance with of Part 9 of this Section. This
shall be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete
repair material without distortion or movement during placement.

12 The formwork shall be watertight at all joints between panels and between the formwork
and the existing concrete surface so as to prevent grout leakage.

13 The formwork shall be constructed from appropriate materials as agreed with WOQOD
REPRESENTATIVE to achieve the required finish.

14 Formwork surfaces that are to be in contact with the repair micro-concrete shall be
treated with a suitable mould release agent. This shall be used in accordance with the
manufacturer's recommendations.

15 The entry point of the feed pipe into the form shall be at the lowest point of the void.
Sufficient hydrostatic head or pumping pressure shall be maintained to ensure that the
void is filled completely and no air remains entrapped.

16 Where necessary, provision shall be made for controllable bleed points to prevent air
entrapment and enable the extent of flow of the repair material to be assessed.
17 The formwork shall be inspected by WOQOD REPRESENTATIVE and, if approved, filled
with clean water which demonstrates that the formwork is grout-tight and saturates the
prepared concrete surfaces. The formwork shall be then be completely drained and
resealed.

17 In situations where the completed repair will be subjected to constant immersion an

epoxy bonding agent shall be applied in accordance with the manufacturers instructions.

18 Both the Compressive strength and Flexural strength shall be at a water:powder ratio of
0.18 and tested at 20 oC

19 The thermal conductivity and the elastic modulus of the repair material shall be
compatible with the host concrete.

20 If requested by WOQOD REPRESENTATIVE, recent test results of the material for the
following properties shall be submitted:
(a) thermal conductivity
(b) elastic modulus, BS 1881
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 11

(c) expansion characteristics, ASTM C 827, CRD 621-82A

(d) flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.

21 The micro-concrete shall be mixed and placed in accordance with the manufacturer's
recommendations, particularly with regard to water content, mixing equipment and
placing time.

22 As far as possible the placing of the micro-concrete shall be continuous. The mixing
operation shall be timed so that there is minimal interruption in the material flow. If,
however, placing is interrupted, the operation shall recommence as soon as possible
while the repair material retains its flow characteristics.

23 The formwork shall not be removed until the repair micro-concrete has achieved a
compressive strength of at least 10 MPa or as directed by WOQOD REPRESENTATIVE.

24 Immediately after removal of the formwork the repair area shall be cured in accordance
with Part 10 of this Section.

25 The repair material shall:

(a) be shrinkage compensated in both liquid and cured states
(b) contain no metallic expansion system
(c) be prepacked and factory quality controlled
(d) be a free-flowing cementitious material that has a coefficient of thermal
expansion fully compatible with the host concrete and which complies with the
requirements of Table 16.3.

Table 16.3

Property requirements of micro concrete

Property Test Method Minimum Value

Compressive strength BS EN 12390-3 @ 28 d 50 Mpa
Flexural strength BS 4551 @ 28 d 10 Mpa
Anchorage bond BS 8110 Passes

16.7.3 Crack injection

1 This clause of the specification covers non-active cracks within concrete elements
caused by shrinkage or other structural movement. Non-active cracks shall be injected
with a low viscosity epoxy resin to fill and seal the crack and restore the structural
integrity.

2 Before to starting the injection operation it shall be established by testing and

investigation work that cracks manifest within concrete elements due to either or both
shrinkage or structural movement are non-active.

3 The extent of the cracks to be filled will be as directed by WOQOD REPRESENTATIVE.

The cracks to be filled shall be marked out in detail on the concrete elements by
CONTRACTOR and agreed with WOQOD REPRESENTATIVE before proceeding.

4 The extent of the work may be adjusted by WOQOD REPRESENTATIVE as the project
proceeds, according to the conditions found.
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 12

5 Grease, oil or other contaminants shall be removed. Algae and other biological growth
shall also be removed by scrubbing with bactericide or detergent and clean water. If
necessary, wire brushes shall be used.

6 Loose or spalling areas of concrete, laitance, traces of paint or other coating materials
within the marked out scope of the work shall be removed.

7 All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the
concrete surface and the cracks shall be allowed to dry thoroughly before continuing.

8 The injection nipples shall be fixed at intervals along the length of each crack. The
distance between each nipple will depend on the width and depth of the crack.

9 Spacing shall be close enough to ensure that the resin will penetrate along the crack to
the next point of injection. This will normally be between 200 mm and 100 mm.

10 Each nipple shall be firmly bonded to the concrete surface by using a sealant. The
sealant shall be supplied in two pans (liquid base and hardener system). The two
components shall be thoroughly mixed together for 3 to 4 min until a putty-like
consistency is achieved.

11 The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They
shall be pressed firmly into place and held for several seconds until secure. The mixed
sealant shall be applied around each embedded nipple, ensuring a complete seal is
made. In this way, all the nipples shall be fixed along the length of the crack.

12 In the case of a wall or slab which is cracked all the way through, nipples shall be located
on both sides with those at the back placed at midway points between those it the front.

13 The surface of the cracks between the nipples shall be sealed with a band of sealant 30
to 40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a
wall or slab shall be sealed in this way.

14 The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures
(5 °C to 12 °C) the curing time will be extended and CONTRACTOR shall ensure that the
surface sealant has adequately cured before continuing.

15 One end of the injection hose shall be attached to the lowest nipple on vertical cracks or
to either end of horizontal cracks.

16 Each crack shall be treated in a single, continuous operation. Sufficient material shall
therefore be made ready before the commencement of the work.

17 CONTRACTOR shall to ensure that sufficient cracks are prepared to provide effective
use of the mixed material.

18 The preparation, mixing and application of the materials shall be undertaken in strict
accordance with the manufacturer's recommendations. CONTRACTOR is to ensure that
all necessary tools and equipment are on Site.
19 Both the compressive strength and flexural strength shall be tested at 7 d.

20 The material shall exhibit excellent bond to concrete and when tested for tensile adhesion
the failure shall be in the concrete and not at the interface.
WOQOD PETROL STATION Section 5 Part 16 Miscellaneous Page 13

21 The injection resin shall be of a prepackaged or preweighed type and only the use of full
units will be allowed. No part packs or on-Site batching will be allowed under any
circumstances.

22 In all operations of storage, mixing and application, CONTRACTOR shall comply with the
health and safety recommendations of the manufacturer and governing authorities.

23 The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this
time.
24 The nipples and bands of surface sealant shall then be removed and damaged areas
made good to the satisfaction of WOQOD REPRESENTATIVE.
25 The injection material shall be compatible with the host concrete and shall have the
properties shown in Table 16.4 when tested in accordance with the relevant standards.

Table 16.4
Property Requirement for Epoxy Crack Injection Material

Property Method Minimum Value

Compressive strength BS 4551, BS 2782 BS 6319 70 MPa
Flexural strength BS EN 12390-5

END OF PART