Pago 1 of 13 NEW ZEALAND RAIL LTD Operations Group : Code Supplement | Numb: CSw/0403 | Subject: REINFORCED CONCRETE CONSTRUCTION issue | Prepared (P), Reviewed (R), Amended (A) By: Number 2 {A) PS Holmes If this Statement i: in RED, this is a CONTROLLED POCUME! This Document Supersedes cawma0gNow Zealand Rail Limitad : Operations Group Effective Date : 1 August 1995 Issue 2 Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 2 of 13 CONTENTS Page (ntroduction 2 Reinforced Concrete Fundamentals 3 e Materials 4 Materials Testing 7 Formwork 8 Placing Steel 9 Placing Concrete 10 Concrete Repairs 12 Standard Specifications 12 1. INTRODUCTION These notes are intended to assist Structures staff working with new concrete or with the repair of damaged or deteriorated concrete. Instructions and procedures described in this Code Supplement do not take e@ precedence over specification clauses written for particular jobs but, where conflict exists, they are to be taken in preference to clauses found in NZS (New Zealand Standard Specification) documents. In this document, references to “the Engineer" mean Manager, Structures Engineering's technical staff,a New Zealand Rail Limited : Operations Group Effective Date : 1 August 1995 Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 3 of 13 Reference should be made to Code Supplements CSW/0405, “Specification for Concrete"; CSW/0406, "Specification for Reinforcement" and CSW/0502, “Supervision of Contracts" for more information on reinforced concrete. REINFORCED CONCRETE FUNDAMENTALS Concrete is basically a mix of mineral aggregates and hardened cement paste. Aithough the aggregates make up 60 to 80 percent of the concrete volume and their quality is important for a variety of reasons, concrete strength is largely dictated by the quality of the cement paste. This in turn is dependent on the ratio of water to cement used in the mix, too much or too little water producing inferior concrete. The correct proportion of water to cement is essential in order that the chemical reactions between the compounds present in the cement can be completed and that the concrete mix is plastic and workable, A properly cured, weil designed concrete mix has good compressive strength but poor tensile properties. Also, concrete shrinks as it dries and, if restrained, will crack. In structural elements, reinforcing steel (usually mild steel) is provided to overcome the tensile limitations of concrete and to assist with the distribution of shrinkage cracks. Some steel (always high tensile steel) may be given a permanent initial tension resisted by compression in the concrete. This results in a prestressed concrete member, Although well designed and constructed reinforced concrete may be considered a low maintenance material, it is not always the durable substance many people imagine. The use of aggregates which react chemicallyNew Zealand Rail Limited : Operations Group Effective Date ; 1 August 1995 Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 4 of 13 with components in the cement can cause severe cracking in concrete after several years of service and can not be readily remedied. Poorly placed concrete may provide insufficient protection for the reinforcing steel which may rust, expand and cause the concrete to crack and spall, particularly in a marine environment. Also, the in-service environment may not always be as anticipated with the result that concrete suffers abrasion, cracking or other forms of damage. Most of the above problems can be overcome by ensuring that reinforced concrete is constructed to a high quality, with care and in accordance with proper standards. MATERIALS 3.1 Cement Several different types of cement are often available for construction including ordinary portland cement and rapid hardening portiand cement. Unless specified to the contrary, ordinary portland cement complying with NZS 3122, “Specification for Portland Cement" is to be used for all Operations Group projects. High alumina cement is NOT to be used. Cement must be kept dry before use. !t should be stored in a dry shed with bags stacked together to reduce air circulation and preferably covered with tarpaulins. Small quantities of cement held on site for periods not exceeding one week may be stacked clear of the ground on a dry base and covered with tarpaulins. Dry cement stored for long periods may pack down to some extent and give the appearanceNew Zealand Rail Limited : Operations Group Effective Date : 1 August 1995 Section CSW/0403 | Subject : REINF. CONCRETE CONSTRUCTION Page 5 of 13 3.2 3.3 of having solidified, however, it can quickly and effectively be restored by rolling the unopened bags on the ground. Cement which has become lumpy must not be used if the lumps do not break up into powder easily. Aggregates Aggregates are classified as coarse or fine. Both types of aggregate must be clean and free of significant quantities of deleterious materials (such as pumice, soft rocks or wood} and must meet the grading requirements of NZS 3121, "Specification tor Water and Aggregate for Concrete". In addition, before incorporation in Operations Group work, samples of coarse and fine aggregates must have been passed as satisfactory as a result of a petrographic examination and report by a qualified geologist in order to ensure that the aggregates are not potentially reactive with alkalies in the cement. ‘When stored on site, aggregates of different grades are to be kept separate, stored on clean surfaces and protected from the weather. Water Water for concrete work must be free from significant quantities of contaminants which could affect the setting, strength or durability of the finished product. Clay particles, oils, detergents and acids in particular can be damaging. NZS 3121 describes the requirements for water quality. In general though, water which is fit to drink should be suitable for concrete work.New Zealand Aeil Limited : Operations Group Effective Date : 1 August 1995 Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 6 of 13 3.4 Additives 3.5 Materials may be added to a concrete mix in order to accelerate or retard the set or to improve the concrete’s workability and for other purposes. However, some additives may be harmful to the long term serviceability of the structure. For this reason, no additive is to be included in a concrete mix unless expressly instructed by the Engineer. In particular, calcium chloride is not to be used in Operations Group work. When additives are approved, they are to be used strictly in accordance with the method specified. Reinforcing $ Various types of reinforcing steel are available for differing purposes. Types commonly encountered are mild steel (Grade 300) and high yield steel {Grade 430), both are available as plain or deformed bars complying with NZS 3402, "Steel Bars for the Reinforcement of Concrete”. High tensile steel is used for prestressing work. Grade 430 deformed reinforcing bars can be identified by a smooth pattern (or missing deformations} on one side of the bar at intervals of about 1.3 metres. Grade 430 plain bars also carry identification marks. Reinforcing steel has to interact with the concrete so. a good bond must form between the two materials. For this reason, at the time of concreting, the steel must be free from dirt, loose scale or rust, paint, oil, grease or any other contaminant which could reduce the bond, Tightly adhering rust or scale which would need a wire brush to be removed is, however, acceptable.New Zealand Rail Limitad : Operations Group Effective Date : 1 August 1995 Issue Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 7 of 13 Steel must be stacked clear of the ground and vegetation and should be protected from the weather if it is to be stored for any length of time. It is particularly important to keep the steel stacks some distance removed from diesel or other fuelling points where spillage could occur. MATERIALS TESTING Reinforcing and prestressing steel will rarely require to be tested by or on the behalf of Operations Group staff as its suitability for incorporation in a structure is determined by the test certificates supplied with each bundle of steel by the manufacturer. If there is any doubt as to the origin of a particular batch of steel, it should be rejected. Alternatively, Track and Structures Manager can arrange for samples to be tested for compliance. Samples of aggregates must be taken and tested in accordance with NZS 3111, "Methods of Test for Water and Aggregate for Concrete’. This procedure determines the strength, density, absorption, potential reactivity and other properties of the aggregate. A separate petrographic report is also required for aggregates as outlined in Section 3.2 above. Concrete must be sampled and tested strictly in accordance with NZS 3112, "Methods of Test for Concrete". Any departures from the procedures laid down in this Standard even in quite small ways could negate the results of the test in a contract situation and make it difficult for substandard concrete work to be rejected. NZS 3112 covers both slump tests and the making of test blocks. This work is also dealt with in summary form in Code Supplement CSW/0502, "Supervision of Contracts”.New Zaaland Rail Limited : Operations Group Effective Date : 1 August 1995 Section CSW/0403 Subject : REINF, CONCRETE CONSTRUCTION Page 8 of 13 5. FORMWORK It is usually only in major works that concrete formwork is designed by a registered engineer. In other cases, it is up to the contractor or the construction gang to provide suitable temporary work, although the Engineer may check a contractor's proposal for adequacy. Concrete appearance will be largely determined by the quality of the formwork which should be constructed to give an appropriate and acceptable surface finish and structural dimensions within specified tolerances. NZS 3109, "Specification for Concrete Construction" should be used as code of practice for formwork if no particular formwork specification is provided. It should be noted that: a) Formwork must be strong enough and sufficiently braced to prevent bulging under the weight of wet concrete and allowance must be made for the additional forces caused by the impact of concrete falling from the delivery chute. b) Allowance may need to be made for deflections in the formwork and provision made for adjustment to temporary works to allow for any settlement under load. c} Formwork joints must be mortar tight to prevent loss of fine material from the structure's surface. d) Formwork should be designed with filleted corners and constructed so that it may be removed without damage to the finished concrete. Any release agents applied to the formwork must be non- staining.New Zealand Rail Limited : Operations Group Effective Date : 1 August 1995 Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 9 of 13 e) After about half the concrete pour has been completed, the upper formwork clamps should be checked and re-tightened if necessary. Concrete vibrators can loosen these clamps. PLACING STEEL Reinforcing and prestressing steel must be of the grade specified for the work, must be accurately fabricated to the required dimensions with standard hooks and bends and securely fixed in position to the specified tolerances. Requirements for cover and minimum bar spacing are to be noted. in the absence of any particular standard being specified for the work, NZS 3109 is to be followed. It should be noted that: a) Hooks and bends must not be formed to a sharper radius than specified in NZS 3109. b) Welding of any reinforcement unless specifically directed by the Engineer is not allowed. Reinforcing and, particularly, prestressing materials must not even have weld spatter deposited on them. Where this note is contrary to the provisions of NZS 3109, this note is to be followed. c} Where details are not specificaily provided, laps in bars shall be as given in NZS 3109 or 40 bar diameters, whichever is the greater. Grade 430 steel requires 50% greater lap lengths than grade 300 steel (i.e. 60 bar diameters}. If bar centres are closer than 3 bar diameters, the Engineer will determine tap lengths.‘New Zealand Rail Limited : Operations Group Effective Date : 1 August 1996 Issi Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 10 of 13 d) Stee! must be clean and free from bond reducing contaminants at the time of concreting {see Section 3.5 above). PLACING CONCRETE For most works, concrete to NZS 3104, "Concrete Production - High Grade and Special Grade" as specified by the Engineer will be delivered to the site ready mixed. Only for the smallest of jobs involving non-structural work should non-certified concrete be mixed on site by Operations Group staff and even then, the provisions of NZS 3104 (or NZS 3108 for ordinary grade concrete) should be adopted. Additional water, over and above the quantities specified, must never be added to a mix without the approval of the Engineer. Even small quantities of extra water may significantly reduce the strength and durability of a batch of concrete. However, in the case of free fall concrete in piles where the slump must be a minimum of 150 mm and where the Engineer can demonstrate that the design water/cement ratio will not be exceeded, water may be added gradually (and the concrete slump constantly checked) until the desired mix has been achieved. Concrete is to be placed as specified. {f no specification exists, the provisions of NZS 3109 and Code Supplement CSW/0405, "Specification for Concrete” are to be adopted. In general, concrete may only be placed in clean, properly constructed formwork. It should be placed as near as possible in its final position in layers not more than 300 mm thick when sections deeper than 1 metre are involved and thinner layers for shallower sections. The concrete must not be allowed to drop freely so as to allow segregation of coarse aggregateNew Zealand Rail Limited : Operations Group Effective Date : 1 August 1996 issu Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 11 of 13 from the mix. A tremie or a concrete pump may be needed to deposit concrete in deep foundations and will certainly be needed if the concrete is placed under water. As the concrete is placed, it is to be compacted with vibrators until the concrete becomes uniformly plastic. It is not to be over vibrated nor is it to be moved along the forms with the vibrators as each of these actions can cause segregation. A good rule of thumb is that the vibrator should not be left running in the same spot for longer than 10 seconds. When the formwork is filled, surplus concrete should be screeded off and the surface finished to the appropriate specified standard. Construction joints are formed by roughening and cleaning the surface of previously placed concrete, wetting and applying a cement mortar to this interface before pouring the next section. Construction joints are only to be formed at locations shown on the drawings or as directed by the Engineer. Concrete surfaces exposed to the air must not be allowed to dry out through evaporation and must be prevented from freezing in cold temperatures. Surfaces must be kept continually moist by spraying or by covering with wet sacking for a minimum period of seven days after concreting. Surfaces exposed by early stripping of formwork must also be protected. In this case, a curing membrane should be applied immediately the boxing is removed. Minimum stripping times for the removal of the formwork are to be as specified for the work or as stated in NZS 3109.New Zealand Rall Limited : Operations Group Effective Date : 1 August 1995 Section CSW/0403 ssut Subject : REINF. CONCRETE CONSTRUCTION Page 12 of 13 CONCRETE REPAIRS Concrete repair work may be required for a variety of reasons. in some cases, such as damage caused by vehicle impact, the reason for the damage may be obvious, but at other times it will be less so. It is essential that in all cases the reason for failure is diagnosed as correctly as possible. Failure to take this step may result in repair work which is totally inadequate. Simple repairs to overcome damage from physical causes may only involve plastering with mortar or an epoxy mortar. More complicated repairs may involve concrete replacement. This sort of repair may not be effective, for problems where corroded reinforcing exists in association with old, cracked or spalling concrete which is no longer capable of providing protection for the steel. Similarly, pressure grouting excessively wide shrinkage or flexural cracks may be an appropriate and effective remedial treatment, but is unlikely to be of any assistance in overcoming cracks caused through alkali-aggregate reaction. Therefore, for al! concrete repair other than the most superticial, the Engineer will provide instructions concerning method and procedures for remedial work. STANDARD SPECIFICATIONS A number of New Zealand Standard Specifications are referred to in this Code Supplement. Most should be available to Inspectors, Clerks of Works or Leading Hands working with reinforced concrete. For reference purposes, the most important of these documents are summarised below.New Zealand Rail Limited : Operations Group Effective Date : 1 August 1995 Issue 2 Section CSW/0403 Subject : REINF. CONCRETE CONSTRUCTION Page 13 of 13 NZS 3104: Concrete Production - High Grade and Special Grade NZS 3108: Concrete Production - Ordinary Grade NZS 3109: Concrete Construction NZS 3111: Methads of Test for Water and Aggregate for Concrete NZS 3112: Methods of Test for Concrete NZS 3121; Water and Aggregate for Concrete NZS 3402: Steel Bars for the Reinforcement of Concrete