SGGP Reference No

P0116-TAK-P01-0073-02
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Revision Change Notices

Rev Location Of Changes Brief Description Of Change

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CONTENTS

1.  INTRODUCTION ....................................................................................................................... 5 

1.1  Purpose .................................................................................................................................. 5 
1.2  Abbreviations ......................................................................................................................... 5 
1.3  Official Name and Location .................................................................................................... 6 
FIGURE 1: LOCATION OF AL-KHALIJ POWER .............................................................................. 6 
1.4  Contract Number .................................................................................................................... 6 
2.  STANDARDS AND CODES ...................................................................................................... 6 
2.1  American Concrete Institute (ACI) ......................................................................................... 6 
2.2  American Society for Testing and Materials (ASTM) ............................................................. 7 
2.3  American Welding Society (AWS) .......................................................................................... 8 
2.4  Equivalent British Standard .................................................................................................... 8 
2.5  National Oil Corporation (NOC) ............................................................................................. 8 
2.6  Supplementary reference ....................................................................................................... 8 
3.  CONSTRUCTION MATERIALS ................................................................................................. 8 
3.1  Portland Cement .................................................................................................................... 8 
3.2  Aggregate............................................................................................................................... 8 
3.3  Water...................................................................................................................................... 9 
3.4  Admixtures ............................................................................................................................. 9 
3.5  Reinforcement ...................................................................................................................... 10 
3.6  Formwork ............................................................................................................................. 11 
3.7  Anchor Bolts ......................................................................................................................... 11 
4.  STORAGE OF MATERIALS .................................................................................................... 12 
5.  CONCRETE QUALITY ............................................................................................................ 12 
5.1  Strength and Proportioning .................................................................................................. 12 
5.2  Consistency.......................................................................................................................... 13 
5.3  Concrete Tests ..................................................................................................................... 13 
6.  MIXING AND PLACING CONCRETE ...................................................................................... 14 
6.1  Equipment ............................................................................................................................ 14 
6.2  Placing ................................................................................................................................. 15 
6.3  Consolidation ....................................................................................................................... 15 
6.4  Hot-Weather Requirements ................................................................................................. 15 
6.5  Cold-Weather Requirements ................................................................................................ 15 
7.  REINFORCEMENT PLACEMENT ........................................................................................... 16 
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7.1  Welding ................................................................................................................................ 16 

7.2  Placement ............................................................................................................................ 16 
8.  JOINTS .................................................................................................................................... 17 
8.1  Construction Joints............................................................................................................... 17 
8.2  Expansion Joints .................................................................................................................. 17 
8.3  Water Bars ........................................................................................................................... 17 
9.  EMBEDDED ITEMS ................................................................................................................. 18 
10.  FINISHES ................................................................................................................................ 18 
10.1  Surface Finishes .................................................................................................................. 18 
10.2  Slabs .................................................................................................................................... 18 
10.3  Surface Repairs ................................................................................................................... 19 
11.  CURING ................................................................................................................................... 19 
12.  GROUTING OF STRUCTURES AND EQUIPMENT ............................................................... 19 
13.  EXECUTION ............................................................................................................................ 20 

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1. INTRODUCTION
General Electrical Company of Libya (GECOL) awarded a contract to Sirt Gulf for Gas
Projects Company (SGGP) to design and construct 4.9 km of new 24" gas pipeline to
Alkhalij Power Station. The new pipeline will tie-in to the existing 34" Brega-Misurata
Coastal Gas Network Pipeline by a barred reduced tee using the cold-cut method at
approximately kilometre 346.8 of the pipeline. The new pipeline will transfer
317.7MMSCFD of gas to Alkhalij Power Plant from the 34” Coastal Gas Network Pipeline
to a new metering station. The project is of strategic importance to Libya and has high
levels of attention from the Government of National Accord, GECOL, and NOC.

SGGP has subcontracted the engineering work of the project to Taknia Libyan
Engineering Company (TLEC). The TLEC engineering scope covers the engineering
activities for the construction of a 24” pipeline, together with a custody metering station,
gas filtration, vent stack, condensate recovery tank and control room. The battery limit is
from and including the tie-in point at the 34” Coastal Gas Pipeline up to the emergency
shutdown valve HV001 inlet flange face upstream of existing Filter Separators (9-FGM-
MF-001 A/B/C) at the Alkhalij Power Plant.

TLEC scope shall cover all FEED and detailed engineering for the 24” pipeline which
includes, preparing all drawings, calculations, data sheets, specifications, bills of
materials and material requisitions.

Taknia Engineers will work closely with SGGP and GECOL representatives throughout
the project to ensure good and efficient communication at all times and a clear, mutual
understanding of the development and progress of the project. Sirte Oil Company (SOC)
will be the ultimate owner and operator of the new pipeline and its facilities. All project
documents has to be approved by SOC.

1.1 Purpose
This Specification defines the materials, strength, mixing, placing, finishing, curing, and
testing of reinforced structural concrete, anchor bolts and embedded items.

Requirements called for on the drawings shall govern over the provisions of this
Specification.

1.2 Abbreviations
Company name abbreviations are used in this procedure as follows:

CLIENT General Electricity Company of Libya (GECOL)

CONTRACTOR/
Sirt Gulf for Gas Projects Company (SGGP)
COMPANY
SUBCONTRACTOR Taknia Libya Engineering Company (TLEC)

OWNER Sirte Oil Company (SOC)

FEED Front End Engineering Design
FEED and Detailed Engineering for EPC Installation of a
PROJECT
24" Gas Transmission Pipeline to Al-Khalij Power Station
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1.3 Official Name and Location

The official name of the Project is:

“FEED and Detailed Engineering for EPC Installation of a 24" Gas Transmission Pipeline
to Al-Khalij Power Station”

The execution centre for engineering activities is Taknia Libya Engineering Company’s
office in Tripoli.

The Project Construction Sites is located in Sirte Gulf in Libya, adjacent to Al-Khalij
Power Station, approximately 20Km west of Sirte city. SeeFigure 1.

Figure 1: Location of Al-Khalij Power

1.4 Contract Number

The TLEC Contract Number is SGGP-9464

2. STANDARDS AND CODES

All concrete design, construction, testing, and acceptance shall conform to the
requirements of the latest edition of the following codes and standards except as
otherwise provided in this specification:

2.1 American Concrete Institute (ACI)

ACI 211.1 Recommended Practice for Selecting Proportions for Normal,

Heavyweight, and Mass Concrete

ACI 216 Recommended Practice for Determining the Fire Resistance

of Concrete and Masonry Construction Assemblies.

ACI 301 Specifications for Structural Concrete.

ACI 304 Recommended Practice for Measuring, Mixing, Transporting and

Placing Concrete

ACI 305 Recommended Practice for Hot Weather Concreting

ACI 308 Recommended Practice for Curing Concrete

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ACI 309 Recommended Practice for Consolidation of Concrete

ACI 315 Recommended Practice for Details and Detailing of Concrete

Reinforcement.

ACI 318 Building Code Requirements for Structural Concrete

ACI 347 Recommended Practice for Concrete Form Work

2.2 American Society for Testing and Materials (ASTM)

ASTM A185 Standard Specification for Welded Steel Wire Fabric for Concrete
Reinforcement

ASTM A497 Standard Specification for Welded Deformed Steel Wire Fabric for
Concrete Reinforcement

ASTM A615 Standard Specification for Deformed Billet-Steel Bars for Concrete
Reinforcement

ASTM C31 Standard Method of Making and Curing Concrete Test Specimens in
the Field

ASTM C33 Standard Specification for Concrete Aggregates

ASTM C39 Standard Method of Test for Compressive Strength of Cylindrical

Concrete Specimens

ASTM C94 Standard Specification for Ready-Mixed Concrete

ASTM C109 Standard Method of Test for Compressive Strength of Hydraulic

Cement Mortars

ASTM C90 Standard Specification for Load Bearing Concrete Masonry Units

ASTM C140 Standard Method for Sampling and Testing Concrete Masonry Units

ASTM C143 Standard Method of Test for Slump of Portland Cement & Concrete

ASTM C150 Standard Specification for Portland Cement

ASTM C171 Standard Specification for Sheet Materials for Curing Concrete

ASTM C172 Standard Method of Sampling Fresh Concrete

ASTM C192 Standard Method of Making and Curing Concrete Test Specimens in
the Laboratory

ASTM C260 Standard Specification for Air-Entraining Admixtures for Concrete

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ASTM A307 Standard Specification for Carbon Steel Externally Threaded Standard
Fasteners

ASTM C309 Standard Specification for Liquid Membrane-Forming Compounds for

Curing Concrete

ASTM A325 Standard Specification for High-Strength Bolts for Structural Steel
Joints

ASTM C494 Standard Specification for Chemical Admixtures for Concrete

ASTMD1557 Moisture-Density Relations of Soils Used 10-Lb Rammer and 18-in

Drop

2.3 American Welding Society (AWS)

AWS D1.1 Reinforcing Steel Welding Code

2.4 Equivalent British Standard

B.S. 1881 Testing Concrete

2.5 National Oil Corporation (NOC)

GES Q.04 Concrete Structures Specification

2.6 Supplementary reference

IGR-080318-1 Soil Investigation Report

SGGP-9464-00-CI-SP-1002 Specification for Site Earthworks

3. CONSTRUCTION MATERIALS

3.1 Portland Cement

Cement shall conform to the requirements of “Standard Specifications for Portland

Cement”, (ASTM Type II or V) conforming to ASTM C150 or B.S.12. Cement for
superstructure concrete shall be ordinary Portland cement (ASTM Type I). All cement
shall be certified by the Manufacturer as complying with the requirements of the above
specification. The Contractor shall supply the Client (or his representative) with the
Manufacturer's test certificates for each batch of cement for approval. Any cement, which
may have deteriorated, or set shall be removed immediately from the site.

3.2 Aggregate

Aggregate shall conform to the requirements of “Standard Specification for Concrete

Aggregates, ASTM C33.
Fine aggregate shall be natural sand having clean, hard, durable uncoated grains free
of chemicals, dust organic matter, or other injurious materials. Fine aggregate shall be
graded within the following limits:

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PERCENTAGE
SIEVE SIZE
PASSING, BY WEIGHT
(9.5 mm) 100
No. 4 (4.75 mm) 95 to 100
No. 8 (2.38 mm) 80 to 100
No. 16 (1.18 mm) 50 to 85
No. 30 (0.60 mm) 25 to 60
No. 50 (0.30 mm) 10 to 30
No. 100 (0.150 mm) 2 to 10

Fineness modulus limits - 2.3 minimum; 3.1 maximum

Clay content - 3 percent maximum by weight

Coarse aggregate shall be washed gravel or crushed stone having clean, hard, strong
and durable particles free of chemicals, coatings of clay, or other fine materials that affect
hydration and bond of the cement paste. Coarse aggregate shall be graded within the
following limits:

SIEVE SIZE PERCENTAGE PASSING - BY WEIGHT

25 mm Max aggregate 20 mm Max aggregate

size Size
25.0 mm 95 to 100 100
19.0 mm -- 90 to 100
12.5 mm 25 to 60 --
9.5 mm -- 20 to 55
No. 4 ( 4.75 mm) 0 to 10 0 to 10
No. 8 ( 2.36 mm) 0 to 5 0 to 5

Clay content - 5 percent maximum by weight.

Nominal maximum size aggregate shall not be larger than 20 mm in diameter.

3.3 Water

Mixing water shall be fresh, clean and free from oil, acid, alkalis, salt, organic materials
or other substances that may be deleterious to concrete or steel. Potable water shall be
suitable for use in mixing concrete.

3.4 Admixtures

Admixtures shall be used only when required and permitted by the Client and shall
conform to the following applicable ASTM specifications:

Air-Entraining Admixtures: “Standard Specification for Air-Entraining Admixtures for

Concrete”, ASTM C260.

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Water Reducing, Retarding, and Accelerating Admixtures: “Standard Specification for

Chemical Admixtures for Concrete”, ASTM C494.

Calcium chloride shall not be used as an admixture.

3.5 Reinforcement

3.5.1 Reinforcing Steel

Reinforcing steel material, fabrication, and placing tolerances shall be in accordance with
“Specifications for Structural Concrete for Buildings”, ACI 301. Splices in reinforcement
shall be made only as permitted on the design drawings.

Reinforcing bars shall conform to the requirements of “Standard Specification for

Deformed and plain Billet-Steel Bars for Concrete Reinforcement”, ASTM A615. All
reinforcing bars shall be deformed, Grade 60 unless otherwise noted on the drawings.

Welded wire fabric shall conform to “Standard Specification for Welded Steel Wire Fabric
for Concrete Reinforcement”, ASTM A185, for plain wire, and “Standard Specification for
Welded Deformed Steel Wire Fabric for Concrete Reinforcement", ASTM A497, for
deformed wire.

The Contractor shall furnish the Client with copies of Manufacturer's test certificates for
all reinforcement that he will be requested to supply.

3.5.2 Fabricating Tolerances

Reinforcing steel may be bent at the job site or shop fabricated before delivery. Bends
shall be made around a pin having a diameter not less than the following:

BAR DESIGNATION PIN DIAMETER

#3, #4 and #5 4 bar diameters

stirrups and ties 6 bar diameters

#3 through #8 8 bar diameters

#9, #10 and #11 10 bar diameters

#14 and #18

All bars shall be cold bent

Fabrication tolerances shall meet the following requirements:

Sheared length ± 25 mm

Depth of truss bars ± 12 mm

Overall dimension of stirrups, ± 12 mm

ties and spirals

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All other bends ± 25 mm

3.6 Formwork

3.6.1 Forms

Forms for concrete work shall be so constructed that the finished concrete will conform
to the shapes, lines, grades, and dimensions indicated on the drawings. Forms shall be
sufficiently tight to prevent the loss of mortar. Forms shall be properly shored, braced,
and supported to maintain the desired position and shape during and after placing
concrete. Formwork shall be in accordance with “Recommended Practice for Concrete
Formwork”, ACI 347.

Forms shall be smooth plywood or metal and shall be treated before installation with non-
staining oil or other suitable agent to prevent adhesion of the concrete to the forms.

Temporary openings shall be provided at the base of column and wall forms for adjusting
reinforcement and inspection. Openings shall be sealed before placing the concrete.

Form ties shall be factory-fabricated, removable or snap-off metal ties of approved

design, fixed or adjustable in length, and shall be free of devices that will leave a hole
larger than 25mm in diameter in the surface of the concrete. The portion of the tie
remaining in the concrete after the removal of exterior parts shall not project beyond the
surface of the concrete and shall be at least 12.5mm from any surface exposed to view
in the finished work. The resulting void shall be filled with cement mortar.

Forms may be removed as soon as the concrete has hardened sufficiently to resist
damage from removal operations. In no case shall the supporting forms be removed until
the members have acquired sufficient strength to safely support their weight and any
construction live loads. Forms shall be removed in such a manner as to ensure the
complete safety of the structure in accordance with ACI 347 R “Removal of forms and
supports’’

3.6.2 Mould Oil

Mould coating shall be of oil or other suitable approved material of such a nature that it
shall not stain the concrete or injure it by chemical action nor is absorbed by the timber.
It is to be slow drying and not liable to neither congeal nor be affected by rain or the water
used for cleaning the shutters. It shall be insoluble in water and not adversely affected by
climatic conditions or temperature.

3.7 Anchor Bolts

All anchor bolts to be carbon steel in accordance with ASTM A307 and A325 and all
threaded rod to be in accordance with ASTM A36 and A325.

Threaded rod with properties meeting A325 may be obtained by the use of appropriate
steel (such as AISI C1040 or C4140), quenched and tempered after fabrication.

Threads to be UNC thread class 2A

Acceptable equivalent European standards are as follows:

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Grade 4.6 Black Bolts and Nuts to B.S.4190, as well as grade 8.8 high strength bolts.

Threads to be isometric coarse pitch series. Class of fit 6H/6g to B.S.3643 Pt. 2

Washers to be black normal diameter (form 4) to B.S.4320

All bolts to be supplied complete with sleeves, heavy hexagonal nuts and washers as
shown on the drawings.

All bolts are to be clearly marked for easy identification.

All threads to be greased with nuts and washers attached to bolts to avoid loss.

Corrosion Allowance - Anchor bolts shall be subject to a corrosion allowance of 3.0mm

to the throat diameter giving an overall reduction of 6.0mm to the diameter. For design,
the net throat diameter shall be determined and 6.0mm added prior to selecting the
minimum bolt diameter

4. STORAGE OF MATERIALS

 Cements shall be stored in weather tight buildings, bins, or silos that exclude
moisture and contaminants.
 Aggregates shall be stored and used in a manner to prevent segregation of
individual aggregates, as well as to prevent mixing of the coarse and fine
aggregates.
 Admixtures shall be stored in such a manner as to avoid contamination,
evaporation, or damage. Liquid admixtures shall be protected from freezing and
from temperature changes that adversely affect their characteristics.
 Reinforcement shall be stored on site in racks or on supports, which will keep it off
the ground in such a manner as to provide easy identification of separate bars, to
avoid distortion and to prevent contamination and corrosion.
 Anchor bolts to be adequately packed in packing cases to avoid loss or damage
during transit or storage on site.

Materials that have deteriorated or been contaminated shall not be used.

5. CONCRETE QUALITY

5.1 Strength and Proportioning

Concrete shall have the following minimum 28-day compressive strengths, unless
otherwise specified on the drawings.

The sampling of freshly mixed concrete shall be to ASTM C172

Cylinder making shall be to ASTM C31/C31M

Slump testing shall be to BS 1881: Part 102

A minimum of three different proportions of cement, aggregate and water, using the
same materials that will be used during concrete work, shall be developed for each grade
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of concrete and submitted by the Contractor to the Client for approval. The concrete mix
design must be approved in writing by the Client prior to start of concrete work. Any
proposed change in mix design during the concrete work must also be approved by the
Client. The mix design shall be in accordance with “Recommended Practice for Selecting
Proportions for Normal and Heavyweight Concrete”, ACI 211.1 - Maximum acceptable
water/cement ratio to be 0.55.

Laboratory test specimens shall be required and shall be made in accordance with
“Standard Method of Making and Curing Concrete Test Specimens in the Laboratory”,
ASTM C 192. A minimum of nine (9) test specimens, three (3) for each of the above mix
designs shall be tested at 28 days. These test results shall be used to establish a graph
(giving the relationship between the cement content and compressive strength) based on
three points each representing the average results of a minimum of three cylinders tested
at 28 days. The acceptable average compressive strength F'cr shall be at least 15 N/mm²
greater than the specified concrete strength F'c. As strength test data becomes available
during the construction stage, the amount by which the value of F'cr exceeds the specified
strength F'c may be reduced using the standard deviation calculated from the actual Job
test data.(minimum 60 test specimens) as approved by the Client.

The Contractor shall bear all costs incurred in preparing and testing specimens or in
obtaining historical data.

5.2 Consistency

Proportions of ingredients for concrete shall be established to provide adequate

workability and proper consistency to permit concrete to be worked into the corners of
forms and around reinforcement. Neither void areas, segregation of ingredients, nor
collection of excess free water on the surfaces shall be permitted.

The consistency of concrete shall be measured by the slump test as specified by the
“Standard Method of Test for Slump of Portland Cement Concrete”, ASTM C143. All
concrete to have a slump of 70mm ± 20 mm.

5.3 Concrete Tests

During the concreting process, test specimens shall be taken in accordance with
“Standard Method of Sampling Fresh Concrete”, ASTM C172. Test specimens shall be
taken by the Contractor under the direct supervision of the Inspector. The Inspector shall
instruct the Contractor when test specimens shall be taken and from which batch of
concrete. Test specimens shall be taken at point of concrete placement. Test specimens
shall be moulded and cured in accordance with either 'Standard Method of Making and
Curing Concrete Test Specimens in the Field', ASTM C31, or 'Concrete Testing',
B.S.1881

The Contractor shall arrange for transportation and testing of specimens. Testing shall
be in accordance with either “Standard Method of Test for Compressive Strength of
Cylindrical Concrete Specimens”, ASTM C39, or 'Concrete Testing' B.S.1881.Tests shall
be conducted at the Contractor's field laboratory, approved and witnessed by the
Inspector, and three copies of the test results shall be furnished to the Client within seven
days after testing. The

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Contractor shall bear all costs incurred in taking, preparing, transporting and testing
specimens.

MINIMUM NUMBER OF TESTS FOR EACH

CONCRETE MIX DESIGN PLACED IN ANY ONE DAY
QUALITY 7-day 28-day Total
Strength Strength Strength
Tests Tests Tests

First 40 m3 or less 1 3 4
Next 40 m3 or less
1 3 4

Each Successive
1 3 4
40 m3 or less

Strength tests shall be taken according to Table 8.1 as a minimum. Additional test
specimens may be taken during the concreting process at the Inspector’s discretion and
included in determining the strength level.

The strength level of the concrete will be considered satisfactory so long as the average
of all tests made at 28-days equals or exceeds the specified strength, and no individual
strength test falls below the specified strength by more than 3.5N/mm². The specimens
tested at 7-days are for information purposes only.

If the strength level of the tests fails to meet the specified strength, the Contractor shall
stop all concreting until corrective measures are taken to ensure adequate concrete
strength. Additional tests of the structures or foundations constructed with under strength
concrete shall be made at the Contractor’s expense. These tests may be compressive
tests of cored samples or load tests of the structures as directed by the Client. Completed
concrete work that fails to meet the requirements of this specification may be accepted
or rejected by the Client. Completed concrete work that is rejected by the Client shall be
removed and replaced at the Contractor’s expense. Accepted work which falls below
specification will be subject to reduced payment.

6. MIXING AND PLACING CONCRETE

6.1 Equipment

All equipment for mixing and transporting the concrete shall be in good mechanical
condition, clean, and of adequate capacity to perform the concrete work. For job-mixed
concrete, mixing shall be done in a batch mixer of approved type. The mixer shall operate
at a speed recommended by the manufacturer, and mixing shall continue for at least 1½
minutes after all materials are in the drum. Ready-mixed concrete shall be mixed and
delivered in accordance with the requirements set forth in “Standard Specification for
Ready-Mixed Concrete”, ASTM C94.

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6.2 Placing

Placing of concrete shall be in accordance with “Recommended Practice for Measuring,

Mixing, Transporting and Placing Concrete”, ACI 304. Concrete shall be conveyed from
the mixer to the place of final deposit by methods that will prevent the segregation or loss
of ingredients. Concrete shall be deposited as nearly as possible in its final position to
avoid segregation due to re handling or flowing. Placing shall be carried on at a rate that
ensures the concrete is at all times plastic and flows readily into the corners of the forms
and the spaces between the reinforcing bars. Concrete that has partially hardened or
been contaminated by foreign materials shall not be used.

After concreting has started, it shall be carried on as a continuous operation until

placement of an entire structure or subsection is completed. Freshly mixed concrete
shall not be placed adjacent to or above concrete that has been allowed to stiffen or
harden, thus forming a cold joint. Successive placements of concrete shall be tied
together by deep spading, Roding, or vibration. Construction joint locations shall be as
shown on the drawings.

6.3 Consolidation

All concrete shall be thoroughly consolidated during placement and shall be worked
around reinforcement and embedded items, and into the corners of the forms.
Mechanical vibrators shall be used to achieve consolidation of concrete. Consolidation
of concrete shall be in accordance with “Recommended Practice for Consolidation of
Concrete”, ACI 309.

6.4 Hot-Weather Requirements

Special procedures shall be employed when concreting operations are performed during
periods of high air temperature and/or low relative humidity. Hot weather concreting shall
be in accordance with “Recommended Practice for Hot Weather Concreting”, ACI 305.

Concrete temperature prior to placement shall not exceed 90o F (32o C). Concrete
temperatures may be reduced by concreting at night, sprinkling or cooling the aggregate,
sprinkling sub grades and surrounding areas, avoiding hot cement, and using cold mixing
water and/or crushed ice.

The surface temperature of reinforcement at concrete placement should be as low as

possible. If it is too hot to hold then the temperature shall be reduced by either sprinkling
the reinforcement with water or keeping it out of direct sunlight for at least the previous
24 hours.

6.5 Cold-Weather Requirements

When temperatures of 40o F (4o C) or lower occur during the mixing and placing of
concrete and during early curing, concreting may proceed only if provisions of
“Recommended Practice for Cold Weather Concreting”, ACI 306, are followed.

Adequate equipment shall be provided for heating materials and protecting the concrete
during curing. All concrete materials, reinforcement, forms, and the ground with which
the concrete comes in contact shall be free from frost and/or ice.

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7. REINFORCEMENT PLACEMENT

7.1 Welding

The splicing of reinforcing bars by welding is not permitted.

7.2 Placement

Reinforcing steel shall be placed accurately in the positions shown on the drawings and
firmly held in place before and during the placing of the concrete by means of built-in
concrete blocks, metallic supports, spacer bars, wires, or other suitable devices. The
method used shall be adequate to insure against displacement during construction and
to keep the steel at the proper distance from the forms. Bar supports and spacers should
be sufficient in number and size to properly support the reinforcing steel, even when
subject to construction loads. The use of rocks, wood blocks, or other unapproved
objects to support the steel shall not be permitted. Chairs on the ground shall be
adequate to prevent settling. Bars shall be tied at all intersections by 18-guage (1.2 mm)
or heavier annealed tie wire. Twisted ends of tie wire shall project away from exterior
concrete surfaces. Laying reinforcement on the bottom and lifting it into place during the
pouring of the concrete shall not be permitted.

At the time concrete is placed, steel reinforcement shall be free from loose rust and scale,
oil, grease, dry concrete, mud or other coatings that would reduce or destroy bond.

Reinforcing steel partially embedded in concrete shall not be field bent except as shown
on the drawings.

Minimum protective concrete covering for reinforcement shall be as follows:

Concrete cast against ground 75 mm

Formed surfaces exposed to weather or in contact with ground

#6 bars and greater 50 mm

#5 bars and smaller 40 mm

Concrete not exposed to weather or not in contact with ground

Slabs, wall, joists 20 mm

Beam stirrups and column

ties or spirals 40 mm

Bars shall be placed to the following tolerances:

Clear distance to formed surfaces 6 mm

Minimum clear spacing between bars db (diameter of bar)

but not less than 25mm

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Top bars in slabs and beams:

Members 200 mm deep or less 6 mm

Members over 200 mm 12 mm

but less than 610 mm

Members over 610 mm Deep 25 mm

Bars may be moved as necessary to avoid interference with other reinforcing steel,
conduits, or embedded items. If bars are moved more than one diameter, or more than
the above tolerances, the resulting arrangement shall be approved by the Consultant.

These placing tolerances shall not allow reduction of the minimum covering for
reinforcement as given above.

8. JOINTS

8.1 Construction Joints

Construction joint locations and details shall only be made as shown on the drawings.
Additional joints, if required, shall be approved by the Client. Joints shall be perpendicular
to the main reinforcement.

All reinforcing shall be continuous through joints. Longitudinal keys at least 40mm deep
shall be provided in all joints in walls and between walls and slabs or footings.

The shuttering for a construction joint shall be prepared and ready at the commencement
of the days concreting. The shuttering for joints through which reinforcement passes shall
be so devised as to prevent undue leakage of concrete. After striking shuttering at the
joint, any concrete which has flowed passed the stop shall be removed. The face of the
concrete shall be well scrabbled and all laitance and loose material removed.

Immediately prior to resumption of concreting the face of the joint shall be soaked with
water and covered with a thin layer of sand/cement mortar.

8.2 Expansion Joints

The location and details of expansion joints shall be as shown on the drawings, and shall
be constructed of fibre expansion material and extending through the slab. Mastic or
polysulphide sealant shall be as indicated on the drawings.

8.3 Water Bars

Water bars shall be of natural or synthetic rubber or extruded high grade un-plasticised
polyvinyl chloride. Joints in rubber water stops shall be vulcanised or sleeve jointed, and
in uPVC. water stops, the joints shall be welded.

The material, design, and location of water stops in joints shall be approved by the
Consultant.
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Each piece of pre moulded water stop shall be of the maximum practical length.

Joints in the water stop at intersections and at ends of pieces shall be made in the manner
most appropriate to the material being used. Joints shall develop effective water
tightness fully equal to that of the continuous water stop material, shall permanently
develop not less than 50 per cent of the mechanical strength of the parent section, and
shall permanently retain their flexibility.

9. EMBEDDED ITEMS

Anchor bolts, water stops sleeves, and other items embedded in concrete shall be
properly located and secured to the forms. Anchor bolts shall be suspended from
templates rigidly attached to the forms in a manner that prevents bolts from being
dislocated during placement of concrete.

10. FINISHES

10.1 Surface Finishes

Unless otherwise noted on the drawings, all concrete surfaces not exposed to public view
shall be left with the finish imparted to it by the forms. Objectionable irregularities shall
be removed and voids pointed up.

Unless otherwise noted on the drawings, all concrete formed surfaces exposed to public
view shall be rubbed with a carborundum stone after the forms are removed and while
concrete is green to remove objectionable irregularities and form marks.

This finish is obtained by the use of properly designed formwork of closely jointed wrought
boards.

All outside corners of exposed concrete shall be chamfered 25 mm.

Exposed horizontal surfaces shall be wood floated to depress coarse aggregate and steel
trowelled to a smooth, even surface free from defects. Concealed horizontal surfaces,
such as the top of footings, shall be screed to the proper elevation.

10.2 Slabs

Exterior slab surfaces shall be laid to the elevations shown on the drawings, floated with
metal or wood floats and then broom finished to a non-skid texture. Slabs shall be finished
true to ±3 mm in 3.0 meters.

Interior slab surfaces shall be finished as shown on the drawings. Where the finish is not
designated, the following finishes shall be used as applicable:

Scratch finishfor surfaces intended to receive a bonded Cement application.

Float finish for surfaces intended to receive roofing waterproofing membrane Trowelled
finish for surfaces intended as walking surfaces, and to receive floor coverings.

Broom finish for sidewalks, ramps and industrial buildings finishes shall be as defined in
ACI 301.
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Steel trowelling of concrete should be delayed as long as possible so that water and fine
material are not worked to the surface. Excessive trowelling while concrete is soft and
plastic results in surface having less wear-resistance and may cause crazing. Spreading
dry cement on a wet surface to absorb excess water shall not be permitted.

10.3 Surface Repairs

All honeycombed areas shall be cut back to solid concrete, with the edges cut as straight
as possible and at right angles to the surface or slightly undercut. The opening thus
formed shall be filled with concrete of the same strength as specified for the section of
work in which the fault occurs. When excessively deep and numerous honeycombs occur
in a portion of the work, the Client shall direct corrective measures to provide a safe and
satisfactory structure.

All projections shall be cut away and depressions, air holes, and other roughness shall
be pointed up with one part cement to one part sand mixture as soon as the forms are
removed.

11. CURING

All concrete shall be maintained above 50o F (10o C) and protected from moisture loss
for not less than seven days after placing in accordance with the requirements of
“Standard Practice for Curing Concrete”, ACI Committee 308. This protection shall begin
immediately after the concrete has taken an initial set or the surface has been finished.
Curing shall be accomplished by one or a combination of the following methods:

 Covering unformed surfaces with two layers of fabric mats or 75 mm of sand. Both
shall be kept continually wet.
 Forms shall be kept wetted while in place and if removed before 7-days, curing
shall be continued as for unformed surfaces.

Concrete surface shall be sealed using liquid membrane curing compound or plastic film.
Liquid compounds shall comply with the requirements of “Standard Specification for
Liquid Membrane-Forming Compounds for Curing Concrete”, ASTM C309. Plastic film
shall conform to the requirements of “Standard Specification for Sheet Materials for
Curing Concrete”, ASTM C171.

12. GROUTING OF STRUCTURES AND EQUIPMENT

Grout shall be used under all base plates of equipment, machines and structures, where
uniform bearing surface is required for the transfer of loads into the foundation. Normal
Portland cement mortar shall have the following composition:

Sand 1.0 m3

Cement 500 Kg

Water/Cement ratio 0.40

Plasticizers as required to obtain a workable grout

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Thickness larger than 25 mm or filling for pockets shall be provided adding fine gravel
(size up to 10 mm) to sand.

Grout shall have a minimum compressive strength of 40 N/mm2 (ASTM C 109) at 28

days.

Anchoring works for pumps base plates and frames, equipment and heavy vibrating
machinery, such as reciprocating and centrifugal compressors, shall be carried out with
non-shrinking grout. Non-shrinking grout, generally factory mixed, shall be prepared in
accordance with the recommendations of product vendor.

13. EXECUTION

Surface shall be clean by concrete residue and any foreign material that adversely affects
the adhesion of bedding to the concrete, such as oil or grease. In addition, surface
preparation shall include chipping and washing of foundation top. The bottom of all
equipment, column bases and anchor bolts shall be aligned and levelled in its final
position and maintained in that position during grouting, by means of shims levelling
screws, levelling nuts or other approved levelling devices.

Where equipment Manufacturer's drawings define a grout material and grouting

procedures, said material and procedures shall be followed. When any cement-based
grouts are used, concrete surfaces shall be kept moist with water 24 hours prior to placing
of grout. Excess surface water shall be removed just prior to grouting.

Mixture shall be prepared dry and water shall be added in such a rate to ensure the use
of mortar within one hour. Mix shall not be reworked with water.

Filling shall be performed introducing mortar or concrete from the edge of from suitable
hole with approved equipment. In such case mixture shall be tamped to achieve adequate
filling of raids and the required level along the whole perimeter of base.

Pouring must be carried out in a short a time as possible, without any interruption, using
a mix of constant composition and water content, taking care to make the mortar and
concrete flow towards holes through which air could escape, so as to avoid any pockets
which could form discontinuities in the casting upon subsequent curing. When the grout
is sufficiently well cured, the edges must be refaced by chipping off the protecting parts
and remaking the visible surfaces with cement grout. After curing, 20 mm chamfer with
the side inclined at 45, shall be formed along the edge of the base.

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