Ref. Title Page No. Ref. Title Page No.

5.1 Concrete Materials and Mixes 5-1 5.1.4.2  Job-Site Mixing 5-9 
5.1.4.3  Ready-Mixed Concrete 5-9 
5.1.1  Description 5-1 
5.1.4.4  Quality Control and Testing – General 5-10 
5.1.1.1  Definitions 5-1 
5.1.4.5  Quality Control – Testing
5.1.1.2  References 5-1 
on Fresh Concrete 5-10 
5.1.1.3  Submittals 5-2 
5.1.4.6  Quality Control – Testing on Hardened
5.1.1.4  Quality Assurance 5-2 
Concrete 5-11 
5.1.2  Materials 5-3 
5.1.5  Method of Measurement 5-12 
5.1.2.1  Portland Cement 5-3 
5.1.5.1  Measured Items 5-12 
5.1.2.2  Silica Fume 5-3 
5.1.5.2  Items Not Measured 5-12 
5.1.2.3  Supplementary Cementing
5.1.6  Basis of Payment 5-12 
Material (SCM) 5-4 
5.1.7  Items in the Bill of Quantities 5-13 
5.1.2.4  Blended Hydraulic Cement 5-4 
5.1.2.5  Aggregates 5-4  5.2 Reinforcing Steel 5-13
5.1.2.6  Water 5-5 
5.2.1  Description 5-13 
5.1.2.7  Admixtures 5-5 
5.2.1.1  References 5-13 
5.1.2.8  Fiber Reinforcement 5-6 
5.2.1.2  Submittals 5-13 
5.1.3  Concrete Mixes 5-6 
5.2.1.3  Quality Assurance 5-13 
5.1.3.1  Design Mixes 5-6 
5.2.1.4  Delivery, Storage and Handling 5-13 
5.1.3.2  Testing Agency 5-6 
5.2.2  Materials 5-13 
5.1.3.3  Reports 5-6 
5.2.2.1  Steel Reinforcement 5-13 
5.1.3.4  Concrete Classes 5-6 
5.2.2.2  Reinforcement Accessories 5-14 
5.1.3.5  Threshold Values for Supplementary
5.2.2.3  Fabricating Reinforcement 5-14 
Cementing Materials (SCM) 5-6 
5.2.3  Construction Requirements 5-14 
5.1.3.6  Limit Values for Supplementary
5.2.3.1  General 5-14 
Cementing Materials (SCM) 5-7 
5.2.3.2  Shipping, Storage and Cleaning 5-14 
5.1.3.7  Water-Cementitious Materials Ratio 5-7 
5.2.3.3  Placing 5-15 
5.1.3.8  Slump Limits 5-7 
5.2.3.4  Concrete Cover 5-15 
5.1.3.9  Total Salt Content 5-7 
5.2.4  Method of Measurement 5-15 
5.1.3.10  Initial Setting Time 5-8 
5.2.5  Basis of Payment 5-15 
5.1.3.11  Test Mixes – Structural Grade
5.2.6  Items in the Bill of Quantities 5-16 
Concrete 5-8 
5.1.3.12  Test Mixes – Blinding and Plain 5.3 Reinforced Concrete
Concrete 5-8  Structures 5-16
5.1.3.13  Adjustments to Concrete Mixes 5-8 
5.3.1  Description 5-16 
5.1.3.14  Absorption Test 5-8 
5.3.1.1  Definitions 5-16 
5.1.3.15  Permeability Tests 5-8 
5.3.1.2  References 5-16 
5.1.3.16  Synthetic Fiber 5-9 
5.3.1.3  Submittals 5-16 
5.1.3.17  Admixtures 5-9 
5.3.1.4  Quality Assurance 5-17 
5.1.4  Construction Requirements 5-9 
5.3.2  Materials 5-17
5.1.4.1  Concrete Mixing 5-9 
Ref. Title Page No. Ref. Title Page No.
5.3.2.1  Form Materials 5-17  5.4.3.3  Placement of Anchorages 5-31 
5.3.2.2  Waterstops 5-18  5.4.3.4  Identification and Testing 5-31 
5.3.2.3  Concrete Curing Cover Sheets 5-18  5.4.3.5  Protection of Prestressing Steel 5-32 
5.3.2.4  Curing Compounds 5-19  5.4.3.6  Ducts 5-32 
5.3.2.5  Concrete Accessories 5-19  5.4.3.7  Grout 5-33 
5.3.2.6  Repair Materials 5-19  5.4.3.8  Tensioning 5-34 
5.3.3  Construction Requirements 5-19  5.4.3.9  Pretension Construction 5-35 
5.3.3.1  Formwork 5-19  5.4.3.10  Post-Tension Construction 5-36 
5.3.3.2  Falsework 5-20  5.4.3.11  Grouting 5-37 
5.3.3.3  Embedded Items 5-20  5.4.4  Method of Measurement 5-39 
5.3.3.4  Removing and Reusing Forms 5-20  5.4.5  Basis of Payment 5-40 
5.3.3.5  Vapor Retarders 5-21  5.4.6  Items in the Bill of Quantities 5-40 
5.3.3.6  Construction Joints 5-21 
5.5 Concrete Bridges and Erection
5.3.3.7  Contraction and Expansion Joints 5-21 
Procedures 5-40
5.3.3.8  Waterstops 5-22 
5.3.3.9  Concrete Placement 5-22  5.5.1  Description 5-40 
5.3.3.10  Hot-Weather Concreting 5-24  5.5.1.1  Scope 5-40 
5.3.3.11  Finishing Plastic Concrete 5-25  5.5.1.2  References 5-40 
5.3.3.12  Curing Concrete 5-25  5.5.2  Materials 5-40 
5.3.3.13  Formed Finishes 5-26  5.5.3  Construction Requirements 5-41 
5.3.3.14  Tolerances 5-26  5.5.3.1  Balanced Cantilever Construction
5.3.4  Method of Measurement, Basis with In-Situ Concrete 5-41 
of Payment and Bill of Quantities 5-27  5.5.3.2  Glued Precast Segmental
Construction 5-42 
5.4 Prestressed Concrete
5.5.3.3  Precast Beam and slab Construction 5-43 
Structures 5-27
5.5.3.4  In-Situ Construction 5-43 
5.4.1  Description 5-27  5.5.4  Method of Measurement, Basis of
5.4.1.1  Scope 5-27  Payment and Items in the Bills
5.4.1.2  Definitions 5-27  of Quantities 5-43 
5.4.1.3  References 5-27 
5.6 Vehicular and Pedestrian
5.4.1.4  Submittals 5-28 
Underpasses and Animal
5.4.2  Materials 5-28 
Crossings 5-44
5.4.2.1  Concrete 5-28 
5.4.2.2  Reinforcing Steel 5-29  5.6.1  Description 5-44 
5.4.2.3  Prestressing Steel 5-29  5.6.1.1  Scope 5-44 
5.4.2.4  Post-Tensioning Anchorages 5.6.1.2  References 5-44 
and Couplers 5-29  5.6.2  Materials 5-44 
5.4.2.5  Epoxy-Bonding Agents for Precast 5.6.3  Construction Requirements 5-44 
Segmental Construction 5-29  5.6.3.1  Excavation 5-44 
5.4.3  Construction Requirements 5-29  5.6.3.2  Structural Concrete 5-45 
5.4.3.1  Placement of Ducts 5-29  5.6.3.3  Concrete Piles 5-45 
5.4.3.2  Placement of Prestressing Steel 5-30  5.6.3.4  Waterproofing 5-45
Ref. Title Page No. Ref. Title Page No.
5.6.3.5  Concrete Pavement Construction 5-45  5.7.3.20  Pavement Marking 5-57 
5.6.3.6  Bituminous Pavement Construction 5-45  5.7.3.21  Field Quality Control 5-57 
5.6.3.7  Electrical Works 5-45  5.7.3.22  Repairs and Protection 5-58 
5.6.4  Method of Measurement 5-45  5.7.3.23  Determination of Concrete Thickness 5-59 
5.6.5  Basis of Payment 5-45  5.7.4  Method of Measurement 5-59 
5.6.6  Items in the Bill of Quantities 5-45  5.7.5  Basis of Payment 5-59 
5.7.6  Items in the Bill of Quantities 5-59 
5.7 Cement Concrete Pavement 5-45
5.8 Joint Sealers for Concrete
5.7.1  Description 5-45 
Pavement 5-59
5.7.2  Materials 5-45 
5.7.2.1  Forms 5-46  5.8.1  Description 5-59 
5.7.2.2  Steel Reinforcement 5-46  5.8.2  Materials 5-59 
5.7.2.3  Concrete Materials 5-46  5.8.2.1  Materials, General 5-59 
5.7.2.4  Admixtures 5-47  5.8.2.2  Elastomeric Hot-Poured Joint Sealants 5-60 
5.7.2.5  Curing Materials 5-47  5.8.2.3  Joint Sealant Backing 5-60 
5.7.2.6  Related Materials 5-47  5.8.2.4  Miscellaneous Materials 5-60 
5.7.2.7  Concrete Mixes 5-47  5.8.3  Construction Requirements 5-60 
5.7.2.8  Concrete Mixing 5-48  5.8.3.1  Examination 5-60 
5.7.2.9  Limitations of Mixing: 5-48  5.8.3.2  Preparation 5-60 
5.7.3  Construction Requirements 5-48  5.8.3.3  Installation of Joint Sealers 5-60 
5.7.3.1  Preparation 5-48  5.8.3.4  Cleaning 5-61 
5.7.3.2  Edge Forms and Screed Construction 5-49  5.8.3.5  Protection 5-61 
5.7.3.3  Steel Reinforcement 5-49  5.8.4  Method of Measurement, Basis
5.7.3.4  Placement of Reinforcement 5-49  of Payment and Bill of Quantities 5-61 
5.7.3.5  Joints 5-49 
5.9 Reinforced Concrete Box Culverts
5.7.3.6  Conditioning of Underlying Course,
and Headwalls, Wingwalls,
Slip-Form Construction 5-52 
Cut-Off Walls and Aprons 5-61
5.7.3.7  Conditioning of Underlying Course,
Side-Form Construction 5-52  5.9.1  Description 5-61 
5.7.3.8  Handling, Measuring, and Batching 5.9.2  Materials 5-61 
Material 5-52  5.9.3  Construction Requirements 5-61 
5.7.3.9  Concrete Protection and Curing 5-53  5.9.4  Method of Measurement 5-62 
5.7.3.10  Concrete Placement 5-53  5.9.5  Basis of Payment 5-62 
5.7.3.11  Concrete Finishing 5-55  5.9.6  Items in Bill of Quantities 5-62 
5.7.3.12  Final Strike-Off, Consolidation
5.10 Waterproofing for Structures 5-62
and Finishing 5-55 
5.7.3.13  Surface Texture 5-56  5.10.1  Description 5-62 
5.7.3.14  Skid Resistant Surfaces 5-56  5.10.1.1  Scope 5-62 
5.7.3.15  Surface Test 5-56  5.10.1.2  References 5-62 
5.7.3.16  Removing Forms 5-57  5.10.2  Materials 5-62 
5.7.3.17  Sealing Joints 5-57  5.10.2.1  Asphalt 5-62 
5.7.3.18  Opening to Traffic 5-57  5.10.2.2  Bitumen 5-62 
5.7.3.19  Pavement Tolerance 5-57  5.10.2.3  Waterproofing Fabric 5-62
Ref. Title Page No. Ref. Title Page No.
5.10.2.4  Self-Adhesive Polyethylene Sheet 5-62  5.11.4  Method of Measurement, Basis
5.10.2.5  Tar for Absorptive Treatment 5-62  of Payment and Bill of Quantities 5-67 
5.10.2.6  Tar Seal Coat 5-63 
5.12 Bridge Load Testing 5-67
5.10.2.7  Proprietary Waterproofing Systems 5-63 
5.10.2.8  Epoxy Coating System 5-63  5.12.1  Description 5-67 
5.10.3  Construction Requirements 5-63  5.12.2  Load Application 5-67 
5.10.3.1  Surface Preparation 5-63  5.12.2.1  Composition of Applied Load 5-67 
5.10.3.2  Inspection, Delivery and Storage 5-63 5.12.2.2  Testing by Static Load 5-68 
5.10.3.3  Asphalt and Bitumen Waterproofing 5.12.2.3  Testing by Moving Load 5-68 
Fabric 5-63  5.12.3  Visual Inspection 5-68 
5.10.3.4  Proprietary Waterproofing 5.12.4  Measurements 5-68 
Membranes 5-64  5.12.5  Method of Measurement 5-68 
5.10.3.5  Damage Patching of Waterproofing 5.12.6  Basis of Payment 5-68 
Fabrics 5-64  5.12.7  Items in the Bill of Quantities 5-68 
5.10.3.6  Dampproofing 5-64 
5.10.3.7  Protection of Waterproofing and
Dampproofing 5-64 
5.10.3.8  Testing 5-65 
5.10.4  Method of Measurement 5-65 
5.10.5  Basis of Payment 5-65 
5.10.6  Items in the Bill of Qquantities 5-65 

5.11 Protective Coating for Concrete 5-65

5.11.1  Description 5-65 
5.11.1.1  Scope 5-65 
5.11.1.2  Submittals 5-65 
5.11.1.3  Performance Requirements 5-65 
5.11.1.4  Quality Assurance 5-65 
5.11.1.5  Testing 5-66 
5.11.2  Materials 5-66 
5.11.2.1  General 5-66 
5.11.2.2  Primer 5-66 
5.11.2.3  Topcoat 5-66 
5.11.2.4  Specifications 5-66 
5.11.3  Construction Requirements 5-66 
5.11.3.1  General 5-66 
5.11.3.2  Inspection of Concrete 5-66 
5.11.3.3  Surface Preparation 5-67 
5.11.3.4  Approval Prior to Coating Application 5-67 
5.11.3.5  Application 5-67 
5.1 Concrete Materials and Mixes ASTM C 114 Standard Test Methods for Chemical
Analysis of Hydraulic Cement
5.1.1 Description ASTM C 117 Standard Test Method for Materials
Finer Than 75 Micrometer (No. 200)
5.1.1.1 Definitions Sieve in Mineral Aggregates by
1 Concrete shall consist of a mixture of cementitious Washing
materials, aggregates, water and additives. ASTM C 127 Standard Test Method for Density,
2 Cementitious Materials: Portland cement alone or in Relative Density (Specific Gravity) and
combination with one or more of blended hydraulic Absorption of Coarse Aggregate
cement, fly ash and other pozzolans, ground granulated ASTM C 128 Standard Test Method for Density,
blast-furnace slag and silica fume. Relative Density (Specific Gravity) and
Absorption of Fine Aggregate
5.1.1.2 References
ASTM C 131 Standard Test Method for Resistance to
AASHTO T26 Standard Method of Test for Quality of Degradation of Small-Size Coarse
Water to be used in Concrete Aggregate by Abrasion and Impact in
1 American Association of State Highways and the Los Angeles Machine
Transportation Officials (AASHTO): ASTM C 142 Standard Test Method for Clay Lumps
2 American Concrete Institute (ACI): and Friable Particles in Aggregates

ACI 117 Specifications for Standard Tolerances ASTM C 143 Standard Test Method for Slump of
for Concrete Construction and Hydraulic Cement Concrete
Materials ASTM C 150 Standard Specification for Portland
ACI 301 Specifications for Structural Concrete Cement
for Buildings ASTM C 172 Standard Practice for Sampling Freshly
ACI 304 Guide for Measuring, Mixing, Mixed Concrete
Transporting, and Placing Concrete ASTM C 186 Standard Test Method for Heat of
3 American National Standards Institute (ANSI): Hydration of Hydraulic Cement

ANSI Q9001 Quality Systems – Model for Quality ASTM C 191 Standard Test Method for Time of
Assurance in Design, Development, Setting of Hydraulic Cement by Vicat
Production, Installation, and Servicing Needle

ANSI Q9002 Quality Systems – Model for Quality ASTM C192/C192M Standard Practice for Making
Assurance in Production, Installation, and Curing Concrete Test Specimens in
and Servicing the Laboratory (AASHTO T126)

4 American Society for Testing and Materials (ASTM): ASTM C 219 Standard Terminology Relating to
Hydraulic Cement
ASTM A 820 Standard Specification for Steel Fibers
for Fiber-Reinforced Concrete ASTM C 227 Standard Test Method for Potential
Alkali Reactivity of Cement-Aggregate
ASTM C31/C31M Standard Practice for Making and
Combinations (Mortar-Bar Method)
Curing Concrete Test Specimens in the
Field (AASHTO T23) ASTM C 289 Standard Test Method for Potential
Reactivity of Aggregates (Chemical
ASTM C 33 Standard Specification for Concrete
Method)
Aggregates
ASTM C 295 Standard Guide for Petrographic
ASTM C39/C39M Standard Test Method for Compressive
Examination of Aggregates for
Strength of Cylindrical Concrete
Concrete
Specimens (AASHTO T22)
ASTM C 311 Standard Test Methods for Sampling
ASTM C 40 Standard Test Method for Organic
and Testing Fly Ash or Natural
Impurities in Fine Aggregates for
Pozzolans for Use as a Mineral
Concrete
Admixture in Portland-Cement
ASTM C 42 Standard Test Method for Obtaining Concrete
and Testing Drilled Cores and Sawed
ASTM C 494 Standard Specifications for Chemical
Beams of Concrete
Admixtures for Concrete
ASTM C 88 Standard Test Method for Soundness of
ASTM C 586 Standard Test Method for Potential
Aggregates by Use of Sodium Sulfate
Alkali Reactivity of Carbonate Rocks for
or Magnesium Sulfate
Concrete Aggregates (Rock Cylinder
ASTM C 94 Standard Specifications for Ready- Method)
Mixed Concrete

♦ 5-1 ♦
ASTM C 595 Standard Specifications for Blended BS EN 12350 Testing Fresh Concrete
Hydraulic Cements BS EN 12390 Testing Hardened Concrete
ASTM C 618 Standard Specifications for Coal Fly BS EN 12620 Specification for Aggregates
Ash and Raw or Calcined Natural
BS EN 197 Cement Specification
Pozzolan for Use as a Mineral
Admixture in Concrete Part 1: Composition and specification

ASTM C 989 Standard Specification for Ground Part 2: Conformity evaluation

Granulated Blast-Furnace Slag for Use 6 Commercial Standards (CS):
in Concrete and Mortars Concrete Plant Manufacturers Bureau - Concrete Plant
ASTM C 1064 Standard Test Method for Temperature Standards
of Freshly Mixed Portland Cement National Ready-Mixed Concrete Association (NRMCA) -
Concrete Check List
ASTM C 1077 Standard Practice for Laboratories 7 Corps of Engineers (CE):
Testing Concrete and Concrete
CE CRD-C119 Test for Flat and Elongated Particles
Aggregates for Use in Construction and
Criteria for Laboratory Evaluation 8 National Standard of Canada:
ASTM C 1105 Standard Test Method for Length CAN/CSA A23.5-M86 Supplementary Cementing
Change of Concrete Due to Alkali- Materials
Carbonate Rock Reaction
5.1.1.3 Submittals
ASTM C 1116 Standard Specification for Fiber-
Reinforced Concrete and Shotcrete 1 Product Data: For proprietary materials and items.
ASTM C 1202 Test Method for Electrical Indication of 2 Design Mixes: For each concrete mix. Include
Concrete’s Ability to Resist Chloride Ion alternative mix designs when characteristics of materials,
Penetration (AASHTO T 277) project conditions, weather, test results, or other
circumstances warrant adjustments.
ASTM D 512 Standard Test Methods for Chloride Ion
in Water 3 Qualification Data: For firms and persons specified in
Paragraph 5.1.1.4 "Quality Assurance" to demonstrate
ASTM D 516 Standard Test Method for Sulfate Ion in
their capabilities and experience. Include lists of
Water
completed projects with project names and addresses,
ASTM E 329 Standard Specification for Agencies names and addresses of engineers and owners, and any
Engaged in the Testing and/or other information required by the Engineer.
Inspection of Materials used in
4 Material Test Reports: From a qualified testing
Construction
agency indicating and interpreting test results for
ASTM E 548 Standard Guide for General Criteria compliance of the following with requirements indicated,
Used for Evaluating Laboratory based on comprehensive testing of current materials:
Competence
5 Material Certificates: Signed by manufacturers and
5 British Standards: Contractor certifying that each of the following items
BS 812 Testing Aggregates complies with specified requirements:
BS 1881 Methods of Testing Concrete i. Cementitious materials and aggregates.
BS 1199 and 1200 Specification for Building Sands from ii. Fiber reinforcement.
Natural Sources iii. Admixtures: Material certificates in lieu of
material laboratory test reports when permitted
BS 4027 Specification for Sulfate-Resisting
by the Engineer. Material certificates shall be
Portland Cement
signed by the manufacturer and the Contractor,
BS 5328 Methods for Specifying Concrete certifying that each material item complies with
Including Ready-Mixed Concrete specified requirements. Provide certification
BS EN 932 Tests of Aggregates for General from admixture manufacturers that chloride
Properties content complies with specified requirements.
BS EN 933 Tests of Aggregates for Geometric 6 Minutes of pre-installation conference.
Properties
5.1.1.4 Quality Assurance
BS EN 1097 Tests of Aggregates for Mechanical
Properties 1 Quality System: Comply with ISO 9001/9002 Quality
BS EN 1367 Tests of Aggregates for Thermal and System and ISO 14001 Environmental Management
Weathering Properties Systems as a minimum. Incorporate all the standard
procedures supplied by the Engineer and the Employer.
BS EN 1744 Tests of Aggregates for Chemical
Properties

♦ 5-2 ♦
2 Codes and Standards: Comply with the latest version
of ACI Manual of Concrete Practice Parts 1, 2, 3, 4 & 5, and
CRSI "Manual of Standard Practice” except where more
stringent requirements are shown or specified.
3 Concrete Quality Control Engineer: Appoint a full-
time Concrete Quality Control Engineer (CQCE) to ensure
that concrete is properly produced, placed, cured and
protected. The CQCE shall be equivalent to a Member of
the Institute of Concrete Technology (MICT) or as
approved by the Engineer and shall be responsible for the
maintenance and submission of all specified records. The
CQCE shall not report to the site construction
management but to the Contractor’s management and to
the Engineer. The CQCE shall set standards of quality and
insist that these standards be followed, prepare a Quality
Control Program for the inspection and testing of concrete
and the maintenance of all reports and records to meet the
specified requirements and requirements of the Engineer.
Depending on the quantity of concrete works in specific
project, the Special Specifications may waive this
requirement.
4 The Contractor shall operate a Quality Assurance
System in accordance with ANSI Q9002. The Quality
Assurance Manager shall be responsible for the
preparation of a Quality Plan for approval of the
operations specified in this Section. The Quality Plan shall
include, among other things, the list and schedule of the
Quality Control audits that the Quality Assurance Manager
shall make.
5 Concrete Manufacturer Qualifications: A firm
experienced in manufacturing ready-mixed concrete
products complying with ASTM C 94/C94M requirements
for production facilities and equipment.
6 Engage an independent testing agency acceptable to
the Engineer to perform material evaluation tests and
qualified according to ASTM C 1077 and ASTM E 329 to
conduct the testing indicated, as documented according to
ASTM E 548 and to design concrete mixes.
i. Personnel conducting field tests shall be
qualified as ACI concrete field testing technician,
Grade 1 according to ACI CP-1 or an equivalent
certification program approved by the Engineer.
7 Materials and installed work may require testing and
retesting at any time during progress of work, if instructed
by the Engineer. Tests, including retesting of rejected
materials for installed work, shall be done at the
Contractor’s expense.
8 Source Limitations: Obtain each type or class of
cementitious material of the same brand from the same
manufacturer's plant, each aggregate from one source,
and each admixture from the same manufacturer.
9 Pre-installation Conference: Conduct conference at
Project site to comply with requirements as follows:
At least 35 days prior to submitting design mixes, conduct
a meeting to review detailed requirements for preparing
concrete design mixes and to determine procedures for
satisfactory concrete operations. Review requirements for
submittals, status of coordinating work, and availability of
materials. Establish preliminary work progress schedule
and procedures for materials inspection, testing, and
certifications. Require representatives of each entity
directly concerned with cast-in-place concrete to attend
conference, including, but not limited to, the following:
- Contractor’s superintendent.
- Agency responsible for concrete design mixes.
- Agency responsible for field quality control.
- Ready-mix concrete producer.
- Concrete subcontractor.
- Primary admixture manufacturers
5.1.2 Materials
5.1.2.1 Portland Cement
1 Portland Cement: Cement shall be low alkali with
chemical composition in accordance with Table 1 of ASTM
C 150 or BS EN 197: Part 1. The magnesia content shall be
limited to 4 percent by weight of cement, as tested in
accordance with ASTM C 114. Use one brand of cement
throughout Project unless otherwise approved by the
Engineer. Manufacturer’s test certification shall be
supplied for each delivery of cement and shall confirm
that the cement complies with the above requirements
and shall be submitted by the Contractor not later than the
day of delivery of the cement. The Engineer shall have the
right to call for tests, the cost of which is to be borne by
the Contractor, on each delivery of cement to confirm that
the cement meets the following requirements.
i. Ordinary Portland cement (OPC) conforms to
ASTM C 150, Type I or BS EN 197. The heat of
hydration shall not exceed 325 kj/kg when tested
in accordance with ASTM C 186. C3A content
shall be a minimum of 5 percent and a maximum
of 13 percent.
ii. Sulfate-resisting Portland cement conforms to
ASTM C 150, Type V or BS 4027; C3A content
shall not be more than 3.5 percent.
iii. Moderate Sulfate: conforms to ASTM C 150 type
II or BS EN 197. C3A content shall be a minimum
of 3.5 percent and a maximum of 8 percent.
2 Sampling shall be carried out in accordance with BS
EN 196: Part 7.
3 Test cement for fineness by air permeability
apparatus in accordance with ASTM C 204 to meet the
requirements of ASTM C 150.
4 Test cement for soundness. Autoclave expansion in
accordance with ASTM C 151.
5.1.2.2 Silica Fume
1 Silica fume (SF), also referred to as microsilica, used
as a cement replacement shall be in accordance with
Type U, specified in Canadian National Standard
CAN/CSA-A23.5 - M86. The silica fume shall be
obtained from an approved supplier.
♦ 5-3 ♦
2 The approved supplier shall provide documentation source and shall not contain substances that cause
to establish the following: spalling. Only aggregates not susceptible to alkali
i. That the silica fume complies with Type U of aggregate reaction shall be used. The Contractor shall
CAN/CSA-A23.5 - M86. supply samples of the materials for approval by the
ii. The silica fume results from the production of Engineer and each aggregate source shall be subject to
silicon or ferro-silicon alloys containing at least monitoring by the Engineer. Grading of aggregate shall be
85 percent silicon dioxide. That source of supply to the compliance of BS EN 12620.
shall remain the same for the construction 2 Coarse aggregate for structural concrete shall be
period of the project. 20mm nominal size, free from material passing a 5mm
iii. That the supply shall be adequate to meet the sieve, and shall consist of crushed stone, selected, re-
anticipated peak requirement. crushed, finish screened and washed with water meeting
iv. Chemical analyses to give the percentages of the the requirements of Paragraph 5.1.2.6 as necessary, and
following materials: shall comply with the following:
Si O2 C
Freq. of
Ca O Fe2 O3 Tests Test Description Standard Limit
Al2 O3 Na2 O (min)

K2 O Mg O Los Angeles ASTM 25%

Initial Abrasion Loss
SO3 C 131 maximum
(Grading A or B)
v. Loss on ignition. Ratio of Los
vi. Percentage of particles greater than 44 μm. Angeles Abrasion ASTM
vii. Specific surface area and method of test, Loss at 100 & 500 0.25%
Initial C 131
together with corresponding particle size. Revolutions maximum
(100/500 Note 6
3 Delivery of silica fume to the concrete batching plant
Revolutions Value)
shall be in dry powder form, with a bulk density between
200 and 650 kg/cu m. Clay Lumps and ASTM 1.0%
1 per day
Friable Particles C 142 maximum
4 Manufacturer's test certification shall be supplied for
each delivery of silica fume and shall confirm that the Material Finer than ASTM 1.0%
1 per day
silica fume complies with the above requirements and 75 Microns C 117 maximum
shall be submitted by the Contractor no later than the day 1 per 7 ASTM 2.0%
of delivery of the silica fume. Water Absorption
days C 127 maximum
5 The Engineer shall have the right to call for tests, the 1 per 3 0.03%
cost of which are to be borne by the Contractor, on each Chlorides as Cl BS 812
days max *
delivery of silica fume, if necessary to establish or confirm
1 per 3 0.3% max
that the silica fume meets the above requirements. Sulfates as SO3 BS 812
days *
5.1.2.3 Supplementary Cementing Material (SCM) Magnesium ASTM
1 per 30 12%
Sulfate Soundness
1 Supplementary cementing materials, if permitted by days C 88 maximum
Loss (5 cycles)
the Engineer, shall be selected from subparagraphs below.
1 per 3 25%
Blending of fly ash or slag with Portland cement shall be Flakiness Index BS 812
days maximum
done at mixing plant.
1 per 3 25%
i. Pulverized Fly Ash: ASTM C 618, Class C or F. Elongation Index BS 812
days maximum
ii. Ground Granulated Blast-Furnace Slag: ASTM C
Per
989, Grade 100 or 120. Each Appendix
ASTM
production Reactive Silica X1.3.7 of
5.1.2.4 Blended Hydraulic Cement C 227
sample ASTM C
1 Blended Hydraulic Cement: conforming to ASTM C 33
595 shall be used solely for grouts if specified or approved 1 per 7 ASTM Minimum
Specific Gravity
by the Engineer. It shall not to be used for making days C 127 2.6
structural concrete. 1 per 2 BS EN
Moisture Content
days 1097-5
5.1.2.5 Aggregates
Each
1 Aggregates shall be normal-weight and shall be from 3%
production Shell Content BS812
maximum
approved sources and shall conform to the requirements sample
of ASTM C 33 and BS EN 12620. Petrographic analyses
Table 5.1.2.1: Coarse Aggregate Specifications and Testing
shall be made in accordance with ASTM C 295.
Aggregates for exposed concrete shall be from a single

♦ 5-4 ♦
* Additionally, the limits specified in Paragraph 5.1.3.9 for tons of fine aggregate and every 80 tons
total salt content shall not be exceeded of coarse aggregate.
3 Fine aggregate, shall pass a 5mm sieve and shall - Chemical analyses shall be carried out on
consist of crushed gravel, crushed stone or natural sand every 100 tons of aggregate.
with rounded or surrounded particles, washed as ii. The Engineer shall have the right to call for
necessary, and shall comply with the following: additional samples at any time for testing of
aggregates delivered to the Site or of aggregates
Test Description Standard Limit at the source of supply in order to confirm that
Clay Lumps and the aggregates meet the above requirements.
ASTM C 142 1.0% maximum
Friable Particles 6 Transportation: During transportation to the Site, all
maximum 3% for aggregates shall be protected from wind-borne
Material Finer natural sand and 5% contaminants. If these contaminants are present at time
ASTM C 117
than 75 Microns for crushed sand of delivery, the aggregates shall be washed with water
with no plastic fines meeting the requirement of Paragraph 5.1.2.6. Transport
Water vehicles shall be cleaned to remove possible
ASTM C 128 1.0% maximum
Absorption contamination due to previous use.
Chlorides as Cl BS 812 0.06% maximum* 7 Storage: Aggregates shall be stored (under shade) on
hard concrete floors or other approved surface having
Sulfates as SO3 BS 812 0.30% maximum*
sufficient slope to ensure adequate drainage of aggregate
Organic Lighter than before being used for concrete. Each size and type shall be
ASTM C 40
Impurities Standard stored in separate heaps without intermixing. Storage
Sand Equivalent AASHTO T176 75% minimum shall prevent contamination of the aggregates by foreign
material including windblown dust. Fine and coarse
Five Cycles of
aggregates shall be separated by permanent substantial
Soundness in
BS 812 15% maximum partitions. Methods of storing, shading and cooling
Magnesium
Sulfate aggregates shall be approved by the Engineer.

Table 5.1.2.2: Fine Aggregate Specifications and Testing 8 Plums used in cyclopean concrete shall consist of
non-reactive broken stone spalls or boulders ranging in
* Additionally, the limits specified in Paragraph 5.1.3.9 for size from 200mm to 300mm. They shall be free from sharp
total salt content shall not be exceeded or angular edges and shall not form more than 30 percent
4 Certification: Obtain from each proposed source of of the total volume of concrete. They shall be evenly
supply test certification to confirm that the aggregates graded and shall be soaked in water prior to incorporation
comply with the above requirements. The following in the mix. Plums shall be evenly distributed in the
information shall be provided: concrete mix with a minimum cover of 100mm.
i. Quarry location. 5.1.2.6 Water
ii. Aggregate type.
iii. Petrographic analysis report. 1 Water used for mixing concrete, ice production,
iv. Grading curve. washing and cooling aggregates, and curing concrete
v. Shape and surface texture. shall be free from impurities, oil, acid, salts, alkali, organic
vi. Flakiness index. matter, and other potentially deleterious substances when
vii. 10 percent fines value. tested in accordance with AASHTO T26, ASTM D 512 and
viii. Impact test. ASTM D 516. Additionally, the limits specified in
ix. Shell content. Paragraph 5.1.3.9 for the total salt content of the concrete
x. Chloride and sulfate content. shall not be exceeded.
xi. Relative density. 2 Once a source of satisfactory supply has been
xii. Water absorption value and moisture content. established, further tests shall be made daily with a
xiii. Silt, clay, and dust content. portable electrical conductivity probe calibrated against
xiv. Results of reactive silica tests. the satisfactory supply. If the conductivity exceeds that of
xv. Organic impurities (fine aggregate only). the satisfactory supply, then further chemical tests shall be
5 Testing: performed.
i. When a source of supply for each aggregate type 5.1.2.7 Admixtures
has been established, samples of materials
delivered to the Site shall be taken for testing in 1 Admixtures containing chlorides shall not be used.
accordance with BS 812 as follows: 2 No admixture shall be used in the concrete without
- Tests for clay, silt and dust, and sieve the Engineer's written approval and under no
analysis shall be carried out for every 40 circumstances shall admixtures containing chlorides or

♦ 5-5 ♦
other corrosive agents be allowed. Admixture i. Fiber: Type 1, cold-drawn wire, or Type 2, cut
compatibility with the type of cement used shall be proven. sheet.
3 The Contractor shall perform a trial batch and casting 2 Synthetic Fiber: Fibrillated or monofilament
to substantiate the manufacturer’s claims of workability, polypropylene fibers engineered and designed for use in
retardation as specified in Clause 5.1.3 Admixtures shall concrete, complying with ASTM C 1116, Type III. Project to
comply with the following standards: ASTM C494/C494 M, specify length.
BS EN 934 and BS EN 480. Also, admixture shall comply
with BS EN 12878 for pigments of cement. 5.1.3 Concrete Mixes
4 Air-Entraining Admixture: No air entraining agent
5.1.3.1 Design Mixes
shall be used.
5 Admixtures shall be incorporated into the mix design 1 Prepare design mixes for each type and strength of
strictly in accordance with the manufacturer’s written concrete determined by either laboratory trial mix or field
instructions. test data bases, according to ACI 211.1 and ACI 301.
6 High-Range Water-Reducing Admixture 5.1.3.2 Testing Agency
(Superplasticizer): ASTM C 494, Type G.
1 Use a qualified independent testing agency
i. If necessary, and only with the Engineer’s
acceptable to the Engineer for preparing and reporting
approval, a naphthalene sulphonate retarding
proposed mix designs for the laboratory trial mix basis.
superplasticizer shall be used to increase
workability of the concrete and retard the initial 2 Do not use the same testing agency for field quality
set. control.
ii. Products: Superplaticizer shall produce fluid,
5.1.3.3 Reports
easily flowing concrete with a slump value at
least 200 mm, but free from segregation, and 1 Submit written reports to the Engineer of each
having the same water/cement ratio as that of a proposed mix for each class of concrete at least 15 days
no slump concrete with admixture. The product prior to start of work. Do not begin concrete production
shall result in concrete that remains workable for until proposed mix designs have been reviewed and
a minimum of 3 hours at +20 deg.C and for a approved by the Engineer.
minimum of 1.5 hours at +40 deg. C.
iii. Obtain from the retarding superplasticizer 5.1.3.4 Concrete Classes
supplier, details of the material for review by the
Concrete class

Engineer and confirmation that it is in Minimum Cement Maximum

accordance with specified requirements. compressive content Water-
Confirmation shall be obtained that the retarding strength at 28 (kg/m3) Cementitious
superplasticizer is compatible with any pozzolan days (MPa) Minimum Materials
that is used. Cylinder / cube / Maximum Ratio

7 Water-Reducing Admixture (Plasticizer): ASTM C 494,

15 15 / 18.5 250 / 350 0.70
Type A.
25 25 / 31 300 / 400 0.52
8 Water-Reducing and Accelerating Admixture: ASTM
C 494, Type E. 30 30 / 37.5 350 / 450 0.50
9 Water-Reducing and Retarding Admixture: ASTM C 35 35 / 43.5 425 / 475 0.48
494, Type D. 40 40 / 50 425 / 500 0.45
10 Corrosion-Inhibiting Admixture: Commercially 45 45 / 56 450 / 500 0.42
formulated, mixed cathodic and anodic inhibitor based on
50 50 / 62.5 450 / 500 0.40
amines and alcohol; capable of forming a protective
barrier and absorbed on the reinforcement surface of 60 60 / 75 450 / 500 0.38
concrete for protecting steel bars and minimizing chloride Table 5.1.3.1: Concrete Classes
reactions with steel reinforcement in concrete.
5.1.3.5 Threshold Values for Supplementary
11 Glare-Reducing Agent: For landscape concrete
paving, provide material for reducing glare. Comply with Cementing Materials (SCM)
ASTM D 209.
1 Add SCM to the mix as necessary to achieve the
5.1.2.8 Fiber Reinforcement strength and durability requirements of the concrete
classes with due account of the maximum water-
1 Carbon-Steel Fiber: ASTM A 820, deformed, cementitious materials ratios specified in Table 5.1.3.1 and
minimum 60 mm long, and of diameter or effective Paragraph 5.1.3.7.
diameter indicated. 2 All the supplementary cementing materials (SCM)
have threshold values of addition below which significant

♦ 5-6 ♦
durability or strength parameters do not develop. Nominal
(Equation 2)
threshold addition values are indicated in Table 5.1.3.2 for:
i. Silica fume
5.1.3.7 Water-Cementitious Materials Ratio
ii. Ground granulated blast-furnace slag (GGBFS)
iii. Pulverized fly ash (PFA) 1 The maximum water-cementitious materials ratio
shall be the lower of the values listed in Table 5.1.3.1 for
SCM Nominal threshold value
the concrete classes and the following values for the
01 Silica fume 7% on [cement + silica fume] exposure:
02 GGBFS 50% on [cement + GGBFS] i. 0.45 for concrete required to have low water
03 PFA 25% on [cement + PFA] permeability.
ii. 0.40 for corrosion protection of steel
Table 5.1.3.2Threshold Addition Values for SCM
reinforcement in concrete exposed to chlorides
3 The actual amount will depend on the quality of the from salt, saltwater, brackish water, seawater, or
supplementary cementing material and mix design spray from these sources.
parameters. iii. 0.45 for concrete subject to moderate sulfate
exposure.
5.1.3.6 Limit Values for Supplementary Cementing iv. 0.42 for concrete subject to severe or very severe
Materials (SCM) sulfate exposure.

1 The upper limiting addition percentage values for 2 The water-cementitious materials ratio shall be
each supplementary cementing material shall be as Table continuously checked at the mixer with due allowance
5.1.3.3. made for water contained in the aggregates. Under no
circumstance shall water be added between the mixer and
Max. the place of concrete placement. The Engineer may
SMA Applicable conditions
% require that the water-cementitious materials ratio be
Silica checked during tests performed on fresh concrete samples
01 10 For all exposures taken at the time of placement as specified in Paragraph
fume
For permanent dry [RH ≤ 50%] 5.1.4.4.
02 GGBFS 55 or damp [RH ≥ 85%]
conditions 5.1.3.8 Slump Limits
For underground damp
03 PFA 30 1 The slump of concrete mixes shall be such that the
exposures [RH ≥ 85%]
concrete can be transported, placed into the forms, and
04 GGBFS 70
For concrete buried in compacted without segregation in accordance with Sub-
05 PFA 45 permanently wet conditions Section 5.3. If no superplasticizer is required, the slump at
time of placement shall be 50-75 mm as measured in
Table 5.1.3.3: Limit Addition Values for SCM accordance with ASTM C 143. The concrete shall be
RH is the relative humidity. sufficiently workable to enable placement in its position
with minimum difficulty.
2 When mixtures of supplementary cementing
materials are designed into the same mix, calculations 5.1.3.9 Total Salt Content
based on proportionate replacement based on the limiting
values shown in Table 5.1.3.3 shall be derived by the use 1 Chlorides: The total chloride content (sum of both
of Equations 1 and 2. acid soluble and water soluble chlorides) of the concrete
from all sources, expressed as chloride ion, shall not
The following equations shall be used for calculating the
exceed the following percentages by weight of dry cement,
limiting partial proportions of each mineral additive in the
inclusive of pozzolan, when tested in accordance with BS
mix design:
1881:
Where
i. Unreinforced concrete 0.60%
x is the % of Silica fume incorporated ii. Concrete made with sulfate resisting
y is the % of GGBFS incorporated and cement 0.15%
z is the % of PFA incorporated iii. Concrete containing embedded metal (reinforced
concrete) made with ordinary Portland
For normal concrete (Table 5.1.3.3: conditions 01, 02 and
cement 0.30%
03)
iv. Prestressed concrete 0.06%
v. Heat cured concrete containing embedded metal
(Equation 1) (reinforced concrete) 0.10%
2 Sulfates: The total sulfate content of the concrete
For wet or dry situations (Table 5.1.3.3: conditions 01, 04 from all sources, expressed as SO3, when tested in
and 05) accordance with BS 1881, shall not exceed the lesser of 0.4

♦ 5-7 ♦
percent by weight of aggregates or 3 percent by weight of
dry cement, inclusive of pozzolan.
5.1.3.10 Initial Setting Time
1 The initial setting time shall be not less than 90
minutes after the production concrete is discharged into
the form. With a maximum time between mixing and
placing concrete of 90 minutes, the total time between
mixing and initial set shall be a minimum of 2 hours.
Maximum setting time shall be 6 hours.
2 When trial mixes are made to determine the
workability of the concrete, the initial setting time of the
cement paste shall be determined using the method
defined in ASTM C 191 at the maximum allowable
temperature and with same proportions of pozzolan and
retarding superplasticizer as specified in this Specification.
5.1.3.11 Test Mixes – Structural Grade Concrete
1 When the proposed workability, proportions of
aggregates and superplasticizer, and strength for each
grade of concrete have been established, test concrete
shall be produced for approval by the Engineer. The
following shall be performed for each grade of concrete:
i. Six separate test mixes shall be made and cured
in accordance with ASTM C 192 and tested in
accordance with ASTM C 39.
ii. The 36 cylinders for each grade of concrete shall
be tested for compressive strength at 28 days
and the mean strength and standard deviation
established for each grade. The test mixes shall
be accepted provided that:
- The mix proportions and workability are
in accordance with this Specification.
- The standard deviation for each grade is
3.5 MPa or less.
- The mean strength for structural concrete
exceeds the specified design strength by
6 MPa.
5.1.3.12 Test Mixes – Blinding and Plain Concrete
1 Concrete for blinding, plain concrete or cyclopean
concrete shall be a designed mix with design strength of
15 MPa. The trial mix proportions shall be at the
discretion of the Contractor. Once they have been chosen,
three separate test mixes shall be made with those
proportions and three test cylinders shall be made from
each mix for testing at 28 days. The trial mix proportions
and water/cement ratio shall be approved if the average
strength of the nine cylinders is not less than 14 MPa.
2 No production test shall be made for this grade of
concrete but the Engineer will monitor the mix
proportions and water/cement ratio.
5.1.3.13 Adjustments to Concrete Mixes
1 Mix design adjustments may be required by the
Engineer when characteristics of materials, job conditions,
weather, test results, or other circumstances warrant.
♦ 5-8 ♦
Laboratory test data for revised mix design and strength
results shall be submitted to and approved by the
Engineer before using in the work.
5.1.3.14 Absorption Test
1 Hardened concrete from the trial mixes for structural
grades shall be tested for absorption to establish the
concrete’s ability to resist the ingress of aggressive salts.
No absorption tests shall be required for blinding, plain
concrete or cyclopean concrete. Absorption tests shall be
in accordance with modified BS 1881: Part 122 as follows:
i. After trial mixes have been accepted, three 150
mm cylinders shall be cast from each grade of
concrete and immersed in water at 20 deg. C for
7 days.
ii. At the end of the curing period, 75 mm diameter
core specimens shall be cut along the
longitudinal axis of each cylinder to a depth of
75 mm.
iii. The specimens shall be dried in an oven at 105
deg. C for 72 hours.
iv. The specimens shall be cooled in a dry airtight
vessel for 24 hours, weighed, and then
immediately immersed in a tank containing
water at 20 deg. C with the longitudinal axis of
the cores horizontal, and with 25 mm depth of
water over the specimens.
v. The specimens shall be immersed for 24 hours,
then removed, shaken, surface dried, and
reweighed. The water absorption shall be
calculated as the increase in mass resulting from
immersion, expressed as a percentage of the dry
mass.
vi. If the cores lengths differ from 75 mm, a
correction factor (graph given in BS 1881) shall
be applied.
vii. The mean of the corrected absorption figure for
each concrete grade shall be calculated and the
absorption of the concrete mixes shall be
acceptable if the mean absorption is less than 2
percent at 30 minutes. The mean absorption
figure and the lowest absorption figure shall be
recorded for each grade and used for
comparison purposes with absorption tests
carried out on cores cut from in-situ concrete, as
scheduled in Paragraph 5.1.4.6.
5.1.3.15 Permeability Tests
1 Depth of penetration tests shall be carried out to
establish the water permeability of concrete on prototype
samples of different components of the structure before
the mix design or manufacturing method are approved.
The prototype samples shall be short sections of not less
than 1.0m x 1.0m x full thickness. The samples shall be
fully reinforced and cast in similar environment as the
actual structure. The tests shall be carried out in
accordance with DIN 1048 at age 28 days and the
maximum value of penetration shall not exceed the
following limits:
 In-situ construction: Less than 25 mm.
Precast units: Less than 20 mm.
2 Chloride permeability of the concrete shall be
determined using cores taken from the prototype samples,
in accordance with AASHTO T277 ‘Rapid Determination of
the Chloride Permeability of Concrete’. The following
limits shall not be exceeded:
In-situ construction: 1500 coulombs.
Precast units: 1000 coulombs.
3 The concrete will be deemed to comply with the
permeability requirements of this specification if all test
results comply with the limits indicated in Points 1 and 2.
4 If any of the DIN 1048 and the rapid chloride
permeability test results of unprotected surfaces of a
sample fail to meet the above requirements, then all the
concrete work represented by such sample shall be
deemed not to comply with the permeability requirements.
5 If, in the opinion of the Engineer, the concrete that
has failed to meet the permeability requirements of this
Specification is likely to cause durability problems, three
cores shall be cut from the area represented by failed
samples for additional DIN 1048 and rapid chloride
permeability testing. The location of the cores shall be
decided by the Engineer.
5.1.3.16 Synthetic Fiber
1 Uniformly disperse in concrete mix at manufacturer's
recommended rate, but not less than 0.60 kg/cu. m.
5.1.3.17 Admixtures
1 Use admixtures according to the manufacturer's
written instructions and in the proportions recommended.
2 Use water-reducing admixture or high-range water-
reducing admixture (superplasticizer) in concrete, as
required, for placement and workability.
3 Use water-reducing and retarding admixture when
required by high temperatures, low humidity, or other
adverse placement conditions.
4 Use water-reducing admixture in pumped concrete,
concrete required to be watertight, and concrete with a
water-cementitious materials ratio below 0.50.
5 Use corrosion-inhibiting admixture in concrete mixes
where indicated.
6 All admixtures shall be used as required and
approved by the Engineer for placement and workability
of concrete, and shall be used in accordance with the
manufacturer’s instructions. The equipment used for
dispensing and the method of incorporating the admixture
into the concrete shall be subject to approval. The
dispensing unit shall be translucent so that the operator
can see the discharge of the admixture.
5.1.4 Construction Requirements
5.1.4.1 Concrete Mixing
1 Concrete production shall be in accordance with ACI
304. A checklist for concrete production shall be produced,
such as that used by the NRMCA or approved equal.
2 Batching of materials shall be by weight. All
weighing equipment shall be calibrated and
documentation shall be provided to establish that the
accuracy is continuously maintained in accordance with
the requirements of ACI 304. Batching scale accuracy
shall be in accordance with the Concrete Plant Standards
of the Concrete Plant Manufacturers Bureau, or approved
equal.
3 Furnish equipment and establish accurate
procedures for determining the quantities of free moisture
in the aggregates. Moisture determinations shall be made
daily and whenever there is an apparent change in the
moisture content. The moisture content shall be recorded
and shall be taken into account in adjusting the weight of
aggregate and the quantity of water incorporated in the
mix.
5.1.4.2 Job-Site Mixing
1 All concrete mixed on Site shall be in a batch mixer
of approved size and design complying with ACI 304 and
producing a uniform distribution of the materials
throughout the mixed concrete in accordance with ASTM
C 94 uniformity test. The contents of the drum shall be
completely discharged before re-charging. After all the
materials are in the mixer, mixing shall continue until the
whole of the materials are uniformly distributed and the
mass is of uniform color and consistency. In the case of
concrete that contains silica fume with a density between
400-650 kg/cu.m, the mixing time shall be 50 percent
greater than the requirement for concrete without silica
fume.
2 Whenever mixing is to be suspended for half an hour
or longer, the drum of the mixer shall be thoroughly
washed out with clean water. Provide a competent
operator who shall be in continuous control of the mixer.
No re-tempering of concrete, which has partially hardened,
by the addition of cement, aggregate, or water shall be
allowed.
3 Provide batch ticket for each batch discharged and
used in the work, indicating Project identification name
and number, date, mix type, mix time, quantity, and
amount of water introduced as well as the load printout,
delivery printout, temperature readout and measured
slump.
5.1.4.3 Ready-Mixed Concrete
1 Ready-mixed concrete shall comply with the
requirements of ASTM C 94 or BS EN 206 and as follows:
i. Concrete shall be centrally mixed off site and
transported in an agitator truck. Truck mixing
shall not be permitted.
♦ 5-9 ♦
 ii. The plant and trucks shall be certified as meeting i.
the requirements of the NRMCA Check List, or
approved equal.
iii. Details and information regarding the supplier
proposed by the contractor shall be submitted to
the Engineer for approval.
iv. The approved supplier of ready mixed concrete
shall not subsequently be changed without
further approval of the Engineer.
2 When air temperature is between 30 deg. C and 32
deg. C, delivery time from the time that water is added to
the mix until it is placed in its final position in the form
shall not exceed 90 minutes. When air temperature is
above 32 deg. C, delivery time shall not exceed 45 minutes.
Further time extension may be given if approved by the
Engineer.
3 Before discharging concrete at the point of delivery,
provide the Engineer with a delivery ticket for each batch
of concrete containing the following information as a
minimum:
i. Name or number of off-site concrete depot.
ii. Serial number for ticket.
iii. Date.
iv. Time of dispatch.
v. Truck number.
vi. Name of supplier.
vii. Grade or mix description of concrete.
viii. Type of cementitious materials.
ix. Cementitious materials content and constitution.
x. Water/cementitious materials ratio.
xi. Nominal maximum size of aggregate.
xii. Source of aggregate, maximum size, weight of
fine and coarse aggregate.
xiii. Type or name of admixture, if included.
ii.
xiv. Percentage variation between design and actual
values for all ingredients.
xv. Quantity of concrete in cubic meters.
xvi. Certifying that chlorides and sulfate contents are
within specified limits and stating their values.
5.1.4.4 Quality Control and Testing – General
1 Testing Laboratory:
i. Employ an independent testing agency to
perform tests and to submit test reports.
ii. Be responsible for taking, identifying and
delivering to the test laboratory all test samples
called for in this Specification. The testing
laboratory shall be responsible for the testing.
Collect all test results and deliver them to the
Engineer in the format and detail as specified.
2 Testing Laboratory Qualifications: The testing
laboratory shall be approved by the Engineer and shall
have a Quality System in accordance with ANSI Q9001.
5.1.4.5 Quality Control – Testing on Fresh Concrete
1 Compressive Strength Test for Structural Concrete:
♦ 5-10 ♦
Sampling, curing and testing shall be performed
using the relevant procedures in ASTM C 31,
ASTM C 39, and ASTM C 172 or BS EN 12350.
- Samples for production concrete cylinders
(or cubes if approved by the Engineer) shall
be taken at the point of placement at the
average rate of one per 100 cu. m of concrete
placed or one for each major placement, with
a minimum of one sample taken every day
that the mix is used. A sample shall consist
of eight 150 mm cylinders molded and stored
for laboratory-cured test specimens except
when field-cured test specimens are required.
Three cylinders are for testing at 7 days after
casting, three for testing at 28 days after
casting, and two reserved for later testing if
required.
- If frequency of testing provides fewer than 5
strength tests for a given class of concrete,
conduct testing from at least 5 randomly
selected batches or from each batch if fewer
than 5 are used.
- When total quantity of a given class of
concrete is less than 100 cu. m, the Engineer
may waive strength testing if adequate
evidence of satisfactory strength is provided
but not less than one sample per day.
- When strength of field-cured cylinders is less
than 85 percent of companion laboratory-
cured cylinders, re-evaluate current on-site
operations and provide corrective procedures
for protecting and curing the in-place
concrete.
Records shall be kept of the mix details and
position in the works of all batches of concrete
and of all samples taken for cylinders and other
specimens and of their test results. A copy shall
be supplied to the Engineer within 24 hours after
recording/testing. Records shall contain, but not
be limited to, the following information:
- Date, time, location, and volume of pour.
- Ambient temperature and humidity.
- Concrete temperature (at time of placement).
- Cementitious materials content and
constitution.
- Types of manufacturers of cementitious
materials.
- Concrete type and class.
- Aggregate type and source.
- Admixture details.
- Water/cementitious materials ratio.
- Identification of test cylinder.
- Name of concrete testing service.
- Date and time of sampling.
- Method of compaction.
 - Date of testing and results of test.
- Age of sample in days, weight in grams,
density in kg/cu. m.
- Crushing load in Newtons and crushing
strength in MPa.
- Signatures of person preparing cylinder and
of person crushing cylinder.
- Results of testing.
iii. For the 28 day tests, the concrete will be deemed
to comply with the specified design strength if
the average strength determined from all sets of
3 consecutive tests is at least equal to the
specified design strength and no individual
strength test falls below the specified design
strength by more than 3.5 MPa. Any concrete
not complying with the specified design strength
shall be at risk for removal and replacement at
the Contractor’s expense.
iv. The 28-day cylinder crushing results shall be
grouped consecutively in groups of 40 and each
group shall have a standard deviation less than
3.5 MPa. If the standard deviation is greater than
or equal to 3.5 MPa, then concrete production
shall be investigated by the Engineer and further
tests on trial mixes may be required.
v. Tests shall be carried out at 7 days to establish a
relationship between the 7 day and 28 day
strengths. This relationship shall be used to
interpret future test results in order to predict the
corresponding 28 day strength. The Engineer
shall be advised without delay if any 7 day test
result indicates that the corresponding 28 day
strength is likely to fail to meet the specified
strength so that any necessary action can be
taken to minimize the effect of such possible
failure.
2 Compressive Strength Test for Blinding or Plain
Concrete: No production tests on blinding or plain
concrete are required. The Engineer may require
compressive strength tests if it is believed that the
characteristic strength is below 15 MPa. Characteristic
strength is defined as the minimum value of cube strength
achieved by 95 percent of all possible test results. If the
tests confirm that the characteristic strength is less than 15
MPa, then the Engineer will require revisions to the mix
design to ensure that the concrete meets the specified
requirements.
3 Measurement of Concrete Temperature: Temperature
measurements shall be in accordance with ASTM C 1064.
Concrete temperature shall be measured 50 mm below
the surface prior to and at the point of placement and
recorded on the pour card for each pour. One reading
shall be taken each hour when air temperature is 4 deg.C
and below and when air temperature is 27 deg.C and
above, and one reading for each set of compressive-
strength specimens. Concreting shall stop if the
temperature of the concrete does not meet the
requirements of Paragraph 5.3.3.10
4 Cementitious Materials Content and Water/
Cementitious Materials Ratio: Samples of freshly mixed
concrete shall be chosen by the Engineer at least once per
month from each structural grade and determination
made of cement content and water/cement ratio in
accordance with BS 1881. If the cement content is less
than 90 percent of the requirement in Paragraph 5.1.3.4 or
the water/cement ratio is greater than 110 percent of the
requirement in Paragraphs 5.1.3.4 and 5.1.3.7 the
Contractor and the Engineer shall investigate to establish
the cause and the Engineer may reject the cast concrete
for the pour from which the samples were taken. The
Engineer may request an analysis of fresh concrete from
any pour. No analysis of freshly mixed concrete is
required for blinding or plain concrete.
5 Salt Content: The total concentration of sulfates and
chlorides in fresh concrete shall be measured at least once
a week for all structural grades of concrete. Tests shall be
in accordance with BS 1881. Concentrations of each ion
shall not exceed the limits specified in Paragraph 5.1.3.9. If
these limits are exceeded, the concrete pour from which
the samples were taken shall be rejected and further tests
performed on the cast concrete in accordance with
paragraph 5.1.4.6 to determine the total extent of the
problem.
6 Slump: Slump tests shall be performed in accordance
with ASTM C 143. A minimum of one test shall be done at
the point of discharge for each day's pour for each type of
concrete. Additional tests shall be performed when
concrete consistency appears to have changed.
5.1.4.6 Quality Control – Testing on Hardened
Concrete
1 General: The Engineer may instruct samples to be
taken and tests carried out on any hardened structural
grade concrete as specified below if he suspects that the
concrete does not meet the specified requirements. If the
tests confirm that the concrete does not meet the
requirements of this Specification, then the Engineer may
require the concrete to be removed at the Contractor’s
expense. If the tests confirm that the concrete meets the
requirements of this Specification, then the cost of taking
the samples shall not be at the Contractor’s expense.
2 Compressive Strength Tests: The Engineer may
instruct cores to be drilled from a particular pour. 100 mm
diameter cores shall be drilled as requested, in accordance
with ASTM C 42, and sent for crushing. If the cores from
that pour have an average compressive strength less than
85 percent of the characteristic strength or if any
individual core has a compressive strength less than 75
percent of the characteristic strength, it shall be evidence
that the concrete from which it was taken is not in
accordance with the specified requirements.
3 Concrete Cover: The Engineer may check the
concrete cover over the reinforcement with a cover meter.
Any indication that the cover is generally less than the
requirements specified in Paragraph 5.2.3.4 shall be
checked by limited surface concrete removal. If it is
♦ 5-11 ♦
confirmed that the actual cover is generally less than
specified, then the concrete shall be removed at the
Contractor’s expense. In the case of localized lack of cover
and where appearance is not important, a repair shall be
effected by removal of the inadequate cover and cutting
back of concrete for 50 mm behind the reinforcement.
Resurfacing of the concrete with the specified cover shall
be carried out as a repair by a specialist subcontractor.
4 Absorption: A sample of three 75 mm diameter cores,
75 mm long, shall be taken from hardened concrete if
directed by the Engineer and tested in accordance with
Paragraph 5.1.3.14. Should the absorption of any core
exceed by more than 1 percent the highest approved test
result, the concrete from which it was cut shall be
removed. No absorption test shall be required for
blinding or plain concrete.
5 Salt Content: Engineer may request samples to be
taken from two 20 mm diameter drillings into the concrete
surface, spaced 75 mm apart. Each drilling shall proceed
in 25 mm increments for a total depth of 100 mm and the
dust from the 4 samples in each hole shall be sent for
sulfate and chloride content analysis in accordance with
BS 1881. Should the tests show that the limits specified in
Paragraph 5.1.3.9 are exceeded, the concrete shall be
removed.
6 Nondestructive Testing: Impact hammer, sonoscope,
or other nondestructive device may be used but shall not
be used as the sole basis for acceptance or rejection of
cast concrete.
7 Additional Tests: The testing agency shall make
additional tests of in-place concrete, as directed by the
Engineer, when test results indicate that specified concrete
strengths or other characteristics have not been attained
in the structure. Testing agency may conduct tests to
determine adequacy of concrete by cored cylinders
complying with ASTM C 42, or by other methods as
directed.
5.1.5 Method of Measurement
5.1.5.1 Measured Items
1 Concrete is measured by the cubic meter for each
type and class, based on dimensions shown on the
Drawings or as otherwise directed by the Engineer.
2 Concrete works shall include mass, reinforced and
prestressed concrete of both in-situ and precast
construction of a general nature, but shall not include
specific components of highway structures, such as
concrete pavement, concrete piles, concrete parapets and
safety barriers, precast concrete curbs and tiles etc., which
are separately prescribed for measurement and payment
in other Sections.
3 Different classes of concrete are measured separately.
4 Concrete formed by different types of form and/or
falsework are each measured separately.
♦ 5-12 ♦
5 Concrete of the same class requiring the same
falsework but with a different class of surface finish are
each measured separately.
6 Voids, openings or gaps 0.05 cubic meters or more
shall be deducted from the volume of concrete in which
they occur.
7 All service ducts, irrespective of diameter, shall be
measured and deducted from the volume of concrete in
which they are located.
5.1.5.2 Items Not Measured
1 Volume of reinforcing bars is not deducted from the
measured volume of concrete.
2 Volume of prestressing ducts, anchors, cones,
couplers and grouting tubes is not deducted from the
measured volume of concrete.
3 Volume of embedded metals, bolts, nuts, anchorages,
hooks etc. is not deducted from the measured volume of
concrete.
4 Holes introduced, with the consent of the Engineer,
by the Contractor for the convenience of transportation,
erection or construction shall not be deducted from the
measured volume of concrete irrespective of the size of
the holes and whether or not the holes are made good.
5 Additional concrete placed, with the consent of the
Engineer, by the Contractor solely for the purpose of
facilitating his work shall not be measured for payment.
5.1.6 Basis of Payment
1 The amount of completed and accepted work,
measured as provided above, will be paid for at the unit
rate for the types and classes of concrete in the Bill of
Quantities, which rate shall be full compensation for:
- Cement and other cementitious materials,
aggregates, water and admixtures including
their testing, storage, handling and
transportation.
- Washing of aggregates, if required.
- Ice, if required, added in the mix water.
- Plant, machinery and equipment required for
the production of concrete.
- Design of mixes, taking samples and testing.
- Transportation and delivery of concrete to work
areas.
- Placing, compacting, vibrating and finishing of
concrete.
- All formwork irrespective of the material used
and the quality of surface finish specified.
- All falsework supporting and stabilizing
formwork.
- Curing of concrete.
- Tooling, if required, to achieve the specified
surface finish.
 - Corrective measures and the means of carrying
them out required in the event of the concrete
being not in accordance with the Drawings
and/or specification.
- Handling, transportation and erection
precast concrete members.
- Grout and/or epoxy used in precast
construction including material and equipment
for temporary prestress, if required.
- Material, plant and equipment associated with
particular methods of construction.
- Joint fillers, joint sealants, weep holes, water
stops, dowel bars and other accessories as
shown on the Drawings including material,
plant handling, transportation testing, storage,
workmanship and associated ancillaries.
- Protective coating.
- All labor, materials and equipment.
5.1.7 Items in the Bill of Quantities
i Concrete (class) in (type of structure),
(location) and (finish) cu.m.
5.2 Reinforcing Steel
5.2.1 Description
5.2.1.1 References
1 American Concrete Institute (ACI):
ACI 315 Standard Practice for Detailing
Reinforced Concrete Structures
ACI 318 Building Code Requirements
Reinforced Concrete
2 American Society for Testing and Materials (ASTM):
ASTM A 82 Standard Specification for Steel Wire
Reinforcement, Plain, for Concrete
Reinforcement
ASTM A 185 Standard Specification for Steel Welded
Wire Fabric, Plain, for Concrete
Reinforcement
ASTM A 496 Standard Specification for Steel Wire,
Deformed, for Concrete Reinforcement
ASTM A 497 Standard Specification for Steel Welded
Wire Reinforcement, Deformed, for
Concrete Reinforcement
ASTM A 615M Standard Specification for Deformed
and Plain Billet- Steel Bars for Concrete
Reinforcement
ASTM A 706M Standard Specification for Low-Alloy
Steel Deformed and Plain Bars
ASTM A 780 Practice for Repair of Damaged and
Uncoated Areas of Hot-Dip Galvanized
Coatings.
3 British Standards (BS):
BS 4449 Specification for Carbon Steel Bars for
the Reinforcement of Concrete
BS 4483 Steel Fabric for the Reinforcement of
of Concrete
4 Concrete Reinforcing Steel Institute (CRSI):
CRSI Manual of Standard Practice
5.2.1.2 Submittals
1 Steel Reinforcement Shop Drawings: Details of
fabrication, bending, and placement, prepared according
to ACI 315, ‘Details and Detailing of Concrete
Reinforcement.’ Include material, grade, bar schedules,
stirrup spacing, bent bar diagrams, arrangement, and
supports of concrete reinforcement. Include special
reinforcement required for openings through concrete
structures.
2 Welding Certificates: Copies of certificates for
welding procedures and personnel.
3 Material Certificates: Signed by manufacturers and
Contractor certifying that the following items comply with
specified requirements:
i. Steel reinforcement and reinforcement
accessories: a copy of the manufacturer’s test
certificate for ultimate strength, elongation and
cold bending, together with the chemical
analysis of the steel shall be submitted to the
Engineer for each consignment of reinforcing
steel delivered to the Site.
5.2.1.3 Quality Assurance
1 Welding: Comply with AWS D1.4, ‘Structural Welding
for Code--Reinforcing Steel’ for procedures and qualification
of personnel for welding operations.
5.2.1.4 Delivery, Storage and Handling
1 Deliver, store, and handle steel reinforcement to
prevent bending and damage. Avoid damaging coatings
on steel reinforcement.
5.2.2 Materials
5.2.2.1 Steel Reinforcement
1 Reinforcing Bars: ASTM A 615M, Grade 60 (420 MPa)
specified yield strength, or BS 4449 grade 460 Type 2
deformed, uncoated. One test per 5000 m length
delivered to site.
2 Higher strength reinforcement bars may be used
subject to approval of the Engineer.
3 Low-Alloy-Steel Reinforcing Bars: ASTM A 706M,
deformed.
4 Plain-Steel Wire: ASTM A 82, as drawn.
5 Plain-Steel Wire: ASTM A 82, galvanized.
6 Deformed-Steel Wire: ASTM A 496 and Steel welded
wire reinforcement to ASTM A 497.
♦ 5-13 ♦
7 Welded Wire Fabric: ASTM A 185, welded steel wire
fabric.
8 All reinforcement shall be new material on delivery
to the Site and at time of installation, material shall be free
from loose rust and loose mill scale, deleterious amounts
of salts and coatings that reduce or destroy bond. Tight
rust and mill scale or surface irregularities are acceptable
if the weight and dimensions, including height of
deformations and tensile properties, of a test specimen
that has been wire-brushed by hand, are not less than
those required by the applicable standards.
9 Galvanized steel shall not be used
10 Reinforcement shall be accurately bent, cut or
formed to the dimensions and configuration shown on
Drawings and within the tolerances specified in ACI 315.
Reinforcement shall be bent cold using approved bending
equipment in accordance with ACI 318. Bars may be
preheated only if prior approval is given by the Engineer.
Reinforcement shall not be rebent or straightened without
prior approval.
i. Reinforcement having a reduced section, kinks,
visible transverse cracks at bends, or otherwise
damaged in any way shall not be used.
ii. Reinforcement shall not be welded unless
specifically shown on Drawings or permitted as
an exception and then only after approval of the
welding method appropriate to the grade of steel
and the type of welding rod to be used.
5.2.2.2 Reinforcement Accessories
1 Provide and fix bar supports: bolsters, chairs, spacers,
and other devices for spacing, supporting, and fastening
reinforcing bars and welded wire fabric in place. Provide
bar supports according to CRSI's ‘Manual of Standard
Practice’ from steel wire, plastic, or precast concrete or
fiber-reinforced concrete of greater compressive strength
than concrete, and as follows:
i. For concrete surfaces exposed to view where
legs of wire bar supports contact forms, use
CRSI Class 1 plastic-protected or CRSI Class 2
stainless-steel bar supports.
ii. Other reinforcement supports shall consist of
concrete spacer blocks made of the same
materials, to the same specified requirements
and with the same inherent properties as the
parent material with the exception that the
maximum aggregate size shall be appropriate for
the thickness of cover to the reinforcement.
2 Joint Dowel Bars: Plain-steel bars, ASTM A 615M,
Grade 60 (420 MPa). Cut bars true to length with ends
square and free of burrs.
3 Mechanical splices (couplers) of deformed high yield
steel bars are to consist of two seamless steel sleeves and
interconnecting high tensile steel stud with plastic
protection caps for threaded section of sleeve and shall
be tested to exceed 135% of the specified yield strength of
grade 60 bar (or higher if higher strength bars are used).
♦ 5-14 ♦
5.2.2.3 Fabricating Reinforcement
1 Fabricate steel reinforcement according to CRSI's
‘Manual of Standard Practice’.
5.2.3 Construction Requirements
5.2.3.1 General
1 Accurately position, support, and secure
reinforcement against displacement. Locate and support
reinforcement with bar supports to maintain minimum
concrete cover. Do not tack weld crossing reinforcing bars.
2 Shop- or field-weld reinforcement according to AWS
D1.4, where indicated.
3 Set wire ties with ends directed into concrete, not
toward exposed concrete surfaces.
4 Install welded wire fabric in longest practicable
lengths on bar supports spaced to minimize sagging. Lap
edges and ends of adjoining sheets at least one mesh
spacing. Offset laps of adjoining sheet widths to prevent
continuous laps in either direction. Lace overlaps with
wire
5 Avoid cutting or puncturing vapor retarder/barrier
and waterproofing membranes during reinforcement
placement and concreting operations. Repair damages
before placing concrete.
5.2.3.2 Shipping, Storage and Cleaning
1 Reinforcement shall be handled and shipped in a
manner to avoid bending or other damage to the bars.
Bars shall be bundled, separated in sizes and clearly
marked by diameter size preferably for one placement, in
accordance with the placement schedule and as follows:
i. Bars for separate structures shall not be bundled
together. Bars for small structures may be
bundled together but each bar or group of bars
that have the same piece mark shall be tagged
and coded.
ii. Metal tags or approved equal shall be provided
and labeled with legible markings.
iii. All bundles shall be tagged at each end. Tags
shall show piece marks corresponding to the
mark numbers on the placement drawings and
on the bar list.
iv. Bars shall be bundled in the largest size practical
for handling and shipping.
2 Reinforcement shall be stored 1m above ground on
platforms, skids or other approved supports and suitably
spaced. Contact with the soil shall be avoided. Proper
drainage and protection from the elements shall be
provided to minimize corrosion.
3 Clean reinforcement of loose rust and mill scale,
earth, ice, and other materials that reduce or destroy bond
with concrete.
5.2.3.3 Placing 5.2.4 Method of Measurement
1 Comply with CRSI's ‘Manual of Standard Practice’ for 1 Bar and mesh reinforcement is measured by the
placing reinforcement. theoretical quantity in metric tonnes complete in place as
shown on the Drawings or placed as ordered by the
2 Accurately position, support, and secure
Engineer. No allowance is made for clips, wire or other
reinforcement against displacement. Locate and support
fastening devices, reinforcement chairs to separate slab
reinforcement on concrete blocks of a size to give the
steel or similar reinforcement or to retain wall steel or
correct cover to the reinforcement
similar. The rates in the Bill of Quantities shall be deemed
3 Where cathodic protection is utilized, reinforcement to cover for the above.
shall be isolated from the electrical grounding system.
2 Measurement of splices or laps in reinforcement
4 Chairs made of reinforcement shall be used to not shown on the Drawings will not be made.
support the top mats of slab reinforcement and shall be so
3 Calculated weights for high tensile and mild steel
dimensioned as to be stable during concreting operations.
reinforced bars shall be based upon the following Table:
The chairs shall themselves be supported on concrete
blocks as specified in Clause 5.2.2.2.
5 Place reinforcement to maintain minimum coverage

Diameter

Diameter

Diameter
Weight

Weight

Weight
as indicated for concrete protection. Arrange, space, and

Kg/m

kg/m

kg/m
mm

mm

mm
securely tie bars and bar supports to hold reinforcement in
position during concrete placement operations. Ties at
intersections shall be made with 1.5 mm diameter
annealed wire with wire ends directed into concrete, not 5 0.154 18 2.000 34 7.130
toward exposed concrete surfaces. 6 0.222 20 2.470 36 7.990
6 All lap splices shall be in accordance with ACI 318 7 0.302 22 2.980 38 8.900
class B tension lap splice unless otherwise shown on
8 0.395 24 3.550 40 9.870
Drawings. All reinforcement bars shall be cut bent and
fixed in accordance with ACI 318 unless otherwise shown 10 0.617 26 4.170 45 12.500
on Drawings. 12 0.888 28 4.830 50 15.400
7 Welded wire fabric shall be lapped 1.5 mesh 14 1.210 30 5.550
(opening size) plus the extension on the wires unless 16 1.580 32 6.310
otherwise shown on Drawings. Table 5.2.4.1 Reinforcing Bars Weights

5.2.3.4 Concrete Cover 4 No separate measurement is made for bars of

different diameters. The unit rates in the Bill of Quantities
1 Concrete cover to reinforcement shall be as indicated
shall be deemed to cover for all diameters.
on Drawings but shall not be less than the following:
5 Fabric mesh reinforcement is measured separately
i. Concrete exposed to salt water and
by weight based on the theoretical quantity of metric
splash zone 100 mm
tonnes complete in place as shown on the Drawings or
ii. Concrete of all substructure elements cast
placed as ordered by the Engineer. No separate
against earth 100 mm
measurement is made for different mesh sizes or different
iii. Concrete of all substructure elements exposed to
wire diameters. For standard fabric, the weight will be
weather 75 mm
based on the mass in kg/sq.m. listed in Table A.1 of BS
iv. Apron slabs 60 mm
4483.
v. Superstructure cast-in-situ concrete exposed to
weather 60 mm 6 The quantity of steel reinforcing bars and fabric mesh
vi. Interior faces of superstructure cast-in-place reinforcement shall be calculated to the nearest three
concrete except slabs 40 mm decimal places.
vii. Cast-in-situ slabs 30 mm
viii. Precast superstructure elements, exposed 5.2.5 Basis of Payment
surfaces 40 mm
1 The amount of completed and accepted material,
ix. Precast superstructure elements, interior
measured as provided above, will be paid for at the unit
faces 30 mm
rate for reinforcing steel (bar and mesh), in the Bill of
x. Precast parapets, concrete barriers, curbs,
Quantities, which rate shall be full compensation for
etc. 30 mm
supplying, fabricating, transporting, delivering, erecting
2 Cover to reinforcement shall be checked before any and fixing, materials, labor, equipment, tools and other
concrete is cast. The bending of reinforcement at a cold items necessary for the proper completion of the work as
joint is not permitted. Concrete cover shall be checked specified in Sub-Section 5.2.
with a cover meter as soon as formwork is removed.

♦ 5-15 ♦
5.2.6 Items in the Bill of Quantities ASTM C 171 Standard Specification for Sheet
Materials for Curing Concrete (AASHTO
i Mild steel bar reinforcement of any
M 171)
diameter t.
ASTM C 219 Standard Terminology Relating to
ii High tensile steel bar reinforcement
Hydraulic Cement
of any diameter t.
ASTM C 309 Standard Specification for Liquid
iii Fabric wire mesh reinforcement of
Membrane-Forming Compounds for
any size t.
Curing Concrete (AASHTO M 148)
ASTM C 881 Standard Specification for Epoxy-Resin-
5.3 Reinforced Concrete Structures Base Bonding Systems for Concrete
ASTM C 920 Standard Specification for Elastomeric
5.3.1 Description
Joint Sealants
5.3.1.1 Definitions ASTM C 1315 Specification for Liquid Membrane –
Forming compounds having Special
1 Forms and Formwork: Temporary works used to give
Properties for Curing and Sealing
the required shape and support to poured concrete,
Concrete
constructed mainly of sheet material, such as wood,
plywood, metal sheet or plastic sheet, in direct contact ASTM C 1059 Specification for Latex Agents for
with the concrete, and joists or stringers to support the Bonding Fresh To Hardened Concrete
sheeting. For bridges it is recommended to use only metal ASTM D 448 Classification for Sizes of Aggregates
sheets. for Road and Bridge Construction
2 Falsework: Temporary structure used to support a ASTM D 1751 Standard Specification for Preformed
permanent concrete structure while it is not self- Expansion Joint Filler for Concrete
supporting. Paving and Structural Construction
3 Scaffold: Temporary structure to provide access, to (AASHTO M213)
work under construction. ASTM D 1752 Specification for Preformed sponge
4 Tower: Composite structure to provide access to high Rubber and Cork Expansion Joint Fillers
work under construction and to carry vertical loading. for Concrete Paving and Structural
Construction (AASHTO M153).
5 Camber: Upward curvature of the formwork,
designed to compensate for subsequent deflection under ASTM D 994 Specification for Preformed Expansion
load. Joint Filler for Concrete (AASHTO M33).
ASTM D 4397 Specification for Polyethylene Sheeting
5.3.1.2 References
for Construction, Industrial, and
1 American Association of State Highway and Agricultural Applications
Transportation Officials (AASHTO): ASTM E 154 Test Methods for Water Vapor
AASHTO M182 Standard Specification for Burlap Cloth Retarders used in Contact with Earth
Made from Jute or Kenaf under Concrete Slabs, on Walls or as
Ground Cover.
2 American Concrete Institute (ACI):
ASTM E 1745 Specification for Plastic Water Vapor
ACI 117 Specifications for Standard Tolerances
Retarders used in Contact with Soil or
for Concrete Construction and Materials
Granular Fill under Concrete Slabs.
ACI 304 Guide for Measuring, Mixing,
4 Corps of Engineers (CE):
Transporting, and Placing Concrete
CE CRD-C300 Curing Compound
ACI 305 Hot Weather Concreting
CE CRD-C513 Rubber Waterstops
ACI 309 Guide for Consolidation of Concrete
CE CRD-C572 PVC Waterstops
ACI 347 Formwork for Concrete
ACI 504R Guide to Joint Sealants for Concrete 5.3.1.3 Submittals
Structures
1 Formwork Shop Drawings: Prepare shop drawings
3 American Society for Testing and Materials (ASTM): for formwork indicating fabrication and erection of forms
ASTM C 33 Specification for Concrete Aggregates for specified finish concrete surface. Show form
ASTM C 109/C109M Test Method for Compressive construction including jointing, especial form joints or
Strength of Hydraulic Cement Mortars reveals, location and pattern of form tie placement.
(Using 2-in. or 50 mm Cube Specimens i. Design of formwork includes design of
ASTM C 150 Standard Specification for Portland falsework, scaffold and towers as defined in
Cement Paragraph 5.3.1.1.

♦ 5-16 ♦
 ii. Prepare formwork drawings by or under the i. Without prejudice to the Engineer’s rights to
supervision of a qualified professional engineer inspect, approve or reject or suspend any work,
detailing fabrication, assembly, and support of the CQCE shall be authorized to:
formwork. - Postpone concreting operations until
iii. Design and engineering of formwork for outstanding requirements are corrected.
structural stability and efficiency are the
- Reject materials or workmanship that do
Contractor's responsibility.
not conform to this Specification.
iv. Indicate proposed schedule and sequence of
stripping formwork, removing supports and re- - Prevent the use of equipment that could
shoring. cause improper construction relative to
v. If the Contractor intends to use readymade this Specification.
proprietary formwork and falsework, he shall - Stop any work that is not being done in
submit all relevant data, including independent accordance with specified requirements.
test certificates, to enable the Engineer to - Report within 24 hours and provide
determine if the proposals are acceptable. records to and as required by the
Engineer’s review of formwork design is limited Engineer upon discovery of non-
to architectural aspects only and shall not be compliance.
construed as approval of structural or other
3 Implement a Quality Assurance System as specified
matters, all of which are the Contractor’s sole
in Paragraph 5.1.1.4.
responsibility
4 Mockups: Before casting concrete that is exposed to
2 Material Certificates: Signed by manufacturers and
view in the completed structure, cast a mockup for each
Contractor certifying that each of the following items
exposed element to demonstrate typical joints, surface
complies with specified requirements:
finish, texture, color, tolerances, quality of materials and
i. Waterstops. standard of workmanship in the completed work. Where
ii. Curing materials. specified or directed by the Engineer, the mock up shall be
iii. Bonding agents. a trial construction representative of the actual structure
iv. Adhesives. (pier, cross-head, part of deck) in dimensions and all
v. Vapor retarders. details including reinforcement, using the Contractor’s
vi. Epoxy joint filler. proposed construction technique, concrete mix, formwork,
vii. Joint-filler strips. cutting and placing of reinforcement, etc.
viii. Repair materials.
i. Build mockups in the location and of the size
3 Samples: Samples of materials as requested by the indicated or, if not indicated, as directed by the
Engineer, with names, sources, and descriptions, Engineer.
including, but not limited to, the following: ii. Notify the Engineer seven days in advance of
i. Color finishes. dates and times when mockups will be
ii. Reglets. constructed.
iii. Waterstops, reinjectable hosing, water swelling iii. In the presence of the Engineer, damage parts of
gaskets. exposed surfaces as selected by the Engineer,
iv. Vapor retarder/barrier. and demonstrate materials and techniques
v. Form liners. proposed for repairs to match adjacent
vi. Joint fillers. undamaged surfaces.
vii. Sealants. iv. Obtain the Engineer's approval of mockups
before starting cast-in-place concrete elements
5.3.1.4 Quality Assurance exposed to view.
1 Codes and Standards: Comply with the latest edition v. If the Engineer determines that any mockup does
of not meet requirements, demolish and remove
from the site and cast another until the mockup
i. AASHTO LRFD Bridge Construction
is approved.
Specifications.
vi. Maintain mockups during construction in an
ii. ACI Manual of Concrete Practice Parts 1, 2, 3, 4 &
undisturbed condition as a standard for judging
5.
the completed work.
iii. CRSI "Manual of Standard Practice” except
vii. Demolish and remove mockups when directed.
where more stringent requirements are shown
or specified.
5.3.2 Materials
2 Concrete Quality Control Engineer: Appoint a full-
time Concrete Quality Control Engineer (CQCE) as 5.3.2.1 Form Materials
specified in Paragraph 5.1.1.4
1 Forms for Exposed Finish Concrete: Plywood, metal,
metal-framed plywood faced, or other acceptable panel-

♦ 5-17 ♦
type materials to provide continuous, straight, smooth,
exposed surfaces. Furnish in largest practicable sizes to
minimize number of joints and to conform to joint system
shown on Drawings.
i. Use overlaid plywood complying with U.S.
Product Standard PS-1 "A-C or B-B High Density
Overlaid Concrete Form," Class I.
ii. Use plywood complying with U.S. Product
Standard PS-1 ‘B-B (Concrete Form) Plywood,’
Class I, Exterior Grade or better, mill-oiled and
edge-sealed, with each piece bearing legible
inspection trademark.
2 Forms for Unexposed Finish Concrete: Plywood,
lumber, metal, or another acceptable material. Provide
lumber dressed on at least two edges and one side for
tight fit.
3 Forms for Textured Finish Concrete: Units of face
design, size, arrangement, and configuration to match the
Engineer's control sample. Provide solid backing and
form supports to ensure stability of textured form liners.
4 Forms for Cylindrical Columns and Supports: Metal,
glass-fiber-reinforced plastic, or paper or fiber tubes that
will produce smooth surfaces without joint indications.
Provide units with sufficient wall thickness to resist wet
concrete loads without deformation.
5 Pan-Type Forms: Glass-fiber-reinforced plastic or
formed steel, stiffened to support weight of placed
concrete without deformation.
6 Carton Forms: Biodegradable paper surface, treated
for moisture-resistance, structurally sufficient to support
weight of plastic concrete and other superimposed loads.
7 Form Release Agent: Proprietary form release agent
with a maximum of 350 g/L volatile organic compounds
(VOCs) that will not bond with, stain, or adversely affect
concrete surfaces and will not impair subsequent
treatments of concrete surfaces.
i. Release agent for steel faced formwork shall
incorporate rust inhibitor.
8 Form Ties: Factory-fabricated, adjustable-length,
removable or snap-off metal form ties designed to prevent
form deflection and to prevent spalling of concrete upon
removal. Provide units that leave no embedded metal
closer than 38 mm to the surface of the exposed concrete.
No permanent metallic part shall have less concrete cover
than the reinforcement. Provide ties that, when removed,
will not leave holes larger than 25 mm in diameter in the
concrete surface. Provide ties with integral water-barrier
plates for walls indicated to receive damp-proofing or
waterproofing.
9 Void Forms: Biodegradable paper surface, treated for
moisture resistance structural sufficient to support weight
of plastic concrete and other superimposed loads.
10 Chamfer Strips: Wood, metal, PVC, or rubber strips of
the size indicated on the Drawings.
♦ 5-18 ♦
5.3.2.2 Waterstops
1 Waterstops: Provide flat, dumbbell-type waterstops
at construction joints and other joints in accordance with
AASHTO LRFD Bridge Construction Specifications Article
8.9.2.6 or as specified herein. Waterstops shall be sized to
suit joints and shall be of the profiles shown on the
Drawings or as directed or appropriate for the particular
application. Fittings for angles junctions etc shall be
factory formed.
i. Flexible Rubber Waterstops: CE CRD-C 513, for
embedding in concrete to prevent passage of
fluids through joints.
ii. Flexible PVC Waterstops: CE CRD-C 572, for
embedding in concrete to prevent passage of
fluids through joints.
2 Self-Expanding Strip Waterstops: Proprietory
rectangular or trapezoidal strip, sodium bentonite or other
hydrophylic material for adhesive bonding to concrete.
3 Re-injectable Hosing: Proprietary re-injectable hosing
complying with the following requirements:
- The hose shall consist of a hollow PVC core
with lateral openings covered by neoprene
valves. The hose shall be laid and injected by
an approved applicator. in 10 to 12 m lengths
with entry port and vent ends terminating in
junction boxes.
- Joints shall be hydraulically tested to a
pressure at least 2.0 bar higher than the
expected local conditions. If the hose fails to
hold the pressure for 10 minutes, it shall be
injected with a vinyl ester based flexible resin
as required to seal the joint and then retested.
5.3.2.3 Concrete Curing Cover Sheets
1 Vapor retarding sheet materials shall be one of the
types specified in paragraphs 2 to 5 below or as directed
by the Engineer.
2 ASTM E 1745, Class C, of one of the following
materials; or polyethylene sheet 0.25mm thick
i. Nonwoven, polyester-reinforced, polyethylene
coated sheet; 0.25 mm thick.
ii. Three-ply, nylon- or polyester-cord-reinforced,
laminated, high-density polyethylene sheet; 0.18
mm thick.
3 Vapor retarder: ASTM E 1745, Class B, five-ply,
nylon- or polyester-cord-reinforced, high-density
polyethylene sheet; 0.25 mm thick.
4 Vapor retarder: ASTM E 1745, Class A, three-ply,
nylon- or polyester-cord-reinforced, high-density
polyethylene sheet; laminated to a nonwoven geotextile
fabric, 0.76 mm thick.
5 Vapor retarder: 2.8 mm thick, semi-flexible, seven-ply
sheet membrane consisting of reinforced core and carrier
sheet with fortified asphalt layers, protective
weathercoating, and removable plastic release liner.
Furnish manufacturer's accessories including bonding
asphalt, pointing mastics, and self-adhering joint tape.
i. Water-Vapor Permeance: ASTM E 154.
ii. Tensile Strength: 24.5 kN/m; ASTM E 154.
iii. Puncture Resistance: 400 N; ASTM E 154.
6 Absorptive Cover: Burlap cloth made from jute or
kenaf weighing approximately 0.29 kg/sq.m and
complying with AASHTO M182, Class 2.
7 Moisture Retaining Cover: ASTM C 171. polyethylene
sheet, polyethylene coated burlap or Kraft paper.
5.3.2.4 Curing Compounds
1 Curing compounds shall be one of the types
specified in paragraphs 2 to 6 below, or as directed by the
Engineer
2 Evaporation Retarder: Waterborne, monomolecular
film forming, manufactured for application to fresh
concrete
3 Clear, solvent-borne, membrane-forming curing
compound: ASTM C 309, Type 1, Class B.
4 Clear, waterborne, membrane-forming curing
compound: ASTM C 309, Type 1, Class B.
5 Clear, solvent-borne, membrane-forming curing and
sealing compound: ASTM C 1315, Type 1, Class A.
6 Clear, waterborne, membrane-forming curing and
sealing compound: ASTM C 1315, Type 1, Class A.
5.3.2.5 Concrete Accessories
1 Joint-Filler Strips: ASTM D 1751, asphalt-saturated
cellulosic fiber.
2 Joint-Filler Strips: ASTM D 1752, cork or self-
expanding cork.
3 Joint-Filler Strips: ASTM D 1751, asphalt-saturated
cellulosic fiber, or ASTM D 1752, cork or self-expanding
cork.
4 Epoxy Joint Filler: Two-component, semi-rigid, 100
percent solids, epoxy resin with a Shore A hardness of 80
per ASTM D 2240.
5 Bonding Agent: ASTM C 1059, Type II, non-
redispersible, acrylic emulsion or styrene butadiene.
6 Epoxy-Bonding Adhesive: ASTM C 881, two-
component epoxy resin, capable of humid curing and
bonding to damp surfaces, of class and grade to suit
requirements, and as follows:
i. Type II, non-load bearing, for bonding freshly
mixed concrete to hardened concrete.
ii. Types I and II, non-load bearing, for bonding
hardened or freshly mixed concrete to
hardened concrete.
iii. Types IV and V, load bearing, for bonding
hardened or freshly mixed concrete to
hardened concrete.
7 Reglets: Fabricated from not less than 0.55 mm thick
galvanized steel sheet. Temporarily fill or cover face
opening of reglet to prevent intrusion of concrete or debris.
8 Dovetail Anchor Slots: Hot-dip galvanized steel sheet,
not less than 0.85 mm thick, with bent tab anchors.
Temporarily fill or cover face opening of slots to prevent
intrusion of concrete or debris.
5.3.2.6 Repair Materials
1 Repair Underlayment: Cement-based, polymer-
modified, self-leveling product that can be applied in
thicknesses from 3 mm and that can be feathered at edges
to match adjacent floor elevations.
i. Cement Binder: ASTM C 150, Portland cement
or hydraulic or blended hydraulic cement as
defined in ASTM C 219.
ii. Primer: Product of underlayment manufacturer
recommended for substrate, conditions, and
application.
iii. Aggregate: Well-graded, washed gravel, 3 to 6
mm or coarse sand as recommended by
underlayment manufacturer.
iv. Compressive Strength: Not less than 30 MPa at
28 days when tested according to ASTM C
109M.
2 Repair Topping: Traffic-bearing, cement-based,
polymer-modified, self-leveling product that can be
applied in thicknesses from 6 mm.
i. Cement Binder: ASTM C 150, Portland cement
or hydraulic or blended hydraulic cement as
defined in ASTM C 219.
ii. Primer: Product of topping manufacturer
recommended for substrate, conditions, and
application.
iii. Aggregate: Well-graded, washed gravel, 3 to 6
mm or coarse sand as recommended by
topping manufacturer.
iv. Compressive Strength: Not less than 40 MPa at
28 days when tested according to ASTM C
109M.
5.3.3 Construction Requirements
5.3.3.1 Formwork
1 Design, erect, shore, brace, and maintain formwork,
according to ACI 301, to support vertical, lateral, static,
and dynamic loads, and construction loads that might be
applied, until concrete structure can support such loads.
Design of formwork shall be the sole responsibility of the
Contractor.
2 Construct formwork so that concrete members and
structures are of size, shape, alignment, elevation, and
position indicated, within tolerance limits of ACI 117.
3 Limit concrete surface irregularities, designated by
ACI 347R as abrupt or gradual, as follows:
i. Class A, 4 mm.
♦ 5-19 ♦
 ii. Class B, 6 mm.
iii. Class C, 10 mm.
iv. Class D, 25 mm.
4 Construct forms rigid and tight enough to prevent
loss of concrete mortar.
5 Fabricate forms for easy removal without hammering
or prising against concrete surfaces. Provide crush or
wrecking plates where stripping may damage cast
concrete surfaces. Provide top forms for inclined surfaces
steeper than 1.5 horizontal to 1 vertical. Kerf wood inserts
for forming keyways, reglets, recesses, and the like, for
easy removal.
i. Do not use rust-stained steel form-facing
material.
6 Set edge forms, bulkheads, and intermediate screed
strips for slabs to achieve required elevations and slopes
in finished concrete surfaces. Provide and secure units to
support screed strips; use strike-off templates or
compacting-type screeds.
7 Provide temporary openings for cleanouts and
inspection ports where interior area of formwork is
inaccessible. Close openings with panels tightly fitted to
forms and securely braced to prevent loss of concrete
mortar. Locate temporary openings in forms at
inconspicuous locations.
8 Chamfer exterior corners and edges of concrete
receiving applied waterproofing membranes.
9 Unless otherwise indicated, provide 20x20 mm
chamfer on all exposed corners and edges of concrete.
10 Form openings, chases, offsets, recesses, keyways,
grooves, blocking, screeds, and bulkheads required in the
work.
11 Clean forms and adjacent surfaces to receive
concrete. Remove chips, wood, sawdust, dirt, and other
debris just before placing concrete.
12 Retighten forms and bracing before placing concrete,
to prevent mortar leaks and maintain proper alignment.
13 Coat contact surfaces of forms with specified form
release agent approved by the Engineer, according to the
manufacturer's written instructions, before placing
reinforcement Petrol oil may be used.
14 Where it is required to use internal ties and spacers,
their type, spacing and use shall be to the approval of the
Engineer. In no circumstances shall these ties protrude out
of the finished concrete, all ties must be cut back into the
structural concrete and the surface made good to satisfy
the requirements of the minimum spacing and cover.
5.3.3.2 Falsework
1 Falsework and centering shall be designed to provide
the necessary rigidity to support all vertical and horizontal
loads placed upon it without settlement or deformation in
excess of the permissible tolerance for the structure given
in the Specifications. Falsework columns shall be
supported on hardwood, concrete pads or metal bases if
the underlying ground is liable to sink under the column
♦ 5-20 ♦
load. Falsework shall not be supported on any part of the
structure, except the footings, without the written
permission of the Engineer. The number and spacing of
falsework columns, the adequacy of sills, caps and
stringers and the amount of bracing in the falsework
framing shall be subject to approval of the Engineer.
2 Timber for falsework shall be sound, in good
condition and free from defects that might impair its
strength. If the vertical members are of insufficient length
to cap at the desired elevation for the horizontal members,
they shall preferably be capped and frames constructed to
the proper elevation. Ends of the vertical members shall
be cut square for full bearing to preclude the use of
wedges. If vertical splices are necessary, the abutting
members shall be of the same approximate size, the ends
shall be cut square for full bearing, and the splices shall be
scabbed in a manner approved by the Engineer.
3 The Contractor shall compute falsework settlement
and deflection for bridges so that when the final
settlement is complete, the structure will conform to the
required camber, section and grade as shown on the
Drawings.
4 The Contractor shall provide means for accurately
measuring settlement in falsework during placement of
concrete, and shall provide a competent observer to
observe and correct the settlement.
5 Screw jacks, if used, shall be designed for use with a
slenderness ratio not exceeding 60. The slenderness ratio
shall be taken as the ratio of the clear distance between
effective bracing in both horizontal directions to the
diameter of the screw jack measured at the root of the
thread. The manufacturers' certificate showing the
ultimate load capacity of the screw jack shall be submitted
with the design calculations for the falsework. If directed
by the Engineer, the Contractor shall furnish a test
certificate carried out at an approved independent
laboratory.
6 Props and towers supporting forms or partially
completed structures shall be interconnected in plan
orthogonally at levels to be determined in the design.
They shall also be interconnected by diagonal bracings in
orthogonal vertical planes.
7 If the concrete is required to be post-tensioned in the
field, the falsework shall be designed to support any
increased or readjusted loads caused by the prestressing
forces.
5.3.3.3 Embedded Items
1 Place and secure anchorage devices and other
embedded items required for adjoining work that is
attached to or supported by cast-in-place concrete. Follow
templates, diagrams, instructions, and directions
furnished with items to be embedded.
5.3.3.4 Removing and Reusing Forms
1 General: Formwork, for sides of beams, walls,
columns, and similar parts of the work, that does not
support weight of concrete may be removed after
cumulatively curing at not less than 10 deg.C for 24 hours
after placing concrete provided concrete is hard enough to
not be damaged by form-removal operations and
provided curing and protection operations are maintained.
2 The Engineer shall be notified when the Contractor
intends to remove any formwork at least 6 hours in
advance
i. Leave formwork, for beam soffits, joists, slabs,
and other structural elements that supports
weight of concrete in place until concrete has
achieved: At least 70 percent of 28-day design
compressive strength but not less than 7 days
after casting.
ii. Determine compressive strength of in-place
concrete by testing representative field- or
laboratory-cured test specimens according to
ACI 301.
iii. Remove forms only if shores have been
arranged to permit removal of forms without
loosening or disturbing shores.
3 Clean and repair surfaces of forms to be reused in
the work. Split, frayed, delaminated, or otherwise
damaged form-facing material will not be acceptable for
exposed surfaces. Apply new form release agent.
When forms are reused, clean surfaces, remove fins and
laitance, and tighten to close joints. Align and secure
joints to avoid offsets. Do not use patched forms for
exposed concrete surfaces unless approved by the
Engineer.
5.3.3.5 Vapor Retarders
1 Vapor Retarder: Place, protect, and repair vapor
retarder sheets according to ASTM E 1643 and
manufacturer's written instructions. Cover with fine
graded granular material or fill as specified in paragraphs
2 or 3 below.
2 Fine-Graded Granular Material: Cover vapor retarder
with fine-graded granular material, moisten, and compact
with mechanical equipment to elevation tolerances of plus
0 mm or minus 20 mm.
3 Granular Fill: Cover vapor retarder with granular fill,
moisten, and compact with mechanical equipment to
elevation tolerances of plus 0 mm or minus 20 mm.
i. Place and compact a 15 mm thick layer of fine-
graded granular material over granular fill.
4 Place vapor retarder/barrier sheeting in position with
longest dimension parallel with direction of pour.
Lap joints 150 mm and seal with manufacturer's
recommended mastic or pressure-sensitive tape. Cover
vapor retarder/barrier with sand cushion and compact to
depth indicated.
5.3.3.6 Construction Joints
1 Follow the requirements of AASHTO LRFD Bridge
Construction Specifications Sub-Section 8.8 as
complemented herein.
2 Construct joints true to line with faces perpendicular
to surface plane of concrete.
3 Construction joints shall be made only where
specified in the contract documents, or shown in the
pouring schedule, unless otherwise approved by the
Engineer.
4 Unless otherwise specified in the contract documents,
horizontal joints may be made without keys, and vertical
joints shall be constructed with shear keys in accordance
with AASHTO LRFD Bridge Construction Specifications
Article 8.8.2.
5 All construction joints shall be cleaned of surface
laitance, curing compound, and other foreign materials
before fresh concrete is placed against the surface of the
joint. Abrasive blast or other approved methods shall be
used to clean horizontal construction joints to the extent
that clean aggregate is exposed. All construction joints
shall be flushed with water and allowed to dry to a surface
dry condition immediately prior to placing concrete.
6 Bonding and doweling to existing structures shall be
as specified in AASHTO LRFD Bridge Construction
Specifications Article 8.8.3.
7 The use of expanded metal or other perforated
material is prohibited in construction joints.
8 Place construction joints perpendicular to main
reinforcement. Continue reinforcement across
construction joints except as indicated otherwise. Do not
continue reinforcement through sides of strip placements.
9 Where needed, unscheduled, construction joints shall
be placed as directed by the Engineer and, if directed,
additional reinforcement steel dowels shall be placed
across the joint. Such additional steel shall be furnished
and placed at the Contractor’s expense.
10 Space vertical joints in walls as indicated, or as
required by the Engineer.
11 Use a bonding agent at locations where fresh
concrete is placed against hardened or partially hardened
concrete surfaces.
12 Use epoxy-bonding adhesive at locations where
fresh concrete is placed against hardened or partially
hardened concrete surfaces.
13 Waterstops/Re-injectable Hoses: Provide waterstops
or re-injectable hoses in construction joints as indicated.
Install waterstops to form a continuous diaphragm in each
joint. Support and protect exposed waterstops during
progress of work. .
5.3.3.7 Contraction and Expansion Joints
1 Follow the requirements of AASHTO LRFD Bridge
Construction Specifications Sub-section 8.9 as
complemented herein.
♦ 5-21 ♦
2 Expansion and contraction joints shall be constructed
at the locations and in accordance with the details
specified in the contract documents. Such joints include
open joints, filled joints, joints sealed with sealants or
waterstops, and joints with combinations of these features.
3 Contraction Joints in Slabs-on-Grade: Form
weakened-plane contraction joints, sectioning concrete
into areas as indicated. Construct contraction joints for a
depth equal to at least one-fourth of concrete thickness, as
follows:
i. Grooved Joints: Form contraction joints after
initial floating by grooving and finishing each
edge of joint to a radius of 3 mm. Repeat
grooving of contraction joints after applying
surface finishes. Eliminate groover tool marks
on concrete surfaces.
ii Sawed Joints: Form contraction joints with
power saws equipped with shatterproof
abrasive or diamond-rimmed blades. Cut 3
mm wide joints into concrete when cutting
action will not tear, abrade, or otherwise
damage surface and before concrete develops
random contraction cracks.
4 Isolation Joints in slabs-on-grade: After removing
formwork, install joint-filler strips at slab junctions with
vertical surfaces, such as column pedestals, foundation
walls, grade beams, and other locations, as indicated.
i. Extend joint-filler strips full width and depth of
joint, terminating flush with finished concrete
surface, unless otherwise indicated.
ii. Terminate full-width joint-filler strips not less
than 12 mm or more than 25 mm below
finished concrete surface where joint sealants,
are indicated.
iii. Install joint-filler strips in lengths as long as
practicable. Where more than one length is
required, lace or clip sections together.
5 Dowel Joints: Install dowel sleeves and dowels or
dowel bar and support assemblies at joints where
indicated.
i. Use dowel sleeves or lubricate or asphalt-coat
one-half of dowel length to prevent concrete
bonding to one side of joint.
6 Pourable sealants for placement along top edges of
contraction or filled expansion joints shall be one of the
following:
i. Hot-poured sealants shall conform to ASTM D
3406 (AASHTO M 282), except when the
sealant will be in contact with asphaltic
material, it shall conform to AASHTO M 301.
ii. Cold-poured sealant shall be silicone type, as
specified in AASHTO LRFD Bridge Construction
Specifications Article 8.9.2.4. The sealant shall
be a one-part, low-modulus silicone rubber
type with an ultimate elongation of 1200
percent.
♦ 5-22 ♦
iii. Polyethylene foam strip, for use when shown
in the contract documents, shall be of
commercial quality with a continuous,
impervious, glazed top surface, suitable for
retaining the liquid sealant at the proper
elevation in the joint while hardening.
5.3.3.8 Waterstops
1 Install waterstops in accordance with AASHTO LRFD
Bridge Construction Specifications Sub-section 8.9.3.4.
2 Flexible Waterstops: Install in construction joints as
indicated to form a continuous diaphragm. Install in
longest lengths practicable. Support and protect exposed
waterstops during progress of work.
3 Self-Expanding Strip Waterstops: Install in
construction joints and at other locations indicated,
according to manufacturer's written instructions, bonding
or mechanically fastening and firmly pressing into place.
Install in longest lengths practicable.
5.3.3.9 Concrete Placement
1 General: Comply with AASHTO LRFD Bridge
Construction Specifications Sub-sections 8.6 and 8.7 as
complemented herein for protection from environmental
conditions during placing and curing and for handling and
placement of concrete.
2 Concrete shall be handled, placed, and consolidated
by methods that will not cause segregation of the mix and
will result in a dense homogeneous concrete that is free of
voids and rock pockets. The methods used shall not cause
displacement of reinforcing steel or other materials to be
embedded in the concrete. Concrete shall be placed and
consolidated prior to initial set and in no case more than
1.5 hours after the water was added to the mix. Concrete
shall not be re-tempered.
3 Inspection: Before placing concrete, inspect and
complete formwork installation, reinforcing steel, and
items to be embedded or cast in. Notify other trades to
permit installation of their work. Concrete shall not be
placed until the condition of the reinforcement, other
embedded items, and the formwork has been inspected
and approved by the Engineer. All mortar from previous
placements, debris, and foreign material shall be removed
from the forms and steel prior to commencing placement.
The forms and subgrade shall be thoroughly moistened
with water immediately before concrete is placed against
them. Temporary form spreader devices may be left in
place until concrete placement precludes their need, after
which they shall be removed.
4 Transportation: Concrete, after being discharged
from the mixer, shall be transported as rapidly as possible
to its final position in the Work by agitator trucks, which
shall prevent adulteration, segregation, loss of workability
or contamination of the ingredients. The containers that
convey the concrete shall be kept clean and free from
hardened or partially hardened concrete.
 i. The addition of water at the point of discharge
is prohibited and trucks shall have the water
tank completely disconnected from the drum.
ii. The use of chutes, spouts, skips and pumps
shall be permitted if approval is obtained.
Under no circumstances shall any aluminum
pipe or other conveying equipment containing
aluminum be allowed to contact fresh concrete
when it is conveyed to its point of placement.
iii. Method of pouring and pouring sequence shall
be submitted by the Contractor to the
Engineer’s approval.
5 Concrete exposed to salt or brackish water shall
follow the requirements of AASHTO LRFD Bridge
Construction Specifications Sub-section 8.6.6.
6 Do not add water to concrete during delivery, at
Project site, or during placement, unless approved by the
Engineer.
7 Placement of concrete for each section of the
structure shall be done continuously without interruption
between planned construction or expansion joints. The
delivery rate, placing sequence, and methods shall be
such that fresh concrete is always placed and consolidated
against previously placed concrete before initial set has
occurred in the previously placed concrete.
8 During and after placement of concrete, care shall be
taken not to damage the concrete or break the bond with
reinforcing steel. Workers shall not walk in fresh concrete.
Platforms for workers and equipment shall not be
supported directly on any reinforcing steel. Once the
concrete is set, forces shall not be applied to the forms or
to reinforcing bars which project from the concrete until
the concrete is of sufficient strength to resist damage.
9 Sequence of Placement: Whenever a concrete
placement plan or schedule is specified or approved, the
sequence of placement shall conform to the plan.
10 Placement of Vertical Members: Concrete for
columns, substructure and culvert walls, and other similar
vertical members shall be placed and allowed to set and
settle for a period of time before concrete for integral
horizontal members, such as caps, slabs, or footings, is
placed. Such period shall be adequate to allow completion
of settlement due to loss of bleed water and shall be not
less than 12 h for vertical members over 4500 mm in
height and not less than 30 min for members over 1500
mm but not over 4500 mm in height. When friction collars
or falsework brackets are mounted on such vertical
members and unless otherwise approved, the vertical
member shall have been in place at least seven days and
shall have attained its specified strength before loads from
horizontal members are applied
11 Placement of Superstructure: Unless otherwise
permitted, no concrete shall be placed in the
superstructure until substructure forms have been
stripped sufficiently to determine the character of the
supporting substructure concrete.
i. Concrete for T-beam or deck girder spans
whose depth is less than 1200 mm may be
placed in one continuous operation or may be
placed in two separate operations; first, to the
top of the girder stems, and second, to
completion. For T-beam or deck girder spans
whose depth is 1200 mm or more, and unless
the falsework is non-yielding, such concrete
shall be placed in two operations, and at least
five days shall elapse after placement of stems
before the top deck slab is placed.
ii. Concrete for box girders may be placed in two
or three separate operations consisting of
bottom slab, girder stems, and top slab. In
either case, the bottom slab shall be placed
first and, unless otherwise permitted by the
Engineer, the top slab shall not be placed until
the girder stems have been in place for at least
five days.
12 Placement of Box Culverts: In general, the base slab
or footings of box culverts shall be placed and allowed to
set before the remainder of the culvert is constructed. For
culverts whose wall height is 1500 mm or less, the
sidewalls and top slab may be placed in one continuous
operation. For higher culvert walls, the requirements for
vertical members shall apply.
13 Placement of Precast Elements: The sequence of
placement for concrete in precast elements shall be such
that sound, well-consolidated concrete that is free of
settlement or shrinkage cracks is produced throughout the
member.
14 Placing Methods: Concrete shall be placed as nearly
as possible in its final position, and the use of vibrators for
extensive shifting of the weight (mass) of fresh concrete
will not be permitted.
i. Concrete shall be placed in horizontal layers of
a thickness not exceeding the capacity of the
vibrator to consolidate the concrete and merge
it with the previous lift. In no case shall the
depth of a lift exceed 600 mm. The rate of
concrete placement shall not exceed that
assumed for the design of the forms as
corrected for the actual temperature of the
concrete being placed.
ii. When placing operations would involve
dropping the concrete more than 1500 mm, the
concrete shall be dropped through a tube fitted
with a hopper head or through other approved
devices, as necessary to prevent segregation of
the mix and spattering of mortar on steel and
forms above the elevation of the lift being
placed.
15 Equipment:
i. All equipment used to place concrete shall be
of adequate capacity and designed and
operated so as to prevent segregation of the
mix or loss of mortar. Such equipment shall
♦ 5-23 ♦
 not cause vibrations that might damage the
freshly placed concrete. No equipment shall
have aluminum parts which come in contact
with the concrete. Between uses, the mortar
coating inside of placing equipment which sets
or dries out shall be cleaned from the
equipment before use is resumed.
ii. Chutes shall be lined with smooth watertight
material and, when steep slopes are involved,
shall be equipped with baffles or reverses.
iii. Concrete pumps shall be operated such that a
continuous stream of concrete without air
pockets is produced. When pumping is
completed, the concrete remaining in the
pipeline, if it is to be used, shall be ejected in
such a manner that there will be no
contamination of the concrete or separation of
the ingredients.
16 Consolidation:
i. All concrete, except concrete placed under
water and concrete otherwise exempt, shall be
consolidated by mechanical vibration
immediately after placement.
ii. Except as noted herein, vibration shall be
internal. External form vibrators may be used
for thin sections when the forms have been
designed for external vibration.
iii. Vibrators shall be of approved type and design
and of a size appropriate for the work. They
shall be capable of transmitting vibration to the
concrete at frequencies of not less than 75 Hz.
iv. The Contractor shall provide a sufficient
number of vibrators to properly compact each
batch of concrete immediately after it is placed
in the forms. The Contractor shall also have at
least one spare vibrator immediately available
in case of breakdown.
v. Vibrators shall be manipulated so as to
thoroughly work the concrete around the
reinforcement and embedded fixtures and into
the corners and angles of the forms. Vibration
shall be applied at the point of deposit and in
the area of freshly deposited concrete. The
vibrators shall be inserted and withdrawn out
of the concrete slowly. The vibration shall be of
sufficient duration and intensity to thoroughly
consolidate the concrete but shall not be
continued so as to cause segregation. Vibration
shall not be continued at any one point to the
extent that localized areas of grout are formed.
Application of vibrators shall be at points
uniformly spaced and not farther apart than 1.5
times the radius over which the vibration is
visibly effective.
vi. Vibration shall not be applied either directly to,
or through the reinforcement, or to sections or
layers of concrete which have hardened to the
♦ 5-24 ♦
degree that the concrete ceases to be plastic
under vibration. Vibrators shall not be used to
transport concrete in the forms.
vii. Vibration shall be supplemented by such
spading as is necessary to ensure smooth
surfaces and dense concrete along form
surfaces and in corners and locations
impossible to reach with the vibrators.
viii. When approved by the Engineer, concrete for
small noncritical elements may be consolidated
by the use of suitable rods and spades.
17 Underwater Concreting:
i. Only concrete used in cofferdams to seal out
water may be placed under water, unless
otherwise specified in the contract documents
or specifically approved by the Engineer.
ii. If other than concrete class 50 or 60 is to be
placed under water, the minimum cement
content of the mix shall be increased by ten
percent to compensate for loss due to wash.
iii. A tremie shall consist of a watertight tube
having a diameter of not less than 250 mm and
fitted with a hopper at the top. The tremies
shall be supported so as to permit free
movement of the discharge end over the entire
top surface of the work and so as to permit
rapid lowering when necessary to retard or
stop the flow of concrete. The discharge end
shall be sealed closed at the start of work so as
to prevent water from entering the tube before
the tube is filled with concrete.
iv. After placement has started, the tremie shall be
kept full of concrete to the bottom of the
hopper. If water enters the tube after
placement is started, the tremie shall be
withdrawn, the discharge end resealed, and the
placement restarted.
v. When a batch is dumped into the hopper, the
flow of concrete shall be induced by slightly
raising the discharge end, always keeping it in
the deposited concrete. The flow shall be
continuous until the work is completed. When
cofferdam struts prevent lateral movement of
tremies, one tremie shall be used in each bay.
vi. Concrete pumps used to place concrete under
water shall include a device at the end of the
discharge tube to seal out water while the tube
is first being filled with concrete. Once the flow
of concrete is started, the end of the discharge
tube shall be kept full of concrete and below
the surface of the deposited concrete until
placement is completed.
5.3.3.10 Hot-Weather Concreting
1 When hot weather conditions exist that would impair
quality and strength of concrete, place concrete complying
with ACI 305 and as specified.
2 Cool ingredients before mixing to maintain concrete
temperature at time of placement to below 25 deg.C.
Mixing water may be chilled or chopped ice may be used
to control temperature, provided water equivalent of ice is
calculated to total amount of mixing water.
3 Concrete temperature shall not exceed 32 degree C
and the temperature differential shall not exceed 25
degree C.
4 No concreting operation shall be carried out at
ambient temperature of 40 deg. C or more.
5 For bridge decks that are located over or adjacent to
salt water the maximum temperature of the concrete at
time of placement shall be 27 deg. C.
6 Cover reinforcing steel with water-soaked burlap if it
becomes too hot, so that steel temperature will not exceed
the ambient air temperature immediately before
embedding in concrete.
7 Fog spray forms, reinforcing steel, and subgrade just
before placing concrete. Keep subgrade moisture uniform
without puddles or dry areas.
8 Use water-reducing retarding admixture when
required by high temperatures, low humidity, or other
adverse placing conditions, as acceptable to the Engineer.
9 Shade mixing plant and trucks, aggregates, water
tank, and cement silo.
10 Paint the mixing plant, trucks, water tank, and
cement silo with white or reflective paint
11 Insulate the water tank and supply piping.
12 Protect concrete during pouring, and formwork, from
direct sunlight by use of shades and keep shades in
position for 7 days from time of pouring, .
13 Concrete placing shall be completed as quickly as
possible to reduce transit time.
14 Curing of exposed concrete shall be immediately
carried out.
5.3.3.11 Finishing Plastic Concrete
1 General: Unless otherwise specified in the contract
documents, after concrete has been consolidated and
prior to the application of cure, all surfaces of concrete
that are not placed against forms shall be struck-off to the
planned elevation or slope and the surface finished by
floating with a wooden float sufficiently to seal the surface.
While the concrete is still in a workable state, all
construction and expansion joints shall be carefully tooled
with an edger. Joint filler shall be left exposed.
2 Roadway Surface Finish: All bridge decks, approach
slabs, and other concrete surfaces for use by traffic shall
be finished to a smooth skid-resistant surface in
accordance with AASHTO LRFD Bridge Construction
Specifications Sub-section 8.10.2 for the following
sequence of operations:
i. Striking-off and floating, Article 8.10.2.1. Bridge
decks or top slabs of structures serving as
finished pavements shall be finished using
approved power-driven finishing machines.
Hand-finishing methods may be used if
approved by the Engineer for short bridges 15
m or less in length or for irregular areas where
the use of a machine would be impractical.
ii. Straightedging, Sub-section 8.10.2.2.
iii. Texturing, Sub-section 8.10.2.3
iv. Surface testing and correction, Sub-section
8.10.2.4.
3 Pedestrian Walkway Surface Finish: comply with
AASHTO LRFD Bridge Construction Specifications Sub-
section 8.10.3.
4 Troweled and Brushed Finish: comply with AASHTO
LRFD Bridge Construction Specifications Sub-section
8.10.4.
5 Surface under Bearings: comply with AASHTO LRFD
Bridge Construction Specifications Sub-section 8.10.5.
5.3.3.12 Curing Concrete
1 All newly placed concrete shall be cured so as to
prevent loss of water by use of one or more of the
methods specified in AASHTO LRFD Bridge Construction
Specifications Sub-section 8.11. Unless otherwise
specified in the contract documents, curing shall
commence immediately after the free water has left the
surface and finishing operations are completed. If the
surface of the concrete begins to dry before the selected
curing method can be applied, the surface of the concrete
shall be kept moist by a fog spray applied so as not to
damage the surface.
2 Curing shall continue uninterrupted for seven days
except for when pozzolans in excess of ten percent, by
weight (mass), of the Portland cement are used in the mix.
When such pozzolans are used, the curing period shall be
ten days.
3 For other than top slabs of structures serving as
finished pavements, the above curing periods may be
reduced and curing terminated when test cylinders cured
under the same conditions as the structure indicate that
concrete strengths of at least 70 percent of that specified
have been reached but not in any case less than 3 days.
4 When directed by the Engineer during periods of hot
weather, water shall be applied to concrete surfaces being
cured by the liquid membrane method or by the forms-in-
place method, until the Engineer determines that a cooling
effect is no longer required. Such application of water will
be paid for as extra work.
5 Methods:
i. Forms-in Place Method: Formed surfaces of
concrete may be cured by retaining the forms
in place for the required time without
loosening.
ii. Water Method: Concrete surface shall be kept
continuously wet by ponding, spraying, or
covering with absorptive materials that are
kept continuously and thoroughly wet.
♦ 5-25 ♦
 iii. Liquid Membrane Curing Compound Method: as fins and surface discoloration shall, however, be made
The liquid membrane method shall not be good as and when required by the Engineer,
used on surfaces where a rubbed finish is 4 Class F4. No special requirements. To be used in the
required or on surfaces of construction joints earth-face or below ground structures if no waterproofing
unless it is removed by sand blasting prior to membrane will be applied.
placement of concrete against the joint. Type 2,
5 Permanently exposed concrete surfaces to classes F1,
white pigmented, liquid membranes may be
F2 and F3 finish shall be protected from rust marks and
used only on the surfaces of bridge decks, on
stains of all kinds. Internal ties and embedded metal parts
surfaces that will not be exposed to view in the
will not be permitted.
completed work, or on surfaces where their
use has been approved by the Engineer. 5.3.3.14 Tolerances
Details of the application are set in AASHTO
LRFD Bridge Construction Specifications Sub- 1 In-Situ Construction
section 8.11.3.3. i. Length: The horizontal and vertical dimensions
iv. Waterproof Cover Method: This method shall of in-situ concrete members, but not cross-
consist of covering the surface with a sections, shall be within the following
waterproof sheet material so as to prevent tolerances:
moisture loss from the concrete. This method Length (mm) Tolerance (mm)
may be used only when the covering can be Up to 3000 ±3
secured adequately to prevent
3001-4500 ±6
moisture loss. Details of the application are set
in AASHTO LRFD Bridge Construction Vertical lines out of plane ± 5 + (1 for every 3000 out
Specifications Sub-section 8.11.3.4. of true line)
v. Steam or Radiant-Heat Curing Method: This ii. Cross-Section: Slab and wall thicknesses and
method may be used only for precast concrete the cross-sectional dimensions of beams,
members manufactured in established plants. columns, piers etc., shall be within the
Details of the application are set in AASHTO following tolerances:
LRFD Bridge Construction Specifications Sub- Member Dimensions (mm) Tolerance (mm)
section 8.11.3.5. Up to 500 ±6
6 Bridge Decks: The top surfaces of bridge decks shall 501-750 ± 10
be cured by a combination of the liquid membrane curing
Additional for every subsequent
compound method and the water method. The liquid
100 mm ± 1 mm
membrane shall be Type 2, white pigmented, and shall be
applied from finishing bridges progressively and 2 Precast Construction
immediately after finishing operations are complete on i. Length: The horizontal and vertical dimensions
each portion of the deck. The water cure shall be applied of members, but not cross-sections, shall be
not later than 4 h after completion of deck finishing or, for within the following tolerances:
portions of the decks on which finishing is completed.
Length (mm) Tolerance (mm)
5.3.3.13 Formed Finishes Up to 3000 ±2
3000 and over ±5
1 Class F1. This class of surface finish denotes a
special finish required from aesthetic considerations as ii. Cross-Section: Slab and wall thicknesses and
stated in the Special Specification. the cross-sectional dimensions of beams,
columns, piers etc., shall be within the
2 Class F2. Formwork shall be lined with a material
following tolerances:
approved by the Engineer to provide a smooth finish of
uniform appearance. This material shall leave no stain on Member Dimensions (mm) Tolerance (mm)
the concrete and shall be so joined and fixed to its backing Up to 500 ±6
so that it imparts no blemishes. It shall be of the same
501-750 ±9
type and obtained from only one source for any one
structure. The Contractor shall make good any Additional for every subsequent
imperfections in the finish as directed by the Engineer. 250 mm ± 3 mm
Internal ties and embedded metal parts will not be 3 Squareness: For in-situ and precast construction the
permitted unless otherwise approved by the Engineer. tolerance between the short side and the long side shall
3 Class F3. Irregularities in the finish shall be no be within the following limits:
greater than those resulting from the use of wrought thick Member Size (mm) Tolerance (mm)
square edged boards arranged in a uniform pattern. The Up to 3000 ±3
finish is intended to be left as struck. Imperfections such
3000 and over ±6

♦ 5-26 ♦
4 Straightness: For in-situ and precast construction the 3 Pretensioning: The process when the prestressing
straightness or bow, defined as deviation from the steel is tensioned against independent anchorages before
intended line, shall be within the following tolerances: the concrete is placed round it. The prestressing strand or
Member Length (mm) Tolerances (mm) tendons are stressed prior to casting the concrete. After
the concrete has attained the required strength, the
Up to 3000 ±3
prestressing force is released from the external
3000 and over ±6 anchorages and transferred, by bond, into the concrete.
5 Alignment: The alignment of members shall be 4 Combined Method: Part of the reinforcement is
within the following tolerances: pretensioned and part post-tensioned.
Columns and piers. : 1:400 of column or pier 5 Cable and Tendon: Cable and tendon both refer to a
length. bundle of prestressing steel of the same type and size
Others. : 1:600 of length bundled together to be contained within a duct and
6 Flatness: The flatness of a surface, measured with a stressed, individually or collectively, from the same
straight edge of 1.5 meter, shall be not greater than 6 mm anchorage.
at any point. 6 Prestressing System: A proprietary system of
7 Twist: Twist, measured as the deviations of any applying prestress and includes anchorages, couplers and
corner from the plane containing the other three corners, jacks but does not necessarily include prestressing steel
shall be within the following limits: and cable ducts.
Member Length (mm) Tolerance (mm)
5.4.1.3 References
Up to 6000 ± 6
1 American Association of State Highway and
Above 6000 ± 12
Transportation Officials (AASHTO):
AASHTO 2008 AASHTO LRFD Bridge Construction
5.3.4 Method of Measurement, Basis of
Specifications, 2nd Edition, 2004, 2008
Payment and Bill of Quantities
Interim Revisions.
1 No separate items are measured or included in the AASHTO 2008 AASHTO LRFD Bridge Design
Bill of Quantities for any part of Sub-section 5.3 and no specifications, 3rd Edition, 2004, 2008
separate payment will be made therefore. The costs are Interim Revisions.
deemed to be covered in the rates and prices in the Bill of
AASHTO 1999 Guide Specifications for Design and
Quantities for Sub-sections 5.1 and 5.2.
Construction of Segmental Concrete
Bridges, 2nd Edition.
5.4 Prestressed Concrete Structures
2 American Society for Testing and Materials (ASTM):

5.4.1 Description ASTM A 416/A 416 M Specification for Steel Strand,

Uncoated Seven-Wire for Prestressed
5.4.1.1 Scope Concrete (AASHTO M 203).

1 This Sub-section specifies the requirements for ASTM A 421/A 421 M Specification for Uncoated
prestressing precast or cast-in-situ concrete by furnishing, Stress-Relieved Steel wire for
placing, and tensioning of prestressing steel. It includes Prestressed Concrete (AASHTO M 204).
prestressing by either the pre-tensioning or post- ASTM A 722/ A 722 M Specification for Uncoated
tensioning methods or by a combination of these methods. High-Strength Steel Bars for
2 This work includes furnishing and installation of any Prestressing Concrete (AASHTO M 275).
appurtenant items necessary for the particular ASTM C 939 Test Method for Flow of Grout for
prestressing system to be used, including but not limited Preplaced-Aggregate Concrete (Flow
to ducts, anchorage assemblies, and grout used for Cone Method).
pressure grouting ducts. ASTM C940 Test Method for Expansion and
Bleeding of Freshly Mixed Grouts for
5.4.1.2 Definitions
Preplaced-Aggregate Concrete in the
1 Prestressing Steel: Steel wire, strand or bars used for Laboratory.
prestressing of concrete. ASTM C1202 Test Method for Electrical Indication of
2 Post-Tensioning: The process when the prestressing concrete’s Ability to Resist Chloride Ion
steel is tensioned after the concrete has hardened. The Penetration (AASHTO T 277)
tendons are installed in voids or ducts within the concrete 3 British Standards:
and are stressed and anchored against the concrete after
BS4447 Specification for the Performance of
the development of the required concrete strength. As a
Prestressing Anchorages for Post-
final operation under this method, the voids or ducts are
Tensioned Construction
pressure-grouted.

♦ 5-27 ♦
BS EN 5896 Specification for High Tensile Steel
Wire and Strand for the Prestressing of
Concrete.
5.4.1.4 Submittals
1 Design:
i. Where the design for the prestressing work is
not fully detailed in the contract documents,
the Contractor shall determine the details or
type of prestressing system for use and select
materials and details conforming to this
Specification as needed to satisfy the
prestressing requirements specified. The
system selected shall provide the magnitude
and distribution of pre-stressing force and
ultimate strength required by the contract
documents without exceeding allowable
temporary stresses.
ii. Unless otherwise shown in the contract
documents, all design procedures, coefficients
and allowable stresses, friction, and prestress
losses, as well as tendon spacing and
clearances, shall be in accordance with either
or both the AASHTO LRFD Bridge Design
Specifications.
2 Working Drawings and Shop Drawings
i. Where the contract documents do not include
complete details for a prestressing system and
its method of installation, or where complete
details are provided in the contract documents
and the Contractor wishes to propose any
change, the Contractor shall prepare and
submit to the Engineer working drawings of
the prestressing system proposed for use.
Fabrication or installation of prestressing
material shall not begin until the Engineer has
approved the drawings.
ii. The working drawings of the prestressing
system shall show complete details and
substantiating calculations of the method,
materials, and equipment the Contractor
proposes to use in the prestressing operations,
including any additions or rearrangement of
reinforcing steel and any revision in concrete
dimensions from that specified in the contract
documents. Such details shall outline the
method and sequence of stressing and shall
include complete specifications and details of
the prestressing steel and anchoring devices,
working stresses, anchoring stresses, tendon
elongations, type of ducts, and all other data
pertaining to the prestressing operation,
including the proposed arrangement of the
prestressing steel in the members.
iii. Working drawings shall be submitted
sufficiently in advance of the start of the
affected work to allow time for review by the
♦ 5-28 ♦
Engineer and correction by the Contractor of
the drawings without delaying the work.
iv. Shop drawings for post-tensioning and other
embedments, such as expansion joints,
bearings, and anchor bolts submitted by
suppliers shall be reviewed and approved by
the Engineer for conformance with the design
concept and compliance with the design
drawings and Specifications.
v. Where contract-document information on post-
tensioning systems is modified by the
Contractor, or where contract drawings do not
provide detailed dimensional information on
the post-tensioning system, it is the
Contractor's responsibility to coordinate the
placement of the post-tensioning system with
other embedments, and to correct any
interferences created by the Contractor-
supplied prestressing system or other
substitutions. The post-tensioning layout shall
govern the layout of the secondary
nonprestressed reinforcement. Where
necessary, location of nonpre-stressed
reinforcement should be adjusted to clear
tendons, subject to the approval of the
Engineer.
3 Integrated Drawings: Where required by the contract
documents, in addition to all required working drawings,
the Contractor shall prepare composite placing drawings
to scale and in sufficient detail to show the relative
positions of all items that are to be embedded in the
concrete, and their embedment depth, for the portions of
the structure that are to be prestressed. Such embedded
items shall include the prestressing ducts, vents,
anchorage reinforcement and hardware, reinforcing steel,
anchor bolts, earthquake restrainers, deck joint seal
assemblies, drainage systems, utility conduits, and other
such items. Such drawings shall be in sufficient detail to
confirm that there will be no conflict between the planned
positions of any embedded items and that concrete cover
will be adequate.
4 Material Certificates: Signed by manufacturers and
contractor certifying that each of the following items
complies with specified requirements:
i. Prestressing steel
ii. Prestressing system.
iii. Records for the anchorage device acceptance
test as specified in AASHTO LRFD Bridge
Construction Specifications Article 10.3.2.3.12.
5.4.2 Materials
5.4.2.1 Concrete
1 Concrete for prestressed construction shall be
produced and supplied in accordance with the relevant
requirements of Section 5.1 “Concrete Materials and
Mixes”.
5.4.2.2 Reinforcing Steel
1 Non-prestressed reinforcing steel shall be supplied,
cut, bent and fixed in accordance with the relevant
requirements of Section 5.2 “Reinforcing Steel”.
5.4.2.3 Prestressing Steel
1 Steel Wire: Steel wire shall comply with ASTM A
421/A 421 M (AASHTO M 204), or with BS 5896.
2 Stress-Relieved Seven-Wire Strand: Stress-Relieved
Seven-Wire Strand shall comply with ASTM A 416/A416 M
low relaxation (AASHTO M 203) or with BS 5896 low
relaxation.
3 High Tensile Steel Bar: High tensile steel bars for
prestressed concrete shall comply with ASTM A 722/A 722
M (AASHTO M 275) or with BS 4486.
5.4.2.4 Post-Tensioning Anchorages and Couplers
1 Post-tensioning anchorages and couplers shall be in
accordance with the requirements of AASHTO LRFD
Bridge Construction Specifications Article 10.3.2.
2 Prestressing components, such as cable ducts,
anchorages and couplers, shall be of approved types
suitable for types of cables and bars used.
3 All anchorages and couplers shall develop at least 96
percent of the actual ultimate strength of the prestressing
steel, when tested in an unbonded state, without
exceeding anticipated set.
4 The coupling of tendons shall not reduce the
elongation at rupture below the requirements of the
tendon itself. Couplers and/or coupler components shall
be enclosed in housings long enough to permit the
necessary movements. Couplers for tendons shall be used
only at locations specifically indicated in the contract
documents and/or approved by the Engineer. Couplers
shall not be used at points of sharp tendon curvature
5 If the Engineer is not satisfied with the testing
certificates submitted for the prestressing system, he may
request post-tensioning anchorages and couplers to be
tested in accordance with AASHTO LRFD Bridge
Construction Specifications Article 10.3.2 at no extra cost.
5.4.2.5 Epoxy-Bonding Agents for Precast Segmental
Construction
1 Epoxy bonding agents for match cast joints shall be
thermosetting 100 percent solid compositions that do not
contain solvent or any nonreactive organic ingredient
except for pigments required for coloring. Epoxy bonding
agents shall be of two components, a resin and a hardener.
The two components shall be distinctly pigmented, so that
mixing produces a third color similar to the concrete in the
segments to be joined, and shall be packaged in pre-
portioned, labeled, ready-to-use containers.
2 Epoxy bonding agents shall be insensitive to damp
conditions during application and, after curing, shall
exhibit high bonding strength to cured concrete, good
water resistivity, low creep characteristics, and tensile
strength greater than the concrete. In addition, the epoxy
bonding agents shall function as a lubricant during the
joining of the match cast segments, as a filler to accurately
match the surface of the segments being joined, and as a
durable, watertight bond at the joint.
3 The physical, chemical and mechanical properties of
epoxy bonding agents shall satisfy the recommendations
of the AASHTO LRFD Bridge Design Specifications or the
Federation Internationale de la Precontrainte (FIP)
"Proposals for a standard for acceptance tests and
verifications of epoxy bonding agents for segmental
construction".
5.4.3 Construction Requirements
5.4.3.1 Placement of Ducts
1 Ducts shall be rigidly supported at the proper
Iocations in the forms by ties to reinforcing steel which are
adequate to prevent displacement during concrete
placement. Supplementary support bars shall be used
where needed to maintain proper alignment of the duct.
Hold-down ties to the forms shall be used when the
buoyancy of the ducts in the fluid concrete would lift the
reinforcing steel.
2 Polyethylene duct and metal duct for longitudinal or
transverse post-tensioning in the flanges shall be
supported at intervals not to exceed 600 mm. Polyethylene
duct in webs for longitudinal post-tensioning shall be tied
to stirrups at intervals not to exceed 600 mm, and metal
duct for longitudinal post-tensioning in webs shall be tied
to stirrups at intervals not to exceed 1200 mm.
3 Joints between sections of duct shall be coupled with
positive connections which do not result in angle changes
at the joints and will prevent the intrusion of cement paste.
Joints in adjacent ducts shall be staggered by at least 300
mm.
4 After placing of ducts, and reinforcement and
forming is complete, an inspection shall be made to locate
possible duct damage. All unintentional holes or openings
in the duct shall be repaired prior to concrete placing.
5 Grout openings and vents shall be securely anchored
to the duct and to either the forms or to reinforcing steel
to prevent displacement during concrete-placing
operations.
6 After installation in the forms, the ends of ducts shall
at all times be sealed as necessary to prevent the entry of
water or debris.
7 Where members are made up of precast units
stressed together, the ducts in the joints between the units
shall be in perfect alignment and joined securely so as to
allow unimpeded cable threading and pulling and prevent
the ingress of the epoxy mortar used for gluing the several
units together before stressing. Details of such joints shall
first be approved by the Engineer. The tolerance in the
location of the sheath shall be plus or minus 3 mm.
8 Additionally the following shall apply:
♦ 5-29 ♦
 i. Entrance and exit angles of tendon paths at
anchorages and/or at faces of concrete shall be
within ± 3 degrees of desired angle measured
in any direction and any deviations in the
alignment are accomplished with smooth
transitions without any kinks.
ii. Angle changes at duct joints shall not be
greater than ±3 degrees in any direction and
must be accomplished with smooth transitions
without any kinks.
iii. Locate anchorages within ± 3 mm of desired
position laterally and ±25 mm along the tendon
except that minimum cover requirements shall
be maintained.
iv. Position anchorage confinement reinforcement
in the form of spirals, multiple U-shaped bars
or links to be properly centered around the
duct and to start within 12 mm of the back of
the main anchor plate.
v. If conflicts exist between the reinforcement and
post-tensioning duct, position the post-
tensioning duct and adjust the reinforcement
locally with the Engineer's approval.
9 Ducts shall be kept free of any matter detrimental to
the bond between the sheath and the grout and, except for
material sealing a sheath joint, between the sheath and
the concrete.
10 All ducts for continuous structures shall be supplied
with outlets at the high and low points of the duct profile,
except where the profile changes are small, as in
continuous slabs, and at additional locations as specified
in the contract documents. Low-point outlets shall remain
open until grouting is started.
11 Upon completion of concrete placement, the
Contractor shall prove that the post-tensioning ducts are
free and clear of any obstructions or damage and are able
to accept the intended post-tensioning tendons by passing
a torpedo through the ducts. The torpedo shall have the
same cross-sectional shape as the duct, and 6 mm smaller
all around than the clear nominal inside dimensions of the
duct. No deductions shall be made to the torpedo section
dimensions for tolerances allowed in the manufacture or
fixing of the ducts. For straight ducts, a torpedo at least
600 mm long shall be used. For curved ducts, the length
shall be determined so that when both ends touch the
outermost wall of the duct, the torpedo is 6 mm clear of
the innermost wall. If the torpedo will not travel
completely through the duct, the Engineer shall reject the
member, unless a workable repair can be made to clear
the duct, to the satisfaction of the Engineer. Upon
completion of the repairs, the torpedo shall pass through
the duct easily, by hand, without resorting to excessive
effort or mechanical assistance.
12 Before stressing and grouting internal or external
tendons, install all grout caps, inlets and outlets and test
the tendon with compressed air to determine if duct
connections require repair. In the presence of the Engineer,
♦ 5-30 ♦
pressurize the tendon to 345 kPa and lock-off the outside
air source. Record pressure loss for 1 minute. A pressure
loss of 170 kPa is acceptable for tendons having a length
of equal to or less than 45 m and a pressure loss of 100
kPa is acceptable for tendons longer than 45 m. If the
pressure loss exceeds the allowable, repair the leaking
connections using methods approved by the Engineer and
re-test.
13 The ends of all ducts shall be sealed and protected until
the tendon is threaded through and the stressing
operations are commenced. Where tendons in sheaths or
sheath on its own are left exposed to atmosphere, rust
inhibitors shall be used as per the maker's specification to
prevent rusting and corrosion of the inside of sheaths.
They shall be flushed with clean water before the tendons
are grouted. The Contractor is responsible for carrying
out these measures at his own expense
5.4.3.2 Placement of Prestressing Steel
1 General:
i. All wires or strands stressed at the same time
shall be taken from the same parcel. Each
cable shall be tagged with its number and the
coil number of the steel used.
ii. Tendons shall not be welded within the length
to be tensioned and, unless other methods of
cutting are approved by the Engineer, tendons
shall be sawn or cropped using an abrasive
disc cutter.
iii. Tendons shall be built into the work strictly in
accordance with the system which is being
employed.
iv. Tendons shall not be kinked or twisted and
individual wires or strands shall be readily
identifiable at each of the members. No strand
which has become unravelled shall be used in
the work.
2 Placement for Pretensioning:
i. Prestressing steel shall be accurately installed
in the forms and held in place by the stressing
jack or temporary anchors and, when tendons
are to be draped, by hold-down devices. The
hold-down devices used at all points of change
in slope of tendon trajectory shall be of an
approved low-friction type.
ii. Prestressing steel shall not be removed from
its protective packaging until immediately prior
to installation in the forms and placement of
concrete. Openings in the packaging shall be
resealed as necessary to protect the unused
steel. While exposed, the steel shall be
protected as needed to prevent corrosion.
3 Placement for Post-Tensioning:
i. All prestressing steel preassembled in ducts
and installed prior to the placement of concrete
shall be accurately placed and held in position
during concrete placement.
 ii. When the prestressing steel is installed after
the concrete has been placed, the Contractor
shall demonstrate to the satisfaction of the
Engineer that the ducts are free of water and
debris immediately prior to installation of the
steel. The total number of strands in an
individual tendon may be pulled into the duct
as a unit, or the individual strand may be
pulled or pushed through the duct.
iii. Anchorage devices or block-out templates for
anchorages shall be set and held so that their
axis coincides with the axis of the tendon and
anchor plates are normal in all directions to the
tendon.
iv. The prestressing steel shall be distributed so
that the force in each girder stem is equal or as
required by the contract documents, except as
provided herein.
v. For box girders with more than two girder
stems, at the Contractor's option, the
prestressing force may vary up to five percent
from the theoretical required force per girder
stem provided the required total force in the
superstructure is obtained and the force is
distributed symmetrically about the centerline
of the typical section.
4 Protection of Steel after Installation:
i. Prestressing steel used in post tensioned
concrete members that is not grouted within
the time limit specified below, shall be
continuously protected against rust or other
corrosion by means of a corrosion inhibitor
placed in the ducts or directly applied to the
steel. The prestressing steel shall be so
protected until grouted or encased in concrete.
Prestressing steel installed and tensioned in
members after placing and curing of the
concrete and grouted within the time limit
specified below will not require the use of a
corrosion inhibitor described herein and rust
which may form during the interval between
tendon installation and grouting will not be
cause for rejection of the steel.
ii. The permissible interval between tendon
installation and grouting without use of a
corrosion inhibitor for various exposure
conditions shall be taken as follows:
- Very Damp Atmosphere or over saltwater
(Humidity > 70 percent) 7 days
- Moderate Atmosphere (Humidity from 40
percent to 70 percent) 15 days
- Very Dry Atmosphere (Humidity < 40
percent) 20 days
iii. After tendons are placed in ducts, the openings
at the ends of the ducts shall be sealed to
prevent entry of moisture.
iv. When steam curing is used, unless anchorage
systems mandate its installation, steel for post-
tensioning shall not be installed until the steam
curing is completed.
v. Such tendons shall be protected against
corrosion by means of a corrosion inhibitor
placed in the ducts or on the steel, or shall be
stressed and grouted within seven days after
steam curing.
vi. Whenever electric welding is performed on or
near members containing prestressing steel,
the welding ground shall be attached directly
to the steel being welded. All prestressing steel
and hardware shall be protected from weld
spatter or other damage.
5.4.3.3 Placement of Anchorages
1 The Contractor is responsible for the proper
placement of all materials according to the design
documents of the Engineer and the requirements
stipulated by the anchorage device supplier. The
Contractor shall exercise all due care and attention in the
placement of anchorage hardware, reinforcement,
concrete and consolidation of concrete in anchorage zones.
2 Modifications to the local zone details verified under
provisions of AASHTO LRFD Bridge Design Specifications
Article 5.10.9.7.3 and AASHTO LRFD Bridge Construction
Specifications Article 10.3.2.3, ‘Special Anchorage Device
Acceptance Test’, shall be approved by both the Engineer
and the anchorage device supplier.
5.4.3.4 Identification and Testing
1 All wire, strand, or bars to be shipped to the site shall
be assigned a lot number and tagged for identification
purposes. Anchorage assemblies to be shipped shall be
likewise identified.
2 Before approval, at least two samples of the
prestressing steel shall be tested at the Contractor's
expense, at an approved independent laboratory for
chemical composition, mechanical strength, relaxation
and physical characteristics.
3 Subsequently, each lot of wire or bars and each reel
of strand reinforcement shall be accompanied by a
manufacturer's certificate of compliance, a mill certificate,
and a test report. The mill certificate and test report shall
include:
i. Chemical composition (not required for strand),
ii. Cross-sectional area,
iii. Yield and ultimate strengths,
iv. Elongation at rupture,
v. Modulus of elasticity, and
vi. Stress strain curve for the actual prestressing
steel intended for use.
All values certified shall be based on test values and
nominal sectional areas of the material being certified
♦ 5-31 ♦
4 The Contractor shall furnish to the Engineer for
verification testing samples selected at random from each
lot as follows. The actual strength of the prestressing steel
shall not be less than specified by the applicable ASTM
Standard stated in Paragraph 5.4.2.3.
i. Pretensioning Tendons: one sample at least
1500 mm long shall be furnished in accordance
with the requirements of Sub-Section 9.1 of
ASTM A 416/A 416M.
ii. Post-Tensioning Tendons: for 20 tonnes, or
portion thereof, lot of material used in the
work:
- For wires not requiring heading: sufficient
length to make up one parallel-lay cable 1500
mm long consisting of the same number of
wires as the cable to be furnished.
- For strand to be furnished with fittings: 1500
mm between near ends of fittings.
- For bars to be furnished with threaded ends
and nuts: 1500 mm between threads at ends.
5 Anchorages:
i. Before approval, at least two anchorages shall
be tested at the Contractor's expense, at an
approved laboratory to BS 4447. Subsequently,
the Engineer may require additional samples,
selected at random from materials on site, to
be similarly tested.
ii. For each anchorage type used in the Works, the
characteristic value of anchorage efficiency,
determined in accordance with BS 4447, shall
be not less than 90%.
6 For prestressing systems previously tested and
approved on projects having the same tendon
configuration, the Engineer may waive the anchorage
testing.
7 Epoxy Bonding Agents: Epoxy bonding agents shall
be tested for and satisfy the requirements of all the tests
listed in the recommendations of FIP "Proposal for a
standard for acceptance tests and verification of epoxy
bonding agents for segmental construction".
5.4.3.5 Protection of Prestressing Steel
1 All prestressing steel shall be protected against
physical damage and rust or other results of corrosion at
all times from manufacture to grouting. Prestressing steel
shall also be free of deleterious material such as grease,
oil, wax or paint. Prestressing steel that has sustained
physical damage at any time shall be rejected. The
development of pitting or other results of corrosion, other
than rust stain, shall be cause for rejection.
2 Prestressing steel shall be packaged in containers or
shipping forms for the protection of the strand against
physical damage and corrosion during shipping and
storage. A corrosion inhibitor which prevents rust or other
results of corrosion shall be placed in the package or form,
or shall be incorporated in a corrosion inhibitor carrier-
♦ 5-32 ♦
type packaging material, or when permitted by the
Engineer, may be applied directly to the steel. Packaging
or forms damaged from any cause shall be immediately
replaced or restored to original condition.
3 The shipping package or form shall be clearly marked
with a statement that the package contains high-strength
prestressing steel, and the type of corrosion inhibitor used,
including the date packaged.
4 All anchorages, end fittings, couplers, and exposed
tendons, which will not be encased in concrete or grout in
the completed work, shall be permanently protected
against corrosion.
5 Corrosion Inhibitor:
i. The corrosion inhibitor shall have no
deleterious effect on the steel or concrete or
bond strength of steel to concrete or grout.
ii. Corrosion inhibitor shall consist of a vapor
phase inhibitor (VPI) powder conforming to the
provisions of Federal Specification MIL-P-
3420F-87 or as otherwise approved by the
Engineer.
iii. When approved, water soluble oil may be used
on tendons as a corrosion inhibitor.
5.4.3.6 Ducts
1 Ducts formed by sheath left in place shall be a type
that will not permit the intrusion of cement paste. They
shall transfer bond stresses as required and shall retain
shape under the weight (mass) of the concrete and shall
have sufficient strength to maintain their correct
alignment without visible wobble during placement of
concrete.
2 Metal Ducts:
i. Sheathing for ducts shall be metal, except as
provided herein. Such ducts shall be
galvanized ferrous metal and shall be
fabricated with either welded or interlocked
seams. Galvanizing of welded seams will not
be required.
ii. Rigid ducts shall have smooth inner walls and
shall be capable of being curved to the proper
configuration without crimping or flattening.
iii. Semi-rigid ducts shall be corrugated and, when
tendons are to be inserted after the concrete
has been placed, their minimum wall thickness
shall be as follows: 0.45 mm for ducts less than
or equal to 65 mm diameter 0.60 mm for ducts
greater than 65 mm diameter.
iv. When bar tendons are preassembled with such
ducts, the duct thickness shall not be less than
0.25 mm.
3 Plastic Ducts:
i. For locations in saltwater environment, plastic
duct material shall be considered and is
recommended.
 ii. Corrugated plastic duct to be completely metal polyolefin (polyethylene or
embedded in concrete shall be constructed polypropylene), and shall be air and watertight
from either polyethylene or polypropylene. The and of sufficient strength to prevent distortion
minimum acceptable radius of curvature shall or displacement of the ducts during concrete
be established by the duct supplier according placement and/or tendon grouting.
to standard test methods. The duct shall have a ii. All ducts or anchorage assemblies shall be
thickness as below: provided with pipes or other suitable
Duct Shape Duct Diameter Duct Thickness connections at each end of the duct for the
in millimeters in millimeters injection of grout after prestressing. As
specified in Article 5.4.3.1(10), ducts shall also
Flat any size 2.0
be provided with ports for venting or grouting
Round 23 2.0 at high points and for draining at intermediate
Round 60 2.0 low points.
Round 75 2.5 iii. Vent and drain pipes shall be at least 20 mm
Round 85 2.5 diameter for strand and at least 12 mm
diameter for single-bar tendons and three or
Round 100 3.0
four strand flat duct tendons. Connection to
Round 115 3.5 ducts shall be made with metallic or plastic
Round 130 4.0 structural fasteners. The vents and drains shall
Round 145 4.0 be mortar tight, taped as necessary, and
constructed with either mechanical or shrink
iii. Ducts shall have a white coating on the outside
wrap connections. Vents and drains shall
or shall be of white material with ultraviolet
provide means for injection of grout through
stabilizers added.
the vents and for sealing to prevent leakage of
iv. Polyethylene duct shall be fabricated from grout.
resins meeting or exceeding the requirements
of ASTM D 3350 with a cell classification of 5.4.3.7 Grout
345464A.
1 Grout shall be in accordance with the requirements
v. Polypropylene duct shall be fabricated from of AASHTO LRFD Bridge Construction Specifications Sub-
resins meeting or exceeding the requirements section 10.9.
of ASTM D 4101 with a cell classification range
2 Grouts may be either a unique design for the project
of PP0340B14541 to PP0340B67884.
or supplied in a pre-bagged form by a grout manufacturer.
vi. Use resin containing antioxidant(s) with a
3 Unless otherwise directed or agreed as a result of
minimum Oxidation Induction Time (OIT)
grouting trials, uniquely designed grouts shall consist only
according to ASTM D 3895 of not less than 20
of ordinary Portland cement and water. The water-cement
minutes. The OIT test shall be performed on
ratio shall be as low as possible consistent with necessary
samples taken from the finished product.
workability and under no circumstances be higher than
vii. Rigid smooth black polyethylene ducts for use 0.45 and not be subject to bleeding in excess of 2 percent
where the tendon is not embedded in concrete after 3 hours, or 4 percent maximum. When measured at
shall be rigid pipe manufactured from 100 18 degrees C in a covered glass cylinder approximately
percent virgin polyethylene resin meeting the 100 mm water shall be reabsorbed after 24 hours.
requirements of ASTM D 3350 with a minimum
4 Grout shall be mixed for a minimum of two minutes
cell class of 344464C. A resin containing
and until a uniform consistency is obtained. The
antioxidant(s) with a minimum oxidation
pumpability of the grout may be determined in
induction time (OIT) according to ASTM D 3895
accordance with the US Corps of Engineers Method CRD-
of not less than 40 min shall be used. The OIT
C79 in which case the efflux time of the grout sample
test shall be performed on samples taken from
immediately after mixing shall not be less than 11 seconds.
the finished product. The duct shall be
manufactured with a dimensional ratio (DR) of 5 Admixture containing chlorides or nitrates shall not
17.0 as established by either ASTM D 3350 or be used. Other admixtures may be used only with the
ASTM F 714 as appropriate for the written permission of the Engineer and shall be applied
manufacturing process used. strictly in accordance with the manufacturer's instruction.

4 Duct Area: The provisions of AASHTO LRFD Bridge
Design Specifications, Article 5.4.6.2, ‘Size of Ducts,’ shall
apply.
5 Duct Fittings:
i. Coupling and transition fittings for ducts
formed by sheathing shall be of either ferrous
6 The design for grout mix shall be tested in
accordance with ASTM C 49 for longitudinal change. Each
design mix and each batch mix shall be tested for vertical
dimensional change.
7 Daily field testing of the grout for the following
properties shall be required:

♦ 5-33 ♦
 i. Fluidity to ASTM C 939 or the modified test
described in AASHTO LRFD Bridge
construction Specification Table 10.9.3-2,
ii. Bleed at 3 h to ASTM C 940 as modified in
AASHTO LRFD Bridge construction
Specification Table 10.9.3-2,
iii. Permeability to ASTM C1202 (AASHTO T 277).
8 Manufacturers of pre-bagged post-tensioning grout
shall submit for approval certified test reports from an
audited and independent Cement Concrete Research
Laboratory (CCRL) which shows the material meets all the
requirements specified herein.
9 Preapproved pre-bagged grout shall be mixed in
accordance with the Manufacturer's recommendations.
10 Grouts shall achieve a non-bleeding characteristic.
Grout shall not contain aluminum powder or gas
generating system that produces hydrogen, carbon
dioxide, or oxygen. Cementitious grout shall meet or
exceed the specified physical properties stated herein as
determined by the following standard and modified ASTM
test methods.
11 Grout Classes shall be taken as specified in AASHTO
LRFD Bridge Construction Specifications Table 10.9.3-1
and Grout Properties shall be as specified in AASHTO
LRFD Bridge Construction Specifications Table 10.9.3-2.
5.4.3.8 Tensioning
1 Tensioning may be accomplished by pre-tensioning,
post-tensioning, or the combined method; as specified in
the contract documents, or on the approved working
drawings, or approved in writing by the Engineer.
2 During stressing of strand, individual wire failures
may be accepted by the Engineer, provided not more than
one wire in any strand is broken and the area of broken
wires does not exceed two percent of the total area of the
prestressing steel in the member.
3 Concrete Strength: Prestressing forces shall not be
applied or transferred to the concrete until the concrete
has attained the strength specified for initial stressing. In
addition, cast-in-place concrete for other than segmentally
constructed bridges shall not be post-tensioned until at
least ten days after the last concrete has been placed in
the member to be post-tensioned.
4 Prestressing Equipment:
i. Hydraulic jacks used to stress tendons shall be
capable of providing and sustaining the
necessary forces and shall be equipped with
either a pressure gage or a load cell for
determining the jacking stress.
ii. All jacks used for prestressing shall be of the
5 Sequence of Stressing: When the sequence of
type applicable to the system adopted. The
stressing individual tendons is not otherwise specified in
accuracy of the load metering equipment shall
the contract documents or on the approved working
be checked to the satisfaction of the Engineer
drawings, the stressing of post-tensioning tendons and
at the start of the work each day it has to be
the release of pretensioned tendons shall be done in a
used and whenever the equipment is moved to
sequence that produces a minimum of eccentric force in
a different job.
the member.
♦ 5-34 ♦
iii. Documentary proof shall be provided
confirming that all jacks have been fully
overhauled and checked by an agent approved
by the manufacturer of the equipment. Each
jack shall be accompanied by a test certificate
indicating that it has been tested and calibrated
by the manufacturer or by an approved testing
laboratory up to a load equal to the full
capacity of the jack within a period of six
months prior to the commencement of
prestressing.
iv. The jacking system shall provide an
independent means by which the tendon
elongation can be measured. The pressure
gage shall have an accurate reading dial at
least 150 mm in diameter or a digital display,
and each jack and its gage shall be calibrated
as a unit with the cylinder extension in the
approximate position that it will be at final
jacking force, and shall be accompanied by a
certified calibration chart or curve.
v. All gages, load cells, dynamometers and other
devices used for measuring the stressing force
shall have an accuracy of within plus or minus
1.5 percent. Pressure gages shall have a
capacity and calibrated cell such that the
working pressure required to stress the
tendons to the fully stated load lies within the
central half of the range of the gage.
vi. Each gage shall have a calibration certificate
issued by an approved test laboratory. All
pressure gages shall be so constructed that
they may be calibrated, either directly by an
approved testing laboratory, or by
compressing with a meter gage which has
itself been calibrated by an approved testing
laboratory.
vii. All pressure gages shall be re-calibrated before
use and at intervals of 14 days during the
prestressing operation. The Engineer will
order re-calibration of any pressure gage at any
time should he have reason to suspect damage
to or faulty operation of the gage.
viii. The accuracy of all prestressing and load
measuring equipment shall be checked
whenever required by the Engineer. The
Contractor shall provide a rig suitable in the
opinion of the Engineer, for all checking and
calibration of any jacking system consisting of
jacks and associated load devices, pressure
gages and dynamometers.
6 Measurement of Stress:
i. A record of gage pressures and tendon
elongations for each tendon shall be provided
by the Contractor for review and approval by
the Engineer. Elongations shall be measured to
an accuracy of 1.5 mm. Stressing tails of post-
tensioned tendons shall not be cut off until the
stressing records have been approved.
ii. The stress in tendons during tensioning shall
be determined by the gage or load-cell
readings and shall be verified with the
measured elongations. Calculations of
anticipated elongations shall utilize the
modulus of elasticity, based on nominal area,
as furnished by the Manufacturer for the lot of
steel being tensioned, or as determined by a
bench test of strands used in the work.
iii. All tendons shall be tensioned to a preliminary
force as necessary to eliminate any take-up in
the tensioning system before elongation
readings are started. This preliminary force
shall be between 5 and 25 percent of the final
jacking force. The initial force shall be
measured by a dynamometer or by other
approved method, so that its amount can be
used as a check against elongation as
computed and as measured. Each strand shall
be marked prior to final stressing to permit
measurement of elongation and to ensure that
all anchor wedges set properly.
5.4.3.9 Pretension Construction
1 The strand stress prior to seating (jacking stress)
shall not exceed 80 percent of the minimum ultimate
tensile strength of the prestressing steel. This allowable
stress, which slightly exceeds the values allowed in
AASHTO LRFD Bridge Design Specifications, Article 5.9.3,
may be permitted to offset seating losses and to
accommodate compensation for temperature differences
specified below.
2 In pretensioned members where tendons are
specified as debonded from the concrete, they shall be
covered with sleeves of PVC or other material approved by
the Engineer. The ends of the sleeves shall be taped to
the tendon to prevent the ingress of grout.
3 Stressing shall be accomplished by either single-
strand stressing or multiple-strand stressing. The amount
of stress to be given to each strand shall be as shown in
the contract documents or on the approved working
drawings.
4 All strands to be stressed in a group (multiple-strand
stressing) shall be brought to a uniform initial tension
prior to being given their full pre-tensioning. The amount
of the initial tensioning force shall be within the range
specified in Article 5.4.3.8 (6) Measurement of Stress, and
shall be the minimum required to eliminate all slack and to
equalize the stresses in the tendons as determined by the
Engineer. The amount of this force will be influenced by
the length of the casting bed and the size and number of
tendons in the group to be tensioned.
5 Draped Pretensioned Tendons:
i. Draped pretensioned tendons shall either be
tensioned partially by jacking at the end of the
bed and partially by uplifting or depressing
tendons, or they shall be tensioned entirely by
jacking, with the tendons being held in their
draped positions by means of rollers, pins, or
other approved methods during the jacking
operation.
ii. Approved low-friction devices shall be used at
all points of change in slope of tendon
trajectory when tensioning draped
pretensioned strands, regardless of the
tensioning method used.
iii. If the load for a draped strand, as determined
by elongation measurements, is more than five
percent less than that indicated by the jack
gages, the strand shall be tensioned from both
ends of the bed, and the load as computed
from the sum of elongation at both ends shall
agree within five percent of that indicated by
the jack gages.
6 When ordered by the Engineer, prestressing steel
strands in pretensioned members, if tensioned
individually, shall be checked by the Contractor for loss of
prestress not more than 3 hours prior to placing concrete
for the members. The method and equipment for checking
the loss of prestress shall be subject to approval by the
Engineer. All strands that show a loss of prestress in
excess of three percent shall be retensioned to the original
computed jacking stress.
7 Stress on all strands shall be maintained between
anchorages until the concrete has reached the
compressive strength required at time of transfer of stress
to concrete.
8 When prestressing steel in pretensioned members is
tensioned at a temperature more than 14 deg. C lower
than the estimated temperature of the concrete and the
prestressing steel at the time of initial set of the concrete,
the calculated elongation of the prestressing steel shall be
increased to compensate for the loss in stress due to the
change in temperature, but in no case shall the jacking
stress exceed 80 percent of the specified minimum
ultimate tensile strength of the prestressing steel.
9 Members shall be free to accommodate the
horizontal and vertical movements due to the application
of prestress. Side and flange forms that restrain deflection
shall be removed before release of pre-tensioning
reinforcement.
10 When the concrete has attained the specified
strength, the load shall be transferred gradually without
severance of the tendons
11 Except when otherwise shown in the contract
documents, all pretensioned prestressing strands shall be
cut off flush with the end of the member, and the exposed
♦ 5-35 ♦
ends of the strand and a 25 mm strip of adjoining concrete
shall be cleaned and painted. Cleaning shall be by wire
brushing or abrasive blast cleaning to remove all dirt and
residue that is not firmly bonded to the metal or concrete
surfaces. The surfaces shall be coated with one thick coat
of zinc-rich paint conforming to the requirements of U.S.
Military Specification MIL-P-24441/20. The paint shall be
thoroughly mixed at the time of application, and shall be
worked into any voids in the strands.
12 All members shall be indelibly marked to show the
specified member mark, the production line on which they
were manufactured, the date on which the concrete was
cast, the load applied and, if they are of symmetrical
section, the face which will be uppermost when the
member is in its correct position in the work. The
markings shall be so located that they are not exposed to
view when the member is in its permanent position.
5.4.3.10 Post-Tension Construction
1 The standard stress prior to seating (jacking stress)
and the stress in the prestressing steel immediately after
seating shall not exceed the values allowed in AASHTO
LRFD Bridge Design Specifications, Sub-section 5.9.3.
2 Immediately before tensioning, the Contractor shall
demonstrate to the satisfaction of the Engineer that all
tendons are free to move between jacking points and that
members are free to accommodate the horizontal and
vertical movements due to the application of prestress.
3 Unless otherwise specified, concrete shall not be
stressed until it has reached the age at which at least 2 test
specimens taken from it attain the specified transfer
strength. The test specimens shall be cured in similar
conditions to the concrete to which they relate. The
Contractor shall cast sufficient specimens to demonstrate
that the required strength of the concrete at transfer has
been reached.
4 Where members consist of jointed elements the
strength at transfer of the jointing material shall be at least
equivalent to the specified transfer strength of the
member.
5 Tension Procedures:
i. The Contractor shall establish the datum point
for measuring extension and jack pressure to
the satisfaction of the Engineer.
ii. The Contractor shall add to the specified forces
an allowance where necessary for anchorage
friction, wedge pull-in, jack losses and friction
due to duct alignment and curvature. The total
forces and calculated extensions shall be
agreed with the Engineer before stressing is
commenced.
iii. Immediately after anchoring, the stresses in the
tendons shall not exceed 75 percent of their
ultimate tensile strength or as defined in the
contract documents. During stressing the
value shall not exceed 80 percent.
♦ 5-36 ♦
iv. The tendons shall be stressed at a gradual and
steady rate until they attain the force and
extension specified.
v. If the measured extension differs by more than
5 percent from the estimated extension,
corrective action shall be taken as directed by
the Engineer.
vi. The force in the tendons shall be obtained from
reading on a load cell or pressure gage, and
the extension of the tendons measured. Due
allowance must be made for taking up slack in
the tendons.
vii. Stressing shall be from both ends unless
otherwise specified or agreed by the Engineer.
viii. Where stressing from one end only, the pull-in
at the end remote from the jack shall be
accurately measured and the appropriate
allowance made in the measured extension at
the jacking end.
ix. When the specified force, including any
overload of short duration, has been applied, to
the satisfaction of the Engineer, the tendons
shall be anchored. The jack pressures shall
then be released in such a way as to avoid
shock to the anchorage of tendons.
x. If the pull-in of the tendons at completion of
anchoring is greater than that stipulated by the
Engineer, tensioning shall be carried out afresh.
xi. If it is necessary to cut the tendons to enable
the ducts to be grouted, this shall be delayed
as long as practicable up to the time of
grouting. In all other cases, unless agreed
otherwise by the Engineer, the tendons shall
not be cropped less than 3 days after grouting.
6 Records: A record of the following post-tensioning
operations shall be kept for each tendon installed:
i. Project name, number,
ii. Contractor and/or subcontractor,
iii. Tendon location, size and type,
iv. Date tendon was first installed in ducts,
v. Coil/reel number for strands or wires and heat
number for bars and wire,
vi. Assumed and actual cross-sectional area,
vii. Assumed and actual modulus of elasticity,
viii. Date stressed,
ix. Jack and gage numbers per end of tendon,
x. Required jacking force,
xi. Gage pressures,
xii. Elongations (anticipated and actual),
xiii. Anchor sets (anticipated and actual),
xiv. Stressing sequence (i.e., tendons before and
after this tendon),
xv. Stressing mode (one end/two
ends/simultaneous),
 xvi. Witnesses to stressing operation (Contractor
and Inspector),
xvii. Date grouted, days from stressing to grouting,
grouting pressure applied, and injection end,
xviii. Record any other relevant information
including pour back and bitumastic installation
dates.
The Engineer shall be provided with a complete copy of
stressing operations, and the jack calibration forms within
24 hours of each tensioning operation.
7 Protection of Tendons: Within 4 hours after stressing
5 Preparation of Ducts:
and prior to grouting, tendons shall be protected against
corrosion or harmful effects of debris by temporarily
plugging or sealing all openings and vents; cleaning rust
and other debris from all metal surfaces which will be
covered by the grout cap; and placing the grout cap,
including a seal, over the wedge plate until the tendon is
grouted.
5.4.3.11 Grouting
1 Grout should be injected from low points pumping
toward the high-point vent. For segmental, span-by-span
construction, grout shall be injected through a grout inlet
at midspan.
2 Ducts shall be grouted as soon as practicable after
the tendons have been stressed and the Engineer's
permission to commence has been obtained. The ducts
shall be completely filled with grout. Grout shall be
injected in one continuous operation and allowed to flow
from the vents until the consistency is equivalent to that
6 Equipment:
being injected or more than 11 seconds.
3 Grout shall not be above 32 deg. C during mixing or
pumping. If necessary, cool the mixing water.
4 A grouting operation plan shall be submitted for
approval at least 45 days in advance of any scheduled
grouting operations. Written approval of the grouting
operation plan by the Engineer shall be required before
any grouting of the permanent tendons in the structure
takes place. At a minimum, the following items shall be
provided in the grouting operation plan:
i. Provide names, and proof of training and
experience records for the grouting crew and
7 Mixing of Grout:
the crew supervisor in conformance with this
Specification;
ii. Type, quantity, and brand of materials used in
grouting including all required certifications;
iii. Type of equipment furnished, including
capacity in relation to demand and working
condition, as well as back-up equipment and
spare parts;
iv. General grouting procedure;
v. Duct pressure test and repair procedures;
vi. Method to be used to control the rate of flow
within ducts;
vii. Theoretical grout volume calculations;
viii. Mixing and pumping procedures;
ix. Direction of grouting;
x. Sequence of use of the inlets and outlet pipes;
xi. Procedures for handling blockages; and
xii. Procedures for possible post grouting repair.
Before grouting operations begin, a joint meeting of
the Contractor, grouting crew and the Engineer shall
be conducted. At the meeting, the grouting operation
plan, required testing, corrective procedures, and any
other relevant issues shall be discussed.
i. Each duct shall be air pressure tested prior to
the installation of the prestressing steel into the
ducts. If leaks are indicated during the test, the
duct shall be repaired to eliminate the leakage
or minimize the consequences of the leakage.
ii. All ducts shall be clean and free of deleterious
materials that would impair bonding or
interfere with grouting procedures.
iii. Ducts with concrete walls (cored ducts) shall be
flushed to ensure that the concrete is
thoroughly wetted. Metal ducts shall be flushed
if necessary to remove deleterious material.
iv. Water used for flushing ducts may contain
slack lime (calcium hydroxide) or quicklime
(calcium oxide) in the amount of 0.012 kg/l.
v. After flushing, all water shall be blown out of
the duct with oil-free compressed air.
i. The grouting equipment shall include a high-
speed shear mixer capable of continuous
mechanical mixing which will produce a grout
free of lumps and undispersed cement, a grout
pump, and stand-by flushing equipment with
water supply. The equipment shall be able to
pump the mixed grout in a manner which will
comply with all requirements.
ii. The equipment shall be as per ASTM LRFD
Bridge Construction Specification Article
10.11.3.
i. Water shall be added to the mixer first,
followed by cement grout.
ii. Grout shall be mixed in accordance with the
manufacturer's instructions using a colloidal
mixer to obtain homogeneous mixture. A
fluidity test shall be performed on the mixed
grout prior to beginning the injection process.
Target flow rates as a function of mixer type
used and ambient temperatures shall be
obtained from the grout manufacturer. The
♦ 5-37 ♦
 grouting process shall not be started until the
proper grout properties have been obtained. Property Test Value Test Method
iii. Mixing shall be of such duration as to obtain a Max. 0.08% by
uniform, thoroughly blended grout, without Total Chloride weight of ASTM
Ions cementitious C1152/C1152M
excessive temperature increase or loss of
material
expansive properties of the admixture. The Fine Aggregate Max. Size ≤ No. ASTM C 33
grout shall be continuously agitated until it is (if utilized) 50 Sieve
pumped. Volume
0.0% to+0.2% at ASTM C 1090*
iv. Water shall not be added to increase grout Change at 28
24 h and 28 days
days
flowability which has been decreased by
≤2.0% for up to 3
delayed use of the grout. Expansion ASTM C 940
h
8 Injection of Grout: Compressive
i. All grout vents shall be opened before grouting Strength ASTM C 942
≥6 ksi
28 day (average
starts. Injection and ejection vents with
of 3 cubes)
positive shut-offs shall be provided. Grout shall
Initial Set of Min. 3 h ASTM C 953
be allowed to flow from the first injection vent
Grout Max. 12 h
until any residual flushing water or entrapped
Fluidity Test**
air has been removed prior to closing that vent.
Efflux Time
Remaining vents shall be closed in sequence in from Flow Min 11 s
the same manner. A continuous flow of grout ASTM C 939
Cone Max. 30 s or
at a rate between 10 000 mm and 15 000 mm ASTM C
a) Immediately Min. 9 s
939***
of duct per minute shall be maintained. after Mixing Max. 20 s
ASTM C 939
b) 30 min after Max. 30 s or
ii. The pumping pressure at the injection vent ASTM C
Mixing with Max. 30 s
should not exceed 1.0 MPa. Normal operations 939***
Remixing
shall be performed at approximately 0.5 MPa. for 30 s
If the actual grouting pressure exceeds the ASTM C
Bleeding at 3 h Max. 0.0%
maximum allowed, the injection vent shall be 940****
closed and the grout shall be injected at the Permeability at Max. 2500 AASHTO T 277
next vent that has been, or is ready to be 28 days coulombs at 30 (ASTM C 1202)
closed, as long as a one-way flow is volts for 6 h
maintained. Grout shall not be injected into a Table 5.4.3.1 Grout Properties for
succeeding vent from which grout has not yet Volume Change at 28 Days
flowed. Table 5.4.3-1 Notes
*Modify ASTM C 1090 to include verification at both
Iii Grout shall be pumped through the duct and
24 h and 28 days.
continuously wasted at the ejection vent until
no visible slugs of water or air are ejected. A **Adjustments to flow rates will be achieved by strict
fluidity test shall be performed on each tendon compliance with the manufacturer’s
recommendations.
in accordance with paragraph 5.4.3.7 (7)
measuring the grout fluidity from the discharge ***Grout fluidity shall meet either the standard ASTM
outlet. The measured grout efflux time shall C 939 flow cone test or the modified test described
not be faster than the efflux time measured at herein. Modify the ASTM C 939 test by filling the cone
the inlet or the minimum efflux time to the top instead of to the standard level. The efflux
time is the time to fill a 1.0 liter container placed
established in Table 5.4.3.1. If the grout efflux
directly under the flow cone.
time is not acceptable, additional grout shall be
discharged from the discharge outlet. Grout ****Modify ASTM C 940 to conform with the wick
efflux time shall be tested. This cycle shall be induced bleed test described below:
continued until acceptable grout fluidity is a) Condition dry ingredients, mixing water,
achieved. To ensure that the tendon remains prestressing strand and test apparatus overnight
filled with grout, the ejection and injection at 21 to 25 deg. C.
vents shall be closed in sequence, respectively, b) Insert 800 milliliters of mixed conditioned grout
with conditioned water into the 1000 milliliters
under pressure when the tendon duct is
graduated cylinder. Mark the level of the top of
completely filled with grout. The positive shut- the grout.
offs at the injection and ejection vents shall not c) Wrap the strand with 50 mm wide duct or
be removed or vents opened until the grout electrical tape at each end prior to cutting to
has set. avoid splaying of the wires when it is cut.
iv. The maximum allowable ambient temperature
to start grouting is 32 degrees C.

♦ 5-38 ♦
 Degrease (with acetone or hexane solvent) and
wire brush to remove any surface rust on the
strand before temperature conditioning. Insert
completely a 500 mm length of conditioned,
cleaned, ASTM A 416/A 416M seven wire strand
12.7 mm diameter into the 1000 milliliter
graduated cylinder. Center and fasten the strand
so it remains essentially parallel to the vertical
axis of the cylinder (possibly using a centralizer).
Mark the level of the top of the grout.
d) Store the mixed grout at the temperature range
listed above in (a).
e) Measure the level of the bleed water every 15 min
for the first hour and hourly afterward for 2 h.
f) Calculate the bleed water, if any, at the end of the
3 h test period and the resulting expansion per
the procedures outlined in ASTM C 940, with the
quantity of bleed water expressed as a percent of
the initial grout volume. Note if the bleed water
remains above or below the top of the grout.
9 Vertical Grouting: In lieu of a positive shut-off,
vertical or near vertical tendon ducts for grouting shall
terminate in reservoirs at the upper-most point. The
reservoir shall have sufficient capacity to store excess
grout bleed water. Visible grout level shall be maintained
in the reservoirs. The reservoirs shall be maintained until
the grout has set. Grout shall be injected at a rate of 5000
mm of duct per minute.
10 Post-Grouting Inspection: Vacuum grouting shall be
used to fill any voids that expose strands discovered in the
grouting process. Where possible, all anchorages and
high-point vents shall be drilled and probed 48 hours after
grouting, until the Engineer is assured that no bleed water
or subsidence (settlement) voids exist. After the Engineer
is assured that voids do not exist, only one or two
anchorages per span shall be drilled and probed to ensure
quality grouting. Any voids discovered should be filled
immediately with the approved grout.
11 Finishing:
i. Valves, caps and vent pipes shall not be
removed or opened until the grout has set.
ii. The ends of vents shall be removed at least 25
mm below the concrete surface after the grout
has set.
iii. The void shall be filled with epoxy grout. All
miscellaneous material used for sealing grout
caps shall be removed before carrying out
further work to protect end anchorages.
12 Protection of End Anchorages: Permanent grout caps
constructed from either stainless steel or polymer shall be
specified. The following requirements apply:
i. Within seven days upon completion of the
grouting, the anchorage of post-tensioning
bars and tendons shall be protected as
indicated in the contract documents. The
application of the elastomeric coating may be
delayed up to 90 days after grouting. Plastic or
stainless steel threaded caps shall be used to
plug all grout inlets/outlets. A sand-filled epoxy
grout suitable for machinery base plate shall
be used to construct all pour-backs located at
anchorages of expansion joints or other areas
exposed to the elements.
ii. All laitance, grease, curing compounds, surface
treatments, coatings, and oils shall be removed
by grit blasting or water blasting using a
minimum 70.0 MPa nozzle pressure. The
surface shall be flushed with water and blown
dry. Surfaces shall be clean, sound, and
without any standing water. In case of dispute,
ACl 503 shall be followed for substrate testing
and a minimum of 1.2 MPa tension (pull-off
value) be developed.
iii. Epoxy shall be mixed and applied as
manufacturer's current standard technical
guidelines. All pour-backs shall be in leak proof
forms creating neat lines. The pumping of
epoxy grout shall be permitted for proper
installation. Forms shall be constructed to
maintain a liquid head to insure intimate
contact with the concrete surface. Vents shall
be used as needed to provide for the escape of
air to insure complete filling of the forms.
iv. The exposed surfaces of pour-backs or grout
caps, except on transverse tendons, shall be
coated with an elastomeric coating system
having a thickness of 760 to 1140 μm. Concrete,
grout caps or other substrates shall be
structurally sound, clean, and dry. Concrete
shall be a minimum of 28 days old. Laitance,
grease, curing compounds, surface treatments,
coatings, and oils shall be removed by grit
blasting or water blasting using a minimum
70.0 MPa nozzle pressure to establish the
anchor pattern. Surfaces shall be blown with
compressed air to remove the dust or water.
v. A 600 x 1200-mm concrete test block shall be
constructed with a similar surface texture to
the surfaces to be coated and a vertical face
shall be coated with the elastomeric coating
system chosen. The number of coats required
to achieve a coating thickness between 760 to
1140 μm without runs and drips shall be
determined. The elastomeric coating shall be
mixed and applied as per Manufacturer's
current standard technical specifications. Spray
or roller application may be permitted; spray
application is preferred. Coatings shall be
applied using approved and experienced
personnel with a minimum of 3 years
experience applying similar polyurethane
systems. Credentials of these persons shall be
submitted to the Engineer for review and
consideration for approval.
5.4.4 Method of Measurement
1 Concrete shall be measured under the provisions of
Section 5.1.
♦ 5-39 ♦
2 Non-prestressed reinforcing steel shall be measured iv. Plant, equipment and labor for all stressing and
under the provisions of Section 5.2 . grouting operations, including making good all
3 Prestressing steel shall be measured by the weight in anchorage pockets as shown on the Drawings
metric tonnes for each size and quality of wire, strands or or as directed by the Engineer.
bar furnished, installed, completed and accepted. The v. All testing required in the Specifications.
weight shall be calculated based on the nominal mass of
each diameter wire, strand or bar as stated in the 5.4.6 Items in the Bill of Quantities
standards listed in Paragraph 5.4.21.3.
i Prestressing wires
4 In post-tensioning work, the prestressing steel shall
(state size and type) t.
be measured in t based on the actual length between the
ii Prestressing strands
outermost surfaces of the anchorages except where
(state size and type) t.
couplers are used in which case, the prestressing steel
shall be assumed to be continuous, without any flares, iii Prestressing bars
through the coupler. (state size and type) t.
5 In pre-tension work, the prestressing steel shall be
measured in t based on the actual length between the 5.5 Concrete Bridges and Erection
outermost faces of the member. Procedures
6 Items not measured: Measurement of prestressed
concrete is restricted to the items stated in items 1, 2 and 3 5.5.1 Description
above. No separate measurement is made for any other
5.5.1.1 Scope
component or work.
i. Cable ducts, duct couplers, grout tubes and 1 This Sub-section describes requirements for erection
steel chairs for the correct duct/tendon location of concrete bridge structures and decks in conformity with
are not measured for payment. the lines, grades and dimensions shown on the Drawings
ii. Anchor blocks for use in pre-tension work are and in accordance with the Specifications. These
not measured for payment. requirements are additional to the requirements for
concrete work generally as specified in the preceding Sub-
iii. Prestressing steel used in connection with
sections of this Section
temporary works is not measured for payment
even if such steel is left permanently in the 5.5.1.2 References
member.
1 American Association of State Highway and
iv. Epoxy bonding agent used in precast
Transportation Officials (AASHTO):
segmental construction shall not be measured
for payment. AASHTO 2008 AASHTO LRFD Bridge Construction
Specifications, 2nd Edition, 2004, 2008
v. Shear keys and location dowels used in precast
Interim Revisions.
segmental construction shall not be measured
for payment. AASHTO 2008 AASHTO LRFD Bridge Design
specifications, 3rd Edition, 2004, 2008
vi. Prestressing steel and anchorages used for
Interim Revisions.
applying temporary prestress to glued
segments shall not be measured for payment. AASHTO 1999 Guide Specifications for Design and
Construction of Segmental Concrete
vii. Anchorages and couplers shall not be
Bridges, 2nd Edition.
measured for payment.
2 Fédération Internationale de la Précontrainte (FIP)
5.4.5 Basis of Payment FIP Proposal for a Standard for Acceptance
Tests and Verification of Epoxy Agents
1 The amount of completed and accepted work for Segmental Construction.
measured as provided for above shall be paid at the rates
in the Bill of Quantities. These rates shall be full
5.5.2 Materials
compensation for the provision of materials, equipment,
labor, tools, testing and other items necessary for proper 1 Materials shall conform to the relevant requirements
completion of the Work. The rates shall include: of the following Sub-sections of the Specification:
i. Items not measured as described in Item 5.4.4 - Concrete Sub-section 5.1 Concrete
(6). Materials and
ii. Cement, water and additive used in making the Mixes
grout. - Reinforcing Steel Sub-section 5.2 Reinforcing
iii. All prestressing equipment and its calibration. Steel

♦ 5-40 ♦
- Pre-stressing Sub-section 5.4 Pre-stressed
Concrete
Structures
5.5.3 Construction Requirements
5.5.3.1 Balanced Cantilever Construction with In-Situ
Concrete
1 General:
i. This work consists of installing temporary
bearings, casting concrete units in-situ and
setting the superstructure on permanent
bearings. The Contractor shall submit
complete details and descriptions of all
methods, arrangements and equipment which
he intends to adopt, for approval before
construction work is started.
ii. The construction method statement shall
include casting of units, method of the tie-
down of superstructure during cantilever
construction, method of application of all
temporary forces to be used for adjusting
horizontal and vertical alignment and to place
the structure on permanent bearings, details of
work plans and safety measures. It shall also
include control methods to ensure the accuracy
of alignments of the constructed superstructure.
iii. Work equipment includes all machinery,
devices, labor and material which are to be
used for construction but which will not
become a permanent part of the completed
superstructure. Construction equipment and
other loads shall not be placed upon any part
of the superstructure at any stage of
construction other than that which specifically
meets the requirements of total working load
3 Casting Procedures:
per unit, or has the approval of the Engineer.
This includes the post-tensioning, jointing,
jacking, grouting equipment, any other
equipment whatsoever, workmen and
materials of any kind.
iv. Unbalanced Load: During construction the
cantilever may be unbalanced by only one unit
at any time and be consistent with the holding-
down method adopted. In addition to the
unbalanced load due to one unit, 0.5 kN/m2
load is permissible anywhere on the cantilever.
This load includes workmen, miscellaneous
equipment and stored materials. The
Contractor shall take care to ensure that this
allowable load is not exceeded.
2 Construction Schedule:
i. The Contractor shall submit a construction
schedule showing the order of every phase and
stage of erection and construction of the
superstructure. The Contractor shall prepare a
table of elevations and alignments required at
each stage of construction at the check points
listed below, or an alternative of his choice and
submit the same for the Engineer's approval.
The check points are:
- One of the lowest corners at the top surface
of any temporary bearing pad which is to
be used as datum during construction.
- All four corners of the top slabs of the pier
units to establish grade and top levels.
- Two points on the longitudinal center line
of each pier unit, one on each end to
establish alignment.
- One point on the longitudinal center line,
and at least on one corner of each unit
along every joint between cast-in-place
units to establish elevations and
alignments at every stage of construction.
ii. The alignment and elevations of the cantilever
shall be checked by the Contractor and the
Engineer independently within 1 hour of
sunrise on each day that the units are to be
cast. The measurements made by the Engineer
and the Contractor shall agree to within 5 mm.
iii. The temporary bearing pads at the piers shall
be carefully placed. The top surface of these
pads must have the correct elevations,
alignments and slopes as required by the
working drawings and as established by the
procedure described above. Shims may be
used underneath the pads to accomplish
accuracy. The Contractor shall check
elevations and alignment of the structure at
every stage of construction and shall maintain
a record of all these checks and of all
adjustments and corrections made.
i. Casting of the units shall not begin until
approval of the shop drawings, calculations
and the post-tensioning system has been given.
ii. Sequence. The units shall be match cast
beginning with each pier unit. After the pier
unit is cast all units on either side of the pier
unit may be cast in order so long as match
casting is maintained.
iii. Care shall be taken in the set-up of each unit.
All materials to be encased within the concrete
of the segment shall be properly positioned
and supported. Before any concrete is placed,
the set up will be inspected and checked by the
Engineer. All ducts shall be located within
3mm of the location given on approved
drawings. The top surface of the units shall be
free of depressions or high spots.
iv. Forms shall not be removed until the concrete
has achieved the specified compressive
strength has been proved by test cylinders
made and cured in the same manner as the
♦ 5-41 ♦
 unit. Care shall be taken in removing the forms
to prevent spalling and chipping of the
concrete.
4 Tolerances:
i. Formwork for box girder segments must satisfy
the following tolerances:
- Web thickness, +10 mm or -5 mm.
- Thickness of bottom slab +5 mm, but 0
reduction in depth.
- Thickness of top slab +5 mm, but 0
reduction in depth.
- Overall width of unit, ±5 mm.
- Overall depth of unit, ±5 mm.
- Length of match cast unit, ±10 mm, but not
cumulative and a maximum of 50 mm per
span.
- Diaphragm dimensions, +10 mm or -5 mm.
- Grade at top and bottom flanges, ±3.
ii. After erection, final post-tensioning, final
corrections and adjustments are completed
and the structure has been placed on its
permanent bearings, the superstructure shall
conform to the grade and alignment shown on
the Drawings with due consideration for creep
and superimposed load and dead load
deflections within a tolerance of ± 5 mm
horizontally and ± 10 mm vertically.
5.5.3.2 Glued Precast Segmental Construction
1 Where bridge decks are precast in segments and
assembled in position for glueing and stressing, the
Contractor shall satisfy the Engineer that his proposed
construction method will achieve the required standard of
workmanship and finish. The Contractor shall submit
details for approval of all his forms, falsework, precasting
factory and his method of lifting, transporting, assembling,
supporting, threading cables, glueing and stressing the
precast units before commencement of any work.
2 Epoxy Adhesive:
i. The epoxy resin adhesive shall be supplied by
an approved manufacturer.
ii. It shall be made up and packaged by approved
formulators and to specifications agreed by the
Engineer.
iii. The material shall be supplied in accurately
measured packs with the pack containing the
hardener clearly distinguished by both size and
labelling. The pack containing the resin shall
be large enough to permit the addition of the
hardener. Resin and hardener shall be
pigmented with dissimilar colours to indicate
when even mixing has been completely
attained and to produce an even gray colour to
match the concrete.
♦ 5-42 ♦
iv. Each batch of resin mixed shall be tested for
setting by compression and shear tests as
described below. No permanent prestress
shall be applied to a joint until the epoxy has
achieved the required strength. Should this
test show that the resin is not setting the joint
shall be broken and the resin removed. Set
resin shall be removed by grit blasting. Further
tests may be requested by the Engineer at
various times to ensure that the material as
mixed is complying with the Specification.
v. All the instructions of the manufacturer and/or
the formulator shall be submitted to the
Engineer for agreement. Such agreed
instructions shall be adhered to in all respects.
vi. The supplier shall carry out a program of
testing as described in FIP "Proposal for a
standard for acceptance tests and verification
of epoxy bonding agents for segmental
construction", after consultation with the
Engineer on the range of temperatures and
work cycles that are to be considered in the
tests. The Engineer may require the tests to be
witnessed either in person or by an approved
independent authority.
3 Surface Preparation: The interface of the units shall
be lightly grit blasted before erection to remove laitance.
Before applying the epoxy the interfaces must be clean
and free from laitance or any bond breaking material. Any
oil or grease which may be harmful shall be removed.
The surface shall have no free moisture.
4 Application of Epoxy: Application shall begin
immediately after a batch has been mixed. Application
shall be to both interfaces to a total nominal thickness of 2
mm with a spatula or by hand. No epoxy may be applied
within 25mm of any duct.
5 Preliminary Prestress: Immediately after the
interfaces are coated with epoxy, the unit shall be brought
into position and the preliminary prestress applied. This
preliminary prestress is to be just sufficient to start
squeezing epoxy resin out of the joint. The amount of
prestress required will depend on the formulation of resin
chosen by the Contractor. If this operation is not
completed within the life time of the first batch of epoxy to
be applied, the units shall be moved apart. All the epoxy
on both interfaces shall be removed with spatulas and an
approved solvent. No epoxy may be applied to the joint
until 24 hours after a solvent has been used. The life time
shall be reckoned from the end of the pot life unless the
manufacturer's instructions direct otherwise. All excess
epoxy shall be cleaned off from the outer faces of the
webs and the soffit in such a way as not to smear the
concrete face.
6 Records of Joining: The Contractor shall keep a
record of each joint with the following details:
i. Joint Number
ii. Date and Time of jointing
 iii. Batch number of resin and hardener
iv. Weather conditions (temperature and
humidity) continuously recorded
v. Results of tests.
7 Tolerances: These shall be similar to those
prescribed for balanced cantilever construction.
5.5.3.3 Precast Beam and slab Construction
1 Manufacture of Prestressed Beams:
i. The details of method of manufacture shall be
approved by the Engineer before work is
started. No changes shall subsequently be
made without the consent of the Engineer.
ii. The Contractor shall inform the Engineer in
advance of the date of commencement of
manufacture and the dates when tensioning of
tendons, casting of members and transfer of
stress will be undertaken for the first time for
each type of beam.
iii. The Contractor shall submit to the Engineer,
not more than 7 days after the transfer of
stress, a certificate showing the force and
strain in the tendons immediately after they
were anchored, the strength and age of the test
cylinders cast in accordance with this
Specification, and the minimum age in hours
of the concrete at the time stress was applied
to the members. Copies of all 28 day cylinder
test results relating to the work shall be kept so
that the identity of those who stressed the
tendons, cast the concrete and transferred the
stress, on any member or line of members, can
be traced.
iv. Where the Engineer requires tests to be carried
out on beams, the beams to which these tests
related, shall not be dispatched to Site until the
tests have been satisfactorily completed.
2 Storage and Handling of Prestressed Members:
Members shall be firmly supported at such bearing
positions as will ensure that the stresses induced in them
are always less than the permissible design stresses.
Members shall be lifted or supported only at the points
specified and shall be handled and placed without impact.
3 Tolerance in Precast Members:
i. Dimensional variations shall not exceed the
tolerances given below:
- Length ±12 mm
- Width and depth ± 6 mm
- Bow in the vertical plane +15 mm or -0 mm
- Bow in the horizontal plane ±12 mm
- Difference between longest and
shortest dimensions (check for
squareness of beam) in any plane 6 mm
- Twist (measured by the deviation
of any corner from the plane
containing the other 3 corners) 6 mm
- Flatness (the maximum deviation
from a 1.5 meter straight-edge
placed in any position on
nominally plane surface) 6 mm
- Cover to reinforcement +5 or -0 mm
- Prestressing tendons 3 mm in any direction
- Dowel holes 3 mm in any direction
4 Composite Slab Construction:
i. Where in-situ concrete deck is cast to act
compositely with precast beams, the beams
shall be installed to correct line and level,
starting from the outermost beam and working
inwards progressively. When the beams are
laid side by side just before erection the
difference in soffit level between adjacent
beams shall nowhere exceed 6 mm. Where
permanent soffit shutters are used, they shall
be to the approval of the Engineer and they
shall be fixed securely so that there is no
movement or grout loss during deck
concreting.
ii. The in-situ concrete deck over any one span
shall be poured in one continuous operation
and shall be placed in such a sequence that the
advancing edge of the freshly deposited
concrete over the full width of deck or between
longitudinal construction joints is
approximately parallel to the deck supports.
Lateral displacement of beams shall be
prevented during the placing of in-situ concrete.
iii. The width of the in-situ deck shall be within
+25 mm of that specified. On curved bridge
deck, the in-situ deck may be in a series of
straights such that the width is within +25 mm
of that specified.
5.5.3.4 In-Situ Construction
1 Where bridge decks are constructed in-situ, the
details of all forms and falsework shall first be approved
by the Engineer. Dimensional variations shall not exceed
the following tolerances:
- Length ± 12 mm
- Width ± 10 mm
- Thickness ± 6 mm
- Levels + 10 mm or -0 mm
- Void Location 6 mm in any direction
- Cover to reinforcement + 5 mm or -0 mm
- Prestressing tendons 5 mm in any direction
5.5.4 Method of Measurement, Basis of
Payment and Items in the Bills of
Quantities
1 Concrete bridge construction is measured and
identified in the Bill of Quantities in accordance with
♦ 5-43 ♦
Clause 5.1.7. Measurement and basis of payment will be in 2 Finishes to floors and walls, including tiles, plaster
accordance with the stipulations for the corresponding paint and special finishes shall be as described in the
items in Sub-sections 5.1, 5.2 and 5.4. No direct payment Special Specification.
will be made for the stipulations of this Sub-section 5.5,
which work is considered to be subsidiary to the 5.6.3 Construction Requirements
requirements of Sub-sections 5.1, 5.2 and 5.4. The rates
and prices for the relevant items of Sub-sections 5.1, 5.2 5.6.3.1 Excavation
and 5.4 shall be deemed to include for all the stipulations
1 The Contractor shall provide the Engineer with
of this Sub-section 5.5. detailed written proposals of construction methods of
temporary and permanent works for the underpass
5.6 Vehicular and Pedestrian excavation. Details of ground water lowering, excavation
Underpasses and Animal support and support of adjacent existing structures shall
Crossings be accompanied by relevant shop drawings and
calculations. The work shall not proceed until the
Engineer has given approval to these construction
5.6.1 Description
proposals together with the relevant construction program
5.6.1.1 Scope for these works. Such approval, when given, shall not
relieve the Contractor of his responsibility for the
1 This Sub-section specifies the requirements for
correctness, safety and adequacy of such proposal.
concrete underpasses and animal crossings. These
2 Excavation and earthwork shall comply with the
requirements are additional to the requirements for
requirements of Section 2.
concrete generally, as described in the preceding Sub-
sections of this Section. 3 The Contractor shall comply with arrangements to
maintain the flow of pedestrian and vehicular traffic as
5.6.1.2 References stated in Section 1 of the Specification and as detailed on
the Drawings or as instructed by the Engineer. The
1 The relevant stipulations of the following Sections or
Contractor's attention is specifically drawn to his
Sub-sections of this Specification shall apply to this Sub-
responsibilities regarding the safety of such traffic near to
section.
open excavations for the works and the operation of heavy
Section 2 Earthworks plant and equipment and the provision and maintenance
Section 5 Concrete and Concrete Structures of adequate fences and barriers.
Section 6 Structural Steel and Other Metalwork 4 The Contractor shall protect and support existing
Section 8 Drainage statutory services during the excavation works as stated in
Section 1 and Section 18 of the Specification and co-
Section 10 Piling
operate with all statutory services to ensure efficiency of
Section 12 Sidewalks, Paved Areas and Curbs diversion of such services where necessary. In the event
Section 15 Road Lighting and Electrical that services are uncovered during excavation that have
Installations not been previously located on Drawings, the Engineer's
attention shall be drawn to the matter without delay.
5.6.2 Materials 5 Particular care shall be taken by the Contractor to
1 Materials shall conform to the relevant requirements minimize noise, dust and vibration caused by excavation
of the following Sections and Sub-sections of the operations especially where such nuisances prove
Specification: hazardous to existing structures.

Piles Section 10 6 Where ground water lowering operations prove

necessary the phasing of pumping operations and their
Concrete Sub-section 5.1
termination on completion of the underpass structure
Reinforcing Steel Sub-section 5.2 shall be approved by the Engineer.
Structural Steel and Other Metal Section 6 7 Where the Drawings show the use of piles or
Backfilling Sub-section 2.7 diaphragm walls to support the underpass structure or
Road Pavement Sections 3, 4 retain the subsoil the Contractor shall submit to the
Engineer for his approval a detailed method statement
Concrete Pavement Sub-section 5.7
and work program for this work together with the names
Waterproofing Sub-section 5.10 of any specialist firms he intends to use for this work.
Pipe culverts Sub-section 8.1
Drainage Section 8
Sidewalks, Paved Areas Section 12
Electrical Installations Section 15

♦ 5-44 ♦
5.6.3.2 Structural Concrete
1 The Contractor shall provide the Engineer with
detailed written proposals for the formwork design of all
major parts of the underpass structure together with
proposals for transporting, placing and curing concrete
and sizes of pours. The works shall not proceed until the
Engineer has given approval to these proposals; such
approval when given shall not relieve the Contractor of his
responsibility for the efficacy of such proposals.
2 The structural concrete work shall generally comply
with the relevant requirements of the following sections:
Section 5.1 Concrete Materials and Mixes
Section 5.2 Reinforcing Steel
Section 5.3 Reinforced Concrete Structures
Section 5.4 Prestressed Concrete Structures
5.6.3.3 Concrete Piles
1 The reinforced concrete construction of piling works
shown as the Drawings to support the underpass structure
or retain the subsoil shall comply with the relevant
requirements of Section 10.
5.6.3.4 Waterproofing
1 The waterproofing of the underpass structure shall
be generally carried out in compliance with Section 5.10
"Waterproofing for Structures".
2 Where membrane materials are specified on the
Drawings for special use, such as P.V.C. membranes, the
manufacturer's instructions for storage, handling and
installation of such membranes shall be strictly complied
with. Where special details of junctions of such
membranes with walls and piles are necessary, drawings
shall be submitted to the Engineer for approval before
work commences.
3 Tucks and seals for waterproofing shall be provided
at points of discontinuity such as edges, expansion joints
and rainwater drains. Sharp internal and external edges
shall be chamfered with minimum 40mm x 40mm fillets.
The waterproofing membrane shall be protected from
damage during the execution of the work.
4 Where the Drawings show the use of waterstops in
concrete walls and slabs at construction joints and
expansion joints the Contractor shall supply samples of
waterstop material for approval and provide details of
waterstop assembly for approval.
5 The standard of acceptance of waterproofing shall be
that there shall be no damp patches or visible leaks on the
inside face of walls, roof or floor of the underpass
structure.
5.6.3.5 Concrete Pavement Construction
1 Concrete pavement construction shall be in
accordance with all relevant requirements of Section 5.7
“Concrete Pavement”.
5.6.3.6 Bituminous Pavement Construction
1 Bituminous pavement construction shall be in
accordance with all relevant requirements of Section 4
“Bituminous Pavement”.
2 Drainage works shall be constructed in accordance
with all relevant requirements of Sub-Section 8.4
“Drainage of Structures”.
5.6.3.7 Electrical Works
1 The installation of lighting and electrical works for
shall be in accordance with details shown on the Drawings
and the general requirements of Section 15 "Electrical
Installations".
5.6.4 Method of Measurement
1 Excavation, backfilling, piling, concrete,
reinforcement, road pavement, sidewalks and paved areas,
drainage, ducts, waterproofing of concrete and electrical
work shall be measured in accordance with the relevant
Sections of this Specification.
2 Floor and wall finishes shall be measured in
accordance with the Special Specification for the
particular work.
5.6.5 Basis of Payment
1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
unit rates for the various items in the Bill of Quantities,
which rate shall be full compensation for supplying
materials, transporting and placing, labor, equipment,
tools and other items necessary for the proper completion
of the work.
5.6.6 Items in the Bill of Quantities
All work in underpasses and animal crossings is
separately identified in the Bill of Quantities and the
relevant items, as stated in the respective Sections of the
Specification are included.
5.7 Cement Concrete Pavement
5.7.1 Description
1 This Sub-section specifies the requirements for
cement concrete pavement, with or without reinforcement,
on a prepared base all as and where shown on the
Drawings. These requirements are additional to the
requirements for concrete generally contained in the
preceding Sub-sections of this Section
5.7.2 Materials
1 Cementitious Materials: Portland cement alone or in
combination with one or more of blended hydraulic
cement, expansive hydraulic cement, fly ash and other
pozzolans, ground granulated blast-furnace slag, and silica
fume.
♦ 5-45 ♦
2 Base Course: Cement treated base course or throughout the work, unless otherwise accepted by
aggregate base course placed beneath the concrete Engineer.
pavement. 2 Portland Cement: ASTM C 150, Type I. In particular
cases, where the design requires the use of Sulfate
5.7.2.1 Forms
Resistant Cement (SRC), the Contractor shall submit to the
1 Form Materials: Plywood, metal, metal-framed Engineer’s approval an SRC material complying with the
plywood, or other approved panel-type materials to requirements of ASTM C 150, Type II.
provide full-depth, continuous, straight, smooth exposed 3 Aggregate: ASTM C33 or BS EN 12620, shall consist
surfaces. Use flexible or curved forms for curves of a of crushed stone, crushed or uncrushed gravel, or natural
radius 30 m or less. sand. The aggregate shall be composed of sound, tough,
2 Form-Release Agent: Commercially formulated durable particles and shall meet the requirements for
form-release agent that will not bond with, stain, or deleterious substances given in ASTM C33 or BS EN 12620.
adversely affect concrete surfaces and will not impair The aggregate in any size group shall not contain more
subsequent treatment of concrete surfaces. than 8 percent by weight of flat or elongated pieces when
tested in accordance with ASTM D4791. A flat or
5.7.2.2 Steel Reinforcement elongated particle is one having a ratio between the
1 Reinforcement Bars: ASTM A 615, Grade 60, maximum and the minimum dimensions of a
deformed. circumscribing rectangular prism exceeding 5 to 1.
Uniformly graded, from a single source, with coarse
2 Plain Steel Wire: ASTM A 82, cold-drawn steel.
aggregate as follows:
3 Welded Deformed Steel Wire fabric: ASTM A497.
4 Fine Aggregate: Conform to the requirements of
4 Joint Dowel Bars: Plain steel bars, ASTM A 615, ASTM C33 (Table 5.7.2.1) or BS EN 12620.
Grade 60. Cut bars true to length with ends square and
free of burrs. Sieve Designation Percentage by Weight
5 Dowel Bars: High tensile plain steel bars conforming (square openings) Passing Sieves
to BS 4449, ASTM A615, ASTM A616, or ASTM A617, and 3/8 in (9.5 mm) 100
shall be free from burring or other deformation restricting No. 4 (4.75 mm) 95-100
slippage in the concrete. Before delivery to the
No. 8 (2.36 mm) 80-100
construction site, a minimum of two-thirds of the length of
each dowel bar shall be painted with one coat of zinc- No. 16 (1.18 mm) 50- 85
chromate. If plastic or epoxy-coated steel dowels are used, No. 30 (600 micro-m) 25- 60
no zinc-chromate coating is required, except when No. 50 (300 micro-m) 10- 30
specified for a particular situation on the contract plans. No. 100 (150 micro-m) 2- 10
Coated dowels shall conform to the requirements given in
No. 200 (75 micro-m) 0- 3
AASHTO M254.
6 Tie Bars: ASTM A 615M, Grade 60, deformed. Table 5.7.2.1: Gradation for Fine Aggregate ASTM C33

7 Sleeves: Metal, of an approved design to cover 50 1 Coarse Aggregate: Conform to the requirements of
mm to 75 mm of the dowel, with a closed end and with a ASTM C33 (Table 5.7.2.2) or BS EN 12620.
suitable stop to hold the end of the bar at least 25 mm
from the closed end of the sleeve. Sleeves shall be of Sieve Designation Percentage by Weight
such design that they will not collapse during construction. (square openings) Passing Sieves
in (mm) 19 mm – 2.36 mm
8 Hook Bolts: ASTM F 568M, Property Class 4.6,
internally and externally threaded. Design hook-bolt joint 1 (25) 100
assembly to hold coupling against pavement form and in 3/4 (19) 90 - 100
position during concreting operations, and to permit
1/2 (12.5) -
removal without damage to concrete or hook bolt.
3/8 (9.5) 20 - 55
9 Bar Supports: Bolsters, chairs, spacers, and other
devices for spacing, supporting, and fastening No. 4 (4.75) 0 – 10
reinforcement bars, welded wire fabric, and dowels in
No. 8 (2.36) 0–5
place. Use wire bar type supports complying to CRSI's
"Manual of Standard Practice". Table 5.7.2.2: Gradation for Coarse Aggregate ASTM C33
10 Epoxy Repair Coating: Liquid two-part epoxy repair The percentage of wear shall be no more than 30% when
coating, compatible with epoxy coating on reinforcement. tested in accordance with ASTM C131.

5.7.2.3 Concrete Materials 6 Water: Water used in mixing or curing shall be as

clean and free of oil, salt, acid, alkali, sugar, vegetable, or
1 General: Use the same brand and type of other substances injurious to the finished product as
cementitious material from the same manufacturer possible. Water will be tested in accordance with the

♦ 5-46 ♦
requirements of AASHTOT26, ASTM C94. Water known to cellulosic fiber, or ASTM D 1752 for cork or self-expanding
be of potable quality may be used without testing. cork.
2 Joint filler shall be furnished in a single piece for the
5.7.2.4 Admixtures
full depth and width required for the joint, unless
1 General: Admixtures certified by manufacturer to otherwise specified by Engineer. When the use of more
contain not more than 0.1 percent water-soluble chloride than one piece is authorized for a joint, the abutting ends
ions by mass of cement and to be compatible with other shall be fastened securely and held accurately to shape by
admixtures. stapling or other positive fastening means satisfactory to
2 Approval Process: The use of any material added to Engineer.
the concrete mix shall be approved by Engineer. Submit 3 Joint sealer shall: meet the requirements of Sub-
certificates indicating that the material to be furnished section 5.8 of the Specification and shall be of the type(s)
meets all of the requirements indicated below. In addition, specified on drawings.
the Engineer may require the submittal of complete test 4 Dowels: Galvanized steel, to the dimensions shown
data from an approved laboratory showing that the on drawings.
material to be furnished meets all of the requirements of
5 Bonding Agent: ASTM C 1059, Type II, non-re-
the cited specifications. Subsequent tests will be made of
dispersible, acrylic emulsion or styrene butadiene.
samples taken by Engineer from the supply of the material
being furnished or proposed for use on the work to 5.7.2.7 Concrete Mixes
determine whether the admixture is uniform in quality
with that approved. 1 Prepare design mixes, proportioned according to ACI
211.1 and ACI 301, for each type and strength of normal-
3 Chemical Admixtures: Water reducing, set-retarding,
weight concrete determined by either laboratory trial
and set-accelerating admixtures shall meet the
mixes or field experience.
requirements of ASTM C494.
2 Use a qualified independent testing agency for
i. Water-Reducing Admixture: ASTM C 494,
preparing and reporting proposed mix designs for the trial
Type A. batch method. Do not use Employer’s field quality-control
ii. High-Range, Water-Reducing Admixture: testing agency as the independent testing agency.
ASTM C 494, Type F. 3 Proportion mixes to provide concrete with the
iii. Water-Reducing and Accelerating Admixture: following properties using test specimens prepared in
ASTM C 494, Type E. accordance with ASTM C31 and tested with ASTM C78:
iv. Water-Reducing and Retarding Admixture: i. Flexural Strength (28 Days): 4.6 MPa
ASTM C 494, Type D. ii. Compressive Strength (28 Days): 35 MPA.
5.7.2.5 Curing Materials iii. The minimum cementitious material content
shall be 300 kg. per cubic meter. The ratio of
1 Absorptive Cover: AASHTO M 182, Class 2, burlap water to cementitious material, including free
cloth made from jute or kenaf, weighing approximately. surface moisture on the aggregates but not
305 g/sq.m. dry. including moisture absorbed by the aggregates
2 Moisture-Retaining Cover: ASTM C 171, shall not be more than 0.50 by weight.
polyethylene film or white burlap-polyethylene sheet. 4 Slump Limit:
3 Water: Potable. i. The mix determined shall be workable concrete
4 Evaporation Retarder: Waterborne, monomolecular having a slump for side-form concrete between
film forming, manufactured for application to fresh 25 mm and 50 mm as determined by ASTM
concrete. C143.
5 Clear Solvent-Borne Liquid-Membrane-Forming ii. Slump Limit for Concrete Containing High-
Curing Compound: ASTM C 309, Type 1, Class B. Range Water-Reducing Admixture: Not more
6 Clear Waterborne Membrane-Forming Curing than 200 mm after adding admixture to plant-
Compound: ASTM C 309, Type 1, Class B. or site-verified, 50- to 75-mm slump.

7 White Waterborne Membrane-Forming Curing
Compound: ASTM C 309, Type 2, Class B.
5.7.2.6 Related Materials
1 Pre-molded joint filler shall conform to the
requirements of ASTM D1751 and shall be punched to
admit the dowels where called for on the plans.
Expansion and isolation joint-filler strips shall conform to
the requirements of ASTM D 1751 for asphalt-saturated
iii. Absorption and permeability tests on hardened
concrete shall be carried out in accordance
with ASTM C642.
5 Chemical Admixtures: Water-reducing and set-
controlling admixtures shall be added to the mix in the
manner recommended by the manufacturer and in the
amount necessary to comply with the specification
requirements. Tests shall be conducted on trial mixes,
during the mix design, in accordance with ASTM C494.

♦ 5-47 ♦
6 Slip-form Construction: A high degree of uniformity
in the plastic concrete is required. Some edge slump of
the wet concrete behind the side form on the paving
machine will occur, even with low slump concrete. This
may continue, though very slowly, until initial set has
taken place.
5.7.2.8 Concrete Mixing
1 Ready-Mixed Concrete: Comply with requirements
and with ASTM C 94 and ASTM C 1116. Discharge of the
concrete shall be completed within a maximum of 1½
hours, or before the drum has revolved 300 revolutions,
whichever comes first. Mixing time shall be measured
from the time all materials, except water, are emptied into
the drum. However, when air temperature is between 30
deg. C and 32 deg. C, reduce mixing and delivery time
from 1½ hours to 75 minutes; and when air temperature is
above 32 deg. C, reduce mixing and delivery time to 60
minutes.
i. The minimum required revolutions of the
mixing speed for transit mixed concrete may
be reduced to not less than that recommended
by the mixer manufacturer.
ii. The number of revolutions recommended by
the mixer manufacturer shall be indicated on
the manufacturer's serial plate attached to the
mixer.
2 Concrete:
i. Concrete may be mixed at the work site
location in a central mix plant approved by the
Engineer and shall be transported in truck
mixers. The mixer shall be of an approved
type and capacity.
ii. Furnish test data acceptable to Engineer
verifying that the model of the mixer will
produce uniform concrete conforming to the
provisions of ASTM C 94 at the reduced
number of revolutions shown on the serial
plate.
3 When mixed at the work site or in a central mixing
plant, the mixing time shall not be less than 50 seconds
nor more than 90 seconds. Mixing time ends when the
discharge chute opens. Transfer time in multiple drum
mixers is included in mixing time. The contents of an
individual mixer drum shall be removed before a
succeeding batch is emptied therein.
4 Mixer:
i. The mixer shall be operated at the drum speed
recommended by the manufacturer as stated
nameplate on the mixer. Any concrete mixed
less than the specified time shall be discarded
at Contractor’s own expense.
ii. The volume of concrete mixed per batch shall
not exceed the mixer's nominal capacity, as
shown on the manufacturer's standard rating
plate on the mixer.
♦ 5-48 ♦
iii. An overload up to 10 percent above the mixer's
nominal capacity may be permitted provided
concrete test data for segregation and uniform
consistency are satisfactory, and provided no
spillage of concrete takes place.
5 Batch: Constituents shall be charged into the drum so
that a portion of the mixing water enters in advance of the
cement and aggregates. The flow of water shall be
uniform, and all water shall be in the drum by the end of
the first 15 seconds of the mixing period. The throat of the
drum shall be kept free of such accumulations as may
restrict the free flow of materials into the drum.
6 Mixed Concrete:
i. Central mixing plant concrete shall be
transported in truck mixers, truck agitators, or
non- agitating trucks. Non-agitating trucks are
allowed to be used only when the location of
the mixing plant is very close to the site and to
the approval of the Engineer.
ii. The time elapsing from the time water is added
to the mix until the concrete is deposited in
place at the work site shall not exceed 30
minutes when the concrete is hauled in non-
agitating trucks, nor 45 minutes when the
concrete is hauled in truck mixers or truck
agitators. All these operations must be
performed within 45 minutes after the initial
mixing operations and the water-cement ratio
must not be exceeded.
iii. Admixtures for increasing the workability or for
accelerating the set will be permitted only
when specified for in the contract.
5.7.2.9 Limitations of Mixing:
1 No concrete shall be mixed, placed, or finished when
the natural light is insufficient, unless an adequate and
approved artificial lighting system is operated.
2 During periods of hot weather when the maximum
daily air temperature exceeds 30 deg. C, the following
precautions shall be taken: the forms and/or the
underlying material shall be sprinkled with water
immediately before placing the concrete. The concrete
shall be placed at the coolest temperature practicable, and
in no case shall the temperature of the concrete when
placed exceed 32 deg, C. The aggregates and/or mixing
water shall be cooled as necessary to maintain the
concrete temperature at or not more than the specified
max. Refer to ACI 305 R-77 for Hot Weather Concreting.
5.7.3 Construction Requirements
5.7.3.1 Preparation
1 Proceed with pavement layers only after
nonconforming conditions have been corrected and
subgrade is ready to receive pavement.
2 Remove loose material from compacted sub-base
surface immediately before placing concrete.
5.7.3.2 Edge Forms and Screed Construction
1 Set, brace, and secure edge forms, bulkheads, and
intermediate screed guides for paving to required lines,
grades, and elevations. Install forms to allow continuous
progress of work and so that forms can remain in place at
least 24 hours after concrete placement.
2 Forms shall be securely set so that they can
withstand impacts and vibration of consolidating and
finishing equipment without visible spring or settlement.
Extend flange braces on the base outward for not less
than two thirds of the height of the form. Remove bent,
twisted or broken forms, and forms with damaged top
surfaces. Use repaired forms only with inspection and
approval. Built-up forms will not be allowed, unless
specifically approved. The top faces of forms are not to
vary from a true plane by more than 3 mm in 3m. The
upstanding leg shall be perpendicular to the base and is
not to vary horizontally from true alignment by more than
6 mm at any point. The ends of abutting sections lock
together tightly for secure setting. Local defects, such as
kinks in steel forms, will not be allowed.
3 Setting: Forms shall be set ahead of concrete
placement and staked into place with at least three pins
for each 3 m section. A pin shall be placed at each side of
every joint. Form sections shall be tightly locked and free
from movement in any direction. Excessive settlement or
springing from operation of the finishing machine will not
be allowed. Forms shall be cleaned and oiled before
concrete placement. The alignment and grade elevations
of the forms shall be checked, and corrections made
immediately before placing concrete. Reset and recheck
forms when they have been disturbed, or when the grade
has become unstable.
4 Clean forms after each use and coat with form
release agent as required, to ensure separation from
concrete without damage.
5 Removal: Do not remove forms until the concrete
has set for at least 12 hours, unless otherwise approved or
where auxiliary forms are used temporarily in widened
areas. Remove forms carefully to avoid damaging the
pavement, and after removal, the side of the slab shall be
cured by the method specified in the current specification.
5.7.3.3 Steel Reinforcement
1 General: Comply with CRSI's ‘Manual of Standard
Practice’ for fabricating reinforcement and with
recommendations in CRSI's "Placing Reinforcing Bars" for
placing and supporting reinforcement.
5.7.3.4 Placement of Reinforcement
1 Reinforced Concrete Pavement: Comply with
Concrete Reinforcing Steel Institute's recommended
practice for ‘Placing Reinforcing Bars’, for details and
methods of reinforcement placement and supports, and as
herein specified:
i. At the time concrete is placed the reinforcing
bars shall be free of mud, oil or other organic
matter that may adversely affect or reduce
bond. Reinforcing steel with rust, mill scale, or
a combination of both will be considered
satisfactory, provided the minimum
dimensions, weight, and tensile properties of a
hand wire-brushed test specimen are not less
than the applicable ASTM specification
requirements.
ii. Accurately position, support, and secure
reinforcement against displacement by
formwork, construction, or concrete placement
operations. Locate and support reinforcing
bars by metal chairs, runners, bolsters, spacers,
and hangers, as required.
iii. Arrange, space, and securely tie bars and bar
supports to hold reinforcement in position
during concrete placement operations. Set wire
ties so ends are directed into concrete, not
toward exposed concrete surfaces.
iv. Install welded wire fabric in as long lengths as
practicable. Lap adjoining pieces at least one
full mesh and lace splices with wire. Offset end
laps in adjacent widths to prevent continuous
laps in either direction.
5.7.3.5 Joints
1 General: Form construction, expansion, and
contraction joints and tool edgings true to line with faces
perpendicular to surface plane of concrete. Construct
transverse joints at right angles to centerline, unless
otherwise indicated. When joining existing pavement,
place transverse joints to align with previously placed
joints, unless otherwise indicated.
2 Construction Joints: Set construction joints at side
and end terminations of pavement and at locations where
pavement operations are stopped for more than one-half
hour, unless pavement terminates at isolation joints.
3 Expansion Joints: Form expansion joints of
preformed joint-filler strips abutting concrete curbs, catch
basins, manholes, inlets, structures, walks, other fixed
objects, and where indicated.
i. Locate expansion joints at intervals indicated
on drawings.
ii. Extend joint fillers full width and depth of joint.
iii. Terminate joint filler not less than 12 mm or
more than 25 mm below finished surface if
joint sealant is required.
iv. Place top of joint filler flush with finished
concrete surface if joint sealant is not indicated.
v. Furnish joint fillers in one-piece lengths.
Where more than one length is required, lace
or clip joint-filler sections together.
vi. Protect top edge of joint filler during concrete
placement with metal, plastic, or other
temporary preformed cap. Remove protective
♦ 5-49 ♦
 cap after concrete has been placed on both
sides of joint.
4 Longitudinal and Transverse Joints: Construct as
indicated on the Drawings and in accordance with the
following requirements:
i. All joints shall be constructed true to line with
their faces perpendicular to the surface of the
pavement.
ii. Joints shall not vary more than 12mm from a
true line or from their designated position.
iii. The vertical surface of the pavement adjacent
to all expansion joints shall be finished to a
true plane and edged to a radius of 6mm or as
shown on the plans.
iv. The surface across the joints shall be tested
with a 3m straightedge as the joints are
finished and any irregularities in excess of
6mm shall be corrected before the concrete has
hardened.
v. Transverse joints shall be at right angles to the
centerline of the pavement and shall extend the
full width of the slab.
vi. The transverse joints in succeeding lanes shall
be placed in line with similar joints in the first
lane. All joints shall be so prepared, finished,
or cut to provide a groove of the width and
depth shown on the plans.
5 Slip-Form Construction: Transverse joints with
dowels shall be carefully placed to ensure the dowels are
accurately placed and not disturbed during concrete
placement.
i. Transverse dowels will require use of an
apparatus to firmly hold the dowels
perpendicular to the joint and parallel to the
slab surface.
ii. During the concrete placement operation, it is
advisable to place plastic concrete directly on
the dowel assembly immediately prior to
passage of the paver to help maintaining dowel
alignment.
6 Tie Bars: Deformed bars shall be fixed in longitudinal
joints as shown on the Drawings.
i. Tie bars shall be placed at right angles to the
centerline of the concrete slab and shall be
spaced at intervals shown on Drawings.
ii. Tie bars shall be held in position parallel to the
pavement surface and midway between the
surfaces of the slab.
iii. When tie bars extend into an unpaved lane,
they may be bent at right angles against the
form at longitudinal construction joints, unless
threaded bolt or other assembled tie bars are
specified.
iv. Tie bars shall not be painted, greased, or
enclosed in sleeves.
♦ 5-50 ♦
7 Dowel Bars: Dowel bars or other load-transfer units
of an approved type shall be placed across transverse or
other joints in the manner as specified on the Drawings.
i. They shall be of the dimensions and spacing as
shown and held rigidly in the middle of the
slab depth in the proper horizontal and vertical
alignment by an approved assembly device left
permanently in place.
ii. The dowel or load-transfer and joint devices
shall be rigid enough to permit complete
assembly as a unit ready to be lifted and placed
into position.
iii. A metal, or other type dowel expansion cap or
sleeve shall be furnished for each dowel bar
used with expansion joints.
iv. These caps shall be substantial enough to
prevent collapse and shall be placed on the
ends of the dowels as shown on the Drawings.
v. The caps or sleeves shall fit the dowel bar
tightly and the closed end shall be watertight.
8 Fix dowel bars and support assemblies at joints
where indicated. Lubricate or asphalt-coat one-half of
dowel length to prevent concrete bonding to one side of
joint.
9 Joints Installation:
i. The top of an assembled joint device shall be
set at the proper distance below the pavement
surface and the elevation shall be checked.
Such devices shall be set to the required
position and line and shall be securely held in
place by stakes or other means during the
pouring and finishing of the concrete. The pre-
molded joint material shall be placed and held
in a vertical position; if constructed in sections,
there shall be no offsets between adjacent
units. Dowel bars shall be checked for exact
position and alignment as soon as the joint
device is staked in place, and the device shall
be tested to determine whether it is firmly
supported. The maximum permissible
tolerance on dowel bar alignment in each plane,
horizontal and vertical, shall not exceed 2
percent or 6mm per 300 mm of a dowel bar.
The most effective way to obtain proper
alignment is with well-fabricated dowel baskets
and dowel assemblies.
ii. When joints in concrete pavements are sawed,
the joints shall be cut as shown on the
Drawings. The circular cutter shall be capable
of cutting a groove in a straight line and shall
produce a slot at least 3mm wide and to the
depth shown on the plans. When shown on the
plans or required by the specifications, the top
portion of the slot groove shall be widened by
means of a second shallower cut or by suitable
and approved beveling to provide adequate
space for joint sealers. Sawing of the joints
 shall commence as soon as the concrete has
hardened sufficiently to permit cutting without
chipping, spalling, or tearing. Sawing shall be
carried on both during the day and night as
required. The joints shall be sawed at the
required spacing consecutively in sequence of
the concrete placement, unless otherwise
approved by Engineer.
10 Contraction Joints: Form weakened-plane
contraction joints, sectioning concrete into areas as
indicated. Construct contraction joints for a depth equal to
at least one-fourth of the concrete thickness, as follows:
i. Grooved Joints: Form contraction joints after
initial floating by grooving and finishing each
edge of joint with groover tool to the radius
shown on drawings. Repeat grooving of
contraction joints after applying surface
finishes. Eliminate groover marks on concrete
surfaces.
ii. Sawed Joints: Form contraction joints with
power saws equipped with shatterproof
abrasive or diamond-rimmed blades. Cut
joints into concrete to the width shown on
drawings, when cutting action will not tear,
abrade, or otherwise damage surface and
before developing random contraction cracks.
11 Longitudinal Joints:
i. Construction type: longitudinal construction
joints necessary for lane construction shall be
formed against suitable side forms as indicated
in the plans. Wooden forms may be used
under special conditions, when approved by
Engineer. Where butt-type joints with dowels
are designated, the dowels for this type shall
be painted and greased. The edges of the joint
shall be finished with a grooving tool or edging
tool, and a space or slot shall be formed along
the joint of the dimensions, as indicated, to
receive the joint sealing material. Longitudinal
construction joints shall be sawed to provide a
groove at the top conforming to the details and
dimensions indicated on the plans. Provisions
shall be made for the installation of tie bars as
noted on the plans.
ii. Contraction or weakened - plane type:
longitudinal groove-formed or sawed joints in
the top of the slab shall be formed where
indicated on the Drawings. The groove shall
be formed in the plastic concrete with suitable
tools or material to obtain the width and depth
specified, or it shall be sawed with approved
equipment in the hardened concrete to the
dimensions required. When the groove is
formed in plastic concrete, it shall be true to
line with not more than 6mm variation in 3m; it
shall be uniform in width and depth; and the
sides of the groove shall be finished even and
smooth with an edging tool. If an insert
material is used, the installation and edge
finish shall be according to the manufacturer's
instructions. The sawed groove shall be
straight and of uniform width and depth. In
either case, the groove shall be clean cut so
that spalling will be avoided at intersections
with transverse joints. Tie bars shall be
installed across these joints where indicated on
the plans.
iii. Expansion type: longitudinal joints shall be
informed as indicated on the Drawings. The
pre-molded filler, of the thickness shown shall
extend for the full depth and width of the slab
at the joint, except for space for sealant at the
top of the slab. The filler shall be securely
staked or fastened into position perpendicular
to the proposed finished surface. A metal cap
shall be provided to protect the top edge of the
filler and to permit the concrete to be placed
and finished. After the concrete has been
placed and struck off, the cap shall be carefully
withdrawn leaving the space over the pre-
molded filler. The edge of the joint shall be
finished and tooled while the concrete is still
plastic.
12 Transverse Joints:
i. Expansion Type:
- Transverse expansion joints shall be
installed at the locations and spacing as
shown on the plans. The joints shall be
installed at right angles to the centerline
and perpendicular to the surface of the
pavement. The joints shall be formed and
finished to ensure complete separation of
the slabs. Joint filler shall be of a pre-
molded type as specified and shown on the
Drawings and shall extend the full width of
the pavement strip.
- All concrete shall be cleaned from the top
of the joint material. Before the pavement
is opened to traffic, it shall be swept clean
and filled with approved joint sealing
material.
- All devices used for the fixing expansion
joints shall be approved by the Engineer.
They shall be easily removable without
disturbing the concrete and held in proper
transverse and vertical alignment.
Immediately after forms are removed, any
concrete bridging the joint space at the
ends shall be removed for the full width
and depth of the joint.
- When specified, expansion joints shall be
equipped with dowels of the dimensions
and at the spacing and location indicated
on the Drawings. The dowels shall be
firmly supported in place and accurately
aligned parallel to the subgrade and the
♦ 5-51 ♦
 centerline of the pavement by means of a
dowel assembly, which will remain in the
pavement and will ensure that the dowels
are not displaced during construction.
ii. Transverse contraction joints, weakened-plane
joints, or both, shall be formed at the locations
and spacing as shown on the Drawings by
forming a groove or cleft in the top of the slab
while the concrete is still plastic or by sawing a
groove into the concrete surface after the
concrete has hardened in the same manner as
specified. Dowel bar assemblies shall be
installed as shown on the Drawings.
iii. Transverse construction joints shall be formed
at the end of each day's placing operations and
at any other points within a paving lane when
concrete placement is interrupted for more
than 30 minutes or it appears that the concrete
will obtain its initial set before fresh concrete is
placed. Construction joints planned in advance
shall be located at a contraction or expansion
joint where possible but they shall not be
located within 2500 mm of a regular spaced
transverse joint. If the pouring of the concrete
is stopped, causing a joint to fall within this
limit, it shall not be formed, and the fresh
placed concrete shall be removed back to the
2500 mm limit.
13 Edging: Tool edges of pavement, gutters, curbs, and
joints in concrete after initial floating with an edging tool
to the radius shown on drawings. Repeat tooling of edges
after applying surface finishes. Eliminate tool marks on
concrete surfaces.
5.7.3.6 Conditioning of Underlying Course, Slip-Form
Construction
1 The base course on which the pavement will be
placed shall extend approximately 900 mm beyond the
paving machine track, or wider if required, to support the
paver without any noticeable deformation.
2 If damage occurs to the base course, it shall be relaid
for the full depth or the damaged areas filled with concrete
integral with the pavement. If traffic is allowed to use the
prepared grade, the grade shall be checked and corrected
immediately before the placement of concrete.
3 The prepared grade shall be well moistened with
water, without saturating, immediately ahead of concrete
placement to prevent rapid loss of moisture from concrete.
5.7.3.7 Conditioning of Underlying Course, Side-Form
Construction
1 The prepared grade shall be well moistened with
water, without saturating, immediately ahead of concrete
placement to prevent rapid loss of moisture from the
concrete.
♦ 5-52 ♦
2 If damage occurs to the base course, it shall be relaid
for the full depth, or the damaged areas filled with
concrete integral with the pavement.
3 A multiple-pin template weighing not less than 454
kg. per 6 m or other approved template shall be provided
and operated on the forms immediately in advance of the
placing of the concrete. The template shall be propelled
only by hand and not attached to a tractor or other power
unit. Templates shall be adjustable so that they may be
set and maintained at the correct contour of the
underlying course. The adjustment and operation of the
template shall be such as to provide an accurate re-test of
the grade before placing the concrete thereon. All excess
material shall be removed. Low areas may be filled with
concrete integral with the pavement.
5.7.3.8 Handling, Measuring, and Batching Material
1 Batch plant site: layout, equipment, and provisions
for transporting material shall assure a continuous supply
of material to the work.
2 Stockpiles: Build up stockpiles in layers of not more
than 900 mm in thickness. Each layer shall be completely
in place before beginning the next layer and shall not be
allowed to "cone" down over the next lower layer.
Aggregates from different sources and of different grading
shall not be stockpiled together. Improperly placed
stockpiles will not be accepted by Engineer.
3 Aggregates: Handle from stockpiles or other sources
to the batching plant in such manner to secure the
specified grading of the material. Aggregates that have
become segregated or mixed with earth or foreign
material shall not be used. All aggregates produced or
handled by hydraulic methods, and washed aggregates,
shall be stockpiled or binned for draining at least 12 hours
before being batched.
4 Cement: Store in weather tight structures with raised
floors or in suitable silos. Different consignments of
bagged cement shall be used separately and in the order
of delivery. Cement manufactured more than twelve
months prior to proposed use on site shall not be used. If
cement becomes partially set or contains lumps of caked
cement, it shall be rejected. Cement salvaged from
discarded or used bags shall not be used.
5 Aggregate: Fine and coarse aggregate shall be
separately weighed into hoppers in the respective
amounts approved by Engineer in the job mix. Cement
shall be measured by weight. Separate scales and hopper,
with a device to positively indicate the complete discharge
of the batch of cement into the batch box or container,
shall be used for weighing the cement.
6 When required by the contract or when permitted,
batching plants shall be equipped to proportion
aggregates and bulk cement, by weight, automatically
using interlocked proportioning devices of an approved
type.
7 Water shall be measured either by volume or by
weight accurately measured to within plus or minus 1
percent of required amounts. Unless the water is to be
weighed, the water-measuring equipment shall include an
auxiliary tank from which the measuring tank shall be
filled. The measuring tank shall be equipped with an
outside tap and valve to provide for checking the setting,
unless other means are provided for readily and
accurately determining the amount of water in the tank.
The volume of the auxiliary tank shall be at least equal to
that of the measuring tank
8 Methods and equipment for adding air-entraining
agent or other admixtures to the batch, when required,
shall be approved by Engineer. All admixtures shall be
measured into the mixer with an accuracy of plus or
minus 3 percent.
5.7.3.9 Concrete Protection and Curing
1 General: Protect concrete against loss of moisture
and rapid temperature changes for at least seven days
from beginning of the curing operation. Unhardened
concrete shall be protected from rain and flowing water.
All equipment needed for adequate curing and protection
of the concrete shall be on hand, ready to use before
concrete placement begins. A standby water truck
capable of dispensing a fine spray of water shall be
continuously available during paving operations to keep
the concrete moist until the curing compound has been
applied. Provide protection as necessary to prevent
cracking of the pavement due to temperature changes
during the curing period.
2 Membrane Curing: Apply a uniform coating of white
pigmented-type membrane curing compound to the entire
exposed surface of the concrete by means of an approved
automatic spraying machine as soon as free water has
disappeared from the finished surface. Coat formed
surfaces immediately after the forms are removed and in
no case longer than one hour after removal of forms. Do
not allow concrete to dry before application of the
membrane. If any drying has occurred, moisten the
surface of the concrete with a fine spray of water and
apply curing compound as soon as the free water
disappears. The spraying machine shall be self-propelled
and shall ride on the side forms, or previously constructed
pavement straddling the newly paved lane. The machine
shall have one or more spraying nozzles that can be
controlled and operated to completely and uniformly
cover the pavement surface with the required amount of
curing compound. The curing compound shall be
thoroughly and continuously mechanically agitated in the
drum used for the spraying operation throughout the full
depth of the drum during application. Air agitation may
be used only to supplement mechanical agitation. Provide
sufficient spraying pressure to produce a fine spray to
cover the surface thoroughly and completely with a
uniform film. Maintain spray equipment in good
mechanical condition, and provide adequate wind guard
to the spray nozzle. Apply curing compound with an
overlapping coverage that will give a two-coat application
at a coverage rate of not more than 0.1 Liter per/sq.m. for
each coat or as recommended by the manufacturer. The
application of curing compound by hand-operated
pressure sprayers will be permitted only on small widths
or shapes of slabs as approved, and on concrete surfaces
exposed by removal of forms. When application is made
by hand-operated sprayer, apply the second coat in a
direction approximately at right angles to the direction of
the first coat. The compound shall form a uniform,
continuous, cohesive film that will not check, crack or peel,
and is free of pinholes and other discontinuities. Apply an
additional coat, if pinholes, abrasions or other
discontinuities exist, to the affected areas within 30
minutes. Re-spray concrete surfaces that are subjected to
heavy rainfall or abrasive wind-blown sand within three
hours after the curing compound has been applied. Re-
spray areas where the curing membrane is damaged by
subsequent construction operations within the curing
period.
i. Precautions shall be taken to ensure that
concrete is properly cured at sawed joints, but
that no curing compound enters the joints.
Tightly seal top of joint opening and joint
groove at exposed edges before concrete
adjacent to the joint is re-sprayed. Seal joint
groove by using method that will prevent loss
of moisture from the joint during the specified
curing period.
ii. Provide approved standby facilities for curing
concrete pavement at an accessible location at
the jobsite for use in the event of failure of the
spraying equipment, or other conditions that
might prevent correct application of curing
compound at the proper time.
iii. Protect concrete surfaces to which curing
compounds have been applied from pedestrian
and vehicular traffic and from any other
possible damage to the continuity of the
membrane, during the curing period except as
required for joint-sawing operations and
surface testing.
3 Protection: Protect pavement and its appurtenances
from damage caused by traffic. The Engineer will decide
when the pavement may be cleaned and opened to traffic,
but not earlier than 14 days after concrete placing. Protect
freshly placed concrete from premature drying and
excessive cold or hot temperatures. Comply with the
recommendations of ACI 306R for cold weather protection
and ACI 305R for hot weather protection during curing.
5.7.3.10 Concrete Placement
1 Inspection: Before placing concrete, inspect and
complete formwork installation, reinforcement steel, and
items to be embedded or cast in. Notify other trades to
permit installation of their work.
2 Moisten subbase to provide a uniform dampened
condition at the time concrete is placed. Do not place
concrete around manholes or other structures until they
are at the required finish elevation and alignment.
♦ 5-53 ♦
3 Comply with requirements and with
recommendations in ACI 304R for measuring, mixing,
transporting, and placing concrete.
4 Do not add water to concrete during delivery, at Site,
or during placement.
5 Deposit and spread concrete in a continuous
operation between transverse joints. Do not push or drag
concrete into place or use vibrators to move concrete into
place.
6 Consolidate concrete by mechanical vibrating
equipment supplemented by hand-spading, rodding, or
tamping. Use equipment and procedures to consolidate
concrete according to recommendations in ACI 309R.
Consolidate concrete along face of forms and adjacent to
transverse joints with an internal vibrator. Keep vibrator
away from joint assemblies, reinforcement, or side forms.
Use only square-faced shovels for hand-spreading and
consolidation. Consolidate with care to prevent
dislocating reinforcement, dowels, and joint devices.
7 Following the placing of the concrete, it shall be
struck off to conform to the cross section shown on the
Drawings and to level such that when the concrete is
properly consolidated and finished, the surface of the
pavement shall be at the level shown on the Drawings.
8 Screed pavement surfaces with a straightedge and
strike off. Commence initial floating using bull floats or
darbies to form an open textured and uniform surface
plane before excess moisture or bleed water appears on
the surface. Do not further disturb concrete surfaces
before beginning finishing operations or spreading dry-
shake surface treatments.
9 Side Form Method:
i. The concrete shall be deposited on the
moistened grade to require as little re-handling
as possible. Unless truck mixers, truck agitators,
or non agitating hauling equipment are
equipped with means for discharge of concrete
without segregation of the materials, the
concrete shall be unloaded into an approved
spreading device and mechanically spread on
the grade to prevent segregation of the
materials. Placing shall be continuous between
transverse joints without the use of
intermediate bulkheads. Necessary hand
spreading shall be done with shovels - not
rakes. Workmen shall not be allowed to walk in
the freshly mixed concrete with boots or shoes
coated with earth or foreign substances.
ii. When concrete is to be placed adjoining a
previously constructed lane of pavement and
when mechanical equipment will be operated
upon the existing lane of pavement, the
concrete shall be at least 7 days old and at a
flexural strength approved by Engineer.
iii. Concrete shall be thoroughly consolidated
against and along the faces of all forms and
along the full length and on both sides of all
♦ 5-54 ♦
joint assemblies by means of vibrators inserted
in the concrete. Vibrators shall not be
permitted to come in contact with a joint
assembly, the grade, or a side form. In no case
shall the vibrator be operated longer than 15
seconds in any one location, nor shall the
vibrators be used to move the concrete.
iv. Concrete shall be deposited as near to
expansion and contraction joints as possible
without disturbing them but shall not be
dumped from the discharge bucket or hopper
onto a joint assembly unless the hopper is well
centered on the joint assembly.
v. Should any concrete materials fall on or be
worked into the surface of a completed slab,
they shall be removed immediately by
approved methods.
10 Slip-Form Method:
i. The concrete shall be placed with an approved
crawler-mounted, slip-form paver designed to
spread, consolidate, and shape the freshly
placed concrete in one complete pass of the
machine so that a minimum of hand finishing
will be necessary to provide a dense and
homogeneous pavement in conformance with
requirements of the plans and specifications.
The concrete should be placed directly on top
of the joint assemblies to prevent them from
moving when the paver moves over them. Side
forms and finishing screeds shall be adjustable
to the extent required to produce the specified
pavement edge and surface tolerance. The side
forms shall be of dimensions, shape, and
strength to support the concrete laterally for a
sufficient length of time so that no appreciable
edge slumping will occur. Final finishing shall
be accomplished while the concrete is still in
the plastic state.
ii. In the event that slumping or sloughing occurs
behind the paver or if there are any other
structural or surface defects, which, in the
opinion of the Engineer, cannot be corrected
within permissible tolerances, the Engineer
may halt paving operations until proper
adjustment of the equipment or procedures
have been made. In the event that satisfactory
pavement procedures are not achieved after
more than 600 m of single lane paving, the
balance of the work shall be completed with
the use of standard metal forms and the
formed method of placing and curing.
11 Slip-Form Pavers: When automatic machine
placement is used for pavement, submit revised mix
design and laboratory test results that meet or exceed
requirements. Produce pavement to required thickness,
lines, grades, finish, and jointing as required for formed
pavement. Compact subbase and prepare subgrade of
sufficient width to prevent displacement of paver machine
during operations.
12 When adjoining pavement lanes are placed in
separate pours, do not operate equipment on concrete
until pavement has attained 85 percent of its 28-day
compressive strength.
13 Hot-Weather Placement: Place concrete according to
recommendations in ACI 305R and as follows when hot-
weather conditions exist:
i. Cool ingredients before mixing to maintain
concrete temperature at time of placement
below 32 deg. C. Chilled mixing water or
chopped ice may be used to control
temperature, provided water equivalent of ice
is calculated to total amount of mixing water.
Using liquid nitrogen to cool concrete is
Contractor's option.
ii. Cover reinforcement steel with water-soaked
burlap so steel temperature will not exceed
ambient air temperature immediately before
embedding in concrete.
iii. Fog-spray forms, reinforcement steel, and / or
stabilized base just before placing concrete.
Keep aggregate base moisture uniform without
standing water, soft spots, or dry areas.
iv. Concreting shall not be permitted when the
rate of evaporation exceed 1.0 kg./sq.m./h. (ACI
305R "Hot Weather Concreting"). The rate of
evaporation can be estimated from Fig. 2.1.5 of
ACI 305R with the prevailing temperature,
relative humidity, and wind speed. The
evaporation rate can also be determined more
accurately by evaporating water from a cake
pan having an area of approximately 1 ft2
(0.093 sq.m.). The pan is filled with water and
the mass determined every 15 to 20 min to
determine .the evaporation rate, which is equal
to the loss of water mass from the pan. A
balance of at least 2500 g capacity is
satisfactory.
v. No concreting shall take place when the
ambient temperature exceeds 40 deg. C.
5.7.3.11 Concrete Finishing
1 General: Wetting of concrete surfaces during
screeding, initial floating, or finishing operations is
prohibited.
2 Float Finish: Begin the second floating operation
when bleed-water sheen has disappeared and the
concrete surface has stiffened sufficiently to permit
operations. Float surface with power-driven floats, or by
hand floating if area is small or inaccessible to power units.
Finish surfaces to true planes. Cut down high spots, and
fill low spots. Refloat surface immediately to uniform
granular texture.
5.7.3.12 Final Strike-Off, Consolidation and Finishing
1 Sequence: The sequence of operations shall be the
strike-off and consolidation, floating and removal of
laitance, straight edging, and final surface finish. The
addition of superficial water to the surface of the concrete
to assist in finishing operations generally will not be
permitted. If the application of water to the surface is
permitted, it shall be applied as a fog spray by means of
approved spray equipment.
2 Strike-Off of Concrete: Following the placing of the
concrete, it shall be struck off to conform to the cross
section shown on the plans and to an elevation such that
when the concrete is properly consolidated and finished,
the surface of the pavement shall be at the elevation
shown on the plans.
3 Finishing at Joints:
i. Concrete adjacent to joints shall be compacted
or firmly placed without voids or segregation
against the joint material; it shall be firmly
placed without voids or segregation under and
around all load-transfer devices, joint assembly
units, and other features designed to extend
into the pavement.
ii. Concrete adjacent to joints shall be
mechanically vibrated. After the concrete has
been placed and vibrated adjacent to the joints,
the finishing machine shall be operated in a
manner to avoid damage or misalignment of
joints.
iii. If uninterrupted operations of the finishing
machine, to, over, and beyond the joints, cause
segregation of concrete, damage to, or
misalignment of the joints, the finishing
machine shall be stopped when the screed is
approximately 200mm from the joint.
iv. Segregated concrete shall be removed from
the front of and off the joint, the screed shall be
lifted and set directly on top of the joint, and
the forward motion of the finishing machine
shall be resumed. Thereafter, the finishing
machine may be run over the joint without
lifting the screed, provided there is no
segregated concrete immediately between the
joint and the screed or on top of the joint.
4 Machine Finishing:
i. The concrete shall be spread as soon as it is
placed, and it shall be struck off and screeded
by an approved finishing machine. The
machine shall go over each area as many times
and at such intervals as necessary to give the
proper consolidation and to leave a surface of
uniform texture.
ii. Excessive operation over a given area shall be
avoided. When side forms are used, the tops
of the forms shall be kept clean by an effective
device attached to the machine, and the travel
♦ 5-55 ♦
 of the machine on the forms shall be
maintained true without lift, wobbling, or other
variation tending to affect the precision finish.
During the first pass of the finishing machine, a
uniform ridge of concrete shall be maintained
ahead of the front screed for its entire length.
iii. When in operation, the screed shall be moved
forward with a combined longitudinal and
transverse shearing motion, always moving in
the direction in which the work is progressing,
and so manipulated that neither end is raised
from the side forms during the striking-off
process. If necessary, this shall be repeated
until the surface is of uniform texture, true to
grade and cross section, and free from porous
areas.
5 Hand Finishing: Hand finishing methods will not be
permitted, except under the following conditions:
i. In the event of breakdown of the mechanical
equipment, hand methods may be used to
finish the concrete already deposited on the
grade;
ii. In areas of narrow widths or of irregular
dimensions where operation of the mechanical
equipment is impractical.
Concrete, as soon as placed, shall be struck off and
screeded. An approved portable screed shall be used. A
second screed shall be provided for striking off the bottom
layer of concrete when reinforcement is used.
The screed for the surface shall be at least 600 mm longer
than the maximum width of the slab to be struck off. It
shall be of approved design, sufficiently rigid to retain its
shape, and shall be constructed either of metal or of other
suitable material covered with metal. Consolidation shall
be attained by the use of a suitable vibrator.
6 Floating: After the concrete has been struck off and
consolidated, it shall be further smoothed, trued, and
consolidated by means of a longitudinal float, using
approved hand or machine methods.
7 Straight-Edge Testing and Surface Correction:
i. After the pavement has been struck off and
consolidated and while the concrete is still
plastic, it shall be tested for trueness with a
4.8m straightedge. Furnish and use an
accurate 4.8m straightedge swung from
handles 900 mm longer than one-half the width
of the slab.
ii. The straightedge shall be held in contact with
the surface in successive positions parallel to
the centerline and the whole area gone over
from one side of the slab to the other, as
necessary. Advancing shall be in successive
stages of not more than one-half the length of
the straightedge. Any excess water and
laitance shall be removed from the surface of
the pavement.
♦ 5-56 ♦
iii. Any depressions shall be immediately filled
with freshly mixed concrete, struck off,
consolidated, and refinished. High areas shall
be cut down and refinished.
iv. Special attention shall be given to assure that
the surface across joints meets the
requirements for smoothness. Straightedge
testing and surface corrections shall continue
until the entire surface is found to be free from
observable departures from the straightedge
and until the slab conforms to the required
grade and cross section.
v. The use of long-handled wood floats shall be
confined to a minimum; they may be used only
in emergencies and in areas not accessible to
finishing equipment.
5.7.3.13 Surface Texture
1 Brush or Broom Finish:
i. A brush or broom finish shall be formed on all
newly constructed concrete pavements when
the water sheen has practically disappeared,
using mechanical texturing equipment.
ii. The equipment shall operate transversely
across the pavement surface, providing
corrugations that are uniform in appearance
and approximately 2 mm in depth.
iii. The equipment must not tear or unduly
roughen the pavement surface during the
operation. Any imperfections resulting from
the texturing operation shall be corrected.
5.7.3.14 Skid Resistant Surfaces
1 Wire Combing: A skid resistant surface shall be
provided by wire combing in plastic concrete. The wire
combing technique shall use steel combs or tines of
various dimensions to form groove-like texture in the
plastic concrete pavement and shall provide grooves that
are approximately 3 mm by 3 mm spaced 13 mm center-
to-center.
5.7.3.15 Surface Test
1 As soon as the concrete has hardened sufficiently,
the pavement surface shall be tested with a 4.8 m
straightedge or other specified device. Areas in a slab
showing high spots of more than 6 mm but not exceeding
12 mm in 4.8 m shall be marked and immediately ground
down with an approved grinding machine to l within the
tolerance of 6 mm or less. Where the departure from
correct cross section exceeds 12 mm, the pavement shall
be removed and replaced when so directed by Engineer.
2 Any area or section so removed, shall not be less
than 3 m in length, nor less than the full width of the lane
involved. When it is necessary to remove and replace a
section of pavement, any remaining portion of the slab
adjacent to the joints that is less than 3 m in length shall
also be removed and replaced.
5.7.3.16 Removing Forms
1 Unless otherwise specified, forms shall not be
removed from freshly placed concrete until it has set for at
least 12 hours, except where auxiliary forms are used
temporarily in widened areas. Forms shall be removed
carefully to avoid damage to the pavement. After the
forms have been removed, the sides of the slab shall be
cured. Major honeycombed areas shall be considered as
defective work and shall be removed and replaced. Any
area or section so removed shall not be less than 3 m in
length nor less than the full width of the lane involved.
When it is necessary to remove and replace a section of
pavement, any remaining portion of the slab adjacent to
the joints that is less than 3 m in length shall also be
removed and replaced.
5.7.3.17 Sealing Joints
1 The joints in the pavement shall be sealed as shown
on Drawings and as specified in Sub-Section 5.8.
5.7.3.18 Opening to Traffic
1 The Engineer shall decide when the pavement shall
be opened to traffic. The pavement will not be opened to
traffic until test specimens molded and cured in
accordance with ASTM C31 have attained the specified
flexural strength when tested in accordance with ASTM
C78, unless otherwise acceptable to Engineer.
5.7.3.19 Pavement Tolerance
1 Comply with tolerances of ACI 117 and as follows:
i. Level: Plus 6 mm, no minus.
ii. Thickness: Plus 9 mm, minus 6 mm.
iii. Surface: Gap below 3-m long, unleveled
straightedge not to exceed +6 mm.
iv. Lateral Alignment and Spacing of Tie Bars and
Dowels: +/-25 mm.
v. Vertical Alignment of Tie Bars and Dowels:
+/-6 mm.
vi. Alignment of Tie-Bar End Relative to Line
Perpendicular to Pavement Edge: +/-13 mm.
vii. Alignment of Dowel-Bar End Relative to Line
Perpendicular to Pavement Edge: Length of
dowel +/-6 mm per 300 mm.
viii. Joint Spacing: +/-75 mm.
ix. Contraction Joint Depth: Plus 6 mm, no minus.
x. Joint Width: Plus 3 mm, no minus.
2 Surface Roughness: The International Roughness
Index (IRI) for roads shall be complied with on all concrete
finished surfaces. The acceptable range of IRI test results
shall vary between 0 and 1.5 mm/m for highways and
primary roads and between 0 and 3.0 mm/m for secondary,
tertiary and other access roads. Adopt contact type test
instruments for test stretches not exceeding 400 m in
length and non-contact test instruments (optical or sonic)
for stretches exceeding 400 m in length. The Contractor
shall submit for the Engineer’s approval the appropriate
testing instrument(s) and test methodology for the surface
roughness test.
3 Tolerances. The following tolerances are applicable:
i. Lateral deviation from established alignment of
the pavement edge shall not exceed plus or
minus 30 mm in any lane.
ii. Vertical deviation from established grade shall
not exceed plus or minus 12 mm at any point.
iii. Surface smoothness deviations shall not
exceed 6 mm from a 4.8 m straightedge placed
in any direction, including placement along and
spanning any pavement joint or edge.
5.7.3.20 Pavement Marking
1 Do not apply pavement marking paint until layout,
colors and placement have been verified by the Engineer.
2 Allow concrete pavement to harden and gain
strength for 28 days and be dry before starting pavement
marking.
3 Sweep and clean surface to eliminate loose material
and dust.
5.7.3.21 Field Quality Control
1 Slump: Minimum one test at point of discharge for
each day's pour of concrete. Additional tests when
concrete consistency seems to have changed.
2 Concrete Temperature: Test hourly when air
temperature is 4 deg C and below, and when 27 deg C and
above, and each time a set of flexural test beams are
made.
3 Flexural Strength:
i. Flexural test beams shall be made for each
day's pour exceeding 4 cu.m, plus additional
sets for each 40 cu.m. over and above the first
20 cu.m. Each group of test beams shall be
molded from the same batch of concrete and
shall consist of a sufficient number of
specimens to provide two flexural strength
tests at each test age. The specimens shall be
made in accordance with ASTM C31. At the
start of paving operations and when the
aggregate source, aggregate characteristics, or
mix design is changed, additional groups of
test beams may be required until Engineer is
satisfied that the concrete mix complies with
the strength requirements of these
specifications. Test ages shall be 7 days and
28 days.
ii. The flexural strength of the concrete shall meet
the following requirements:
- The average of any 4 consecutive strength
tests, tested at the end of 28 days, shall be
equal to or greater than the specified
flexural strength;
♦ 5-57 ♦
 - Not more than 20 percent of the beams
tested at the end of 28 days shall have a
flexural strength less than the specified
strength;
- No specimen shall have a flexural strength
less than 90% of the specified flexural
strength.
iii. Specimens, which are obviously defective,
shall not be considered in the determination of
the strength. When it appears that the test
specimens will fail to conform to the
requirements for strength, Engineer shall have
the right to order changes in the concrete mix
sufficient to increase the strength to meet the
requirements. When a satisfactory relationship
between 7-days and 28-day strengths has been
established and approved, the 7-day test
results may be used as an indication of the 28-
day strengths. However, the 7-day test results
will not replace the results of the 28-day tests if
the 28-day results fall below the requirements.
4 Testing Agency: Engage a qualified independent
testing and inspection agency to sample materials,
perform tests, and submit test reports during concrete
placement according to requirements specified in this
Clause.
5 Testing Services: Testing shall be performed
according to the following requirements:
i. Sampling Fresh Concrete: Representative
samples of fresh concrete shall be obtained
according to ASTM C 172, except modified for
slump to comply with ASTM C 94.
ii. Slump: ASTM C 143; one test at point of
placement for each flexural and/or
compressive-strength test, but not less than
one test for each day's pour of each type of
concrete. Additional tests will be required
when concrete consistency changes.
iii. Concrete Temperature: ASTM C 1064; one test
hourly when air temperature is 4 deg C and
below and when 27 deg C and above, and one
test for each set of flexural and/or compressive-
strength specimens.
iv. Compression Test Specimens: ASTM C 31/C
31M; one set of four standard cylinders for
each compressive-strength test, unless
otherwise indicated. Cylinders shall be molded
and stored for laboratory-cured test specimens
unless field-cured test specimens are required.
v. Compressive-Strength Tests: ASTM C 39; one
set for each day's pour of each concrete class
exceeding 4 cu.m., but less than 19 cu.m., plus
one set for each additional 38 cu.m. One
specimen shall be tested at 7 days and two
specimens at 28 days; one specimen shall be
retained in reserve for later testing if required.
♦ 5-58 ♦
vi. When frequency of testing will provide fewer
than five compressive-strength tests for a given
class of concrete, testing shall be conducted
from at least five randomly selected batches or
from each batch if fewer than five are used.
vii. When strength of field-cured cylinders is less
than 85 percent of companion laboratory-cured
cylinders, current operations shall be evaluated
and corrective procedures shall be provided for
protecting and curing in-place concrete.
viii. Strength level of concrete will be considered
satisfactory if averages of sets of three
consecutive compressive-strength test results
equal or exceed specified compressive strength
and no individual compressive-strength test
result falls below specified compressive
strength by more than 3.4 MPa.
6 Test results shall be reported in writing to Engineer,
concrete manufacturer, and Contractor within 24 hours of
testing. Reports of compressive-strength tests shall
contain Project identification name and number, date of
concrete placement, name of concrete testing agency,
concrete type and class, location of concrete batch in
pavement, design compressive strength at 28 days,
concrete mix proportions and materials, compressive
breaking strength, and type of break for both 7- and 28-
day tests.
7 Nondestructive Testing: Impact hammer, sonoscope,
or other nondestructive device may be permitted by
Engineer but will not be used as the sole basis for
approval or rejection.
8 Additional Tests: Testing agency shall make
additional tests of the concrete when test results indicate
slump, air entrainment, concrete strengths, or other
requirements have not been met, as directed by Engineer.
Testing agency may conduct tests to determine adequacy
of concrete by cored cylinders complying with ASTM C 42,
or by other methods as directed.
5.7.3.22 Repairs and Protection
1 Remove and replace concrete pavement that is
broken, damaged, or defective, or does not meet
requirements in the Specification
2 Drill test cores where directed by Engineer when
necessary to determine magnitude of cracks or defective
areas. Fill core holes in satisfactory pavement areas with
Portland cement concrete bonded to pavement with epoxy
adhesive.
3 Protect concrete from damage. Exclude traffic from
pavement for at least 14 days after placement. When
construction traffic is permitted, maintain pavement as
clean as possible by removing surface stains and spillage
of materials as they occur.
4 Maintain concrete pavement free from stains,
discoloration, dirt, and other foreign material. Sweep
concrete pavement not more than two days before date the joint shall be removed and replaced at the Contractor's
scheduled for Substantial Completion inspections. expense.

5.7.3.23 Determination of Concrete Thickness

5.7.4 Method of Measurement
1 Thickness of concrete pavement shall be determined
1 Unreinforced concrete pavement shall be measured
by average caliper measurement of cores taken from in cubic meters computed as the paved area multiplied by
sections of the pavement as stated in Item 2 below,
the executed slab thickness as approved by the Engineer.
rounded upwards taken to the nearest mm.
2 Reinforced concrete pavement shall be measured in
2 Pavement sections shall consist of each 300 lin.m.
cubic meters of the paved area multiplied by the executed
length in each paver lane. The last section in each lane
slab thickness (as approved by the Engineer) and shall
shall be 300 m plus the fractional part of 300 m remaining. include the same items detailed in Item 1 of Clause 5.7.4
Other areas such as intersections, entrances, ramps, etc
above plus the reinforcement steel material furnished,
shall be measured as one section each and the thickness
spliced, jointed and placed all as shown on the
of each shall be determined separately. Small irregular Contractor’s shop drawings that are approved by the
unit areas may be included as part of another section,
Engineer.
3 One core shall be taken from each section by the
3 The rates in the Bill of Quantities shall be deemed to
Contractor at approved locations and in the presence of
include furnishing of all associated concrete and joint
the Engineer. When the measurement of the core from component materials, preparation of bases, concrete
any pavement section is not deficient by more than 5 mm
mixing, placing, compacting, finishing and curing, as well
from the specified thickness, the core will be deemed to be
as all joint sawing, cutting and cleaning operations,
of the specified thickness as shown on the Drawings. drilling and installing dowels and deformed tie bars and
4 When the measurement of the core from any other joint accessories, and all tests, all as detailed on
pavement section is deficient by more than 5 mm but not Drawings and in the Specifications.
more than 20 mm, 2 additional cores spaced at not less
than 100 mm shall be taken and used together with the 5.7.5 Basis of Payment
first core to determine the average thickness of such
section. 1 The amount of completed and accepted work,
measured as provided for above, will be paid for at the
5 When the measurement of the core from any
unit rates for the various items in the Bill of Quantities,
pavement section is less than the specified thickness by
which rate shall be full compensation for supplying
more than 20 mm, the average thickness of such section
materials, transporting and placing, for labor, equipment,
shall be determined by taking additional cores at not less
tools and other items necessary for the proper completion
than 5 m intervals parallel to the centerline in each
of the work.
direction from the affected location until, in each direction,
a core is taken which is not deficient by more than 20 mm.
Exploratory cores for deficient thickness will not be used
5.7.6 Items in the Bill of Quantities
in average thickness determinations. i. Unreinforced Cement Concrete
6 Where the average thickness of concrete pavement is Pavement (cu.m.)
deficient by more than 5 mm but not more than 20 mm ii. Reinforced Cement Concrete
adjustments shall be made in the area measurements as Pavement (cu.m.)
shown in Table 5.7.3.1.

Deficiency in Thickness as Proportion of Area 5.8 Joint Sealers for Concrete

Determined by Cores (mm) Measured for Payment Pavement
0.0 to 5.0 100%
5.1 to 10.0 90% 5.8.1 Description
10.1 to 15.0 75%
1 This Sub-section describes joint sealers for concrete
15.1 to 20.0 50%
pavement as shown on Drawings.
> 20.0 0%
Table 5.7.3.1: Concrete Thickness Deficiency 5.8.2 Materials
7 When the pavement is more than 20 mm deficient in 5.8.2.1 Materials, General
thickness, the Contractor shall remove such deficient areas
and replace them with concrete pavement of the specified 1 Compatibility: Provide joint sealers, joint fillers and
quality and thickness, all at his own expense. other related materials that are compatible with one
another and with joint substrates under conditions of
8 When the limits of a deficient area to be removed
service and application, as demonstrated by sealant
and replaced are within 3 m of an expansion, contraction
manufacturer based on testing and field experience.
or construction joint, the entire concrete pavement up to

♦ 5-59 ♦
5.8.2.2 Elastomeric Hot-Poured Joint Sealants
1 ASTM D 3569 - Joint Sealants, Hot-Poured,
Elastomeric, Jet-Fuel-Resistant type, for Portland Cement
Concrete Pavements.
5.8.2.3 Joint Sealant Backing
1 General: Provide sealant backings of material and
type which are non-staining; are compatible with joint
substrates, sealants, primers and other joint fillers; and are
approved for applications indicated by sealant
manufacturer based on field experience and laboratory
testing.
2 Plastic Foam Joint Fillers: Preformed, compressible,
resilient, non-waxing, non-extruding strips of flexible, non-
gassing plastic foam of material indicated below;
nonabsorbent to water and gas; and of size, shape and
density to control sealant depth and otherwise contribute
to producing optimum sealant performance.
3 Bond-Breaker Tape: Polyethylene tape or other
plastic tape as recommended by sealant manufacturer for
preventing sealant from adhering to rigid, inflexible joint
filler materials or joint surfaces at back of joint where such
adhesion would result in sealant failure. Provide self-
adhesive tape where applicable.
5.8.2.4 Miscellaneous Materials
1 Primer: Provide type recommended by joint sealer
manufacturer where required for adhesion of sealant to
joint substrates indicated, as determined from
preconstruction joint sealer substrate tests and field tests.
2 Cleaners for Nonporous Surfaces: Provide non-
staining, chemical cleaners of type which are acceptable to
manufacturers of sealants and sealant backing materials,
which are not harmful to substrates and adjacent
nonporous materials, and which do not leave oily residues
or otherwise have a detrimental effect on sealant adhesion
or in-service performance.
3 Masking Tape: Provide non-staining, nonabsorbent
type compatible with joint sealants and to surfaces
adjacent to joints.
5.8.3 Construction Requirements
5.8.3.1 Examination
1 Examine joints for compliance with requirements for
joint configuration, installation tolerances and other
conditions affecting joint sealer performance. Do not
proceed with installation of joint sealers until
unsatisfactory conditions have been corrected.
5.8.3.2 Preparation
1 Surface Cleaning of Joints: Clean out joints
immediately before installing joint sealers to comply with
recommendations of joint sealer manufacturers and the
following requirements:
♦ 5-60 ♦
i. Remove all foreign material from joint
substrates which could interfere with adhesion
of joint sealer, including dust; paints, except for
permanent, protective coatings tested and
approved for sealant adhesion and
compatibility by sealant manufacturer; old joint
sealers; oil; grease; waterproofing; water
repellants; water and surface dirt.
ii. Remove laitance and form release agents from
concrete.
2 Joint Priming: Prime joint substrates where
indicated or where recommended by joint sealer
manufacturer based on preconstruction joint sealer-
substrate tests or prior experience. Apply primer to
comply with joint sealer manufacturer's recommendations.
Confine primers to areas of joint sealer bond, do not allow
spillage or migration onto adjoining surfaces.
3 Masking Tape: Use masking tape where required to
prevent contact of sealant with adjoining surfaces which
otherwise would be permanently stained or damaged by
such contact or by cleaning methods required to remove
sealant smears. Remove tape immediately after tooling
without disturbing joint seal.
5.8.3.3 Installation of Joint Sealers
1 General: Comply with joint sealer manufacturers'
printed installation instructions applicable to products and
applications indicated, except where more stringent
requirements apply.
2 Hot poured Sealants:
i. The joint sealant shall be applied solid,
uniformly from bottom to top and shall be
filled without formation of entrapped air or
voids. A backing material shall be placed as
shown on the plans and shall be non-adhesive
to the concrete or the sealant material. The
heating kettle shall be an indirect heating type,
constructed as a double boiler. A positive
temperature control and mechanical agitation
shall be provided. The sealant shall not be
heated to more than 11°C below the safe
heating temperature. The safe heating
temperature can be obtained from the
manufacturer's shipping container. A direct
connecting pressure type extruding device with
nozzles shaped for insertion into the joint shall
be provided. Any sealant spilled on the surface
of the pavement shall be removed immediately.
ii. Backup materials and bond breakers shall be
compatible with the sealant, shall not adhere to
the sealant, shall be compressible without
extruding the sealant, and shall recover to
maintain contact with the joint faces when the
joint is open.
5.8.3.4 Cleaning
1 Clean off excess sealants or sealant smears adjacent
to joints as work progresses by methods and with
cleaning materials approved by manufacturers of joint
sealers and of products in which joints occur.
5.8.3.5 Protection
1 Protect joint sealers during and after curing period
from contact with contaminating substances or from
damage resulting from construction operations or other
causes so that they are without deterioration or damage at
time of Substantial Completion. If, despite such protection,
damage or deterioration occurs, cut out and remove
damaged or deteriorated joint sealers immediately and
reseal joints with new materials to produce joint sealer
installations with repaired areas indistinguishable from
original work.
5.8.4 Method of Measurement, Basis of
Payment and Bill of Quantities
1 No separate measurement is made for joint sealers
and no items are included in the Bill of Quantities. The
work is considered as subsidiary to the concrete pavement
and its cost is deemed to be included under payment for
concrete pavement items as measured under Clauses 5.7.4,
5.7.5 and 5.7.6.
5.9 Reinforced Concrete Box Culverts
and Headwalls, Wingwalls, Cut-
Off Walls and Aprons
5.9.1 Description
1 This Sub-section describes the requirements for
construction of reinforced concrete box culverts, in-situ or
precast, and headwalls, wing walls, cut-off walls and
aprons for box and pipe culverts, including earthworks,
structural concrete and all other ancillary items necessary
for the completion of the structures to the lines, grades
and dimensions as shown on the Drawings. These
requirements are additional to the requirements of
preceding Sections of the Specification.
5.9.2 Materials
1 Materials shall conform to the relevant requirements
of the following Sub-sections of the Specification:
- Concrete Sub-section 5.1
“Concrete Materials and Mixes”
- Reinforcing Steel Sub-section 5.2
“Reinforcing Steel”
2 Concrete classes shall be those prescribed on the
relevant Drawings.
3 Backfill shall be as specified in Section 2 “Earthwork”.
5.9.3 Construction Requirements
1 Construction work shall comply with the relevant
requirements of the following sections:
Section 2 Earthwork
Sub-section 5.2 Reinforcing Steel
Sub-section 5.3 Reinforced Concrete Structures.
2 Box culverts, headwalls, wing walls, cut-off walls and
aprons shall be to the lines and levels shown on the
Drawings. Unless otherwise shown, culverts shall have a
constant fall of 1:100 along their centerline.
3 Box culverts shall be constructed in sections such
that expansion joints are located at intervals which shall
be so spaced as to prevent the box culvert from behaving
as a long beam unless such structural action has been
allowed for in the design. Unless shown on the Drawings
or directed by the Engineer, the spacing of expansion
joints shall be no greater than 35 meters.
4 Unless otherwise indicated, expansion joints shall
also be used at the culvert ends where the culvert meets
the wing walls and apron slabs.
5 Where box culverts are located in road embankments,
the embankments shall first be constructed in accordance
with Paragraph 2.5.3.4 "Embankment Construction". The
compacted embankments shall then be excavated in
trenches for the culverts. This requirement may be
dispensed with by a written permission from the Engineer
to so do. Where a culvert is to be constructed under a
high embankment, this requirement may be relaxed or
dispensed with provided the fill is designed to arch over
the culvert or the culvert is specially designed for an
increased surcharge load from the embankment.
Embankments may be constructed to within 1 m above
the culvert then construction carried out as above.
6 For culverts located below firm ground, the
excavation shall be carried out in trenches in accordance
with Section 2 “Earthwork”.
7 Backfilling and compaction shall be carried out in
layers not exceeding 150 mm compacted thickness and
the difference in the levels of backfill on either side of the
culvert shall at no time exceed 500 mm. Start backfilling
after having attained 75 percent of the culvert 28-day
concrete strength.
8 All concreting shall be carried out in dry conditions.
9 Unless otherwise shown on the Drawings or
instructed by the Engineer, the base slab of the box culvert
for its entire length shall first be completed before
proceeding with the walls and roof slab. The construction
joints in the walls shall be located at not less than 100 mm
above the top of the base slab. Unless shown otherwise
on the Drawings or directed by the Engineer, the walls and
roof slabs shall be concreted in one pour between
expansion joints.
10 Unless otherwise shown on the Drawings or
instructed by the Engineer, the cut-off wall shall be cast
against earth.
♦ 5-61 ♦
11 Concrete placing, forms, finishing, curing and ASTM D 173 Specification for Bitumen-Saturated
jointing shall be done in accordance with Section 5.3 Cotton Fabrics Used in Roofing and
“Reinforced Concrete Structures”. Waterproofing (AASHTO M 117)
ASTM D 449 Specifications for Asphalt Used in
5.9.4 Method of Measurement Dampproofing, and Waterproofing
(AASHTO M 115)
1 The work shall be measured according to the
dimensions shown on the Drawings in accordance with ASTM D 450 Specification for Coal-Tar Pitch Used in
the rules for measurement stated in Sub-section 5.1 Roofing, Dampproofing, and
‘Concrete Materials and Mixes’ and Sub-section Waterproofing (AASHTO M 118)
5.2 ’Reinforcing Steel’. ASTM D 490 Specifications for Road Tar (AASHTO M
2 Where the Contractor uses precast units as an 52)
alternative, any extra material and quantity necessary
shall not be measured. 5.10.2 Materials
3 All other work such as excavation for the cut-off walls
5.10.2.1 Asphalt
formwork, construction and expansion joints and the like,
shall be included as subsidiary work whose costs are 1 Waterproofing asphalt shall conform to AASHTO M
deemed to be included in the rates and prices for concrete 115 (ASTM D 449); Type I for use below ground, and Type
and reinforcement. II for use above ground.
2 Primer for use with asphalt in waterproofing shall
5.9.5 Basis of Payment conform to AASHTO M 116 (ASTM D 41).
1 The amount of completed and accepted work, 5.10.2.2 Bitumen
measured as provided for above, shall be paid for at the
unit rates in the Bill of Quantities, which rates shall be full 1 Waterproofing bitumen shall conform to AASHTO M
compensation for supplying, curing, finishing concrete 118 (ASTM D 450); Type II unless otherwise specified.
and cutting, shaping and fixing reinforcing steel and for 2 Primer for use with coal-tar bitumen in dampproofing
labor, materials, equipment, tools and other items and waterproofing shall conform to AASHTO M 121
necessary for the proper completion of the works. (ASTM D 43). It shall be a distillate of coal-gas tar or coke-
oven tar.
5.9.6 Items in Bill of Quantities
5.10.2.3 Waterproofing Fabric
1 Reinforced concrete box culverts, head walls, wing
walls and cut-off walls are separately identified in the Bill 1 Waterproofing fabric shall conform to AASHTO M
of Quantities and the relevant items as stated in Sub- 117 (ASTM D 173).
sections 5.1 and 5.2 are included.
5.10.2.4 Self-Adhesive Polyethylene Sheet

5.10 Waterproofing for Structures 1 Flexible, preformed waterproof membrane

comprising strong, high-density polyethylene film with
5.10.1 Description self-adhesive rubber/bitumen compound, and having the
following minimum properties:
5.10.1.1 Scope - Total thickness : 1.5 mm
2
1 This Sub-section describes waterproofing membrane, - Weight : 1.6 kg/m
sand dampproofing courses to external concrete surfaces 2
- Tensile strength : 42 N/mm
in contact with earth and epoxy coating to internal
- Elongation : 210% long.; 160% trans.
surfaces of concrete walls, slabs, and beds, all as shown
on the Drawings or as directed by the Engineer. - Tear resistance : 340 N/mm long.; 310
N/mm trans.
5.10.1.2 References - Puncture resistance : 220 N 65 mm
1 American Society for Testing and Materials (ASTM):
5.10.2.5 Tar for Absorptive Treatment
ASTM D 41 Specification for Asphalt Primer Used in
Roofing, Dampproofing, and 1 Tar for absorptive treatment shall be a liquid water-
Waterproofing (AASHTO M 116) gas tar that conforms to the following requirements:

ASTM D 43 Specification for Coat Tar Primer Used - Specific gravity, 25ºC 1.030 to 1.100
in Roofing, Dampproofing, and - Specific viscosity at 40ºC (Engler),
Waterproofing (AASHTO M 121) not more than 3.0
- Total distillate, percent by
weight, to 300ºC, not more than 50.0

♦ 5-62 ♦
 - Bitumen (soluble in carbon disulfide)
not less than, percent 98.0
- Water, not more than, percent 3.0
5.10.2.6 Tar Seal Coat
1 Tar seal coat shall conform to AASHTO M 52, Grade
RTCB-5 (ASTM D 490).
5.10.2.7 Proprietary Waterproofing Systems
1 Proprietary waterproofing systems shall be
bituminous membranes reinforced with layers of suitable
reinforcement, bituminous coated polythene sheet,
plasticized polyvinyl chloride sheet, other approved
membranes or applications of resinous reinforced
coatings. The type to be used shall be as indicated on the
Drawings and shall be chosen according to its location
and serviceability. The specific system shall be approved
after site trials, should the Engineer decide these to be
necessary.
5.10.2.8 Epoxy Coating System
1 An approved epoxy coating system shall be
furnished and applied to the internal concrete surfaces of
culverts and open channels as shown on the Drawings or
as directed by the Engineer. The thickness of the epoxy
coating shall be at least 400 microns in accordance with
the manufacturer's recommendations.
5.10.3 Construction Requirements
5.10.3.1 Surface Preparation
1 Waterproofing:
i. All concrete surfaces to be waterproofed shall
be reasonably smooth and free from
projections or holes which might cause
puncture of the membrane. The surface shall
be dry, so as to prevent the formation of steam
when the hot asphalt or tar is applied, and,
immediately before the application of the
waterproofing, the surface shall be thoroughly
cleaned of dust, projecting tying wire and loose
material.
ii. No waterproofing shall be done in wet weather,
nor when the temperature is below 4 degrees C,
without special authorization from the Engineer.
Should the surface of the concrete become
temporarily damp, it shall be covered with a 50
mm layer of hot sand, which shall be allowed
to remain in place from 1 to 2 hours, or long
enough to produce a warm and surface-dried
condition, after which the sand shall be swept
back, uncovering sufficient surface for
beginning work, and the operation repeated as
the work progresses.
2 Dampproofing: The surface to which the
dampproofing coating shall be applied shall be cleaned of
all loose and foreign material and dirt and shall be dry.
When necessary the Engineer may require the surface to
be scrubbed with water and a stiff brush, after which the
surface shall be allowed to dry before application of the
primer.
5.10.3.2 Inspection, Delivery and Storage
1 All waterproofing materials shall be tested before
shipment. Unless otherwise ordered by the Engineer, they
shall be tested at the place of manufacture, and, when so
tested, a copy of the test results shall be sent to the
Engineer by the chemist or inspection bureau which has
been designated to make the tests, and each package shall
have affixed to it a label, seal, or other mark of
identification, showing that it has been tested and found
acceptable, and identifying the package with the
laboratory tests.
2 Factory inspection is preferred, but in lieu thereof
and/or addition thereof, the Engineer may order that
representative samples, properly identified, be sent to him
for test prior to shipment of the materials. After delivery
of the materials, representative check samples shall be
taken which shall determine the acceptability of the
materials.
3 All materials shall be delivered to the work in original
containers, plainly marked with the manufacturer's brand
or label.
4 Waterproofing and dampproofing material shall be
stored in a dry, protected place. Rolls of waterproofing
fabric and membranes shall not be stored on end.
5.10.3.3 Asphalt and Bitumen Waterproofing Fabric
1 Asphalt shall be heated to a temperature between
150 degrees C and 175 degrees C and tar for hot
application shall be heated to a temperature between 93
degrees C and 120 degrees C with frequent stirring to
avoid local overheating. The heating kettles shall be
equipped with thermometers.
2 In all cases, the waterproofing shall begin at the low
point of the surface to be waterproofed, so that water will
run over and not against or along the laps.
3 The first strip of fabric shall be of half-width; the
second shall be full-width, lapped the full-width of the first
sheet; and the third and each succeeding strip shall be full-
width and lapped so that there will be two layers of fabric
at all points with laps not less than 50 mm wide. All end
laps shall be at least 300 mm.
4 Beginning at the low point of the surface to be
waterproofed, a coating of primer shall be applied and
allowed to dry before the first coat of asphalt is applied.
The waterproofing shall then be applied as follows.
5 Beginning at the low point of the surface to be
waterproofed, a section about 500 mm wide and the full
length of the surface shall be mopped with the hot asphalt
or tar. Immediately following the mopping, the first strip
of fabric, or half-width, shall be rolled and pressed into
place so as to eliminate all air bubbles and obtain close
conformity with the surface. This strip and an adjacent
♦ 5-63 ♦
section of the surface of a width equal to slightly more
than half of the width of the fabric being used shall then
be mopped with hot asphalt or tar, and a full width of the
fabric shall be rolled into this, completely covering the first
strip, and pressed into place as before. This second strip
and an adjacent section of the concrete surface shall then
be mopped with hot asphalt or tar and the third strip of
fabric "shingled" on so as to lap the first strip not less than
50 mm. This process shall be continued until the entire
surface is covered, each strip of fabric lapping at least 50
mm over the last strip. The entire surface shall then be
given a final mopping of hot asphalt or tar.
6 The completed waterproofing shall be a firmly
bonded membrane composed of two layers of fabric and
three moppings of asphalt or tar, together with a coating
of primer. Under no circumstances shall one layer of
fabric touch another layer at any point or touch the surface,
as there must be at least three complete moppings of
asphalt or tar.
7 In all cases the mopping on concrete shall cover the
surface so that no gray spots appear, and on cloth it shall
be sufficiently heavy to completely conceal the weave. On
horizontal surfaces not less than 49 liters of asphalt or tar
shall be used for each 10 square meter of finished work,
and on vertical surfaces not less than 61 liters shall be
used for each 10 square meter. The work shall be so
regulated that, at the close of a day's work, all cloth that is
laid shall have received the final mopping of asphalt or tar.
Special care shall be taken at all laps to see that they are
thoroughly sealed down.
8 At the edges of the membrane and at any points
where it is punctured by such appurtenances as drains or
pipes, suitable provisions shall be made to prevent water
from getting between the waterproofing and the
waterproofed surface.
9 All flashing at curbs and against girders, spandrel
walls, etc., shall be done with separate sheets lapping the
main membrane not less than 300 mm. Flashing shall be
closely sealed either with a metal counter-flashing or by
embedding the upper edges of the flashing in a groove
poured full of joint filler.
10 Joints which are essentially open joints but which are
not designed to provide for expansion shall first be
caulked with oakum and lead wool and then filled with hot
joint filler.
11 Expansion joints, both horizontal and vertical, shall
be provided with sheet copper or lead in "U" or "V" form in
accordance with approved details. After the membrane
has been placed, the joint shall be filled with hot joint filler.
The membrane shall be carried continuously across all
expansion joints.
12 At the ends of the structure the membrane shall be
carried well down on the abutments and suitable
provision made for all movement.
♦ 5-64 ♦
5.10.3.4 Proprietary Waterproofing Membranes
1 Proprietary waterproofing membranes shall be
installed strictly in accordance with the manufacturer's
instructions and shall be laid so that no air is trapped
between it and the concrete surface or between successive
layers of sheeting.
2 Unless otherwise specified, joints between sheets
shall be lapped with end laps of at least 150 mm and side
laps of at least 100 mm. The joints shall be arranged so
that, at no points, are there more than three thicknesses of
sheeting and, as far as possible so that water will drain
away from the exposed edge.
5.10.3.5 Damage Patching of Waterproofing Fabrics
1 Care shall be taken to prevent injury to the finished
fabric membrane by workmen or wheelbarrows, or by
throwing any material on it. Any damage which may
occur shall be repaired by patching. Patches shall extend
at least 300 mm beyond the outermost damaged portion
and the second ply shall extend at least 75 mm beyond the
first.
2 Proprietary waterproofing membranes shall be
repaired according to the manufacturer's specifications
and as directed by the Engineer.
5.10.3.6 Dampproofing
1 Concrete, brick, or other surfaces to be protected by
dampproofing shall be thoroughly cleaned before the
primer is applied. The surfaces shall then be brush or
spray painted with two or more coats (as indicated on the
Drawings) of tar or asphalt for absorptive treatment.
Below ground not less than two coats shall be applied,
using 0.56 L/square meter of surface. On the well-primed
surface one application of tar or asphalt seal coat shall be
applied by brush, using 0.45 L/square meter.
2 Care shall be taken to confine all paints to the areas
to be waterproofed and to prevent disfigurement of any
other parts of the structure by dripping or spreading of the
tar or asphalt.
5.10.3.7 Protection of Waterproofing and Dampproofing
1 Waterproofing membranes and dampproofing
courses shall be covered by a protective layer which,
unless otherwise specified or shown on the Drawings,
shall be a 50 mm coat of mortar composed of one part
Portland cement and two parts sand, reinforced midway
between its top and bottom surfaces with wire netting of
150 mm mesh and No. 12 gauge, or an approved
equivalent. The top surface shall be troweled to a smooth,
hard finish and, where required, true to grade.
2 The protection course shall follow the waterproofing
so closely that the latter will not be exposed without
protection for more than 24 hours.
3 Unless otherwise shown on the Drawings or directed
by the Engineer, vertical faces waterproofed or
dampproofed shall be protected by a porous concrete
block wall of not less than 225 mm thickness. If approved
by the Engineer, a proprietary synthetic sheeting may be
used as the protective layer in lieu of the porous concrete
block wall.
5.10.3.8 Testing
1 Unless otherwise agreed by the Engineer in writing,
at least one site trial application of the waterproofing
system shall be carried out to determine the suitability of
the surface preparation, method of application and
effectiveness of the protective layer. The size of
membrane laid shall be not less than 2.0 meters wide and
5.0 meters long.
5.10.4 Method of Measurement
construction in corrosive or marine environments or other
severe exposure conditions as shown on the Drawings.
2 The coating system shall be used for the protection
of reinforced concrete structures against carbonation or
chloride induced corrosion. Work includes, but not
necessarily limited to coating for:
- Piers, columns, frames and exposed surfaces
of abutments and retaining walls.
- Deck soffit and sides and other exposed
surfaces of deck.
- Precast concrete girders and other precast
concrete elements.
- Concrete parapets.

1 Waterproofing membrane shall be measured by the 5.11.1.2 Submittals

square meter of each type, furnished, laid, completed and
accepted.
2 Tar or bituminous painting to surfaces permanently
in contact with backfilled material shall be measured by
the square meter of surface area so painted.
3 Epoxy coating to internal surfaces of concrete shall
be measured by the square meter of the surface area so
coated.
4 Protection to waterproofing membrane and
dampproofing course shall not be measured for direct
payment but shall be deemed to be included in the rates
for waterproofing and dampproofing.
5 Site trials of waterproofing membranes shall not be
measured for direct payment but shall be deemed to be
included in the rates for waterproofing.
1 Proprietary special coating system for the protection
of exposed concrete surfaces shall be proposed by the
Contractor and shall be subject to the Engineer's approval.
Submittal shall include the details of the coating type and
coating manufacturer and a list of projects, executed in
environmental conditions similar to those experienced in
the project site, in which the same protective coating
system was successfully used.
2 The Contractor's submittal shall be accompanied by
the manufacturer's detailed product specifications
together with application instructions, and guarantee that
the product is suitable for use at the operating
temperatures in the Sultanate.
3 Trial Panels as specified in Paragraph 5.11.1.4 (1)
shall be provided.

5.10.5 Basis of Payment 5.11.1.3 Performance Requirements

1 The amount of completed and accepted Work
measured as provided for above will be paid at the unit
rates as specified in the Bill of Quantities, which unit rates
shall be full compensation for furnishing all materials,
labor, equipment, tools, supplies and all other items
necessary for the completion of the Work.
1 The coating system shall provide in-depth protection
against carbonation and chloride penetration while
permitting water vapor transmission from the concrete.
2 Final color shall be selected by the Engineer.
5.11.1.4 Quality Assurance

5.10.6 Items in the Bill of Qquantities
i Tar or bituminous paint
(State type, number of coats)
ii Membrane waterproofing
(State type, thickness)
iii Epoxy coating to internal
surfaces of concrete
(State type, thickness)
5.11 Protective Coating for Concrete
5.11.1 Description
5.11.1.1 Scope
1 This Sub-section describes protective coating on
exposed surfaces of reinforced and prestressed concrete
1 Trial Panels:
i. Prior to applying the system, trial applications
sq.m. shall be carried out on trial panels made by the
Contractor to the specified finishes. The trial
sq.m. shall demonstrate the method proposed for
applying the system, coverage, coating
thickness, color and final appearance of the
coating. Representatives of the coating
manufacturer shall be present at the trials and
sq.m.
the surface preparation and application of the
coating shall be carried out under their
direction. The Contractor shall, at his own
expense, coat as many panels as required by
the Engineer until a trial panel has been
accepted by the Engineer as satisfactory. The
coated panel, when accepted, will form the
standard against which the corresponding
coating in the works shall be judged. No

♦ 5-65 ♦
 application of the coating in the works shall be 5.11.2.3 Topcoat
undertaken until trials have been completed to
1 The topcoat shall be a pure aliphatic acrylic resin,
the Engineer’s satisfaction.
decorative, high performance water based, pigmenting
ii. Trial panels shall be tested for permeability in coating. It shall have resistance to water, carbon dioxide
accordance with DIN 1048 and AASHTO T 277 and other air-borne acids and have the ability to allow
as defined in Paragraph 5.1.3.15 as a check on passage of water vapor from within the structure. The
the effectiveness of the coating. Acceptance of topcoat shall have elastomeric and flexural capabilities.
the coating shall be based on compliance with The color shall be selected by the Engineer.
the following acceptance limits. Based on this
result, the Engineer may reject the work or 5.11.2.4 Specifications
require additional coating.
1 The material employed for the coating shall comply
- DIN 1048 results for coated surfaces: one with the following requirements:
fifth of the limits for the unprotected
- Wet film thickness 650 microns
surfaces defined in Paragraph 5.1.3.15.
- Dry film thickness 400 microns
- AASHTO T 277 test results for coated
surfaces: charge passed should be less - Carbon dioxide diffusion
than 500 coulombs. resistance R value at 325μ
greater than 161
5.11.1.5 Testing m
1 Testing of the coating shall conform to the following: - Water vapor transmission greater than 13
g/m2.day
- Carbon dioxide diffusion resistance (R
value) - Chloride ion diffusion 3.63 x 10-10
Taywood Engineering Laboratories cm2/sec
- Water vapor transmission - Reduction in chloride ion
Taywood Engineering Laboratories penetration minimum 94 %
at 28 days
- Chloride ion diffusion
- Tear resistance 7.3 kN/mm2
Taywood Engineering Laboratories
- Crack bridgeability 1.5 mm
- Reduction in chloride ion penetration
BS 1881: Part 124 - Adhesion minimum 1.0
N/mm2
- Tear resistance
ASTM D624 - Reduction in water absorption minimum 82
(measured against a control % at 28 days
- Crack bridgeability concrete sample) when tested at a
BRE method water-cement
2 Where test methods are not specified, the procedure ratio 0.5
for establishing compliance with the specification
requirements shall be agreed with the Engineer. 5.11.3 Construction Requirements
5.11.3.1 General
5.11.2 Materials
1 The Contractor shall adhere strictly to the
5.11.2.1 General
manufacturer's recommendations regarding the use,
1 The coating system shall consist of a penetrating, storage, application and safety rules in respect of the
reactive primer and an acrylic topcoat system to minimize approved materials.
ingress of acidic gases, chlorides and water. 2 During storage, mixing and application, the
Contractor shall comply with the health and safety and
5.11.2.2 Primer
environmental protection recommendations of the
1 The primer shall be a low viscosity silane-siloxane manufacturer and governing authorities.
acrylic blend dissolved in a penetrating organic carrier.
5.11.3.2 Inspection of Concrete
The primer shall have the capability to penetrate and
produce a chemically bound hydrophobic barrier to 1 The Contractor shall not proceed with the surface
prevent the passage of chloride and sulfate ions. The finish or making good of concrete surfaces until he has
primer shall also be film forming to condition and stabilize received the Engineer’s permission to do so and he shall
the substrate prior to the application of the topcoat. The not apply cement slurry or mortar or any other coating to
primer shall be applied in full accordance with the the concrete surfaces from which the formwork has been
manufacturer’s instructions. struck until the Engineer has inspected and approved the
concrete.

♦ 5-66 ♦
5.11.3.3 Surface Preparation
1 Before application, all surfaces must be dry and free
from oil, grease, loose particles, decayed matter, moss or
algae growth and general curing compounds.
2 All such contamination and laitance must be
removed by the use of sweep sand blasting, high pressure
jetting or equivalent mechanical means.
3 Before proceeding to apply the protective coatings,
all surfaces which are not to be coated, but which may be
affected by the application of the coating shall be fully
masked.
4 Blow holes and areas of pitting shall be made good
with a one part modified cementitious material and
allowed to cure in accordance with the manufacturer’s
recommendations. In particular, the application shall be in
accordance with the manufacturer’s recommendations,
with respect to the maximum application thickness.
5.11.3.4 Approval Prior to Coating Application
1 The Engineer’s approval must be obtained prior to
applying the coating system in the works. Before giving
the approval, the Engineer will need to be satisfied as to
the following:
i. All construction work in the immediate vicinity of
the structure to be coated has been completed.
ii. The surface preparation of the structure has
been completed.
iii. The whole of the structure can be coated in a
continuous operation.
iv. Adequate measures have been taken to protect
the property of third parties, including vehicles,
from coating splatters.
v. The weather conditions accord with the coating
manufacturer’s directions for coating application.
5.11.3.5 Application
1 The exposed concrete surfaces shall be conditioned
by the application of the penetrating hydrophobic primer.
The primer shall be allowed to dry in accordance with the
manufacturer’s requirements.
2 The Contractor shall then apply two coats of the
pigmented topcoat in accordance with the manufacturer’s
instructions. The finished coating shall be pinhole free.
The color and finish shall be agreed with the Engineer.
3 The coating shall be applied by spray, roller or brush
to achieve a finish acceptable to the Engineer.
5.11.4 Method of Measurement, Basis of
Payment and Bill of Quantities
1 No separate measurement is made for protective
coating and no items are included in the Bill of Quantities
for direct payment. The work is considered as subsidiary
work, the cost of which will be deemed to be included in
the unit rates for the relevant BOQ Items for concrete
described and measured for payment under the provisions
of Section 5.1 “Concrete Materials and Mixes”.
5.12 Bridge Load Testing
5.12.1 Description
1 All bridges shall be load tested unless otherwise
agreed by the Engineer.
2 The aim of the testing is not to measure the actual
factor of safety of the bridge but intended to verify the
design and construction of the bridge under normal
loading conditions. Measurements are, accordingly, meant
to give an order of magnitude and fine precision is not
required.
3 The date of conducting the load testing shall be fixed
by the Engineer and shall be at least 90 days after all
concrete structural elements are constructed. Load testing
may be carried out before or after opening the bridge for
traffic.
4 If the bridge is open to traffic before being load
tested, the Engineer may impose restrictions on highway
loading over the bridge until testing is satisfactorily
completed, such as banning the passage of heavy traffic
loading of the order of the Oman Special Truck, or any
other measures.
5 Load testing comprises:
i. Application of load as described in Clause 5.12.2.
ii. Detailed visual inspection before, during and
after the testing as described in Clause 5.12.3.
iii. Measurement of deflections and other quantities
as described in Clause 5.12.4.
6 If the Works include a number of similar bridges
testing may be limited as follows:
i. At least one bridge shall be tested for all the
tests specified in this Sub-Section.
ii. The other bridges may be subject only to testing
by static loads.
iii. The latter test may be further simplified by
reducing the number of tests. It is
recommended, however, to measure the
deflection at, at least, one point per span.
7 Bridges are considered similar when their
superstructures have the same design, same material
specifications and are constructed by the same contractor.
8 If the results of the load testing are unfavorable, and
leave some doubt as to the ability of the bridge to
withstand the loads it is supposed to carry, more elaborate
testing shall be considered, including non-destructive full-
scale testing.
5.12.2 Load Application
5.12.2.1 Composition of Applied Load
1 The applied load shall consist of a number of loaded
trucks sufficient to satisfy the requirements of this Clause.
2 The loads shall be applied in two types of tests: by
static loads and moving loads.
3 The loads shall be restricted to the carriageways and
no load is applied on the sidewalks.
♦ 5-67 ♦
4 The stipulations of this Clause are set as minimum
requirements. In particular cases, when there is doubt
about the quality of the bridge, the Engineer may impose
more severe loads.
5.12.2.2 Testing by Static Load
3 After the completion of testing, a detailed visual
inspection shall also be carried out to all accessible parts
of the bridge.
4 Visual inspections shall be complemented with
photographs.

1 The loaded trucks shall be positioned on the 5.12.4 Measurements

carriageways and grouped together in the longitudinal
and transverse directions such that the straining actions
they develop are between 67 and 75 percent of the
maximum straining actions developed by all unfactored
loading cases.
2 The straining actions considered do not include any
load factor magnification.
3 The test starts by loading the bearings before
applying any loads on the spans in order to activate
immediately the bearing deformation, and then the
measured deflections will be significant.
4 Bridges with simply supported spans shall have the
loads applied independently on every span.
5 Bridges with continuous spans shall have the loads
applied independently on every span, then on every two
adjacent spans, with no loads on the others, to obtain the
maximum hogging (negative) bending moment over the
support. The latter loading shall be repeated for every
intermediate support.
6 The loads shall be applied gradually, one truck at a
time. After each load increment, there will be a
consolidation period of one hour, or as instructed by the
Engineer, during which no load is applied. Measurements
shall be recorded at the beginning and end of the loading
increment period and of the consolidation period.
7 Removal of the load shall also be done by equal
decrements with a consolidation period of one hour, or as
instructed by the Engineer. Measurements shall be
recorded at the beginning and end of the loading
decrement period and of the consolidation period.
5.12.2.3 Testing by Moving Load
1 Out of the loaded trucks used for static loading of the
bridge, a number shall be selected equal to the number of
traffic lanes. The selection shall consider those with the
heaviest axle loads. The trucks shall travel in one direction
along the whole length of the bridge at the largest
possible speed with due consideration of safety measures.
2 Measurements shall be recorded during passage of
the moving load.
1 As a minimum the deflections of each span and the
deformation of the bearings shall be measured.
2 Measurement of the deflections will be carried out by
topographic equipment or by deflectometers installed on
scaffoldings independent of the structure as instructed by
the Engineer.
3 If specified or instructed by the Engineer, additional
measurements may be requested such as the strains in
the steel reinforcement and/or concrete surface.
4 Digital recording of measurements by electronic
means is encouraged for important structures, particularly
for strain measurements and moving load testing. It may
be imposed by instruction of the Engineer.
5 The ambient temperature shall be recorded with
every measurement made.
6 A report shall be prepared by the Contractor
including the testing procedure, measurements,
interpretation and conclusion.
5.12.5 Method of Measurement
1 Load testing of the bridge shall be measured by the
number of bridges tested as instructed by the Engineer,
inclusive of all static load cases and moving load testing
and inclusive of the provision and operation of the loaded
trucks, measuring and recording equipment of any type
and their calibration, platforms and scaffoldings for visual
inspection and of accepted testing report.
5.12.6 Basis of Payment
1 The amount of completed and accepted work
measured as provided for above shall be paid at the unit
rates in the Bill of Quantities. These rates shall be full
compensation for the provision of labor, materials,
equipment, tools and other items necessary for proper
completion of the Work.
5.12.7 Items in the Bill of Quantities
i Bridge loading test nr.

5.12.3 Visual Inspection

1 All parts of the structure that can be accessed by
platforms, scaffoldings or other means shall be visually
inspected jointly by the Engineer and the Contractor
before start of testing.
2 During static load testing, visual inspection shall also
be carried out in the consolidation periods at reasonable
at intervals.

♦ 5-68 ♦