S Aa Civ Concrete (Rev.0 2010)
S Aa Civ Concrete (Rev.0 2010)
S Aa Civ Concrete (Rev.0 2010)
CIVIL WORKS
( SPECIFICATION )
CONTENTS
1 GENERAL...................................................................................................................3
2 TECHNICAL DESCRIPTION ...................................................................................3
2.1 General..........................................................................................................................3
2.2 Concrete........................................................................................................................3
2.3 Form-Work ...................................................................................................................5
2.3.1 General..........................................................................................................................5
2.3.2 Form-Work Classes .......................................................................................................5
2.3.3 Form-Work Removal.....................................................................................................6
2.4 Reinforcement ...............................................................................................................6
2.4.1 Material.........................................................................................................................7
2.4.2 Fabrication ....................................................................................................................7
2.4.3 Site Installation and Handling ........................................................................................8
2.4.4 Epoxy Coated Reinforcement ........................................................................................9
2.5 Cement..........................................................................................................................9
2.6 Aggregates ..................................................................................................................10
2.7 Admixtures..................................................................................................................10
2.8 Tests and Properties.....................................................................................................11
2.8.1 Testing ........................................................................................................................11
2.8.2 Concrete Quality Requirements ...................................................................................13
2.8.3 Particular Requirements...............................................................................................13
2.8.4 Construction and Expansion Joints...............................................................................14
2.8.5 Construction Joints ......................................................................................................14
2.8.6 Expansion Joints..........................................................................................................14
2.8.7 Joint Filler Board.........................................................................................................15
2.9 Special Requirements for Safety against Cracking .......................................................15
3 GENERAL FOR PRE-CAST CONCRETE CONSTRUCTION .............................15
1 GENERAL
This part of the Specification shall cover all items related to concrete and reinforced concrete
works for the Project. Works shall include all items required for the tendered Project, as well as
all auxiliary works as/and where required.
All works shall further be carried out in full compliance with all local rules and regulations and
the Specification shall further be read if applicable for the Project.
For applicable technical standards, tests, reference shall be made to:
S-AA-CIV-GEN - General Requirements
(Applicable Technical Standards, Tests, etc.)
2 TECHNICAL DESCRIPTION
2.1 General
This article shall apply to all concrete and reinforced concrete works within this Project. All
works shall be designed and executed in accordance with the structural analysis and the approved
design. All work shall be performed according to the working drawings designed by the
Bidder/Contractor and approved by ADDC/AADC.
Concrete and reinforced concrete shall be placed either in-situ or by prefabricated units.
This Article also covers the reinforcement steel, as well as the form-work required for the
particular structural member.
2.2 Concrete
Before executing any load bearing structural members, the Bidder/Contractor shall furnish
ADDC/AADC with a concrete mix design and a detailed concreting programme, which shall be
subject for approval.
Only ready-mix concrete shall to be used and one trial mix has at least to be carried out
successfully for every mix. The batching plant has to be approved by ADDC/AADC. If a known
mix, which was successfully used before, is proposed, trial mixing can be waived The
composition of one batch concrete, its aggregates, the cement and water content and the
additives, if any, in kg or litre per m3 of compacted concrete shall be displayed legibly at the
batching plant.
Concrete shall be placed and compacted in its final position within 90 minutes of the water being
added to the mix. If the Bidder/Contractor proposes the use of pumps for the transporting and
placing of concrete, he shall submit a detailed method statement. Bidder/Contractor shall ensure
that pumping shocks shall not be transferred from the pipeline to the form-work, previously laid
concrete or the structure. The initial discharge of any pumped concrete shall be discarded
completely.
Concrete shall be placed and compacted/vibrated in horizontal layers of not more than 300 mm
thickness each. For large areas to be cast proven technique (e.g. staggered layers) may be
proposed for approval at Site. The rate of delivery of concrete during concreting operations shall
be such that the interval between batches shall be minimised to avoid cold joints, if cold joints
cannot be avoided, a stop-end vertical surface joint shall be provided.
For slabs thicker than 900 mm, thermocouples shall be provided to control and record the
temperature of the concrete during curing.
For concreting in hot weather, ACI Standard 305R "Hot Weather Concreting" and the "CIRIA
and Concrete Societys Guide to the construction of reinforced concrete in the Arabian
Peninsular. and its recommendations shall be followed and various means may be employed to
lower the temperature of concrete such as:
Cooling coarse aggregate with water by sprinkling and shading
Using chilled water
Using crushed ice
Avoiding the use of the hot cement
Shading mixer drums, facilities and material by use of permanent wet burlap coverings
Adequately watering of sub-grade, form-work and reinforcement
Insulating water supply lines and tanks and/or painting exposed portions white
Working only at cooler daytime
Covering freshly poured concrete with polythene sheets
Intensive moist-curing with potable water of the concrete placed
Curing the concrete continuously with water at least for 7 days and as detailed in CIRIA
and Concrete Societys Guide to the construction of reinforced concrete in the Arabian
Peninsular. Attention to curing requirements is important at all times; it is especially in
hot, dry weather because of greater danger of cracking. The use of ice to lower the
temperature of fresh concrete must be carefully controlled. If flaked ice is used in the mix,
it must be of such a size that it will melt completely in the mix and that no ice remains
once the batching is complete. The temperature of fresh concrete must in no case exceed
+ 30C. When discharged in the form-work, particular care shall be given for thick section
(>900mm) where insulation boards shall be used to reduce temperature gradient.
2.3 Form-Work
2.3.1 General
The stability of the form-work, false work and scaffolding shall be proven by static analysis.
Form-work and its supporting structures shall be constructed in accordance with the static
analysis and shall safely resist all occurring forces, including the effect of the concreting rate and
the method of compaction. For columns and walls, the strength of form-work shall be adjusted to
the rate of placing the concrete. All timber for form-work shall have selected quality and shall
have a flexural stress "Sigma b" minimum 10 N/mm2.
All form-work and moulds shall be of such tight construction that slurry cannot flow out at the
joints during pouring and compaction. If required, joints shall be sealed with foam rubber strips.
shall be strong and held rigidly and accurately to the prescribed alignment. Any form-work
material that will produce the required surface may be used.
Applicable for: exposed fire walls, projected columns, frames and beams on elevations.
Class F5 (rough-faced)
This finish shall be used for structural surfaces where plaster or stucco is to be applied.
Rough-faced form boards shall be used.
Aluminium lining for form-work will not be permitted.
Applicable for super-structural work where plaster is to be applied or if a rough surfaces is
required.
2.4 Reinforcement
For Reinforcement, reference shall be made to the below listed drawings, which are provided in
the Drawings Section.
Drawing No. Title
DWG AA CIV 06 01 Typical Stair Reinforcement
DWG AA CIV 06 02 Temperature Reinforcement
DWG AA CIV 06 03-1 Column Reinforcement (Sheet 1)
DWG AA CIV 06 03-2 Column Reinforcement (Sheet 2)
2.4.1 Material
Reinforcement is to be hot-rolled deformed high yield steel in accordance with DIN 488 DIN EN
ISO 15360 or BS 4449 Grade 460, or higher. Before use, any matter liable to impair the bond
shall be removed from the steel, e.g., dirt, grease, organic matter, and rust. Particular care shall
be taken to ensure that the reinforcing bars are given the shape (including diameter of curvature),
length and position conforming to the reinforcement drawings.
Any reinforcement shall be so far cold deformable that it will stand the cold bending test, where
the space between the two limbs of the piece bent through 180 must be equal to twice the
diameter of the rod under test. No cracks shall occur on the tensioned side.
Reinforcing steels of group IIIa shall be weldable by the flash welding process to produce
welded joints, which pass the cold bending test.
Steel fabrics of group IVb shall be of steel whose elastic limit and tensile strength are guaranteed
by special cold working, however, steel fabrics shall not be welded or heat-treated in any other
way.
Fabric reinforcement shall be bent accurately to the required shapes before the fabric is laid in
position all bending and cutting shall be done cold and no heating or welding is allowed. All
the fabric shall be lapped and tied together on both the longitudinal and transverse wires and all
lapping shall be sufficient for the steel to develop its full strength.
Pre-stressing reinforcement shall comply with BS 5896-1980 or DIN 10138 and DIN EN
ISO 15630.
2.4.2 Fabrication
All reinforcements shall be bent cold unless otherwise permitted by ADDC/AADC. Bar cutting
and bending equipment for coated reinforcement shall have padded supports and contact areas
and shall be fitted with nylon or plastic mandrels supplied by, or approved by, the coating
factory representative.
The top reinforcement shall be secured against being pushed down by using steel chairs/supports
positioned between top and bottom layers of reinforcement. Steel supports shall be made of new
steel of similar type and quality of the main reinforcement.
Reinforcement bars shall normally not be connected to the earthing system. Separate earthing
mesh shall be provided instead. Earthing to be routed through piles must be isolated from the pile
reinforcement.
To receive good bonding and to avoid corrosion, plastic spacers shall be fixed between form-
work and reinforcement minimum four per m2.
2.4.4.1 General
Reinforcement of piles only, up to 100 mm below the top level of pile cap and subject to ensure
sufficient anchorage of the pile reinforcement into the pile cap, shall be reinforcement with a
fusion-bonded epoxy coating. The coating shall be applied in accordance with ASTM
A775/775M-01, and shall be carried out by an approved coating factory using approved epoxy
resins.
Bending procedures shall follow the coating factory' s recommendations. The coating factory
representative shall ensure his product is used fully in accordance with his recommendations.
2.5 Cement
The type of cement to be used shall depend on the constructional circumstances and on the
prevailing local conditions. Portland cement, Type I, may be used at places not exposed to
chemical aggressiveness, whereas Portland cement, Type V, shall in general be used for all
concrete work in foundations and plinths and in concrete structures covered by soil.
Moderate sulphate resistant cement as per ASTM C 150, type 2, may be used only after
ADDC/AADC' s explicit written approval to replace the type V cement.
Cement shall be of recent manufacture and shall be used within a period of 3 months from
production.
Total cementitious contents in the mix shall be limited to avoid excessive risk of thermal and
shrinkage cracking. It shall always be in the range of 350 400 kg/m3 unless otherwise approved
by ADDC/AADC. The proportioning of mixes for durability will be primarily controlled through
the specified limits on free W/C ratio. The W/C ratio shall always lie in the range of 0.36-0.45.
Appropriate use shall be made of approved admixtures to simultaneously meet the requirements
for W/C ratio and workability.
Before supplying cement to Site or receiving ready-mixed concrete, the Bidder/Contractor shall
submit to ADDC/AADC, the manufacturers statement of Specification and test certificate
together with date of manufacture of any cement to be used. ADDC/AADC reserves the right to
take samples and order any additional / re-tests in accordance with BS EN 196-7 : 1992, BS EN
196-6, BS 4450 and ASTMC 186.
In mix designs with an emphasis on durability, ground granulated blast furnace slag as per BS
6699 or EN 197 or microsilica may be incorporated in the mix. Proportions of slag shall
normally not exceed 60 %, those of microsilica shall not exceed 8%, for items thicker than 1.2m,
these proportions shall not exceed 10%.
2.6 Aggregates
Aggregates shall be crushed rock type and conform to the relevant applicable standard BS
882:1992. The combined aggregate shall be as coarse-grained and dense-graded as possible and
shall be according to the guidelines of BS 882. The maximum particle size shall be so chosen as
to be compatible with mixing, handling, placing and workability of the concrete.
For underwater concrete, proof shall be given that the mix is adequately cohesive and maintains
this property during placing by using under-water admixtures.
Aggregates shall - for all groups except the dune sand - be a product of crushed rock, with the
source and type being subject to ADDC/AADCs approval. Only for exceptional cases and upon
ADDC/AADCs specific written approval, aggregates of other origin may be used for certain
parts of the work.
Size of aggregate used in concrete: maximum aggregate size shall be 20mm, except for thick
elements (>900mm) where particular heat of hydration control is required. There, aggregate of
28mm max size may be used. For the required concrete of Grade 40 (C28 = 40 N/mm2), at least
one particle size fraction shall be in the 0-4 mm range.
2.7 Admixtures
No admixtures shall be used without approval of ADDC/AADC and unless the suitability of
admixtures must be proven in trial mixes in presence of ADDC/AADC.
Admixture containing chlorides shall not be used under any circumstance.
2.8.1 Testing
Throughout the construction period the quality of concrete mixed at and/or delivered to Site has
to be controlled. Tests shall be carried out in the presence of ADDC/AADC or under the
supervision of an approved office for testing of such kind of works. The following minimum
numbers of tests shall be carried out:
a) Aggregates
Sampling of Aggregate: Sampling and testing of Aggregate shall be carried out in accordance
with BS 812 and BS 882. However, the Client reserves the right to call for additional tests
whenever felt necessary.
b) Cement
b1) For site mixed concrete if applicable and or approved by ADDC/AADC
One setting test to vicat per car-load
One boiling test per car-load.
b2) For ready mixed concrete
Mill certificates of the cement used in the plant
Chemical composition in line with DIN 1164 or BS 12.
c) Water
One chemical water analysis every 3 months of construction. First analysis before start of
foundation works.
d) Admixtures and Additives
Three (3) samples of each kind of admixture and additive before start of casting of the first load
bearing structural member.
e) Concrete delivered to Site
One set of at least six (6) test cubes for every 100 m3 or every daily pour of concrete or as
directed by ADDC/AADC.
The compression strength tests shall be carried out after seven (7) days for the first two
cubes of each set, and after 28 days for the second two cubes of the set, and - if requested
the last two cubes of each set may be tested in case of failure of a cube.
Slump tests are to be executed for every truck load supplied during concreting and as per
ADDC/AADC' s instructions, provided concreting is proceeding.
Notes:
* Water retaining structures and Basements in areas with high water table
** Marine structures and structures in areas with highly aggressive soil conditions, classified
as class 4 & 5 as per the BRE Digest 363.
The dimensions of the finished pre-cast units shall be within the following limits at the time of
placement in the structure:
Overall dimensions of member 3.0 mm
Cross-sectional dimensions:
Sections less than 75 mm 1.5 mm
Sections over 75 mm and less than 300 mm 3.0 mm
Sections over 300 mm 5.0 mm
Deviation from straight line in long sections less than 5 mm per 6 m
Deviation from camber 1.5 mm per 3 m of span
No pre-cast units shall be considered for diaphragm action horizontal pre-cast elements. Normal
weight concrete topping is to be used for such behaviour.
Bond/Anchorage test must be performed in the Factory on at least 2 samples of each thickness of
Hollow Core Slabs.
Full scale load tests shall be carried out on each panel of typical design in accordance with ACI
318M-89/318RM-89. The purpose of such load tests is to determine the behaviour of the slabs
under working conditions. Acceptance criteria shall be as follows:
Applied test load T shall be equal to 0.85 (1.4 D + 1.7 L). (D = dead load, L = live load under
consideration of reductions permitted in the general design). Loads shall be applied in at least
four (4) increments and the final load shall be kept for at least 24 hours.
The test load shall be removed immediately after reading of the initial deflection and the final
reading shall be taken 24 hours after removal of the test load.
If visual evidence of failure, e.g. cracking, spaling, excessive deflection, etc., appears, the tested
member shall be considered to have failed the test. If no visual indications of failure occur,
following shall be the limiting criteria to define acceptable behaviour:
Maximum deflection of beams, floor or roof shall be less than l2 / 20,000 h. (l = clear span
and h = thickness)
If the above is exceeded, the deflection recovery within 24 hours after removal of the test
load shall be at least 75% of the maximum deflection for non-pre-stressed concrete or 80%
for pre-stressed concrete
For cantilevers, l shall taken as twice the distance from cantilever support to end.
Deflection shall be adjusted for support movements.
Retesting:
If nonprestressed concrete fails to show the required 75% recovery of deflection, may be re-
tested not earlier than 72 hours after first test load removal. The re-tested portion of the structure
may be considered satisfactory if it shows no visible sign of failure, and the deflection recovery
caused by the second test load is at least 80% of the maximum deflection in the second test.
Pre-stressed concrete construction shall not be re-tested.