SUB-DIVISION 03100

CONCRETE

CONTENTS

PART 1 - GENERAL 1.1 1.2 1.3 1.4 1.5 Scope Codes of Practice Standards Quality Assurance Submittals

PART 2 - MATERIALS 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 Aggregates Fine Aggregates Coarse Aggregates Combined Aggregates Cement Water Admixtures Reinforcement Accessories Formwork Material Arrangement of Information

PART 3 - WORKMANSHIP 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 Insitu Concrete Mixes, Casting and Curing Formwork for Insitu Concrete Construction Striking Reinforcement for Insitu Concrete Fixing Designed Joints in Insitu Concrete Worked Finishes to In Situ Concrete Preparing Concrete Surfaces for Painting or Protective Coating Deviations and Tolerances

PART 4 - DESCRIPTION OF THE WORK 4.1 General

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PROJECT SPECIFICATION SUB-DIVISION 03100

03100 - CONCRETE

PART 1 - GENERAL 1.1 Scope

This sub-division contains the specification of materials and workmanship for concrete to be used supplied, placed, cured and finished for plain and reinforced in-situ, precast and prestressed concrete. It also deals with the installation of items to be embedded in concrete, but supplied in the work of other Sub-divisions. The Contractors attention is brought to the fact that the building structure has been completed based on the original design of the tower being residential. The design has been adjusted to be a Hotel and Serviced Apartments. The new design requires major demolition/alterations of the existing structural elements, namely in the Basement floors, Ground, Mezzanine floors and Level 48, 55 and 56, to meet the Hotel operational requirements. Works include demolition of existing reinforced slab to form openings for new lift shafts, service shafts and staircase voids by saw cutting and trimming back reinforced bars and making good sides of openings. Also, demolishing of existing reinforced concrete staircase including sloping slabs, steps and landings. Alterations shall include pouring concrete over existing concrete slabs to make up new levels including all necessary tying-in all rounds to existing concrete slab. Columns implantation, extending existing reinforced concrete walls and casting reinforced concrete slab to voids will be introduced to connect to existing structures.

1.2

Codes of Practice

To be read in conjunction with the Qatar Construction Specification, the Preliminaries and General Conditions

1.3

Standards

The British Standards referred to in this section are: BS 12: 1996: ENV 197-1 1992: BS 146: 1973: BS 812: BS 882, 1201: BS 1370:1979: BS 1881: BS 3148: 1980: BS 4027:1980: BS 5075:1982: BS 5328: 1981: BS 4461 BS 4466 BS 4483 BS 4486 BS 4550
September 2008

Ordinary and rapid-hardening Portland cement Fly Ash or Pulverized Fuel Ash Portland blast furnace cement Methods for sampling and testing mineral aggregates, sands and fillers Aggregates from natural sources for concrete Low heat Portland cement Method of testing concrete Tests for water for making concrete Sulphate resisting Portland cement Accelerating admixtures, retarding admixtures and water reducing admixtures Methods for specifying concrete including ready-mixed concrete Cold worked steel bars for the reinforcement of concrete. Bending dimensions and scheduling of reinforcement for concrete. Steel fabric for the reinforcement of concrete. Hot rolled and hot rolled and processed high tensile alloy steel bars for the prestressing of concrete. Methods of testing cements.
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BS 4887 BS 5075 BS 5328 BS 5835 BS 5896 BS 6073

Mortar plasticisers. Concrete admixtures. Methods of specifying concrete, including ready mixed concrete. Recommendations for testing of aggregates. Specification for high tensile steel wire for the prestressing of concrete. Precast concrete masonry units.

ASTM C 150 - 78a Sulphate resisting Portland cement. AASHTO T-277 : Testing Concrete

1.4

Quality Assurance A. Prior to commencement of concrete Work, submit samples of materials to the Engineer before sending them to the laboratories for testing in accordance with relevant Section, in order to establish the probability of the materials passing tests for specified requirements. Material testing to be carried out by an approved laboratory. Such samples shall be in sufficient amounts to enable tests to be carried out and shall be not less than the quantities stated below: 1. Cement: A mixed sample of equal quantities taken from at least one bag in every twenty, totalling 50 kgs, or 112 pounds, for every batch of cement delivered to the site. Fine aggregate and sand for mortar: 1 cubic foot for each mix of concrete or for each size of aggregate. Coarse aggregate: 1 cubic foot for each mix of concrete or for each size of aggregate. Reinforcing steel: Sufficient for 3 tensile tests and 3 cold-bend tests per 20 tonnes of bars or portions thereof, and for each different size of quality. Water: Sufficient samples of water used for washing aggregates, mixing of concrete, washing out forms, and curing of concrete. Tests shall be determined by the A.A.S.H.T.O. Specification T-26 Method of Test for Quality of Water to be used in Concrete. Accessories: Submit one sample for each type of the following items proposed for use: Form ties, support accessories for reinforcement, binding wire.

B.

2.

3.

4.

5.

6.

C.

After the Engineer is satisfied that the samples with their sources are truly representative samples and sufficient quantities of these materials are readily available for the completion of all concrete Work, then they shall be sent to the laboratories for testing in accordance with relevant Section. The Contractor shall supply and deliver to the laboratory all samples and have all laboratory tests made at his own expense. During construction, sample and test all concrete, aggregates, cement, and water as frequently as deemed necessary by the Engineer. Obtain samples in accordance with BS 1881; Part 1: 1970.

D.

E.

F.

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G.

Before concrete is placed, supply the Engineer with details of concrete mixes, aggregates, additives, and sources of supply. State where each concrete mix is to be used.

1.5

Submittals A. B. Product Data: For each type of product indicated. Design Mixtures: For each concrete mixture submit alternate design mixtures when characteristics of materials. Project conditions, weather, test results, or other circumstances warrant adjustments 1. Indicate amounts of mixing water to be withheld for later addition at Project site.

C.

Steel Reinforcement Shop Drawings: Placing drawings that detail fabrication, bending, and placement. Include bar sizes, lengths, material, grade, bar schedules, stirrup spacing, bent bar diagrams, bar arrangement, splices and laps, mechanical connections, tie spacing, hoop spacing, and supports for concrete reinforcement. Formwork Shop Drawings: Prepared by or under the supervision of a qualified professional engineer detailing fabrication, assembly, and support of formwork. Samples: For waterstops, vapor retarder, steel reinforcement. Welding certificates. Qualification Data: For Installer, manufacturer, testing agency. Material Test Reports: For the following, from a qualified testing agency, indicating compliance with requirements: 1. Aggregates: include service record data indicating absence of deleterious expansion of concrete due to alkali aggregate reactivity. Steel reinforcement bars: material test reports to BS 4449

D.

E. F. G. H.

2. I.

Material Certificates: For each of the following, signed by manufacturers: 1. 2. 3. 4. 5. 6. 7. 8. 9. Cementitious materials. Admixtures. Form materials and form release agents. Steel reinforcement and accessories. Fiber reinforcement. Waterstops. Curing compounds. Floor and slab treatments. Bonding agents.
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10. 11. 12. 13. 14. J.

Adhesives. Vapor retarders. Semi-rigid joint filler. Joint-filler strips. Repair materials.

Floor surface flatness and levelness measurements to determine compliance with specified tolerances. Field quality-control test and inspection reports Minutes of pre installation conference.

K. L.

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PART 2 - MATERIALS 2.1 Aggregates: A. Select and grade aggregates to produce a dense concrete, free from voids and of good workability, without requiring an excessive amount of water. All aggregates shall consist of tough, hard, durable, and uncoated particles. Be responsible for the processing of this material to meet the requirements of the Specification. Approval of aggregate quality and/or gradation shall not waive the responsibility of the Contractor to produce concrete to the strength specified. Store aggregates in such a manner as to prevent segregation and contamination or the admixture of foreign materials. Build up aggregate stockpiles, and remove, in layers not exceeding one meter in thickness, on hard and clean surfaces. Elevate the center of the storage area and slope gently to the sides in order to provide proper drainage of excess moisture. Aggregate which has become segregated or contaminated with foreign matter during storage or handling shall be rejected, removed and replaced with material of acceptable quality. Store aggregates in sufficient quantity to ensure that shortage is not the cause of interruption of concreting work at any time.

B.

C.

2.2

Fine Aggregates A. General: Conform to the requirements of BS 882, except where more stringent requirements are set out in this specification. Do not mix or store fine aggregates from different sources of supply in the same pile, nor use them alternately in the same class of construction or mix. Clay, silt, and dust, not to exceed 3% in natural sand or crushed gravel, nor 5% in crushed rock. At the Engineers sole discretion these limits may be waived provided that the chloride and sulphate limits are not exceeded, and the proportion of clay, silt and dust does not exceeded 2% of the total of fine and coarse aggregates.

B.

2.3

Coarse Aggregates A. Generally: 1. Conform to the requirements of BS 882 except where more stringent requirements are set out in this specification. Coarse aggregates shall not contain, harmful material, such as iron pyrites, coal, mica, laminated materials, or any materials which may attack the reinforcement in such a way or in sufficient quantity to affect adversely the strength or durability of the concrete.

2.

B.

Organic Matter: The total amount of organic matter shall not exceed 0.5% by weight of coarse aggregates/ Clay, Silt, and Dust: Not to exceed 1% in natural or crushed gravel, nor 3% in crushed rock.
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C.

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2.4

Combined Aggregates A. Approved fine and coarse aggregates in each batch of concrete shall be combined in proportion, as approved by the Engineer, according to test results giving the required compressive concrete strength as indicated on the drawings or in this specification. All in percent for clay, silt and dust (combined aggregates) shall not exceed 2% as defined in BS 812. Special combined aggregate gradation shall be sued for concrete members with reinforcement too close to permit proper placement and consolidation of the concrete. Change from one gradation to another shall not be made during the progress of the Work, unless approved by the Engineer. Such changes will be admitted only after satisfactory test results.

B.

2.5

Cement: A. Ordinary Portland Cement: Conform to the requirements of BS 12, ASTM C150 Type 1. Use only one brand and source of cement for throughout the Project. Sulphate-Resistant Cement: Confirm to the requirements of BS 4027. Cement shall be accepted in bulk only if a central mixing plant is used. Cement shall be delivered to the site in original sealed bags of 50 Kgs net or other containers of the manufacturer, in batches not exceeding 100 tonnes. The name and brand of manufacturer shall be plainly marked on bags or other containers. All bags or other containers shall be in good conditions at the time of inspection. Store all cement in suitable weatherproof building, which will protect the cement from dampness. The building shall be placed in locations approved by the Engineer. Provisions for storage shall be ample, and the consignments of cement, as received shall be separately stored in such a manner as to provide easy access for the identification and inspection of each consignment. Stored cement shall meet the test requirements at any time after storage should a retest be ordered by the Engineer. Cement shall be used in the order of delivery. Keep accurate records of the deliveries of cement and of its use in the Work. Provide copies of these records to the Engineer in such form as may be required.

B. C. D.

E.

F.

2.6

Water: A. Water for washing forms, for mixing of concrete, and for curing of concrete shall be fresh, clean, and substantially free of oil, acids, alkali, sewage, deleterious mineral or organic matter. Inorganic contamination shall not exceed the limits in Table 12 in C.I.R.I.A. Guide. It shall not contain any impurities in amounts sufficient to cause a change in the time of setting concrete compressive strength of mortar of more than 5 percent, compared to results obtained with distilled water. It shall not have a PH lower than 6. Water for curing concrete, in addition to the above requirements, shall not contain impurities in sufficient amount to cause discolouration of the concrete.
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B.

C. D.
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2.7

Admixtures A. Use admixtures to concrete only when approved by the Engineer in writing before use, and following trials as described. Do not use any admixtures which contain calcium chloride. The use of admixtures is to comply fully with manufacturers instructions and all admixtures are to be obtained from a single source when more than one is used. Each admixture is to be dispensed separately into the mix. Retarding agent, with or without water-reducing unction, shall comply with the requirements of BS 5075, Part 1. Standard plasticising agents shall comply with the requirements of BS 5075, Part 1 Super plasticising agents shall comply with the requirements of ASTM C494 (F and G). Carry out trials of any admixture proposed for use, before installing in the finished Work. Use the cements, aggregates, and water which are to be used in the specific Work.

B. C.

D.

E. F.

G.

2.8

Reinforcement A. All steel reinforcing bars shall comply with the requirements of BS 4449 (or ASTM A615), and steel fabric to BS 4483 Strengths are noted on the Drawings. Deformed bars to type 2 bond classification, as defined in BS 4449 (or ASTM A615). Subject to the written approval of the Engineer, steel manufactured to an equal internationally accepted standard may be accepted, but full, independent sampling and testing shall be carried out to confirm the quality. Should the tests prove unsatisfactory, then the reinforcement may not be used in the Work and shall be removed from the site immediately. Provide to the Engineer, manufacturers test certificates for all classes of reinforcement properly correlated to the material being supplied. Carry out testing at the rate of 3 sample for every 30% delivered to site. Binding wire shall be 16 swg soft pliable annealed steel wire complying with BS 4482, galvanized. Mechanical splices shall develop 125% of the yield strength of the connected bars. Reinforcement shall comply accurately with the drawings, regarding diameter, lengths, bending, placing, supports, and cover. Qualities and strengths are indicated on the Drawings. The Engineers review of bar lists and bending diagrams shall not relieve the Contractor of his responsibility for the correctness of such lists and diagrams. Any expenses incident to the revision of this material shall be borne by the Contractor.

B.

C.

D.

E. F.

H.

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I.

Fabrication: 1. Bars are to the accurately cut and bent to the shapes indicated on the Drawings, and the bending as a general rule, completed before the Steel is fixed in position. Bars are to be bent cold. Straight portions of bars must be true and bends must be kept from winding. Bending dimensions shall comply with BS 4466. The internal radius of bends shall in no case be less than three times the bar diameter for bars up to 20 mm diameter and four times for bars over 20 mm dia., except for mild steel stirrups, column ties, and wall shear bars which are to be bent to fit closely around the main bars with a radius of two times diameter. Reinforcement temporarily left projecting at joints shall not be sent without prior approval of the Engineer. All reinforcement shall be furnished in the full lengths indicated on the Drawings. Splicing of bars, except where shown on the Drawings, will not be permitted without the written approval of the Engineer. Splices shall be staggered as far as possible. Bars shall be bonded to the lightning protection system as detailed on drawings and specified in relevant section.

2. 3. 4.

5. 6.

7.

2.9

Accessories A. B. Comply with manufacturers instructions. Dovetail anchor slot: galvanized styro foam filled. The dovetail anchor slots to be discontinuous, 200 mm long at location of each anchor. Epoxy adhesive, BS 5442. Vapour barrier: 0.25 mm polyethylene, BS 4646: 1970 (1982) - high density, or BS 3012: 1970 (1982) - low density E. F. Waterproof building paper: BS 1521: 1980 Floor surface hardener: Non-metallic, natural gray colour (emery aggregate) and as per relevant section. Saw-cut joint filler, gray polysulphide, BS 4254: 1983, 3712 AND 5215. The Contractor is permitted to use local suppliers for providing ancillary material for Blockwork and plaster (like galvanized angle/stop beads, metal laths, control joint beads, strip mesh, dove and fishtail etc.) subject that products offered meet the requirements of the relevant British Standards. The Contractor is permitted to use local suppliers for providing miscellaneous chemical material (like admixtures, surface treatments, grouts, resin anchors, repair compounds and mortars, flooring products, membranes and sealants, waterstops, adhesives and timber treatment, etc.) subject that products offered meet the requirements of he relevant British standards.

C. D.

G. H.

I.

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2.10

Formwork Material A. Use formwork materials which are new at start of Work except that, for unexposed locations such as foundations, used materials may be substituted. Circular Sections where concrete is exposed in the finished structure: formwork from any approved manufacturer or produced by the Contractor, as long as the finish achieved is of the quality specified. Grooves, Reglets, and Chambers: Hardwood selected for straightness and accurately dressed to size 1 to 3 draw unless otherwise shown. Continuous saw-cut at back of strip. Form Tiles: As described below or equivalent as approved. 1. Ties to be threaded internal disconnecting type which leave no metal closer than the specified cover from concrete surface, and which are fitted with plastic cones and permanent end plugs. Depth of cone shall allow end of plastic plug to be set back 6mm from the face of the concrete. Plastic plugs to be same colour as the concrete.

B.

C.

D.

E.

Plastic Tape for Sealing Panel Joints: Bs 3924: 1978 or equal to approval of Engineer. Form Coating and Release Agent: Cement and Concrete Association, Type 5. Non-staining, colourless, mineral oil, free of Kerosene and compatible with the permanent finish coating of concrete surface.

F. G.

2.11

Arrangement of Information:

The different parts of insitu concrete construction are specified in separate sections as follows: E10 Insitu concrete mixes, casting and curing E20 Formwork E30 Reinforcement E 40 Designed joints E 41 Worked finishes to concrete E 42 Preparing concrete surfaces for painting or protective coating E 50 Deviation and Tolerances Clauses dealing with particular aspects of certain types of construction may thus be dispersed over several sections.

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PART 3 - WORKMANSHIP

3.1

Insitu Concrete Mixes, Casting and Curing

To be read with Preliminaries, General Conditions and Section E 05

3.1.1

Concrete Mixes:

Make concrete mixes having the appropriate strength grade to produce finished work as scheduled in this Clause and in the General Notes drawing or as otherwise directed. All aggregate to be stored under shade and kept cool and dry. Water temperature should not exceed 280 Celsius otherwise a cooling system should be introduced.

COMPLIANCE WITH BS 5328: Constituent materials, composition of mixes, production of concrete, information to be provided, sampling, testing and compliance to be in accordance with BS 5328 unless otherwise specified. READY-MIXED CONCRETE may be used provided that it is obtained from a plant which holds a current Certificate of Accreditation under the Quality Scheme for Ready-mixed Concrete. Each mix must be obtained from only one source unless otherwise approved. Confirm name and address of supplier(s) to the Engineer before any concrete is delivered. Retain all delivery notes for inspection.

3.1.2 Delivery Ticket To Provide: Name and number of ready-mixed concrete dept Serial number of ticket Date Truck number Name of purchaser Name and location of job Grade or mix of concrete including minimum cement content if specified. Workability Type of cement Nominal maximum size of aggregate Type name and quantity of admixtures, if included Quantity of concrete in cubic meters Time of loading Time of introduction of the mixing water or of cement if later than the loading time. Type of aggregate

3.1.2.1 Supplier to Provide: 1 cubic meter of each mix before it is required for use on site to allow contractor to carry out workability tests.

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3.1.3 -

Concrete for Piles, Mat Foundation, Whole Sub Structure and Slabs on Grade: Designed mix to BS 5328, the following grades shall be used: PILES: Grade 35 MAT FOUNDATION: Grade 35 COLUMNS IN BASEMENTS: Grade 60 CORE WALL: Grade 60 BASEMENT WALLS: Grade 35 BASEMENT SLABS, RAMPS: Grade 45 GROUND FLOOR SLAB & BEAMS: Grade 45 SLAB ON GRADE: Grade 35

Cement(s): ASTM Type II or OPC BS 12 (1996), DD ENV 197-1 (1995), CEM 1, CLASS 42.5 LOI not more than 3.0% Insoluble residue not more tan1.5% Sulphate (S03) not more than 3% Chloride not more than 0.10% Heat of Hydration not more than 325KJ/kg Specific Surface (Blaine) production target 280 m2/kg (range 270-290) Alkali (Na 20+0.658 K20) not more than 0.60%. Aggregate(s): to BS 882 and 1201- GABBRO Washed Sand Nominal maximum size of aggregate: 20 mm Minimum cement content: 380 kg/cu m except where replaced by appropriate pozzolanic material. Microsilica: use around 8% of the weight of cement to enhance concrete durability. Fly Ash or Pulverized Fuel Ash BS 12 (1996), ENV 197-1 1992 DD ENV 197-1 (1995) LOI not more thatn 3.0% (Production target 1.0%) Si 02 greater than 50% AL2 03 greater than 30% Ca0 not more that 5% S03 less than 0.5% Chlorides less than 0.10% Production target specific surface (Blaine) 300m2/kg Not more than 12% larger that 45 micron Maximum free-water/cement ratio: 0.40 Admixture : to the approval of the Engineer Corrosion inhibiting admixture: Batch concrete mix for piles, mat foundation and retaining wall with calcium nitrite based corrosion inhibitor, DCI-S Corrosion Inhibitor manufactured by Grace Construction Products, or equivalent approved, at a rate of 12.5 liters per m3. The calcium nitrite content of the admixture shall be 30% 2% by weight, and the admixture shall be specifically formulated at the manufacturing plant with component to neutralize set acceleration. The corrosion inhibitor must be based on an original 30% solution of calcium nitrite and not reformulated from powdered calcium nitrite. Provide test data to substantiate the performance of the submitted calcium nitrite inhibitor in concrete for a minimum period of 10 years. Make due allowance for the water content of DCI-S when calculating the free/water cement ratio (0.85 liters of water per liter of DCI-S).

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Plasticizers and super-plasticizers: Use strictly to manufacturers recommendations and prior approval by the Engineer. Admixtures containing calcium chloride: Do not use. Rate of sampling for compressive strength testing: one sample per 25 cu m but not less than one for each day of use, a sample is to consisting of three cubes.

3.1.4

Concrete for Above Ground Columns, Core Wall, Beams and Floor Slabs Designed mix to BS 5328, the following grades shall be used: COLUMNS UP TO FLOOR 35: Grade 60 COLUMNS ABOVE FLOOR 35: Grade 45 CORE WALL: Grade 60 FLOOR SLABS & BEAMS: Grade 45 STAIRS: Grade 45 Cement(s): OPC to BS 12 Aggregate(s): to BS 882, 1201- GABBRO Washed Sand Nominal maximum size of aggregate: 20 mm Minimum cement content: 380 kg/cu m Microsilica and Fly Ash or Pulverized Fuel Ash as detailed in clause 130 above. Maximum free-water/cement ratio: 0.40 Admixture: to the approval of the Engineer and as detailed in Clause 130 above. Rate of sampling for compressive strength testing: one sample per 25 cu m but not less than one for each day of use, a sample is to consisting of three cubes.

3.1.4.1 Mass Concrete Fill and Blinding Designed mix to BS 5328, Grade C15P Cement(s): SRPC to BS 4027 Aggregate(s): to BS 882, 1201 Nominal maximum size of aggregate: 20 mm Admixture: to the approval of the Engineer 3.1.5 Constituent Materials

3.1.5.1 Chloride Content of Mixes: The total chloride ion content of the constituents of each mix, expressed as a percentage by weight of cement (including G.G.B.F.S or PFA if used) in the mix, must not exceed the following: Concrete made with sulphate resisting Portland cement or supersulphated cement 0.15 Concrete made with ordinary Portland cement and containing embedded metal: 0.30

3.1.5.2 Sulphate Content of Mixes: The total sulphate content of the constituents of each mix, expressed as SO3, must not exceed 3.70% by weight of the cement in the mix. Submit certification and calculations demonstrating compliance.

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3.1.5.6 Testing of Cement/Test Certificate: Submit certificates and test results to Engineer's approval, test s to be made for 1. Fineness 2. Chemical composition 3. Compressive strength 4. Setting time 5. Soundness 3.1.5.7 Storage of Aggregates: Store on hard paved self-drained areas or in suitable hoppers or containers. Check by visual inspection each load before tipping and each batch before mixing for consistency of particle shape, accuracy of grading, segregation of particle sizes and cleanliness. Ensure consistency of moisture content of fine aggregate at time of batching, if necessary by allowing stockpiles to drain for not less than 16 hours before use.

3.1.5.8 Testing of Coarse & Fine Aggregates: Specify according to BS 882 & 81, submit test results regarding: Sieve analysis/grading, density, moisture content/absorption, chemical contents (Sulphate and Chloride contents), shell content, abrasion resistance, alkali-aggregate reaction etc. (refer also D20 item 750). Certificates must not be older than 4 weeks prior to making concrete. 3.1.5.9 Marine (Sea Dredged) Aggregates: Do not use. 3.1.6 Design and Mixing

3.1.6.1 Evidence of Suitability: For each designed mix, before making concrete for use in the works and whenever a change in the materials or mix proportions is proposed, submit and obtain approval of: Details of proposed quantities of each ingredient per cubic meter of compacted concrete and proposed workability. Either existing data or details of appropriate tests on trial mixes to show that the proposed constituent materials and method of manufacture will produce concrete of the required quality, which will not segregate or bleed and will be capable of being fully compacted. 3.1.6.2 Water Content Water content of concrete must be carefully controlled and adjusted to allow for moisture content of aggregates to give consistent quality and workability. Water shall be potable and shall not contain chemical impurities exceeding 2000 ppm. 3.1.6.3 Admixtures: Use only if specified or approved. Admixtures to satisfy requirements of BS 5077. Make trial mixes and in consultation with the Engineer adjust the dosage and/or mix proportions in order to give suitable properties in the fresh and hardened concrete.

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PROJECT SPECIFICATION SUB-DIVISION 03100

Do not use admixtures containing calcium chloride or proprietary admixtures containing more than 0.02% of equivalent or hydrous calcium chloride by weight of cement in the final mix. See Clause 130 above. 3.1.7 Testing/Certification of Concrete

3.1.7.1 Sampling Sampling for compressive strength testing must be one per 30 m3 concrete and not less than one for each day of placing concrete. 3.1.7.2 Complete Correlated Records Must be maintained for each mix type, including: Composition of the mixes tested, including any admixtures. All sampling and site tests. Identification marks or numbers of all specimens tested in the laboratory. The location of the part(s) of the structure represented by each sample. The location in the structure of the batch from which each sample is taken. 3.1.7.3 Testing Laboratory: Submit for the Engineer approval the laboratory, names of persons responsible for testing and testing materials. 3.1.7.4 Durability: Samples of concrete grade 35 and above to be tested at 28 days to ensure that the mix proportions achieve sufficient durability at 28 days. - Water absorption BS 1881 Part 122 - Water Penetration DIN 1048 - Rapid chloride Permeability AASHTO T277 - Initial Surface Absorption BS 1881 Part 208 less than 1.8% less then 10 mm less than 1500 Coulombs less than 0.15 ml/m2/sec

3.1.7.5 Failures: If a concrete sample fails to achieve specified criteria or to pass specified tests, inform the Engineer without delay and submit: Confirmation of the validity of the test results, and/or Proposals for further tests to assess the strength of the concrete in the structure, as set out in BS6089, and/or Proposals for rectification. Obtain approval of all such evidence and proposals before proceeding. The Engineer may issue instructions for the work to be stopped or delayed until reasons for the failure have been established; possible consequences assessed and appropriate preventative and remedial measures taken. 3.1.7.6 Concrete Rejected For non-compliance of mix to be cut out and replaced with complying concrete at contractors expense.

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3.1.8

Placing and Compacting

3.1.8.1 Obtain written permission from the Engineer for pouring any concrete and allow inspection of reinforcement and surfaces against which concrete will be palced. Agree with consultant the period of notice to be given. 3.1.8.2 Construction Joints: Carefully brush and spray surface while concrete is still green to remove surface laitance and expose aggregate finish to the Engineer satisfaction. Obtain approval for any alternative method. Surface to be clean and damp when fresh concrete is placed against it.

3.1.8.3 Cleaning: At time of placing ensure that all surfaces on which concrete is to be placed are clean, with no debris, tying wire clippings, fastenings or free water. 3.1.8.4 Transporting: During transport of concrete avoid contamination, segregation, loss of ingredients and excessive evaporation. 3.1.8.5 Placing: No concrete to be placed when weather temperature is 38o Celsius or more. Record time, date and location of all pours. OBTAIN Engineers approval before any pour Place concrete in position and sequences as indicated on the drawings, the specifications or as directed by the Engineer Place while sufficiently plastic for full compaction. Do not add water or re-temper mixes. Place in final position in one continuous operation up to construction joints. Avoid formation of cold joints. Do not discharge from an excessive height or through reinforcement or other obstructions in a way, which may cause uneven dispersal, segregation or loss of ingredients. Use suitable chutes or trunking to place concrete where necessary. Place in layers no thicker than can be effectively compacted with the equipment being used. Take appropriate measures specified hereinafter for casting thick concrete slabs more than 1000mm thick. See Clause E 10/860. Do not use vibrators to make concrete flow horizontally into position, except where necessary to achieve full compaction under void formers and cast in accessories and at vertical joints. Use appropriate admixture (e.g. superplasticiser) to place self-flowing and selfcompacting concrete in heavily reinforced sections.

3.1.8.6 Compacting: Fully compact concrete to full depth (until air bubbles cease to appear on the top surface), especially around reinforcement, cast-in accessories, into corners of formwork and at joints. Ensure amalgamation with previous batches, but do not damage adjacent partly hardened concrete. Use mechanical vibrators of not less than 10,000 oscillations per minute.
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3.1.8.7 Placing Concrete for Slabs on Grade: To be cast in long strips between expansion joints in alternate strips and to the approval of the Engineer. 3.1.9 Curing and Protection

3.1.9.1 Curing: Prevent surface evaporation from concrete throughout the period(s) specified below by: Retaining formwork in position and, if necessary, covering exposed surfaces immediately after striking and Covering top surfaces of fresh concrete immediately after completion of placing and compaction of each bay, removing covering only to permit any finishing operations and replacing immediately thereafter. Maintain detailed records of location and timing of casting of individual batches, of formwork and removal of coverings. Keep on site, available for inspection. 3.1.9.2 Coverings Coverings for curing may be suitable impervious sheet materials or a suitable curing compound with an efficiency of at least 75%, and: Must be effective in preventing evaporation of water from the concrete, particular attention being paid to sealing at edges and junctions. Must not disfigure permanently exposed surfaces. Must not affect the satisfactory bond of subsequent construction and finishes. Until the exposed top faces of fresh concrete are in a state suitable to receive sheets in direct contact or a sprayed curing compound as applicable, cover with waterproof sheeting held clear of the surface and well sealed against draughts at edges and junctions.

3.1.9.3 Curing Periods: Concrete surfaces shall be protected and kept moist by wetting hessian cover for a minimum period of 7 days or as directed be the Engineer. 3.1.9.4 Protection: Prevent damage to concrete, including: Surfaces generally: From site, indentation and physical damage. Surfaces to be exposed in the finished work: From dirt, rust marks and other disfiguration. Immature concrete: From thermal shock, physical shock, overloading, movement and vibration.

3.1.10 Concreting In Extreme Conditions Do not carry out concreting operation in the open during storms or heavy rains. Erect cover for protection of materials, plant and formwork. Take additional precautions to protect against strong wind, driving rains and dust. IN HOT WEATHER provide suitable means to avoid premature stiffening of concrete placed in contact with hot surfaces.
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Shield surfaces and reinforcement against which concrete is to be placed from direct rays of the sun. Take adequate measure against the detrimental effects of wind and low humidity in hot concreting conditions. Take necessary measures, as described below, when prevailing conditions are such that the concrete placing temperature might exceed 30oC. Insulate or paint white all concrete handling equipment. Shade forms, moulds and mixed concrete from sun light. Restrict transit time of concrete supply to a minimum, taking account of the use of admixture, etc.

(a) (b) (c)

(d) (e)

(f) (g)

Shade aggregate stockpiles, water tanks and pipes. Cool mix constituents and plant. Spray coarse aggregates with cold water. Carry out concreting operation at night when the ambient temperature is lower. Arrange adequate lighting at all points of mixing, transportation and placing of concrete to the satisfaction of the Engineer. Limit temperture of placed concrete by measures as described in Clause 860. Add crushed ice to mixing water to reduce concrete placing temperature.

3.1.11 Concreting of Thick Sections Take extra precautions when concreting section of 1000mm thickness or more, to limit the temperature difference between any two points within the section to about 30oC during the casting and curing period, so as to avoid cracking due to excessive thermal strains. The proposed precaution shall be to Engineers approval. Provide a method statement to include some or all of the following measures: Keep cement content to a minimum by use of a special designed mix. Use a low-heat cement in the designed mix. Provide an insulating layer on the exposed surfaces as part of the means of curing. Install special cooling methods including the incorporation of circulation pipes in the concrete section and circulate chilled water through them. Install at least two thermocouples inside the section, one near the middle, the other near the edge, to accurately record temperature. Place concrete in horizontal layers of about 500mm thickness to facilitate loss of heat from inside and also to achieve better compaction. Do not start water curing until inside concrete temperature dissipated sufficiently Do not keep concrete face more than 30 minutes before fresh concrete is deposit against it.

3.2

Formwork for Insitu Concrete

To be read in conjunction with the Qatar Construction Specification, the Preliminaries and General Conditions. 3.2.1 Generally/Preparation 3.2.1.1 Loadings: Design and construct formwork to withstand the worst combination of: Total weight of formwork, reinforcement and concrete.
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Construction loads including dynamic effects of placing, compacting and construction traffic. Wind loads. Assign responsibility of scaffolding, access or shoring to specialist erector to the approval of the Engineer.

3.2.1.2 Works below Ground: Vertical faces of strip footing, bases and slabs may be cast against faces of excavation, provided: Prior approval is obtained The faces are sufficiently accurate and stable Adequate measures are taken to prevent contamination of concrete Faces of walls must be cast against formwork 3.2.1.3 Under-Slab on Grade Polythene Damp Proof Membrane: Manufacturer and reference: Visqueen, (made by ICI) or similar approved. Thickness: 250 microns (minimum 1200 gauge) Lay membrane on a level blinding of concrete, not less than 50 mm thick, or as shown on drawings. Double lock welts all edges and hold down with adhesive tape. Adequately protect membrane from puncturing using sand cement screed and carefully repair any punctures which do occur. 3.3 3.3.1 Construction Accuracy:

Construct formwork accurately and robustly with adequate supports to produce finished concrete to the required dimensions. Formed surfaces must be free from twist and bow blow-holes and honeycombing (other than any required cambers). All intersections, lines and angles shall be square, plumb and true. 3.3.2 Joints in Forms:

Construct formwork, including joints in form linings and between forms and completed work, to prevent loss of grout, using seals when necessary. Secure formwork tight against adjacent concrete to prevent formation of steps. 3.3.3 Inserts, Holes, Chases: Confirm positions and details to ensure that alterations to and decisions about their size and location are not made without knowledge and approval of Engineer. Fix inserts or box out as required in correct positions before placing concrete. Form all holes and chases. Do not cut hardened concrete without approval.

3.4 3.4.1

Striking Responsibility:

Strike formwork without disturbing, damaging or overloading structure, and without disturbing props. Notwithstanding other clauses in this specification and any checking or approvals by the Engineer, the responsibility for safe removal of any part of the formwork and any supports without damaging the structure rests with the Contractor.

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3.4.2

Minimum Periods:

Refer to the Qatar Construction Specification, Section 5. Obtain the Engineers instructions if certain parts of the formwork to be left in place for a longer period.

3.5

Reinforcement for Insitu Concrete

To be read in conjunction with the Qatar Construction Specification, the Preliminaries and General Conditions. 3.5.1 Submit

Drawings and documents including but not limited to: - Detailed shop drawings - Bar Binding Schedule

3.5.2

Plain Bar Reinforcement

To BS 4449, Grade 250. 3.5.3 DEFORMED BAR REINFORCEMENT for columns beams slabs and other members to BS 4449, Grade 460 (QASCO GRADE 410). DESIGNATED FABRIC REINFORCEMENT for slabs on grade and any other members to be steel fabric to BS 4483 Cleanliness:

3.5.4

3.5.5

Store reinforcement clear of the ground and prevent contamination by other materials. At time of placing concrete, reinforcement to be clean and free of corrosive pitting, loose mill scale, loose rust, oil and other substances which may adversely affect the reinforcement, concrete, or bond between the two. 3.6 3.6.1 Fixing Laps or Splices:

Obtain instructions if details are not shown on drawings. 3.6.2 Laps In nominal bar reinforcement to be according to BS 8110: Part 1: 1997, if not shown on drawings. LAPS in fabric reinforcement to slabs to be not less than 250 mm. 3.6.3 Fix Reinforcement

Adequately, using tying wire, approved steel clips. Wire or clips must not encroach into the concrete cover. Use PVC coated wire with Epoxy-coated reinforcement. 3.6.4 Trolytic Action:

Do not fix or place reinforcement in contact with non-ferrous metals

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3.6.5

Tack Welding

Do not tack weld reinforcement 3.6.6 Spacers and Chairs:

In addition to supports shown on drawings or schedules, provide spacers and chairs at not more than 1 m centers or closer spacing as necessary to support reinforcement in position and maintain the specified cover. Reinforcement must be fixed in position before the concrete is placed. Cover spacers to be not closer than 300 mm centers and staggered on adjacent parallel bars. 3.6.7 Cover Spacers:

Type(s) which will adequately support the reinforcement, adequately resist displacement, not cause indentation of the formwork and made from: Plastics (perforated to at least 25% of their area), or Fiber cement, or Concrete spacers of strength and durability to match surrounding concrete. 3.6.8 Request

Engineers inspection of the fixed reinforcement in advance of concrete pouring.

3.7

Designed Joints in Insitu Concrete

To be read in conjunction with the Qatar Construction Specification, the Preliminaries and General Conditions. 3.7.1 Accuracy:

All joints to be accurately located, straight and well-aligned, and truly vertical or horizontal or parallel with the setting out lines of the building. 3.7.2 Construction Joints In Concrete Exposed To View,

additional to joints required by the designer, will not be permitted. 3.7.3 Construction Joints In Concrete Wearing Surface Floors,

additional to joints required by the designer, will not be permitted. 3.7.4 Formed Joints:

Construct using rigid, grout-tight side forms or stop ends designed to accommodate projecting bars or fabric without temporary bending or displacement. 3.7.5 Formed Joints

in concrete wearing surface floors: Forms to be square edged with a steel top surface and in good condition. Compact thoroughly at edges to give level, closely abutted joints with no lapping.

3.7.6

Roughening of Construction Joint Faces:

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Brush and spray surface of formed contraction joints while concrete is still green to leave a thoroughly roughened exposed aggregate finish. For concrete section more than 300 mm thick, appropriate keys to be formed along all construction joints. 3.7.7 Crack Inducing Grooves: Depth 50 mm, width 20mm Either, form by inserting temporary strip into the fully compacted concrete, re-compact and re-level the slab, and remove strip. Or, if the type of aggregate used so permits, cut with a saw sufficiently early to prevent random cracking (within 24 hours of casting the slab).

3.7.8

Expansion Joints and Kicker Joints: Manufacturers

Where shown on drawings, construct rigid stop-ends and formwork. instruction/procedures to be followed when using any water bars or joint fillers. 3.7.9 Day Work Joints:

Construction joint as 230 above

3.7.10 Stoppage Due To Plant Breakdown: Scrabble the face to at least 100 mm before new concrete to be placed next to it. Apply bonding agent before placing fresh concrete. 3.8 Worked Finishes to In Situ Concrete

To be read in conjunction with the Qatar Construction Specification, the Preliminaries and General Conditions. 3.8.1 Timing:

Carry out all finishing operations at optimum times in relation to the setting and hardening of the concrete. Do not wet surfaces of concrete to assist surface working. Do not sprinkle cement on to surface. 3.8.2 Smooth Floated Finish

Use a hand float; skip float or power float to give an even surface with no ridges or steps. 3.8.3 Trowelled Finish Float concrete to an even surface with no ridges or steps, then immediately commence curing as specified in section E10. When the concrete is suitably stiff, hand or power trowel to give a uniform smooth but not polished surface, free from trowel marks and other blemishes, and suitable to receive the specified flooring material. Resume specified curing without delay. Adequately protect the surface from construction traffic until flooring material is laid. If, because of inadequate finishing or protection, the surface of the concrete is not suitable to receive the specified flooring material, it must be made good by application of a smoothing compound by and to the satisfaction of the flooring subcontractor. Allow for the cost of any such making good.
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3.8.4

Trowelled Finish

For wearing surfaces: - Float concrete to an even surface with no ridges or steps, then immediately commence curing as specified in section E10. - Successively hand or power trowel at intervals, applying sufficient pressure to close the surface, to give a uniform smooth finish free from trowel marks and other blemishes. - Resume specified curing without delay. - Complete a sample area of the finished work, size 10 sq. m, in advance of the remainder, in an approved location, and obtain approval of appearance before proceeding. 3.8.5 Surface Sealer:

Apply an approved resin sealer to concrete wearing surface floors in accordance with manufacturer's recommendations.

3.9

Preparing Concrete Surfaces for Painting or Protective Coating

Code of Practice : Comply generally with the provisions of BS 6150: 1982: Painting of buildings unless specified otherwise. 3.9.1 Generally:

Produce finished surface using approved formwork material. Blow holes not more than 3mm in diameter will be permitted but otherwise surface to be free from voids, honeycombing and other defects. Remove release agents by washing with a weak detergent solution and rinse off with clean water. Obtain instruction if removal is not achieved. The surface finish is to be left as struck but blow holes and form tie holes are to be made good by filling with matching cement/sand mortar to an approved sample. 3.9.2 Make Good:

Holes, cracks, defective joints and other defects in surfaces to be prepared and coated. 3.9.3 Prepare:

Surfaces in accordance with paint manufacturers recommendations. 3.9.4 Drying Out:

Before painting, allow surfaces to dry thoroughly. 3.9.5 Brush Down:

All surfaces immediately before painting to remove dust.

3.10

Deviations and Tolerances

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3.10.1 Generally: Reference must be made to QCS. The permissible deviations to concrete structural floors to be : 1) 2) Abrupt irregularities: Nil Gradual irregularities: when measured with a slip gauge to BS 8204 Part 2, Fig 3 or equivalent, the variation in gap under a straight edge (with feet) placed anywhere in the surface to be not more than the following : Floors which are to be self-finished, and floors to receive sheet or tile finishes directly bedded in adhesive: 3mm under a 3000mm straight-edge 2mm under a 1000mm straight edge Floors to receive screeds/topping/beds up to 45mm thick: 10mm under a 3000mm straight-edge 3.10.2 Level : permissible diviation to be : Any Point on the floor from designated level : + 15mm. Floor Level between any two points 6000mm apart : 10mm ADJUST Level between the outside edge of the building and the face of any central core walls, if the shortening of the vertical members or columns at the edges exceeds the above permissible limits, at any floor. 3.10.3 Pre-Cambering CONSTRUCT floor slabs and supporting beams with pre-camber such that at no point on the floor the vertical deflection due to live loads only exceeds 1/480 of the span and that due to total service load does not exceed 1/360 of the relevant span. OBTAIN Loading information from the Engineer for calculating deflection or camber where relevant. PRE-CAMBER Cantilever beams/slabs, so that the deflections do not exceed the above limits or adversely affect the cladding/curtain walling or finishes.

PART 4 - DESCRIPTION OF THE WORK

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4.1

General

For description of the works, refer to the following sub-divisions: 03500 Precast concrete

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