TS 0710 Concrete

EngineeringServices
TechnicalStandard
TS0710
Concrete
Revision:1.0
Date:21November2016
2016 SAWaterCorporation.Allrightsreserved.
ThisdocumentmaycontainconfidentialinformationofSAWaterCorporation.
Disclosureordisseminationtounauthorisedindividualsisstrictlyprohibited.
Unauthorisedprintedcopiesareuncontrolled.
TS0710Concrete
SAWaterTechnicalStandard
Copyright
ThisStandardisanintellectualpropertyoftheSouthAustralianWaterCorporation.Itis
copyrightandallrightsarereservedbySAWater.Nopartmaybereproduced,copiedor
transmittedinanyformorbyanymeanswithouttheexpresswrittenpermissionofSAWater.
TheinformationcontainedinthisStandardisstrictlyfortheprivateuseoftheintended
recipientinrelationtoworksorprojectsofSAWater.
ThisStandardhasbeenpreparedforSAWatersowninternaluseandSAWatermakesno
representationastothequality,accuracyorsuitabilityoftheinformationforanyother
purpose.
Application&InterpretationofthisDocument
ItistheresponsibilityoftheusersofthisStandardtoensurethattheapplicationof
informationisappropriateandthatanydesignsbasedonthisStandardarefitforSAWaters
purposesandcomplywithallrelevantAustralianStandards,Actsandregulations.
UsersofthisStandardacceptsoleresponsibilityforinterpretationanduseoftheinformation
containedinthisStandard.Usersshouldindependentlyverifytheaccuracy,fitnessforpurpose
andapplicationofinformationcontainedinthisStandard.
OnlythecurrentrevisionofthisStandardshouldbeusedwhichisavailablefordownloadfrom
theSAWaterwebsite.
Significant/MajorChangesIncorporatedinThisEdition
Nil.
ThisisthefirstissueofthisTechnicalStandard.
ThisTechnicalStandardssupersedesthefollowingSAwaterTechnicalStandards:
TS1a SupplyandDeliveryofLeanMix,NoFines,Grade20or25Concrete
TS1b SupplyandDeliveryofGrade32,40or50Concrete
TS3b FineandCoarseAggregatesforConcreteforWaterRetainingStructuresandin
AggressiveEnvironments(ExcludingLightweightAggregate)
TS3c FineandCoarseCalcareousAggregates(Marble)forConcreteSewerageStructures
(ExcludingLightweightAggregate)
TS68 ReinforcedConcreteConstructionforLiquidRetainingStructuresand/orAggressive
Environments
Revision1.021November2016
ForOfficialUseOnly
DocumentID:SAWSENG0710
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Uncontrolledwhenprintedordownloaded
TS0710Concrete
DocumentControls
RevisionHistory
Revision Date
Author
Comments
21November
2016
HanyHabib
1.0
Template:TechnicalStandardVersion6.00,10/05/2016
Approvers
Role
SignatureandDate
ResponsibleDisciplineLead
30/11/2016
HanyHabib
X
Signer's Name
Signed by: HA003047
ManagerEngineeringTechnicalServices
30/11/2016
MuratAksoy
X
Signer's Name
Signed by: AK003305
SeniorManagerEngineeringServices
12/12/2016
RichardGray
X
Signer's Name
Signed by: GR001964
Reviewers
Role
Name
Revision
ReviewDate
PrincipalEngineerMaterialsScience
PaulVince
1.0
22Nov2016
ForOfficialUseOnly
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TS0710Concrete
Contents
1
Introduction..............................................................................................................10
1.1
Purpose........................................................................................................................10
1.2
Glossary........................................................................................................................10
1.3
References...................................................................................................................10
1.3.1
AustralianandInternational...................................................................................10
1.3.2
SAWaterDocuments..............................................................................................14
1.4
Definitions....................................................................................................................14
2
Scope.........................................................................................................................16
DesignLife.................................................................................................................16
QualityAssurance......................................................................................................16
5
Concrete....................................................................................................................17
NormalClassConcrete.................................................................................................17
5.1
5.2
SpecialClassConcrete.................................................................................................17
5.3
LeanConcrete..............................................................................................................17
5.4
NoFinesConcrete.......................................................................................................18
5.4.1
Scope......................................................................................................................18
5.4.2
CoarseAggregate....................................................................................................18
5.4.3
Cement...................................................................................................................18
5.4.4
MixDesignRequirements.......................................................................................18
5.4.5
SupplyandDelivery................................................................................................18
5.4.6
Placement,CompactionandFinish........................................................................18
5.4.7
Curing......................................................................................................................19
5.5
OtherTypesofConcrete..............................................................................................19
6
ConstituentMaterialsofConcrete.............................................................................19
6.1
CementitiousMaterials...............................................................................................19
6.1.1
Cement...................................................................................................................19
6.1.2
FlyAsh.....................................................................................................................19
6.1.3
GroundGranulatedBlastFurnaceSlag...................................................................19
6.1.4
AmorphousSilica....................................................................................................20
6.2
Aggregates...................................................................................................................20
6.2.1
General...................................................................................................................20
6.2.2
FineAggregate........................................................................................................21
6.2.3
CoarseAggregates..................................................................................................22
6.2.4
AdditionalRequirementsforCalcareousAggregates.............................................23
6.3
MixingWater...............................................................................................................23
6.4
Admixtures...................................................................................................................24
6.5
OtherAdditives............................................................................................................25
6.6
SolubleSalts.................................................................................................................26
6.7
StorageofMaterials....................................................................................................26
6.7.1
StorageofCementitiousMaterials.........................................................................26
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6.7.2
6.7.3
StorageofAggregates.............................................................................................27
MoistureContentofAggregates............................................................................27
7
DesignofConcreteMixes...........................................................................................27
7.1
RequirementsforFreshConcrete................................................................................27
7.1.1
Consistency.............................................................................................................27
7.1.2
SlumpwithMidRangeandHighRangeWaterReducingAdmixture....................28
7.1.3
DryingShrinkage.....................................................................................................28
7.1.4
Bleed.......................................................................................................................28
7.1.5
AirContent..............................................................................................................29
7.2
RequirementsforHardenedConcrete........................................................................29
7.2.1
DesignRequirements..............................................................................................29
7.2.2
TypicalConcreteCharacteristicsandDurabilityRequirementsforConcretebased
onExposureClassifications.....................................................................................29
7.2.3
CoverToleranceRequirements..............................................................................35
7.2.4
MaximumCrackWidthRequirement.....................................................................35
7.2.5
RequirementsforConcreteandConcreteStructuresinContactwithPotable
Water......................................................................................................................36
8
DesignandAcceptanceofConcreteMix....................................................................36
8.1
General........................................................................................................................36
8.2
ProposedMixDesign...................................................................................................36
8.3
TrialMix.......................................................................................................................38
8.3.1
General...................................................................................................................38
8.3.2
TrialMixTestRequirements...................................................................................38
8.3.3
TrialMixReport......................................................................................................39
8.4
ApprovalofConcreteMixDesign................................................................................40
8.4.1
VariationstoApprovedConcreteMixDesign........................................................40
8.4.2
TrialPours...............................................................................................................41
8.5
ConcreteMaximumTemperature...............................................................................41
8.6
ConcreteMaximumTemperatureDifferentials..........................................................42
9
SupplyandDeliveryofConcrete................................................................................42
9.1
General........................................................................................................................42
9.2
ConcreteDelivery........................................................................................................42
9.3
OnsiteTransportation................................................................................................43
9.3.1
ConcretePump.......................................................................................................43
9.3.2
ConcreteBucketorKibble......................................................................................43
9.3.3
Chute.......................................................................................................................44
9.3.4
BeltConveyor.........................................................................................................44
9.4
PeriodforCompletionofDischarge,PlacementandCompaction..............................44
9.5
RetemperingwithadditionofWaterorAdmixtureafterMixing................................45
10 ConcretePlacementandCompaction........................................................................45
10.1
ConcretePlacing..........................................................................................................45
10.1.1
General...................................................................................................................45
10.1.2
Preparation.............................................................................................................45
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10.1.3
Placement...............................................................................................................46
10.1.4
AdverseWeatherConditions..................................................................................47
10.1.5
UnscheduledInterruptionstoConcretePlacing....................................................49
10.1.6
DimensionsofConcretePlacing.............................................................................49
10.1.7
ConcretePlacingSequence....................................................................................49
10.1.8
UnderwaterConcretePlacement...........................................................................50
10.1.9
UseofRockSpalls...................................................................................................50
10.1.10
TraceabilityofConcrete..........................................................................................50
CompactionofConcrete..............................................................................................50
10.2
10.3
Screeding.....................................................................................................................51
11 FinishingofUnformedConcreteSurfaces...................................................................51
11.1
General........................................................................................................................51
11.2
ClassU1........................................................................................................................52
11.3
ClassU2........................................................................................................................52
11.4
ClassU3........................................................................................................................52
11.5
ClassU4........................................................................................................................52
11.6
ClassU5........................................................................................................................53
11.7
ReferenceSampleSlabs...............................................................................................53
12
FormedConcreteSurfaces.........................................................................................53
13 ConcreteCuringandProtection.................................................................................53
13.1
General........................................................................................................................53
13.2
CuringafterPlacement................................................................................................53
13.3
CuringafterHardened.................................................................................................54
13.4
LiquidMembraneFormingCuringCompound............................................................54
13.5
RetentionofFormwork...............................................................................................55
13.6
AcceleratedHeatCuring..............................................................................................55
13.7
CuringDuration............................................................................................................56
14 Joints.........................................................................................................................56
14.1
General........................................................................................................................56
14.2
ConstructionJoints......................................................................................................56
14.3
ControlJoints...............................................................................................................57
14.4
ConcreteJointsforWaterRetainingandExcludingStructures...................................57
14.4.1
GeneralRequirements............................................................................................57
14.4.2
WaterstopProvenDurabilityandRequirements...................................................57
15 ConcreteTemperatureandStrainMonitoring............................................................58
15.1
ThermalBlock..............................................................................................................58
15.2
SiteMonitoring............................................................................................................58
16 PrecastConcreteUnits...............................................................................................59
16.1
General........................................................................................................................59
16.2
TraceabilityofPrecastConcreteUnits........................................................................60
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17 SprayedConcrete.......................................................................................................60
17.1
General........................................................................................................................60
17.2
CompetencyofPersonnelInvolvedinSprayedConcrete...........................................61
17.3
PrequalificationofSprayingProcedure.......................................................................61
17.3.1
General...................................................................................................................61
17.3.2
PreparationofTestPanels......................................................................................61
17.3.3
SamplingandTestingofPanels..............................................................................62
17.3.4
Prequalification.......................................................................................................62
17.4
ApplicationofSprayedConcrete.................................................................................62
17.4.1
Equipment..............................................................................................................62
17.4.2
SurfacePreparation................................................................................................63
17.4.3
Application..............................................................................................................63
17.4.4
Finishing..................................................................................................................64
17.4.5
TolerancesonSurfaceofSprayedConcrete...........................................................64
17.4.6
Joints.......................................................................................................................65
17.4.7
InspectionandSoundnessofFinishedSprayedConcrete......................................65
17.4.8
RepairofDefectiveAreas.......................................................................................65
18
CrackInspectionandAssessment..............................................................................65
19
SiteConcreteCoverMeasurements...........................................................................66
20
WallConcreteCompactionforLiquidRetainingStructures........................................66
21 ConcreteRepair.........................................................................................................67
21.1
General........................................................................................................................67
21.2
ConcreteRepairMaterialsandProcedures.................................................................67
21.3
RepairedConcreteTolerances.....................................................................................68
21.4
RepairedConcreteQualityControl..............................................................................68
22 ConcreteQualityControl...........................................................................................69
22.1
General........................................................................................................................69
22.2
ConcreteQualityCriteria.............................................................................................69
22.3
BatchCertificates.........................................................................................................69
22.4
RequirementsforTestingFacilitiesandPersonnel.....................................................70
22.5
TestingFrequency........................................................................................................70
22.6
SamplingandTesting...................................................................................................70
22.7
Noncompliances.........................................................................................................70
22.8
RejectionofConcrete..................................................................................................71
23 SuperWorkableConcrete..........................................................................................71
23.1
General........................................................................................................................71
23.2
RequirementsforFreshSuperWorkableConcrete.....................................................71
23.3
SamplingandTesting...................................................................................................72
23.4
SelfCompactingConcrete(SCC)..................................................................................72
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TS0710Concrete
24
UltraHighPerformanceConcrete..............................................................................72
25
AlkaliActivatedConcrete...........................................................................................72
26 FormworkandFalsework...........................................................................................73
26.1
General........................................................................................................................73
26.2
FormworkConstruction...............................................................................................73
26.3
FormTies.....................................................................................................................74
26.4
RemovalofFormwork.................................................................................................74
26.5
ProprietaryFormworkandFalseworkSystem............................................................75
27 InsertandSupport.....................................................................................................75
27.1
EmbedmentofInserts.................................................................................................75
27.2
Supports.......................................................................................................................76
28
BarChairsandSpacers...............................................................................................76
29 Reinforcement...........................................................................................................76
29.1
SteelReinforcement....................................................................................................76
29.1.1
Materials.................................................................................................................76
29.1.2
Schedules................................................................................................................76
29.1.3
Fixing.......................................................................................................................77
29.1.4
Bending...................................................................................................................77
29.1.5
Splicing....................................................................................................................77
29.1.6
Welding...................................................................................................................77
29.1.7
Surfaceconditionofreinforcement.......................................................................78
29.1.8
ProtectionofSteelReinforcement.........................................................................78
29.2
StainlessSteelReinforcement.....................................................................................79
29.2.1
Materials.................................................................................................................79
29.2.2
Schedules................................................................................................................79
29.2.3
Fixing.......................................................................................................................79
29.2.4
Bending...................................................................................................................79
29.2.5
Splicing....................................................................................................................80
29.2.6
Welding...................................................................................................................80
29.2.7
29.3
PrestressingTendons..................................................................................................80
29.3.1
General...................................................................................................................80
29.3.2
PrestressingAnchorages.......................................................................................81
29.3.3
PrestressingSheathing..........................................................................................81
29.3.4
InspectionofConcreteinPrestressingElements..................................................81
29.4
FibreReinforcedPolymerReinforcement...................................................................81
29.4.1
Materials.................................................................................................................81
29.4.2
Schedules................................................................................................................81
Fixing.......................................................................................................................82
29.4.3
29.4.4
HandlingandStorage.............................................................................................82
29.4.5
Bending...................................................................................................................82
29.4.6
Splicing....................................................................................................................82
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29.4.7
30
DissimilarMetalsEmbeddedinConcrete...................................................................83
31 FibreReinforcedConcrete..........................................................................................83
31.1
SteelFibreReinforcedConcrete(SFRC).......................................................................83
31.1.1
General...................................................................................................................83
31.1.2
SupplyandDelivery................................................................................................84
31.2
SyntheticFibreReinforcedConcrete...........................................................................85
32
ContractorWorksMethodStatementforConcreteincludingEarlyAgeThermalCrack
Assessment................................................................................................................86
Listoffigures
Notableoffiguresentriesfound.
Listoftables
Table1MinimumFrequencyofTestingforFineAggregates...................................................22
Table2MinimumFrequencyofTestingforCoarseAggregates...............................................23
Table3MaximumAcidSolubleChlorideIonContentinConcrete.........................................26
Table4MaximumShrinkageStrainofConcreteSpecimens....................................................28
Table5TypicalConcreteCharacteristics..................................................................................32
Table6ToleranceonLocationsofReinforcement...................................................................35
Table7MaximumAcceptableCrackWidth.............................................................................35
Table8AllowableTimefromBatchingtoPlacing.....................................................................44
Table9MinimumAcceptableCriteriaforFreshSuperWorkableConcrete............................71
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TS0710Concrete
Introduction
SAWaterisresponsibleforoperationandmaintenanceofanextensiveamountofengineering
infrastructure.
Thisstandardhasbeendevelopedtoassistinthedesign,maintenance,construction,and
managementofthisinfrastructure.
1.1 Purpose
Thepurposeofthisstandardistodetailminimumrequirementstoensurethatassetscovered
bythescopeofthisstandardareconstructedandmaintainedtoconsistentstandardsand
attaintherequiredassetlife.
TheaimofthisTechnicalStandardistoachieveconcreteoftherequiredstrength,durability
andsurfacefinish.Itdescribesthematerials,supply,placing,compacting,finishing,curingof
concrete,includingmassconcrete,reinforcedconcrete,prestressedconcrete,leanmixandno
finesconcrete.
1.2 Glossary
Thefollowingglossaryitemsareusedinthisdocument:
Term
Description
SAWater
SouthAustralianWaterCorporation
TG
SAWaterTechnicalGuideline
TS
1.3 References
1.3.1
AustralianandInternational
ThefollowingtableidentifiesAustralianandInternationalstandardsandothersimilar
documentsreferencedinthisdocument:
Number
Title
AS1012.1
MethodsoftestingconcreteSamplingofconcrete
AS1012.2
MethodsoftestingconcretePreparingconcretemixesinthelaboratory
AS1012.3.1
MethodsoftestingconcreteDeterminationofpropertiesrelatedtotheconsistencyof
concreteSlumptest
AS1012.3.5
MethodsoftestingconcreteDeterminationofpropertiesrelatedtotheconsistencyof
concreteSlumpflow,T500andJringtest
AS1012.4.1
MethodsoftestingconcreteDeterminationofaircontentoffreshlymixedconcrete
Measuringreductioninconcretevolumewithincreasedairpressure
AS1012.4.2
MethodsoftestingconcreteDeterminationofaircontentoffreshlymixedconcrete
Measuringreductioninairpressureinchamberaboveconcrete
AS1012.6
MethodsoftestingconcreteDeterminationofbleedingofconcrete
AS1012.8.1
MethodsoftestingconcreteMethodformakingandcuringconcreteCompression
andindirecttensiletestspecimens
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TS0710Concrete
Number
Title
AS1012.8.4
MethodsoftestingconcreteMethodformakingandcuringconcreteDrying
shrinkagespecimenspreparedinthefieldorinthelaboratory
AS1012.9
MethodsoftestingconcreteCompressivestrengthtestsConcrete,mortarandgrout
specimens
AS1012.11
MethodsoftestingconcreteDeterminationofthemodulusofrupture
AS1012.13
MethodsoftestingconcreteDeterminationofthedryingshrinkageofconcretefor
samplespreparedinthefieldorinthelaboratory
AS1012.14
MethodsoftestingconcreteMethodforsecuringandtestingcoresfromhardened
concreteforcompressivestrength
AS1012.20.1
MethodsoftestingconcreteDeterminationofchlorideandsulfateinhardened
concreteandconcreteaggregates
AS1012.21
MethodsoftestingconcreteDeterminationofwaterabsorptionandapparentvolume
ofpermeablevoidsinhardenedconcrete
AS1141.5
MethodsforsamplingandtestingaggregatesParticledensityandwaterabsorptionof
fineaggregate
AS1141.6.1
MethodsforsamplingandtestingaggregatesParticledensityandwaterabsorptionof
coarseaggregateWeighinginwatermethod
AS1141.6.2
MethodsforsamplingandtestingofaggregatesParticledensityandwaterabsorption
ofcoarseaggregatePycnometermethod
AS1141.11.1
MethodsforsamplingandtestingaggregatesParticlesizedistributionSieving
method
AS1141.13
MethodsforsamplingandtestingaggregatesMaterialfinerthan2micrometre
AS1141.14
MethodsforsamplingandtestingaggregatesParticleshape,byproportionalcalliper
AS1141.15
MethodsforsamplingandtestingaggregatesFlakinessindex
AS1141.22
MethodsforsamplingandtestingaggregatesWet/drystrengthvariation
AS1141.23
MethodsforsamplingandtestingaggregatesLosAngelesvalue
AS1141.24
MethodsforsamplingandtestingaggregatesAggregatesoundnessEvaluationby
exposuretosodiumsulphatesolution
AS1141.25.3
MethodsforsamplingandtestingaggregatesDegradationfactorFineaggregate
AS1141.31
MethodsforsamplingandtestingaggregatesLightparticles
AS1141.34
MethodsforsamplingandtestingaggregatesOrganicimpuritiesotherthansugar
AS1141.35
MethodsforsamplingandtestingaggregatesSugar
AS1141.25.3
MethodsforsamplingandtestingaggregatesDegradationfactorFineaggregate
AS1141.60.1
MethodsforsamplingandtestingaggregatesPotentialalkalisilicareactivity
Acceleratedmortarbarmethod
AS1141.60.2
MethodsforsamplingandtestingaggregatesPotentialalkalisilicareactivity
Concreteprismmethod
AS1141.65
MethodsforsamplingandtestingaggregatesAlkaliaggregatereactivityQualitative
petrologicalscreeningforpotentialalkalisilicareaction
AS1141.66
MethodsforsamplingandtestingaggregatesMethyleneblueadsorptionvalueoffine
aggregateandmineralfillers
AS1289.2.1.1
MethodsoftestingsoilsforengineeringpurposesSoilmoisturecontenttests
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TS0710Concrete
Number
Title
Determinationofthemoisturecontentofasoil Ovendryingmethod(standard
method)
AS1289.2.1.2
DeterminationofthemoisturecontentofasoilSandbathmethod(subsidiarymethod)
AS1289.2.1.4
DeterminationofthemoisturecontentofasoilMicrowaveovendryingmethod
(subsidiarymethod)
AS1289.2.1.5
DeterminationofthemoisturecontentofasoilInfraredlightsmethod(subsidiary
method)
AS1289.2.1.6
DeterminationofthemoisturecontentofasoilHotplatedryingmethod
AS1289.5.1.1
MethodsoftestingsoilsforengineeringpurposesSoilcompactionanddensitytests
Determinationofthedrydensity/moisturecontentrelationofasoilusingstandard
compactiveeffort
AS/NZS1314
Prestressinganchorages
AS1379
Specificationandsupplyofconcrete
AS1418.15
Cranes(includinghoistsandwinches)Concreteplacingequipment
AS1478.1
Chemicaladmixturesforconcrete,mortarandgroutAdmixturesforconcrete
AS1478.2
Chemicaladmixturesforconcrete,mortarandgroutMethodsofsamplingandtesting
admixturesforconcrete,mortarandgrout
AS/NZS1554.3
StructuralsteelweldingWeldingofreinforcingsteel
AS/NZS1554.6
StructuralsteelweldingWeldingstainlesssteelsforstructuralpurposes
AS1597.1
PrecastreinforcedconcreteboxculvertsSmallculverts(notexceeding1200mmspan
and1200mmheight)
AS1597.2
PrecastreinforcedconcreteboxculvertsLargeculverts(exceeding1200mmspanor
1200mmheightanduptoandincluding4200mmspanand4200mmheight)
AS2159
PilingDesignandinstallation
AS/NZS2425
BarchairsinreinforcedconcreteProductrequirementsandtestmethods
AS2758.1
AggregatesandrockforengineeringpurposesConcreteaggregates
AS/NZS3582.1
SupplementarycementitiousmaterialsFlyash
AS3582.2
SupplementarycementitiousmaterialsSlagGroundgranulatedblastfurnace
AS/NZS3582.3
SupplementarycementitiousmaterialsAmorphoussilica
AS3600
Concretestructures
AS3610
Formworkforconcrete
AS3610.1
FormworkforconcreteDocumentationandsurfacefinish
AS3735
Concretestructuresretainingliquids
AS3799
Liquidmembraneformingcuringcompoundsforconcrete
AS3850.1
PrefabricatedconcreteelementsGeneralrequirements
AS3850.2
PrefabricatedconcreteelementsBuildingconstruction
AS3972
Generalpurposeandblendedcements
AS/NZS4020
Testingofproductsforuseincontactwithdrinkingwater
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TS0710Concrete
Number
Title
AS/NZS4058
Precastconcretepipes(pressureandnonpressure)
AS4198
Precastconcreteaccesschambersforsewerageapplications
AS/NZS4680
Hotdipgalvanized(zinc)coatingsonfabricatedferrousarticles
AS/NZS4672.1
SteelprestressingmaterialsGeneralrequirements
AS/NZS4672.2
SteelprestressingmaterialsTestingrequirements
AS4997
Guidelinesforthedesignofmaritimestructures
AS/NZS4671
Steelreinforcingmaterials
AS/NZS4676
Structuraldesignrequirementsforutilityservicespoles
AS5100.5
BridgedesignConcrete
AS/NZISO9001
Qualitymanagementsystemsrequirements
BS1881204
Testingconcrete.Recommendationsontheuseofelectromagneticcovermeters
BS6744
Stainlesssteelbarsforthereinforcementofanduseinconcrete.Requirementsandtest
methods
BS79732
SpacersandchairsforsteelreinforcementandtheirspecificationPart2:Fixingand
applicationofspacersandchairsandtyingofreinforcement.
BS8666
Scheduling,dimensioning,bendingandcuttingofsteelreinforcementforconcrete.
Specification.
BSEN14721
Testmethodformetallicfibreconcrete.Measuringthefibrecontentinfreshand
hardenedconcrete
BSEN148891
FibresforconcretePart1:SteelfibresDefinitions,specificationsandconformity
BSEN148892
FibresforconcretePart2:PolymerfibresDefinitions,specificationsandconformity
EN2061
ConcretePart1:Specification,performance,productionandconformity
ISO17025
Generalrequirementsforthecompetenceoftestingandcalibrationlaboratories
ISO229651
ConcretePart1:Methodsofspecifyingandguidanceforthespecifier
ACI117
GuideForToleranceCompatibilityInConcreteConstruction
ACI224R01
ControlofCrackinginConcreteStructures
ACI30510
GuidetoHotWeatherConcreting
ACI440.6M
SpecificationForCarbonAndGlassFibrereinforcedPolymerBarMaterialsForConcrete
Reinforcement
ASTMA380
StandardPracticeforCleaning,Descaling,andPassivationofStainlessSteelParts,
Equipment,andSystems
ASTMA955M
StandardSpecificationforDeformedandPlainStainlessSteelBarsforConcrete
Reinforcement
ASTMC1074
PracticeforEstimatingConcreteStrengthbytheMaturityMethod
ASTMC1018
StandardTestMethodforFlexuralToughnessandFirstCrackStrengthofFibre
ReinforcedConcrete(UsingBeamWithThirdPointLoading)(Thisstandardhasbeen
withdrawnbutthemethodcanstillbeused)
ASTMC1603
TestMethodforMeasurementofSolidsinWater
ASTMC1611
StandardTestMethodforSlumpFlowofSelfConsolidatingConcrete
ASTMC1621
StandardTestMethodforPassingAbilityofSelfConsolidatingConcretebyJRing
ASTMC1293
StandardTestMethodforDeterminationofLengthChangeofConcreteDuetoAlkali
ForOfficialUseOnly
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TS0710Concrete
Number
Title
SilicaReaction
CIAZ5
ShotcretinginAustralia
CIAZ7/01
DurabilityPlanning
CIAZ7/04
GoodPracticeThroughDesign,ConcreteSupplyandConstruction
CIAZ7/07
PerformanceTeststoAssessConcreteDurability
CIAZ9
CIACuringofConcrete
CIAZ12
CIAPumpedConcrete
CIAZ40
SuperworkableConcrete
CIRIAC660
EarlyageThermalCrackControlinConcrete
AWWAB100
GranularFilterMaterial(byAmericanWaterWorksAssociation)
FHWARD02099 GuideforCuringofPortlandCementConcretePavements:FinalReport
SAHB79
AlkaliAggregateReactionGuidelinesonMinimisingtheRiskofDamagetoConcrete
StructuresinAustralia
HB84
GuidetoConcreteRepairandProtection
NTBUILD443
Concrete,hardened:Acceleratedchloridepenetration
NTBUILD492
Concrete,mortarandcementbasedrepairmaterials:Chloridemigrationcoefficient
fromnonsteadystatemigrationexperiments
NP:PCH
PrecastConcreteHandbookbytheNationalPrecastConcreteAssociationAustralia
(NPCAA)inconjunctionwiththeConcreteInstituteofAustralia
ICRI310.2R
SelectingandSpecifyingConcreteSurfacePreparationforSealers,Coatings,Polymer
Overlays,andConcreteRepair
NationalCodeofPracticeforPrecastTiltUpandConcreteElements
1.3.2
SAWaterDocuments
ThefollowingtableidentifiestheSAWaterstandardsandothersimilardocumentsreferenced
inthisdocument:
Number
Title
TS0002
PVCWaterstop
1.4 Definitions
Thefollowingdefinitionsareapplicabletothisdocument:
Term
Description
SAWatersRepresentative
TheSAWaterrepresentativewithdelegatedauthorityunderaContractor
engagement,including(asapplicable):
SuperintendentsRepresentative(e.g.AS4300&AS2124etc.)
SAWaterProjectManager
SAWaternominatedcontactperson
ResponsibleDisciplineLead
ForOfficialUseOnly
TheengineeringdisciplineexpertresponsibleforTS0710definedonpage3
Page14of88
TS0710Concrete
Term
Description
(viaSAWatersRepresentative)
ForOfficialUseOnly
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TS0710Concrete
Scope
ThisTechnicalStandardappliestotheconstructionofconcretestructures;itappliestobothin
situworksandconstructionusingprefabricatedconcreteelements.ThisTechnicalStandard
doesnotapplyto:
Temporaryconcretestructures.
Alltypesoflightweightconcrete.
Specialtechnologies/innovativedesigns.
Grout.
Mortar.
Recycledconcrete.
Expansiveconcrete.
Polymerconcrete.
ThisTechnicalStandarddoesnotcoverhealthandsafetyaspectsofconcretemanufacturing,
supplyandconstructionorthirdpartysafetyrequirements.
ThisTechnicalStandardshallbereadinconjunctionwithAustralianStandardsandother
TechnicalStandardsasappropriate.
DesignLife
ThedesignlifefortheWorksshallbeinstructedbySAWatersRepresentativeandshall
include:
1.
50years::Buildinganddepots,shedsandwarehouses,externaltankaprons,
hardstands,slabsonground,ramps,switchboardplinthsandtransformers
bundings,accessstructuresandworkingplatforms,stormwater
channelsetc.
2.
100years:Water/wastewatertreatmentplantsandpumpingstations,storagetanks,
valvechambers,Maintenanceholes,pipechairs,thrustandanchorblocks,
bridgesandjettystructuresetc.
3.
Anotherperiod:Asstipulatedintheprojectspecification.
QualityAssurance
ThefollowingrequirementsareinadditiontothosecontainedintheContract.
TheContractorshallplan,establishandmaintainaqualitysystemfortheprojectwhich
conformstothisStandardandcomplies,asaminimum,withalltherelevantsystemelements
ofAS/NZSISO9001andincludesmaterialscertification,methodstatements,qualityrecords
includinginspectionandtestplans(ITPs),holdpoints,witnesspointsandworkinstructions.
QualitymanagementsystemsandqualityplansbytheContractorincludingallSubcontractors
shallbeusedasanaidtoachievingconformancewiththisStandard,buttheyshallnotrelieve
theContractoroftheresponsibilitytocomplywiththeContractrequirements.
AcopyofthequalityplanshallbesubmittedtoSAWatersRepresentativeforapprovalprior
tocommencementofworks.
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TS0710Concrete
TheContractorshallprovideSAWatersRepresentativeatalltimeswithaccesstothe
Contractor'squalityproceduresandrecordstoenablemonitoringandqualityauditing.This
alsoincludesthetakingofrandomsamplesforprooftestingortocarryoutortoarrangefor
destructiveornondestructivetesting.
AuditingandprooftestingbySAWatersRepresentativeshallinnowayrelievetheContractor
ofanyoftheobligationsunderthisstandard.
Concrete
Allconcreteshallconformtotheapprovednominatedconcretemixes.
Allconcreteshallbemanufactured,suppliedanddeliveredinaccordancewiththe
requirementsofAS1379andtheadditionalrequirementsofthisTechnicalStandard.
ConcreteisdesignatedasnormalclassorspecialclassasdescribedinClauses5.1and5.2
below.
5.1 NormalClassConcrete
NormalClassconcretecanbespecifiedfornoncriticalelementsinnonaggressiveexposure
conditions.SpecifiedconcreterequirementsarelimitedinAS1379andkeyitemsare:
1.
Strengthgradeof20,25,32,40,50MPa.
2.
Slumpof20to120,nominatedin10mmintervals.
3.
Maximumaggregatesizeof10,14,20mm.
4.
Aircontenttomaximum5%.
NormalClassconcreterequiresarangeofconcretepropertiestobeachievedinAS1379,
includingdryingshrinkageupto1,000microstrain(56dayvaluetoAS1012.13).
GuidanceonNormalClassconcreteisgiveninCIAZ7/04.
5.2 SpecialClassConcrete
Unlessotherwisespecifiedandapproved,allconcretesuppliedinaccordancewiththis
StandardshallbeSpecialClassconcreteasdefinedinAS1379.
ThisStandarddescribestheadditionalpropertiestobespecifiedandcriteriatobemetfor
SpecialClassconcretes.
5.3 LeanConcrete
Unlessspecifiedotherwiseintheprojectspecificationordesigndrawings,leanconcreteshall
conformtothisStandard.
Theleanconcreteshallhaveaminimumstrengthof10MPa.
Theminimumcementitiousmaterialcontentshallbe220kg/m,themaximumwaterto
cementitiousmaterialratioshallnotexceed0.90andthemaximumsizeofaggregateshallbe
20mm.
Theslumpoftheleanconcreteshallbe100mmincludinguseofanytypeofwaterreducing
admixturesthatshallhavethepriorapprovalofSAWatersRepresentative.
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TS0710Concrete
5.4 NoFinesConcrete
5.4.1
Scope
ThisClausedefinestherequirementsforthesupplyofallmaterialsandconstructionofno
finesconcreteinareasshownontheDrawings.
Nofinesconcreteshallconsistofcoarseaggregate,uniformlymixedwithPortlandcement,
andwater.
5.4.2
CoarseAggregate
Coarseaggregateshallconsistofunweathered,dense,sound,clean,hard,strong,durable
piecesofcrushedrockfreefromdeleteriouscoatingsanddustandshallcomplywithallthe
requirementsofAS2758.1.
Theaggregateshallbeanominal20mmsinglesizedaggregate.
TheflakinessindexoftheaggregatetestedinaccordancewithAS1141.15shallnot
exceed35%.
5.4.3
Cement
CementshallbePortlandCementTypeGPcomplyingwithAS3972andshallbeinaccordance
withClause6.1.1fortherequirementsthatapplyforTypeGP.
5.4.4
MixDesignRequirements
Thenofinesconcretemixdesignshallcomplywiththefollowingrequirements:
1.
Minimumcementcontent210kg/m.
2.
Maximumwater/binderratioof0.5.
Theproposedone(1)mnofinesconcretemixdesignandallcertificatesoftest(fromaNATA
accreditedauthority)toconfirmcompliancewiththeStandardrequirementsshallbe
submittedbytheContractortoSAWatersRepresentativeforreviewandapprovalatleast10
workingdayspriortouseintheWorks.
ThenofinesconcreteshallnotbeusedintheWorksuntilthemixdesignisapprovedbySA
WatersRepresentative.
5.4.5
SupplyandDelivery
Nofinesconcreteshallbemanufacturedanddeliveredinaccordancewiththerequirementsof
AS1379.
5.4.6
Placement,CompactionandFinish
ThenofinesconcreteshallnotbelessthanthedimensionsshownontheDrawings.
Theareainwhichnofinesconcreteisproposedtobeplacedshallbeinspectedandchecked
immediatelypriortocommencementofplacing.Thenofinesconcreteshallbeplacedinsuch
mannerastorequireaminimumofrehandlingandshallbesodistributedwhencompacted
andfinishedasrequiredbytheDrawings.
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TS0710Concrete
Nofinesconcreteshallberoddedsufficientlyonlytoensuretheformiscompletelyfilled.It
shallbescreededtotherequiredsurfacelevelwithouttampingorvibrating.
5.4.7
Curing
Nofinesconcreteshallbecuredforatleastfourdaysbycoveringimmediatelyafterplacing
andfinishingwithpolythenesheetingorsimilarmaterialapprovedbySAWaters
Representative.Theuseofwetsandoranyothermaterialwhichcanenterthevoidsorcuring
membranethatcannotcoverallthevoidedsurfacesshallnotbeusedforcuringpurposes.
5.5 OtherTypesofConcrete
RefertoClauses7,8,16,17,23,24,25and31.
ConstituentMaterialsofConcrete
6.1 CementitiousMaterials
CementitiousmaterialsorbinderhavethesamemeaninginthisStandard.
6.1.1
Cement
ThecementshallbeGeneralPurposecement(TypeGP),ShrinkageLimitedcement(TypeSL)or
Blendedcement(TypeGB),inaccordancewithAS3972andthisStandard.TheContractorshall
providemanufacturerstestcertificatesshowingallcementhasbeensampledtestedand
conformsinallrespectswithAS3972.Cementmorethanthreemonthsoldshallberetested
forconformance.Cementshowingevidenceofdeteriorationorhardeningshallnotbeused.
Cementshallbefromonemanufacturerandofonebrand,typeandgrindunlessapproved
otherwisebySAWatersRepresentative.Anyvariationtothemanufacturer,brand,typeand
grindconstitutesachangeinmaterialandsubmissionofanewtrialmixdesignisrequiredas
perClause8.3ofthisStandard.
BlendedcementTypeGBshallconsistofaspecifiedminimumquantityofPortlandcementin
combinationwithGroundGranulatedBlastFurnaceSlag,FlyAshand/orAmorphousSilicaand
asspecifiedinthisStandard.Blendingofcementshallbeateitherthecementmanufacturers
facilitiesorattheconcretebatchingplant.
Highearlystrengthcement(TypeHE)canbeusedonlywiththewrittenapprovalofSAWaters
RepresentativeandissubjecttomeetingallotherrequirementsofthisStandard.
6.1.2
FlyAsh
FlyashshallconformtoAS/NZS3582.1andthisStandard.
TheuseofGrade2flyashissubjecttomeetingallotherrequirementsofthisStandard.
Flyashshallbefromasinglesourceofpowerstationandgrade.Variationstothesourceofthe
flyashsupplyanditsgradeintheProjectshallrequiresubmissionofanewtrialmixdesignas
perClause8.3ofthisStandard.
6.1.3
GroundGranulatedBlastFurnaceSlag
GroundgranulatedblastfurnaceslagshallconformtoAS3582.2andthisStandard.
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TS0710Concrete
NOTE:HereafterinthisStandard,theapprovedgroundgranulatedblastfurnaceslagis
referredtoasslag.
Slagshallbefromasinglesource.VariationstothesourceoftheslagsupplyintheProject
shallrequiresubmissionofanewtrialmixdesignasperClause8.3ofthisStandard.
6.1.4
AmorphousSilica
AmorphoussilicashallconformtoAS/NZS3582.3andthisStandard.
Amorphoussilicashallbefromasinglesource.Variationstothesourceoftheamorphoussilica
supplyintheProjectshallrequiresubmissionofanewtrialmixdesignasperClause8.3ofthis
Standard.
6.2 Aggregates
6.2.1
General
AllaggregateshallcomplywithalloftherequirementsofAS2758.1andthisStandard.
Aggregatesshallconsistofhard,dense,durable,uncoatedrockparticlesandshallbefreefrom
organicmatterandinjuriousamountsofdust,claylumps,softorflakyparticles,shale,alkali,
loamorotherdeleterioussubstances.
Calcrete,scoria,nonquarryrock,Adelaidequartzite,volcanicbreccia,mudstone,sandstone,
shale,highlyweatheredoralteredrocks,argillaceousrocks,arenaceousrocks,lightweight
aggregates,aggregatecontaininganyphyllite,andanymaterialwithpotentialtocause
deleteriousalkalisilicate(ASR)oralkalicarbonate(ACR)reactionsshallnotbeusedas
aggregateorasasourcerockformanufacturedfineaggregate.
TheContractorshallnominatethesource,typeandgradingofthefineandcoarseaggregates
theyintendtouse.Variationstothesourceoftheaggregatessupplyandtypeand/orthe
gradingoftheaggregatesdeviatedmorethanthemaximumpermissibledeviationspecifiedin
AS2758.1constituteachangeinmaterialandsubmissionofanewtrialmixdesignisrequired
asperClause8.3ofthisStandard.
Theaggregatesshallconsistsubstantiallyofparticlesofsatisfactoryshape,definedashavinga
maximumdimensionnotgreaterthanthreetimestheminimumdimension.
Petrographictestingofaggregatesshallbeundertakentoprovideinformationonalkali
aggregatereactivity(AAR),ASRorACRrisk,byAS1141.65orotherSAWaterRepresentative
approvedtestmethod.
Fineandcoarseaggregatesshallbeseparatelytestedforpotentialalkaliaggregatereactivity
(AAR)usingtheAcceleratedMortarBarTest,AS1141.60.1orsimilarapprovedmethod.An
alternativetestmethodistheAcceleratedConcretePrismTest,AS1141.60.2orsimilar
approvedmethodsuchasASTMC1293.Aggregatesforuseinconcreteshallbeclassifiedas
nonreactivewhentestedusingthesamecementtypeasnominatedfortheWorks.
RecentlycompletedlaboratorytestdatamaybeacceptedatthediscretionoftheSAWater
Representative.
TheriskforAARinconcreteisoutlinedinSAHB79andguidanceisgivenonuseofflyash,slag
andsilicafumeasamitigationmeasureforaggregatesthatwouldbereactivewhenusingonly
Portlandcement.Useofflyash,slagandsilicafumeinthismannerissubjecttotheapproval
ofSAWaterRepresentative.ThisapproachisinaccordancewithSAHB79.
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TS0710Concrete
6.2.2
FineAggregate
ThesizegradingoffineaggregatewhentestedaccordingtoAS1141.11.1,shallcomplywith
thelimitsspecifiedinTableB2ofAS2758.1.
Whenmorethanonetypeoffineaggregateisproposedforuseinthemix,theindividual
aggregategradingshallconformtothelimitsspecifiedinTableB2ofAS2758.1.
WhereanominatedgradingoutsidethespecifiedlimitsinTableB2ofAS2758.1isproposed,
additionalinformationshallbeprovidedtoSAWaterRepresentativedemonstratingthatthe
concreteproducedshallmeetallotherrequirementsofthisStandard,togetherwithadditional
evidenceofacceptableperformanceforsegregation,bleeding,plasticshrinkageandfinishing
properties.
Themaximumamountofwaterabsorptionforfineaggregateshallnotexceed2.5%when
testedaccordingtoAS1141.5.
Manufacturedfineaggregatefromasourcethatcomplieswithalloftherequirementsofthis
Standardwillbepermitted,providedthatthefollowingrequirementsineitheritems(a)and
(b),oritems(b)and(c)aremet.
a.
TheexposureclassificationoftheconcreteinaccordancewithAS3600isB1or
less;
b.
Therequireddesignlifeoftheconcreteisnotexceeding50years;
c.
Theconcreteisusedasasacrificiallayerwherethefaceoftheconcretestructure
isexposedtoaggressivesewerenvironment.
Otherwise,amaximumof25%ofmanufacturedfineaggregatefromasourcethatcomplies
withalloftherequirementsofthisStandardwillbepermitted.Considerationmayalsobe
giventoapprovetheuseofuptoamaximumof50%ofmanufacturedfineaggregatebySA
WaterRepresentativeifobjectivedocumentedevidenceisprovidedthatconcretemadewith
suchhigheramountofmanufacturedfineaggregatecomplieswithallotherrequirementsof
thisStandardbothinthefreshandhardenedstates,includingevidenceofacceptable
performanceregardingtendencyforsegregation,bleeding,plasticshrinkage,satisfactory
compaction,finishingandabrasionresistanceproperties.
Manufacturedfineaggregateshallbecrushedfromrockfromwhichcoarseaggregateis
produced,conformingtoClause6.2.3.Productionprocessesshallensurethatthe
manufacturedfineaggregatestockpilesarenotcontaminatedwithweatheredorhighly
alteredrockorwithclayseamsorothercontaminants.Crushingofmultiplesourcerocksintoa
singlemanufacturedfineaggregatestockpileshallnotbepermittedunlessitcanbe
demonstratedthatsuchaprocessisunderblendcontrolandproducesaconsistentproduct.
Formanufacturedfineaggregate,thedeleteriousfinesindex(DFI)shallnotexceed100when
testedinaccordancewithAS1141.66.
Fineaggregatesshallbetestedatafrequencywhichissufficienttoensurethatconcretecomplies
withthespecifiedrequirements.ThefrequencyshallnotbelessthanthatshowninTable1below.
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TS0710Concrete
Table1MinimumFrequencyofTestingforFineAggregates
TypeofTest
TestMethod
MinimumFrequencyofTesting1
ParticleSize
AS1141.11.1
1.
Atthestartoftheproject;and
2.
1per500tonnesofaggregate
productionorpartthereof.
WaterAbsorption
AS1141.5
Halfyearlyinterval
Materialfinerthan0.002
mm
AS1141.13
LightParticles
AS1141.31
Monthlyinterval
Sodiumsulfatesoundness
AS1141.24
Halfyearlyinterval
Organicimpuritiesother
thansugar
AS1141.34
Monthlyinterval
Sugar
AS1141.35
Monthlyinterval
1.
2.
SulfateContent
AS1012.20.1
Atthestartoftheproject
ChlorideContent
AS1012.20.1
AlkaliAggregateReactivity
AS1141.60.1
Yearlyinterval
PetrographicExamination
AS1141.65
Yearlyinterval
Degradationfactor
2
Deleteriousfinesindex
AS1141.25.3
Quarterlyinterval
AS1141.66
Quarterlyinterval
NotestoTable1:
1
Anychangeinproductionparametersorchangeinquarryfaceshallinitiatethe
commencementofanewtestcycle.
Applicableformanufacturedfineaggregatesonly.
6.2.3
CoarseAggregates
ThesizegradingofcoarseaggregatewhentestedaccordingtoAS1141.11.1,shallcomplywith
thelimitsspecifiedinTableB1ofAS2758.1.
Themaximumamountofwaterabsorptionforcoarseaggregatesshallnotexceed2.0%when
testedaccordingtoAS1141.6.1orAS1141.6.2.
InadditiontotherequirementsspecifiedinAS2758.1,theproportionofmisshapenparticles
inthecoarseaggregateretainedonthe9.50mmtestsieveshallnotexceed25%when
determinedinaccordancewithAS1141.14usinga2:1ratio.
Forwearingsurfacesofallexposureclassifications,surfacessubjecttohydraulicabrasionfrom
liquidvelocitiesgreaterthan4m/sorconcreteswiththerequireddesignlifeinexcessof50
years,thedurabilityoftheaggregateshallconformtotherequirementsforexposure
classificationCspecifiedinAS2758.1.
Coarseaggregatesshallbetestedatafrequencywhichissufficienttoensurethatconcrete
complieswiththespecifiedrequirements.Thefrequencyshallnotbelessthanthatshownin
Table2below.
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TS0710Concrete
Table2MinimumFrequencyofTestingforCoarseAggregates
TypeofTest
TestMethod
MinimumFrequencyofTesting1
ParticleSize
AS1141.11.1
1.
2.
WaterAbsorption
AS1141.6.1or
AS1141.6.2
Halfyearlyinterval
Materialfinerthan2
microns
AS1141.13
1.
2.
ParticleShape
AS1141.14
Halfyearlyinterval
FlakinessIndex
AS1141.15
Halfyearlyinterval
LosAngelesvalue
AS1141.23
Halfyearlyinterval
Sodiumsulfatesoundness
AS1141.24
Halfyearlyinterval
Wetstrengthandwet/dry
strengthvariation
AS1141.22
Halfyearlyinterval
Sugar
AS1141.35
Monthlyinterval
SulfateContent
AS1012.20.1
ChlorideContent
AS1012.20.1
AlkaliAggregateReactivity
AS1141.60.1
Yearlyinterval
PetrographicExamination
AS1141.65
Yearlyinterval
Table2Notes:
1
Anychangeinproductionparametersorchangeinquarryfaceshallinitiatethe
commencementofanewtestcycle.
6.2.4
AdditionalRequirementsforCalcareousAggregates
Bothfineandcoarsecalcareousaggregatesincludingbutnotlimitedtolimestone,marbleand
dolomitemaybeusedinacidicconditionwherethepHislessthan4.0ifanapprovedcoating
orlinerisusedtoisolatetheconcretefromtheacidiccondition.Otherwise,thecalcareous
aggregatesshallnotbeused,unlessallofthefollowingcriteriaaremet:
1.
Boththefineandcoarsecalcareousaggregateshaveaminimumacidsolubilityof94%
whentestedinaccordancewithAWWAB100;and
2.
Thecalcareousaggregateisusedasasacrificialaggregateandtheconcretecoveris
increasedbyanamountequaltothelossthatwouldoccuroverthedesignlife.This
additionalcoverissacrificialandnotconsideredtomakeanycontributiontothe
strengthofthemember.
Wherethecalcareousaggregatesareusedassacrificialaggregateandthesurfacesarenot
subjecttohydraulicabrasionfromacidicliquidwithflowgreaterthan2m/s,themaximumLos
AngelesIndexvalueoftheaggregatemayberelaxedbutshallnotexceed55%loss.
6.3 MixingWater
Mixingwatershallconsistof:
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TS0710Concrete
1.
Batchwater(waterweighedormeteredthroughthebatchingplant);
2.
Ice;
3.
Wateraddedbytruckoperator;
4.
Washwaterretainedinthedrumforuseinthenextbatchofconcrete;
5.
Waterintheadmixturesused;and
6.
Freemoistureontheaggregates.
ThequalityofthemixingwatershallcomplywiththerequirementsofthisStandardandAS
1379andshallhavetotalsolidsnotexceeding50,000ppmwhentestedaccordingtoASTM
C1603.
Allnonpotablewatershallbesampledandtestedasaminimumatsixmonthlyintervalsto
demonstratethecompliancewiththerequirementsofthisStandardandAS1379.
6.4 Admixtures
AdmixturesshallconformtotherequirementsofAS1478.1andshallbeusedinaccordance
withAS1379,themanufacturersrecommendationandthisStandard.
TheContractormayelecttouseairentrainingadmixturesfortheconcretewithexposure
classificationB1orless.Theuseofairentrainingadmixturesinallotherexposure
classificationsandforfreezethawresistanceshallbesubjecttoapprovalbySAWater
Representative.
SetacceleratingandhydrationcontroladmixturesshallnotbeusedunlessapprovedbySA
WaterRepresentative.
Admixturesshallhavenoharmfuleffectwhatsoeveruponthequalityoftheconcreteorupon
anyreinforcementorprestressingsystemorotherfixturesembeddedtherein.
Wheretwoormoreadmixturesareproposedforincorporationintoaconcretemix,their
compatibilityshallbecertifiedinwritingbythemanufacturer(s).
WhereadmixturesareproposedthefollowinginformationshallbeprovidedtoSAWater
Representative:
1.
Name,type,manufacturersdetailanddosagerate;
2.
Purpose/reasonforinclusion;
3.
Methodofuse,includingstorageandmethodforcontrollingandmeasuringdosage;and
4.
Conformingtestresultsfromthemanufacturer.
TheContractorsPremixSuppliermayneedtouseawaterreducingsetretardingadmixtureto
achievethespecifiedwater/cementratioandworkabilityrequirements.Whereawater
reducingadmixtureisused,thePremixSuppliershallshowbyteststhattheuseofthe
admixture,incombinationwiththeothermaterialstobeusedintheWorks,producesthe
desiredeffectwithoutaffectingtheotherqualitiesrequiredfortheconcrete,andwithout
endangeringthereinforcement.
Thewaterreducingsetretarding(WRRe)admixtureshallcomplywiththerequirementsfora
TypeWRReadmixturespecifiedinSection2,AS1478.1.Thedosageusedineachmixand
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TS0710Concrete
sectionoftheworksshallbeasapprovedbySAWatersRepresentativewiththemixdesignat
Clause8.4.
Forhighslumpconcreteindeeppourwalls,theContractormayneedtouseamidrange
(MWR)orhighrange(HWR)admixturetoincreaseworkability,plusacompatiblewater
reducingsetretardingadmixture,complyingwiththerequirementsspecifiedinSection2,AS
1478.1.ThedosagerateshallbeasapprovedbySAWatersRepresentativewiththemix
designatClause8.4.
Thetotalalkalicontributionlevels(measuredasNa2Oequivalent)ofalladmixturesusedina
mixshouldnotexceed0.20kg/m.TotalNa2Oequivalentfromadmixturesmayexceed0.20
kg/msubjecttotheoveralllimitof2.8kg/mNa2Oequivalentforconcreteisnotexceeded.
Theconcreteforthefloorslabofwatertanksonlythataretypically150mmthickandupto
200mmthickmaycontainanapprovedshrinkagereducingadmixturetoSAWaters
Representativeapproval,includingthedosagerate.Notethattheadditionoftheshrinkage
reducingadmixturemayreducethecompressivestrengthcomparedtoareferenceconcrete
withouttheadmixtureandtheContractorsPremixSuppliermayneedtomakeadjustmentsto
thewater/binderratiotoachievetherequiredstrength.Usageshallbeinaccordancewiththe
admixturemanufacturersrecommendationsandapprovalofmixdesignatClause8.4.
Useofintegralwaterproofingadmixturesintheconcreteshallonlybeusedwiththeprior
writtenapprovalofSAWatersRepresentativetoincreasewatertightintegrity(e.g.insitu
jointsinprecastwallsofwatertanks)andtoincreaseresistancetoacidicoracidsulfatesoilsin
theabsenceofamembrane.
6.5 OtherAdditives
MaterialsotherthanthosedetailedinClauses6.1to6.4areconsideredasadditives.
RefertoClause31.1fortheuseofsteelfibresthatcomplywithBSEN148891CEMarking
System1andareusedforstructuralpurposes.
RefertoClause31.2fortheuseofpolymerfibresEN148892ClassIIthatcomplywithCE
MarkingSystem1andareusedforstructuralpurposes.
Allothertypesofsteelfibresandpolymerfibresshallbeclassifiedasadditives.
TheuseofadditivesshallbeusedinaccordancewithAS1379,themanufacturers
recommendationandthisStandard.
Theadditivesshallhavenoharmfuleffectwhatsoeverupontheconstituentmaterialsusedin
theconcrete,thequalityoftheconcreteoruponanyreinforcementorprestressingsystemor
otherfixtureembeddedtherein.
Whereadditivesareproposedforincorporationintoaconcretemix,theircompatibilitywith
theconcreteadmixturesshallbecertifiedinwritingbythemanufacturer(s).Wheretwoor
moreadditivesareproposedforincorporationintoaconcretemix,theircompatibilityshall
alsobecertifiedinwritingbythemanufacturer(s).
WhereadditivesareproposedthefollowinginformationshallbeprovidedtoSAWater
Representative:
1.
2.
Purpose/reasonforinclusion;
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TS0710Concrete
3.
4.
6.6 SolubleSalts
Sulfateandchlorideioncontentsfortheconcretemixshallbereportedfortheproposedmix
designsbasedonthevaluesintheconstituentmaterials.Sulfateandchlorideioncontents
shallalsobedeterminedbytestingofhardenedconcreteinaccordancewithAS1012.20.1.
ThesulfatecontentofconcreteexpressedasthepercentagebymassofacidsolubleSO3tothe
totalcementitiousmaterialshallnotbegreaterthan5%generallyand4%forsteamandheat
acceleratedcuredconcrete.
Themassofacidsolublechlorideionperunitvolumeofconcreteshallnotexceedthevalues
giveninTable3.
Table3MaximumAcidSolubleChlorideIonContentinConcrete
Exposure
classification
Maximumacid
solublechloride
ioncontent
(kg/m3)
0.8
B1
0.6
B2
0.4
C1
0.3
C2
0.3
D&U
Todurability
assessment
6.7 StorageofMaterials
6.7.1
StorageofCementitiousMaterials
Allcementitiousmaterialsincludingcement,flyash,slagand/oramorphoussilicainsolidform
shallbedeliveredandstoredinaccordancewiththerequirementsofAS3972,AS1379and
thisStandard.Thecementitiousmaterialsshallbedryandfreefromcontamination.All
transportationunitsandstoragesincludingsilos,binsorshedsshallbearaclearindicationof
thetypeofbinderinthem.Differenttypesofcementitiousmaterialshallnotbemixedinthe
sametransportationunitsandstorages.
Inaddition,cementitiousmaterialinbagsshallbestoredabovegroundlevelinasuitable
weatherproofstructureofwhichtheinteriorshallbedry,protectedfromdampnessandwell
ventilatedatalltimes.Differenttypesofcementitiousmaterialinbagsshallbeclearly
distinguishedbyvisiblemarkingsandshallbestoredinseparatestacks.Cementitiousmaterial
inbagsshallbeusedintheorderinwhichitisdelivered.Cementitiousmaterialfrombroken
bagsshallberejected.
Cementitiousmaterialshallbesuppliedinthemanufacturerssealedunbrokenbagsorinbulk
andshallbefreeflowingandfreeoflumpsorsignsofmoistureabsorption.Cementitious
material,whichhasdeteriorated,becomehardenedorlumpyornotconformingtothis
Standardinanyway,shallberejected.
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TS0710Concrete
6.7.2
StorageofAggregates
AllaggregatesshallbedeliveredandstoredinaccordancewiththerequirementsofAS1379
andthisStandard.
Eachtypeornominalsizeofcoarseaggregateandfineaggregateshallbekeptseparatedand
suitableprecautionsshallbetakentopreventtheaggregatesfrombeingcontaminatedbythe
groundorbywindblowndustorotherforeignmatter.Aggregatesshallalsobedeliveredand
storedinsuchamannerthattheywillprevententryofsurfaceorgroundwater,allowfree
drainageofrainwaterandwillnotsegregate.
Thestorageofaggregatesshallbearrangedsothatdryingoutandheatinginhotweatherare
preventedinordertoavoidfluctuationsinwatercontentandreducetemperatures.
6.7.3
MoistureContentofAggregates
Themoisturecontentofthefineandcoarseaggregatesshallbedeterminedpriortoconcrete
productionforthedayandwheneverconditionschangeorfreshaggregatesaredelivered.
Themoisturecontentofthefineandcoarseaggregatesshallbedeterminedtoconstantmass
inaccordancewithAS1289.2.1.1,AS1289.2.1.2,AS1289.2.1.4,AS1289.2.1.5orAS
1289.2.1.6.Moisturemetersorotherequivalentdevicesmayalsobeusedprovidedtheyare
calibrated,asaminimum,onamonthlybasis.
Correspondingcorrectionsshallbemadetothemassofallaggregatesandthevolumeof
waterusedinthemixsothatthenominatedwatertocementitiousmaterialratioisachieved.
DesignofConcreteMixes
7.1 RequirementsforFreshConcrete
7.1.1
Consistency
Theconsistencyandworkabilityofconcreteshallbesuchthatitcanbehandledand
transportedwithoutsegregationandcanbeplacedusingthesitefacilities,workedand
compactedintoallcorners,anglesandnarrowsectionsofforms,andaroundall
reinforcement.
Theconsistencyofeachbatchofconcreteshallbecheckedbymeansoftheslumptest.
SamplingandtestingshallbecarriedoutinaccordancewithAS1012.1andAS1012.3.1,
respectively.
Whereaslumpinexcessof180mmisproposed,theContractorshalldemonstratebywayof
trialpourinaccordancewithClause8.3thattheconcretecanbeplaced,compactedand
finishedwithoutdeleteriouseffects.
SlumpflowshallbespecifiedandtestedinaccordancewithAS1012.3.5whenaslumpgreater
than200mmisrequired.
TolerancesonslumpvaluesshallbeinaccordancewithAS1379andforslumpflowin
accordancewiththespecifiedvaluesforconsistencygreaterthan200mmslumptaking
accountofAS1012.3.5.
Aspecifiedslumpof150mmorgreater(e.g.18040mm)maybeconsideredforwall
constructiontoassistcompactiondependingonwallheight,thickness,slumpretention(i.e.
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TS0710Concrete
higherslumpwillretainworkabilitylonger,particularlyinhotweatherconcreting)and
formworkdesigntowithstandthefreshconcrete.
Concreteplacedunderwatershallcontainanapprovedantiwashoutadmixture.
7.1.2
SlumpwithMidRangeandHighRangeWaterReducingAdmixture
Aconcretemixdesignwithamidrange(MWR)orhighrange(HWR)admixtureshallhavea
trialmix(referClause8.3)completedbeforeWorksusetodeterminetheconcreteproperties
includingtotalwatercontentandreversiontime.
Aconcretemixdesignwithamidrange(MWR)orhighrange(HWR)admixtureaddedafterall
otherconcretematerialshavebeenmixedshallhavetrialmixslumptestscompletedbefore
andaftertheadditionoftheadmixture.
TolerancesonslumpvaluesshallbeinaccordancewithClause7.1.1.
7.1.3
DryingShrinkage
Dryingshrinkageshallbelimitedtoreducedryingshrinkagecracking.
Dryingshrinkageshallbemeasuredfortheconcretemixdesignandacceptance(referClause
8)inaccordancewithAS1012.13to56daysbasedontheaverageofthreeconcretedrying
shrinkageprismsandshallnotexceedthevaluesgiveninTable4.
Table4MaximumShrinkageStrainofConcreteSpecimens
Exposure
classification
Maximumdrying
shrinkage()
at56daysof
drying
750
B1
700
B2
650
C1
650
C2
650
D&U
Todurability
assessment
Ashrinkagereducingadmixtureshallbeusedinfloorslabsofwatertanksinaccordancewith
Clause6.4tominimisedryingshrinkage.
7.1.4
Bleed
Bleedshallbelimitedinordertocontrolplasticsettlementortheformationofbleedchannels
thatmightprejudicetheconcretedurabilityorappearance.Bleedshallbemeasuredin
accordancewithAS1012.6.Bleedshallnotexceed:
1.
3%forslabs;
2.
2%forwalls;
3.
1%forpilesanddiaphragmwalls;
4.
2%forotherelements.
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TS0710Concrete
Concretebleedhasanimpactonplasticcrackingincombinationwiththeevaporationrate
(referClause10.1.4.4).
7.1.5
AirContent
AircontentofconcreteshallbemeasuredusingoneofthemethodsprovidedintheAS
1012.4.1orAS1012.4.2.
Theaircontentofconcreteshallnotexceed:
1.
3%forhigherdurabilityconcrete(e.g.concreteinstructuresforwater
retaining/excluding,wastewater,dams,desalination,belowgroundliquidexcluding,
etc.)notsubjecttofreezing;
2.
Aspecificaircontentwherefreezethawresistanceisrequiredinaccordancewith
AS3600Section4.7byuseofairentrainmentadmixture(referClause6.4);
3.
4%forallothercontent.
7.2 RequirementsforHardenedConcrete
7.2.1
DesignRequirements
TheContractorshallberesponsibleforalldesignrequirementsforDesignandConstruct
Contracts.
NOTE:TheContractorshalldiscusswithSAWaterRepresentativepriortoundertakingany
designthatdepartsfromthisStandardincludingallreferencesinClause1.3.
7.2.2
TypicalConcreteCharacteristicsandDurabilityRequirementsfor
ConcretebasedonExposureClassifications
TheconcreteusedshallhavethetypicalcharacteristicsgiveninTable5subjecttoproject
specificstructuralanddurabilityrequirementsandtotheapprovalofSAWater
Representative.
Thedurabilityrequirementsforconcreteelementsbasedonexposureconditionsarerelated
tothedesignlife(referClause3)fortheWorksaslistedbelow:
1.
2.
50yearsinaccordancewithAS3600andAS3735:
a.
Therequirementsareforplain,reinforcedandprestressedconcretestructuresand
membersfor50years+/20%aregiveninAS3600Section4.1;
b.
AS3735durabilityreferstoAS3600sothesamerequirementsapply;
c.
AS3600requirementscanapplywithoutadditionaldurabilityreviewforAS3600
exposurecategoriesA1andA2;
50yearsinaccordancewithAS3600/AS3735plusadditionaldurabilityreview;
a.
AS3600Section4.1Notesgivenbelowthatcanjustifydurabilityreviewbythe
DesignerusingaDurabilityConsultantasrequired;
Morestringentrequirementswouldbeappropriateforstructureswithadesign
lifeinexcessof50years(e.g.monumentalstructures),whilesomerelaxationof
therequirementsmaybeacceptableforstructureswithadesignlifelessthan
50years(e.g.,temporarystructures).
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TS0710Concrete
Durabilityisacomplextopicandcompliancewiththeserequirementsmaynot
besufficienttoensureadurablestructure."
b.
3.
4.
AS3600/AS3735requirementsneedadditionaldurabilityreviewforallAS3600
exposurecategoriesexcludingA1andA2.Theextentofreviewwillvaryfromminor
forexposurecategoryB1tomoredetailedforexposurecategoriesB2,C1,C2and
U;
100yearsinaccordancewithAS5100.5;
a.
ForstructuresdesignedtoAS3600andAS3735withadesignlifeof100yearsuse
AS5100.5durabilitysincerequirementsareforplain,reinforcedandprestressed
concretestructuresandmembersfor100years.Forconcreteelementsdesignedin
accordancewithAS3735for100yearsdesignlife,increasethecoverofAS3735by
10mmforClassB1/B2andby15mmforClassC;
b.
AS5100.5requirementscanapplywithoutadditionaldurabilityreviewforAS
5100.5exposurecategoriesAandB1nonaggressivesoils.Additionaldurability
reviewisrequiredforallotherexposurecategories;
100yearsinaccordancewithAS5100.5plusadditionaldurabilityreview;
a.
AS5100.5Section4.1Notesgivenbelowthatcanjustifydurabilityreviewbythe
DesignerusingaDurabilityConsultantasrequired;
Somerelaxationoftherequirementsmaybeacceptablefortemporary
structures.
Durabilityisacomplextopicandcompliancewiththeserequirementsmaynot
besufficienttoensureadurablestructure.AS5100.5Supp1(Commentaryto
thisStandard)containsbackgroundtoandguidanceontheprovisionsofthis
Clause."
b.
AS5100.5requirementsneedadditionaldurabilityreviewforallAS5100.5
exposurecategoriesexcludingAandB1nonaggressivesoils.Theextentofreview
willvaryfromminorforexposurecategoryB2tomoredetailedforexposure
categoriesCandU.
5.
Durabilityreviewisrequiredforspecificexposurecategoriesofliquidretainingand
excludingstructuresinAS3735;
6.
AS2159providesexposureconditionsbelowgroundlevelfor50and100yearsdesign
life;
7.
Greaterthan50yearsandlessthan100yearsshallusetheaboverequirementsfor100
yearstogetherwithdurabilityreviewtodetermineifanyrelaxationoftherequirements
canapply;
8.
Greaterthan100yearsinaccordancewithAS5100.5plusadditionaldurabilityreviewby
aDurabilityConsultant;
9.
AConcreteDurabilityPlanspecifictotheWorksthatwillachievetheintentofthis
ClauseshallbesubmittedfortheapprovalofSAWaterRepresentativepriorto
proceedingwiththework.
10.
AlldurabilityreviewinputgivenaboveshallbeinaccordancewithCIAZ7/01.
NOTE:ExposurecategoriesaregiveninAS3600,AS4997,AS5100.5andAS2159.The
exposurecategoriesarelimitedandguidanceonabroaderrangeofexposurecategoriesarein
internationalStandardssuchasISO229651andEN2061.
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TS0710Concrete
ItisintendedthatthisClauseofthisStandardwillbereviseduponthereleaseofthefollowing
documents:
1.
NewAustralianStandardforBridgeDesignPart5:Concrete(currentlyindraftDRAS
5100.5);
2.
CIAZ7/02DurabilityExposureClasses(draftinprogress)andCIAZ7/03Durability
DeemedtoComplyRequirements(draftinprogress).
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TechnicalStandardConcrete
SAWater
Table5TypicalConcreteCharacteristics
Exposure
classification
Minimum
Cementitiousmaterial
content(1)
fc(MPa)
(kg/m3)
at28days
Minimum
Maximum
Maximum(2)
waterto
cementitious
materialratio
Maximum
Apparent
volumeof
permeable
voids(3)
Chlorideionpenetrationinmarine
andsalineexposure
Maximumchloridetestcoefficients
at20oC
Supplementarycementitiousmaterial(5)
Flyash(%bymass)
GGBFS(%bymass)
(x1012m2/sec)(4)
NTBuild443
(De)
NTBuild492
(DRMC)
Minimum
Maximum
Minimum
Maximum
25
280
320
0.56
30
40
B1
32
320
400
0.50
14%at28
days
30
40
B2
40
360
450
0.45
13%at28
days
3.5
8.0
20
50
40
70
C1
50
420
500
0.40
12%at56
days
2.0
4.0
25
50
50
70
C2
50
450
500
0.36
12%at56
days
2.0
4.0
30
50
60
70
D&U
TotheassessmentofaDurabilityConsultantandSAWaterRepresentativeapproval
Table5Notes:
Note1:Cementcontentmaximumandminimumvaluesaresubjecttovariationsinsourceofcementitiousmaterials,binderproportions,qualityofbinder
materials,etc.andthereforesomevariationscanoccurovertimeandbeappliedforspecificWorkstoSAWatersRepresentativewrittenapproval.
Inaddition,thecementcontentwillvarywithseasonaltemperaturevariations.
Note2:Thewater/cementratiomustnotbelessthan0.32forcastinplaceconcreteand0.28forprecastconcrete,toensurecementhydration.
Note3:%ApparentvolumeofpermeablevoidsasdeterminedbytestmethodAS1012.21withspecimenpreparedinaccordancewithAS1012.8.1.
Note4:FortheMaximumchloridetestcoefficients,thefollowingtermsapply:
DedenoteseffectivediffusioncoefficientfromNordtestNTBuild443.
DRMCdenotesrapidmigrationcoefficientfromNordtestNTBuild492.
Version1.021November2016
ForOfficialUseOnly
Page32of88
SAWater
ContinuouslystandardmoistcureafterdemouldingspecimensfortheNordtestNTBuild443andNTBuild492testsandtestatanageof56and
28daysrespectively.
ThespecifiedcoefficientsarebasedontheminimumconcretecoversspecifiedinAS5100.5:2004Table4.10.3(A).
ThePrincipalmaymodifythespecifiedcoefficientsiftheconcretecoverisincreased.
Thespecifiedcoefficientsareforatesttemperatureof20oC.Modifytherequiredcoefficientsforagiventemperatureasfollows:(Deor
DRMC)req=4.15e0.0703T1whereT1isthespecifiedtemperature.
Note5:
Minimumandmaximumfiguresdonotapplytoatripleblendmix;
GGBFSshouldbeusedformemberssubjecttoacidicenvironment;
Thecontractorshalladdressthepotentialoflowerearlystrengthdevelopment,curingandstrippingtimesandconcretestrengthrequirementsfor
earlylifting;
AmorphoussilicaorsilicafumeshallnotbeusedunlessotherwiseapprovedbySAWaterRepresentative;and
ForexposureclassificationsAandB1,concretemadewithblendedcementmustcontainaminimumof240kg/m3ofGeneralPurposeorShrinkage
Limitedcementtolimitcarbonation.
Note6:Forsewageandwastewaterstructuresofitem2exposuresinTable4.1ofAS3735,installapprovedphysicalbarrier(protectivecoatingsorliner)to
protecttheconcreteagainstacidattacks.Thebarriershallcovertheentireconcretesurfaceabovewaterlevel(includingcoverslabsoffit)and
extendtoaminimumof500mmbelowthelowwaterlevel.Thedesignlifeofthephysicalbarriershallbe100years.Alternatively,subjecttothe
approvalofSAWaterRepresentative,thephysicalbarriershallbeinstalledsuchthatitcanbereplacedorrepairedwithoutmajorwork.The
minimumdesignlifeforthisalternativeapproachshallnotbelessthan25years.
Note7:Concretecharacteristicsfordams,desalinationplants,etc.aswellasD&UexposuresshallbeprojectspecifictotheassessmentofaDurability
ConsultantandapprovalofSAWaterRepresentative.
Note8:PrecastconcreteshallbeaccordingtoTable5.Precasteralternativeconcretemixmaybeconsideredforanyprecastconcreteelementssubjectto
SAWaterRepresentativereviewandwrittenapproval.
Note9:UnlessotherwisespecifiedontheDrawings,orapprovedbySAWaterRepresentative,theconcreteslumpofthenominatedmixshallnotexceed
180mm.Whereanominatedslumpinexcessof180mmisproposed,demonstratethattheconcretemaybeplaced,compactedandfinished
withoutdeleteriouseffects.
Note10:ForconsistencyofconcretemixreferClause7.1.1and7.1.2.
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SAWater
Note11:DryingShrinkageshallnotexceedClause7.1.3requirements.
Note12: ConcretebleedshallnottoexceedClause7.1.4requirement.
Note13:AircontentoftheconcreteshallnotexceedClause7.1.5requirement.
Note14:MaximumcrackwidthshallnotexceedClause7.2.4requirement.
NOTE:SAWaterencouragesandpromotesresearch,developmentandinnovation.SAWaterwillconsidertheuptakeofnewconcreteproductand
technologythathavesignificantpotential.TheContractorshalldiscusswithSAWaterRepresentativepriortousingtheproductand/ortechnology.
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TS0710Concrete
7.2.3
CoverToleranceRequirements
ThetoleranceonconcretecovershallbeinaccordancewithAS3600for50yearsdesignlifeand
AS5100.5forgreaterthan50yearsupto100yearsdesignlifeunlessSAWatersRepresentative
requirescompliancewiththetolerancesonminimumcovergiveninTable6.Concreteelements
designedtoAS3735shallhavetoleranceonconcretecoverof0mm,+10mm.
Table6ToleranceonLocationsofReinforcement
7.2.4
Element
ToleranceonMinimumCover(mm)
Beams,columns,wallsandsuspendedslabs
0,+15
Slabsongrade
0,+30
Footingscastagainstground
0,+50
MaximumCrackWidthRequirement
UnlessotherwisedesignatedintheContract,concreteshallhavenocracksatanystageafter
constructionmeasuredattheconcretesurfaceofwidthgreaterthanthevalueslistedinTable7.
Table7MaximumAcceptableCrackWidth
Exposure
classification
Maximum
acceptablecrack
width(mm)
0.3
B1
0.2
B2
0.15
C1
0.1
C2
0.1
D&U
Todurability
assessment
Note:GuidanceonthedurabilityofconcretewithcrackwidthsisgiveninCIRIAC660andwillbe
availableinthefuturefromCIARecommendedPracticeZ7/06.Bothincludetheacceptablecrack
widthfromaparticularviewingdistancereducesastheprestigeofthestructureincreases.Guidance
isalsogiveninACI224R01.TheContractorshallrefertoCampbellAllen,D.,1979.TheReductionof
CrackinginConcrete.UniversityofSydneyinassociationwithCementandConcreteAssociationof
Australia,Sydney,May.
ConcreteearlyagethermalcrackriskassessmentisrequiredatClause32.
AS3735Suppl2001providesmeancrackwidthsfordesignofconcretestructuresretainingliquids
forconditionsofearlyagethermal,shrinkageandrestraintpluslimitingsteelstressforserviceability.
Inaddition,whereaconcreteelementisrequiredtobeliquidretainingorexcluding,concreteshall
havenocracksatanystageafterconstructionmeasuredattheconcretesurfaceofwidthgreater
than0.2mm.Allcracksofsurfacewidthgreaterthan0.1mmandcrackswithanyvisiblewater
leakageinconcreteelementstobeliquidretainingorexcludingshallberecordedbytheContractor
inaccordancewithClause18forassessmentandrepairtoSAWatersRepresentativerequirements.
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TS0710Concrete
Note:Theliquidretainingorexcludingrequirementsforconcretestructurescanalsoapplywherea
liquidisincontactwiththeconcrete.Forexample,thesuspendedroofslabofawatertankorthe
suspendedroofslabofachlorinebuildingisrequiredtobewatertight.Inaddition,belowground
concretestructuresmayberequiredtobewatertight.
AllcracksgreaterthanthecrackwidthspecifiedinTable7shallbeclassifiedasnoncompliant.All
cracksshallbeinspectedandassessmentincludingtheneedforrepairinaccordancewithClause18
andanyrepairsrequiredshallbeinaccordancewithClause21.
7.2.5
RequirementsforConcreteandConcreteStructuresinContactwith
PotableWater
ThisclauseappliestoallconcretethatisincontactwithPotableWater(e.g.concretewaterstorage
tanks,etc.).
Alladditives,admixtures,releaseagents,sealcoats,paints/linings,repairmaterialsandcuring
compoundsthatwillremainonthesurfaceofconcretethatwillbeincontactwithpotablewater
(including,butnotlimitedtoproduction,treatment,storageanddistribution)shallcomplywith
AS/NZS4020.
TheContractorshallprovideevidenceintheformofcertificationbyaNATAaccreditedlaboratoryto
SAWatersRepresentative.
Variationstothesourceoftheconstituentmaterialsofconcreteand/orthemixdesignconstitutea
changeinmaterialandsubmissionofanewcertificationisrequired.
Inthecircumstancewherethecostoftestingorthetimeavailabletogettestingcompletedisnot
feasible,theContractorshallapplyaAS/NZS4020certifiedcoatingorlineronthesurfaceofthe
concretethatcomesincontactwithpotablewater.
DesignandAcceptanceofConcreteMix
8.1 General
TheContractorshallberesponsibleforthedesignandproductionofallconcretesothatthespecified
durability,strengthandotherrequirementsofthehardenedandfreshconcreteareachieved.The
concreteusedshallbeinaccordancewithAS1379andthisStandardandcanbereadymixedor
batchedonsite.
Note:Theuseofreadymixedconcreteorprecastconcreteshallinnowaylessenorremovethis
responsibility.
SprayedconcreteorshotcreteshallonlybeusedifapprovedbySAWaterRepresentative.
Undernocircumstancesshallhandmixedconcretebepermitted.
8.2 ProposedMixDesign
TheContractorshallsubmitdetailsofthemixdesignforeachspecifiedclassofconcretetoSAWater
Representativepriortothecommencementofthetrialmix.Themixdesignshalluseonlythe
constituentmaterialsthathavebeenshownbytestingtomeettherequirementsofClause6ofthis
Standard.
Theproposedmixdesignsubmissionshallincludethefollowinginformation:
1.
Cementitiousmaterial,includingbutnotlimitedto:
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TS0710Concrete
2.
3.
4.
5.
6.
7.
a.
Brandandtype;and
b.
Currenttestresultsforallcementitiousmaterialsdemonstratingconformancewith
Clause6.1;
Aggregates,includingbutnotlimitedto:
a.
Materialsourceandgeology;
b.
Nominatedcombinedaggregategrading;and
c.
CurrenttestresultsforallaggregatesdemonstratingconformancewithClause6.2;
Admixturesandadditives,includingbutnotlimitedto:
a.
Manufacturerstechnicaldatasheet;
b.
Manufacturersmaterialsafetydatasheet;and
c.
Manufacturerscertificationofcompatibility;
Premixsupplierproposedmixdesigndetails,includingbutnotlimitedto:
a.
Mixcode;
b.
Quantityofeachconstituentmaterial,includingalladmixturesandadditives,basedon
1mandaggregatesatsaturatedsurfacedry(SSD);
c.
Methodofcontrollingalkaliaggregate
d.
Targetwatertocementitiousbinderratio;
e.
Slumpatpointofdischarge;and
f.
Forconcretecontaininghighrangewaterreducers:finalslumpandreversiontime.
Batching,mixingandtransport,includingbutnotlimitedto:
a.
Methods;
b.
Levelofcontrolandaccuracyofbatching;
c.
Levelofcontrolandaccuracyofdeterminationoftheaggregatemoisturecontent;
d.
Minimummixingtime;and
e.
Maximumperiodforcompletionofdischarge;and
f.
ComplianceofbatchplantequipmentandtransitmixerswithAS1379;
Placementofconcrete,includingbutnotlimitedto:
a.
Methodsfortransfer,placementandcompactiononsitenotingspecifiedslumpandpour
geometries;
b.
Concretedeliveryrateandnumberofvibratorsonsite;
c.
Sequenceofcasting;
d.
Maximumdropheighttoavoidsegregation;
e.
Anynonstandardsitetestingrequirementssuchasslumpflowforconcretesgreaterthan
200mmslump;and
f.
Particularrequirementsforsprayedorotherspecialpurposeconcrete;
HardenedconcretepropertiesasperClause8.3.2andforconcretecharacteristicsinTable5,
includingbutnotlimitedto:
a.
Targetmeancompressivestrength;
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TS0710Concrete
b.
Targetmeandryingshrinkage;and
c.
Targetandlimitingvaluesforanyotherspecifiedproperties,includingbutnotlimitedto:
Flexuralstrength,Sulfateandchlorideioncontents,apparentvolumeofpermeablevoids,
chloridediffusioncoefficient,andchloridemigrationcoefficient.
TheContractormaysubmitforconsiderationtheresultsoftestscompletedwithintheprevious
12monthsfromsimilarmixesproducedfromtheplantandmaterialsproposedfortheProject.The
SAWaterRepresentativewillinstructwhetheratrialmixshallbeundertakenasperClause8.3.
TheContractorshallsubmittheproposedconcretecuringmethodinaccordancewithClause13.1at
thesametimeofsubmittingtheconcretemixdesign.
8.3 TrialMix
8.3.1
General
TheContractorshallmaketrialmixesforallclassesofconcretehavingacharacteristicstrength
greaterthan20MPaunlessdirectedotherwisebySAWaterRepresentative.
TheContractormaysubmitforSAWaterRepresentativeconsiderationproposedconcretemix
designswiththeresultsofconcretemixtestsandmaterialsdataforalltherequirementsinClauses
8.3.2and8.3.3completedwithintheprevious12monthsfromsimilarmixesproducedfromtheplant
(orsimilarwithjustification)andsimilarmaterialsproposedfortheWorksasanalternativeto
concretetrialmixes.SAWaterRepresentativeshallreviewthesubmissionanddetermineifa
concretetrialmixisrequiredbytheContractor.
Theconcretemixesshallbemadeusingtheplantanddegreeofqualitycontrolproposedforthe
Project.Theminimumvolumeofthetrialmixshallbe25%oftheratedcapacityofthemixer.
Whereconcreteisnotbatchedandmixedonthesite,atimedelayequaltoanaveragedeliverytime
onsiteshallbeappliedbetweenthemixingoftheconcreteandthesamplingforslumpandother
samplesfortheperformancerequirementtests.
Asanalternativetothetrialmixapproach,theContractormayconductthetrialmixinaccordance
withAS1012.2usingaNATAaccreditedlaboratory.Followingthelaboratorytrial,theContractor
shallconductasitetrialmixwithaminimumvolumeof25%oftheratedcapacityofthesitemixerto
verifythelaboratoryresultsofslump,watertocementitiousmaterialratioand28dayscompressive
strength.
SAWatersRepresentativemaypermittheContractortousetheremainingtrialmixconcreteina
noncriticalstructure.
8.3.2
TrialMixTestRequirements
Eachtrialmixshalldemonstratebywayoftestingthatalltheperformancerequirementsasspecified
inClause7areachieved.
Plasticconcretetestingshallinclude:
1.
Concretetemperature;
2.
Slump;
3.
Aircontent;
4.
Massperunitvolume;
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TS0710Concrete
5.
Bleed;and
6.
ReversiontimeconsistencytestingtoClause7.1.1untilan80mmslumpisreachedfor
concretecontainingmediumorhighrangewaterreducer(AS1478.1TypeMWRorHWR).
UnlessotherwisespecifiedandapprovedbySAWatersRepresentative,themeasuredslumpafter
addingwaterreducingadmixturesshallbewithintheallowablerangespecifiedinAS1379ofthe
targetslump.
Notlessthantwelve(fifteenif56dayagestrengthsarerequired)concretecylindersandthree
concretedryingshrinkageprismsshallbecastandcuredinaccordancewithAS1012.8.1andAS
1012.8.4,respectively.Thefollowinghardenedpropertiesshallbetested:
1.
Seven(7)dayscompressivestrengthbasedontheaverageofthreeconcretecylinders;
2.
28dayscompressivestrengthbasedontheaverageofthreeconcretecylinders;
3.
Ifspecified,56dayscompressivestrengthbasedontheaverageofthreeconcretecylinders;
4.
DryingshrinkageaftertotalperiodsofairdryinginaccordancewithAS1012.13ofseven(7),
14,21,28and56daysbasedontheaverageofthreeconcretedryingshrinkageprisms;
5.
Acidsolublesulfateandchlorideioncontents.
6.
%AVPVat28and56daysbasedontheaverageoftwocylindersperagemouldedandcured
toAS1012.8.1andtestedinaccordancewithAS1012.21.
Additionalconcretecylinders(aminimumofthreeperage)shallberequiredifstrengthgainistobe
assessedforearlystrippingorloading.
Thefollowinghardenedpropertiesshallalsobetestedforconcretewherechlorideinduced
reinforcementcorrosionisapotentialdurabilityriskduringthedesignlifewithchloridesfrom
exposurethatismarine,inlandsaline,operationalorothers:
1.
ChlorideDiffusionTestNTBUILD443basedontheaverageoftwoconcretecylinders;and
2.
RapidChlorideMigrationTestNTBuild492basedontheaverageoftwoconcretecylinders.
8.3.3
TrialMixReport
TheContractorshallsubmitaTrialMixReporttoobtainapprovaloftheproposedconcretemix
designcontainingthefollowingminimumrequirementsforinclusionintheTrialMixReport:
1.
Classofconcrete;
2.
Supplierofconcrete(ifreadymixed);
3.
Mixdesignonecubicmetreproportions(byweightandwaterbyvolume)ofallmaterials
comprisingthemixincludinganyproposedadmixtures(byvolume);
4.
NameofsupplierandCertificatesofCompliancewithcurrentqualitycontroltestresults
requiredbythisStandardnotmorethan12monthsoldforallmaterialsusedinthemix(i.e.
cementitiousbinders,aggregates,water,admixtures).Coarseandfineaggregatesinformation
ontype,sourceandrequiredtestdatatobeinaccordancewithClause6.2;
5.
Concretemixdesignandperformancetestdataforanysimilarrecentconcreteknownand
availabletobesuppliedbytheContractorthatwillassisttheconcretetrialmixassessment;
6.
Trialmixperformancetobereportedshallincludethebelow:
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a.
Actualbatchedquantitiesofallmaterialsandcomparisonwiththeproposedmixdesign;
b.
Moistureconditionofallaggregatesusedinthetrialmix;
c.
PlasticandhardenedconcretepropertiesrequiredbyClause8.3.2;
d.
Concretecontainingmediumorhighrangewaterreducer(AS1478.1TypeMWRorHWR):
Totalwateradded,water/binderratio,slump,andreversiontime;
7.
TrialmixconcretetestingshallbecompletedinaccordancewithrelevantAustralianStandards
unlessallowedorspecifiedotherwiseinthisStandard;
8.
TrialmixreportshallbeingeneralaccordancewithAS1012.2asaguidelineapproach.
8.4 ApprovalofConcreteMixDesign
NoconcreteshallbeplaceduntilapprovalofthetrialmixhasbeenobtainedfromSAWaters
Representative.Thedetailsofeachproposedmixtogetherwithacertificatestatingthatthe
nominatedtrialmixanditsconstituentsconformtothisStandardshallbeprovidedbeforethetrial
mixisapproved.
Alltrialmixtestresultsshallbeprovidedpriortothemixbeingapprovedforuse.
Thetrialmix,theplantandthedegreeofqualitycontrolshallbeapprovedifthetrialmixtestvalues
achievethespecifiedperformanceasdetailedinClause7.
Thetestvaluesobtainedfromtheapprovedtrialmixshallbecometheapprovedbenchmarkfor
assessingtheconcreteusedintheProject.AllconcreteofthesameclassusedintheProjectshall
havethesameperformanceortestresults,withinatoleranceasdetailedinAS1379orthisStandard.
SAWatersRepresentativemaygiveprovisionalapprovalofamixbasedonearlytesting.
Notwithstandinganysuchprovisionalapproval,alltheconcreteshallmeetallperformance
requirements.
If,duringthecourseoftheProject,thedegreeofqualitycontrolisnotmaintained(asevidencedbya
declineintheperformancetestvaluesand/orbyadeteriorationinthemethodsemployedin
batchingandmixing),SAWatersRepresentativemaywithdrawtheapprovalofthemixpending
establishmentofimprovedqualitycontrol,orifnecessary,aredesignofthemix.
8.4.1
VariationstoApprovedConcreteMixDesign
ApprovedconcretemixesshallnotbealteredwithouttheapprovalofSAWatersRepresentative.
Theapprovedmixshallbeuseduntilapprovalisgivenforanalteredmix.
Thequantitiesoftheconstituentsinanapprovedmixmaybevariedtoimprovethequalityofthe
concreteormaintaingradecompliance.Variationstothequantitiesofconstituentsinthenominated
mixshallnotexceedthefollowingandshallstillconformtotheotherrequirementsofthisStandard:
1.
Cementitiousmaterials:3%bymassofeachconstituent;
2.
Aggregates:5%bymassofeachconstituent;and
3.
Admixtures:5%byvolumeand/ormassofeachadmixture.
Thevariedconcretemixshallconformtotheminimumcementitiousmaterialcontent,maximum
watertocementitiousmaterialratioandwithinthespecifiedproportionofcementand
supplementarycementitiousmaterialasspecifiedinTable5.Theamountofadmixtureusedinthe
variedconcretemixshallwithinthemanufacturersrecommendations.Allsuchvariationsshallbe
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notifiedinatimelymannertotheSAWaterRepresentative,whowillinstructanyrequirementfor
mixtrialstodemonstratecontinuedcompliance.
Variationoftheapprovedmixbeyondthelimitsstatedabove,orchangestothetypeorsourceof
anyconstituent,shallrequiresubmissionofanewtrialmixdesign.
8.4.2
TrialPours
Trialpoursshallbeperformedonsitebeforemakingconcretefortheactualworkwheninstructedby
SAWaterRepresentative.
ThemixestobeusedinthetrialpoursshallbethoseapprovedinaccordancewithClause8.3.3.The
purposeofthetrialsistoverifythatconcretemanufacturedinaccordancewiththisStandardcanbe
placed,compactedandcuredinaccordancewiththisStandardusingtheplant,equipmentand
proceduresproposedbytheContractor.Inadditionthequalityassuranceproceduresshallbein
effectonthesetrialpours.Thetrialpourshallnotbeincorporatedintheactualworkunless
approvedbySAWaterRepresentative.
SAWaterRepresentativewillnominatethescopeofthetrialpours,includingpreparationofa
procedurefordeterminingtheperformanceofthenominatedconcretemix(es).Theproposedtrial
shallinvolveatleasttwoconsecutivepours,withtheproceduredetailingthefollowinginformation:
1.
Transportandplacement,includingplantandequipmenttobeused;
2.
Dimensionsoftheproposedpour,torepresentapourforthelargestsectionstobe
constructed,butnottobelessthanavolumetobenominatedbySAWaterRepresentative,
placedinapourofapproximatelyequaldimensions(width,lengthanddepth);
3.
Temperaturecontrol;
4.
Temperaturemonitoring;
5.
Curingregimeandtimebetweenplacementofconsecutivepours;
6.
Crackinspection,recordingandmonitoring;and
7.
Othermattersspecifictothetrialpour(e.g.forsprayedconcrete).
Thetrialpoursshallbeavailableforinspectionuptofourteen(14)daysafterplacement.Ifthetrial
pourfailstomeetanyrequirementsofthisStandardthemixdesignandtrialpourprocedureshallbe
reviewedandamendedasnecessary.AnewtrialpourshallbeconductedasdirectedbytheSA
WaterRepresentativeandtheresultssubmittedforapproval.
8.5 ConcreteMaximumTemperature
Themaximumtemperatureofallprecastandcastinsituconcreteduringthefirst28daysshallnot
exceedthevaluesbelowinaccordancewithCIAZ7/04:
1.
70CforcementtypeGPcement;and
2.
80Cforotherapprovedcementsystemsincorporatingaspecifiedminimumquantityof
40%slag,20%flyashor8%silicafume).
TheearlyageconcretecrackriskshallbeassessedinaccordancewithClause32whenthemaximum
concretetemperatureislikelytoexceed70C.
Themaximumtemperaturevaluesabovearerequiredforallprecastandcastinsituconcreteto
minimisetheriskofdelayedettringiteformation(DEF)inaccordancewithCIAZ7/04.
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8.6 ConcreteMaximumTemperatureDifferentials
Allprecastandcastinsituconcreteshallhaveasaguidancemaximumtemperaturedifferential
acrossanysectionlimitedtovaluesbelowinaccordancewithCIAZ7/04andCIRIAC660:
SiliceousGravel:20C
Granite:28C
Basalt:32C
Limestone:35C.
Theearlyageconcretecrackriskresultingfromtemperaturedifferentialsshallbeassessedin
accordancewithClause32,whichshalltakeprecedenceovertheaboveguidancevalues.
SupplyandDeliveryofConcrete
9.1 General
Allconcretesuppliedshallconformtotheapprovedconcretemixandshallbedeliveredin
accordancewithAS1379andthisStandard.TheContractorisresponsibletoensuretheconcreteis
thoroughlyanduniformlymixedbeforedischargingtheconcrete.
Thesizeofeachconcretebatchshallbedeterminedconsideringthetypeandpropertiesofconcrete,
capacityandperformanceofmixingequipment,methodoftransportation,typeofconstructionand
quantityofconcretetobeplaced.
TheContractorsConcreteSuppliershallprovideandmaintainandoperatethebatchingequipment
soastoaccuratelydetermineandcontroltheamountofeachseparatematerialenteringthe
concretetothetolerancesspecifiedinAS1379.
MixingofconcreteshallcomplywiththerequirementsofAS1379.
TheContractorsConcreteSuppliershallusetruckmixersthatcomplyandhavebeenmaintainedin
accordancewiththerequirementsofAS1379.
TheContractorsConcreteSuppliershallkeepfullanddetailedbatchinganddeliveryrecordsand
thesewillbemadeavailabletoSAWatersRepresentativewithinthree(3)workingdaysofany
request.
9.2 ConcreteDelivery
Concreteshallbetransportedwithminimumdelayandinamannerwhichwillpreventsegregation,
lossofmaterialorprematurestiffening.
Concretewhichhasbeguntostiffenshallnotbeused.
Ifconcreteisdeliveredusingamixeroragitator,thesizeofeachconcretebatchshallnotexceedthe
ratedcapacityoftheagitatordrum.
InadditiontotheinformationrequiredbyAS1379thefollowinginformationshallalsoberecorded
onthedeliverydocket:
1.
Concretemixuniqueidentificationcodeusedbytheconcretepremixsupplierasperthe
approvedmixdesign;
2.
Nominatedwatertocementitiousmaterialratio;
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3.
Actualwatertocementitiousmaterialratioatdischarge;
4.
Nominatedinitialslump;
5.
Timeatdischarge;
6.
Totalactualwaterinthebatch,includingbutnotlimitedto:
7.
8.
9.
a.
MoisturecontentsofbothfineandcoarseaggregatesasrequiredbyClause6.7.3;
b.
Batchwaterandanyaddedattheslumpstand;
c.
Totalamountofwaterpermittedtobeaddedonsitethatwillnotexceedthe
water/binderratio;and
d.
Wateraddedonsitebeforecommencementofdischarge,includingwaterusedtowash
downthemixingbladesofthemixeroragitator;
Cementitiousbinder,includingbutnotlimitedto:
a.
Brandandtype;
b.
Totalmassofcementitiousbinder;and
c.
Proportionsofcomponentsbymass;
Chemicaladmixtures,includingbutnotlimitedto:
a.
Types;and
b.
Amounts;
Anyotheradditivestoabatch.
9.3 OnsiteTransportation
Concretetransportationequipmentusedonsiteshalldeliverconcretewithminimumdelayandina
mannerwhichwillpreventsegregation,lossofmaterialorprematurestiffening.
Appropriatemeasuresshallalsobetakenforprotectingtheconcretefromsunlightandweather.
9.3.1
ConcretePump
TheuseofconcretepumpshallbeinaccordancewiththerequirementsofAS1418.15andthis
Standard.PumpingconcreteshallbeinaccordancewithCIAZ7/04andCIAZ12.
Theconcretepumplocationandpipelinerouteshallbedeterminedsothatthepipelinedistanceand
thenumberofbendsareminimised.
Thepipelinediametersshallbeselectedinviewofthetypeandqualityofconcrete,themaximum
sizeofcoarseaggregate,fibresizeandcontent,pumpingconditions,easeandsafetyofpumping.
Thetypeandnumberofconcretepumpsshallbedeterminedbasedonthepumpingload,discharge
rateandtherateofplacement.
Priortocommencementofplacingconcrete,thepumpandpumplineshallbeprimedwithagrout
mixandtheinitialdischargeofconcreteshallbothbepumpedtowasteuntilaconsistentworkable
mixisdischarged.Aluminiumpipesshallnotbeusedforthedeliveryofconcrete.
9.3.2
ConcreteBucketorKibble
Theconcretebucketandkibbleshallbefabricatedsothat:
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1.
Nosegregationwhenconcreteispouredinanddischarged;
2.
Concretecanbedischargedatacontrolledrateeasilywhenopened;and
3.
Concretedoesnotleakwhenclosed.
Thesizeoftheconcretebucketandkibbleshallbedeterminedbasedontherateofplacement.
9.3.3
Chute
Theslopeofthechuteshallpreventsegregationofconcrete.
Priortocommencementofplacingconcrete,thechuteshallbewettedandtheinitialconcretethat
flowsdownthechuteshallbecartedtowasteuntilconsistentworkablemixisdischarged.
Theuseofwaterinthechutetoassistmovementofconcreteshallnotbepermitted.
9.3.4
BeltConveyor
Wherebeltconveyorisused:
1.
Appropriatemeasuresshallalsobetakenforprotectingtheconcretefromsunlightand
weather;
2.
Baffleplatesandafunneltubeshallbeprovidedatthedischargeendoftheconveyorto
preventthesegregationofconcrete;and
3.
Adeviceshallbeinstalledattheendoftheconveyortopreventthedepositionofconcreteon
thereturnbelt.
9.4 PeriodforCompletionofDischarge,PlacementandCompaction
Thetimefromtheadditionofthecementtotheaggregatestoconcreteplacementandcompaction
shallnotexceedthetimesinTable8withoutthepriorapprovalofSAWatersRepresentative:
Table8AllowableTimefromBatchingtoPlacing
Concretetemperatureattimeof
discharge(oC)
Maximumelapsedtime
ConcreteStructures
32C
90m
Allconcreteunlessapproved
otherwisebySAWaters
Representative
35C
60m
ConcretethatSAWaters
Representativeapprovesconcrete
placementtemperatureupto35C
andconsideringtheconcreteearly
agecrackassessmentatClause32.
(minutes)
ThetimesgiveninTable8maybevariedwhereithasbeendemonstratedbytrialsthattheuseofset
retarding(AS1478TypeReorWRRe)admixturesprovidesadequateretentionofconsistencyfor
longerperiodsatthenominatedtemperature.GuidanceonthismatterandgiveninCIAZ7/04.
Nonetheless,concreteshallnotbeincorporatedintotheProjectWorksatanytimeifitsworkability
isoutsidethespecifiedlimits.
Retemperingoutsidethemaximumalloweddischargetimeusingadmixturesorwatershallnotbe
allowedunderanycircumstances.
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9.5 RetemperingwithadditionofWaterorAdmixtureafterMixing
Watermaybeaddedtoamixedbatchofconcretepriortothecommencementofdischarge
providingthefollowingconditionsaresatisfied:
1.
ProcedureisinaccordancewiththeContractorsapprovedConcreteWorksMethodStatement
(referClause32);
2.
Theworkabilityoftheconcreteismeasuredbeforeandafterwateraddition,andthe
workabilityafteradditionshallbecompliantwiththisStandard;
3.
ApprovalisgivenbySAWatersRepresentative,theContractorandtheconcretesupplier;
4.
TheadditionalwaterismeasuredandrecordedbytheContractor,andwitnessedbySA
WatersRepresentative;
5.
Immediatelyaftertheadditionofanywater,operatethemixingmechanismatmixingspeed
untiltheconcreteachievestherequireduniformity;
6.
Thetotalwaterdoesnotexceedtheallowableadditionalwatercontentrecordedonthe
deliverydocketbasedonthewaterbinder/rationottobeexceeded;
7.
Thewater/binderratioisnotexceeded;
8.
TheperiodforconcretecompletionshallbeinaccordancewithClause9.4;and
9.
Theconcreteistestedforcompressivestrengthaftertheadditionofwater.
Aconcretemixdesignwithamidrange(MWR)orhighrange(HWR)admixturemayhaveadmixture
addedonsiteusingtheaboverequirementsforadditionofwater(i.e.thenormalbatching
procedureisadditionoftheseadmixturesatthebatchplant).
10 ConcretePlacementandCompaction
10.1 ConcretePlacing
10.1.1
General
AllconcreteshallbeplacedinaccordancewithAS1379andAS3600andAS5100.5,asappropriate.
GuidanceonallconcreteplacementandcompactionmattersisprovidedinCIAZ7/04.
TheContractorshallprovidethesequenceandconcreteplacingmethodologyandtheprecautions
takeninadverseweatherconditionstoSAWaterRepresentative.
UnlessotherwiseapprovedbySAWaterRepresentative,concreteshallnotbeplacedinwettrenches
orinrunningwater.
10.1.2
Preparation
Whereconcreteisplacedonearth,sandorrockfoundations,theearthorsandshallbecompacted
toatleast95%ofMaximumDryDensityasdeterminedbyAS1289.5.1.1,unlessotherwisespecified
intheContract,andtherockfreedofloosematerial.WherespecifiedintheContractorshowninthe
Drawingsthefoundationshallbecoveredwithalayerofblindingorleanconcreteasspecifiedin
Clause5.3.
WherespecifiedintheContractorshownintheDrawingsorwheretheconcreteelementiswithina
coveredstructureandisconstructedongroundsurfacesoronfoundationbedding,apolythene
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sheetseparatorofthicknessnotlessthan0.2mmshallbeemployedbetweentheground/bedding
andtheconcrete.Theseparatorshallextendnotlessthan300mmbeyondtheconcretework.Care
shallbetakentoavoidpuncturingortearingtheseparator.Shouldpuncturingortearingoccur,the
damageshallberepairedpriortoconcreting.Jointsintheseparatorshallbemadebyoverlapping
thesheetsaminimumof300mmorbyoverlappingandtaping.Whenminimisinghorizontalbase
restraintbyuseofpolythenesheetingisnotrequired(e.g.watertankfloorslab150to200mmthick
requiresbaserestraintminimised),analternativetothepolythenesheetingisawaxbasedcuring
membranetoAS3799(referSection13)subjecttoContractorsubmissionforreviewandapprovalby
SAWatersRepresentative.
TheContractorshallrefertoClause14forplacingconcreteagainstaconstructionjoint.
Immediatelybeforeplacingconcrete,allsurfacesagainstwhichtheconcreteistobeplacedshallbe
freefromstandingwater,mudanddebris.Allreinforcementshallbefixedinaccordancewith
Clause29.Surfacesofexistingconcreteagainstwhichconcreteistobeplacedshallbecleanedwith
airand/orwaterjets.Allsurfacesofforms,reinforcementandembeddedmaterialsthathave
becomeencrustedwithdriedmortarorgroutfromconcretepreviouslyplacedshallbecleansedofall
suchmortarorgroutbeforethesurroundingoradjacentconcreteisplaced.
Anyabsorbentsurfacewhenincontactwithconcreteshallbemoistenedtosaturatedsurfacedry
conditionandanyexcessfreewatershallberemoved.
10.1.3
Placement
Concreteshallnotbeplacedandshallberejectediftheconsistencyisoutsidetheacceptablelimits
asspecifiedinClause7.1.1.
Theconcreteshallbeplacedinhorizontallayersnotexceeding75%ofthelengthoftheimmersion
vibratorsbeingused,exceptthatthefirstlayerofthefirstliftshallnotbemorethan350mmthick
andeachlayershallbecompactedinaccordancewiththerequirementsspecifiedinClause10.2
beforetheprecedinglayerhastakenitsinitialset.
Concreteshallnotbeplacedfromaheightfromwhichsegregationcanoccur.Theconcrete
placementmaximumheightwithoutsegregationshallbedeterminedbytheContractorforeach
concretemixinaccordancewithCIAZ7/04.Voidedconcreteresultingfromplacingconcreteata
heightthatgivessegregationand/orinadequatecompactionwillbenoncompliant.
Freshconcreteshallbedepositedwithintheformsasnearaspossibletoitsfinallocation.Excessive
useofvibratorstomovetheconcretealongtheformsshallnotbepermitted.
Formworkshallnotbedisturbedoradjustedduringtheconcretingoperation,andshallremain
undisturbeduptotheremovalofformworkasspecifiedinClause26.4.Nostrainshallbeplacedon
anyprojectingreinforcingsteelforaperiodofatleast12hoursfollowingcompletionofconcreting.
Ifseveresegregationisidentifiedduringtheplacementofconcrete,theplacementshallbestopped
andamethodforreducingsegregationshallbedeterminedandimplemented.
Exceptatplannedconstructionjoints,theplacementofconcreteshallbecarriedoutcontinuously
untiltheplacementiscompleted.
Whenanewlayerofconcreteisplacedonapreviouslyplacedlayer,vibratorsshallbeinsertedinto
theunderlyinglayerforcompactioninaccordancewithClause10.2.
Incaseswhenbleedingwaterappearsatthesurfaceduringtheplacementofconcrete,thewater
shallberemovedusingappropriatemethods,beforeplacingmoreconcrete.Bleedwaterrequiring
removalcanresultinconcretedefects(especiallyatthesurface)andtheContractorshallcompletea
concretemixreviewandsubmitforSAwatersRepresentativereviewandapprovalbeforethesame
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concretemixisusedintheWorks.Whereexcessivebleedoccursthathascausedconcretesurface
defectsandmayimpactdurabilitytheContractorshallsubmitaproposaltorepairorreplacethe
concreteforconsiderationbySAWatersRepresentative.
10.1.4
AdverseWeatherConditions
Allfreshconcreteshallbeprotectedwhererequiredfromsunlight,windand/orrain,untilcuringis
implemented.
Concreteshallberejectedifthetemperatureoftheconcreteislessthan10oCormorethan32oCor
35oCinaccordancewithClause9.2.
TheContractorshallberesponsibleformeasuringandrecordingtheconcretetemperatureandair
temperature,relativehumidityandwindvelocity,at1mabovetheconcretetobeplacedto
determineevaporationconditionsbeforetheconcreteisplacedandtotakerelevantprecaution
measures.
TheContractorshallimplementprecautionmeasuresforconcretinginadverseweatherconditions
includingbutnotlimitedtocoldweather,hotweather,windy,dryorrainconditions.Such
precautionmeasuresshallbeapprovedbySAWaterRepresentative.
10.1.4.1
ColdWeatherRequirements
Iftheambientairtemperatureisbelow5oCandfreezingconditionsareconfinedtogroundfrosts
duringthenighttheContractorshalltakeprecautionmeasurestoensurethatconcreteisplacedand
compactedataconcretetemperatureofnotlessthan10Candtheconcreteshallsubsequentlybe
curedinaccordancewiththerequirementsinClause13.
Concreteshallnotbeplacedagainstanysurfacebearingfrostorice.
Note:Asaguide,dependingupontheseverityoftheconditions,thefollowingprecautionsmaybe
applied:
1.
Formworktobeinsulated;
2.
Insulatingcoverstobeprovidedforconcrete;
3.
Concreteplacementtemperaturenotlowerthan10C;
4.
Concretetemperaturetobekeptnotlessthan5Casmeasuredatthesurfaceuntiltheendof
thecuringperiod,whichshouldbeatleastseven(7)days;
5.
Aggregatebinstobecovered;and
6.
Areasinwhichconcreteistobeplacedtobeattemperaturesabove0C,includingformwork
andreinforcement.
10.1.4.2
HotWeatherRequirements
Placementofconcreteshallonlybepermittedproviding;
1.
Concretemixtemperaturepriortoplacementshallatnotimeexceed32C;andeither;
2.
Ambientshadetemperatureislessthan38Candfalling;or
3.
Ambientshadetemperatureislessthan38Candrising,butplacementcanbecompleted
beforetheambienttemperatureexceeds38C.
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Maximumdeliverytemperatureslessthan32Cmaybespecifiedforlargethicknessconcretepours
orconcreteelementswithhighrestraintwheretheconcreteearlyagethermalassessmentin
accordancewithClause32ofthisStandardindicatesthatlowerinitialtemperaturesarenecessary.
Wherespecified,suchtemperaturesshallnotbeexceededforthepoursconcerned.
Steelformwork,steelreinforcementandanyothermetalsurfacesthatwillcomeincontactwiththe
concreteshallbecooledtobelow32Cbeforetheconcreteisplaced.
Concreteshouldbecoveredwithanimperviousmembraneafterscreedinginadditiontouseof
evaporationretardersuntilhardenedcuringbeginsandcuringcompoundsmaybeusedbutarenot
aseffectiveassealingandmoistcuringmethods(referClause13.3).Measuresshallbetakento
minimiseevaporativemoisturelosses(RefertoClause10.1.4.4).
Concreteshallberejectedifthetemperatureoftheconcreteattheplacingpointismorethan32C.
Note:Asaguide,thefollowingprecautionsmaybeappliedforgoodconcretingpracticeinhot
weatherconditions:
1.
Shadingaggregatestockpilesandwatercoolingexposedcoarseaggregateinacontrolled
manner;
2.
Addingchilledmixingwaterorcrushedicetoreplacemixingwater(inpart);
3.
Formworkandreinforcementtobecontinuouslysprayedwithcoldwaterinadvanceofthe
concreting,withallfreewaterremovedfromtheformwork;
4.
Concretetobemixed,transported,placedandcompactedasrapidlyaspracticable;
5.
Placingtheconcreteatatimeofdayornightwhentheairtemperatureislowerthanthe
maximum;
6.
Internalcoolingusingcoolingpipeswithintheconcrete;
7.
Suitablebarrierstobeprovidedtoprotectfreshlyplacedconcretefromtheevaporative
influenceofwind;and
8.
Excessivetemperaturerisestobereducedbyshadingtheworkareasandtheconcretefrom
directsunlightand/orcoveringwithareflectivesheetduringcuring.
10.1.4.3
WetWeatherRequirements
TheContractorshalltakemeasurestoprotectthefreshlyplacedconcretefromrain.
Concreteaffectedbyrainwillberejected.
10.1.4.4
EvaporationorDryingRequirements
TheContractorshalltakeadditionalprecautions(refertoClause10.1.4)tominimiseevaporative
moisturelossesthatcancreateplasticcrackingintheconcreteexposedsurfacewhenthe
evaporationrateexceeds0.5kg/m2/hourasdeterminedusingtheformulaandwebcalculatorgiven
inFHWARD02099thatisbasedonthemonographinACI30510.TheContractorcanobtain
guidanceonconcreteplasticcrackingandevaporationratesinCIAZ7/04.Whenevaporationexceeds
theconcretebleedratewaterisdrawnoutfromtheconcretesurfacesoconcretebleedshallbe
consideredasdetailedinCIAZ7/04.
Theevaporationshallbeevaluatedpriortoplacingconcreteandduringthecuringperiod.
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10.1.5
UnscheduledInterruptionstoConcretePlacing
Freshconcreteshallnotbeplacedagainstconcretewhichhastakenitsinitialset.Initialsetisdefined
forthispurposeonlyastheconcretesurfacenotbeingabletobeeasilypenetratedbya12mmbar.
Ifconcreteplacingisinterruptedandtheconcretehastakenitsinitialset,theContractorshall
immediatelyinformSAWaterRepresentativeandtakethenecessaryactiontoformaconstruction
jointasperClause14attheplaceofstoppageinthemannerthatshallleastimpairthedurability,
appearanceandproperfunctioningoftheconcrete.Otherwise,theconcreteisliableforrejection.
Note:Asageneralguidance,ifaninterruptiongreaterthan45minutesoccurs,aconstructionjoint
approvedbySAWaterRepresentativeshallbeplacedforinsitucastconcrete.
Forprecastconcrete,theinterruptiongreaterthan45minutesshallbeidentifiedasanon
conformanceandtheunitshallberejected.
TheContractorshalleliminateasfaraspossiblefeatheredgesandadverselyslopingtopsurfacesand
shallthoroughlycompacttheconcretealreadyplacedinaccordancewithClause10.2.Allworkon
theconcreteshallbecompletedwhileitisstillplasticanditshallnotthereafterbedisturbeduntilit
ishardenoughtoresistdamage.
Sufficientequipmentandmaterialstocomplywiththisrequirementshallbereadilyavailableatall
timesduringconcreteplacing.
BeforeconcretingisresumedaftersuchaninterruptiontheContractorshallcutoutandremoveall
damagedoruncompactedconcrete,featheredgesoranyotherundesirablefeaturesandshallleave
acleansoundsurfaceagainstwhichthefreshconcretemaybeplaced.
IfitbecomespossibletoresumeconcreteplacingwithoutcontraveningthisStandardandSAWater
Representativeapprovessuchresumption,thenewconcreteshallbethoroughlyworkedinand
compactedagainsttheexistingconcretesoastoeliminateanyconstructionjoints.
10.1.6
DimensionsofConcretePlacing
ThepositioningofconstructionjointsifnotshownontheDrawingsshallbesubjecttoapprovalofSA
WaterRepresentative.TheContractorshallnotchangethepositionofconstructionjointswithout
thepriorwrittenapprovaloftheDesignerandSAWatersRepresentative.
TheContractorshallsubmitdetailsoftheconcreteplacingsequenceandplanintheWorksmethod
statement(referClause32)toSAWaterRepresentative.
ConcreteshallbeplacedtothefullplannedheightofallpoursshownontheDrawingsandtothe
requirementsofthisStandardincludingconcreteconsistency(referClause7.1.1),placement(refer
Clause10.1.3)adverseweatherconditions(referClause10.1.4),unscheduledinterruptions(refer
Clause10.1.5)andearlyagethermalcrackriskassessment(referClause32).
10.1.7
ConcretePlacingSequence
Inordertopreventcrackingduetorestraintofearlierlifts,theContractorshallarrangethatasfaras
possibletheintervalsbetweenplacingsuccessiveliftsofconcreteinonesectionoftheprojectareof
equalduration.
Note:Asaguide,thisdurationshallnormallybenotlessthanthreeormorethanseven(7)days
undersimilartemperateweatherconditionsunlessjustifiedbyaconcreteearlyagethermalcrack
riskassessment(referClause32)approvedbySAWaterRepresentative.
WhentheDrawingscallforcontractiongapsinconcrete,theseshallbeofthewidths,detailsandin
thelocationsshownontheDrawingsandtheyshallnotbefilleduntilthefulltimeintervalshownon
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theDrawingshaselapsed.Concreteplacementincontractiongapstypicallywillbesubjecttohigh
restraintwhereaconcreteearlyagethermalcrackriskassessment(referClause32)isrequired.
10.1.8
UnderwaterConcretePlacement
TheContractorshallsubmitthemethodologyforunderwaterconcretingpriortoconcretingforthe
reviewofSAWaterRepresentative.Concreteshallnotbeplaceduntiltheproposedmethodology
hasbeenapprovedbySAWaterRepresentative.
Note:Asaguide,thefollowingtechniquesmaybeemployed:
1.
Pump;
2.
Tremie;
3.
Slipform;
4.
Dewateringofformwork.
TheContractorshallnotplaceconcreteinwaterhavingatemperaturebelow5oC.
10.1.9
UseofRockSpalls
SpallsofsolidrockmaybeusedinmassconcreteconstructionwhereapprovedbySAWater
Representative.
Thespacingofthespallsshallbesuchthatthecleardistancebetweenthespallsandtheirclearance
fromfacesofformsshallnotbelessthan150mm.
Thespallsshallbesurfacewettedandbeddedbyhand,andtheconcreteshallbevibratedinplaceall
aroundthespalls.
10.1.10 TraceabilityofConcrete
Allconcretebatchesplacedshallberecordedandtraceablefromthebatchplanttoitsgeneral
locationintheconcreteelementbytheserialnumberonthedeliverydocket.
10.2 CompactionofConcrete
Compactionofconcretebymeansofmechanicalvibrationshallcommenceimmediatelyafterthe
concreteisplaced.Compactionshalleitherbeachievedbytheuseofinternalvibratorsorexternal
formvibrators.TheamountandtypeofvibrationusedshallbeinaccordancewithCIAZ7/04and
approvedbySAWaterRepresentative.
CompactionbyhandtampingshallnotbeusedwithouttheapprovalofSAWaterRepresentative.
Vibrationshallbeappliedtothefulldepthofeachlayerandextendedintothetop100mmofthe
underlyinglayer.Vibrationshallcontinueateachpointuntilairbubblesceasetoemergefromthe
concrete,thenwithdrawnslowly.Concreteshallnotbevibratedtothepointwheresegregationof
theingredientsoccurs.
Vibrationshallnotbeappliedeitherdirectlyorthroughthereinforcementtoanyconcretewhichhas
takenitsinitialset.
Whereinternalvibratorsareused,theyshallbeinsertedverticallyatsuccessivelocationsatspacing
notexceedingthemanufacturer'sstatedzoneofinfluence,andshallnotbeallowedtorestonthe
steelreinforcement.
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Whereintensecompactionisspecified,theformworkshallbemadeofrigidmetalcomplyingwith
Clause26andtheuseofexternalformvibratorsismandatory.Internalvibratorsshallbeusedin
conjunctionwithexternalformvibrators.
Note:Forgoodconcretingpractice,theContractorshallprovideatleasttwovibratorsingood
workingorderonstandbyonsiteduringtheconcreteplacement.
10.3 Screeding
Immediatelyafterplacingandcompaction,exposedsurfacesshallbescreededofftothespecified
levelsandprofiles.
Afterscreeding,theContractorshallprotectthesurfaceandcomplywiththerequirementsof
Clause13.2sothatnodryingoutofthesurfaceoccurs.Bleedwatershallbedealtwithinaccordance
withClause10.1.3.Waterforcuringshallnotbeintroducedontheconcretesurfaceuntilithas
hardenedandshallbeinaccordancewithClause13.3.
Cracksshouldnotappearontheconcretesurfaceduringthescreedingorfinishingwhencuringis
completedinaccordancewithClause13.However,anycracksthatformduringscreedingand
finishingshallbeclosedupbyrevibratingtheconcretewhiletheconcreteisstillinaplasticstate.
TheContractorshallsubmitdetailsofanycracksthatformduringscreedingandfinishingtoSA
WatersRepresentativewithintwo(2)daysoffinishingtheconcreteandcrackinspectiononthese
areasshallbecompletedinaccordancewithClause18.
11 FinishingofUnformedConcreteSurfaces
11.1 General
Allunformedsurfacesshallbefinishedtruetolinesandlevelswithinthetolerancesspecifiedinthe
Drawings,AS3600andAS5100.5,asappropriate.
Finishingofexposedconcretesurfacesshallbecarriedoutaftertheconcretehasbecomesufficiently
hardtosupportthefinishingoperation.Workingoftheunformedsurfacesshallbetheminimum
necessarytoproducethedesiredfinish.
Theedgesoftheunformedsurfacesshallbeneatlyroundedwithanapprovedjointingtool,havinga
minimumradiusof5mm,toafinishconformingtotherequirementsofthisStandard.
Unlessspecifiedotherwise,toppingsshallnotbeused.
Thefinishedsurfacesgradedfordrainageshallnotretainpoolsofsurfacewater.
TheclassesoffinishforunformedsurfacesshallbeasspecifiedorasshownontheDrawings.
ThedesignatedclassesforunformedsurfacesareU1,U2,U3,U4andU5asdefinedinClauses11.2to
11.6.
CuringshallcommenceimmediatelyinaccordancewithClause13followingtheprogressive
completionatanylocationoffinalfinishingoperations.
ForthepurposeofthisClause,abruptirregularitiesisdefinedasverticaloffsetsandbeassessedby
directmeasurement.Gradualirregularitiesshallbemeasuredfromastraighttemplate3mlong.
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11.2 ClassU1
ClassU1finishisahardandsmoothsteeltrowelledfinishproducedbythesuccessivetrowellingofa
ClassU3finish.Poweredsteeltrowels,vibratingscreedorplatefinishmaybeusedinlieuofhand
trowelswhereappropriate.
AClassU1finishshallbeusedwherespecifiedandonuncoveredslabsincontrolrooms,switchboard
rooms,chlorinationstationsandwhereappearanceandcleanlinessareofparamountimportance
andwhereaddedresistancetowearandresistancetoerosionandcavitationundertheactionof
waterathighflowvelocitiesarerequired.
ForClassU1finish,gradualirregularitiesshallbelessthan5mmandshallnotcontainanyabrupt
irregularities.
11.3 ClassU2
ClassU2finishisa'broomed'steeltrowelledfinishusedonsurfaceswherespecifiedandonall
walkwaysandslabsthatwillbewalkedonregularlyduringsubsequentoperationandwillbe
periodicallywettedbyrainand/orwashdownwater.Suchsurfacesincludewalkways,externalcover
slabsontanksatwaterfiltrationworks,andwetwellfloorsinwaterandsewagepumpingstations.
ThesurfaceshallbefirstworkedtoaClassU3finish.Itshallthenbebroomfinishedatan
appropriatestagewhentheconcretehashardenedtoastatewhereabroomfinishcanbeapplied
without'tearing'thesurfaceandonewhichmatchesthefinishofthereferencesampleslab(Referto
Clause11.7).
Broomingshallbeinonedirectiononlyanditshallbecarriedoutusingamediumstifflonghandled
broomandbyapplyingthenecessarypressuretoproducethedesirednonslipfinish.
Theaveragetexturedepthshallbenotlessthan0.8mm.
11.4 ClassU3
ClassU3finishisasteeltrowelledfinishandshallapplyonlytosurfacesspecifiedforthisfinish.It
includesallflattrafficsurfaces,allsurfaceswhichareperiodicallywettedbutnotusedaswalkways,
suchasthetopsoftankwalls,valvechambers,foundations,stairwells,exposedfloorsofwater
retainingstructures,andallexpansionandcontractionjointseatings.
ThepreliminaryoperationsasspecifiedforClassU4finishshallbecarriedoutandanynecessary
cuttingwithedgingorjointingtoolsandanyfillshallbedoneduringfloating.
Steeltrowellingshallbeginimmediatelyafterfloating.Itshallbeperformedwithafirmpressurethat
willflattenandsmooththesandytextureofthepreviouslyfloatedsurface,andshallproducea
dense,uniformsurfacefreefromblemishesandtrowelmarks.
11.5 ClassU4
ClassU4finishisawoodfloatfinishandshallapplyonlytosurfacesspecifiedtoreceivethisfinish.
Thisfinishshallnotapplytowaterretainingsurfaces.ClassU4finishisalsousedasthesecondstage
offinishesU3,U2andU1.
ThesurfaceshallbefirstlevelledandscreededasforClassU5finish.Floatingshallonlybeginwhen
thescreededsurfacehasstiffenedsufficientlyandonlyafterallbleedwaterhasevaporatedorhas
beenremoved.Forfinishinglargerfloorareasortoeliminateanyridgesandfillinanydepressions
leftbythestraightedge,floatingoperationsbytheuseofbullfloatingordarbyingmaybeemployed.
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AClassU4finishshallbeasurfaceuniformintextureandfreefromscreedmarks.AClassU4finish
shallnothaveanyabruptand/orgradualirregularitiesofmorethan5mm.
11.6 ClassU5
ClassU5finishappliestosurfaceswhereroughnessisnotobjectionablesuchasthoseuponor
againstwhichfillmaterialorconcretewillbeplacedandsurfacesthatwillotherwisebepermanently
concealed.Itisalsothefirststageofallotherfinishes.
Thefinishingoperationsshallconsistoflevellingandscreedingtheconcretetoproduceaneven
uniformsurface.Surplusconcreteshallberemovedimmediatelyaftercompactionbystrikingitoff
withasawingmotionusingastraightedgeorscreedacrosswoodormetalstripswhichhavebeen
setasguide.Specialscreedsshallbeusedforcurvedsurfaces.
AClassU5finishshallnothaveanyabruptand/orgradualirregularitiesofmorethan10mm.
11.7 ReferenceSampleSlabs
AttherequestofSAWatersRepresentative,theContractorshallcastonsiteasampleslabof
approximately1.0x0.5metresasareferenceforanyoneormoreofthespecifiedsurfacefinishes.
ThesurfacefinishoftheapprovedsampleslabswillbeusedbySAWatersRepresentativeasa
referenceforacceptanceoffinishedwork.
12 FormedConcreteSurfaces
TheclassesoffinishforformedconcretesurfacesshallbeasspecifiedorasshownontheDrawings.
FormedconcretesurfacesshallbedefinedinaccordancewithAS3610.1.
13 ConcreteCuringandProtection
13.1 General
Allfinishedconcretesurfacesshallbeprotectedfromdamagefromanycauseincludingmortar
splashesandstains,timberstains,ruststains,chemicalattack,additives,oils,drainagewater,
protectivecoatings,foreignmatterandthelike.
Thecuringofunformedsurfacesofconcreteshallcommenceassoonastheconcreteisplacedin
accordancewithCIAZ7/04.
TheContractorshallsubmitfulldetailsoftheproposedmethodologyofcuring,includingbutnot
limitedtomaterialsandperiodofcuring,aspartoftheproposedconcretemixdesignsubmissionto
SAWaterRepresentativeforapproval.
Asfarasispracticableconcreteshallnotbeexposedtoaggressiveenvironments,includingbutnot
limitedtoseawaterorliquidswithpH<5,untiltheendofthecuringperiod.
Theconcreteshallbemaintainedatatemperatureabove5C.
13.2 CuringafterPlacement
Theconcreteshallbekeptmoistfromtimeofplacementuntilsurfacefinishingiscompletedwhen
hardenedcuringbeginsbyuseofsprayinganevaporationretardanttopreventplasticshrinkage
crackingand/orcrusting.Reapplytheevaporationretardantasweatherconditionsjustify.
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13.3 CuringafterHardened
Hardenedconcretecuringofexposedconcretesurfacescommencesassoonassurfacefinishing
operationsarecompletedwhentheconcretehashardenedsufficientlytopreventdamage.The
concretesurfaceshallbekeptcontinuouslymoistandthewholesurfaceprotectedfromtheeffects
ofwindandsun.Acceptablecuringmethodsinclude:
1.
Maintainwatersaturationofconcretebypondorcontinuouslysprinklethesurfacewith
water.Intermittentcuring,suchassprayingwithwateronceaday,isnotacceptable;
2.
Coveringwithsealedplasticfilmtopreventmoistureevaporationfromtheconcretesurfaceby
coveringcompletelywithpolythenesheetingorequivalentcoveringmaterialsecurelyheldin
position.Thecoveringshallbeinfullcontactwiththeconcretesurface.Theedgesofthe
sheetingshallbetapedorshallbeoverlappedbyatleast200mmandthewholeshallbe
securelyheldinposition.Anydamagetoordisplacementofthesheetingduringconstruction
operationsshallimmediatelybemadegood.Anadditionalmeasureforconsiderationisthe
topconcretesurfaceshallbekeptcontinuouslymoistbytheuseofanabsorbentcoverbeing
saturatedwithwaterandthenimmediatelybeingcoveredbythepolythenesheet;
3.
Applyanapprovedliquidcuringcompoundtoexposedconcretesurfaceswhereapprovedby
theSuperintendent;
4.
Coveringwithwetadsorptivematerial(e.g.hessian,geotextile,canvas,etc.)andwrappingthis
withsealedplastic;
5.
Retainformworkinplace.
13.4 LiquidMembraneFormingCuringCompound
Generalandspecificcharacteristicsofcuringcompoundsandtestingthereofshallcomplywiththe
requirementsofAS3799.
TheContractorshallprovidethefollowingcuringcompoundinformationtoSAWaterRepresentative
withallcuringsubmissioninaccordancewithClause13.1:
1.
1.
2.
AcurrentCertificateofCompliancefromthemanufacturer;and
3.
Foreachbatchdelivered,aCertificateofUniformityfromthemanufacturer.
Onlywaxbased(AS3799,ClassA),resinbased(AS3799,ClassB),andwaterborne(AS3799,ClassZ)
curingcompoundsthatcomplywiththerequirementsofAS3799maybeused.
Allcuringcompoundsappliedtoconcretethatwillcomeincontactwithdrinkingwatershallbe
approvedforuseinpotable/drinkingwaterinaccordancewithAS/NZS4020.
Apressurisedsprayertogiveuniformcovershallapplythecuringcompound.Thesprayershall
incorporateadeviceforcontinuousagitationandmixingofthecompoundinitscontainerduring
spraying.Thecuringcompoundshallbeappliedusingafinesprayattheratestatedonthe
CertificateofCompliance.
CuringcompoundsshallbeusedinaccordancewiththemanufacturersrecommendationandCIAZ9.
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Thecuringcompoundshallbeappliedtounformedsurfacesimmediatelyaftercompletionofall
finishingoperations,andtoformedsurfaceswithin30minutesoftheremovalofformworkfromthe
section.
Anyrequiredrepairofconcretesurfacesnotcompletedpriortoapplicationofthecuringmembrane
shallonlybeperformedaftercompletionofthecuringperiodand(atleastlocal)removalofthe
curingmembrane.Eachrepair,afterbeingapplied,shallbemoistenedandcoatedwithcuring
compoundinaccordancewiththeforegoingrequirements.
Curingcompoundshallnotbeappliedtoconstructionjointsunlessthejointistohavecuring
compoundremovalbyroughenedorblastcleaningatalaterstagepriortoconcreting
Curingcompoundshallnothaveadeleteriouseffectontheconcreteorstrainthesurfaceofthe
concrete.
Anycuringcompoundshallbecompatiblewithboththeconcretemixandtheappliedfinishesand
shalltakeaccountofallpossiblefinishes(e.g.protectivecoatings,waterproofingorsurfacesystem)
tobeappliedtotheconcrete,andconsiderconcretesurfacepreparationforsuchfinishes.Ifthe
curingmembranehasanimpactontheconcretesurfacepreparation(e.g.requiringblastcleaning
removal)alternativecuringmethodsshallbeconsidered.
Curingcompoundsshallnotbeusedonsurfacesagainstwhichfreshconcreteisrequiredtobond.
Thecuringmembraneshallbemaintainedintactafteritsinitialapplication,fortherequiredcuring
period.Anydamagetothecuringmembraneshallbemadegoodbyresprayingoftheaffectedareas
withoutdelay.
TrafficandotheroperationsbytheContractorshallbesuchastoavoiddamagetocoatingsofcuring
compoundforthewholeperiodofcuring.Whereitisimpracticablebecauseofconstruction
operationstoavoidtrafficoversurfacescoatedwithcuringcompound,theconcretesurfaceshallbe
protected(e.g.byacoveringofsandnotlessthan25mminthickness,polythenesheetingplus
plywoodformworkorbyothereffectivemeans.Theprotectivecoveringshallnotbeplaceduntilthe
curingcompoundiscompletelydry.TheContractorshallremoveallprotectivecoveringafter
completionofthecuringperiod.Anycuringcompoundthatisdamagedorthatpeelsfromconcrete
surfacesshallberepairedwithoutdelay.
13.5 RetentionofFormwork
Whereformworkisleftinplaceforcuringpurposes,anyexposedsurfacesoftheconcreteshallbe
curedbyothermeansinaccordancewithClause13.Theformworkshallalsobesealedagainst
evaporativemoisturelossesforthedurationofcuring.
Wherepartoforalltheformworkistobestrippedbeforetherequiredcuringperiodiscompleted,
curingoftheformedsurfaceshallcommencewithin30minutesofstrippingandcontinueforthe
remainderofthecuringperiod.
13.6 AcceleratedHeatCuring
Whereacceleratedheatcuringisproposed,theContractorshallsubmitthemethodofsteamor
temperaturecontrolandproposedcuringcycle,durationofheatcuringtoSAWaterRepresentative
withallcuringsubmissioninaccordancewithClause13.1.
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13.7 CuringDuration
Curingshallbeundertakentosatisfyshorttermrequirementstopreventplasticcrackingandlong
termrequirementsofensuringcontinuedcementhydration.Curingshallbecontinueduntilthe
requirementsofOptions1,2or3describedbelowaremet:
1.
Option1:7daysminimumcuringforGPcement;
2.
Option2:14daysminimumcuringforGBorLHcement;
3.
Option3:Untiltheconcreteinthecoverzoneachieves60%ofitscharacteristicstrengththat
shallbedeterminedbycoverzonematuritymonitoringinaccordancewithASTMC1074or
strengthtestingofadditionalcylinderscastbythepremixconcretesupplierandcuredina
similarmannertothecoverzoneconcreteitrepresents.
Notrafficshallbeallowedtopassoverandnomaterialsshallbedepositedonanyconcreteduringits
curingperiodwithouttakingprecautionstopreventdamagetotheconcrete.
14 Joints
14.1 General
Allcontrolandconstructionjointsshallbecompletedstraightandplumb.Alltransversejointsshall
benormaltolongitudinaljoints.
TheuseofwaterstopsforwaterretainingorexcludingstructuresshallcomplywithTS2(PVC
waterstop)andClause14.4.
14.2 ConstructionJoints
ConstructionjointsshallbeinaccordancewithAS3735,AS3600andAS5100.5,asappropriate,
exceptwherespecifiedotherwiseinthisstandard.
Thenumberofconstructionjointsshallbekepttoaminimum.
TheContractorshallproposeconstructionjointlocationsandshallsubmittheirconstructionjoint
proposalstoSAWaterRepresentativeforapproval.
Constructionjointsshall,unlessotherwisedetailedoragreed,betrulyhorizontalorverticaland
madewithasmallformedchamferorotherapprovedmeansofensuringthatastraight,cleanline
appearsatthejointoncompletion.
Concreteagainstwhichnewconcreteistobeplacedshallbeintentionallyroughenedbyremovingall
laitanceandsufficientmortartoexposethecoarseaggregatetoadepthof3mm.Theroughened
surfaceshallbecleanedofforeignmatter,laitanceandlooseorporousmaterialandotherforeign
materiallikelytoaffectbondingofnewtooldconcrete.Thesurfaceshallbeinasaturatedsurface
dryconditionimmediatelybeforeplacingofnewconcrete.
Greencuttingortheuseofwaterand/orairjettingpriortofinalsetofconcretetoroughenthe
constructionjointsurfacemaybepermittediftheContractorcanprovideproofofcompetencywith
theuseofthismethodinaccordancewiththerequirementsofthisStandardandtothesatisfaction
ofSAWaterRepresentative.
Alternatively,SAWaterRepresentativemayallowtheuseofanapprovedsurfaceretarder.The
surfaceretardershallbeusedinaccordancewiththeManufacturer'swritteninstructions.The
ContractorshallprovidethefollowinginformationtoSAWaterRepresentative:
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1.
2.
3.
14.3 ControlJoints
AllcontroljointsshallbeprovidedaslocatedanddetailedontheDrawingsorintheContract.
14.4 ConcreteJointsforWaterRetainingandExcludingStructures
14.4.1
GeneralRequirements
TheContractorshalldevelopaMethodStatementforallconstructionjointdetailinstallations,
includingproposedmaterialstobeused,andsubmitforSAWatersRepresentativeapprovalatleast
28dayspriortoanyconstructionjointworks.
Allwaterproofingmaterialsthatcomeincontactwithwaterintendedforhumanconsumptionshall
beapprovedforuseindrinkingwaterinaccordancewithAS/NZS4020.
Intheeventofanunscheduleddelayinaconcretingoperation,anyproposalbytheContractorto
introduceanunplannedconstructionjointshallbesubjecttoapprovalbySAWatersRepresentative.
TheSuperintendentmaydirectremovaloftheconcreteandreplacementwithfreshconcreteathis
discretion.
Waterstops,sealantsandcoatingsshallbesubjecttoapprovalforusebySAWatersRepresentative,
includingdurabilityreviewtoachievethedesignlife.
Constructionandexpansionjointsurfacesshallreceivespecialattentionwhenplacingconcreteto
ensuretheyhavesoundconcretewithnovoids.
Theapproachforconcretejointsshallprovide:
1.
Multiplebarriersinordertoprovidelevelsofredundancyandbackup;
2.
Highworkabilityconcretewithslumpgreaterthan150mmforwalljointsmaybean
acceptablebarriersubjecttotheSAWaterRepresentativesreviewandapproval;
3.
Accessforjointmaintenanceasoperationalconstraintsallow(e.g.sealantinjointgroovecan
bereplacedbutwaterstopswithintheconcretearenotintendedtobereplaced);
4.
Abilitytoreturnanddrilltheconcretetoallowgroutinjectionofanyleakswithpolyurethane
orotherapprovedmethods;
5.
Abilitytoreturnandtreatleaksbyinjectingreinjectabletubingwhereprovided.
14.4.2
WaterstopProvenDurabilityandRequirements
SurfacesealantmaterialsproposedtobeusedbytheContractorshallhavewrittenconfirmation
fromthemanufacturerthattheyhaveaminimum15yearservicelifeincontactwithchlorinated
and/orchloraminatedpotablewaterwithanyqualificationstotheapprovalofSAWaters
Representative.
PlasticwaterstopsproposedtobeusedbytheContractorshallhavewrittenconfirmationfromthe
manufactureroftheminimumservicelifewhencastintoconcretethatshallachievetheWorks
designlife.
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TheContractorshallprovideevidencefromthesealantmaterialmanufacturerofthelongtermuse
oftheproductselsewhere,samplesofthesealantmaterialsandthenamesandexperienceofthe
applicatorstotheSAWaterRepresentativeforapprovalatleasttwoweekspriortoinstallation.
Waterstopsatwatertightjointsshallincludethefollowingasnominatedonthedrawings:
1.
Rearguardandcentrebulbwaterstopsinstalledintheconcrete;
2.
Hydrophilicsealsinstalledwithintheconcrete,withminimumconcretecoverrequiredbythe
hydrophilicsealmanufacturer.Concreteisrequiredtobeacceptablycompactedsincevoided
concreteabovethehydrophilicsealwillallowwaterpenetrationaroundthehydrophilicseal.
Useofhydrophilicsealsinwaterretainingorexcludingstructuresrequirementsassessmentin
accordancewithCIAZ7/04.UnlessotherwiseapprovedbySAWaterRepresentative,swellable
hydrophilicsealsshallnotbeusedastheprimarywaterstopinwaterretainingstructures;
3.
Gunappliedpolyurethanesealantinagrooveontheconcretesurface.
Alljointsealingsystemsshallbeinstalledinaccordancewiththemanufacturersrecommendations.
TheContractorshallprovidetheSuperintendentwithwrittenconfirmationthatthejointinstallation
hasbeencompletedinaccordancewiththemethodofinstallationrecommendedbythejoint
materialmanufacturer.
15 ConcreteTemperatureandStrainMonitoring
TheContractorshallproposemethodsofassessmentoftheinsituconcretetemperaturerise,
monitoringofpourtemperaturesandstrainwhichshallbesubjecttoapprovalbySAWaters
Representative.
Athermalblockorhotbox(referClause15.1)shallbecastandmonitoredforconcretethatrequires
concreteearlyagethermalcrackassessment(referClause32)anddataisnotavailableforthesame
orsimilarconcreteasdeterminedbySAWatersRepresentative.
SitemonitoringoftemperatureandstrainshallbeconductedoninitialconcretepourstoClause15.2
foreachconcretemixtypeandtheresultsinterpolatedforfuturesimilarconstructedcomponents.
AdditionalsitemonitoringshallbeasdirectedbySAWatersRepresentativewherethetestdata
cannotbeinterpolated.
15.1 ThermalBlock
ThethermaltestblockshallbecompletedinaccordancewithCIAZ7/07toobtainsemiadiabatic
temperaturefortheconcretethatshallbepredictedtoadiabatictemperatureusingguidancefrom
CIAZ7/07.
15.2 SiteMonitoring
Thermocouplesandvibratingwirestraingaugesshallbepositionedatarangeofpositionsto
determinetheconcretepeaktemperature,differentialtemperatureandstrainacrosstheconcrete
section(inaccordancewithCIAZ7/07)ofliquidretaining/excludingandothercriticalelements(e.g.
minimumofoneinsituelementfirstconstructed).Locationsoftemperatureandstrainmonitoring
pointsshallbesubmittedbytheContractorforapprovalbySAWatersRepresentativeandDurability
Consultantthatcompletestheconcreteearlyagethermalcrackassessment(referClause32).
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16 PrecastConcreteUnits
16.1 General
ThisClauseprovidesthespecialrequirementsforprecastconcreteunitsconstruction.
TheContractorisresponsibleforthedesign,manufacture,storage,handling,deliveryanderectionof
precastconcreteunit.Theprecastconcretesuppliershallimplementandmaintainaquality
managementsysteminaccordancewithAS/NZISO9001.
TheContractorshallproduceallshopdrawingsfortheprecastconcreteunitandtheshopdrawings
shallbesubmittedtoSAWaterRepresentativeforapproval.TheContractorshopdrawingsshall
indicatethepositionoftheprecastelementsinthestructure,allreinforcements,prestressing,ducts,
embeddeditemsetc.TheseshopdrawingsshallbesubmittedtoSAWatersRepresentativefor
approvalaminimumof14workingdaysbeforecommencingproductionoftheprecastelements.
Allowaminimumof14workingdaysforreview.Approvaloftheshopdrawingsdoesnotrelinquish
theContractorfromanyresponsibilityofconstructingthestructureinaccordancewiththedesign.
TheContractorshallalsosubmit,forreviewbySAWaterRepresentative,detailsofthelifting
calculationandproposedhandlingandsupportingmethodologypriortoliftingandsupportingthe
units.ThecalculationshallbecertifiedbyacompetentandexperiencedStructuralEngineer.
TheContractorshalldesign,manufacture,store,handle,deliveranderectprecastconcreteunitsin
accordancewith:
1.
AllrequirementscontainedwithinthisStandard;
2.
Allrequirements,recommendationsandguidanceinthefollowingAustralianStandards,as
appropriate:
a.
AS1597.1;
b.
AS1597.2;
c.
AS2159;
d.
AS3850.1;
e.
AS3850.2;
f.
AS/NZS4058;
g.
AS4198;
h.
AS/NZS4676;and
i.
AS5100.5;
3.
Allrequirements,recommendationsandguidanceinNationalCodeofPracticeforPrecast,
TiltUpandConcreteElementsinBuildingConstruction;
4.
Manufactureandacceptanceofprecastconcreteelementsshallbeinaccordancewiththis
Standard,theDrawings,andthePrecastConcreteHandbook(NP:PCH2009)bytheNational
PrecastConcreteAssociationAustralia(NPCAA)inconjunctionwiththeConcreteInstituteof
Australia.
Inthecaseofadiscrepancyamongtheabovedocuments,thisStandardshallgovern.Theorderof
precedenceisthenfollowedbytherelevantAustralianStandard;NationalCodeofPracticefor
Precast,TiltUpandConcreteElementsinBuildingConstructionandPrecastConcreteHandbook.The
ContractorshallalsonotifySAWaterRepresentativeofthesediscrepanciesimmediately.
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Wheretherequirements,guidanceandrecommendationscontainedamongtheabovedocuments
arenotdefined,theContractorshallseekclarificationfromSAWaterRepresentative.
Maximumtemperatureofconcreteduringacceleratedcuringofprecastmanufactureshallnot
exceed70Ctominimisetheriskofdelayedettringiteformation(DEF),exceptwhereatleast20%fly
ash,or40%slagor8%silicafumebymassofbinderisincorporated,inwhichcasethemaximum
temperatureshallnotexceed80C.
Theprecastelementsshallbestored,handledandplacedstrictlyinaccordancewiththeprecasters
recommendations.
Ifholesorliftinglugsareusedintheprecastelementsforhandlingpurposes,theholesorlug
recessesshallbefilledwithaSAWatersRepresentativeapprovedproprietaryshrinkage
compensatinggroutafterinstallation.AnadditionalsurfacecoatingapprovedbySAWaters
Representativeshallbeappliedoverliftinglugpointswheretheconcretecovertothelugdoesnot
meetthespecifiedcover.
Precastconcreteunitsshallbeliableforrejectioniftherequirements,guidanceand
recommendationscontainedintheabovedocumentsarenotfollowed.
Anyunitsdamagedordistortedinexcessofthespecifiedtolerancespriortoorduringerectionshall
bereplacedattheContractorsexpense.
16.2 TraceabilityofPrecastConcreteUnits
Allmanufacturedprecastconcreteunitsshallbetracedfromthecompletionofmanufacturetotheir
finallocationbyauniqueidentificationnumber.
Theidentificationnumber,dateofcasting,themanufacturersnameorregisteredmarkandthe
maximummassshallbemarkedoneveryprecastunit.
Temporaryidentificationshallbemadeonthesurfaceoftheunitwhereitcanbeeasilyidentified.
Finalmarkingshallbemadebyindeliblemarkingmaterial,usinglettersapproximately40mmhigh.
17 SprayedConcrete
17.1 General
ThisClauseprovidesthespecialrequirementsforapplicationofwetprocesssprayedconcrete(i.e.
shotcrete)anddryprocesssprayedconcrete(i.e.gunite).ThisStandarddoesnotcovertheuseof
proprietarysprayappliedcementitiousmaterials.
Onlyshotcreteshallbeusedforstructuralapplicationsincludingbutnotlimitedtoretainingwalls,
soilnailwalls,tunnellinings,supportinginsituexcavatedmaterial,surfaceimprovementandshort
termsupport.
Shotcreteandgunitemaybeusedforconcreterepairworksandfortheconstructionofoverlaysfor
cathodicprotection(CP)ofconcretestructures.
InformationdetailedinCIAZ5,particularlyonmixdesignandmaterialsusedinsprayedconcretecan
beusedtosupplementthisStandardasdeemedsuitablebythedesigner.CIAZ5alsocontainsdetails
onsuitablemethodsofsprayedconcreteapplicationofandtheseprocessescanbespecifiedby
referencetoCIAZ5.ThetestmethodsgiveninthisStandardaresimilartothoseinCIAZ5anditis
recommendeddesignersconsidertherecommendationsontestsandtestfrequencygiveninCIAZ5
whenfinalisingaprojectspecification.
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Sprayedconcreteshallneitherbeappliedinliquidnorappliedinaggressiveenvironmentincluding
butnotlimitedtoseawaterandliquidswithpH<5.
InadditiontotherequirementsspecifiedinClause9.1,anyacceleratorsandotheradmixturesthat
areaddedtoconcreteatthenozzleoratthedeliveryhoseshallbedispensedbycalibrated
mechanicalmeansatdosageratesnotexceedingthemaximumrecommendedbythemanufacturer.
Allchemicaladmixturesaddedtowetprocesspremixedconcreteatthenozzleoratthedelivery
hoseshallbeincludedaspartoftheconcretemixdesignreviewedinaccordancewiththe
requirementsofClause8.2.
RefertoClauses31.1and31.2fortheuseofsteelandsyntheticfibres.
17.2 CompetencyofPersonnelInvolvedinSprayedConcrete
Personnelundertakingthesprayedconcreteworksincludingthenozzleoperator,supervisorand
finisher,shallhaveaminimumof5yearsexperienceinsprayedconcreteapplicationanda
demonstratedcompetencyforsubstratepreparation,sprayedconcreteplacementtechniquesand
inspection,sprayedconcretematerialquality,equipmentoperation,encapsulationofsteel
reinforcement,finishingandcuring.
Thenozzleoperatorshallhaveademonstratedcompetenceandabilitytoproducesprayedconcrete
complyingwiththisStandardandhaveprequalificationtothesprayedconcreteprocedure
requirementsasstatedinClause17.3.
Thesprayedconcretesupervisorshallbetrainedandqualifiedonallaspectsofsprayedconcrete
applicationtechniquesandshallbepresentateachstageoftheworks.Installationpersonnelshall
betrainedandskilledintheapplicationprocedurestobeused.
Documentedevidenceshallbeavailabletodemonstrateexperience,qualification,skillsandtraining
ofpersonnel.
17.3 PrequalificationofSprayingProcedure
17.3.1
General
TheContractorshallsubmitdetailsoftheproposedsprayedconcreteoperations,includingthe
proposedtypeofsprayedconcrete,mixdesign,substratepreparation,methodofapplication,
equipmentandnozzleoperatorsforreviewbySAWaterRepresentativepriortocommencementof
thesprayedconcreteoperation.
TheContractorshallproduceevidenceofthenozzleoperatorspreviousexperienceinthe
applicationofsprayedconcrete.Thenozzleoperatorsshallhavedemonstratedcompetenceand
abilitytoproducesprayedconcretecomplyingwiththisStandard.
17.3.2
PreparationofTestPanels
Twotestpanels750mmx750mmandthegreaterofthespecifiedthicknessor150mmshallbe
constructedbytheContractorforeachnominatednozzleoperatorpriortocommencingfullscale
sprayconcreteoperation,forthepurposeofcheckingthesuitabilityoftheproposedmixdesign,
materials,plantandequipment,themethodofworkingandthecompetenceoftheoperator
intendedfortheProject.
Thetestpanelsshallberepresentativeofthesprayingoperation(s)tobeadopted,theinsitu
material(s),thelocationandtheactualorientation(i.e.vertical,overheadetc.)ofthesprayed
concrete.
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Sprayingofconcreteintothetestpanelswhenplacedhorizontallyonthegroundshallnotbe
allowed.
AdditionalpanelswillberequirediftheContractorshouldchangethemixdesign,plantand
equipmentoroperator.Thetestpanelsshallbestoredandcuredundersimilarconditionstothe
sprayedconcreteplacedinsituandinaccordancewiththerequirementsofthisStandard.
Wherereinforcementintheformofsteelfabricorsteelreinforcement,ortitaniumanodemeshfor
cathodicprotection,istobeusedthesamereinforcementdetailingandnumberoflayersormesh
shallbeprovidedinthetestpanel.
17.3.3
SamplingandTestingofPanels
TheContractorshallcutsampleofcoresfromeachtestpanel,inaccordancewithAS1012.14,at
rightanglestotheplaneofthepanelapproximately48hoursafterthepanelhasbeensprayed.
Coresshallnotbetakenwithin125mmoftheedgesofthepanel.
TheContractorshallensurethat2corespertestpanelarecutfromconcreteadjacenttoorthrough
steelreinforcementforthepurposeofvisualassessmentofthequalityofthesprayedconcrete
adjacenttosteelreinforcement
17.3.4
Prequalification
SprayedconcreteshallnotbeplaceduntilSAWaterRepresentativehasreviewedallprequalification
procedures,theresultsoftesting,andvisualinspectionofboththecoressampledandthetest
panelsinaccordancewiththerequirementsofClause17.3.3.Concreteshallnotbesprayeduntilthe
mixdesignhasbeenreviewedbySAWaterRepresentative.
Whereitisshownthatthesamematerials,mixdesigns,equipment,proceduresandpersonnelhave
givensatisfactoryresultsinsimilarworks,SAWaterRepresentativemayaccepttheconstructionof
testpanelsconcurrentlywiththefirstsprayedconcreteplacedintheWorks.
Theprequalifiedsprayedconcreteprocedureshallbeadheredtothroughoutthesprayedconcrete
operation.Sprayedconcreteshallonlybecarriedoutbythesamenozzleoperatorwhoperformed
theprequalifiedprocedureandproducedtheconformingtestpanels.
Theprequalifiednozzleoperatorandprequalifiedsprayedconcreteproceduremayonlybechanged
afterfurtherprequalificationandwiththeapprovalofSAWaterRepresentative.
17.4 ApplicationofSprayedConcrete
17.4.1
Equipment
Theequipmentusedshallhaveadequatecapacityandbecapableofdeliveringtheconcrete
constituentstothenozzleatauniformratesuchthatthesprayedconcreteleavesthenozzleina
continuousuninterruptedstreamandatavelocityofdischargewhichwillmaximisecompaction,
minimisereboundandoversprayandpreventsaggingoftheappliedconcrete.
Equipmentshallbecapableofallowingthenozzletobemaintainedperpendicular.Forhandspraying
operation,theequipmentshallbeatadistanceoflessthan1mfromthereceivingsurface,and
exceptwherenecessaryattherequiredanglewhichwillproduceadenseinsituconcretewith
maximumadherenceofmaterialontothepreparedsubstrate.
Formachinesprayingoperation,theequipmentshallbeatadistanceoflessthan2moras
recommendedbythemanufacturerfromthereceivingsurface.
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Deliveryhosesshallhaveaninternaldiameterforunimpededflowofmaterialwithoutblockages,
ballingoffibreorsegregationofaggregateand/orfibre.
Chemicaladmixturedispensingequipmentshallbesubjecttoregularmaintenanceandcalibratedat
threemonthlyintervals.
17.4.2
SurfacePreparation
17.4.2.1
SurfaceofInSituMaterial
Excavationtotherequiredlineandgradeshallbecarriedoutinaccordancewiththeproject
drawingsandearthworksspecification.
Theintegrityofthesurfaceoftheinsituorexcavatedinsitumaterialshallbemaintainedfreeof
excessivewettingordryingpriortotheapplicationofthesprayedconcrete.
Actionshallbetakentocontrolgroundwaterbytheinstallationofdrainstopreventcontactwiththe
newlysprayedconcretesurfaceorthedevelopmentofhydrostaticpressuresbehindthesprayed
concrete,effectiveforthedesignlife.
Looseandunsoundmaterialwhichmayaffectadhesionofthesprayedconcretetotheinsitusurface
shallberemovedandthesurfaceshallbecleanedbeforeapplyingsprayedconcrete.Thesurface
shallbedampbutwithoutfreewaterandpreparedsothatnoabruptchangesinthethicknessofthe
sprayedconcreteoccur.
17.4.2.2
ConcreteSurfaces
Looseandunsoundmaterialshallberemovedfromtheexistingconcretesurface.Theconcrete
surfaceshallbethoroughlycleaneddowntoremoveanytracesofdirt,grease,oil,remnantsof
curingcompoundsandorganiccontaminants(i.e.moss,algae,etc.),orothersubstancesthatcould
interferewiththebondofthenewlyplacedsprayedconcrete.Wheresprayedconcreteistobe
placedagainstasmoothconcretesurface,thesurfaceshallberoughenedasaminimumtoan
exposedaggregatefinish(notlessthanCSP7perICRI310.2R2013)bysuitablemeans.Theconcrete
substrateshallbeadequatelyprewettedpriortotheapplicationofthesprayedconcrete.The
surfaceshallbepreparedsuchthatnoabruptchangesinthicknessofthesprayedconcreteoccur.
ForconcreterepairandCPoverlayworkscompletedwithproprietarysprayappliedcementitious
mortarstheconcretesubstrateshallbepreparedinaccordancewiththerequirementsoftheoverlay
manufacturer.
17.4.2.3
SteelworkandReinforcement
Steelworkandreinforcementbarsshallbefreeoflooseorthickrust,oil,grease,paint,mudorany
otherharmfulcoatinginaccordancewithClauses29.1.7,29.2.7or29.4.7asappropriatepriortothe
applicationofsprayedconcrete.
Reinforcementshallbefirmlyfixedtoprovidethecover,clearancesandlapsdescribedinthe
drawings.
17.4.3
Application
Sprayedconcreteshallnotbeplaceduntiltheevidencethatthesubstratepreparation,
reinforcement,andembedmentshavebeenreviewedbySAWaterRepresentative.
Sprayedconcreteshallbeappliedassoonasispracticalfollowingthepreparationofthesubstrateas
specifiedinClause17.4.2.
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Thefinishedsprayedconcreteshallbedenseandhomogeneousforitsfullthickness,without
segregationofaggregateorfibres,andwithoutcollapsing,excessivereboundorothervisible
imperfections.
Eachlayerofthesprayedconcreteshallbebuiltupbymakingseveralpassesovertheworkingarea.
Duringstartingandstoppingofthesprayingoperationorwheneverflowbecomesintermittentor
irregularforanycausethenozzleoperatorshalldirectthenozzleawayfromtheworkuntilitagain
becomesconstant.
Wherealayerofsprayedconcreteistobecoveredbysucceedinglayers,itshallbeallowedtoset
priortoapplicationofthesucceedinglayer.Thesurfaceshallbecheckedforsoundness,segregated,
looseorotherwiseuncompactedsprayedconcrete.Defectiveconcreteshallberemoved,repairedas
specified,cleaned,andwettedusingablastofairandwater.
Forverticalandnearverticalsurfacesapplicationshallcommenceatthebottom.Foroverhead
surfacessprayedconcreteshallbeappliedfromtheshouldertothecrown.
Layerthicknessshallbelimitedtoamaximumof150mmtoensurethatthematerialdoesnotsagor
delaminate.
Thespraynozzleshallbeheldatsuchadistanceandangletoensureplacementofconcretebehind
andaroundsteelreinforcementbeforeanyconcreteisallowedtoaccumulateonitsfrontface.
Sprayedconcreteshallnotbeplacedthroughmorethanonelayerofsteelfabric,reinforcementor
titaniumanodemeshinoneapplication.
Anyareaswherereboundcannotescapeorbeblownfreeshallbefilledwithsoundconcrete.All
oversprayorreboundshallberemoved,priortotheplacementofsprayedconcreteontoadjacent
surfaces.
Wherethesprayingprocessisadverselyaffectedbywindorotheradverseeffectsduringapplication,
sprayingshallbediscontinuedunlessspecialprecautionscanbeimplementedtoensurecompliance
withtherequirementsofthisclause.
SprayedconcreteshallonlybeappliedinaccordancewiththerequirementsofClauses10.1and13
17.4.4
Finishing
UnlessotherwisespecifiedintheContract,thesurfacefinishofsprayedappliedstructuralconcrete
retainingwalls,soilnailwalls,tunnelliningsandotherstructuralcomponentsformingpartof
permanentWorksshallbesteelfloatedandsatisfytherequirementsofClause11.3forClassU2
surfacefinish.
UnlessotherwisespecifiedintheContract,othersprayedconcretesurfacesshallbeleftassprayed.
Allsurfacefinishesshallbeuniformintextureandfreefromanyblowholesorsurfaceimperfections.
17.4.5
TolerancesonSurfaceofSprayedConcrete
TolerancesforsprayedappliedstructuralconcreteshallsatisfytherequirementsofClause21.3.
Wheresprayedconcreteistobeplacedtoaspecifiedshapeitshallbewithin25mmofthatshape
andcontainnodepressiongreaterthan15mmbelowa2metrestraightedge.Forsprayedconcrete
onnaturalsurfacesorsurfaceswithundefinedshapethethicknessshallbewithin0mm+15mmof
thenominalthickness.
TheContractorshallutiliseprobesduringapplicationofsprayedconcretetoenablethemonitoring
oftherequiredthickness.
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TheContractormayproposealternativemethodsforthemonitoringofsprayedconcretethickness
duringapplication,fortheapprovalofSAWaterRepresentative.
17.4.6
Joints
ThepositionsandtypesofjointsshallbeasshownonthedrawingsorspecifiedintheContract.
Theuseofinternalwaterstopsisnotpermitted.
UnlessotherwisespecifiedintheContract,theconstructionjointshallbeofoneoftheapproaches
showninFigure9.12and9.13oftheConcreteInstituteofAustraliasRecommendedPracticeZ5
ShotcretinginAustralia,SecondEdition,preparedbyAustralianShotcreteSociety,excepttheuseof
unformedjoint.
17.4.7
InspectionandSoundnessofFinishedSprayedConcrete
TheContractorshallundertakeavisualinspectionandasoundnessinspectionofthefinished
sprayedconcreteattheageofatleast28days.Visualinspectionshallbefordefectssuchaslackof
compaction,drypatches,voidsorsandpockets.Soundnessinspectionshallbebytappingwitha
small(0.8kg)handheldhammertolocatedrummyorhollowresponseareasthatmightindicatea
possiblelackofbond,delaminationorotherdefect.TheContractorshallremoveandrectifysuch
defects.
17.4.8
RepairofDefectiveAreas
Areasofthefinishedworkthatexhibitalackofcompactionorbonding,drypatches,voidsandsand
pockets,orhaveslumpedorsagged,shallberemovedandrepairedwithasinglecomponent,
shrinkagecompensatingproprietarycementitiousmaterialinaccordancewiththerequirementsof
Clause21toachievethespecifiedlevelofdurability.Theexposedsurfaceoftherepaireddefective
areashallbesimilarintextureandcolourtothesurroundingsprayedconcrete.
18 CrackInspectionandAssessment
Asitecrackinspectionshallbecompletedonallconcretesurfacesinaccordancewiththeprocedures
containedinCIAZ7/07bytheContractorinthepresenceofSAWatersRepresentative:
1.
Atthecompletionofthecuringperiodandwhentheconcretehascooledtoambient
conditions(approximately7daysaftercast).Thiswillidentifyanyunexpectedcrackingand
allowadjustmentsasneededforfutureconcretepours;
2.
Immediatelyafterallconstructionactivitiesarecompleted(priortobackfillingofsoilif
requiredforbelowgroundlevelstructures)andallowingsufficienttimepriortooperational
usetodocumentcrackpositionsandmeasurethesurfacewidthofanycracksthathave
formedandcompleteanyrepairsthatarejustified;
3.
12monthsaftercompletionoftheProjectorpriortotheendofthedefectsliabilityperiod,
whicheverisearlier;
4.
Inadditionforliquidretainingstructures,detailedinspectiononthelastdayoftestingfor
liquidtightnessinaccordancewithAS3735Section7toidentifyanyvisiblewaterleakageor
darkercolouredconcretethatindicateswaterpenetrationthroughcracks,plusother
constructionjoints,surfacevoidsorotherrequirementsofthisStandard.
Allinspectionsshalldeterminethepresenceofanycrackswithwidthgreaterthanthatspecifiedin
Clause7.2.4.
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WherecrackwidthgreaterthanthatofspecifiedinClause7.2.4,theyshallbeidentifiedasanon
conformance.Inaddition,theContractorshall:
1.
MeasurelengthandwidthofcracksinaccordancewithCIAZ7/07;
2.
MarkcracksonplanandelevationdrawingsandissueasAsBuiltConcreteCracksdrawings
inaccordancewithaformatacceptabletoSAWatersRepresentativeandissuethedatainan
MSExcelspreadsheet;
3.
Undertakeanassessmenttoevaluatetheinfluenceofthenonconformingcracks(moredetails
below);
4.
Establishthecause(s)ofthecracks,crackwidth,themoistureconditionofthecrackand
whetheracrackisactiveorinactiveincludingconcreteearlyagethermalcrackassessmentin
accordancewithClause32;
5.
SAWatersRepresentativemayrequirerepresentative50mmdiametercoresamplestobe
takenthroughrepresentativecrackstotheinteriorreinforcementdepthtoassistinevaluation
offuturedurabilityandcrackrepairsrequired;and
6.
SubmitacrackrepairmethodologyforSAWaterRepresentativereview,priortoanyrepair
worksbeingundertakeninaccordancewithClause21.
Theassessmentofthecrackedconcretestructureandtheproposedcrackrepairmethodologyshall
beundertakenbyaDurabilityConsultantoranexperiencedconcretetechnicalspecialistwitha
minimumof5yearspracticalexperienceinthediagnosticassessmentandinvestigationofconcrete
structures.Thecrackrepairmethodologyshallincludedetailsofthecrackfillingmaterialproperties,
location,surfacepreparationandmethodofapplication,likelypostrepairedcrackbehaviour,and
effectontherequirementsspecifiedinthisStandard,thestructuraladequacyimpactanddurability
impacttoachievetherequireddesignlifewithoutincreasedmaintenancebycomparisonto
uncrackedconcrete.
Note:GuidanceonthedurabilityofconcretewithcrackwidthsisgiveninCIRIAC660andwillbe
availableinthefuturefromCIARecommendedPracticeZ7/06.
19 SiteConcreteCoverMeasurements
Asitecoverinspectionshallbecompletedafterconstructiononarepresentativenumberofexterior
andinteriorareasusingacovermeterwithcapabilitiescomplyingwithBS1881204.Inspectionshall
beconductedinthepresenceoftheSAWaterrepresentative.Wheremorethan5%fornormal
compactionandqualitycontrol,and1%forintensecompactionandhighlevelofqualitycontrol,of
covermeasurementsarelessthanspecified,theContractorshallcommissionadurabilityreviewbya
DurabilityConsultantandrectifytheprobleminaccordancewiththerecommendationsofthe
DurabilityConsultant,andtotheacceptanceofSAWatersRepresentative.GuidanceisgiveninCIA
Z7/04.
20 WallConcreteCompactionforLiquidRetainingStructures
Concretecompactionatthebaseofwallshasthegreatestriskofinadequatecompactionandshallbe
inspectedandtestedaftercompletionasbelow.
1.
Visualinspectiontodetermineanysurfacevoidsorbleedchannels.Photographsshallbetaken
torecordallvisibledefects;
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2.
Mechanicalhammertapping(veryhardwitha1kghammer)oftheconcretesurfaceto
determineanyskimconcretematrixovervoidedinteriorconcrete.Photographsshallbetaken
torecordallvisibledefectsidentifiedbyanysurfaceskimremoval;
3.
Concretecoresamplingshallbecarriedoutonconcreteinthetrialwallcasting,whereatrialis
carriedout,oronthefirstwallcastofeachconstructiontype,andifconcretevoiddefectsare
indicatedbyvisualinspectionormechanicalhammertappinginvestigations,whereinstructed
bySAwatersRepresentative.Aminimumoftwocoresshallbetakenfromthewallelement
tobetested:
4.
a.
Coresamplesshallbe50mmdiameter.Thecorelocationsshallbedeterminedbyvisual
inspectionandmechanicalhammertappingfindingsandshallbeinareasofworst
defects,ifany.Thecoresshallbelocatedtoavoidreinforcementbarsbyuseofcover
meterrebardetection;
b.
Coresshallbefromtheexteriorsurfaceofthewallunlessthedefectsareclearlyonthe
innerface.Thecoresshallgotomiddepthofthewallonly;
c.
Photographsshallbetakentorecordallcorepositions(i.e.surfacebeforecoring),cores
extracted,andallcoreholesshowinginsituconcrete;
AllcoresamplingshallbeundertakenbytheContractor.
21 ConcreteRepair
21.1 General
ThisClauseappliesonlytorepairofminorandnonstructuralconcretedefectsincludingcracks,
voids,honeycombing,blowholes,airpockets,bleedvoids,concretewhereformworkremovalcreates
spallsortheconcretesurfacenotconformingtothesurfacefinishclassasspecifiedinClause11.
TheContractorshallmakegoodanyconcretedefectsandremoveanyprotrusionsorexcessconcrete
tothespecifiedfinishrequirementsasrequiredbythisStandardinaccordancewiththeprocedures
containedinHB84.
TheContractorshallprovideadetailedRepairMethodStatementforconductofeachrepair
includingtechnicaldatasheetsofproprietarymaterialstobeused,bondingagents,coatings,extent
ofsawcuttingandbreakout,surfacepreparation,placementmethod,curing,qualitycontrolanda
summaryoftheRepairContractorsrelevantexperience,submittedtoSAWatersRepresentativeat
leastseven(7)workingdayspriortocommencementofrepairwork.Repairsshallnotproceeduntil
theContractorsRepairMethodStatementhasbeenapprovedbySAWaterRepresentative.SA
WaterRepresentativemayrequestsubmissionofindependenttestdatatoconfirmperformance
parametersstatedonproductdatasheet.
21.2 ConcreteRepairMaterialsandProcedures
Contractorrepairofconcretedefects(referClause21.1)shallbetotheapprovalofSAWaters
Representative,andtoachieveacolourmatchwithadjoiningexternalsurfaceconcretewhenrepair
workhasset.
RepairofconcreteshallbeperformedbyacceptablyskilledworkersapprovedbySAWaters
Representative.TheContractorshallkeepSAWatersRepresentativeadvisedastowhenrepairof
concretewillbeperformed.
UnlessinspectioniswaivedbySAWaterRepresentativeineachspecificcase,repairofconcreteshall
beperformedonlyinthepresenceofSAWaterRepresentative.
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TherepairedconcretesurfacesshallbetotherequirementsofthisStandard.
Accordingtothenatureofthedefecttoberepaired,repairsshallbebyoneofthefollowing
methods:
1.
Prebaggedproprietarycementitiousrepairmortarforconcretedefectstypicallyofdepth
0mmto70mm;
2.
Proprietarycementitiousmicroconcreteforconcretedefectstypicallyofdepth50mmto
200mm;
3.
Concreteasspecifiedintheworksforexcessivevoidsorconcretereplacement;
4.
Epoxyresinbasedrepairmortarforconcretedefectsafterfullevaluationofpotential
incompatibilitywithconcreteduetodifferentialmovement(e.g.thermalandmoisture
gradients)plusbondadhesionwithinepoxyopentime;
5.
Polyurethaneresinorsimilarflexiblematerialsinjectionofcracksfordurabilityrepair;
6.
Lowviscosityepoxyresininjectionofcracksforstructuralrepair;
7.
Protectivecoatingsorfinishesforinadequatecover;and
8.
OtherstobeapprovedbySAWatersRepresentative.
Allproprietaryrepairmaterialsshallbeusedstrictlyinaccordancewiththemanufacturers
instructions.
Protectionandcuringofcementitiousrepairmaterialsshallbecarriedoutinaccordancewiththe
requirementsoftheproductmanufacturersinstructions,minimumseven(7)dayscuringin
accordancewithClause13.3andasapprovedbySAWatersRepresentative.
WheredirectedbySAWatersRepresentative,areasofconcretetoberepairedshallbeTrial
RepairstoproveacceptablematerialsandmethodsasstatedintheContractorsRepairMethod
Statementpriortoproceedingwithfullscalerepairworks.Thetrialareashallbeaminimumof
0.5morasdirectedbySAWatersRepresentativeandtheentiretrialrepairprocessshallbe
observedbySAWatersRepresentative.
21.3 RepairedConcreteTolerances
Thetoleranceonedgesandsurfacesinplanandlevelshallbe3mm.
Maximumallowanceforirregularitieswhenmeasuredwitha2.0metrestraightedgeshallbe3mm.
Inaddition,evennessshallnotdeviatebymorethan1mmwhencheckedwitha300mm
straightedge.
21.4 RepairedConcreteQualityControl
TheContractorshallcompleteavisualinspectionanddelaminationsurvey(refertoCIAZ7/07)to
identifyanydefectsofallconcreterepairareasatseven(7)daysaftertherepairsarecompletedand
immediatelypriortotheapplicationofanycoating.Thedelaminationsurveyshallbeconducted
usingasmallhammeralongthewholesurfaceareaoftheconcretepatchrepairsanddelaminated
areasshallbecharacterisedbyadrummyorhollowsound.Testingfordelaminationareasshallbe
conductedinthepresenceofSAWatersRepresentativeunlesspriorapprovedotherwise.Bond
adhesionstrengthtestingoftherepairtothesubstrateconcreteshallbecompletedatthediscretion
ofSAwatersRepresentative.
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ThereshallbenodefectsintheconcreteaslistedatClause21.1,includingnocracksattheinterface
oftheconcreterepairwiththeexistingconcrete.
AlldefectsidentifiedbytheContractorshallberecordedandsubmittedtoSAWaters
Representativewithinthree(3)daysofcompletingthesiteinspection.
Alldefectiverepairsincludingdelaminatedpatchrepairsshallberemovedandrepairedin
accordancewiththerequirementsofClauses21.1and21.2tothesatisfactionofSAWaters
Representative.
TheContractorshallrecordanddocumentallrepaircompletedincludingrepairmethodstatement,
locationofrepairs,depthandextent,materialsusedplustechnicaldatasheets,qualitycontroltests
conductedandrepresentativephotostothesatisfactionofSAWatersRepresentative.
22 ConcreteQualityControl
22.1 General
TheContractorshallberesponsibleforalltesting,asspecified,toprovecompliancewiththe
requirementsofthisStandard.Thisincludesanyinspections,checks,calibrationsorselfauditsas
requiredbythisStandard.
IrrespectiveofthetestingcarriedoutbytheContractor,SAWatersRepresentativereservestheright
tocarryoutindependentinspectionsandaudittesting.ThesecostsshallbebornebythePrincipal,
exceptinthecaseoffailureandsubsequentreteststovalidateconformity;theyshallbeatthe
Contractor'sexpense.
SAWatersRepresentativemaydirecttheContractortocarryoutadditionaltesting(increaseinthe
frequencyoftesting)tothatspecified.ThecostofadditionaltestingwillbeatthePrincipal's
expense,butwherefailuretocomplywiththespecifiedrequirementshasbeenidentified,theyshall
bebornebytheContractor.Thecostofretestingofworkwhichhasfailedandbeensubsequently
rectifiedasaresultofadditionaltestingshallbebornebytheContractor.
22.2 ConcreteQualityCriteria
AllconcretetobeincorporatedintheWorksshallbemanufacturedinaccordancewithAS1379
exceptasotherwisestatedinthisStandard.Concretematerialsshallbeproportionedsothat,when
transported,placed,compactedandcuredinaccordancewithAS3600foradesignlifeupto50years
andAS5100.5foradesignlifegreaterthan50yearsupto100years,thehardenedconcretewill
complywiththestrengthgradesgiveninthisStandard,asshownontheDrawingsandasdefinedin
AS1379.
Allconstructionmaterialsthatwillcomeincontactwithdrinkingwaterwhentheconcreteisin
operationuseshallbeapprovedforuseindrinkingwaterinaccordancewithAS/NZS4020.
22.3 BatchCertificates
Allconcretesuppliedshall,atarrivalonsite,beprovidedwithbatchplantcertificatesforthe
respectivebatches.Batchcertificatesshallcontainallinformationabouttheconcretesuppliedas
requiredbyAS1379andinadditiontherequirementsofClause9.2.
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22.4 RequirementsforTestingFacilitiesandPersonnel
AlltestingfacilitiesandfieldtestingpersonnelshallholdcurrentaccreditationtoISO17025fromthe
NationalAssociationofTestingAuthorities,Australia(NATA)fortherelevanttestmethods,unless
specificallyexemptedbySAWatersRepresentative.
TheContractorshallsupplyacopyofalltestresultstoSAWatersRepresentativenolaterthantwo
(2)workingdaysaftertestinghasbeencompletedforcompressionstrengthandnolaterthanfive(5)
workingdaysaftertestingforallothertests.
22.5 TestingFrequency
InspectionandTestPlans(ITPs)shallnominatetheproposedtestingfrequencytoverifyconformity
oftheitemanditshallnotbelessthanrequirementsinthisStandard.Whereaminimumfrequency
isnotspecifiedaminimumfrequencyshallbenominatedforapprovalbySAWatersRepresentative.
VariationstoreducethefrequencyoftestingshallbeatthediscretionofSAWatersRepresentative.
WheretheContractorhasimplementedasystemofstatisticalprocesscontrolandcandemonstrate
thatalowerfrequencycanassurethequalityoftheproduct,SAWatersRepresentativemayagree
toalowerfrequency.
22.6 SamplingandTesting
FreshconcreteshallbesampledandtestedinaccordancewithAS1379andAS3600Section17.1.6,
forprojectassessmenttesting.
TestspecimensshallbetestedinaccordancewithrequirementsinthisStandard.
22.7 Noncompliances
TheContractorshallrecordandimmediatelyreportallnoncomplianceswiththisStandard,including
allreferencedtestswithintheStandardfromthelistatClause1.3,toSAWatersRepresentative.The
recordshallindicatethenatureofthenoncompliance,thecorrectiveactiontakenandthe
location(s)withintheWorkspotentiallyoractuallyaffectedbythenoncompliance.
ThefollowingstepsshallbetakenbytheContractortotheapprovalofSAWatersRepresentative.
1.
Identifytheextentandcauseofthenoncompliance;
2.
Takemeasurestopreventreoccurrence,includingsuspendingworks;
3.
Proposeinvestigationstodeterminethequalityoftheconcreteandothermaterialsinthe
works;
4.
Proposerepairactionstoreinstatetheappearance,strengthanddurabilityoftheaffected
Works,withdurabilityreviewinparticularforwatertightnessofliquidretainingorexcluding
elements;and
5.
TheContractorshallengageaDurabilityConsultant(referCIAZ7/01)foranymattersthat
reducedurabilityincludingtoachievetherequireddesignlifewithoutadditionalinspection
andmaintenance.
SAWatersRepresentativeshallreviewallnoncompliancesanddeterminerejectionofconcretein
accordancewithClause22.8orconcreterepairinaccordancewithClause21.
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22.8 RejectionofConcrete
ConcretesuppliedtositebutdeemedbySAWatersRepresentativetonotcomplywiththe
acceptancecriteriawillberejectedbySAWatersRepresentative.Hardenedconcretethatexhibits
anyofthedefectslistedinSection17.1.7ofAS3600shallberejected.
Hardenedconcretewhichexhibitsa7daycompressivestrengthbelow60%usingGPcementor50%
usingGBorLHcementofthe28daycharacteristicstrengthforthatgradeofconcreteshallbe
consideredasasufficientbasisforrejection.ThisshallconstitutesufficientgroundsforSAWaters
RepresentativetoinstructtheContractortowithholdfurtherworkonthosecomponentswhich:
1.
Constitutemajorstructuralmembers;or
2.
Aresupportedorconnectedtothecomponentswiththeconcreteofsuspectquality.
Untilthe28daycharacteristicstrengthoftheconcreteisobtainedandtheconcreteacceptedor
rejectedaccordingly.TheContractorshallnotbeentitledtoanyclaimforcompensationorContract
extensionoftimeconsequentialtotheissuanceofSAWatersRepresentativeinstructiontowithhold
suchworkirrespectiveofthe28daystrengthofthesuspectconcrete.
AnyconcreterejectedbecauseofnoncompliancewiththerequirementsofthisStandardshallbe
replacedatthecostoftheContractor.Thecostofremovalandreplacingothercomponentsor
worksdeemednecessarybecauseoftheirconnectiontotherejectedconcreteshallbebornebythe
Contractor.SAWatersRepresentativewillnotconsideranyclaimarisingfromtherejectionofnon
complyingconcretesupplyorinstallation.
23 SuperWorkableConcrete
23.1 General
UnlessspecifiedotherwiseinthisClause,superworkableconcreteshallconformtothisStandard.
Superworkableconcreteshallonlybeusedinveryheavilyreinforcedelements,ininaccessibleareas
andwhereveryrapidconcreteplacingisdesired.Theuseofsuperworkableconcreteshallbe
approvedbySAWaterRepresentative.GuidanceisavailableformCIAZ40.
Wheresuperworkableconcreteisproposed,atrialmixismandatoryandshallbeundertakenin
accordancewiththerequirementsspecifiedinClause8.Thesuperworkableconcretesuppliershall
implementandmaintainaqualitymanagementsysteminaccordancewithAS/NZISO9001forthe
concretebatchingandproductionprocess.
Thesuperworkableconcretemixingmethodshallbedeterminedbasedontheexistingrecordsorby
conductingtests.
Therequirementsforslumpflow,differencebetweenslumpflowandJringflow,timeforthe
concretetoreach500mmdiameter(T500)andVisualStabilityIndexshallbeappliedinlieuofthe
slumprequirements.
23.2 RequirementsforFreshSuperWorkableConcrete
Table9MinimumAcceptableCriteriaforFreshSuperWorkableConcrete
Property
TestMethod
AcceptableCriteria
SlumpFlow
AS1012.3.5
550mmto800mmSpread
DifferencebetweenSlumpFlowand
JRingFlow
AS1012.3.5
50mm
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Property
TestMethod
AcceptableCriteria
Timefortheconcretetoreach500
mmdiameter
AS1012.3.5
5seconds
VisualStabilityIndex
ASTMC1611
23.3 SamplingandTesting
Samplingandtestingforsuperworkableconcreteshallbeinaccordancewiththerequirementsof
concreteinthisStandardexceptthattheslumpflow,differencebetweenslumpflowandJringflow,
timefortheconcretetoreach500mmdiameter(T500)andVisualStabilityIndexshallbesampled
andtestedatthesamefrequencyastheslumptestforothertypeofconcrete.
Whenmakingtestcylindersforsuperworkableconcretethetestsampleshallbeplacedintothe
cylindermouldsfromaheightnotexceeding100mmfromthetopofthemould.Theplacingofthe
concreteintothemouldsshallbedoneinonecontinuousmotion.Withtheexceptionoflighttapping
ofthesidesofcylindermouldswithaplasticmallet,roddingorvibrationshallnotbeappliedtotest
cylindersmadeupofsuperworkableconcrete.
23.4 SelfCompactingConcrete(SCC)
InadditiontotherequirementsspecifiedinClause23.1to23.3,compactionasperClause10.2shall
notapplywithSCCtobeselfconsolidatingwithoutcompaction.Untiltheconcreteishardened,self
compactingconcreteshallnotbesubjectedtoanyphysicaldisturbanceafterplacement.
24 UltraHighPerformanceConcrete
ForthepurposeofthisStandard,ultrahighperformanceconcreteisahighstrength,ductileconcrete
withcompressivestrengthinexcessof100MPawhentestedaccordingtoAS1012.9,modulusof
ruptureinexcessof18MPawhentestedaccordingtoAS1012.11andfractureenergyinexcessof
10N/mmwhentestedaccordingtoASTMC1018.
UnlessspecifiedotherwiseinthisClause,ultrahighperformanceconcreteshallconformtothis
Standard.TheuseofultrahighperformanceconcreteshallbeapprovedbySAWaterRepresentative.
TheContractorshallprovideaprojectexecutionplanandmethodologyforusingultrahigh
performanceconcrete,basedonthefullunderstandingofmaterialcharacteristicsduringplacement
andafterhardening.Theultrahighperformanceconcretesuppliershallimplementandmaintaina
qualitymanagementsysteminaccordancewithAS/NZSISO9001fortheconcretebatchingand
productionprocess.
Trialmixismandatoryandshallbeundertakeninaccordancewiththerequirementsspecifiedin
Clause8.Thefreshandhardenedconcreterequirementsshallbebasedonappropriateindices
containedwithinthisStandardaccordingtothetypeofultrahighperformanceconcrete,
constructionconditionsandconstructionmethodsandshallbedemonstratedbywayoftesting.
25 AlkaliActivatedConcrete
ForthepurposeofthisStandard,alkaliactivatedconcreteisconcretemadeofessentiallyanybinder
systemderivedbythereactionofanalkalimetalsource,eithersolidordissolved,withasolidsilicate
oraluminosilicaterichpowder.
UnlessspecifiedotherwiseinthisClause,alkaliactivatedconcreteshallconformtothisStandardand
alltechnicalrequirementsofthisStandardshallbemet.Alkaliactivatedconcreteshallalsocomply
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withAS1379.Whilealkaliactivatedconcretemaynotcontaincement,inthisStandard,theterm
ConcreteinAS1379shallbeinterpretedtoincludealkaliactivatedconcrete.
TheuseofalkaliactivatedconcreteshallbesubjecttoapprovalbySAWaterRepresentative.
TheContractorshallprovideaprojectexecutionplanandmethodologyforusingalkaliactivated
concrete,basedonthefullunderstandingofmaterialcharacteristicsduringplacementandafter
hardening.Thealkaliactivatedconcretesuppliershallimplementandmaintainaquality
managementsysteminaccordancewithAS/NZSISO9001fortheconcretebatchingandproduction
process.
Trialmixismandatoryandshallbeundertakeninaccordancewiththerequirementsspecifiedin
Clause8.3.Thefreshandhardenedconcreterequirementsshallbebasedonappropriateindices
containedwithinthisStandardaccordingtothetypeofultrahighperformanceconcrete,
constructionconditionsandconstructionmethodsandshallbedemonstratedbywayoftesting.
Wherealkaliactivatedconcreteisproposed,thealkaliactivatedconcretesuppliershallimplement
andmaintainaqualitymanagementsysteminaccordancewithAS/NZSISO9001fortheconcrete
batchingandproductionprocess.
26 FormworkandFalsework
26.1 General
Formworkandfalseworkincludingalltemporarysupportingmembers,shallconformtoSafeWork
AustraliaFormworkandfalseworkguidancematerial,therelevantAustralianStandardsincludingbut
notlimitedtoAS3610andAS3610.1,andthisStandard.
Formworkandfalseworkshallbedesignedconsideringthetype,scaleandimportanceofthe
structureandtheconditionsofconstructionandenvironment.
Formworkandfalseworkshallbedesigned,inspectedandcertifiedbycompetentandexperienced
engineer(s)suchthattheerectionofformworkandfalseworksatisfytheperformancerequirements.
Errorsinlineorleveloftheformwork,orpositioningand/orquantityofsteelreinforcementshallbe
correctedpriortoplacingconcrete.TheContractorwillberesponsibleforanydefectstothe
formwork,reinforcement,embeddedcomponents,ortheformedconcretesurface,whichmay
becomeapparentduringoraftercastingtheconcrete.
UnlessitiswaivedbySAWaterRepresentativeineachspecificcase,therelevantCertificateof
ComplianceforformworkandfalseworkshallbesubmittedtoSAWatersRepresentative.The
applicationofanyloadshallnotproceeduntiltheCertificateofComplianceoftheconstructed
formworkhasbeenreviewedbySAWatersRepresentative.
Formworkdrawingsanddesigncomputations,ifrequiredbySAWaterRepresentative,shallalsobe
preparedbytheContractorandsubmittedforexamination.
Blockouts,inserts,ducts,embeddeditems,etc.shallbelocatedandfixedsothattheconstruction
tolerancesspecifiedarecompliant.
26.2 FormworkConstruction
Formworkshallbewatertight,bracedandtiedtogethertoconfinefreshlyplacedconcreteand
maintainpositionandshapeduringconstruction.Formworkshallbeconstructedinsuchawaythatit
canberemovedwithoutdamagetotheconcrete.
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Whereformworkisintendedforreuse,thedeteriorationofthematerialsfollowingtheiruseand
handlingshallbeassessed.Formswhichbecomeunsatisfactoryshallnotbeused.
UnlessspecifiedotherwiseintheContract,allcornersofcastinplaceorprecastconcreteshallhave
20mmx20mmchamfersorfillets.Chamfersandfilletsshallbeformedandcastintegrallywiththe
concretemember.Cuttingorgrindingofchamfersshallnotbeallowed.
Theinteriorsurfaceofformworkshallbethoroughlycleanedoutandtreatedwithreleaseagentor
lubricanttopreventadhesionoftheexposedconcretesurface,inaccordancewiththe
manufacturersinstructions.Thereleaseagentorlubricantshallbeofthenonstainingtypeandshall
notdiscolourthesurfaceoftheconcrete.Thereleaseagentorlubricantshallbeapplieduniformlyin
athinfilmandanysurplusremovedpriortotheconcreteplacement.Reinforcementandother
embedmentsshallnotbesoiledbythereleaseagentorlubricant.InaccordancewithClause7.2.5
thereleaseagentshallbecompliantwithAS/NZS4020ifresidualamountscomeincontactwith
potablewater.
Allformsshallbecleanedandfreefromsand,shavings,tiewireendsandotherdebris.Surpluswater
shallbedrained.Ifnecessary,temporaryopeningsshallbeprovidedatappropriatepositionsinthe
formtofacilitatecleaning,inspectionandplacingconcrete.Anytemporaryopeningsshallbeclosed
inpropermannerpriortoplacingconcrete.
26.3 FormTies
Formtiesshallconsistofbolts,rodsorotherfasteningsystemsthatwillensurethatformsor
falseworkarerigidlyfixed.
Formtiesforuseinwaterretainingandwaterexcludingstructuresshallbeapprovedproprietary
productsspecificallydesignedandmanufacturedtobewatertight.Onlyapprovedwatertightformtie
productsbymanufacturersPCH,Peri,MaxFrankorequivalentapprovedshallbeused.
Formtiesthatafterremovalleaveaholeextendingthroughoutthethicknessofaconcretesection
willnotbepermitted.
Anyembeddedformtiesshallremainembeddedandshallterminatenotlessthantheminimum
coverspecifiedintheContractorthisStandard.
HolesorgapsleftfromformtiesshallberepairedinaccordancewithClause21andthetie
manufacturersinstructions.
Topformtiesshallnotbelocatedwithin150mmofthetopofthepour.
26.4 RemovalofFormwork
Formworkandfalseworkshallberemovedinsuchamannerandsequencethattheconcrete
elementisnotsubjectedtoimpact,excessiveloadoreccentricloadandnodamagetotheconcrete
surfaceoccurs.
Minimumformworkstrippingtimesshallbeinaccordancewiththeminimumformworkstripping
timessetoutinTable5.4.1ofAS3610andguidancegiveninCIAZ7/04.
Formworkandfalseworkshallnotberemoveduntiltheconcretehasachievedsufficientstrengthto
carryitsownweightandanyloadssuperimposedduringthecourseoffurtherconstruction.
TheContractorshalldeterminethetimingandsequenceoftheremovaltakingthestrengthof
concrete,thestructuretypeandimportance,membertypesanddimensions,loadsimposedonall
members,temperature,weatherandventilationintoappropriateconsideration.Formworkfor
successivewallliftsshallnotbesupportedbypreviouslyplacedconcreteuntilthatconcretehas
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achievedaminimumcharacteristicstrengthof15MPa.Horizontalforms(forsuspendedslabsand
beams)shallnotberemoveduntilacompressivestrengthof25MPahasbeenachieved.The
ContractormaysubmitStructuralEngineercertifiedcalculationsforlowerstrengthformwork
supportorremovalforreviewandapprovalbySAWatersRepresentative.
Incaseswhenthestructureissubjectedtoloadsimmediatelyaftertheremovalofformworkand
falsework,theconcretestrength,thestructuretypeandthecharacteristicandvalueofimposed
loadsshallbecarefullyconsideredinordertoavoidharmfulcracksandotherdamagetothe
structure.
Toreducethelikelihoodofcrackingduetothermalshock,formworkshallnotbestrippedinthe
coldestpartoftheday.Theperiodoftimebeforestrippingshouldbeincreasediftheaverage
temperatureoverthecuringperiodislessthan5C.AS3600providesguidanceontheincreased
durationinthisperioddependingontheambienttemperature.
NotwithstandingtheminimumstrippingtimesinTable5.4.1ofAS3610,formworkshallonlybe
removedwhereitcanbedemonstratedthatdoingsowillnotinitiateearlyageconcretecracksby
prematureremovalofplywoodformwork,ifplywoodformworkisused.
Curingshallbeimmediatelyappliedtotheexposedconcretesurfaceiftheformworkisremoved
withinthecuringperiod(referClause13.7).
26.5 ProprietaryFormworkandFalseworkSystem
WhereproprietaryformworkproductsareapprovedbySAWaterRepresentative,theContractor
shallinstallsuchformworkinaccordancewiththemanufacturer'sspecificationand
recommendation.
27 InsertandSupport
InsertsandsupportsshallbeinaccordancewithAS3600orAS5100.5asappropriate,asspecifiedin
thisStandardandtothesatisfactionofSAWaterRepresentative.
InsertsandsupportsshallbeaccuratelycastintotheconcretebytheContractor,within4mmof
theirindicatedpositionunlessshownotherwiseontheDrawings.Theprovisionofholesorpockets
andthesubsequentgroutingofinsertsandsupportswillnotbeallowedunlessapprovedinwriting
bySAWaterRepresentative.
Tappedholesandotherrecessesshallbesealedandthesealingmateriallaterremoved.After
strippingofformwork,allconcreteandothermaterialsshallbecleanedfromthesurfacesofinserts
andsupports.
27.1 EmbedmentofInserts
TheContractorshallinstall,fixandcastinallpipes,pipesleeves,bolts,conduits,frames,castings,
steelbeamsandotheritems,whicharerequiredtobewhollyorpartiallyembeddedintheconcrete,
asshownontheDrawings.
Beforecastingofinsertsandopenings,theContractorshallchecktheirpositioning,alignmentand
elevationtoensuretheyareaccuratelyplacedandadequatelysupportedinsuitabletemplates,
framesandforms.Anymisplacementordeviationfromthespecifiedtoleranceshallbecorrectedby
theContractorattheContractor'sexpensetothesatisfactionofSAWatersRepresentative.
Metalembedmentitemsshallbefixedinplacebytyingwithtiewiremadeofthesamemetaland
samegrade,orbyanchoringtotheformsusingfixingsmadeofthesamemetalandsamegrade.
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TheContractorshallensureproperplacementandadequatecompactionoftheconcreteare
achievedaroundtheinsertsandopeningsasspecifiedinClause10.2.
27.2 Supports
TheContractorshallcheckthepositioningofsupportsforfloorplates,floorgratings,orotherfixtures
requiringevenanduniformbearing,beforesettingthesupportswithconcreteormortar.Failureto
obtainsatisfactoryuniformityofbearingshallberectifiedbytheContractor,asdirectedbythe
DesignerandapprovedbySAWatersRepresentative,attheContractor'sexpense.
28 BarChairsandSpacers
AllbarchairsandspacersshallcomplywithAS/NZS2425andthisStandard,subjecttoapprovalby
theSAWaterRepresentative.AllspacersandchairsshallbemanufacturedinanAS/NZISO9001
approvedproductionfacility.
Barchairsandspacersforconcreteinwaterretainingorwaterexcludingstructuresshallbe:
1.
Concreteofnotlesserdurabilitycharacteristicsthantheconcretetobeplacedaroundthem,
andshallotherwisecomplywiththerequirementsofAS/NZS2425;and
2.
Highdurabilityproprietaryfibrecementmouldingsorextrusions.
Note:Responsibilityforfixingreinforcementwiththecorrectcoverandforensuringthatspacersand
chairsarecorrectlyspacedandhavetherequiredperformancecharacteristicsrestswiththe
Contractor.
29 Reinforcement
29.1 SteelReinforcement
29.1.1
Materials
AllsteelreinforcementmaterialsshallconformtoAS/NZS4671andthisStandard.
Thereinforcementmaterialsupplierincludingbutnotlimitedtomanufacturersandprocessors,shall
becertifiedbytheAustralasianCertificationAuthorityforReinforcingandStructuralSteelsforthe
supplyofthesteelreinforcement.
Ifrequested,theContractorshallsupplytoSAWatersRepresentativecopiesofthemanufacturers
testcertificatesidentifiablewiththereinforcementsuppliedorprovidedocumentaryevidencethat
allproductsmeettherequirementsofAS/NZS4671andthatthesupplierhasasysteminplaceto
preventnonconformingmaterialfrombeingsupplied.
29.1.2
Schedules
TheContractorshallberesponsiblefortheproductionofallreinforcementschedules,shopdrawings
ofallprefabricatedreinforcementcagesthatmaybenecessaryforthefabricationofthe
reinforcement,includingalltiewire,supportbars,spacerbarsandthelike.
Acopyofthereinforcementschedulesandprefabricatedreinforcementcageshopdrawingsshallbe
submittedtoSAWaterRepresentative.
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29.1.3
Fixing
Reinforcementshallbeadequatelytiedtogethersuchastoformarigidcage,whichprevents
displacementofbarsormeshesandmaintainsdimensionaltolerancesunderallloadsappliedbefore
andduringtheconcreteplacement.TherequirementssetoutinBS79732shallberegardedasa
minimumforfixingthereinforcement.Allsteelreinforcementinpositionshallbeinspectedand
approvedbySAWatersRepresentativebeforetheconcreteplacementcommences.
Note:ResponsibilityforsecurelyfixingreinforcementrestswiththeContractor.
Tiewireshallbeannealedsteelwirehavingadiameterofnotlessthan1.2mm.Plastictiesorclips
arenotpermitted.
TheminimumclearcovertothetiewireshallbeequaltothatspecifiedinthisStandardorthat
designatedintheContractforthereinforcementbeingtied,lessthediameterofthetiewire.
Projectingendsoftiesshallnotencroachintotheconcretecoverzone.
Theendsofreinforcementformingalappedspliceshallbetiedtogetherinatleasttwoplaces.
TackweldingshallcomplywithClause29.1.6.
29.1.4
Bending
ReinforcementshallbecutandbenttocomplywiththedimensionshownontheDrawings.
Reinforcementshallnotbebentorstrainedinamannerthatshalldamageit.Wherebendingof
reinforcementisrequiredbytheDrawingsthediameterofsuchbendsandthemethodofbending
shallberestrictedtotherequirementsofAS3600andAS5100.5,whereappropriate.
DuctilityclassLreinforcementshallnotbeheatedorhotbent.
29.1.5
Splicing
WheresplicesinreinforcementarenotshownontheDrawingsandarerequiredbytheContractor,it
constitutesachangeindesigndetailsandalllocationsofsuchsplicesshallbesubmittedtoSAWater
Representativeforapproval.AllsplicesshallbeinaccordancewiththerequirementsofAS3600and
AS5100.5,whereappropriate.
29.1.6
Welding
Reinforcementshallnotbeweldedunless:
1.
IsrequiredbytheProject;
2.
IsapprovedinwritingbySAWaterRepresentative;or
3.
IsrequiredforcathodicprotectionasperClause29.1.8.3.
Whereweldingisapproved,allweldingshallbeundertakeninaccordancewithAS/NZS1554.3and
thisStandard.ThetermPrincipalinAS/NZS1554.3shallmeanSAWaterRepresentative.
Forallloadbearingweldsforliftingandtransportofprefabricatedreinforcement,theContractor
shalldesignandsubmittheweldingandhandlingdetails,takingintoaccountstaticanddynamic
loadingsandanystressreversalsthatmayoccurduringlifting,movingandtransport,toSAWater
Representative.
WiththeexceptionoffabricatingreinforcingmeshbyanAustralasianCertificationAuthorityfor
ReinforcingandStructuralSteelscertifiedfabricator,DuctilityclassLreinforcementshallnotbe
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weldedunlesstheContractorcandemonstratebywayoftestingthattheweldproceduredoesnot
resultinthelossofductility.
29.1.7
Surfaceconditionofreinforcement
Reinforcementshallbefreefromdamage,kinksandotherunwantedbendsanddeformations.
Thereinforcementshallalsobemaintainedfreefromsurfacecontamination,loosemillscale,loose
rust,mud,oil,greaseandothercoatingsthatwouldreducethebondbetweentheconcreteandthe
reinforcement.
Inaddition,thesurfaceconditionofsteelreinforcementshallcomplywiththefollowing
requirements:
1.
Anysteelreinforcementprojectingfromapreviousconcretingoperationshallbecleanedfree
ofadheringconcreteorslurrypriortoanyfurtherembedment;
2.
Anysteelreinforcementinstalledwithin1kmofthecoastlineshallbethoroughlywashedwith
ahighpressurepotablewaterjetimmediatelypriortopouringconcretetoremoveanysalts
depositedduringstorageandplacement;
3.
Steelreinforcementwhichhasbeenaccidentlysubmergedbytidalorfloodwatersshallbe
cleanedwithahighpressurepotablewaterjetassoonaspossibleafterrecovery,orinany
casepriortopouringconcrete;
4.
Withtheexceptionofcastinplaceconcreteelements,constructionorplacementofsteel
reinforcementintidalwaterorliquid,orsubmergedinstandingliquidshallnotbepermitted.
29.1.8
ProtectionofSteelReinforcement
29.1.8.1
Galvanising
WhererequiredbytheProject,steelreinforcementshallbehotdipgalvanisedtoatleastGrade
HDG600inaccordancewithAS/NZS4680.Thehotdipgalvanizedcoatingshallhaveaminimum
averageweightof600g/m2andaminimumaveragecoatingthicknessof85m.
Thegalvanisingofreinforcementshallbeundertakenafterallcutting,bendingandweldingof
reinforcementcagesiscomplete.Repairstocutendsandbeaksinthecoatingshallbeundertakenin
accordancewithAS/NZS4680.
Aftergalvanising,thereinforcementshallbepassivatedusinga0.2%sodiumdichromatesolutionby
thegalvaniser.
Theuseofgalvanisedreinforcementinconjunctionwithstainlesssteelreinforcementisprohibited.
29.1.8.2
EpoxyCoating
UnlessotherwisedesignatedintheContractandapprovedbytheSAWaterRepresentative,epoxy
coatedsteelreinforcementshallnotbeused.
29.1.8.3
CathodicProtection
Cathodicprotectionofreinforcedconcretemaybeafuturemaintenancerepairoptioninvery
aggressivechlorideexposureenvironments.Designstagedurabilityassessmentshalldeterminethe
needforcathodicprotectionrepairinstallationduringthedesignlife,plusanylikelyextendedservice
life,andconsequentreinforcementelectricalcontinuitydesignrequirementsforfuturecathodic
protection.TheContractorshallinstallallreinforcementcontinuitydetailsshownonthedrawings
includingweldingofreinforcement,additionalreinforcementandelectricalcontinuitytesting.
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29.2 StainlessSteelReinforcement
29.2.1
Materials
Wheretheuseofstainlesssteelreinforcementisspecified,stainlesssteelreinforcementshallcomply
withtherequirementsofBS6744orASTMA955M.
Thestainlesssteelreinforcementshallbedesignedbytakingintoaccountitsphysicalandmechanical
properties.
Thestainlesssteelreinforcementshallbemanufactured,processed,fabricatedandsuppliedonlyby
anAustralianStainlessSteelDevelopmentAssociationaccreditedsupplier.
TheContractorshallsupplytoSAWatersRepresentativecopiesofthemanufacturer'stest
certificatesidentifiablewiththereinforcementorprovidedocumentaryevidencethatallproducts
meettherequirementsofBS6744andthatthemanufacturerhasasysteminplacetopreventnon
conformingmaterialfrombeingsupplied.Wheresuchcertificatescannotbesupplied,theContractor
shallarrangetestingofreinforcementfortension,bendingandductilitytoBS6744.
29.2.2
Schedules
RefertoClause29.1.2.
29.2.3
Fixing
Stainlesssteelreinforcementshallbeadequatelytiedtogethersuchastoformarigidcage,which
preventsdisplacementofbarsormeshesandmaintainsdimensionaltolerancesunderallapplied
loadsappliedbeforeandduringtheconcreteplacement.TherequirementssetoutinBS79732shall
beregardedasaminimumforfixingthereinforcement.Allstainlesssteelreinforcementinposition
shallbeinspectedandapprovedbySAWatersRepresentativebeforetheconcreteplacement
commences.
Note:ResponsibilityforsecurelyfixingreinforcementrestswiththeContractor.
Tiewireusedtotiestainlesssteelshallbeofthesamegradewiththereinforcementandshallhavea
diameterofnotlessthan1.2mm.Plastictiesorclipsarenotpermitted.
TheuseofmetalchairsorspacersasperClause28otherthanthosemadestainlesssteelofsame
gradeisprohibited.
TheminimumclearcovertothetiewireshallbeequalledtothatofspecifiedinthisStandardorthat
ofdesignatedintheContractforthestainlesssteelreinforcementbeingtied,lessthediameterofthe
tiewire.Projectingendsoftiesshallnotencroachintotheconcretecover.
Theendsofstainlesssteelreinforcementsformingalappedspliceshallbetiedtogetherinatleast
twoplaces.
TackweldingshallcomplywithClause29.2.6.
29.2.4
Bending
Stainlesssteelreinforcementshallbecutandbenttocomplywiththedimensionshownonthe
DrawingswiththedimensionaltolerancecomplyingwithAS3600andAS5100.5,asappropriate.
Stainlesssteelreinforcementshallnotbebentorstrainedinamannerthatshalldamageit.Where
bendingandformingofstainlesssteelreinforcementisrequiredbytheDrawingsthediameterof
suchbendsandthemethodofbendingshallberestrictedtotherequirementsofBS8666.
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Hotbendingofstainlesssteelreinforcementshallbeinaccordancewithmethodsrecommendedby
themanufacturer.Pinsusedforbendingstainlesssteelshallbemadefromstainlesssteel.
29.2.5
Splicing
29.2.6
Welding
Weldingofstainlesssteelreinforcementshallbeinaccordancewiththerequirementsof
AS/NZS1554.6andClause29.1.6ofthisStandard.
Inaddition,stainlesssteelreinforcementshallbeweldedonlyinaweldingworkshopspecificallyset
upforthepurpose.Suchfacilityshallmaintainconditionspreventinganycontaminationofthe
stainlesssteelandconsumablesusedintheproperperformanceoftheweldingofstainlesssteel.
Precautionsshallbetakentopreventtheformationofheattintatwelds.Whereheattintisformed
itshallberemovedbypicklingandpassivationinaccordancewithASTMA380totheapprovalofthe
SAWaterRepresentative.
29.2.7
InadditiontotherequirementsinClause29.1.7ofthisStandard,stainlesssteelreinforcementshall
notbecontaminatedbycontactwithothersteel,grease,oilandiron.Grinding,weldingorcuttingof
othersteeloranyotherstructuralsteelshallnotoccurafteranystainlesssteelreinforcementhas
beenplaced.
Toolsforfabricating,lifting,fixingorbendingstainlesssteelreinforcementshallnothavebeenused
andshallnotbeusedforothermaterials.
29.3 PrestressingTendons
29.3.1
General
SteeltendonsshallbemultiplewirestressrelievedsteelstrandcomplyingwithAS/NZS4672.1.
WireorstrandorbarwhichhasbeenusedpreviouslyshallnotbeusedintheWorks.
AllprestressingmaterialinstalledintheWorksshallbecleanandfreefromlooserust,greaseand
millscaleatthetimeoffixinginpositionandsubsequentconcreting.Slightrustingofthesteelis
acceptablebutthesurfaceshallnotbepitted
Eachdeliveryofmaterialsshallbeaccompaniedbydocumentationshowingthelotnumbersfrom
whicheachcoilorbaristaken,togetherwithacertificate,fromalaboratorywithappropriateNATA
accreditation,whichindicatesconformancewiththerelevantstandard.
Inaddition,testingofwire,strandandbarshallbecarriedoutinaccordancewiththetesting
requirementsofAS/NZS4672.2.Thefrequencyoftestingshallbeatleastthreesamplesfromeach
15tonneofmaterialorpartthereof.Testingsamplesshallbefromthesamesource.
ThefollowinginformationshallbeobtainedduringtestingandsubmittedtotheSAWaters
RepresentativepriortouseintheWorks:
1.
Breakingforce;
2.
Yieldstrengthandelongation;
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3.
Loadstrainplot;
4.
Crosssectionalareaofstrand,wireorbar;
5.
100hourrelaxationlossat70%and80%ofmaximumbreakingload;
6.
Source(s)ofstrand,wireorbar.
Hightensilesteelwireandstrandshallbesuppliedincoilsconformingtotherequirementsof
AS/NZS4672.1.Prestressingsteelandcouplersshallbeprotectedfromdamageanddeterioration
atalltimes.Tendonsshallbestoredoffthegroundinsuitableweatherproofsheltersandshallnot
bekinkedorbent.
29.3.2
PrestressingAnchorages
Nodamagedanchoragedevicesshallbeused.Allpartsshallbeprotectedfromcorrosionatall
times.Allthreadedpartsshallbeprotectedbygreasedwrappingsandalltappedholesshallbe
protectedbysuitableplugsuntilused.Theanchoragecomponentsshallbekeptfreefrommortar,
looserustandanyotherdeleteriouscoating.
AnchoragesshallbeinaccordancewithAS/NZS1314.
Grippingefficiencyofthecombinedanchorageshallbemaintainedbyachievingtherequired
manufacturingtolerancesforeachcomponentasspecifiedinthemanufacturersrequirements.
Anchoragesshallbepositionedandmaintainedduringconcretingsothatthecentrelineoftheduct
shallpassaxiallythroughtheanchorageassemblyandshallbenormaltothebearingsurfaces.
Allbearingsurfacesoftheanchoragesshallbecleanpriortoconcretingandtensioning.
29.3.3
PrestressingSheathing
SheathingshallbeHDPEinaccordancewiththeDrawings,soconstructedthatingressofmortar
duringconcretingisprevented.
29.3.4
InspectionofConcreteinPrestressingElements
TheContractorshallgivetheSAWatersRepresentativeaminimumoffive(5)workingdaysnoticeof
theContractorintentiontoplaceconcrete.UnlessinspectioniswaivedbySAWaters
Representativeineachspecificcase,placingofconcreteshallbeperformedonlyinthepresenceof
theSAWatersRepresentative.Concreteshallnotbeplacedoutsidenormalworkinghourswithout
thepriorapprovaloftheSAWatersRepresentative.
29.4 FibreReinforcedPolymerReinforcement
29.4.1
Materials
Materialsforfibrereinforcedpolymer(FRP)reinforcementshallcomplyinallrespectswiththe
requirementsofACI440.6M.
Thethermosettingresinsystemshallbeavinylesterorepoxyresinbasedsystemwithaglassto
rubbertransitionTgpointorheatdistortiontemperature(HDT)notlessthan100C.HigherTg
valuesmightbespecifieddependingontheoperatingtemperaturerangeofthestructure.
29.4.2
Schedules
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29.4.3
Fixing
TheContractorshalltieallintersectionsusingplasticcoatedornylonzipties,ornonrustingmaterial
instructedbytheManufacturerandasapprovedbySAWaterRepresentative.
TheContractorshallplaceandfixtheFRPreinforcementinaccordancewiththeManufacturers
instructions.
AllFRPreinforcementshallbesecuredtoandsupportedwithinformworkasrequiredtoprevent
displacementbyconcreteplacementorworkers.
AllFRPreinforcementshallbeaccuratelysupportedusingnoncorrosivechairsandspacersbefore
concreteplacementisstarted.TheuseofplasticchairsandspacersthatconformtoAS2425is
permitted.Inaddition,theContractorshallusechairsandspacersthatincorporateapositivelocking
mechanismtorestrainFRPreinforcementfromfloatingduringconcreteplacement.
TheContractorwillbeallowedtocuttheFRPreinforcementwithahighspeedgrindingcutter,fine
bladesaw,diamondbladeormasonrybladewiththepriorapprovalofSAWaterRepresentative.
ShearingFRPreinforcementwillnotbeallowed.
TheContractorshallplacetheFRPreinforcementwithinthetolerancesasspecifiedinACI117.
TheContractorshallremoveformoilfromFRPbarsusingamethodapprovedbytheManufacturer
beforeplacingconcrete.
29.4.4
HandlingandStorage
TheContractorshallload,haul,store,andhandletheFRPreinforcementsinaccordancewiththe
Manufacturersinstructiontopreventdamage.Specialcareisrequiredintheloading,hauling,
storageandhandlingofthereinforcementtopreventdamage.
Bundlingbandsshallbepaddedorsuitablebandingshallbeusedtopreventdamagetothe
reinforcement.
Ifthereinforcementsaretobestoredonsiteformorethan3months,thereinforcementsshallbe
coveredwithanopaquematerialtoavoidUVradiationandexposuretochemicalsubstances.
FRPreinforcementsareverylightandflexible;therefore,hoistingbundlesofFRPreinforcements
shallbeperformedwithastrongbackspreaderbarormultiplesupportstoavoidexcessivelybending
ofthereinforcements.TheFRPreinforcementshallnotbedroppedordragged.
29.4.5
Bending
FRPreinforcementshallbebenttothepropershapebythemanufacturerduringfabrication,
minimumbendradiishallconformtoTable10.1ofACI440.6M.Absolutelynofieldbendingofthe
barsispermitted.ShouldmodificationstotheFRPreinforcementberequired,theContractorshall
notifySAWaterRepresentative.
29.4.6
Splicing
LapslicesshallbeusedwhereverdetailedorspecifiedontheDrawingsandwherecontinuityis
requiredinthereinforcement.Theuseofmechanicalconnectionoradhesivebondedsplicesisnot
permitted.
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29.4.7
Thesurfacefinishofthereinforcementshallbesanded(sandappliedduringmanufacture),sanded
braidedordeformed.PropertiesoftheproposedreinforcementshallbesubmittedtotheSAWater
Representativeforapprovalpriortouse.
Thesurfaceshallbecleananddry,freeofphysicaldamage,freeofcontaminantsandindicationsof
exposuretoUVlightduringstorage(e.g.chalking,crazing,etc.).
MaterialthathaschalkedorshowsotherdamageduetoUVexposureshallnotbeused.
30 DissimilarMetalsEmbeddedinConcrete
Contactbetweendifferenttypesorgradesofmetalembedmentsandreinforcementsshallnotbe
allowedunlesstheexpectedpotentialdifferenceissuchthatcorrosioneffectswillbenegligible.For
example,Grades304and316stainlesssteelcanbecoupledtocarbonsteelreinforcementprovided
thatallcomponentsarefullyembeddedintheconcrete.Ifthestainlesssteelelementisexposedat
theconcretesurface(e.g.asferrulesorholddownbolts)thetwometalsshallbeelectricallyisolated.
Wherepotentiallydeleteriouscontactbetweensuchdissimilarmetalsembeddedinconcreteis
unavoidable,thetwodifferentmetalsshallbeelectricallyisolatedtopreventgalvanicorbimetallic
corrosion.
ElectricalisolationmaybeeffectedbyutilisingPVCconduitsleeves,suitablesoftplasticwrappingor
tapesorbyotherapprovedmeans.
31 FibreReinforcedConcrete
31.1 SteelFibreReinforcedConcrete(SFRC)
31.1.1
General
ThisClauseshallapplywheresteelfibresareusedtoimprovetheperformanceandcapacityofa
concreteelement.TheContractorshallcomplywithClauses7and8ofthisStandardand
demonstratethatthedesignmeetstheintendedperformancerequirements.
StructuralapplicationsofsteelfibresarecurrentlyoutsidethescopeofthisStandard.Design
proceduresforsomesteelfibreshavebeenestablishedbythesteelfibremanufacturers/suppliers,
buttodate,noindependentgenericdesignruleshavebeendevelopedforcommonuseofthese
materials(i.e.nodesigninAustralianCodes/StandardsorRecommendedPractices).
Steelfibrerequirementsshallinclude:
1.
SteelfibresshallbecolddrawnwireinaccordancewithBSEN148891;
2.
Allfibresshallbecrimpedorotherwisedeformedtoprovideanendanchorage;
3.
Theminimumtensilestrengthofthewireshallbe1,050MPa;
4.
Theminimumlengthofthefibresshallbedeterminedfortheprojectwithparticular
considerationforsprayedapplication(e.g.consider50mmorlessnormallyand35/25or
2.5timeaggregatesizeforsprayedapplication);
5.
Thetypicalminimumaspectratio(length:diameter)shallbe65:1;
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6.
Thetypicalminimumdosageshallbe25kg/m;thedosageofsteelfibresshallbedetermined
bytrialmixes(referClause8.3)tomeettheperformancecriteriasetoutinthisStandard;
7.
Fibresshallbestoredindrysealedcontainersuntilrequiredforuseandshallbefreefrom
corrosion,oil,grease,chloridesanddeleteriousmaterialswhichmayreducethebondbetween
thefibresandtheconcrete;
8.
Fibreswhichtendtoformfibreballsduringbatchingandmixingshallnotbeusedandfibre
shakingtables/separatorscanbeimplementedtoavoidballingoffibrespriortobatch
addition;
9.
Visualinspectionofbatchmixesshallbeundertakentoensureballingdoesnotoccur;
10.
ApprovaltoAS/NZS4020productsforuseincontactwithdrinkingwaterplusacceptabletoSA
WatersRepresentativeinaccordancewiththeDepartmentofHealthrequirements;
11.
Useoffibresshallconsidertheimpactoffibrespartiallyexposedontheconcretesurfacethat
cangivecorrosionstaining,thefibre(orpart)becomingdislodgedfromtheconcreteduring
thedesignlifeandtheapplicationofanysurfacecoatingsontheconcretewithfibres
exposed);and
12.
Concretetrialcasting(referClause8.4.2)ofelementsshallbecompletedtoSAWaters
Representativerequirementswhereanyuncertaintyexistsonthelikelyconcreteperformance.
NOTE:ThereisnoAustralianStandardfordesigningsteelfibrereinforcedconcreteatthetimeof
publishingthisStandard.TheContractorisencouragedtodiscusswithSAWaterRepresentativeprior
toundertakingdesign.TheDraftforPublicCommentAustralianStandardforBridgeDesignPart5:
Concretedated2014(DRAS5100.5)hastheprovisionforSteelFibreReinforcedConcrete.Itis
intendedthatthisClauseofthisStandardwillberevisedupontheStandardispublishedinitsfinal
state.
Steelfibresshallnotberelieduponatconstructionsjoints.TheContractorshallprovidethe
constructionjointdetailstoSAWatersRepresentativedemonstratingthatthatthecontinuityofthe
loadtransferringandcarryingcapacityoftheconcreteelement.
31.1.2
SupplyandDelivery
Fibresshallbefreefromcorrosion,oil,grease,chloridesanddeleteriousmaterialswhichmayreduce
theefficiencyofmixingorplacementprocess,orwhichmayreducethebondbetweenthefibresand
theconcrete.
Somefibresmayhaveafilmthatprovideslimitedcorrosionprotectionbeforeplacinginconcrete
whileothersmayhavenoprotection(guidancefromCIAZ7/04).Duringstoragefibresareproneto
corrosionandunlikereinforcingbarevenasmallamountofcorrosioncanhaveasignificanteffecton
performance.Corrosionofthefibresmaynotbeimmediatelyapparent,particularlywherebagsare
dispenseddirectlyintotheconcretemixer.Hencepartofthequalityassuranceproceduresshouldbe
toopensufficientbagsoffibresandtocheckthatthebatchoffibrestobeusedarefreefrom
corrosion.
Fibresofthetypeandquantityspecifiedshallbeaddedinacontrolledprocessensuringthattheyare
disperseduniformlythroughtheconcretemix.Ifaddedafterthemainmixingprocess,theconcrete
shallberemixeduntilthefibreshavebeencompletelydispersedthroughoutthebatch.
Ballingofsteelfibresshallbeavoided.
Thesteelfibrereinforcedconcretemixshallremainworkableuntilitisfullyplaced.
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InadditiontotheinformationrequiredinClause9.2,fibretypeanddosageshallbeshownonthe
deliverydocket.
Determiningthesteelfibrecontent
Wheresteelfibreshavebeenspecifiedinaconcretemix,testingandreportingofhomogeneityof
thesteelfibresinthefreshconcreteshallbecarriedinaccordancewithBSEN14721MethodB.
1.
Thefirstbatchfor50mofSFRCintheWorksshallbetested,unlessotherwisedirectedbySA
WatersRepresentative;
2.
Onetestismadeupofthreesamples,oneineachthirdofthesameloadasfollows:
a.
atthebeginningoftheload(fromthefirstthirdofthemix),after0.5misunloaded;
b.
inthemiddleoftheload(fromthesecondthirdofthemix);and
c.
attheendoftheload(fromthelastthirdofthemix),withmin0.5mleftintruck;
3.
Allsamplesshallbetakendirectlyoutoftheconcretestreamattheendofthechute(not
outofawheelbarrow,becausethatgivessegregation);
4.
Eachsamplerequiresaminimumconcretevolumeof10litres;
5.
Theresultofatesttakenastheaverageof3samplesshallnotbelessthan90%ofthe
specifiedsteelfibrecontent;
6.
Theresultofasinglesampleshallnotbelessthan85%ofthespecifiedsteelfibrecontent;
7.
SAWatersRepresentativeshalldeterminetestrequirementsafterthefirst50mofSFRCin
theWorkstakingintoaccountthetrialmixtestingandfirstbatchtested.
31.2 SyntheticFibreReinforcedConcrete
ThisClauseshallapplywheresyntheticfibres,commonlytermedmonofilamentfibres,areusedto
improvetheperformanceandcapacityofaconcreteelement.Therearetwotypesofsyntheticfibre,
structuralsyntheticsormacrofibres,andmicrofibres(referCIAZ7/04):
1.
Structuralsyntheticsthatcanbesimilartothatofsteelfibreconcretehowever,allstructural
designmattersshallbeassessed.Typicalfibrelengthcanbe40+mm.Structuralapplicationsof
syntheticfibresarecurrentlyoutsidethescopeofthisStandard;
2.
Microsyntheticfibresareusedtoassistwithplasticcrackcontrolortoassistwithwater
blockageandexplosivespallingintheeventoffires.Typicalfibrelengthcanbe18+mm.The
useofsyntheticfibrestocontrolplasticshrinkagecracking,ortopreventexplosivespallingof
coverconcreteduringseverefires,isapotentialriskmitigationmeasurehowever,thedesign
isoutsidethescopeofthisStandard(theirefficacyintheseapplicationsiswelldocumented,
butisproprietaryinformation).Examplesforconsiderationareuseinwatertankfloorslabsfor
plasticcrackcontrolandwallsofwatertankwallsinbushfirerisklocations.
Syntheticfibrerequirementsshallinclude:
1.
100%virginpolypropylenemonofilamentfibrecontainingnoreprocessedmaterialsand
complywiththerequirementsofBSEN148892;
2.
Thetypicalminimumfibrecontentshallbe1.0kg/m;
3.
Onlythefibretype,coating,diameter,lengthanddosageshallbedeterminedtomeetthe
performancerequirementssetoutthisStandard;
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TS0710Concrete
4.
ApprovedtoAS/NZ4020productsforuseincontactwithdrinkingwaterplusacceptabletoSA
WatersRepresentativeinaccordancewiththeDepartmentofHealthrequirements;
5.
Thefibretype,coating,diameter,lengthanddosageshallbedeterminedtomeetspecific
Worksperformancerequirements;and
6.
Useoffibresshallconsidertheimpactoffibrespartiallyexposedontheconcretesurface,the
fibre(orpart)becomingdislodgedfromtheconcreteduringthedesignlifeandtheapplication
ofanysurfacecoatingsontheconcretewithfibresexposed(e.g.anepoxyprotectivecoating
application).
TheContractorshallcomplywithClauses7and8ofthisStandardanddemonstratethatthedesign
meetstheintendedperformancerequirements.
NOTE:TheContractorisencouragedtodiscussuseofsyntheticfibresinreinforcedconcretewithSA
WaterRepresentativepriortoundertakingdesignwithsyntheticfibres.
Designproceduresforsomehighperformancesyntheticfibreshavebeenestablishedbythe
monofilamentfibremanufacturers/suppliers,buttodate,noindependentgenericdesignruleshave
beendevelopedforcommonuseofthesematerials(i.e.nodesigninCodes/Standardsor
RecommendedPractices).
TheContractorusingsyntheticfibresshouldfollowthemanufacturer/suppliersdesignguidelines,
andconfirmtheresultsbyspecialstudiesforthespecificWorks.
TheContractorshallberesponsibleforthesyntheticfibrescastintheconcrete,allconcrete
placementsandfinishingprocedurestoachieveconcreteinaccordancewiththisStandard.
Concretetrialsmixes(referClause8.3)andtrialcasting(referClause8.4.2)ofelementsshallbe
completedtoSAWatersRepresentativerequirementswhereanyuncertaintyexistsonthelikely
concreteperformance.
32 ContractorWorksMethodStatementforConcreteincluding
EarlyAgeThermalCrackAssessment
TheContractorshallissueaContractorWorksMethodStatementforConcretetoSAWaters
Representativeatleast20workingdayspriortocommencinganyconcreteworkscoveringall
concretesupply,testing,placementcompactionandcuringmattersinaccordancewiththisStandard
andtheDrawings,includingbutnotlimitedtothebelow:
1.
Premixsuppliername,location,plantsupplycapability,agitatorfleetcapacityincluding
breakdownimpact(referClause9.1);
2.
Concretemixdesignfrompremixsupplier(referClause8.2);
3.
Concretepoursizeandsequence(referClause10.1.6);
4.
Constructabilityapproachforslump,workability,settingtime,reinforcementcongestion,
reinforcementcoverspacers,etc.(referClauses7.1.1and7.1.2);
5.
Concreteplacementmethod(referClauses9,10,11and12,withpourstartandfinishtimes
(selectedtominimisetheriskofconcretecracks),placementmethod(e.g.pumporcrane),
compactionmethod,expectedfinishingtime,finishingmethod,etc.Methodtoinclude
equipmentandmanpowerplanningtoachieveacceptableconcretequality;
6.
Curingmethod(referClause13.1);
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7.
Precastconcreterequirements(referClause16)includingshopdrawings;and
8.
Qualitycontroltestingtobecompletedbefore,duringandafterconcreteplacement(refer
Clause22).
TheContractorshallobtainwrittenapprovalofSAWatersRepresentativeacceptanceofthe
ContractorWorksMethodStatementforConcrete,priortocommencinganyconcreteconstruction
works.
TheConcreteTrialMixReport(referClause8.3)andapprovedmixdesign(referClause8.4)shallbe
issuedtoSAWatersRepresentativeatleast10workingdayspriortocommencinganyconcrete
works.AnyamendmentstotheContractorWorksMethodStatementforConcretefromtheconcrete
trialmixresultsshallbeissuedinaRevision1withallchangesmarkedSAWatersRepresentative
review,atleast10workingdayspriortocommencinganyconcreteworks.
TheContractorshallcommissionaDurabilityConsultanttoassesstheconcreteearlyagethermal
crackriskassessmentforallconcreteelementsgreaterthan500mminminimumdimension,and
concreteelementswithhighrestraintincorporatingeachmixdesign.Theassessmentshallconsider:
1.
Cementcontentandtype;
2.
Concreteelementthickness,lengthandwidth;
3.
Elementtype(floor,wallroof);
4.
Elementrestraint;
5.
Concreteplacementtemperature;
6.
Concreteadiabatictemperaturepredictedfromthermalblocktestingwhenrelevantdatais
notavailable;
7.
Concretethermalexpansion/contractionstrainfromthermalblockdatawhenrelevantdatais
notavailable;
8.
Concreteshrinkagefromtrialmixdata;
9.
Reinforcementratios,diameterandspacing;
10.
Timeofwatercontactafterconcreteconstructionforliquidretainingorexcludingstructures;
11.
Environmentalconditionsattimeofconstruction;
12.
Formworktypeandstrippingtime;
13.
Temperatureofadjacentconcrete;and
14.
Allothermattersinfluencingconcretetemperatureandrestraint.
TheDurabilityConsultantshallproduceastatementofoutcomesfromtheassessmentand
recommendationsonitemstobeaddressed,ifany,thattheContractorshallsubmittoSAWaters
Representative.
TheContractorshallmakeanynecessarychangestomaterialsormethodologytocomplywiththe
assessmentandobtainwrittenapprovalfromSAWatersRepresentativepriortoproceedingwith
concreteworks.
TheaboverequirementsarenotapplicablewheretheContractorhascompletedadesignstage
concreteearlyagethermalcrackriskassessmentwithaDurabilityConsultantandthePrincipal,and
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approvedbySAWatersRepresentative.TheContractorshallprovideevidenceofsuchconcrete
earlyagethermalcrackriskassessmenttoSAWatersRepresentativeandapplyfortherequirement
tobewaived.
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