DURABILITY OF CONCRETE STRUCTURES

CHAPTER - 13

Sample Specification For - Formwork &

Reinforcement For Concrete
13.1 The specification given in the chapter are sample specification only and
shall not be used as such. Fresh specifications should be drawn for each
work depending upon the type and requirements of structure, environmental
conditions prevailing etc.

13.2.0 Sample specification for Formwork for inclusion in tender document.

13.2.1 Scope : This Part contains requirements which, where relevant to

this Contract, shall apply to formwork and reinforcement for concrete.

13.2.2 Reference standards : Unless otherwise specified, formwork and

reinforcement shall comply with the relevant IS Codes and in absence of IS
Codes ASTM/BS/DIN Codes.

13.2.3 Submissions by the contractor : Submissions required from the

contractor in relation to formwork and reinforcement shall include the
following where relevant:

• calculations for design of formwork

• drawings of formwork
• manufacturers data on accessories and mechanical couplings.
• manufacturers test certificates for each delivery of steel
reinforcement and prestressing steel tendons, as required by the
relevant quality standard
• details of proposed welding procedures and welders qualifications
• test certificates for mechanical couplings
• samples of steel reinforcement for testing.

13.2.4 Formwork

13.2.4.1. Materials for formwork : Formwork shall be constructed of timber,

sheet metal or other approved material. Ties shall be of the rod and cone or
other approved proprietary type. Ties for use in water-retaining structures
300mm thick or less shall incorporate a diaphragm not less than 50mm dia.
welded to the mid point of the tie, designed to prevent water passing along the
tie.

13.2.4.2 Design and layout of formwork : The design and construction of

formwork shall take account of safety and of the surface finish required. The
formwork shall be sufficiently rigid and tight to prevent loss of grout or mortar
from the fresh concrete or the formation of fins or other blemishes on the

concrete. The contractor shall appoint a Falsework Coordinator to carry out

work on behalf of the contractor.
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Formwork and its supports shall maintain their correct shapes and
profile so that the final concrete structure is within the limits of the specified
dimensional tolerances. They shall be designed to withstand the worst
combination of self-weight, reinforcement weight, wet concrete weight,
concrete pressure, construction and weather loads, together with all incidental
dynamic effects caused by placing, vibrating and compacting the concrete.
Formwork shall not be tied to or supported by the reinforcement.

On formwork to external faces which will be permanently exposed, all

horizontal and vertical formwork joints shall be so arranged that joint lines will
form a uniform pattern on the face of the concrete. Where the contractor
proposes to make up the formwork from standard sized manufactured
formwork panels, the size of such panels shall be approved by the Engineer
before they are used in the construction of the works. The finished
appearance of the entire elevation of the structure and adjoining structures
shall be considered when planning the pattern of joint lines caused by
formwork and by construction joints to ensure continuity of horizontal and
vertical lines.

13.2.4.3 Erection of formwork : Faces of formwork in contact with concrete

shall be free from adhering foreign matter, projecting nails and the like, splits
or other defects, and all formwork shall be clean and free from water, dirt, or
other foreign matter.

Except where the surface is subsequently to be rendered, formwork in

contact with the concrete shall be treated with a suitable non-staining release
agent before the steel is fixed or the concrete placed to prevent the concrete
adhering to it. Care shall be taken to prevent the release agent from touching
the reinforcement or concrete at construction joints. Surface retarding agents
shall not be used unless specified.

All exposed exterior angles on the finished concrete of 90 degree or

less shall be given 20mm by 20mm chamfers.

Formwork shall be provided for the top surfaces of sloping work where
the slope exceeds fifteen degrees from the horizontal unless otherwise
specified, and shall be anchored so that the concrete can be properly
compacted and to prevent flotation. Care shall be taken to prevent air being
trapped.

Where ties are built into the concrete for the purpose of supporting
formwork, part of any such supports shall be capable of removal so that no
part remaining embedded in the concrete shall be within 50mm of the surface
in the case of reinforced concrete or 150mm in the case of unreinforced
concrete. Holes left after removal of such supports shall be neatly filled with
epoxy or well rammed dry-pack mortar.
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Openings for inspection of the inside of the formwork, for the removal
of water used for washing down and for placing concrete shall be provided
and so formed as to be easily closed before or during placing concrete.
Before placing concrete all bolts, pipes or conduits or any other fixtures which
are to be built in shall be fixed in their correct positions, and cores and other
devices for forming holes shall be held fast by fixing to the formwork or
otherwise. Holes shall not be cut in any concrete without prior approval of the
Engineer.

13.2.4.4 Removal of formwork : Formwork shall be so designed as to

permit easy removal without resorting to hammering or levering against the
surface of the concrete.

The periods of time elapsing between the placing of the concrete and the
striking of the formwork shall have regard to the following factors:

i concrete strength;
ii stresses in the concrete during construction including for precast
units any disturbance and handling stresses;
iii curing;
iv subsequent surface treatment requirements:
v the presence of re-entrant angles requiring early removal of
formwork to avoid thermal cracking.

The time shall be as approved by the Engineer after consideration of

the loads likely to be imposed on the concrete and shall in any case be not
less than the periods specified in the Code.

Notwithstanding the foregoing the Contractor shall he held responsible

for any damage arising from removal of formwork before the structure is
capable of carrying its own weight and any incidental loading.

13.2.5 Defects in formed surfaces : Workmanship in formwork and

concreting shall be such that concrete shall normally require no making good,
surfaces being perfectly compacted and smooth.

Any minor surface blemishes shall be repaired to the satisfaction of

the Engineer immediately after removal of formwork. Remedial measures may
include, but shall not be limited to, the following:

Holes left by formwork supports shall be thoroughly cleaned out

to remove all loose material and the sides shall be roughened, if
necessary, to ensure a satisfactory bond. They shall then be filled with
epoxy or dry-pack mortar.

Fins, pinhole bubbles, surface discolouration and minor defects

may be rubbed down with sacking and cement immediately the
formwork is removed.
 DURABILITY OF CONCRETE STRUCTURES

Abrupt and gradual irregularities may be rubbed down with

carborundum and water after the concrete has been fully cured.

Small defects and minor honeycombing shall be chipped out

perpendicular to the face of the concrete to a depth of at least 25mm
and filled with epoxy or dry-pack mortar.

Where deeper or more extensive defects occur, the Contractor

shall obtain the approval of the Engineer to the methods of repair
proposed which may include, but shall not be limited to, cutting out to a
depth of at least 25mm with a diamond saw to give a regular edge to
the repair and further chipping to form a hole with undercut edges to
sound concrete or to a total depth of 75mm whichever is the greater.
If reinforcing steel is exposed the concrete shall be removed to a depth
of 25mm beyond the back side of the reinforcement. Steel mesh
reinforcement shall then be sprung into the hole, which shall be refilled
with concrete or suitable epoxy resin mortar.

The contractor shall thoroughly clean any hole or defective area

that is to be filled and break out any loose, broken or cracked concrete
or aggregate.

Where the remedial work is to be carried out using dry-pack

mortar or concrete, the concrete surrounding the hole shall be
thoroughly soaked after which the surfaces shall be dried so as to
leave a small amount of free water on the surface. The surface shall
then be dusted lightly with cement by means of a small dry brush until
the whole surface that will come into contact with the dry-pack mortar
has been covered and darkened by absorption of the free water by the
cement. Any dry cement in the hole shall be removed.

Dry-pack mortar shall be mixed and placed as specified.

Where concrete is to be used, the concrete mix shall be as

approved by the Engineer and shall be placed and compacted into the
hole, using formwork as necessary.

Where the remedial work is to be carried out using epoxy resin

mortar or other special material, the surface of the cleaned hole shall
be prepared and primed and the repair material placed, compacted and
finished in accordance with the manufacturer's instructions.

Where, in the opinion of the Engineer the defect is too extensive

to permit satisfactory repair, either from the point of view of structural
integrity or appearance, the concrete containing the defect shall be
broken out and replaced.
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13.2.6 Dry-pack mortar : Dry-pack mortar for filling holes and repairing
surface blemishes shall be made from one part by weight of cement and three
parts fine aggregate passing a 1mm sieve. The colour of the mortar shall
match that of the surrounding concrete. The mortar shall be mixed with just
sufficient water to make the materials stick together when being moulded in
the hands.

The dry-pack material shall be placed and packed in layers having a

thickness not greater than 15mm. The compaction shall be carried out by
use of hardwood stick and hammer and shall extend over the full area of the
layer, particular care being taken to compact the dry-pack against the sides of
the hole. After compaction the surface of each layer shall be scratched before
further loose material is added. Holes shall not be over filled and the surface
shall be finished by laying a hardwood block against the dry-pack fill and
striking the block several times. Steel finishing tools shall not be used and
water shall not be added to facilitate finishing.

13.3.0 Sample specification for reinforcement :

13.3.1 Steel for reinforcement shall confirm to any one of the following:

i Mild steel and medium tensile steel bars conforming to IS:432 (Pt.I)
ii High strength deformed steel bars confirming to IS: 1786
iii Structural steel confirming to grade A and B of IS:2062

13.3.2 Accessories : Spacer blocks for maintaining concrete cover to

reinforcement shall be of concrete of the same strength, durability, porosity
and appearance as the in-situ concrete. They shall be cast in the form of a
truncated cone or pyramid with the smaller face having a minimum dimension
of 50mm.

Chairs and other accessories for maintaining reinforcement and

prestressing tendons in position shall be of steel. Binding wire shall be No.16
gauge (1.60mm) galvanised iron wire free from corrosion.

13.3.3 Cutting and bending of reinforcement : Bars shall be bent in

accordance with the provisions of IS Code. Bending shall be carried out
slowly, at a steady even pressure, without jerk or impact. The temperature of
the steel at the time of bending shall be not less than 5 0C. If necessary
reinforcement maybe warmed to a temperature not exceeding 100 0C to
facilitate bending, after which it shall be allowed to cool slowly in air. Hot bars
shall not be cooled by quenching with water. Bent bars shall not be re-bent
unless permitted by the Engineer.

13.3.4 Storage of reinforcing bars and steel fabric : The contractor shall
stack separately and label different types of reinforcement for positive
identification. Reinforcement shall not be subjected to mechanical damage
or shock loading prior to embedment.
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Steel reinforcing bars shall be kept clean and shall be free from pitting,
loose rust, mill scale, oil, grease, earth, paint, or any other material which may
impair the bond between the concrete and the reinforcement .

All materials shall be stored under cover on wooden or concrete

supports at least 150mm clear of the ground.

13.3.5 Fixing of reinforcement : All reinforcement shall be securely and

accurately fixed in positions shown on the Drawings using approved concrete
spacers, spacer blocks or chairs. These shall be not more than 1m apart and
at closer intervals if necessary. All intersections of bars shall be secured with
soft iron wire, the ends being turned into the body of the concrete. The
contractor shall ensure that all reinforcement is maintained in correct position
at all times, particular care being taken during placing of the concrete.

Concrete cover to reinforcement shall be as detailed on the drawings

and shall be maintained in accordance with the tolerance. Top
reinforcement in slabs shall be maintained in position by chairs, sized and
spaced to provide adequate support and fixity for the reinforcement.

No part of the reinforcement shall be used to support formwork,

access ways, working platforms or placing equipment, or for the conducting of
an electric current other than as pole of an earthing system during the site
welding of reinforcement.

13.3.6 Welding of reinforcement : The contractor shall not weld any

reinforcement on site except where this has been specified in the contract or
is permitted by the Design Engineer in writing who will examine the weldable
quality of steel.

Reinforcement which is to be welded shall be welded in accordance

with the recommendations of the manufacturer. The contractor shall
demonstrate by bend and tensile tests on specimen welds that the strength of
the parent metal is not reduced and that the weld possesses a strength not
less than that specified for the parent metal. The welding procedure
established by successful test welds shall be maintained and no departure
from this procedure shall be permitted.

Following the establishment of a satisfactory welding procedure, each

welder to be employed on the works shall carry out welder performance
qualification tests on reinforcing bars of the same metal and size as those on
the works.

Details of welding procedure and welder qualification tests shall be

submitted for the approval of the Engineer before welding of reinforcement.
Tack or other welds in positions other than those shown on the drawings shall
not be permitted, unless specifically authorised by the Engineer.
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13.3.7 Mechanical couplings : Mechanical couplings shall be used where

shown on the Drawings, and shall be obtained from an approved
manufacturer. The contractor shall demonstrate by tensile tests on sample
joints of all sizes required for use in the works,

Equipment used for making the couplings shall be supplied by the

coupling manufacturer and shall be operated in accordance with the
manufacturer's instructions.

13.3.8 Drilled and grouted reinforcement bars : Reinforcing bars for

drilling and grouting into existing concrete shall be deformed high yield steel
bars. The depth of the holes shall be at least 45 times the diameter of the bar
to be grouted except where otherwise approved by the Engineer. The
diameter of the hole shall be 7mm larger than the nominal bar diameter.

The hole shall be thoroughly cleaned and the surface wetted before
introducing 1:3 cement/sand grout into the hole. The bar shall be pushed into
the grout and held in position to maintain a uniform annulus of grout all around
the bar until the grout has set. The grouted bars shall not be disturbed for a
period of at least 7 days before building them in concrete.

13.3.9 Coated reinforcement : Where shown on the Drawing the reinforcing

bars shall be coated. The coating of the reinforcement shall comply with the
specifications. Repairs to minor damage to coatings shall be carried out in
accordance with the recommendations of the coating manufacturer. Copies
of the manufacturer's test certificate shall be provided to the Engineer.

13.3.10 Testing of samples of reinforcement : The Engineer may

require to witness routine testing of steel reinforcement at the manufacturer’s
works. When required by the Engineer the contractor shall take samples
from reinforcement delivered to site and shall arrange for the samples to be
tested by an approved testing agency. Test certificates from that agency shall
be submitted to the Engineer.

13. 3.11 Bar schedules : Any bar schedules the contractor shall be entirely
responsible for checking the correctness of such schedules before arranging
for the supply cutting and bending of steel reinforcement. In the event of any
information being apparently missing or incorrect in the drawing the contractor
shall promptly refer to the Engineer.

13.4.0 Sample specifications for prestressing steel and sheathing :

13.4.1 The Prestressing steel shall be any of the following.

i Plain hard - drawn steel wire conforming to IS: 1785 )Part I).
ii Indented wire for prestressed concrete conforming to IS: 6003.
iii Uncoated stress - relieved strand conforming to IS: 6006.
iv Uncoated stress - relieved low relaxation seven - ply stand for
prestressed concrete conforming to IS: 14268.
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13.4.2 Specification for sheathing: Sheathing Unless otherwise

specified, the material shall be Cold Rolled Cold Annealed (CRCA) mild steel
intended for mechanical treatment and surface refining but not for quench
hardening of tempering.

The material shall normally be bright finished, however, in case of use

in aggressive environment, galvanised or lead coated mild steel strips may be
adopted.

Sheathings shall be preferably machine manufactured and of large

enough bore to allow being easily threaded on to the cable or bar in long
lengths.

The thickness of the strips shall be a minimum of 0.24 mm + 0.02 mm

for internal diameter of sheathing ducts upto and including 51mm and shall be
0.30 mm + 0.02 mm for diameters beyond 51 mm and upto 91 mm.

The sheaths shall be of such strength as not to be dented or deformed

during handling or concreting. They shall conform to the requirements as per
tests specified below and a test certificate to this effect shall be furnished by
the manufacturer.

13.4.2.1 Tests on sheathing ducts : All tests specified below shall be

carried out on the same sample in the order given below. At least 3 samples
for one lot supply (not exceeding 7000 m length) shall be tested. The tests are
applicable for sheathing transported to site in straight lengths where the
prestressing tendon is threaded inside the sheathing prior to concreting.
These tests are not applicable for sheathing ducts placed in position without
threading of prestressing cable prior to concreting.

i) Workability test : A test sample of 1100 mm long is soldered to a

fixed base plate with a soft solder (Fig. 13.1). The sample is then
bent to a radius of 1800mm alternately on either side to complete
3 cycles. Thereafter, the sealing joints will be visually inspected to
verify that no failure or opening has taken place.

ii) Transverse load rating test : The test ensures that stiffness of
the sheathing is sufficient to prevent permanent distortion during
site handling. The sample is placed on a horizontal support 500
mm long so that the sample is supported at all points of outward
corrugations. A load as specified in Table-13.1 is applied
gradually in increments at the centre of the supported portion
through a circular contact surface of 12mm dia. Couplers shall
be placed so that the load is applied approximately at the centre
of two corrugations (Fig. 13.2). The sample is considered
acceptable if the permanent deformation is less than 5 percent.
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Table 13.1
TRANSVERSE LOAD RATING TEST

Diameter of sheathing Load

(mm) (N)
25-35 250
35-45 400
45-55 500
55-65 600
65-75 700
75-85 800
85-90 1000

iii) Tension load test : The test specimen is subjected to a tensile

load. The hollow core is filled with a wooden circular piece having
a diameter of 95 percent of the inner diameter of the sample to
ensure circular profile during test loading (Fig. 13.3). A coupler is
screwed on and the sample is loaded in increments, till load
specified in Table-13.2. If no deformation of the joints nor
slippage of couplers is noticed, the test shall be considered
satisfactory.

Table 13.2

TENSION LOAD TEST

Diameter of sheathing Load

(mm) (N)
25-35 300
35-45 500
45-55 800
55-65 1100
65-75 1400
75-85 1600
85-90 1800

iv) Water loss test : The sample is sealed at one end. It is then
filled with water. After the other end is also sealed as shown in
Fig. B-4, it is connected to a system capable of applying a
pressure of 0.05 N/mm2 and kept constant for 5 minutes. The
sample is acceptable if the loss of water does not exceed 1.5
percent of the volume.

For working out the volume, another sample 500mm long

is sealed at one end and the column of hollow space is arrived at
DURABILITY OF CONCRETE STRUCTURES

by pouring water from a measuring cylinder. The computation of

relative profile volume is worked out as follows:

L = length of the specimen

φ = nominal internal diameter of the sheathing
Va = pre-measured quantity of water in a measuring cylinder
Vb = balance quantity of water left in the cylinder after
completely filling of the test sample.

Actual volume Vp = Va - Vb

Vp − πφ 2 L / 4
Relative profile volume cm2 / cm
πφL

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DURABILITY OF CONCRETE STRUCTURES