ABU DHABI SEWERAGE SERVICES COMPANY

(ADSSC)

GENERAL SPECIFICATION FOR CIVIL WORKS

DIVISION 3 CONCRETE

SECTION 03400 PRECAST CONCRETE

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 1 of 13

General Specification for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

DOCUMENT CONTROL SHEET

Revision No.

Date

Revision Description / Purpose of Issue

01

April 2008

First Issue.

02

Jan. 2011

ADSSC new logo

03

04

05

06

07

08

09

10

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 2 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

TABLE OF CONTENTS
1

GENERAL ....................................................................................................... 4
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.5
1.6

PRODUCTS ..................................................................................................... 9
2.1
2.2

SCOPE AND GENERAL REQUIREMENTS ......................................... 4

CONCRETE CASTING YARD.............................................................. 4
REINFORCEMENT FABRICATION YARD........................................... 5
COATING YARD .................................................................................. 5
AIR CONDITIONED STORES .............................................................. 5
SITE LABORATORY ............................................................................ 5
RELATED DOCUMENTS ..................................................................... 6
STANDARDS ....................................................................................... 6
SUBMITTALS ....................................................................................... 6
PRODUCTS AND MATERIALS APPROVAL ........................................ 6
METHOD STATEMENTS ..................................................................... 7
DRAWINGS ......................................................................................... 7
SAMPLES ............................................................................................ 7
QUALITY CONTROL............................................................................ 8
DELIVERY, STORAGE AND PROTECTION........................................ 8
GENERAL ............................................................................................ 9
PRECAST CONCRETE UNITS ............................................................ 9

EXECUTION .................................................................................................. 10
3.1
3.2
3.3
3.4

ADSSC/GSCW

FABRICATION ................................................................................... 10
PRECAST CONCRETE MANHOLE UNITS ....................................... 11
SURFACE TREATMENT AND REPAIR ............................................. 12
ERECTION......................................................................................... 12

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 3 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

GENERAL

1.1

SCOPE AND GENERAL REQUIREMENTS

a) This section of the specification gives the requirements for the
production of precast units.
b) Precast concrete work shall be executed by an approved commercial
precast company, having the following facilities, unless otherwise
approved by the Engineer.

1.1.1

CONCRETE CASTING YARD

a) The area of the yard should be minimum 900m2
b) The yard shall be enclosed from all sides with a boundary wall with a
minimum height of 1.5m and be provided with gates at suitable locations.
c) The yard shall have concrete or asphalt paved flooring and be provided
with elevated working platforms.
d) The yard shall be covered with a properly designed roofing system. The
roof shall be either sufficiently high to accommodate the lifting and
transportation equipment or provided with well designed openings in the
roof for the same.
e) The yard shall have an adequate water supply for casting and curing
purposes. It shall be provided with underground water tanks and
overhead insulated tanks preferably of GRP for sufficient storage of
sweet water either from ADWEA or other suitable sources.
f)

Water points shall be provided at convenient locations and be equipped

with flexible hosepipes.

g) The yard shall be adequately illuminated and provided with overhead

floodlights to facilitate 24 hour working.
h) The yard shall be adequately equipped with lifting and transportation
equipment.
i)

The yard shall be equipped with a sufficient number of poker vibrators

along with a minimum of one vibrating table.

j)

The yard shall be equipped with a stationery concrete pump with suitable
piping system and all necessary conveyors, chutes and hoppers
required for satisfactory concreting procedures.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 4 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

1.1.2

REINFORCEMENT FABRICATION YARD

a) The area of the yard should be minimum 200m2
b) The yard shall have a concrete floor and elevated platform for storage of
reinforcement.
c) The yard shall be provided with a suitable roof, designed so as to
accommodate the lifting and transportation equipment.
d) The yard shall be equipped with bar bending and cutting machines and
all relevant tools and equipment.

1.1.3

COATING YARD
a) The yard shall be fully covered and enclosed and shall have a minimum
area of 50m2
b) The yard shall be equipped with both manual and spray painting
equipment and be provided with a sand blasting facility.
c) Equipment for tests on coating (i.e. coating thickness, pull off tests,
holiday tests, etc.) and humidity and temperature measuring devices
shall be readily available.
d) The coating work shall be supervised by experienced and qualified
personnel.

1.1.4

AIR CONDITIONED STORES

Air conditioned store shall have a minimum area of 50m2 and shall be
provided for storage of materials at ambient temperature conditions. It shall
be equipped with suitable air conditioning system to maintain inside
temperature at 22oC at all times.

1.1.5

SITE LABORATORY
a) A sufficiently equipped laboratory shall be provided on site to carry out
the concrete and aggregates tests as specified in Section 03300.
Qualified and trained QC personnel shall be appointed to carry out the
testing works in the site laboratory. Minimum requirements for the
laboratory shall be established on site depending on the contractors
proposal whether or not he intends to employ an independent testing
laboratory.
b) Within a reasonable time prior to commencement of precast concrete
work, the Contractor shall schedule a pre-construction meeting with the
Engineer to discuss design, materials, methods of work, forming
systems, quality control, testing, transporting and erection.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 5 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

1.2

RELATED DOCUMENTS
The following sections of the specification shall be read in conjunction with
this section.
Section 01000-07
Section 01000-08
Section 01000-09
Section 03100
Section 03200
Section 03300
Section 03500
Section 03600
Section 05100

1.3

Submittals
Quality control
Materials and equipment
Concrete formwork
Concrete reinforcement
Cast in place concrete.
Concrete repair and grouting.
Concrete protection and waterproofing.
Structural steelwork.

STANDARDS
All activities relating to this section of the specification shall comply with the
following or approved equal standards.
BS 5911-1

BS EN 1916
BS EN 1917
BS EN 13369
ISO 9000

Concrete pipes and ancillary concrete products.

Specification for unreinforced concrete pipes (including
jacking pipes) with flexible joints
Concrete pipes and fittings, unreinforced, steel fibre
and reinforced
Concrete manholes and inspection chambers,
unreinforced, steel fibre and reinforced .
Common rules for precast concrete products.
Quality management systems.

1.4

SUBMITTALS

1.4.1

PRODUCTS AND MATERIALS APPROVAL

a) In order to verify compliance with the specification the Contractor shall
submit information for all products and materials used in the Works to
the Engineer for approval sufficiently in advance of their use in
accordance with the Contract programme allowing for ordering and
approval times. Reference shall also be made to Section 01000-09 of
the specification on products and materials approval. Information to be
submitted shall comprise but not necessarily be limited to:
i.
ii.
iii.

iv.
ADSSC/GSCW

Details of the permanent precasting facility as specified in clause

1.01B.
Organisation chart, complete with names, functions and experience.
Quality assurance and quality control procedures for the fabrication
of the precast concrete units with particular attention to checking
processes and final inspections.
Description of formwork systems.

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 6 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

v.

Sources, characteristics and test certificates for all constituent

materials to be used in the production of precast concrete units.
vi. Technical data for all lifting devices and embedded items.
vii. Proposal for isolating reject items or rework items.
viii. Complete design calculations for the precast concrete units
including:

1.4.2

Design standards.
Design loadings.
Reinforcement details.
Hoisting requirements.
Connection details.
Anchoring devices.
Stability requirements.

METHOD STATEMENTS
a) The Contractor shall submit method statements to the Engineer for
approval 4 weeks in advance of commencing the site activity in
accordance with Section 01000-07 of the specification. These shall
comprise but not necessarily be limited to:
i.
ii.

1.4.3

Procedures for manufacturing, finishing, curing, patching and

repairing precast concrete units.
Procedures for testing, lifting, transporting, and erecting the precast
concrete units.

DRAWINGS
a) The Contractor shall submit drawings to the Engineer for approval in
advance of commencing the site activity in accordance with Section
01000-07 of the specification. These shall comprise but not necessarily
be limited to:
i.

Layout plans and detailed fabrication and placement drawings for

each structural precast unit which shall include:

1.4.4

Reinforcement details.
Connection and anchorage details.
Lifting devices, locations and handling limitations.
Openings, sleeves, inserts and embedded items.
Precast concrete unit location.
Relationship to adjacent units and/or structures.
Precast concrete unit identification number.

SAMPLES
a) Representative samples, as agreed with the Engineer, must be
submitted for at least the following items at the same time as the
particulars are submitted.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 7 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

i.

1.5

Sample of precast panel as agreed with the Engineer to be

representative of the Works to be constructed to demonstrate
adequacy of precasting operations.

QUALITY CONTROL
a) Prior to dispatch of any product and/or material from source the
Contractor shall notify the Engineer in writing in sufficient time to allow
the Engineer the opportunity to inspect and test the product and/or
material prior to delivery in accordance with Section 01000-08 of the
specification.
b) Products and materials shall be from a manufacturer/supplier who
operates a quality system which is registered to ISO 9000 series or
approved equal.
c) To allow the Engineer to inspect the Works the Contractor shall give the
Engineer a minimum of 24 hours notice of carrying out the following
activities on site.
i.

ii.
iii.
iv.

Completion of formwork and reinforcement erection prior to casting

to enable the formwork and reinforcement to be inspected for
correct dimensions, shape, alignment, spacing and size of
reinforcement and cleanliness.
Delivery and placement of concrete.
Delivery to site.
Erection at site.

d) Designer and fabricator shall be an approved company specialised in

performing the work of this Section with 3 years experience in the
successful completion of projects of a similar design and size.
e) Erector shall be a company specialising in performing the work of this
Section with 3 years experience in the erection of projects of a similar
size.
f)

The general requirements applicable to the manufacture of precast

concrete units shall conform to BS EN 13369.

g) Works proof load crushing test for precast concrete manhole shaft and
chamber sections and works load tests for precast concrete manhole
slabs shall be in accordance with BS 5911.
1.6

DELIVERY, STORAGE AND PROTECTION

a) Delivery, storage and handling of products and materials shall be in
accordance with the manufacturers recommendations, Section 0100009 of the specification and the following provisions.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 8 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

i.
ii.

iii.

iv.

Delivery, storage and handling shall at all times be performed in a

manner to avoid product damage.
Transport and handle precast concrete units in position consistent
with their shape and design. Lift and support only from support
points.
Lifting and handling devices shall be capable of supporting precast
concrete units in positions anticipated during manufacture, storage,
transportation, and erection.
Precast concrete units shall be stored off the ground on level
supports and in a manner which will not result in damage or
deformation to the units or in contamination of the units. Precast
concrete units shall be protected from damage and damaged units
shall not be used in the permanent work unless permitted by the
Engineer.

PRODUCTS

2.1

GENERAL
a) For exposed architectural concrete obtain sufficient cement, aggregates
and water from a single source to complete the entire structural precast
concrete work to assure regularity of appearance and uniformity of
colour.
b) Materials for formwork, reinforcement, concrete, concrete repair
materials, concrete protection and waterproofing system and joints shall
be in accordance with the requirements of the relevant sections of
Division 3 of the specification.
c) Unless noted otherwise all precast concrete units shall be manufactured
using Grade C40/20 concrete as specified in Section 03300 of the
specification.

2.2

PRECAST CONCRETE UNITS

a) Design precast concrete units to withstand all loadings such as service,
earth, wind, traffic, thermal movement loads, restraint conditions,
durability and fire resistance from initial fabrication to the completion of
the structure, including form removal, storage, transportation, and
erection.
b) Design precast concrete units exposed to the weather to allow for
movement of components without damage, failure of joint seals, undue
stress or other detrimental effects on fixings when subjected to seasonal
and cyclic day/night temperature ranges.
c) Design system to accommodate construction tolerances, deflection of
other structural members, clearances of intended openings, jointing
details and penetrations.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 9 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

d) Design anchor bolts, inserts, plates, angles and other cast in items with
sufficient anchorage and embedment to support applicable loads.
e) Surfaces of precast concrete units in contact with sewage or sewage gas
aggressive liquids and/or atmospheres shall be lined in accordance with
the requirements of Section 03600 of the specification.
f)

Surfaces of precast concrete units in contact with ground water shall be

lined in accordance with the requirements of section 03600 of the
specification.

EXECUTION

3.1

FABRICATION
a) Maintain plant records and quality control program during production of
precast concrete units. Make records available upon request. Such
records shall include:
i.
ii.
iii.
iv.
v.
vi.

Certificates showing manufacturers name.

Precast concrete unit identification number.
Date of manufacture.
Concrete test results.
Type and duration of curing.
Date of delivery to site.

b) Provide an individual number or letter for identification purposes for each

mould. Ensure that the number or letter is either embossed on or
recessed into the mould so that each precast concrete unit cast in a
particular mould will bear the identification of that mould.
c) Formwork liners shall be used for all precast concrete units unless
otherwise approved by the Engineer.
d) The formwork shall not deviate from its desired position and elevation
during concreting.
e) Formwork joints shall not be permitted on faces exposed to view in the
finished work.
f)

Ensure reinforcing steel, anchors, inserts, plates, angles, and other cast
in items are embedded and located as indicated on the drawings and will
not be misplaced during concreting.

g) Place and vibrate concrete to ensure proper consolidation, elimination of

cold joints, and minimise entrapped air on vertical surfaces to the
approval of the Engineer.
h) Cover to the reinforcement shall be checked with a cover meter after
casting and the results reported.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 10 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

i)

Locate lifting devices to permit removal after erection.

j)

All work shall be performed to provide a homogeneous concrete having

the required strength, surface finish, durability and be free of
honeycombs, air pockets, cracks, voids, projections and other defects.

k) Ensure surface finishes of exposed precast concrete units are uniform in

colour and appearance and match accepted sample panel.
l)

Finishes to units shall be in accordance with Sections 03100 and 03300

of the specification.

m) Deviations in formed surfaces shall not exceed the tolerances outlined in

Table 3.1.1 below.
Table 3.1.1 Deviations in Formed Surfaces
Criterion

Tolerance

Length

5mm

Width

3mm

Flange thickness

2mm

Cast in item location

0.2%

Straightness

3mm over 3m

End squarness

3mm

n) Do not move or transport precast concrete units from the place of

casting until an approved curing period has elapsed and the design
strength has been attained. Curing of concrete shall be in accordance
with Section 03300 of the specification.
3.2

PRECAST CONCRETE MANHOLE UNITS

a) For precast concrete manhole units, provide markings on units in
accordance with BS EN 1917.
b) Joints between precast concrete manhole units shall be of the rebated
type. Methods of providing watertight joints shall be submitted to the
Engineer for approval. Seals and sealants shall be tested to ensure their
suitability for the environment in which they are to be placed.
c) For precast concrete manhole units fabrication tolerances shall be in
accordance with BS5911.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 11 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

3.3

SURFACE TREATMENT AND REPAIR

a) Minor cracks and spalls not affecting the structural integrity of the unit
may be patched with approved repair materials in accordance with
Section 03600 of the specification at the Engineers discretion.
b) Site manufactured repair materials shall not be allowed.
c) Cracks and honeycombs in anchorages, bearings or otherwise critical
zones shall not be acceptable.

3.4

ERECTION
a) Verify that site conditions are ready to receive work and field
measurements are as shown on the drawings.
b) Prepare temporary support equipment for the erection procedure
required to control alignment, deflection and stress levels.
c) Contact surfaces between cast-in-place and precast concrete units shall
be prepared as specified in Section 03300 of the specification.
d) Dimensional tolerances shall be checked before the precast concrete
units are lifted into position.
e) Erect precast concrete units without damage to structural integrity,
shape, or finish. Replace, or if permitted by the Engineer repair,
damaged precast concrete units.
f)

Lift precast concrete units using the design lifting hooks.

g) Maintain temporary bracing in place until final support is provided.

h) Erection tolerances for precast concrete units shall be as given in Table
3.4.1 below.

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 12 of 13

General Specifications for Civil Works

Abu Dhabi Sewerage Services Company
(ADSSC)

Table 3.4.1 Erection Tolerances

Criterion

Tolerance

Variation from plumb

6mm in any 6m run, 12mm total in any 12m

run or longer run
6mm in any 6m run, 12mm in any 12m run,
total 12mm at any location

Variation from level or elevation

Variation from position in plan

12mm max at any location

Offsets in alignment of adjacent members at

any joint

1.5mm in any 3m run, 6mm max

i)

Welding of precast concrete units shall be in accordance with the

requirements of Section 05100 of the specification. Control heat build up
during welding using appropriate measures to ensure that spalling or
heat damage of concrete, which is unacceptable, does not occur.

j)

Field cutting of holes shall be carried out with power saws or core drills
up to a maximum size of 150mm all to the Engineers approval.

k) Complete joints, gaps and connections by filling with grout, mortar,

sealant or other material as specified and as shown on the drawings to
the approval of the Engineer.

END OF SECTION

ADSSC/GSCW

Division 03

Section 03400

Precast Concrete

Rev: 02

Jan. 2011

Page 13 of 13