1.

PROJECT INFORMATION

The Employer: ,

Co-financier: KfW Bankengruppe,

-9
60325 Frankfurt am Main, Germany

The Contractor: JV LUDWIG PFEIFFER Hoch- und Tiefbau GmbH & Co. KG,

EMIT Ercole Marelli Implanti tecnologici S.p.A.

Via Lampdedusa 13, 2041 Milano, Italy;

Project title: Design and construction of object ''Waste Water Treatment

Plant in Bihac''

Contract No.: BMZ ID 2007 65 925

Document title: Concrete Mix Design

Approved by: civil engineer

Designed by: civil engineer

Checked by: civil engineer

Engineer:

Date of issue: July 2015

Revision: Rev C

3
 2. GENERAL INFORMATION

As a part of the works, the Contractor is required to perform reinforced concrete works that
are subject of this project.
Amount of concrete which has to be placed is:
Concrete c8/10...........................................726 m3.
Concrete c16/20.........................................135m3
Concrete c20/25...........................................22m3
Concrete c25/30.............................................7m3
Concrete c30/37 ,XF3,XA2,XC4 (with Sulphate-resistant cement)................................140m3
Concrete c30/37, XF3,XA1,XC4 (with Portland cement)..............................................6856m3
__________________________________________________________________________
Total amount of concrete: 7886m3

3. DESCRIPTION OF CONCRETE INGREDIENTS

3.1. AGGREGATE (GRANULATE)

For the production of concrete will be used

made of the following fractions:

a) 0-4mm

b) 4-8 mm

c) 8-16mm

3.2. CEMENT

For the production of concrete will be used cement from Cemex Split.

3.3. WATER

For the production of concrete will be used drinking tap water.

3.4. CONCRETE ADDITIVES

For the production of concrete will be used cement additive READYPLAST VP 342 and
READYAIR L300, manufacturer CEMEX.
Retarders and glycol will be used if necessary.

4. METHOD OF CONCRETE PRODUCTION

4.1. MAIN CONCRETE PLANT

Concrete that will be placed in structural elements will be produced at the concrete plant,
type HB1000, manufacturer AB GROUP, owned by company

Concrete plant is located in Ostrozac (Cazin), the distance from the Construction Site is
approximately 20 km. Concrete plant facility is automated, its capacity is 45m3 of concrete
per hour and it consists of:

4
 1. Total capacity of silo for fraction ........................................................... 500 m3.
2. Number of silo chambers for fraction ....................................................... 5 pcs.
3. Total volume of cement storage ......................................................... 200 tons.
4. Number of cement silos ........................................................................... 2 pcs.
5. Cement scale capacity 500 kg.
6. Water scale capacity ......................................................................... 300 liters.
7. Aggregate scale capacity 2500 kg.
8. Additive scale capacity ........................................................................ 30 liters.

This equipment is intended to be used for the concrete production by dosing and mixing of
raw materials that have different granulation and density. Ingredients control for the concrete
production is in terms of the Regulations for technical standards for concrete and reinforced
concrete and according to sampling and testing plans.

5. QUALITY CONTROL PROGRAMME AND CONTROL OF CONCRETE

PRESSURE STRENGTH

Concrete quality control includes:

1. Production control of concrete at the concrete plant- tested in terms of Standard BAS
EN 206-1/A(EN 206-1:2000/A2:2005 ITD) and according to sampling plan. It is
performed by the Concrete Manufacturer by the time it is delivered to the Contractor.
2. Quality control on the construction site is done by the Contractor from the time of
manufacturer delivery till the end of concrete curing.

5.1. CONCRETE PRODUCTION CONTROL

Manufacturer is responsible for the proper concrete production management. All concrete
should be subject of production control which includes all necessary steps in order to keep
concrete properties in terms of needed properties. It includes:
- Material selection and concrete mix design
- Testing of production capability of concrete mixing plant
- Fresh concrete control
- Testing of hardened concrete
- Use of component material testing results from fresh and hardened concrete

Responsibility of all staff that is managing, performing and verifying the quality of the works
shall be specified with the documented system of the control production. This especially is
referred to the staff that needs organizational freedom and surveillance authority in order to
minimize the risk of concrete poor quality and for the staff that should identify and report
every problem of concrete quality.
Intended frequency of testing and monitoring shall be documented with the reports.

5.2. CONCRETE QUALITY CONFIRMATION

The samples for quality control confirmation shall be in terms of prescribed properties and
shall be taken from the laying location and according to the schedule from control plan.
When concrete is delivered to the construction site from the concrete plant, properties control
of fresh concrete shall be done. It includes following actions:
- Bill of lading control
- Visual inspection of consistency with each delivery of concrete
- Consistency measurement for every 20m3 of concrete in making of control samples
for compressive strength and at reasonable doubt, in terms of the Standard BAS EN
12350-2.

5
 - Temperature measurement of fresh concrete at the beginning of laying and while
taking of testing samples in order to define compressive strength and in case of
doubting the quality of concrete mixer (Standard BAS U.M1.032.)
- Taking of testing samples in order to define compressive strength in terms of the
Standard BAS EN 12350-1.
- Taking of samples for testing of concrete hardness in terms of the Standard
U.M1.005 i BAS EN 12390-2(3 samples for each structural concrete)
- Testing of fresh concrete in terms of the Standard BAS.U.M1.032 i BAS EN 12350-2.

Properties Control of hardened concrete includes the following:

1. Compressive strength of concrete is tested on concrete blocks, dimensions

15x15x15cm which are taken and cured in terms of the Standard BAS EN 12390-
3;2003 Testing of hardened concrete Part 3; Compressive strength of tested
samples (EN 12390-3:2001). Concrete compressive strength should be tested 28
days after it has been placed.
2. Testing of watertight is performed in terms of the Standard U.M1.015 and BAS EN
121390-8:2007 Hardened Concrete Testing- Part 8; Water penetration depth under
the pressure (EN 12390-8:2000) 28 day after the concrete has been placed. One
series includes 3 samples, dimensions 15x15x15cm of the same homogeneous
concrete mixture.
3. Concrete freezing resistance testing is performed in terms of the BAS U.M1.016 28
days after the concrete has been placed. One series includes 15 samples,
dimensions 15x15x15cm of the same homogeneous concrete mixture. In terms of the
mentioned Standard samples are exposed to cross freezing (14-16 h on temperature
of -20 to degrees of Celsius) and thawing (14-
degrees of Celsius) in 50 (Mediterranean), 100(Continental), 150 or 200 (Mountain
Region) cycles. Damaged surface shall be within the limitations of the Standard in
order to be claimed as resistant.
4. Concrete testing of frost and salt resistance is performed 28 days after the concrete
has been placed and in terms of BAS U.M1.055. One series includes 3 samples,
dimension 15x15x15cm of the same homogeneous concrete mixture. In terms of the
mentioned Standard samples are exposed to cross freezing (14-16 h on temperature
of -20 to degrees of Celsius) and thawing (14-16 h on temper
degrees of Celsius) in 50 (Mediterranean), 100(Continental), 150 or 200 (Mountain
Region) cycles. Damaged surface shall be within the limitations of the Standard in
order to be claimed as resistant.

Plan of taking test samples depends on the quantity of placed concrete. Taking and testing of
test samples is determined by the actual dynamics of works execution and according to
below listed criteria:
1. Testing of compressive strength:
-One sample minimum per every day of concreting for each type of concrete,
-One sample minimum per each 100m3 of placed concrete,
-One sample minimum per day for structural elements significant for the safety of the
structure, regardless of the smaller amount of the built in concrete.

Testing is made in terms of the Standard U.M1.020. Determination of compressed concrete

bodies made of fresh concrete, that in terms of Technical Regulations for Construction
Products that are installed in concrete structures, item Ation.3.1. Taking, preparation and
testing of test samples and testing of fresh concrete characteristics is in terms of the
Standard BAS EN 12350, and testing of hardened concrete characteristics is in terms of the
Standard BAS EN 12390.

2. Testing of the concrete frost resistance:

6
 -One series minimum for the concrete class of compressive strength C30/37 (1
series includes 15 test samples).
Taking, preparation of test samples and testing of concrete frost resistance is performed in
terms of the Standard U.M1.016 that complies with the Regulations of the technical
prescriptions on the construction products which are installed in concrete structures, item
A.3.2.

3. Testing of the concrete frost and de-icing salt resistance

- One series minimum for the concrete class of compressive strength C30/37 (1
series includes 15 test samples).

Taking, preparation of test samples and testing of concrete frost and de-icing salt resistance
is performed in terms of Regulations of the technical prescriptions on the construction
products which are installed in concrete structures; item A.3.2.BAS CEN/TS 12390-9.

7
 6. CONRETING PLAN, WORKS AND EQUIPMENT ORGANIZATION

6.1. CONCRETING PLAN AND WORKS ORGANIZATION

According to the works schedule it is required that all concrete works from this Design should
be executed in 8 months. Total amount of the concrete is approximately 8000m3. Concrete
works organization is planned by the Contractor under constant supervision by
the Engineer that is responsible for the works control. Particular attention should be paid to
concreting of foundation slab.

6.2. PRODUCTION, TRANSPORT AND CONCRETING EQUIPMENT

Concrete will be prepared at the concrete plant, located approximately

20 km from the Construction site.
In order to maintain the continuity of the concreting following equipment is essential (design
calculation for the highest amount of concrete):
-concrete plant with the practical performance 45 /h................1
-transit mixer with capacity of 6 ................................................6
-concrete pump ..............................................................................2
-immersion vibrator..........................................................................5

Averaged time needed for one concrete mixer cycle with capacity of 6 from the
construction plant to the Construction site and back is:
-mixing and filling ......................................................10 min
-transportation time......................................................................20min
-placing time.................................................................................15min
-return time to the concrete plant...................................................15min
Total:........................................................................................60min/6 of concrete

It is planned to use 2 concrete pumps at the time and three teams of workers for the
concreting of the foundation slab and maximum amount of the concrete per day.

In order to maintain the concreting continuity necessary number of concrete mixers will be
involved. All concrete mixers and concrete pump will be inspected and technically approved.
In case of mechanical fault of the vehicles, replacement will be provided. Formwork concrete
filling will be done directly from the machine with the concrete pump or with the crane that is
located at the Construction site. Concrete compaction is performed with the help of
immersion vibrator, diameter 25-90mm, depending on the dimension of the structural
element that is being concreted.

During the transportation, fabrication and placement of the concrete, mixing drum shall rotate
constantly.

Before each concrete pouring direction of rotation of the mixing drum should be rotated and
increase the speed of the rotation in order to accomplish necessary homogenization (1-2
minutes). Extra water addition in the transit mixer is strictly prohibited.

If the correction of consistency is needed it can be performed with adding of plasticizers to

the amount which is given in concrete specification.
With each concrete delivery to the Construction Site, Manufacturer shall hand out bill of
lading with following characteristics:
-C

8
 -Bill of lading serial number
-Concrete formulation the real mixture in delivery note
-Formulation number
-Loading date and time
-Machine number or identification
-B
-
-Amount of concrete in m3
-Time of arrival of the concrete mixer on the Construction
-Unloading start time
-Unloading end time
-
-

6.3. CONTROL BEFORE CONCRETING:

Control before concreting includes:

-
-Access control of planned delivery and of protection layer
-Cleanliness and oiliness of the formwork
-Cleanliness of the prepared formwork
- Inspection of installed reinforcement in terms of the Design
-Control of the elements that needs to be installed in terms of the Design
-Cleanliness of the surfaces which will be concreted
-Control of the possible weak concrete parts which are assembled
-Control of the possible mechanical impacts and seismic actions in the hardening of
concrete phase

Placing of the concrete shall start only when all preparation works are done correctly and
when there is written confirmation of it.

6.4. SCAFFOLDS AND FORMWORKS

Scaffolds and formworks including their supports and foundations shall be designed and
constructed in a way that:
-They are resistant to any activity they are exposed to during the performing of works
-They are strong enough to satisfy tolerance conditioned for the construction

Form, function, appearance and durability of the constant works shall not be compromised or
damaged with the scaffolds and formworks properties and removal of the mentioned.
Scaffolds and formworks shall comply with relevant regulations.
Deformations of the concrete during and after the concreting shall be taken into
consideration. It shall be predicted in the Formwork Design in order to avoid crack of green
concrete.
That can be achieved with:
-limiting the deflection and/or concrete slumping
-control of the concreting and/or with concrete specifying e.g. slowdown of works.

Formwork should provide the required form of the concrete until it is hardened. Formwork
and spring clips between the elements shall be watertight enough to prevent loss of fine
mortar. Formwork that absorbs a significant amount of water shall be properly moistened to
prevent water loss from the concrete, unless it is specially and controlled intended for it.
The inner surface of the formwork shall be cleaned. If used for exposed concrete its finish
shall provide such concrete surface. Scaffolds and formworks shall not be removed until the
concrete is hardened enough:

9
 -Resistant to surface damages during the formwork removal
-Hardened enough to take over all impacts that affect concrete element at the time
-To avoid more deformations than previously specified tolerances of elastic and non-
elastic concrete
Removal should be done in a way that structure is not loaded and damaged. Scaffolding
loads should be discharged gradually to avoid loading of other scaffold elements. Scaffold
and formworks stability should be maintained during load removal.
When the impact reduction of the initial load and successive load is applied and/or avoiding
of bigger deformation, propping or removal procedure should be thoroughly determined.

Formwork oils

Formwork oils should be selected and applied in a way that do not damage the concrete,
reinforcement steel or formwork and that do not harm the environment. Formwork oils must
not affect the quality of the surface, its color and special surface coatings.

6.5. CONCRETE LAYING AND VINRATION

Concrete laying simultaneously comprises pouring and laying of the concrete in the formwork
in a way that it is placed as close as possible to its final position in the structure. These
actions shall be done in such way that there is no segmentation of the concrete mixture.
Following rules should be obeyed:
-Avoid that concrete strikes formwork directly
-Free fall height shall not exceed 1.5 m
-Placement should be equally layered
-Thickness of the layers which are compacted must not exceed 50cm
-Layers of the concrete must be compacted prior to applying next layer
-Before each concreting should exist a concreting plan in relation to particular features
and conditions and when is requested by the Engineer.

When works are stopped with a prolonged delay, they shall be continued after appropriate
technical procedures (surface rinsing, cleaning and after use of adhesion products).
Concrete vibrating is performed with appropriate immersion vibrators whose size depends on
structural element dimensions and layers which is being concreted and of reinforcement
steel. Vibrators shall be immersed in the concrete mix vertically and kept in the water until
the air from the concrete is squeezed out (1-2 min).
shall be done gradually and vertically so
that the formed hole in the concrete should be closed on its own.
Radius impact of immerse vibrator depends on the needle radius and oscillations frequency.
Tame taken for the vibrating in every position is 15 s. Excessive vibration of the surface
should be avoided because of the quality loss.
Consistency correction of the placement position shall be done only by the concreting
technologist, but only if using proper additives for concrete.
Timing of the formwork removal at the Construction Site should be determined by taking the
technological samples of concrete for the strength test and minimal terms shall be satisfied:
-30% of strength for columns, walls and vertical parts of formwork beams
-70% strength for reinforced concrete slab and lower parts of the formwork beams

6.6. CONCRETING AT LOW TEMPERATURES

Concreting at low temperatures is considered to be at the temperatures lower than 5 .

Certain measures characteristic for the concreting works must be taken in winter conditions.
Current practice showed that using of following protective measures shall be taken:
-Water heating, maximum 60 ., for the concrete production
-Aggregate protection for the concrete from the outside effects by covering

10
 -Additives supplementation in the concrete mix, frost resistant
-Concrete placement in a short period without unnecessary reloading
-Covering of opened fresh concrete surfaces at the Construction Site
-Campfires, using old tires (including lot of smoke) in the area of concreting in order to
avoid frosting.

6.7. CONCRETING STOPPAGE AND JOINTS TREATMENT

If stoppage of concreting of certain structural elements happens, then should be proceeded

as follows:
Fresh concrete should be cleaned from the plate elements joints in order to get vertical
plane. After 2-3 hours future joint shall be rinsed to remove cement and small fraction. Before
proceeding with concreting, breaking should be treated with cement mortar that is modified
with polymer dispersive binder or other appropriate additive.
Concreting stoppage, if necessary, should be programmed in the area where are the
smallest static moments of the structure. Concreting continuation shall be as soon as
possible.
Concrete walls shall be treated the same. Concreting continuations shall be vertical on flat
surfaces and elements and on upright surfaces and elements shall be horizontal.

The Contractor is required to provide written proposal for continuation of concreting works. It
has to be submitted to the Engineer. After their approval, works shall start (or ask the
Designer for solution).
The same stands for any repair damage of the structural elements of the object.

6.8. PROCEDURES IN CASE OF QUALITY DEFECTS

In case of the common defects and mistakes during works performance, as for example, joint
of old and new concrete, segregation, roughness, voids of tying formworks and similar, it is
recommended that these defects should be treated with restoration mortar with adhesion
additives. Restoration mortar should have similar mechanical properties and should have the
same color as the base that is placed on.
Damaged places shall be brushed with the steel brushes and all free parts of concrete and
cement scum that are not tightly connected shall be removed. Then it shall be moistened and
coated with additives in order to continue works. It will be done with the mixture of sand and
cement, 3:1 (in dry condition) and while mixing prepared mixture of silicon coat and water
(SN: water), 3:1.
Granulation of sand can be 0-2 and 0-4 mm depending on the surface and depth damage.
Best results are achieved if reparation is done immediately after the formwork removal, i.e.
while the concrete is fresh. If handling deeper damages, polypropylene fiber should be added
in the mixture.

6.9. CONCRETE CURING

Immediately after the concreting, the concrete should be protected from drying out, from
rapid heat transfer between the concrete and air, from rainfall and water, high and low
temperature, from vibrations and other mechanical damages during concrete setting and
initial hardening. Curing and protection should be implemented at the same time; it will thus
ensure the normal process of hydration. It will also eliminate concrete water evaporation and
will protect the concrete from wind. Protection and curing have substantial effect on the final
topping quality of the concrete. This especially affects quality of concrete layers that protect
reinforcement and core of the concrete from water penetrations and harsh impact. It also
reduces shrinkage.
During higher temperature weather following actions shall be applied:

11
 -Watering several times a day
-Covering with wet jute bags or with other coverings that retain moisture and with
constant to watering of it to remain moisture,
-Coatings that are used for protection of concreted surfaces

If concreting takes place in winter at low temperatures, concrete protection is based on the
protection of concrete elements from heat loss. Concrete is placed with temperature that will
together with the released hydration heat and appropriate isolation, in certain weather
conditions, provide that in predicted period of time curing reaches necessary freezing
resistance.
In the transitional period of the first night frosts and positive daily temperatures, it is sufficient
to cover it with PVC foil lifted up approximately 5cm above the concrete. It will protect the
concrete with the layer of hot air. For the longer duration of low temperatures it is necessary
to use increased protection using the thermo isolation materials (felt, jute, styropor, etc.)

7. MONITORING AND QUALITY CONTROL OF REINFORCED STEEL

Reinforcement steel is produced in terms of the Design of concrete structures. Manufacturer

gives Certificate of Quality for steel, and the Contractor shall provide necessary Manufacturer
Quality documentation. If the documentation is not provided before installation, control
testing of reinforcement bars and grids will be conducted.
Testing samples will be taken at the Construction Site immediately, after or during the
storage phase and after the supporting documentation review.

8. FINAL EVALUATION OF QUALITY

Final evaluation of concrete and concrete works is required and contains:

-Documentation on the quality of concrete components
-Documentation for taking over of concrete by batch lots
-Reviews of the quality of placed concrete on the basis of visual inspection of the
structure, inspection of documentation and of testing resulting results including
comparisons with previous testing results.
Production control evaluation will be given by the concrete supplier, i.e. concrete plant.
Based on the previous testing and controls the Engineer gives in terms of technical norms for
the concrete and reinforced concrete (PBAB 1987.) expert opinion on the quality of works,
installed products and equipment (in terms of Design requirements) and determines that
quality is proved with regulated and documented tests.
Lab tests will be carried out at the concrete plant or at the Construction Site.

12
9. ATTACHEMENTS

- Initial concrete testing report,

- Statement by the company IGH ltd. Mostar regarding factory control production of

concrete on batching plant Duzelic ltd. Cazin,

- Report on testing regarding production capability of batching plant Duzelic ltd. Cazin,

- Declaration of Conformity and Certificates of cement, CEM II_B-M (S-LL) 42,5N i

CEM III_B 32,5 N SR-LH,

- Declaration of Conformity and Certificates of additives, READYPLAST VP 342 and

READYAIR L300,

- Technical guidelines for cement CEM II_B-M (S-LL) 42,5N i CEM III_B 32,5 N SR-LH,

- Technical guidelines for additives READYPLAST VP 342 and READYAIR L300,

13