Standard Technical Specification - 2002 Series 8000: Structures Content

Standard Technical Specification - 2002
Series 8000: Structures Content
SERIES 8000: STRUCTURES

CONTENT
LIST OF TABLES AND FIGURES ................................................................................................ 11 DIVISION 8100: FOUNDATIONS FOR STRUCTURES .................................................................12 8101 Scope ..............................................................................................................................12 8102 Materials .........................................................................................................................12 (a) General ..................................................................................................................12 (b) Rock (for rock fill).................................................................................................12 (c) Crushed stone ........................................................................................................13 (d) Granular fill ...........................................................................................................13 (e) Sand fill .................................................................................................................13 (f) Structural steel .......................................................................................................13 (g) Permanent Pile Casings .........................................................................................13 (h) Driven Pile Casings ...............................................................................................13 (i) Sheet Piles .............................................................................................................13 (j) Grouting.................................................................................................................14 8103 General............................................................................................................................14 (a) Subsurface Data.....................................................................................................14 (b) Channel preservation .............................................................................................14 8104 Cofferdams, Artificial Islands And Dewatering.............................................................14 (a) General ..................................................................................................................14 (b) Access....................................................................................................................15 (c) Dewatering ............................................................................................................15 8105 Excavation ......................................................................................................................15 (a) General ..................................................................................................................15 (b) Ground surface for excavation ..............................................................................16 (c) Excavation .............................................................................................................16 (d) Classification of excavated material......................................................................16 (e) Blasting..................................................................................................................17 (f) Deterioration of foundation excavations ...............................................................17 (g) Excavation safety...................................................................................................17 (h) Inspection ..............................................................................................................17 (i) Excavation by hand ...............................................................................................17 8106 Foundation ......................................................................................................................17 8107 Utilization Of Excavated Material..................................................................................18 8108 Backfill And Fill Near Structures...................................................................................18 (a) General ..................................................................................................................18 (b) Backfill ..................................................................................................................19 (c) Fill..........................................................................................................................19 (d) Select Granular Backfill ........................................................................................19 (e) Fill within restricted areas .....................................................................................20 8109 Foundation Fill ...............................................................................................................20 8110 Grouting Of Rock Fissures .............................................................................................21 8111 Foundation Dowels.........................................................................................................21
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Standard Technical Specification -2002
8112 Foundation Lining.......................................................................................................... 21 8113 Foundation Piling........................................................................................................... 21 (a) General .................................................................................................................. 21 (b) Piling Layout......................................................................................................... 21 (c) Alternative Designs for Piling and Piling Layouts ............................................... 22 (d) Details to be furnished by the Contractor ............................................................. 24 (e) Pile-installation Frames and Equipment ............................................................... 24 (f) Piling Platforms..................................................................................................... 24 (g) Setting Out ............................................................................................................ 24 (h) Ground Surface of Foundation Piling ................................................................... 25 (i) Cast in situ concrete piles...................................................................................... 25 (j) Precast Concrete Piles........................................................................................... 26 (k) Steel Piles.............................................................................................................. 27 (l) Driving Piles ........................................................................................................ 27 (m) Augering and Boring............................................................................................. 29 (n) Rock Sockets......................................................................................................... 30 (o) Obstructions .......................................................................................................... 30 (p) Determining Pile Lengths ..................................................................................... 31 (q) Piling Data............................................................................................................. 31 (r) Stripping the Pile Heads........................................................................................ 32 (s) Construction of Pile-capping Slab ........................................................................ 32 (t) Core Drilling ......................................................................................................... 32 (u) Load Test............................................................................................................... 33 (v) Defective Piles ...................................................................................................... 34 (w) Standing Time in Respect of Piles-installation Frames ........................................ 34 8114 Caissons ......................................................................................................................... 34 (a) General .................................................................................................................. 34 (b) Construction and sinking ...................................................................................... 34 (c) Founding ............................................................................................................... 35 (d) Data ....................................................................................................................... 36 (e) Filling the caissons................................................................................................ 36 (f) Stripping................................................................................................................ 37 (g) Concrete screed below the caisson cover slabs..................................................... 37 8115 Measurement And Payment ........................................................................................... 37 Item 81.01 Additional foundation investigations Provisional Sum .............................. 37 Item 81.02 Excavation of materials............................................................................... 37 Item 81.03 Access lump sum ........................................................................................ 38 Item 81.04 Drainage Lump Sum ................................................................................... 38 Item 81.05 Backfill to excavations utilizing ................................................................. 38 Item 81.06 Fill within restricted areas........................................................................... 39 Item 81.07 Overhaul in excess of 1.0 km, on excavated Material and on material imported for backfill, foundation fill and fill for caissons.................................... 39 Item 81.08 Over break in excavation in hard material .................................................. 39 Item 81.09 Foundation fill............................................................................................. 39 Item 81.10 Establishment on site for the grouting of rock fissures............................... 40 Item 81.11 Move to and set up equipment at each hole to be drilled............................ 40 Item 81.12 Drilling of holes .......................................................................................... 40 Item 81.13 Grouting of holes ........................................................................................ 40 Item 81.14 Doweling into rock...................................................................................... 40 Item 81.15 Foundation lining ........................................................................................ 40 Item 81.16 Establishment on the site for piling............................................................. 41
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Item 81.17 Moving to, and setting up the equipment at each position for installing the piles........................................................................................................................41 Item 81.18 Augered or bored holes for piles .................................................................41 Item 81.19 Driving the temporary casing for driven displacement piling systems for forming holes for piles...........................................................................................42 Item 81.20 Manufacturing, supplying and delivering prefabricated piles .....................42 Item 81.21 Installation of prefabricated piles ................................................................42 Item 81.22 Extra over item 81.18, irrespective of the depth, to form augered and bored pile holes through identified obstructions .............................................................43 Item 81.23 Forming augered and bored pile holes through unidentified obstructions ..43 Item 81.24 Driving temporary casings for driven displacement piling systems or installing prefabricated piles through identified or unidentified obstructions.......43 Item 81.25 Extra over items 81.18, 81.19 and 81.21 for raking piles............................43 Item 81.26 Forming under reams for piles.....................................................................43 Item 81.27 Forming the bulbous bases for piles ............................................................44 Item 81.28 Socketing piles into rock formation ............................................................44 Item 81.29 Installing and removing temporary casings in augered holes for piles .......44 Item 81.30 Installing permanent pile casing for piles...................................................44 Item 81.31 Steel reinforcement in cast in situ piles:......................................................44 Item 81.32 Cast in situ concrete in piles, under reams, bulbous bases and sockets ......44 Item 81.33 Extra over item 81.32 for concrete cast under water...................................45 Item 81.34 Splicing/coupling prefabricated piles for lengthening.................................45 Item 81.35 Stripping/cutting the pile heads ..................................................................45 Item 81.36 Establishment on the site of the load testing of piles ..................................45 Item 81.37 Load tests on piles .......................................................................................45 Item 81.38 Establishment on the site for core drilling...................................................45 Item 81.39 Moving the equipment to and assembling it at each location where cores are to be drilled............................................................................................................45 Item 81.40 Drilling the cores .........................................................................................46 Item 81.41 Standing time for pile-installation frame.....................................................46 Item 81.42 Establishment on the site for constructing the caisson ................................46 Item 81.43 Formwork for caissons ................................................................................46 Item 81.44 Steel reinforcement for caissons..................................................................46 Item 81.45 Cast in situ concrete in caissons and concrete seals ....................................47 Item 81.46 Cutting edge for caissons.............................................................................47 Item 81.47 Sinking caissons through material situated .................................................47 Item 81.48 Excavation for caissons ...............................................................................47 Item 81.49 Filling the caissons ......................................................................................48 Item 81.50 Stripping the caisson heads. ........................................................................48 Item 81.51 Nuclear integrity testing on bored piles:......................................................48 DIVISION 8200 FALSEWORK, FORMWORK, AND CONCRETE FINISHES.................................49 8201 Scope ..............................................................................................................................49 8202 Dimensions .....................................................................................................................49 8203 Material Requirements For Falsework And Formwork .................................................49 (a) Falsework ..............................................................................................................49 (b) Formwork ..............................................................................................................49 8204 Design And Construction Requirements ........................................................................51 (a) Drawings................................................................................................................51 (b) Design....................................................................................................................52 (c) Construction ..........................................................................................................53
(d) Removal of forms and falsework .......................................................................... 57 8205 Formed Surfaces: Classes Of Finish .............................................................................. 59 (a) General .................................................................................................................. 59 (b) Class F1 surface finish .......................................................................................... 59 (c) Class F2 surface finish .......................................................................................... 59 (d) Class F3 surface finish .......................................................................................... 59 (e) Board surface finish .............................................................................................. 59 (f) Protecting the surfaces .......................................................................................... 59 8206 Remedial Treatment Of Formed Surfaces ..................................................................... 60 (a) General .................................................................................................................. 60 (b) Repairs to surface defects ..................................................................................... 60 (c) Rubbing the surfaces ............................................................................................. 60 8207 Unformed Surfaces: Classes Of Finish .......................................................................... 61 (a) Class U1 surface finish (rough) ............................................................................ 61 (b) Class U2 surface finish (floated)........................................................................... 61 (c) Class U3 surface finish (smoothly finished) ......................................................... 61 8208 Measurement And Payment ........................................................................................... 61 Item 82.01 Formwork for indicated class of finish ....................................................... 61 Item 82.02 Vertical formwork for indicated class of finish .......................................... 61 Item 82.03 Horizontal formwork for indicated class of finish ...................................... 61 Item 82.04 Inclined formwork for indicated class of finish .......................................... 62 Item 82.05 Permanent formwork................................................................................... 62 Item 82.06 Formwork to form open joints .................................................................... 62 Item 82.07 Establishment on the site for sliding formwork operations ........................ 62 Item 82.08 Transporting to and setting up the sliding formwork assembly.................. 63 Item 82.09 Forming the concrete by sliding formwork for structures .......................... 63 DIVISION 8300: STEEL REINFORCEMENT FOR STRUCTURES ............................................... 64 8301 Scope.............................................................................................................................. 64 8302 Materials Requirement ................................................................................................... 64 (a) Steel reinforcement ............................................................................................... 64 (b) Mechanical couplers ............................................................................................. 64 (c) Storage of Materials .............................................................................................. 64 8303 Construction Requirements............................................................................................ 64 (a) Equipment ............................................................................................................. 64 (b) Bending of Reinforcement .................................................................................... 65 (c) Surface Conditions................................................................................................ 65 (d) Placing and Fixing ................................................................................................ 65 (e) Cover..................................................................................................................... 66 (f) Laps and Joints...................................................................................................... 67 (g) Welding................................................................................................................. 67 8304 Measurement And Payment ........................................................................................... 68 Item 83.01 Steel reinforcement for structure................................................................. 68 Item 83.02 Mechanical couplers for.............................................................................. 68 Item 83.03 Spacer "ladders" .......................................................................................... 68 DIVISION 8400: CONCRETE FOR STRUCTURES ..................................................................... 69 8401 Scope.............................................................................................................................. 69 8402 Materials......................................................................................................................... 69 (a) Cement .................................................................................................................. 69
(b) Admixtures ............................................................................................................69 (c) Aggregates .............................................................................................................69 (d) Water .....................................................................................................................71 8403 Storage Of Materials.......................................................................................................72 (a) Cement...................................................................................................................72 (b) Aggregates .............................................................................................................72 (c) Storage Capacity....................................................................................................72 (d) Deteriorated Material.............................................................................................72 8404 Concrete For Structures ..................................................................................................73 (a) Concrete Grade and Class .....................................................................................73 (b) Minimum Cement Content ....................................................................................73 (c) Maximum Water/Cement Ratio ............................................................................73 (d) Maximum Cement Content ...................................................................................73 (e) Design of Concrete Mixes for Structures ..............................................................73 (f) Prescribed mix .......................................................................................................74 8405 Construction Requirements ............................................................................................75 (a) Storage and Handling of Material .........................................................................75 (b) Measuring Material. ..............................................................................................76 (c) Batching Plant, Mixers, and Agitators...................................................................76 (d) Mixing ...................................................................................................................77 (e) Delivery .................................................................................................................77 (f) Batching and Mixing .............................................................................................78 (g) Trial Mixes ............................................................................................................80 (h) Consistency and Workability.................................................................................80 (i) Temperature and Weather Conditions...................................................................80 8406 Handling, Placing And Compaction Of Concrete ..........................................................82 (a) General ..................................................................................................................82 (b) Placing ...................................................................................................................83 8407 Construction Joints .........................................................................................................87 (a) General ..................................................................................................................87 (b) Preparation of Surfaces..........................................................................................87 (c) Placing Fresh Concrete at Construction Joints......................................................87 (d) Bonding .................................................................................................................88 (e) Bonding and Doweling to Existing Structures ......................................................88 8408 Expansion And Contraction Joints .................................................................................89 (a) Open joints.............................................................................................................89 (b) Filled joints ............................................................................................................89 (c) Steel joints .............................................................................................................89 (d) Water stops ............................................................................................................89 (e) Compression joint seals .........................................................................................89 (f) Elastomeric expansion joint seal ...........................................................................90 8409 Finishing Plastic Concrete ..............................................................................................90 (a) General ..................................................................................................................90 (b) Striking of Formwork ............................................................................................90 8410 Curing Concrete..............................................................................................................90 (a) General ..................................................................................................................90 (b) Forms inplace method ...........................................................................................91 (c) Water method ........................................................................................................91 (d) Liquid membrane curing compound method.........................................................91 (e) Steam curing (precast units) ..................................................................................92 8411 Pipes And Conduits ........................................................................................................92
8412 Precast Concrete............................................................................................................. 92 8413 Measurement And Payment ........................................................................................... 93 Item 84.01 Cast in situ concrete .................................................................................... 93 Item 84.02 Manufacturing pre-cast concrete members ................................................. 93 Item 84.03 Transporting and erecting pre-cast concrete members ............................... 93 Item 84.04 Epoxy bonding of new concrete surfaces to old ......................................... 93 Item 84.05 Demolishing existing concrete.................................................................... 94 DIVISION 8500 : TIMBER STRUCTURES .................................................................................. 95 8501 scope............................................................................................................................... 95 8502 Material For Timber Structures...................................................................................... 95 (a) Untreated Structural Timber and Lumber............................................................. 95 (b) Treated Structural Timber and Lumber ................................................................ 95 (c) Hardware............................................................................................................... 95 (d) Yard lumber .......................................................................................................... 95 (e) Structural Shapes, Rods, and plates ...................................................................... 95 (f) Paint ...................................................................................................................... 96 (g) Preservative Treatment of Timber ....................................................................... 96 8503 Construction Requirements............................................................................................ 97 (a) General .................................................................................................................. 97 (b) Storage of Materials .............................................................................................. 97 (c) Treated Timber...................................................................................................... 97 (d) Untreated Timber .................................................................................................. 98 (e) Holes for Bolts, Dowels, Rods, and Lag Screws .................................................. 98 (f) Bolts and Washers................................................................................................. 98 (g) Countersinking ...................................................................................................... 98 (h) Framing ................................................................................................................. 98 (i) Framing Bents ....................................................................................................... 98 (j) Caps for all Bents.................................................................................................. 99 (k) Bracing .................................................................................................................. 99 (l) Stringers ................................................................................................................ 99 (m) Plank Floors ........................................................................................................ 100 (n) Transversely Nail-Laminated Decks................................................................... 100 (o) Wheel Guards and Railings................................................................................. 100 (p) Trusses ................................................................................................................ 101 (q) Drains .................................................................................................................. 101 (r) Painting ............................................................................................................... 101 (s) Acceptance .......................................................................................................... 101 8504 Measurement And Payment ......................................................................................... 101 Item 85.01 Untreated structural timber and lumber .................................................... 101 Item 85.02 Treated structural timber and lumber........................................................ 101 DIVISION 8600: PRESTRESSING ............................................................................................ 102 8601 Scope............................................................................................................................ 102 8602 Materials....................................................................................................................... 102 (a) General ................................................................................................................ 102 (b) Prestressing steel ................................................................................................. 102 (c) Anchorages and couplers .................................................................................... 104 (d) Sheaths ................................................................................................................ 104 (e) Cable supports..................................................................................................... 104
(f) Positioning of Tendons and Duct Formers for Pre-stressing Tendons................105 (g) Tendon spacers ....................................................................................................105 (h) Grout....................................................................................................................105 (i) Protecting agents for unbonded tendons..............................................................106 (j) Testing .................................................................................................................106 8603 Construction Requirements ..........................................................................................106 (a) Equipment............................................................................................................106 (b) Technical Data.....................................................................................................108 (c) Prestressing System .............................................................................................109 (d) Drawings Prepared By the Contractor.................................................................109 (e) Precasting ............................................................................................................110 (f) Pre-Tensioning ....................................................................................................111 (g) Post-Tensioning...................................................................................................111 8604 Loss Of Prestress ..........................................................................................................118 8605 Measurement And Payment..........................................................................................118 Item 86.01 Prestressing tendons ..................................................................................118 Item 86.02 Anchorages and couplers...........................................................................118 Item 86.03 Extra over pay item 86.02 for partially tensioning the tendons ................119 DIVISION 8700 BRIDGE BEARINGS ...................................................................................120 8701 Scope ............................................................................................................................120 8702 Bridge Bearings ............................................................................................................120 (a) Material................................................................................................................120 (b) Concrete Hinges ..................................................................................................121 (c) Roofing Felt.........................................................................................................122 (d) Elastomeric Bearings...........................................................................................122 (e) Proprietary Bearings ............................................................................................123 (f) Dowels and Guides..............................................................................................126 (g) Storage and Handling ..........................................................................................126 (h) Installation ...........................................................................................................126 8703 Bridge Parapets, Railings And Sidewalks ....................................................................127 (a) Materials ..............................................................................................................127 (b) Concrete Parapets ................................................................................................127 (c) Metal Railings .....................................................................................................128 (d) Bridge Number Plates..........................................................................................128 (e) Concrete Sidewalks .............................................................................................128 (f) Concrete Surface Finish Requirements ...............................................................129 (g) Construction Tolerances ......................................................................................129 8704 Joints In Structures .......................................................................................................129 (a) General ................................................................................................................129 (b) Movement joints ..................................................................................................129 (c) Materials ..............................................................................................................130 (d) Filled and unfilled joints......................................................................................132 (e) Epoxy Mortar Nosings ........................................................................................132 (f) Concrete Nosings.................................................................................................132 (g) Plug type expansion joint systems.......................................................................133 (h) Sealing Of Joints..................................................................................................133 (i) Proprietary Expansion Joints ...............................................................................135 (j) Installation Of Expansion Joints..........................................................................135 8705 No-Fines Concrete........................................................................................................136 (a) Materials ..............................................................................................................136
(b) Grades on No-Fines Concrete ............................................................................. 136 (c) Batching and Mixing........................................................................................... 136 (d) Placing................................................................................................................. 137 (e) Protection ............................................................................................................ 137 8706 Drainage for Structures ................................................................................................ 137 (a) Weep holes, drainage pipes and channelling ...................................................... 137 (b) No-fines concrete blocks..................................................................................... 137 (c) Synthetic-fibre filter fabric.................................................................................. 137 (d) Crushed stone in drainage strips behind walls .................................................... 138 8707 Measurement And Payment ......................................................................................... 138 Item 87.01 Proprietary bearings .................................................................................. 138 Item 87.02 Installing the proprietary bearings ........................................................... 138 Item 87.03 Bearings .................................................................................................... 138 Item 87.04 Concrete hinges......................................................................................... 138 Item 87.05 Bearing strips ............................................................................................ 139 Item 87.06 Dowels/guides........................................................................................... 139 Item 87.07 Concrete parapets...................................................................................... 139 Item 87.08 Steel railings.............................................................................................. 139 Item 87.09 End blocks................................................................................................. 139 Item 87.10 Numbers for structures.............................................................................. 139 Item 87.11 Proprietary expansion joints...................................................................... 140 Item 87.12 Installation of proprietary expansion joints .............................................. 140 Item 87.13 Expansion joints........................................................................................ 140 Item 87.14 Filled joints: .............................................................................................. 140 Item 87.15 Unfilled joints ........................................................................................... 141 Item 87.16 Sealing joints............................................................................................. 141 Item 87.17 Cast in situ no- fines concrete ................................................................... 141 Item 87.18 Precast no-fines concrete units.................................................................. 141 Item 87.19 Drainage pipes and weep holes ................................................................. 141 Item 87. 20 Drainage gulleys ...................................................................................... 142 Item 87. 21 Synthetic-fiber filter fabric....................................................................... 142 Item 87. 22 Concrete channeling................................................................................. 142 Item 87. 23 Crushed stone in drainage strips .............................................................. 142 Item 87. 24 Nose endings at balustrades ..................................................................... 142 Item 87.25 Concrete transition blocks......................................................................... 142 DIVISION 8800:STRUCTURAL STEELWORK ......................................................................... 144 8801 scope............................................................................................................................. 144 8802 Materials....................................................................................................................... 144 (a) Structural steel..................................................................................................... 144 (b) Bolts, nuts and washers....................................................................................... 144 (c) Friction-grip fasteners ......................................................................................... 144 (d) Welding consumables ......................................................................................... 144 (e) Test certificates ................................................................................................... 144 8803 Codes Of Practice......................................................................................................... 145 8804 Shop Details ................................................................................................................. 145 8805 Fabrication And Assembly........................................................................................... 145 (a) General ................................................................................................................ 145 (b) Marking the steel................................................................................................. 145 (c) Cutting................................................................................................................. 145 (d) Holes for fasteners .............................................................................................. 145
(e) Joints in compression ..........................................................................................145 (f) Hollow sections ...................................................................................................145 (g) Alignment of holes ..............................................................................................146 (h) Welding ...............................................................................................................146 (i) Bolting .................................................................................................................146 (j) Welded Stud Shear Connectors ...........................................................................146 (k) Friction-grip fastening .........................................................................................146 (l) Riveting ...............................................................................................................147 (m) Trimming.............................................................................................................147 (n) Corrosion prevention ...........................................................................................147 8806 Erection.........................................................................................................................147 (a) General ................................................................................................................147 (b) Safety during erection..........................................................................................148 (c) Alignment ............................................................................................................148 (d) Corrections ..........................................................................................................148 (e) Grouting...............................................................................................................148 8807 Testing ..........................................................................................................................149 (a) Testing by the engineer .......................................................................................149 (b) Process control.....................................................................................................149 8808 Measurement And Payment..........................................................................................149 Item 88.01 Structural steel ...........................................................................................149 Item 88.02 Anchor bolts ..............................................................................................150 Item 88.03 Corrosion protection ..................................................................................150 DIVISION 8900: STONE MASONRY STRUCTURES .................................................................151 8901 scope .............................................................................................................................151 8902 Stone Masonry Walls ...................................................................................................151 8903 Classes Of Masonry......................................................................................................151 8904 Material Requirements For Stone Masonry Structures ................................................152 (a) Stone ....................................................................................................................152 (b) Quarry Operations ...............................................................................................154 (c) Mortar ..................................................................................................................154 8905 Construction Requirements ..........................................................................................154 (a) Excavation and backfill .......................................................................................154 (b) Falsework ............................................................................................................155 (c) Selection and Placing ..........................................................................................155 (d) Beds and Joints ....................................................................................................156 (e) Headers ................................................................................................................157 (f) Backing................................................................................................................157 (g) Coping .................................................................................................................157 (h) Parapet walls........................................................................................................157 (i) Facing for Concrete .............................................................................................157 (j) Pointing................................................................................................................158 (k) Weep Holes .........................................................................................................159 (l) Cleaning Exposed Faces......................................................................................159 (m) Weather Limitations ............................................................................................159 8906 Measurement And Payment..........................................................................................159 Item 89.01 Stone masonry walls..................................................................................159
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DIVISION T8000: CONSTRUCTION TOLERANCES FOR STRUCTURES .................................. 161 T8001 Scope...................................................................................................................... 161 T8002 Definitions.............................................................................................................. 161 T8003 Tolerances .............................................................................................................. 161 (a) Foundations......................................................................................................... 162 (b) Footings, pile capping slabs, caisson cover slabs, etc......................................... 163 (c) Columns, walls, pier, abutments, etc .................................................................. 163 (d) Bridge And Culvert Superstructure..................................................................... 164 (e) Precast Beams ..................................................................................................... 164 (f) Precast Beams And Panels.................................................................................. 165 (g) Precast Prestressed Concrete Structural Elements .............................................. 166 (h) Reinforcing Steel................................................................................................. 167 (i) Prestressing ......................................................................................................... 168 (j) Bridge Bearings................................................................................................... 168 (k) Fabrication And Assembly Tolerances For Structural Steel............................... 169 (l) Concrete Pavement Slab ..................................................................................... 169 (m) Miscellaneous...................................................................................................... 172
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Series 8000: Structures List of Tables and Figures
LIST OF TABLES AND FIGURES
Table 8102-1: Rock Classification ..........................................................................................12 Table 8108-1 Select Granular Backfill Gradation...................................................................20 Table 8204-1 Minimum Form/Support Release Criteria.........................................................58 Table 8303-1 Minimum concrete cover over reinforcement...................................................67 Table 8304-1 Mass of Reinforcing Bars .................................................................................68 Table 8402-1 Maximum amount of deleterious substances ....................................................70 Table 8402-2 Grading of Fine Aggregate................................................................................71 Table 8402-3 Nominal Size and Grading of Coarse Aggregate..............................................71 Table 8404-1 Grade of Concrete for Structures ......................................................................73 Table 8404-2 Nominal Mixes..................................................................................................75 Table 8406-1 Hand Held Vibratory Requirements..................................................................87 Table 8409-1 Minimum Period Before Striking Formwork for Concrete for Structures........90 Table 8700-2 Types of movement joints...............................................................................129 Table 8700-1 Grades of No-Fines concrete...........................................................................136
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Series 8000: Structures Division 8100: Foundations For Structures
DIVISION 8100: FOUNDATIONS FOR STRUCTURES

8101 SCOPE This Division provides specifications for the construction of foundations for structures including bridges, retaining walls, box and slab culverts etc. It provides in particular specifications for excavation, and back filling and for the construction of the foundation it self as well as the pile capping slabs or the caisson cover slabs. 8102 MATERIALS (a) General Materials used in the permanent foundation work shall comply with the requirements specified for the particular material in series 8000 of the Specifications. (b) Rock (for rock fill) Stones shall be hard, angular, field or quarry stones of such quality that they will not disintegrate on exposure to water or weathering. The stones shall be free from overburden, shale, and organic material. Neither the breadth nor thickness of a single stone shall be less than one-third its length. Not more than 10% of the total volume of rock fill shall consist of stones having a mass of less than 0.5 of the mass specified and not more than 10% of the total volume of rock fill shall consist of stones having a mass more than 5 times the mass specified. Not less than 50% of the total volume of rock fill shall consist of stones larger than the specified mass. Table 8102-1: Rock Classification Class Description
Description of Hardness Field Indicator Tests
Unconfined Compressive Strength (MPa) 0.7 to 3.0
R1
Very soft rock
R2
Soft rock
R3
Hard rock
R4 R5
Very hard rock Extremely hard rock
Material crumbles under firm (moderate) blows with a sharp end of geological pick and can be peeled off with a knife; it is too hard to cut a tri-axial sample by hand Can just be scraped and peeled with a knife; indentations 1 mm to 3 mm show in specimens with firm (moderate) blows of the pick point Cannot be scraped or peeled with a knife; handheld specimen can be broken with hammer end of a geological pick with a single firm (moderate) blow Hand-held specimen Breaks with hammer end of pick under more than one below Specimen requires many blows with geological pick to break through intact material
3.0 to 10.0
10.0 20.0
to
20.0 to 70.0 More than 70.0
Page8000-12
(c) Crushed stone Crushed stone used for the construction of crushed stone fill shall be from sound unweathered rock approved by the Engineer. (d) Granular fill Granular fill used for the construction of compacted granular fill shall be approved granular material of at least gravel sub-base quality. Granular back fill required for compacting against earth-retaining structures shall consist of well-graded crushed or uncrushed gravel, stone, rock fill, or natural sand or a combination of any of these. It shall not contain a soluble sulphate content exceeding 2.5 g per liter as determined in accordance with the requirements of AASHTO. Not less than 95 per cent of the material shall pass a 125mm BS sieve and at least 90 per cent shall pass the 75mm BS sieve but not more than 10 per cent shall pass the 75-micron BS sieve. (e) Sand fill Sand used for filling of caissons shall be clean, hard and free from lumps of clay, organic or other deleterious matter. (f) Structural steel Steel in steel piles shall comply with the requirements of BS 4360 and/or AASHTO M 183 for the grade of steel specified on the Drawings. I and H sections shall comply with the requirements of BS 4: Part 1. Fabricated sections shall comply with the details shown on the Drawings. (g) Permanent Pile Casings Permanent piles casings shall be sufficiently rigid so as not to deform permanently or damage during handing and construction. The casings shall be sufficiently dense to prevent the fluid components of the concrete from leaking during the placing of the concrete or thereafter. Where steel casings contribute to the strength of the pile, the casings shall have a minimum wall thickness of 4.5 mm and shall comply with the requirements of ASTM A 252-68. Welded joints shall comply with the requirements of Division 8800 of these specifications. (h) Driven Pile Casings Driven pile casings shall have sufficient strength to permit their being driven and not being distorted by the driving of adjacent piles, and they shall be sufficiently watertight to prevent water leaking through the casing walls during the placing of concrete. (i) Sheet Piles For steel sheet piles, conform to AASHTO M 202M or M 223M. For all other sheet piles, conform to the requirements prescribed above for the particular material specified. Make the joints practically watertight when the piles are in place.
(j) Grouting (i) Cement grout
Cement grout shall meet the appropriate requirements of sub-clause 8602(h) of these specifications. (ii) Proprietary-brand grout
Proprietary brand grout shall be prepared and used strictly in accordance with the instructions of the manufacturer. 8103 GENERAL (a) Subsurface Data If it is found during the course of excavation that the load bearing strata differs from that shown on the Drawings, the Contractor shall immediately notify the Engineer. The Engineer shall be entitled, as often as he may deem necessary during the course of excavation, to call upon the Contractor to perform additional foundation investigation and/or tests at or below the respective foundation levels to establish safe bearing pressures and foundation depths. (b) Channel preservation Stream flow and preservation of marine and freshwater life shall be maintained at all times. Access to cofferdams, artificial islands and piling platforms shall be accomplished without disrupting the stream flow at the point of crossing unless otherwise specified in the Special Provisions. On completion of the work surplus excavated materials, including materials excavated from caisson compartments and piles, materials used in cofferdams and other temporary works, as well as in-situ material, shall be removed and disposed of by the Contractor to the original bed level or such lower elevation as agreed to by the Engineer or required for stream channelization works. 8104 COFFERDAMS, ARTIFICIAL ISLANDS AND DEWATERING (a) General This clause covers the provision of access, including the construction of cofferdams, and draining the excavations. Where it is unnecessary to provide access in terms of sub-clause 8104(b), the contractor shall be paid separately for draining the excavations. After Completion of the permanent works, all temporary works shall be completely removed, the ground leveled and the site left neat. Where this is impracticable, such portions as have not been removed, shall be dealt with in accordance with the engineers instructions.
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(b) Access Where temporary banks or artificial islands are constructed in view of affording access to the location where structural members, piles or caissons are to be constructed, the banks or islands shall be adequately compacted in view of supporting any plant and material without any undue settling, which may have a harmful effect on the end product. The contractor may use any material deemed by him to be suitable for constructing the islands, but he shall note that no separate payment will be made in terms of items 81.02(b), 81.22, 81.24 and 81.48(b) for any obstructions or hard materials occurring in the material used for constructing temporary banks or artificial islands. Designing and constructing any cofferdams shall comply with the requirements of BS 8004. Before starting with construction, the contractor shall submit drawings to the engineer, which show details of the cofferdams and the method of construction. (c) Dewatering The Contractor shall be responsible for preventing the ingress of water into excavations. The preventative measures shall include the construction of proper drainage channels, diversion channels, sumps, the supply and operation of the necessary bailing and pumping equipment and the construction of suitable watertight cofferdams. The dewatering measures, with the exception of pumping, shall be maintained until the backfilling has been completed. Between the various construction stages pumping may be interrupted as agreed by the Engineer. Any draining or pumping of water from cofferdams or the interior of any foundation enclosure shall be done in such a manner as to preclude the possibility of any portion of the concrete materials being carried away. 8105 EXCAVATION (a) General This work shall include excavations, not provided for elsewhere in these Specifications, required for the foundation of structures as well as for the excavating required for existing bridges and culverts where these have to be demolished, extended or modified. Excavation required for diverting, channeling or widening streams within 5.0 m of concrete structures shall be measured and paid for under item 81.02. Excavations beyond the 5.0 m limit shall be measured and paid for under the appropriate items of series 3000 and 4000 of these specifications. The Engineer may require additional excavation, to that described in the Contract, to remove any pockets of soft soil or loose rock and the resulting voids and any natural voids shall be filled with Grade 20/20 concrete complying with the requirements of clause 8404 of these specifications or other material as instructed by the Engineer. No trimming of the sides of the excavation shall be carried out within 24 hours of the placing of any blinding concrete. Any additional excavation below the bottom of foundations, including that resulting from removal of material which the Contractor has allowed to deteriorate shall be replaced with Grade 20/20 concrete complying with the requirements of Division 8400 A of these specifications or other material as instructed by the Engineer.
The sides of the excavation for foundations for structures shall either be vertically or sloped at a safe angle for the material to be excavated. Except in rock, vertical sides shall be adequately supported at all times to the satisfaction of the Engineer. All practical measures shall be taken to prevent the ingress of surface water into the excavated foundations. Any water collecting in the excavated foundation shall be removed as soon as possible thereafter. (b) Ground surface for excavation Prior to commencement of any excavation, the Contractor shall notify the Engineer in good time to ensure that measurements, cross sections and levels of the undisturbed ground can be taken in order that an average ground surface from which the excavation is to be measured can be established and agreed upon between the Engineer and the Contractor. (c) Excavation Where, in the opinion of the Engineer, the casting of concrete against the excavated earth faces is not permissible, or where formwork has to be provided, the extremities of the excavation, for purposes of measurement and payment, shall be deemed to be the vertical planes parallel to and 0.6 m outside the perimeter of the member for which formwork is to be provided. Where suitable stable material is encountered during excavation, that part of the trench or foundation pit shall be excavated to the neat dimensions of the base unless directed otherwise by the Engineer. Over excavation (over break) in hard material shall be backfield with the same class of concrete as that in the base or with mass concrete fill as specified or as directed by the Engineer. Where blasting is required, the contractor shall complete the entire foundation excavation before he commences with the construction of any permanent concrete work, unless otherwise approved by the Engineer. Boulders, logs, or any other unsuitable material excavated shall be spoiled. When hard material suitable for foundation is encountered at the foundation level, it shall be cut and trimmed to a firm surface, either level, stepped or serrated, as required. Where the material at the foundation level is soft material or hard material that deteriorates rapidly on exposure, excavation to final grade and elevation shall not be made until just before the blinding layer is placed. Where, in the opinion of the Engineer, unsuitable material is encountered at foundation level, such material shall be removed and replaced with foundation fill in accordance with Clause 8109 and as directed by the Engineer. (d) Classification of excavated material Distinction shall be made for payment purposes between excavation in hard and soft material. All excavation for the foundations of structures shall be classified in accordance with the following classifications:
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(i)
Hard material
Material, which cannot be excavated except by drilling and blasting, or the use of pneumatic tools or mechanical breakers shall be classified as hard material. (ii) Soft material
All material not classified as hard material shall be classified as soft material. (e) Blasting Where blasting is permitted it shall be carried out in accordance with the requirements of the Contract. (f) Deterioration of foundation excavations Where the bottoms or sides of excavations, in which bases are to be cast, are softened due to negligence on the part of the Contractor in allowing storm or other water to enter the excavations, the softened material shall be removed and replaced with foundation fill as directed by the Engineer at the Contractor's expense. (g) Excavation safety The Contractor shall take the necessary precautions to safeguard the stability and safety of the excavations and adjacent structures. The personal safety of any person shall not be placed in jeopardy nor shall any situation be allowed to arise which may result in damage of whatsoever nature. (h) Inspection No concrete shall be placed before the excavation has been properly cleaned and inspected and approved by the Engineer. (i) Excavation by hand Where circumstances prevent the use of mechanical excavators and material can be removed only by hand implements, the Engineer shall authorise the supplementary payment to the contractor for such work at the tendered rates for excavation by hand should he be satisfied that the contractor had been unable to prevent the necessity for excavation by hand by proper planning and precautionary measures. The supplementary rate for excavation by hand shall not apply to minor finishing or clearing jobs in excavations which are otherwise being done by mass excavation plant. 8106 FOUNDATION In consequence of possible variations of anticipated foundation conditions the dimensions and foundation levels specified or shown on the Drawings may have to be varied during construction. The Engineer has the full and absolute power in terms of this contract to order such variations and to specify the actual foundation level for each foundation fill, base, or caisson during construction and his decision shall be final and binding on the Contractor.
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The Contractor shall not be entitled to any additional payment in consequence of any such variation in the dimensions or foundation depths over and above that provided for in Clause 8115 regardless of the stage of construction at which the instruction to vary the dimensions or foundation depths is given. However, if in consequence of such variation order the Contractor is compelled to substitute machines and equipment with other machines and equipment in order to successfully complete the work, the Engineer may, at his discretion, reimburse the Contractor for additional expenses incurred provided that the original machines and equipment were suited to the work required prior to the variation order being issued. No base, caisson, or pile shall be founded unless authorized by the Engineer. Each foundation level shall be accurately measured and recorded. The term foundation level used in these Specifications shall be deemed to have the following meanings in respect of: (i) Foundation fill : The surface of the in-situ material that has been prepared to receive foundation fills. (ii) Bases : The underside of the base. (iii) Piles : The underside of the under ream, bulbous base or rock socket; the tip of the pile shoe or lower pile end, as may be relevant. 8107 UTILIZATION OF EXCAVATED MATERIAL Excavated material and material recovered from temporary work shall, so far as it is suitable, be utilized for backfill. Material unsuitable for use as backfill or in excess of the quantity required to complete the backfill shall be spoiled or utilized as directed by the Engineer. Excavated material not used for backfill or not taken to spoil but used in the construction of embankments or other parts of the work, as directed by the Engineer, will be paid for under foundation excavation as well as under the relevant item for the purpose for which it is used. The free-haul distance on excavated material and imported material for backfill shall be 1.0 km. Excavated and stockpiled material shall be deposited so as not to endanger the uncompleted structure, either by direct pressure or indirectly by overloading the banks contiguous to the structure or in any other way. 8108 BACKFILL AND FILL NEAR STRUCTURES (a) General In placing backfill and fill, the following precautions shall be taken: The material shall be placed simultaneously, in so far as is possible, to approximately the same elevation on both sides of an abutment, pier, or wall where appropriate. If conditions require placing backfill or fill appreciably higher on one side than on the opposite, the additional material on the higher side shall not be placed until authorized by the Engineer and preferably not until the concrete has been in place 14 days, or until tests show that the concrete has attained sufficient strength to safely withstand any pressure created by the backfill or fill, or the method of construction.
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The material behind abutments restrained at the top by the superstructure. e.g., portal type structures, shall be placed as stated on the Drawings or as directed by the Engineer. The material behind the walls of concrete culverts shall not be placed until the top slab is placed and cured, unless authorized otherwise by the Engineer. (b) Backfill Excavated areas around structures shall be backfilled with approved material in horizontal layers, not exceeding 150 mm in depth after compaction, to the level of the original ground surfaces. Each layer shall be moistened or dried to optimum moisture content for the material and compacted to a density of not less than 93% of Modified AASHTO density. (c) Fill To prevent wedge action against the structure and bounding slopes, the slopes shall be benched or serrated. In no case shall the toe of the bounding fill be closer to the concrete face than the height of the exposed face of the abutment or wall. (d) Select Granular Backfill Select granular backfill shall be sound, durable, granular material free from organic matter or other deleterious material (such as shale or other soft particles with poor durability). Select granular backfill shall conform to the following: (i)
(1)
Quality Requirements Gradation according to; Table 8108-1 (2) Shear angle of internal friction, AASHTO T 236 34o min. Note: Samples shall be compacted as per AASHTO T 236 to 95 percent of the maximum density determined according to AASHTO T99 method C or D and corrected for oversized material according to AASHTO T 99, Note 7. (3) Sodium sulfate soundness loss (5 cycles);15% max. according toAASHTO T 104. (4) Los Angeles abrasion, according to AASHTO T96; 50% max. (5) Liquid limit, according to AASHTO T89; 30 max.
(ii)
(1)
Electrochemical requirements 3000 cm min. 5.0 to 10.0 1000 ppm max. 200 ppm max.
Resistively, AASHTO T 226 (2) pH, AASHTO T 289; (3) Sulfate content, AASHTO T 290 (4) Chloride content, AASHTO T 291
Note: Tests for sulfate and chloride content are not required when pH is between 6.0 and 8.0 and the receptivity is greater than 5000 ohm centimeters.
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Table 8108-1 Select Granular Backfill Gradation Sieve Size 100 mm 75 mm 75 m Percent by Mass Passing Designated Sieve (AASHTO T27 and T11) 100 75 100 0 15
(e) Fill within restricted areas The portion of the fill within 3 meters of the concrete faces of the structure and the whole of the spill through portion, or the extent shown on the Drawings, shall be termed "fill within restricted area". Fill within the restricted area shall comply with the requirements of Series 4000 except that it shall be compacted to a density of not less than 93% of Modified AASHTO density. In order to achieve the specified density, the Contractor shall, where necessary, import material of suitable quality. Payment in accordance with Pay item 81.06 for the construction of fill within restricted areas shall only be made when specifically provided for in the Bill of Quantities. 8109 FOUNDATION FILL If it is found during the course of excavation that the material at the indicated foundation depth does not have the required bearing capacity as specified on the Drawings, the excavations shall be extended at the discretion of the Engineer until satisfactory foundation material is encountered. The Engineer reserves the right to order the Contractor to make up the difference in levels with foundation fill. Where the foundation fill consists of rock or crushed stone fill, it shall be constructed in accordance with the requirements of the Special Provisions or as directed by the Engineer. Foundation fill consisting of granular material shall be constructed in layers not exceeding 150 mm in thickness after compaction. Each layer shall be moistened or dried to optimum moisture content for the material and compacted to a density of not less than 95% of Modified AASHTO density. Mass concrete fill to be used shall be of the class or mix as specified or directed by the Engineer. Unless specified or directed otherwise by the Engineer, the minimum foundation fill consisting of rock fill, crushed stone fill or compacted granular fill to be constructed shall be defined by a prism with plan area coinciding with the lower base of a truncated pyramid the sides of which slope at an angle of 60o with the horizontal from the underside of the footing or slab to the foundation level. A concrete blinding of 75mm thickness and Grade 15/20 concrete shall be placed underneath all bases except where mass concrete fill is used or where authorized by the Engineer. Where mass concrete is constructed under a base it shall be constructed accurately to the final levels of the underside of the base.
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8110 GROUTING OF ROCK FISSURES Where specified, fissures in the rock below and around the base shall be sealed by pressure grouting with a neat cement or sand-cement grout with a water cement ratio as agreed to by the Engineer. The extent of fissuring shall be established by water testing under pressure. Holes of at least 40 mm diameter shall be drilled in positions ordered by the Engineer and grout pumped into these holes under suitable pressures. Grouting shall be carried out in 3-meter stages to the maximum depth ordered. Care shall be taken to avoid further fracturing of the rock strata due to excessive grouting pressures. Grouting of rock fissures shall be carried out by specialized operators with adequate experience in this class of work. 8111 FOUNDATION DOWELS Where required, foundation dowels of the specified material, diameter and length shall be installed at the positions and to the dimensions shown on the Drawings or as directed by the Engineer. After exposure, clearing and trimming of the rock formation, holes of not less than 40 mm diameter and of specified depth shall be drilled into the rock into which the dowels shall be fox-wedged and grouted with a 2:1 sand: cement grout. 8112 FOUNDATION LINING Where specified or directed by the Engineer, foundation lining shall be installed as described hereinafter. The Engineer shall have the right to order the use of lining against sides of excavations and underside of bases and slabs in lieu of formwork and concrete building. All surfaces to be lined shall be covered with approved sheeting to provide a clean impervious layer. The material shall be of sufficient strength to provide a durable working surface and to support the concrete and reinforcement without tearing. The joints between strips shall have a 150 mm overlap and the lining shall be held firmly in position by nails, pegs, etc. Polyethylene sheeting of 0.15 mm thickness is generally considered adequate for the use under approach (jockey) slabs and bases. 8113 FOUNDATION PILING (a) General This section covers the construction of bearing piles of concrete or steel or a combination of these materials. (b) Piling Layout The piling layout, the minimum pile size and/or bearing capacity and type together with the steel reinforcement and class of concrete required shall be as detailed and specified on the drawing unless otherwise specified in the project specifications.
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(c) Alternative Designs for Piling and Piling Layouts (i) Submission
The priced schedule of quantities submitted for alterative designs shall be complied strictly in accordance with the relevant measurement and payment clauses of these specifications. Where pay items defined in these specifications have been omitted, it shall mean either that the items do not apply, or that where the engineer requires work falling under such items to be done, it shall be done without any cost to the employer. The inclusion of "rate-only" items will not be permitted. Where pay items not defined in these specifications are used, the measurement and payment requirements for such items shall be specified in detail by the contractor. In the absence of such definitions, or in the case of any ambiguity, the interpretation of the engineer shall be final and binding. Except in piling-only contracts or where otherwise provided in the Project specifications, the contractor shall price the schedule of quantities for the original design irrespective of whether or not an alterative design is offered. (ii) Design
The critical design-load combinations acting upon the underside and the center of gravity of the pile-capping slab, the maximum permissible stet of the pile-capping slab, and the technical data required for designing alternative piles and/or piling layouts will be indicated on the drawings. Alternative designs shall comply with the provisions of the Contract and the prescriptions set out below. For alternative designs submitted the contractor shall submit with his tender a detailed description of the method of analysis used in the design of the piles and the pile-group layouts. The average length of pile and/or of the piles per group on which the quantities in the schedule of quantities for the alternative designs are based shall be stated in each case. The type of pile offered shall be defined in terms of size, materials, working and breaking load. The Contractor shall be responsible for and shall bear the cost for redesigning, drafting and submitting the detail drawings for any structural element affected by the alternative pile design. Any economy or incidental caused by constructing such element as compared to the original design shall be for the account of the contractor. The contractor shall, as specified in the Contract, submit to the Engineer at least three months prior to work being commenced, drawings detailing the piling-group layout and piles, incorporating such amendments to his original design as may be required by the engineer, and drawings detailing the amendments required to the pile-capping slab dimensions and reinforcement as a result of the layout of the piles, all as applicable. No work of whatsoever nature shall be commenced on the piling until the drawings have been submitted to and have been approved by the engineer, in writing. After approval of the drawings, no departure there from shall be made with out authorization by the Engineer. Where the alternative piles fail in regard to the load test specified in sub-clause 8113(u) of these specifications, the contractor shall be responsible for the cost of the work required for improving the piles and pile layout so as to comply with the design requirements.
(iii)
Basis of payment
Where the quantities in the schedule of quantities referred to in sub-clause 8113(c)(i), on the one part, differ from the number of piles and the average pile length given in the submission for the alternative pile design, on the other part, the Engineer shall accept the sum in the said schedule of quantities, correct the quantities, and adjust the rates for the applicable pay items accordingly. In addition to these corrections, the employer shall be justified in using one of the following methods for paying for piles constructed in accordance with the alternative design: Method 1 The employer may check the alternative designs, calculate the quantities and adjust the rates as set out in the first paragraph of sub-clause 8113(c)(iii). The employer will then pay for the work in accordance with the actually measured quantities. Method 2 The employer may use the following formulae for calculating the quantities under pay items 81.17 to 81.35 for payment: Np=Nd Lp = Nd .Ld + Nb(Lb-Ld)K for Nd > Nb and Lp = Nd . Ld + Nd(Lb-Ld)K for Nd < Nb
K= Lb for Ld > Lb Ld
and
K=
Ld for Ld Lb Lb
Where: P = paid, d = designed and, b = built. The term "units" means items of work measured and paid for in the respective pay items such as piles, raking piles, casings, underreams, concrete, etc. Np = number of "units" measured and finally paid for in a particular pile group. Nd =number of "units" provided for in the tender for the alternative design in the same pile group. Nb = number of approved and accepted "units' finally installed in the same pile group. Lp = the length of the "units" measured and paid for or the length to be used in calculating quantities which are a direct function of the length of the "units" for the same pile group. Ld = the average length of the "units" provided for in the tender for the alternative design in the same pile group. Lb = the average length of the Nb "units" actually installed in the same pile group. The values Nd and Ld for each pile group for which an alternative design has been offered shall be supplied with his tender by the contractor for the respective "units". The values of Nd, Nb, Ld and Lb for each pile group for which to be used in the formulae for determining the quantity for a particular pay item shall relate only to the piles the item measured.
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(d) Details to be furnished by the Contractor In all cases where the choice of the type of pile to be used is left to the contractor, full particulars, specifications, calculations and drawings of the piles proposed for use by the contractor shall be submitted with the tender. The contractor shall submit the following information to the Engineer, 2 weeks before any piles are driven or holes are formed: 1) How the piles and casings will be installed or the holes will be formed; 2) How the piles and casings will be installed or the holes will be made through identified obstructions: 3) The mass of the hammer; 4) The set during the last ten blows; 5) The expected size of the bulbous base, underream, rock socket, etc, if any; 6) How concrete or grout is to be placed and compacted in the case of cast in situ piles; 7) How reinforcing steel is to be placed and held in place during placing and compacting the concrete in cast in situ piles; 8) Details of permanent casing, if any; 9) The mix design for the concrete together with an adequate quantity of cement and aggregate to enable the engineer to conduct the necessary tests. (e) Pile-installation Frames and Equipment The pile-installation frames and equipment used for driving the piles or forming the holes of for other methods of sinking the piles shall be in a good working condition and to the prior approval of the Engineer and shall comply with the relevant legal provisions. The contractor shall supply the necessary equipment, gear and instruments required for the prescribed investigations and inspections. The installation frames shall be so designed as to ensure that piles can be installed in their proper positions and true to line and slope. (f) Piling Platforms Piling platforms shall include the prepared in situ material or artificial islands or any structure (excluding the piling equipment) constructed for gaining access to the position where the pile is to be installed and for carrying out the piling operations. Structural piling platforms shall be rigid, and floating barges used for piling operations shall afford sufficient stability to enable piles to be properly installed. On completion of the piling, the contractor shall remove all the artificial, constructed platforms and reinstate the site to the satisfaction of the Engineer. (g) Setting Out The contractor shall set out the pile positions and shall stake these positions with a durable marker.
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Where the level from which the piling is undertaken is above the underside of the pilecapping slab, due allowance shall be made for the offset of raking piles at the underside of the pile-capping slab will be in the correct position. (h) Ground Surface of Foundation Piling Before starting any piling work, the contractor shall notify the Engineer in good time to ensure that levels of the ground surface be taken in order that an average ground surface from which the piling is to be measured can be established and agreed on by the Engineer and the contractor. Where foundation piling at a site is preceded by excavation or the construction of fill, the surface from which the piling is to be done shall be formed as near as possible to the underside of the pile-capping slab as directed by the Engineer. (i) Cast in situ concrete piles (i) Reinforcement
Reinforcement shall not be placed in the pile holes until immediately before concreting. Before the reinforcement is placed in position, all mud, water, and any loose or soft material shall be removed from the hole. Steel reinforcing shall be accurately maintained in position without damage being done to the sides of the hole or the reinforcing itself. Spacers shall be used to keep the reinforcing steel at the required distance from the inside face of the pile casing and wall of the pile hole but shall not cause zones through which aggressive ground water may penetrate to the reinforcement. Pile reinforcement will not be shown in the bending schedules. Only the number, diameter and type of bars and their arrangement will be shown on the drawings. The contractor may replace the bars shown on the drawings with bars with different diameters and spacing and of different types, on a basis of equivalent strength. The reinforcement shall be assembled in cages, which shall be sufficiently robust to prevent their permanent deformation during handing. In the case of cast in situ piles, the inner sides of the cages shall be kept open in view of the unrestricted placing of concrete therein. The longitudinal bars shall project above the cut-off point by the distance shown on the drawings, or by 40 times the bars diameter if no dimension has been given. Splicing the reinforcing may be ordered, and the contractor shall keep available on the site sufficient steel reinforcing so that an additional length of pile reinforcing can be assembled whenever necessary. The assembly of this additional reinforcing shall be carried out expeditiously and before any concreting of any specific pile commences. If splices have to be provided, the longitudinal bars shall overlap for a distance of 40 bar diameters, or as required by the Engineer.
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(ii)
The Concreting of Piles
The concreting of the piles shall not be commenced before the engineer has given his permission therefore. Except in self-supporting pile holes, a temporary or permanent casing shall be installed for the full depth of the hole to prevent lumps of material from falling from the sides of the hole into the concrete. Where concrete is to be placed under the drilling mud, the temporary casing may be omitted, except at the top end of the hole. The concrete shall be so proportioned as to be of sufficient strength, but shall be sufficiently workable to enable it being properly placed, and, where self-compacting concrete is not used, it shall be thoroughly compacted by approved means. Extraction of the temporary casing during placement of the concrete shall be such that no damage is caused to the pile and the advancing concrete level is at all times kept considerably above the temporary casings trailing edge. Concrete shall generally be placed in the dry, but where this is impracticable, it shall be placed by tremie. The requirements of clause 8406 of these specifications together with the following requirements shall apply when concrete is placed under water by tremie: The cement content shall be not less than 400 kg per m3 and the slump shall be such that the concrete of the specified strength and desired density can be obtained. The hopper and tremie shall be a closed unit, which cannot be penetrated by water. The tremie shall be at least 150 mm in diameter for 19.0 mm aggregate and larger for larger aggregates. The concrete shall be so placed as to prevent the mixing of water and concrete. The tremie shall at all times penetrate into the concrete. Placing the concrete in that part of the pile below the water level in the casing shall be done in one operation, and the same method of placing the concrete shall be maintained throughout. All tremies shall be thoroughly cleaned before and after use. Before placing the concrete in the water, the contractor shall ensure that no silt or other materials have collected at the bottom of the hole, and where drilling mud is used, the contractor shall ensure that no drilling mud suspension with a relative density exceeding 1.3 has collected at the bottom of the hole. Whenever practicable, concrete shall be placed in a manner that will prevent segregation. (j) Precast Concrete Piles The piles shall be of reinforced or prestressed concrete and shall be manufactured, handled, stored and installed in accordance with BS 8004, unless otherwise specified in these specifications. (i) Manufacture
The piles may be manufactured in a factory or a casting yard on the site of the works. The contractor shall ensure that the factory or casting yard will at all reasonable times be accessible for inspection by the Engineer.
The relevant requirements of Division 8400 shall apply to the concrete work. Transverse reinforcement shall comply with the requirements of BS 8004. The piles shall be cast on a rigid horizontal platform in approved moulds. Particular care shall ensure that the reinforcement, coupler sockets and piles shoes are accurately in position. Adequate provision shall be made for lifting the piles. Each pile shall be clearly marked with the date of casting, a reference number, and from the tip of the pile at meter intervals, with distance marks. Piles shall be cured for a period sufficient to develop the strength required to withstand, without damage to the pile, the stresses caused by handing, transporting, storing and driving. The piles shall not be driven before the concrete in the pile has attained the specified strength. (ii) Handing, Transport and Storage
Care shall be taken at the stages of lifting, handling and transporting to ensure that the piles are not damaged or cracked. Piles shall be stored on firm ground, which will not settle unequally under the weight of the stack of piles. The piles shall be placed on timber supports, which are truly level and spaced so as to avoid undue bending in the piles. The supports in the stack shall be located vertically above one another. (iii) Lengthening of Precast Piles
Piles shall be lengthened where required by such means and methods as approved by the Engineer. Care shall be taken to ensure that the additional length of pile joined is truly axially in line with the original pile within the tolerance requirements for straightness set out in Division 10100 of these specifications. Driving shall not be resumed until the pile extension and any bonding agent used has attained the required strength. (k) Steel Piles Hollow steel piles may be filled with cast in situ concrete and, provided that adequate connections are provided between the steel and the concrete with a view to transferring the load, the concrete may be deemed to assist in carrying the load. Wherever steel piles are used, they shall be given a protective coating of bitumen, coal-tar pitch or synthetic resins to the satisfaction of the Engineer or as specified. The cross-sectional area of the steel shall be adapted to the aggressiveness of the subsurface conditions to compensate for possible reduction in the pile wall thickness caused by abrasion and corrosion during the service life of the pile. Steel piles shall be used only where permitted by the Engineer. (l) Driving Piles (i) Pile-installation frames
Piles and pile casings shall be driven with a gravity hammer, a rapid-action power hammer or by other approved means. Prestressed-concrete piles shall be driven with a hammer with a mass of at least equal to that of the pile. Other piles shall preferably be driven by a hammer with similar mass
characteristics. The hammer shall not, during driving operations, damage any permanent component of the pile. Pile driving leaders shall ensure freedom of movement of the hammer and shall be held in position to ensure adequate support for the pile or pile casing during installation. Inclined leaders shall be used for installing raking piles. The heads of precast concrete piles shall be protected with packing of resilient material, care being taken to ensure that it is evenly spread and held in place. A helmet shall be placed over the packing, and a dolly of hardwood or other material not thicker than the diameter of the pile shall be placed on top. (ii) Water Jetting
The contractor may employ water jetting to install piles in granular material. Jetting shall be discontinued before the leading end of the pile reaches of depth of 80 percent of the anticipated final depth or a depth as agreed on with the Engineer. After jetting, piles or their casings shall be driven to the required depth, level or set. (iii) Installation Sequence
Unless otherwise specified or ordered, the sequence for installing the piles shall be left of the contractor. However, the sequence for driving the piles in a group shall be programmed to minimize the creation of consolidated blocks of ground into which piles cannot be driven or which cause fictitious penetration values. Piling shall generally commence at the center of the group and be progressively extended to the perimeter piles unless otherwise agreed on by the Engineer. The installation of piles shall be undertaken in such a manner that structural damage, distortion or positioning defects will not be caused to previously installed piles or casings. (iv) Heaving of Piles
In soils in which the installation of piles may cause previously installed piles to heave, accurate level marks shall be placed on each pile immediately after installation and all piles that have heaved shall be redriven to the required resistance, unless redriving tests on neighbouring piles have shown this to be unnecessary. Piles shall not be concerted neither shall any pile-capping slab be constructed until the piles within a heave-influence zone have been redriven as required. (v) Bulbous Bases
Where required, bulbous (enlarged) bases shall be formed after the driven casing has reached the required depth. The base shall be formed by progressively displacing the surrounding subsoil with concrete placed by the repeated action of a gravity hammer. The size of the base will depend on the compressibility of the surrounding subsoil but shall in no case have a diameter of less than 1.5 times the diameter of the pile.
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(vi)
Piling Alignment
Where the inclination of a precast concrete pile deviates from the correct slope during installation, the pile shall not be forced into the correct position, and the slope of the guiding frame shall be adjusted so as to coincide with the actual inclination of the pile to preclude the bending of the pile. Where the verticality or the inclination of the installed pile falls outside the specified tolerances, the pile will be classified as being defective. (m) Augering and Boring (i) Auger and Bore Pile Holes
The augering and boring of pile holes shall be carried out as expeditiously as local conditions permit taking due account of services or other restrictions on the site. Holes shall be cleaned after augering and boring to obtain a clean and level surface. Where indicated by the Engineer, suitable casing shall be installed in those parts of the augered holes where the sides are in danger of caving in before the concreting has been completed. During extraction of the casing, care shall be taken to avoid lifting the concrete and damaging the pile. The use of water for augering and boring holes shall not be permitted unless approved by the Engineer. Surface water shall not be allowed to enter the hole. (ii) Underreaming
Where required, the holes shall be enlarged or belled out to form an underream. The earth excavated shall be removed in a manner, which will not damage the walls of the hole. The shape of the underream shall be a truncated cone of which the base diameter depends on the bearing capacity of the founding material, but it shall be not less than twice the shaft diameter. The base angle of the cone between the inclined face and horizontal plane shall be not less than 60o. Full safety measures shall be enforced to protect workmen working at the bottom of the pile hole. (iii) Bulbous Bases
Bulbous bases shall comply with the requirements of sub-clause 8113 (m). (iv) Inspecting Performed Holes
Immediately before the reinforcement is to be installed or the concrete placed, the Engineer shall be informed thereof with a view to inspecting the pile holes. When piles are to be undreamed, the excavation shall be inspected twice by the Engineer, firstly to ascertain that suitable founding material has been obtained before Underreaming may start, and secondly, after the Underreaming has been completed for approval to be given by the engineer for casting the pile.
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(n) Rock Sockets Where required, rock sockets to the required dimensions shall be formed in rock formations of adequate strength, quality and thickness for transmitting the specified load. (o) Obstructions (i) Definitions
Identified Obstructions Identified obstruction shall mean any obstruction described on the drawings or in the project specifications and for which provision for payment has been made in the schedule of quantities in respect of penetrating the obstructions. Unidentified Obstructions Where provision has been made in the schedule of quantities in terms of pay item 81.22 for penetrating identified obstructions and obstructions not described are encountered, such obstructions shall be classified as unidentified obstructions and the penetration of such obstructions shall be paid for under item 81.23 subject to the condition that the rate of penetration drops to below that achieved for identified obstructions when the same method and effort are used, or subject to additional methods and effort over and above those required for identified obstructions being required for penetrating the obstructions. OR Where no provision has been made in the schedule of quantities for penetrating identified obstructions and obstructions are encountered and, after resorting to the methods specified in the submission in terms of sub-clause 8113(d), it is found to be impossible to form the holes in the proper positions and at the proper inclinations and depths, and the contractor has to resort to additional methods for forming the pile holes successfully, such obstructions shall be classified as unidentified obstructions. (ii) Classification of Materials
For piling only the following classification of materials shall apply to the identification and description of obstructions. Matrix The matrix shall comprise that part of the material which will pass through a sieve with 50 mm x 50 mm openings. Coarse gravel Coarse gravel shall comprise that part of the material (stones, pebbles, cobbles, etc.) which will pass through a 200 mm x 200 mm opening, but will not pass through a 50 mm x 50 mm opening. The gravel shall be obtained from material with at least a class R2 hardness as given in Sub-clause 8102(b) in Table 8102-1 of these specifications. Boulders Boulders shall mean any rock mass with a hardness of at least class R2 which will pass through a square opening with dimensions equal to the maximum size boulder specified in the schedule of quantities but will not pass through a 200 mm x 200 mm opening.
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Rock Formation A rock formation shall be any rock mass with a hardness of at least class R2 which will not pass through a square opening with dimensions equal to the maximum size boulder specified in the schedule of quantities. Where a boulder is cut through and part of it is left imbedded in the wall of the hole, such boulder obstruction shall be classified as rock formation. (iii) Driven Displacement and Prefabricated Piles
Where obstructions make it difficult to install driven displacement and prefabricated piles in the positions and at the inclinations shown and to the proper lengths by the methods specified in the submission in terms of sub-clause 8113(e), the contractor shall resort to additional methods, which are suitable for the type of pile. If the successful installation of a pile proves to be impossible after such methods have been tried, the engineer may order an additional pile or piles to be installed. All such work and additional piles shall be paid for in accordance with the tendered rates where applicable, or where they do not apply, under pay item 81.24. (iv) Auger and Bore Pile Holes
Where identified or unidentified obstructions are encountered when shaping holes for piles, payment for penetrating the obstructions shall be made against the appropriate pay items. (p) Determining Pile Lengths The design of the piles and pile groups, and the quantities in the schedule of quantities are based on the subsurface date shown on the drawings. The Engineer will determine the depth of piles as work proceeds. Where variations in the subsurface conditions occur as regards the material and height of the water table, the engineer shall be informed immediately. If the contractor is not satisfied that the piles will be capable of carrying the specified loads at the depth determined by the Engineer he may, in consultation with the Engineer, lengthen the piles to reach a suitable founding depth. Where the Engineer and the contractor cannot agree on the founding depth, the Engineer may require the contractor to: Undertake additional foundation investigation and/or core drilling in accordance with sub-clauses 8103(a) and 8113(t) respectively and/or Install one or more test piles and conduct a load test in accordance with subclause 8113(u). The engineer will prescribe the positions for each test pile. Test piles shall comply with the specified requirements for piling. (q) Piling Data The following data on each pile installed shall be recorded in a form prescribed by the Engineer: The effort used for driving the pile and the resistance to penetration at founding level.
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A description of subsurface material, the presence of ground water and the quality of material on which the pile is founded. The quality of the materials used in the construction or manufacture of the pile, as well as of the permanent casing if used. The method of placing and compacting the concrete in cast in situ piles. The method of founding of the piles eg. bulbous bases, underreams, rock sockets, etc, and their dimensions. The maximum working load of the pile in the Service Load state. The length of the pile and the accuracy of installation in respect of position and inclination. Nominal dimensions and type of pile. Length and details of any temporary and permanent casings used. (r) Stripping the Pile Heads Precast piles shall be installed to a level of at least 1 .0 m above the cut-off level, and cast in situ piles shall be cast to a level of at least 150 mm above the cut-off level. The excess concrete shall be so stripped off that only sound concrete will project into the pilecapping slab. Before a pile head is stripped, the cut-off plane shall be marked by cutting a 20 mm deep groove with a grinding machine along the full circumference of the pile. Heavy concrete demolishing equipment may not be used for the stripping of pile heads. All loose aggregate shall be removed from the cut-off plane. The concrete shall be so stripped off that the pile below the cut-off level will not be damaged, or, should defective concrete be found in the completed pile, the damaged or defective concrete shall be cut away by the contractor at his own cost and replaced with new concrete well bonded to the old concrete, or the pile shall be replaced as directed by the Engineer. The main reinforcement of the piles shall extend at least 40 times the diameters of the reinforcing bar beyond the cut-off level into the pile-capping slab. This reinforcement shall be left straight unless otherwise directed by the engineer. The cut-off level for piles shall be the level shown on the drawings. (s) Construction of Pile-capping Slab The contractor shall not construct the pile-capping slab before the engineer has confirmed, in writing, that all the relevant load tests have been completed and the piles have been accepted. (t) Core Drilling The Engineer may instruct core drilling to be done with a view to obtaining cores of the founding formation and/or of the concrete in the completed structural member. In the case of piling, the core drilling may precede the piling or may be done through the completed pile, as specified, or as instructed by the Engineer.
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The contractor shall supply the necessary construction plant on the site for drilling under the above conditions. The plant and techniques used shall be suitable for ensuring 100% core recovery. The diameters, depths and lengths of the cores shall agree with the specifications or the instructions of the Engineer. The contractor shall keep accurate records of the drilling, which, together with the cores, shall be handed over to the Engineer. The cores shall be placed in the correct sequence in a clearly identified wooden core box with a lid. (u) Load Test (i) General
The Engineer may order certain selected piles to be load tested. The procedure for loading tests shall comply with the requirements of Division 10112(d) of these specifications. During the period of testing, driving of other piles, which may affect the testing, shall cease. No working pile shall be used as an anchor pile. Where another pile or earth anchors are required for providing reaction, they shall be so placed as to have a minimal effect on the test results. The contractor shall provide the complete testing assembly, the necessary plant, equipment, instruments and labour for carrying out the test and for determining accurately the settlement of the piles under each increase or decrease of the load. The test assembly, plant, equipment and instruments used shall be subject to the approval of the Engineer. Within two days of having completed the tests, the contractor shall supply the engineer with the test results and neatly plotted load against settlement, load against time, and settlement against time graphs. (ii) Loading
The maximum test load applied shall be equal to twice the specified working load or the ultimate test load, whichever shall be the smaller. The maximum working load shall be half of the maximum test load or the test load, which corresponds with the allowable settlement, which ever shall be the smaller. The allowable settlement shall be as specified on the drawings. (iii) Ultimate Test Load
The ultimate test load in the compression load test shall be the load where settlement suddenly increases disproportionately to the load applied. The ultimate test load in the tension-load test shall be the load where upward movement suddenly increases disproportionately to the load applied or the load producing a permanent use of 10 mm at the top of the pile, whichever is the smaller.
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(v) Defective Piles The test piles and the piles represented by the test pile shall be classified as defective if shown in terms of sub-clause 8113(u) to have a maximum working load of less than the specified working load, or to exhibit excessive settlement. Defective piles shall also include piles damaged beyond repair, piles with structural defects, or piles, which do not comply with the tolerance requirements of Division T8000 of these specifications. If required, the defective piles shall be corrected by the contractor at his own cost, by applying one of the following methods approved by the Engineer: Extracting the pile and replacing it with a new pile Installing a new pile adjacent to the defective pile Lengthening the pile to the correct length if defective in length only Altering the design to fit in with the new conditions caused by the defective pile(s). (w) Standing Time in Respect of Piles-installation Frames Standing time shall only be paid for pile-installation frames standing during normal working hours as laid down in the general conditions of contract for such periods during which the pile installation work has come to a standstill following an action by the employer. As soon as the pile-installation frames have come to a standstill, the contractor shall inform the Engineer, in writing, that he intends to claim standing time, and shall also furnish: Full particulars of the action, which gave, rise to the claim. A list of pile-installation frames in respect of which standing time will be claimed, complete with date and time. The period in respect of which a claim is lodged shall become operative from the moment when the notice has been handed over to the Engineer and shall continue until the restriction has been removed and normal procedure may be resumed. 8114 CAISSONS (a) General Caissons shall, for the purposes of these specifications, be hollow concrete vessels, which are wholly or partly constructed at a higher level and lowered by internal excavation or kentledge to the desired founding level to form structural bearing members. Caissons may be of circular, rectangular or any other shape and may contain one or more excavation compartments, all as detailed on the drawings. Unless otherwise specified hereafter, the provisions of BS 8004 shall apply in regard to the construction of caissons. (b) Construction and sinking A firm horizontal base shall be prepared on which the cutting edge of the caisson shall be laid truly horizontally.
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The level of the base shall be determined and shall be agreed on by the engineer and the contractor and shall serve as the ground surface from which the excavation inside the caisson will be measured. Successive stages of the caisson shall be of convenient height, or as directed by the engineer, and shall be lined up accurately with the preceding stages. All precast elements shall have properly constructed joints in accordance with the drawings to ensure that they fit snugly together. For in situ phase construction, all construction joints in the walls shall be reinforced and the joints shall be made as specified in clause 8407 of these specifications. The lowest element of every caisson, which contains the cutting edges, shall be cured for at least 4 days or shall have reached a strength of at least 50% of the specified strength before sinking is commenced. Subsequent elements shall be cast in sufficient good time to ensure adequate strength for safely resisting the applied forces. During constructing and sinking, the caissons shall be maintained truly vertically and kept in their correct positions. The position and inclination of each caisson shall be determined accurately by measurement after every 2 m of sinking, or after sinking through the depth of one element, whichever distance is the smaller. With a view to eliminating excess friction, the contractor may use bentonite or a similar lubricant, or a water-jet system. Excavation inside caisson compartments shall, unless otherwise specified herein, comply with the provisions of clause 8105. In multi-compartmented caissons, the excavation in any one compartment shall not be taken deeper than 0.6 m below that in any other compartment, except where necessary for correcting deviations. Cutting edges shall be frequently inspected or probed to locate obstacles, which shall be removed immediately. The contractor shall supply all grabs, pumps, diving gear and other plant required for sinking and founding all caissons and shall allow the engineer to use the diving suit and equipment for inspection purposes. The contractor shall employ a competent diver to carry out work under water and shall make provision in the rates tendered for the respective items for this cost. Where the caisson strikes a hard inclined layer and work has to be carried out below the cutting edge, such work shall be measured and paid for under the relevant items of clause 8115, and, where no applicable items exist, such work shall be paid for as extra work. Should the contractor wish to apply the pneumatic caisson method (with a compressed air chamber) for construction, he shall furnish the engineer with full details of the plant, equipment and method for approval. (c) Founding The material at the founding level, if sloping and/or irregular, shall in so far as is possible be cut to as nearly level a surface as possible until the entire cutting edge is evenly and firmly supported on the material.
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Subject to the approval of the engineer, blasting may be used for this purpose. If blasting should be resorted to, only light charges may be used and the caisson shall be protected against damage by suitable cushioning being provided. Should the sloping surface be of hard rock which cannot be cut or broken by any safe and feasible means, the foundation shall be built up by means of a solid wedge of concrete which fills the entire space between the bedrock surface and the horizontal plane through the cutting edge. This concrete shall be of the same class as that specified on the drawings or in the schedule of quantities for the concrete seal. The rock or hard material on which the structure is to be founded shall be completely uncovered. The founding surface shall be cleared of all loose material before inspection by the Engineer immediately prior to casting the concrete seal. No concrete shall be placed in the wedge or the seal before the Engineer has inspected and approved the foundation. For this purpose the contractor shall adequately dewater the caisson to enable the engineer to conduct the inspection. In the event of a caisson not being vertical or in its correct position when it has reached the required depth, or in the event of a caisson being cracked during the sinking process, the contractor shall at his own cost carry out the necessary remedial work to the satisfaction of the Engineer. (d) Data The contractor shall provide the Engineer with a complete record of the types of material excavated during sinking, together with the level at which each type of the material was found. In addition, a log showing the rate of sinking shall be kept by the contractor and furnished to the Engineer. (e) Filling the caissons (i) Concrete seal
The seal shall be constructed of mass concrete of the class specified and shall be placed in accordance with the dimensions and levels shown on the drawings or as prescribed by the Engineer. If this seal cannot be placed in the dry and has to be placed under water, the method of placing this concrete shall be approved by the Engineer. The contractor shall cease placing the concrete under water when sufficient concrete has been placed to seal the foundation effectively. After the concrete has been placed, the concrete seal and the head of water over it shall remain undisturbed for a period of at least 7 days after which the caisson shall be dewatered by pumping for inspection. If more water is still leaking into the caisson, the process of sealing as specified herein shall be continued until the water level within the caisson does not rise at a rate exceeding 10 mm per hour. The relevant requirements of Division 8400 of these specifications and 8113(i)(ii) shall apply for placing the concrete under water. For concrete placed under water by methods other than by tremie, the cement content shall be 20% more than the quantity required for ordinary concrete of the same mix but shall be not less than 450 kg per m 3 of concrete.
(ii)
Filling
Subsequent to inspection of the caisson compartments above the concrete seal, the compartments shall be filled with sand. The sand shall be sufficiently wetted to obviate bulking. The first 2.0 m of filling above the concrete seal shall be lowered gently into position. The sand may then be poured from the top and compacted sufficiently to prevent settlement while the cover slab concrete is being placed. The top of the sand fill within the caisson shall be finished off to the level specified below the underside of the caisson cover slab. (f) Stripping Where the walls of the caisson have been overbuilt, the concrete shall be stripped to the required level without damage being done to the concrete below the cut-off level. The longitudinal reinforcement of the caisson shall project above the cut-off level by a distance of at least 40 times the bar diameter. (g) Concrete screed below the caisson cover slabs A concrete screed of the specified thickness and class of concrete shall be provided to the level shown on the drawings over the area covered by the cover slab, including the area within the caissons on top of the sand filling, except where the underside of the cover slab is being formed with formwork. 8115 MEASUREMENT AND PAYMENT Item 81.01 Additional foundation investigations ......................................Provisional Sum A provisional sum is allowed in the Bill of Quantities to cover the cost of this work. Item 81.02 Excavation of materials (a) Excavation of soft material situated in the following successive ranges: (i) (ii) 0 m to 2m .......................................................... ........................cubic meter (m3) Exceeding 2m to 4 m .............. ..................................................cubic meter (m3)
Etc in increments of 1m depth............................................................ cubic meter (m3) (b) for excavation in hard material irrespective of depth ................................. cubic meter (m3) (c) for additional excavation required by the Engineer after the excavation has been completed ............................................................................................................ cubic meter (m3) The limits for the successive depth ranges shall be measured down from the average ground surface [Subclause 8105 (b)] to the agreed foundation level (Clause 8106). The unit of measurement shall be the cubic meter of material, measured in the original position before excavation. The quantity of excavation for each depth range shall be calculated from the neat outlines of the base of floor and the depth of excavation completed within each range. Irrespective of the total depth of the excavation the quantity of material within each depth range shall be measured and paid for separately.
Supplementary payment for excavation by hand as specified in sub-clause 8l05 (i), shall be the full compensation for incidentals for hand-excavating the materials instead of with massexcavating equipment. At the face of any concrete for which formwork has to be provided an additional quantity of excavation shall be measured to 0.6m outside the concrete perimeter to provide for a working space. Where foundation fill is constructed in an excavation, the quantity of excavated material measured for payment shall be the material contained within the vertical planes through the lower base of the truncated pyramid defined in Clause 8109 or as directed by the Engineer. In no case shall any of the following excavation be included in the measurement for payment : The volume of excavation in excess of the above mentioned limits. The volume included with in the excavated road prism, contiguous channels, ditches, etc., for which payment is provided elsewhere in the Specifications. The volume of water or other liquid, except the volume of mud, muck or similar semi-solid matter not resulting from construction operations and which cannot be pumped or drained away. The tender rate shall include full compensation for excavation in each class of material, the spoiling or stockpiling of material, for any additional excavation the contractor may require for additional working space outside the authorized limits, for trimming and cleaning the bottoms and sides of excavation, for strutting, shoring and safeguarding excavations. If, after any foundation excavation is completed, cleaned and trimmed ready for blinding, the Engineer orders further excavations due to changed dimensions and/or foundation conditions, an extra over payment (pay item 81.02(c)) on the additional excavation measured for payment shall be payable in full compensation for any additional costs to the contractor over and above the normal excavation costs. Item 81.03 Access ................................................................................................... lump sum The tendered lump sum shall include full compensation for providing access, which inter alia, shall include constructing temporary banks, artificial islands and/or cofferdams, their protection, safeguarding and maintenance, draining and keeping dry the working areas and draining the excavations within the access, and any incidentals in respect of work to be done below standing water. 75% of the lump sum will be paid when the access has been constructed. The remaining 25% will be paid after the access has been removed. Item 81.04 Drainage............................................................................................. Lump Sum Drainage where no Access has been provided shall be measured in lump sum. Payment will be made for this work by way of a lump sum for each structure or series of structures appearing separately in the schedule of quantities. The lump sum shall be paid on a pro rata basis as the work progresses. The tendered lump sum shall include full compensation for drainage by pumping or in any other way and for any other work necessary for keeping the excavation dry or for working in the dry. Item 81.05 Backfill to excavations utilizing : (a) Material from the excavation..............................................................cubic meter (m3)
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(b)
Imported material ..................................................................... .........cubic meter (m3)
The unit of measurement shall be the cubic meter of backfill material measured in the excavations. The quantity measured shall be calculated from within the neat outlines defined for the excavation under pay item 81.02 and the height over which the backfilling is constructed. The height shall be determined by the upper surface of the road prism or the reference ground surfaces (Sub-clause 8105(b)) whichever is the lower. The tendered rate for each cubic meter of backfill shall include full compensation for furnishing and replacing all materials within the entire excavation, for transporting materials within the free haul distance of 1.0 km, and for preparing, processing, shaping, watering, mixing and compacting the material to the specified densities. Item 81.06 Fill within restricted areas The unit of measurement shall be the cubic meter (m3) and the quantity shall be taken as the total volume of material within the restricted area as defined in Sub-clause 8108 (e). The quantity shall not include the volume of backfill, which is measured, and paid for under pay item 81.05 above. The tendered rate shall include full compensation for all additional work necessitated due to working in the restricted area and for the increased density required in the restricted area. Item 81.07 Overhaul in excess of 1.0 km, on excavated Material and on material imported for backfill, foundation fill and fill for caissons ...........Cubic meter Overhaul shall be measured and paid for as specified in Division 1700 of these specifications and shall apply only to that portion of the material qualifying for payment under pay items 81.02, 81.05(b), 81.09 (a) and (c), and 81.48. Overhaul shall not apply to concrete used in the foundation fill. Item 81.08 Over break in excavation in hard material ................................ Square Meter The unit of measurement shall be the square meter (m2) of surface area of the vertical outer faces of the bases. The tendered rate shall include full compensation for the over break material removed from the excavation, for the concrete fill in accordance with sub-clause 8105 (c) and any additional screeding concrete required. Item 81.09 Foundation fill (a) (b) (c) (d) (e) Rock fill ............................................................................................ .cubic meter (m3) Crushed stone fill................................................................................ cubic meter (m3) Compacted granular fill...................................................................... cubic meter (m3) Mass concrete (Grade indicated)........................................................ cubic meter (m3) Blinding layer (Grade of concrete and thickness indicated) ............. .cubic meter (m3)
The unit of measurement shall be the cubic meter of approved material placed and compacted below the bases as specified or where directed by the Engineer. The quantity of foundation fill to be measured for payment shall be the material contained within the prism specified in Clause 8109 for minimum foundation fill to be constructed or to the outlines shown on the drawings or as directed by the Engineer.
The tendered rate shall include full compensation for the procuring, furnishing, transporting, placing, and compacting of the material. Item 81.10 Establishment on site for the grouting of rock fissures The tendered lump sum shall include full compensation for establishment on site and subsequent removal of all special plant for the grouting of rock fissures and for carrying out operations, the cost of which does not vary with the actual amount of work to be done. This work will be paid for as a lump sum, of which 75% will become payable when all equipment is on the site and the first hole has been grouted, and the remaining 25% will become payable after all the holes have been grouted and the equipment has been removed from the site. Item 81.11 Move to and set up equipment at each hole to be drilled The unit of measurement shall be the number (No) of positions to which the equipment for drilling and grouting of rock fissures has to be moved and set up in position (equals the number of holes to be drilled). The tendered rate shall include full compensation for all costs involved in moving and setting up equipment. Item 81.12 Drilling of holes ......................................................................................... meter The unit of measurement shall be the meter (m) of hole drilled. The tendered rate shall include full compensation for drilling and cleaning of holes as specified. Item 81.13 Grouting of holes ............................................................................................. kg The unit measurement for grouting shall be the mass in kilograms (kg) of cement used in the grouting operation. The tendered rate shall include full compensation for providing and pumping into the drilled holes the grout as specified by the Engineer. Item 81.14 Doweling into rock: (a) (b) Drilling and cleaning .....................................................................................meter (m) Supply and installation of dowel bars....................................... ..............kilogram (kg)
The unit of measurement for the drilling and cleaning of holes in rock shall be the meter of hole drilled. The unit of measurement for the dowel bars shall be the mass in kilograms of bars actually provided and secured in position. The tendered rate shall include full compensation for drilling and cleaning of holes, supplying, positioning and grouting of dowel bars as specified. Item 81.15 Foundation lining .......................................................................... square meter The unit of measurement for foundation lining shall be (type of material and thickness indicated) the square meter (m2) of concrete surface lined. The tendered rate shall include full compensation for the procuring, furnishing, and placing of all material and for labor and incidentals required to complete the work as specified.
Item 81.16 Establishment on the site for piling.................................................... lump sum The tendered lump sum shall include full compensation for generally, leveling the piling site, establishing on the site and subsequently removing all structural platforms, rafts, and all special constructional plant and equipment for foundation piling and for carrying out operations, the cost of which does not vary with the actual amount of piling done. This work will be paid for by way of a lump sum, 50% of which will become payable when all equipment is on the site and the first pile has been installed. The second installment of 25% of the lump sum will be payable after half the total number of piles have been installed, and the final installment of 25% after all the piles have been completed and the equipment has been removed from the site. Item 81.17 Moving to, and setting up the equipment at each position for installing the piles The unit of measurement shall be the number (No) of positions to which the installation equipment has to be moved and set up in position. The quantity measured shall be the number of piles installed plus the number of piles redriven on the instruction of the engineer, plus any piles provided in addition for load tests, which do not form part of a specific pile group. The tendered rate shall include full compensation for all costs involved in moving and setting up any equipment. Item 81.18 Augered or bored holes for piles With a diameter of (diameter indicated) through material situated within the following successive depth ranges: (a) Augered holes: (1) (2) (3) (b) 0 m up to 10 m ....................................................................... ..............meter (m) Exceeding 10 m and up to 15 m.................................. .........................meter (m) Etc in increments of 5 m depths........................................................... meter (m)
Bored holes (1) 0 m up to 10 m .................................................................................. ...meter (m) (2) (3) Exceeding 10 m and up to 15 m................................. ..........................meter (m) Etc in increments of 5 m depths........................................................... meter (m)
The limits for the successive depth ranges shall be measured down from the average ground surface (sub-clause 8113 (i)) to the agreed founding level (clause 8106). The unit of measurement shall be the meter of hole, including the depth of the bulbous base formed, as may be applicable. The depth of the bulbous base shall be deemed to be equal to the diameter of a sphere, the volume of which shall be equal to the quantity of compacted concrete in the bulbous base. Irrespective of the total depth of the hole, the quantity within each, depth range shall be measured and paid for separately. The tendered rates for forming augered holes shall include full compensation for boring, supplying, installing and extracting the driven temporary casing as well as for disposing of surplus material resulting from the hole having been formed.
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Item 81.19 Driving the temporary casing for driven displacement piling systems for forming holes for piles With a diameter of (diameter indicated) through material situated within the following successive depth ranges: (a) (b) (c) 0 m up to 10 m ..............................................................................................meter (m) Exceeding 10 m and up to 15 m ....................................................................meter (m) Etc in increments of 5 m depths.....................................................................meter (m)
The limits for the successive depth ranges shall be measured down from the average ground surface (sub-clause 8113(h)) to the agreed founding level (clause 8106). The unit of measurement shall be the meter of hole plus the depth of bulbous base formed, as may be applicable. The depth of the bulbous base shall be deemed to be equal to the diameter of a sphere, the volume of which shall be equal to the quantity of compacted concrete in the bulbous base. Irrespective of the total depth of the hole, the quantity within each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for supplying, driving and subsequently extracting the temporary casing. Item 81.20 Manufacturing, supplying and delivering prefabricated piles The unit of measurement shall be the meter (m) of accepted prefabricated pile (type and size indicated) delivered on the site in accordance with the engineer's written instructions. The tendered rate shall include full compensation for supplying all the materials, manufacturing, transporting and delivering to the point of use and handling the prefabricated piles. Item 81.21 Installation of prefabricated piles Type and size indicate, through material situated within the following successive depth ranges: (a) (b) (c) 0 m up to 10 m ...............................................................................................meter (m) Exceeding 10 m and up to 15 m ....................................................................meter (m) Etc in increments of 5 m depths.....................................................................meter (m)
The limits for the successive depth ranges shall be measured down from the average ground surface (sub-clause 8113(h)) to the founding depth agreed on (clause 8106). The unit of measurement shall be the meter of prefabricated pile installed. That part of the prefabricated pile projecting above the average ground surface shall not be measured and paid for. Irrespective of the total length of pile installed, the quantity installed within each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for hoisting and driving the pile.
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Item 81.22 Extra over item 81.18, irrespective of the depth, to form augered and bored pile holes through identified obstructions consisting of: (a) (b) (c) Coarse gravel with a matrix content of less than (maximum percentage indicated)..... ....................................................................................................................... meter (m) Boulders (description of and maximum size indicated)............................... .meter (m) Rock formation (description and class of rock indicated)............................. meter (m)
The unit of measurement shall be the meter of pile hole formed through the identified obstruction, measured from the depth at which the identified obstruction is encountered to the depth at which normal auger drilling or boring can be resumed or another type of identified obstruction is encountered. The tendered rates shall include full compensation for all additional work and incidentals required for forming the pile hole through the identified obstruction.
Notes:
Sub Pay item 81.22(a): The matrix content indicated shall be the percentage by volume of matrix in material containing coarse gravel. Where the maximum percentage indicated is exceeded, payment for forming holes through such material shall be made under item 81.18. Unless otherwise specified, the maximum percentage of matrix shall be accepted to be 60%. Where obstructions other than those provided for in Pay item 81.22 can be identified, they shall be described on the drawings and/or in the project specifications. Provision therefore shall be made in the schedule of quantities under extensions to Pay item 81.22. Item 81.23 Forming augered and bored pile holes through unidentified obstructions A provisional sum is allowed in the schedule of quantities for covering the cost of this work. Payment for the work authorized by the engineer shall be in accordance with the provisions of the general conditions of contract. Item 81.24 Driving temporary casings for driven displacement piling systems or installing prefabricated piles through identified or unidentified obstructions A provisional sum is allowed in the schedule of quantities for covering the cost of this work. The method of payment for the work authorised by the Engineer shall be in accordance with the provisions of the general conditions of contract. Item 81.25 Extra over items 81.18, 81.19 and 81.21 for raking piles: (a) (b) (c) Holes for piles of (diameter and rake indicated) .......................................... .meter (m) Temporary casing for driven displacement pile systems (diameter and rake indicated) ....................................................................................................................... meter (m) Prefabricated piles (type, size and rate Indicated)......................................... meter (m)
The tender rates shall include full compensation for all additional work and incidentals for forming the pile holes or for driving and later extracting the temporary casing, or for installing prefabricated piles to the rake shown. Item 81.26 Forming under reams for piles .....................................................number (No) The unit of measurement shall be the number of (No) pile (diameter indicated) holes under reamed.
The tendered rate shall include full compensation for all work to be done in forming the under reams. Item 81.27 Forming the bulbous bases for piles ............................................. number (No) (diameter indicated) The unit of measurement shall be the number (No) of bulbous bases formed. The tendered rate shall include full compensation for al work to be done in forming the bulbous bases but shall exclude the concrete work. Item 81.28 Socketing piles into rock formation.............................................. number (No) (class of rock and length of socket indicated) The unit of measurement shall be the number of (No) sockets, the length of which shall be not less than the specified length, formed in rock, the hardness of which shall be not less than that of the specified class of rock. The tendered rate shall include full compensation for all work to be done for socketing into the rock formation. Item 81.29 Installing and removing temporary casings in augered holes for piles. meter The unit of measurement shall be (diameter indicated) the meter (m) of temporary casing installed as directed by the Engineer or shown on the drawings. Only the installed temporary casing below the average ground surface (sub-clause 8113(h)) shall be measured for payment. The tendered rate shall include full compensation for supplying, installing and removing the temporary casings. Item 81.30 Installing permanent pile casing for piles The unit of measurement shall be (diameter indicated)the meter (m) of permanent casing installed as instructed by the engineer or shown on the drawings. The tendered rate shall include full compensation for supplying and installing permanent pile casing. Item 81.31 Steel reinforcement in cast in situ piles: (a) (b) Mild-steel bars .....................................................................................................ton (t) High-yield stress-steel bars (type indicated)........................................................ton (t)
The unit of measurement for steel bars shall be the ton of reinforcement in place in accordance with the drawings or as authorised. Ties and other steel used for keeping the reinforcing steel in position shall be measured as steel reinforcing under the appropriate Sub-item. The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial welds, placing and fixing the steel reinforcing, including all tying wires, spacers and waste. Item 81.32 Cast in situ concrete in piles, under reams, bulbous bases and sockets ......m3 The unit of measurement shall be the cubic meter (m3) of Concrete placed in the cast insitu piles, under reams, bulbous bases and sockets.
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Item 81.33 Extra over item 81.32 for concrete cast under water ............ cubic meter(m3) The unit of measurement shall be the cubic meter (m3) of concrete cast under water, the quantity being calculated as for pay item 81.32. The tendered rate shall include full compensation for all additional work, incidentals and extra cement required for placing the concrete under water. Item 81.34 Splicing/coupling prefabricated piles for lengthening.................number (No) The unit of measurement shall be (size of pile indicated) the number (No) of splices/couplings in prefabricated piles for each size of pile. The tendered rate shall include full compensation for all work required for splicing/coupling the piles in accordance with the specifications. Item 81.35 Stripping/cutting the pile heads......................................................number(No) The unit of measurement shall be (type and diameter/size of pile indicated) the number (No) of heads of each type and diameter/size of pile stripped/cut. The tendered rate shall include full compensation for providing all tools and stripping/cuffing the pile heads. Item 81.36 Establishment on the site of the load testing of piles ........................ lump sum The tendered lump sum shall include full compensation for the establishment on the site and subsequently removing all the special plant and equipment required for conducting the load tests on piles. This cost does not vary with the number of load tests to be conducted. Payment for this work shall be made by way of a lump sum, 100% of which will paid after the testing assembly has been completely assembled and the first load test has been started. Item 81.37 Load tests on piles ..........................................................................number (No) The unit of measurement shall be (compression/tension test, diameter/size, specified working load indicated) the number (No) of load tests conducted on the instruction of the Engineer, for each specified working load. Test piles, but not anchor piles and anchors, shall be measured as specified above for permanent piles. Anchor piles and anchors shall be deemed to form part of the testing equipment under this item. The tendered rate shall include full compensation for installing the anchor piles and anchors where necessary; conducting load tests, and processing and submitting the results. Item 81.38 Establishment on the site for core drilling ........................................lump sum The tendered lump sum shall include full compensation for the establishment on the site and subsequently removing all the equipment required for conducting the core drilling. This cost does not vary with the quantity of work to be done. This work will be paid for by way of a lump sum, 100% of which will become payable when the equipment has been set up at the first location and drilling has started. Item 81.39 Moving the equipment to and assembling it at each location where cores are to be drilled ....................................................................................number (No) The unit of measurement shall be the number (No) of locations to which the core-drilling equipment is to be moved and at which it has to be assembled.
The tendered rate shall include full compensation for the cost of moving and assembling the equipment. Item 81.40 Drilling the cores (Diameter indicated) in: (a) (b) Concrete .........................................................................................................meter (m) Founding formation: (1) (2) Irrespective of hardness........................................................................meter (m) With a hardness of (hardness indicated)...............................................meter (m)
The unit of measurement shall be the meter of hole drilled. The tendered rate shall include full compensation for drilling, recovering and packing the cores, keeping the drilling records, providing core boxes, providing and installing the casings, and backfilling the holes with grout. Item 81.41 Standing time for pile-installation frame ............................................. hour(h) The unit of measurement for the standing time of a pile- installation frame shall be the hour (h) during which the pile- installation frame is standing in terms of sub-clause 6113(w). The tendered rate shall include full compensation for all fixed costs for the pile-installation frame, which is not connected with its operation and the quantity of work done. Item 81.42 Establishment on the site for constructing the caisson.................... lump sum The tendered lump sum shall include full compensation for the establishment on the site and later removing all special plant and equipment necessary for constructing the caissons. This cost shall not vary in accordance with the number of caissons constructed. This work will be paid for by way of a lump sum, 50% of which will be paid when all the equipment is on the site and the first caisson has been constructed. The second payment of 25% of the lump sum will be paid after half the number of caissons have been completed, and the final installment of 25% after all the caissons have been completed and the equipment has been removed from the site. Item 81.43 Formwork for caissons .................................................................. square meter The unit of measurement shall be (class of finish indicated) the square meter (m2) of formwork, and only the area of formwork in contact with the finished face of the concrete shall be measured. Formwork for construction joints shall be measured for payment under class F1 surface finish but shall be measured only for construction joints shown on the drawings or as prescribed by the Engineer. The tendered rate shall include full compensation for supplying all the materials, erecting the false work and formwork, constructing the forms, forming the grooves, fillets, chamfers, stop ends for construction joints, treating the forms, all accessories, and stripping and removing the formwork after completion of the work. Payment for formwork shall be made only after the formwork has been stripped and the surface finish approved. Item 81.44 Steel reinforcement for caissons: (a) (b) Mild-steel bars .....................................................................................................ton (t) High-yield-stress-steel bars (type indicated) .......................................................ton (t)
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The unit of measurement for steel bars shall be the ton of reinforcement in place in accordance with the drawings or as may have been authorised. Ties and other steel used for positioning the reinforcing steel shall be measured as steel reinforcing under the appropriate sub-item. The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding, trial welding joints, placing and fixing the steel, including all tying wire, spacers and waste. Item 81.45 Cast in situ concrete in caissons and concrete seals...............cubic meter (m3) The unit of measurement for cast in situ concrete shall be (class of concrete indicated) the cubic meter (m3) of concrete in place. Concrete quantities in the caissons shall be calculated from the dimensions shown on the drawings or authorised by the Engineer, and the length of the caisson from the founding level to the specified cut-off level. The quantity of concrete in the concrete seal shall be calculated in accordance with the dimensions shown on the drawings or authorised by the Engineer. The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the material, providing all plant, mixing, transporting, placing and compacting the concrete, all sealing, curing the concrete and repairing defective concrete. Payment shall distinguish between the different classes of concrete. Item 81.46 Cutting edge for caissons ...............................................................number (No) The unit of measurement shall be (diameter/ size indicated) the number (No) of caissons provided with cutting edges, irrespective of the material they have been constructed of. The tendered rate shall include full compensation for manufacturing, supplying, delivering and installing the complete cutting edge as well as for joining the cutting edge to the caisson unit. Where the cutting edge is of concrete and forms part of the bottom element, the tendered rate shall include full compensation for all additional work required for completing the element. Item 81.47 Sinking caissons through material situated Within the following successive depth ranges (diameter/size indicated): (a) (b) (c) Omupt05m..................................................................................................... meter (m) Exceeding 5 m and up to 10 m ...................................................................... meter (m) Etc in increments of 5 m depths .................................................................... meter (m)
The limits of the successive depth ranges shall be measured down from the firm horizontal base (sub-clause 8114(b)) to the agreed founding level (clause 8106). The unit of measurement shall be the meter of caisson sunk. Irrespective of the length of caisson sunk, the quantity for each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for locating and holding in position, dewatering, pumping, kentledge and lubricating the sides of the caisson, and for all work in connection with the sinking of the caisson which is not paid for elsewhere. Item 81.48 Excavation for caissons: (a) Excavating soft material situated within the following successive depth ranges: (1) 0m up to 2m. ............................................................................. cubic meter (m3)
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(2) (3) (b) depth
Exceeding 2 m and up to 4 m ...................................................cubic meter (m3) Etc in increments of 2 m depths ................................................cubic meter (m3)
Extra over sub-pay item 81.48(a) for excavation in hard material irrespective of ............................................................................................................cubic meter (m3)
The limits for the successive depth ranges shall be measured down from the firm horizontal base (sub-clause 8114(b)) to the excavated level inside the caisson. The unit of measurement shall be the cubic meter of material, measured in the original position before excavation. The quantity of excavation for each depth range shall be calculated from the gross area of the caisson in plan and the depth of excavation completed within each depth range. Irrespective of the total depth of excavation, the quantity of material within each depth range shall be measured and paid for separately. The tendered rates shall include full compensation for excavation in the classified material, spoiling or stockpiling the material, hauling the excavated material for the free- haul distance of 1.0 km, trimming the bottom of the excavation, dewatering, pumping and removing the material leaking into the caisson before sealing. Item 81.49 Filling the caissons The unit of measurement shall be the cubic meter of sand placed above the concrete seal in the caisson compartments. The tendered rate shall include full compensation for supplying and placing the sand, transporting the material within a free-haul distance of 1.0 km, and compacting the material as specified. Item 81.50 Stripping the caisson heads. The unit of measurement shall be (size of caisson indicated) the number (No) of caissons of each size stripped. The tendered rate shall include full compensation for cutting away, trimming and disposing of the concrete removed. Item 81.51 Nuclear integrity testing on bored piles: (a) (b) (c) Constructing 5.0 m long calibration piles of (indicate diameter) ............number (No) Installing 65 mm internal diameter steel ducts in the piles............................meter (m) Performing integrity tests using: (1) (2) The nuclear method. ........................................................................number (No) The neutron method.........................................................................number (No)
The unit of measurement for sub-pay item (a) shall be the number of calibration piles constructed. The unit of measurement for sub- pay item (b) shall be the meter of 65 mm internal diameter steel duct installed. The unit of measurement for sub-pay item (c) shall be the number of integrity tests performed by each method. The tendered rates shall include full compensation for procuring and furnishing all materials, constructional plant, equipment, labor and incidentals for forming the bored holes, constructing the calibration piles, installing the steel ducts, and performing the prescribed integrity tests, complete as specified.
Series 8000: Structures Division 8200 Falsework, Formwork, And Concrete Finishes
DIVISION 8200 FALSEWORK, FORMWORK, AND CONCRETE FINISHES

8201 SCOPE This Division covers the design, the specification of materials, supply and erection of all falsework and formwork used in the construction of permanent work.. This Division also covers the specification of materials for classes of concrete surface finishes on formed and unformed concrete surfaces. 8202 DIMENSIONS The dimensions shall be in accordance with the details shown in the Contract. 8203 MATERIAL REQUIREMENTS FOR FALSEWORK AND FORMWORK (a) Falsework Falsework shall consist of either purpose made or proprietary timber or metal, props, beams or ties adequate to support the forces imposed during construction of the concrete structure without excessive deflection. (b) Formwork Formwork shall be provided to produce hardened concrete to the lines, levels and shapes shown on the drawings or specified elsewhere. It shall have adequate strength to carry all applied loads, including the pressure of fresh concrete, vibration loads, weight of workers and equipment, without loss of shape. Forms shall be mortar tight and designed to allow removal without risk of damage to the completed structure. Joints in the formwork shall be perpendicular to the main axis of the shape of the concrete. Design of formwork for high sections shall be such that it shall not be necessary to drop concrete freely from a height greater than 1.6 metres or to move concrete along the formwork after deposition. Material used for formwork shall be sound and suitable for the purpose intended and surface finish specified. Provision shall be made for the accurate location and firm support of fittings, bolts, anchorages and formers of holes as shown on the drawings. Temporary fittings used for the support of the formwork shall be arranged to permit removal without damage to the concrete. The use of wires and or bolts extending to the surface of the concrete shall not be permitted except where shown on the Drawings. Forms for edges of concrete shall be filleted and for re-entrant angles chamfered as shown on the Drawings. Formwork shall consist of purpose made or proprietary timber, metal or plastic boarding or sheeting adequate to support the forces during construction of the concrete structure without excessive deflection. The following are recommended formworks:
(i)
Tongue-and-groove boarding
Tongue-and-groove boarding shall be of suitably dried timber, which will not warp, distort or cause discoloration of the concrete. The widths of the boards shall be as specified on the drawings or in the schedule of quantities or as prescribed by the Engineer. Boards shall be supplied in lengths not shorter than 3 m. (ii) Steel forms to exposed surfaces
For classes F2 and F3 surface finish the individual panels shall be assembled sufficiently rigidly and so clamped as not to deform or kick during handling or under the pressure of the wet concrete. The surfaces of forms, which are to be in contact with the concrete, shall be clean, free from deposits or adhering matter, ridges or spatter, which will impart irregularities and blemishes to the concrete surface, and shall also be free from indentations and warps. (iii) Void formers
Void formers used in permanent work shall be subject to the approval of the Engineer. Where void formers of a special design are required, details thereof will be specified. Void formers shall be manufactured from material which will not leak, tear or be damaged during the course of construction and shall be of such tight construction as to prevent undue loss of the mortar component of the concrete through leakage. The units shall be sufficiently rigid so as not to deform during handling or under the pressure of the wet concrete. For mild-steel spiral-lock-formed void formers, the metal thickness shall be as follows, unless otherwise specified: (1) Unbraced void formers 0.6 mm for diameters of up to 600 mm 0.8 mm for diameters exceeding 600 mm and up to 800 mm 1.0 mm for diameters exceeding 800 mm and up to 1 000 mm. (2) Braced void formers 0.6 mm for diameters of up to 800 mm 0.8 mm for diameters exceeding 800 mm and up to 1 000 mm 1.0 mm for diameters exceeding 1 000 mm and up to 1 200 mm 1.2 mm for diameters exceeding 1 200 mm. The thickness specified for braced void formers shall apply to formers internally braced with timber or equivalent braces. The braces shall be at spacings not exceeding 2.0 m and not further than 1.0 m from the end of each unit. Timber cross braces shall consist of members with cross- sectional dimensions of at least 50 mm x 50 mm. All hollow void-former units shall be provided with a 12 mm diameter drainage hole at each end. (iv) Chamfer and recess fillets
Timber fillets used for forming chamfers and recesses on exposed surfaces shall be made from new material unless otherwise authorized.
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(v)
Jack rods for sliding formwork
The jack rods, base plates and couplers shall be strong enough to carry the design load under all operating conditions without buckling, distorting or causing damage to the concrete. Jack rods which are to remain permanently embedded in the concrete shall comply with the requirements for storing and surface condition of steel reinforcement. Under no circumstances shall bent rods be used in the work. The jack rods used shall have a diameter of at least 25mm. 8204 DESIGN AND CONSTRUCTION REQUIREMENTS (a) Drawings When complete details for forms and falsework are not shown in the Contract, the Contractor shall prepare and submit drawings according to Division 102 of these specifications. The Contractor shall: 1) Design and show the details for constructing safe and adequate forms and falsework that provide the necessary rigidity, support the loads imposed, and produce in the finished structure the required lines and grades. 2) Show the maximum applied structural load on the foundation material. Include a drainage plan or description of how foundations will be protected from saturation, erosion, and/or scour. 3) Precisely describe all proposed material. Describe the material that is not describable by standard nomenclature (such as AASHTO or ASTM specifications) based on manufacturer's tests and recommended working loads. 4) Evaluate falsework material and ascertain whether the physical properties and conditions of the material is such that it can support the loads assumed in the design. 5) Furnish design calculations and material specifications showing that the proposed system will support the imposed concrete pressures and other loads. Provide an outline of the proposed concrete placement operation listing the equipment, labor, and procedures to be used for the duration of each operation. Include proposed placement rates and design pressures for each pour. Include a superstructure placing diagram showing the concrete placing sequence and construction joint locations. 6) Provide design calculations for proposed bridge falsework. 7) A registered professional Engineer proficient in structural design shall design, sign, and seal the drawings. The falsework design calculations shall show the stresses and deflections in load supporting members. 8) Show anticipated total settlements of falsework and forms. Include falsework footing settlement and joint take-up. Design for anticipated settlements not to exceed 25 mm. 9) Design and detail falsework supporting deck slabs and overhangs on girder bridges so there is no differential settlement between the girders and the deck forms during placement of deck concrete. 10) Design and construct the falsework to elevations that include anticipated settlement during concrete placement and required camber to compensate for member deflections during construction.
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11) Show the support systems for form panels supporting concrete deck slabs and overhangs on girder bridges. 12) Show details for strengthening and protecting falsework over or adjacent to roadways and railroads during each phase of erection and removal. 13) Include intended steel erection procedures with calculations in sufficient detail to substantiate that the girder geometry will be correct. 14) Submit details of proposed anchorage and ties for void forms. 15) Submit separate falsework drawings for each structure, except for identical structures with identical falsework design and details. 16) Do not start construction of any unit of falsework until the drawings for that unit are reviewed and accepted. (b) Design (i) General
The contractor's design and drawings of the falsework and formwork shall comply amongst others with all statutory requirements. The Engineer may require the contractor to submit to him for consideration and approval the design and drawings of the falsework and formwork for any structure. The contractor shall submit his design criteria and calculations and detail drawings of the falsework and formwork to the Engineer at least 14 days before the Engineer's approval is required. (ii) Falsework
The contractor shall make his own assessment of the allowable bearing pressure on the foundation material and shall design the footings and falsework to prevent overloading, differential settlement and unacceptable overall settlement. In assessing the allowable bearing pressure, due account shall be taken of the effect of wetting on the foundation material. In designing the falsework, cognizance shall also be taken of the redistribution of load which may occur on account of the effect of temperature, wind force, the prestressing of curved and skewed structures, stage construction, flooding and debris. Particular attention shall be given to providing transverse and diagonal bracing as well as rib stiffeners on cross bearers. (iii) Formwork (1) General
Formwork shall be so designed as to be sufficiently rigid to ensure that the specified dimensional tolerances can be achieved under the combined action of self-weight, dead load and imposed loads as well as the additional loads resulting from the rate of concreting, the layer thickness of the concrete cast in one operation and the method of placing and compaction.
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(2)
Sliding formwork
The contractor shall be responsible for the design of the sliding formwork. Prior to fabrication or bringing the sliding formwork and any additional equipment to the site, the contractor shall submit drawings of the complete sliding- formwork assembly to the Engineer for approval. The drawings shall show full details of the forms, jacking frames, access ladders, hanging platforms, safety rails and curing skirts as well as details of the jacks and jack layouts. The contractor shall be required to submit to the Engineer, before slide casting commences, an instruction manual in which the sliding techniques, jacking procedure, methods of keeping the formwork level, the procedure to be adopted to prevent bonding of the concrete to the forms and a method for releasing the forms in the event of bonding, the instrumentation and monitoring of the slide casting and correcting for verticality, twisting and levelness are described in detail. The formwork panels shall be inclined to give a small taper, the forms being slightly wider at the bottom than at the top. The taper shall be so designed as to produce the specified concrete thickness at the mid-lift level of the form.. The spacing of the jacks with their jack rods shall be so designed that the dead load of the sliding-formwork assembly, the frictional load, and the mass of materials, personnel and equipment will be evenly distributed and within the design capacity of the jacks used. (c) Construction (i) General
Notwithstanding approval given by the Engineer for the design and drawings prepared by the contractor for the falsework and formwork, and the acceptance of the falsework and formwork as constructed, the contractor shall be solely responsible for the safety and adequacy of the falsework and formwork and shall indemnify and keep indemnified the employer and Engineer against any losses, claims or damage to persons or property whatsoever which may arise out of or in consequence of the design, construction, use and maintenance of the falsework and formwork and against all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in respect thereof or in relation thereto. For works on, over, under or adjacent to any railway line which is controlled by a statutory authority, the contractor shall comply, inter alia, with the requirements for the preparation and submission of drawings for falsework and formwork, and the submission of certificates for the proper' construction thereof, all in accordance with the official specifications of such authority. After having constructed the falsework and formwork, and prior to placing the reinforcing steel and/or the concrete, the contractor shall inspect the falsework and formwork. Dimensions shall be checked, unevenness of surface shall be corrected, and special attention paid to the adequacy and tightness of all bolts, ties and bracings as well as to the soundness of the foundations. The contractor shall give the Engineer at least 24 hours notice of his intention to place the concrete to enable the Engineer to inspect all aspects of the completed work. However, before notifying the Engineer, the contractor shall satisfy himself that the work complies in all respects with the specifications.
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Concrete sections with dimension of smaller than 200 mm shall not be formed with sliding formwork unless authorized by the Engineer. Where no provision has been made in the schedule of quantities for sliding formwork, the contractor may, in a covering letter to the tender, submit a lump sum which reflects a saving in the cost for the use of sliding formwork in lieu of conventional formwork. (ii) Falsework
Falsework shall be erected in accordance with the approved drawings incorporating such modifications as required by the Engineer. The contractor shall take precautions to prevent deterioration of the foundations during the course of construction. The falsework shall incorporate features, which will permit adjustment to the alignment of the formwork to neutralize the expected settlement and deflection under load. (iii) Formwork (1) General
The formwork for bridge decks shall be erected to levels calculated from the information given on the plans for roadworks and bridges. The levels shall be adapted to make provision for the specified precamber as well as for the expected deflection and settlement of the fully loaded falsework and formwork. The levels shall be set out and checked at intervals not exceeding 2.50 m. For constructing the formwork, the contractor may, subject to the provisions of clause 8203 of this Division, use any material suitable for and compatible with the class of surface finish and dimensional tolerances specified for the particular member. Formwork shall be sufficiently rigid to maintain the forms in their correct position, shape and profile and shall be of such tight construction that the concrete can be placed and compacted without undue loss or leakage of the mortar component of the concrete. The joints between contiguous formwork elements shall be of a tight fit and, where necessary, the joints shall be caulked, taped or packed with a sealing gasket, all at no extra payment if undue leakage occurs or can be expected. Paper, cloth or similar material shall not be used for this purpose. The formwork construction shall permit accurate erection and easy stripping without shock, disturbance or damage to the cast concrete. Where necessary, the formwork assembly shall permit the removal or release of side forms independently of the soffit forms. Metal supports, ties, hangers and accessories embedded in the concrete shall be removed to a depth of not less than the cover specified for the reinforcement. No wire ties shall be used. All external corners shall be chamfered by fillet strips being fixed into the corners of the formwork to form 25 mm x 25 mm chamfers. Re-entrant angles need not be chamfered unless specified. Where polystyrene or similar material, susceptible to damage is used, it shall be lined with a hard surface on the side to be concreted. The hard material shall be sufficiently resilient to ensure that the required quality of work can be achieved. Where it is specified, all formwork ties shall be provided with recoverable truncated cones between sleeve ends and formwork faces to ensure that sleeve ends are not exposed on concrete surfaces. The cones shall have a minimum depth of 15 mm.
(2)
Formwork to exposed surfaces
The formwork and boards shall be so arranged as to form a uniform and regular pattern in line with and perpendicular to the main axis of the member, unless otherwise approved or directed by the Engineer. Joints between contiguous members shall, after caulking, taping or sealing, be treated to prevent blemishes, stains and undue marks from being imparted to the concrete surface. Bolt and tie positions shall be so arranged that they conform to the symmetry of the formwork panels or boards. Bolt and rivet heads which will be in contact with the formed surface shall be of the countersunk type and shall be treated to prevent marks from forming on the concrete surface. The formwork at construction joints shall be braced to prevent steps from forming in the concrete surfaces at the joints between successive stages of construction. Where moulding or recess strips are specified, they shall be neatly butted or mitred. (3) Formwork for open joints The requirements for formwork for open joints shall, unless otherwise specified, apply only to cases where the distance between opposite concrete surfaces is equal to or less than 150 mm. Formwork for open joints shall be constructed to produce a class F1 surface finish to concealed surfaces or a class F2 or F3 surface finish corresponding to the in-plane surface finish of the bordering concrete surfaces. The material used and construction of the formwork shall permit its complete removal to form the open joint. No solvent shall be used to remove formwork unless approved by the Engineer. (4) Openings and wall chases Openings and wall chases shall be provided only where indicated on the drawings or as authorized by the Engineer. Frames for openings shall be rigid and firmly secured in position to prevent their moving. Temporary holes shall be so formed that they will not create an irregular pattern in relation to the rest of the exposed formed concrete surface. (iv) Sliding formwork (1) Plant and equipment
Unless otherwise specified in the project specifications, hoisting equipment for sliding formwork, which operates stepwise with upward movements of between 10 mm and 100 mm will be acceptable. However, the use of linked hydraulic or pneumatic jacks is preferable, which are reversible and driven by an electrically operated pump, and which can hoist at a steady rate. The jacks shall have independent controls for regulating verticality and levelness. The jacking system shall ensure that the sliding- formwork assembly can be hoisted evenly. The use of hoisting systems, which operate without jack rods, shall be subject to the approval of the Engineer. All equipment shall be thoroughly tested and inspected before installation and shall be maintained in a good working order throughout the entire sliding operation. The contractor shall keep adequate back-up plant, equipment and quantities of materials on the site to ensure that the slide casting can proceed without interruption.
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(2)
Instrumentation and monitoring
The contractor shall supply and install suitable instrumentation on the sliding platform and foundations and against the sides of the structure for monitoring the height, verticality, levelness and twisting at regular distances. The equipment used, its utilization and the frequency of recording any readings shall be approved by the Engineer. The contractor shall be responsible for all monitoring work and shall ensure that records of all readings and measurements taken are filed systematically and are at all times available to the Engineer and the person in control of the sliding operation. Unless otherwise specified, the verticality of the structure shall be controlled with laser alignment apparatus or optical plummets, and the levelness of the sliding forms with a waterlevel system with reference control points placed at strategic locations. Height and verticality shall be monitored at intervals not exceeding 4 hours. The readings shall be plotted immediately on graphs. When the structure is more than 10 mm out of vertical, the Engineer shall be notified immediately. (3) Supervision During the entire period of the sliding operation, a competent person who is fully acquainted with the sliding technique and the contractor's methods of construction shall be in attendance on the sliding platform and in control of the sliding operations. (4) Construction The jacking frame shall be constructed with adequate clearance between the underside of the cross members and top of the formwork to allow the horizontal reinforcement and embedded items to be correctly installed. A control procedure shall be agreed on by the contractor and the Engineer to ensure that all the reinforcement is placed. At all times there shall be horizontal reinforcement above the level of the top of the formwork panel. Guides shall be provided to ensure that the vertical reinforcement can be correctly placed and the specified concrete cover over the reinforcement maintained. Where the jack rods are to be recovered, adequate precautions shall be taken in respect of their removal without damage being caused to the concrete. Where jack rods occur at openings or wall chases, adequate lateral support shall be provided to prevent their buckling. Equipment and material shall be so distributed on the working platforms that the load will be evenly distributed over the jacks. Guard plates shall be provided at the tops of the forms to the outside walls to prevent the concrete from falling down the outside. The framework, forms and platforms shall be regularly cleared and the accumulation thereon of redundant concrete prevented. The contractor shall take all precautions to prevent contamination of the concrete by leaking oil or other causes. (5) The sliding process The contractor shall give the Engineer 24 hours notice of his intention to commence with slide casting.
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Permission to commence with the sliding shall not be given by the Engineer before the sliding-formwork assembly is fully operative and the complete stock of all materials required for the slide casting as well as back-up plant and equipment are on the site. The contractor shall ensure that the rate of sliding is such that the concrete at the bottom of the formwork has obtained sufficient strength to support itself and all loads which may be placed on the concrete at the time, and that the concrete does not adhere to the sides of the forms. The slide-casting operation shall be continuous, without any interruptions, until the full height of the structure has been reached, and shall be geared and organized so as to maintain an average rate of sliding of 350 mm per hour. (6) Interruptions When the sliding operations are delayed for more than 45 minutes, the contractor shall prevent adhesion of the setting concrete to the formwork panels by easing the forms or moving them slightly every 10 minutes, or alternatively, where reversible jacks are used, by lowering the forms by 10 mm to 25 mm. Wherever interruptions occur, emergency construction joints shall be formed and treated in accordance with Division 8400 of these specifications. Before concreting is restarted, the form shall be adjusted to fit snugly onto the hardened concrete so as to prevent steps from being formed on the exposed concrete surface. When slide casting is recommenced, care shall be taken to prevent the fresh concrete from being lifted off from the old concrete. (v) Permanent formwork
Void formers shall be secured in position at regular intervals to prevent displacement and distortion during concreting. The void formers shall be supported on precast concrete blocks or rigid welded steel cradles, all subject to approval by the Engineer. The ties securing the void formers shall be attached to the formwork and cross bearers of the falsework. The void formers shall not be tied to or supported on the reinforcement. Fiber-cement plates shall be supported so that the plate spans in the direction parallel to the orientation of the asbestos fibers. Preparing the formwork The surfaces of forms which are to be in contact with fresh (wet) concrete shall be treated to ensure non-adhesion of the concrete to the forms and easy release from the concrete during the stripping of the formwork. Release agents shall be applied strictly in accordance with the manufacturer's instructions, and every precaution shall be taken to avoid the contamination of the reinforcement, prestressing tendons and anchorages. In the selection of release agents, due regard shall be given to the necessity for maintaining a uniform color and appearance throughout on the exposed concrete surfaces. Before the concrete is placed, all dirt and foreign matter shall be removed from the forms and the forms shall be thoroughly wetted with water. (d) Removal of forms and falsework Falsework and formwork shall not be removed before the concrete has attained sufficient strength to support its own mass and any loads, which may be imposed on it. This condition
shall be assumed to require the formwork to remain in place after the concrete has been placed, for the appropriate minimum period of time given in Table 8204-1. Forms that do not support the dead load of concrete members and forms for railings and barriers may be removed 24 hours after the concrete is placed. Falsework and formwork shall be carefully removed without exposing the cast concrete to damage, disturbance or shock. Weather may be regarded as being "normal" when atmospheric temperatures adjacent to the concrete, as measured by a maximum-and- minimum thermometer, do not fall below 15 C, and as "cold" when temperatures, similarly measured, fall below 5C. When the minimum temperatures fall between these values, the length of the period after which the formwork may be removed shall be determined by interpolation between the periods specified for normal and cold weather. Any period during which the temperature remains below 2C shall be disregarded in calculating the minimum time, which shall elapse before the forms are removed. Table 8204-1 Minimum Form/Support Release Criteria Structural Element Percent of Specified 28-Day Strength (f'c ) Minimum Number of Days Since Last Pour 3 3 14 14
(a) Columns and wall faces (not yet supporting loads) (b) Mass piers and mass abutments (not yet supporting loads) except pier caps (c) Box Girders (d) Simple span girders, T-beam girders, slab bridges, cross beams, caps, pier caps not continuously supported, struts, and top slabs of concrete box culverts. (e) Trestle slabs where supported on wood stringers (f) Slabs and overhangs where supported on steelstringers or prestressed concrete girders (g) Pier caps continuously supported (h) Arches, continuous span bridges, rigid frames
50 50 80 80
70 70 60 90
10 10 7 21
On continuously reinforced concrete structures the falsework and supporting formwork shall not be removed before the concrete of the last pour has reached the appropriate minimum age given in table 8204-1 or the appropriate minimum strength. Where the structure is constructed in stages, the falsework and supporting formwork shall be removed as specified or authorized. On prestressed-concrete structures the falsework and supporting formwork shall be removed after the full prestressing force relating to the particular stage of construction has been applied, unless otherwise specified or authorized.
Page8000-58
Falsework supporting the deck of rigid frame structures, excluding box culverts, shall not be removed, until backfill material is placed and compacted against the vertical legs of the frame. 8205 FORMED SURFACES: CLASSES OF FINISH (a) General In addition to complying with the tolerances specified in Division T8000 of these specifications, the surface finish on formed concrete surfaces shall also comply with the following requirements. (b) Class F1 surface finish After repair work has been done to surface defects in accordance with sub-clause 8206(b), no further treatment of the as-stripped finish will be required. This finish is required on concealed formed surfaces. (c) Class F2 surface finish This finish shall be equivalent to that obtained from the use of square-edged timber panels and boards wrought to the correct thickness, or shutter boards or steel forms arranged in a regular pattern. This finish is intended to be left, as struck but surface defects shall be remedied in accordance with sub-clause 8206(b). Although minor surface blemishes and slight discolorations will be permitted, large blemishes and severe stains and discoloration shall be repaired where so directed by the Engineer. (d) Class F3 surface finish This finish shall be that obtained by first producing a class F2 surface finish with joint marks which form an approved regular pattern to fit in with the appearance of the structure. All projections shall then be removed, irregularities repaired and the surface rubbed or treated to form a smooth finish of uniform texture, appearance and color. This surface finish is required on all exposed formed surfaces unless a class F2 finish is specified. Unless specified to the contrary, steel forms may be used to form surfaces with a class F3 surface finish. (e) Board surface finish This finish shall be that obtained by using tongue-and- groove timber boarding arranged in an approved regular pattern. The finish is intended to be left as struck but surface defects shall be remedied in accordance with sub-clause 8206 (b) and large fins trimmed where directed by the Engineer. (f) Protecting the surfaces The contractor shall ensure that permanently exposed concrete surfaces are protected from rust marks, spillage and stains of all kinds and other damage during construction.
Page 8000-59
8206 REMEDIAL TREATMENT OF FORMED SURFACES (a) General Agreement shall be reached with the Engineer regarding any remedial treatment to be given after the surfaces have been inspected immediately after the formwork has been removed, which treatment shall be carried out without delay. No surfaces may be treated before inspection by the Engineer. (b) Repairs to surface defects Surface defects such as small areas of honeycombing, cavities produced by form ties, large isolated blow-holes, broken corner edges, etc, shall be repaired with mortar having a cement and sand ratio equal to that of the concrete being repaired. For the repair of large or deep areas of honeycombing and defects, special approved methods and techniques, such as pneumatically applied mortar, pressure grouting, epoxy bonding agents, etc, may be used. Where, in the opinion of the Engineer, the extent of the honeycombing or defects is of such a degree that doubt exists about the effectiveness of repair work, the contractor shall at his own cost perform a load test, to prove that the structural safety of the repaired member has not been prejudiced, failing which, the structure shall be rebuilt in part or in full at the contractor's cost. Where the concrete has been damaged by adhesion to the formwork panel, the cracked and loose concrete shall be removed; or where the fresh concrete has lifted off at construction joints, the crack shall be scraped out immediately on both sides of the wall to a depth of at least 50 mm. The cavities so formed shall then be repaired as described above. (c) Rubbing the surfaces If the finish of exposed formed surfaces does not comply with the requirements for uniformity of texture, appearance and color, the contractor shall, when so instructed by the Engineer, rub down the exposed surfaces of the entire structure or of any part of it as specified below. The surface shall be saturated with water for at least one hour. Initial rubbing shall be done with a medium-coarse carborundum stone, where a small amount of mortar, having a sand and cement ratio equal to that of the concrete being repaired, is used on the surface. Rubbing shall be continued until all form marks, projections and irregularities have been removed and a uniform surface has been obtained. The paste produced by the rubbing shall be left in place. The final rubbing shall be carried out with a fine carborundum stone and water. This rubbing shall continue until the entire surface is of a smooth, even texture and is uniform in color. The surface shall then be washed with a brush to remove surplus paste and powder. Where the concrete surfaces formed by sliding formwork require treatment to achieve the surface finish specified for the member, the concrete shall, as soon as the surfaces under the formwork are exposed, be floated with rubber- lined floats to the desired finish.
Page8000-60
8207 UNFORMED SURFACES: CLASSES OF FINISH (a) Class U1 surface finish (rough) This surface finish is required on those portions of bridge decks or culvert decks which are to receive asphalt or concrete surfacing or which are to be covered by backfilling material. Where the placing and compacting of the concrete have been completed as specified in with Division 8400 of these specifications, the top surface shall be screeded off with a template to the required cross-section and tamped with a tamping board to compact the surface thoroughly and to bring mortar to the surface, so as to leave the surface slightly rough but generally at the required elevation. (b) Class U2 surface finish (floated) This surface finish is required on sidewalks; the tops of wing walls and retaining walls; exposed concrete shoulders and unsurfaced areas on bridge decks; the inverts of box culverts; and decks which are to receive surfacing other than asphalt or concrete. The surface shall first be given a class U1 surface finish and after the concrete has hardened sufficiently, it shall be wood-floated to a uniform surface free from trowel marks. For nonskid surfaces such as on sidewalks and bridge decks, the surface shall then be given a broom finish. The corrugations so produced shall be approximately 1 mm deep, uniform of appearance and width and shall be perpendicular to the center line of the pavement. (c) Class U3 surface finish (smoothly finished) This surface finish shall be required at bearing areas and the tops of concrete railings. The surface shall first be given a class U1 surface finish, and after the concrete has hardened sufficiently, it shall be floated with a steel float to a smooth surface to within the dimensional tolerances specified in with Division T8000 of these specifications. Rubbing with carborundum stone after the concrete has hardened shall be allowed but under no circumstances will plastering of the surface be permitted. 8208 MEASUREMENT AND PAYMENT Item 82.01 Formwork for indicated class of finish ........................................ square meter The unit of measurement shall be the square meter (m2) (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable). Item 82.02 Vertical formwork for indicated class of finish........................... square meter The unit of measurement shall be the square meter (m2) (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable). Item 82.03 Horizontal formwork for indicated class of finish...................... square meter The unit of measurement shall be the square meter (m2) (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable).
Page 8000-61
Item 82.04 Inclined formwork for indicated class of finish............................. square meter The unit of measurement shall be the square meter (m2) (class of finish indicated as F1, F2, F3 or board) surface finish to (description of member to which applicable). The unit of measurement shall be the square meter, and only the actual area of formwork in contact with the finished face of the concrete shall be measured. Formwork for the different classes of finish shall be measured separately. Formwork for construction joints shall be measured for payment under class F1 surface finish, but only formwork for mandatory construction joints shall be measured for payment. The tendered rates shall include full compensation for procuring and furnishing all materials required, erecting the falsework and formwork, constructing the forms, forming the grooves, fillets, chamfers and stop-ends for construction joints, treating and preparing the forms, all bolts, nuts, ties, struts and stays, stripping and removing the formwork after completion of the work, all labor, equipment and incidentals, and rubbing and surface treatment. Payment of 80% of the amount due for formwork will be made when the formwork has been removed, and payment of the remaining 20% will be made on approval of the concrete surface finish. Item 82.05 Permanent formwork (a) To form voids of (diameter size of void indicated), in (description of member to which applicable) ............................................................................................square meter (m2) (b) Of (description of material \and member to which applicable) .........square meter (m2) The unit of measurement shall be the square meter of concrete area formed with permanent formwork. The tendered rates shall include full compensation for procuring and furnishing all the materials required, installing the formwork, and labor, equipment and incidentals. Item 82.06 Formwork to form open joints........................................................ square meter (description of member to which applicable, and location) The unit of measurement shall be the square meter of concrete area formed. Surfaces formed prior to the construction of the final surface for completing the joint, shall be measured under items Pay Item 82.01, Pay Item 82.02, Pay Item 82.03 or Pay Item 82.04, as may be applicable. The tendered rate shall include full compensation for procuring and furnishing all the materials required, constructing the formwork and subsequently removing all the material within the joint space, as well as labour, equipment and incidentals. Payment for formwork to open joints shall be made only after the forms and filler material have been completely removed and approval of the surface finish has been obtained. Item 82.07 Establishment on the site for sliding formwork operations ............ lump sum The unit of measurement is tendered in lump sum, shall include full compensation for the establishment on the site and the subsequent removal of the complete sliding-formwork assembly, special plant and equipment, and incidentals for the sliding work, the cost of which does not vary with the actual amount of sliding work done. This work will be paid for by way of a lump sum, 75% of which will become payable when the sliding-formwork assembly, plant and equipment have been fully installed at the first structural member on the site, and the remaining 25% will become payable after all sliding work has been completed and the said items have been removed from the site.
Item 82.08 Transporting to and setting up the sliding formwork assembly ........ number (description of each structure) The unit of measurement shall be the number(No) of structures to which the complete sliding-formwork assembly has to be transported and set up in position ready to be commissioned. The tendered rate shall include full compensation for all costs involved in dismantling, transporting and erecting of the complete sliding-formwork assembly. Item 82.09 Forming the concrete by sliding formwork for structures .....................meter (for description of each structure and class of surface finish to exposed surfaces indicated) The quantity measured shall be the actual height of each structure formed by the sliding technique. The tendered rate shall include full compensation for sliding, instrumentation and monitoring, the maintenance of the complete sliding-formwork assembly, plant and equipment, supplying, installing and recovering the jack rods, floating, repairing and treating the concrete surfaces, forming the emergency construction joints, and all labour, equipment and incidentals.
Page 8000-63
Series 8000: Structures Division 8300: Steel Reinforcement For Structures
DIVISION 8300: STEEL REINFORCEMENT FOR STRUCTURES

8301 SCOPE This Division covers the furnishing and placing of steel reinforcement in concrete structures. 8302 MATERIALS REQUIREMENT (a) Steel reinforcement Reinforcing bars shall comply with NZS 3402P and/or deformed steel bars for concrete shall conform to the requirements of AASHTO M 31 (ASTM A615). Deformed and Plain Billet Steel Bars for Concrete Reinforcement shall be Grade 40 or Grade 60 or ASTM A 706. The nominal area of the bar, as given in Table 1 of AASHTO M 31 or ASTM A 706, shall be used for computation. In all cases where a 25 mm bar is shown on the drawings these can be replaced by a 24 mm bar. Steel fabric reinforcement shall comply with BS 4483 and/or AASHTO M 225, M 55, M 32 OR M 221 as appropriate. Hard drawn mild steel wire reinforcement shall comply with BS 4482 and/or AASHTO M 55, Welded Steel Wire Fabric for Concrete Reinforcement. Deformed Steel Wire for Concrete Reinforcement shall comply with AASHTO M 225 & Cold Drawn Steel Wire for Concrete Reinforcement shall comply with AASHTO M 32. (b) Mechanical couplers Mechanical couplers may only be used with the approval of the Engineer. (c) Storage of Materials Steel reinforcement shall be stacked off the ground and, in aggressive environments, protection shall be provided in the form of sheds or tarpaulins. Mild steel reinforcement and high yield steel reinforcement shall be stored in separate locations and shall be clearly identified. 8303 CONSTRUCTION REQUIREMENTS (a) Equipment The equipment used for the cutting, cropping and bending of the reinforcement shall be capable of producing prefabricated or in-situ assemblies complying with the requirements of this Division.
Page8000-64
(b) Bending of Reinforcement Reinforcement shall be cut and bent to the dimensions shown on the Bending Schedules and in accordance with BS 4466 and/or ACI 318. All reinforcement shall be bent at temperatures in the range of 5oC to 100oC. Contractor shall submit a Bar Bending Schedule at least 30 days prior to the placement of the rebars, for the Engineer's approval. All costs for the preparation of the schedule shall be incidental to the work. No flame cutting of high tensile steel bars shall be permitted except with the approval of the Engineer. Except as approved, all bars shall be bent cold and bending shall be done slowly, a steady, even pressure being used without jerk or impact. If approved, hot bending of bars of at least 32 mm diameter will be permitted, provided that the bars do not depend for their strength on cold working. When hot bending is approved, the bars shall be heated slowly to a cherry red heat (not above 8400 C) and after bending shall be allowed to cool slowly in air. Quenching with water shall not be permitted. Reinforcing bars that have already been bent shall not be re-bent at the location of the original bend without the permission of the Engineer. Cold worked bars and hot rolled high yield bars shall not be straightened or bent again once having been bent. Where it is necessary to bend mild steel reinforcement projecting from the concrete, the internal radius of bend shall be not less than twice the diameter of the bar. (c) Surface Conditions Immediately before the concrete is placed around the reinforcement, the reinforcement shall be clean, free from mud, oil, grease, paint, loose rust, loose mill scale or any other substance that can have an adverse chemical effect on the steel or concrete, or reduce the bond. (d) Placing and Fixing Reinforcement shall be secured against displacement during the placement and compaction of the concrete. Reinforcement shall be positioned as shown on the Drawings and accurately secured in these positions within the tolerance given in Division T8000 of these specifications by tying with 1.6 or 1.25 mm diameter annealed wire or by the use of suitable clips or, where permitted by the Engineer, by tack welding. Cover and spacer blocks required to support the reinforcement shall be as small as possible consistent with their use and be of approved design and material. Projecting ends of ties or clips shall not encroach into the concrete cover. Where protruding bars are exposed to the elements for an indefinite period the bars shall be adequately protected against corrosion and damage and shall be properly cleaned before being permanently encased in concrete. In members that are formed with sliding formwork, spacer "ladders" for the placing and fixing of the wall reinforcement shall be used at spacing indicated on the Drawings or as directed by
the Engineer. The ladders shall consist of two 3.7 m long bars with lateral ties of 4 mm diameter welded to them in the form of a ladder. The ties shall be spaced at multiples of horizontal bar spacing in the wall, and be used to secure the horizontal reinforcement. The laps in the horizontal reinforcement shall be staggered to ensure that no part of two laps in any four consecutive layers lie in the same vertical plane. (e) Cover The term "cover" in this context shall mean the minimum clear thickness of concrete between the surface of the reinforcement and face of the concrete. The cover to any bar in an outer layer of reinforcement shall not be less than the minimum cover shown on the Drawings and shall not exceed the minimum by more than 4% of the overall dimension of the member, measured in the same direction, or by more than 20 mm, whichever is the lesser. Where no cover is indicated, the minimum thickness provided shall not be less than the appropriate values shown in Table 8303-1below. The cover shall be increased by the expected depth of any surface treatment, e.g. when concrete is bush hammered or when rebates are provided. Additional cover as directed by the Engineer shall be provided if porous aggregates are used. Concrete spacer blocks shall be made with 5 mm maximum size aggregate and shall be of the same strength and material source as the surrounding concrete. Tying wire complying with the requirements of this clause shall be cast into the block for the purpose of tying it to the reinforcement. The blocks shall be formed in specially manufactured moulds and the concrete compacted in a table vibrator all to the approval of the Engineer. Cover blocks or spacers required for ensuring that the specified cover is obtained shall be of a material, shape, and design acceptable to the Engineer. The contractor shall provide stools as shown on the drawings, or, where they are not detailed on the drawings, wherever the engineer requires them to be installed. The stools shall be suitably robust, and fixed securely so that they cannot swivel or move. The stools shall have sufficient strength to perform the required functions, taking into account amongst others temporary loads such as the weight of workmen and wet concrete, and forces caused by vibrators and other methods of compacting the concrete.
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Table 8303-1 Minimum concrete cover over reinforcement Water/Cement Ratio SITUATION Direct exposure to salt water Cast against earth (i.e. Bottom of footings) Exterior other than above Interior other than above (i.e. hollow structures) Up to 35 Bar 45 and 55Bars Bottom of cast-in-place slabs Up to 35 Bar 45 and 55Bars Precast soffit form panels Precast Reinforced Piles Non-corrosive environments Corrosive environments Precast Prestressed Piles Cast-in-place Piles Non-corrosive environments Corrosive environments General Protected Shells Auger cast, tremie concrete or slurry construction 0.40 COVER (mm) 80 60 40 0.45 COVER (mm) 100 75 50 0.50 COVER (mm) 120 90 60
32 40 25 40 20 32 60 40 40 60 60 40 60
40 50 25 50 20 40 75 50 50 75 75 50 75
48 60 30 60 24 48 90 60 60 90 90 60 90
(f) Laps and Joints Laps, joints, splices and mechanical couplings shall be made only by the methods specified and at the positions shown on the Drawings, refer ACI 318 or as agreed to by the Engineer. (g) Welding Welding of reinforcement shall only be carried out where shown on the Drawings or agreed to by the Engineer. Refer ACI 318. Flash butt welding shall only be carried out with the combination of flashing, heating, upsetting and annealing to the Engineer's approval and only those machines that automatically control this cycle of operations shall be used. Metal-arc welding of reinforcement shall be carried out in accordance with BS 5135 and the recommendations of the reinforcement manufacturers subject to the approval of the Engineer and the satisfactory performance of trial joints. Other methods of welding e.g. resistance welding may be used subject to the approval of the Engineer and to their satisfactory performance of trial joints. Welded joints shall be full strength welds and their strength shall be assessed by tests to destruction on samples selected by the Engineer.
8304 MEASUREMENT AND PAYMENT Item 83.01 Steel reinforcement for structure (a) (b) (c) Mild steel bars (Type and Grade indicated)........................................................ ton (t) High yield stress steel bars (Type Class and Grade indicated) ............................ton (t) Welded steel fabric................................................................................. Kilogram (kg)
The unit of measurement for steel bars shall be the ton of reinforcement in place in accordance with the Drawings or as authorized by the Engineer. The unit of measurement for welded steel fabric shall be the Kilogram of fabric reinforcement in place and the quantity shall be calculated from the net area covered by the mesh, excluding laps. Clips, ties, separators, chairs, and other steel used for positioning reinforcement shall not be measured unless shown on the Bending Schedule. The tendered rate shall include full compensation for the supply, delivery, cutting, bending, welding, placing and fixing of the steel reinforcement, including all tying wire, spacers, stools, supports and waste. Item 83.02 Mechanical couplers for (diameter of bar indicated) ................Number(No.) The unit of measurement shall be the number of mechanical couplers for each bar diameter installed. The tendered rate shall include full compensation for the supply of all material, for preparing and modifying the bar ends to be joined as well as for all tools, equipment and labor required to complete the work. Item 83.03 Spacer "ladders" The pay item for Spacer "ladders" shall be the ton of steel in place in accordance with the Drawings or as authorized by the Engineer. The tendered rate shall include full compensation for the supply, delivery, cutting, bending, welding, placing and fixing of the "ladders" including all tying wire, spacers, stools, supports and waste. Mass of Reinforcing Bars is shown in the following Table 8304-1, Contractor shall provide the manufacturer's chart for the exact calculations. Table 8304-1 Mass of Reinforcing Bars Bar Diameter in mm 10 12 16 19 22 25 28 32 Mass in kg/m 0.559 0.994 1.55 2.24 3.05 3.98 5.03 6.22
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Series 8000: Structures Division 8400: Concrete For Structures
DIVISION 8400: CONCRETE FOR STRUCTURES

8401 SCOPE This Division covers the manufacture, transport, placing, and testing of concrete used in the Work where plain, reinforced, or prestressed concrete is specified. 8402 MATERIALS (a) Cement Cement used for structures shall be either ordinary Portland or sulphate resisting cement complying with the requirements of AASHTO M-85 or blended hydraulic cement complying with the requirements of AASHTO M-240. (b) Admixtures Admixtures shall not be used in concrete without the approval of the Engineer who may require tests to be made before their use to prove their suitability. Admixtures, if allowed, shall comply with the following: (i) Air-Entraining Admixtures
Air-entraining admixtures shall comply with AASHTO M 154. For structural concrete, air- entraining admixtures shall be admixtures classified as vinsol resin or neutralized vinsol resin. Where the contractor wishes to use an alternative air-entraining agent, he shall demonstrate, to the satisfaction of the Engineer, its compliance with AASHTO M 154 when tested with the cement, aggregates and other admixtures approved for use in the Works. (ii) Chemical Admixtures
Chemical admixtures can be accelerating, retarding and /or water reducing, and combinations thereof , conforming to the requirements of AASHTO M 194. When a retarding admixture is required it shall be Type D, a water - reducing -retarding admixture as designated in AASHTO M 194. Type F or G high range admixtures may be used if approved by the Engineer for additional workability and/or to educe the water cement ratio. Chemical admixtures shall be compatible with the other ingredients of the mix as demonstrated by tests carried out on site by the Contractor in the presence of the Engineer at least 30 days before it is proposed to use the agent. (c) Aggregates (i) General
Aggregates, which are to be used in the works, shall have negligible alkaline reactivity. when tested in accordance with ASTM C 227, the mean mortar bar expansion values at 3 and 6 months shall be less than +0.5% and +0.10% respectively.
When tested in accordance with ASTM 289, the aggregate shall be proven to be non-reactive. Aggregate for structures shall be considered not susceptible to alkali aggregate reaction if all of the significant rock components belong to the petrological group listed below. A significant rock component is defined as one, which forms, more than 4% by weight of the coarse or fine aggregate. The Contractor shall provide the Engineer with details of the significant rock components contained in the aggregates. Any aggregate containing the mineral opal shall be considered susceptible to alkali aggregate reaction. A qualified Geologist shall carry out the identification of rock and its placing in the appropriate group. Aggregates shall not contain deleterious amounts of organic materials such as grass, timber or similar materials as shown in Table 8402-1. Table 8402-1 Maximum amount of deleterious substances Item Maximum Percentage by Mass Fine Coarse Aggregate Aggregate 2.0 2.0 Zero 1.0 2.0 1.0 2.0 Zero 0.5 1.0
Material Passing 0.075 mm sieve Lightweight material Organic matter Clay lumps Other deleterious substances
The sum of the percentage of all deleterious substances in aggregate as delivered to the mixer, shall not exceed 3 percent for fine aggregate and 2 per cent for coarse aggregate. If there is a potential danger of alkali aggregate reaction the Engineers decision as to the suitability of the aggregate shall be final and binding. (ii) Fine Aggregate for Portland Cement Concrete.
Fine aggregate shall consist of natural sand, manufactured sand, or a combination of natural and manufactured sand conforming to AASHTO M 6 class B including the reactive aggregate supplementary requirement, except as amended or supplemented by the following: Material passing standard sieve size 0.075 mm shall not exceed 3.0% when tested in accordance with AASHTO T 11. The Sand equivalent value in accordance with AASHTO T 176 shall not be more than 75. For lightweight fine aggregate, conform to AASHTO M 195.
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Table 8402-2 Grading of Fine Aggregate Sieve size (mm) 10 4.76 2.38 1.19 0.59 0.30 0.15 0.075 (iii) percentage of total mass passing sieve 100 95-100 68 - 86 47 - 65 27 - 42 9 - 20 0-7 0 - 2.5
Coarse Aggregate for Portland Cement Concrete.
Coarse aggregate shall Conform to AASHTO M 80 class A, except as amended or supplemented by the following: (a) The Los Angeles abrasion value shall not exceed 40% when determined in accordance with the requirements of AASHTO T 96. (b) The Adherent coating value shall not exceed 1.0% when determined in accordance with the requirements of FLH T 512. For bridge decks or surface courses, aggregates known to polish or carbonate aggregates containing less than 25 percent by mass of insoluble residue as determined by ASTM D 3042 shall not be used. For lightweight coarse aggregate shall conform to AASHTO M 195. Table 8402-3 Nominal Size and Grading of Coarse Aggregate Nominal Size (mm) 25 20 10 Percentage of total mass passing sieve Sieve size (mm) 19 12.5 10 4.75 0 20 0-2 80 100 10 - 40 0-4 100 90 - 100 40 - 70 0 - 15
31.25 90 - 100
25 100
0.075 0 - 0.5 0 - 0.5 0 - 0.5
(d) Water Water shall be clean and free from detrimental concentration of acids, alkalis, urine, salts, sugar, and other organic or chemical substances. If the water used is not obtained from a public drinking water main the Engineer may require the Contractor to have the suitability of the water proved by tests carried out by an approved laboratory. Such tests shall comply with the requirements of AASHTO T 26 and in particular: The total percentage of solids by weight shall not exceed 2.25 percent. For reinforced concrete construction the requirements are as: Chloride (as Cl2) (ASTM D 512) 400 ppm max. Sulfates (as SO3 ) (ASTM D 516) 500 ppm max. Alkali Carbonates and Bicabonates 750 ppm max
Total dissolved solid (ASTM D 1888) 2000 ppm max. pH 7 to 9 Concrete made with water not meeting the requirements specified herein may be rejected for inclusion in the works. 8403 STORAGE OF MATERIALS (a) Cement Cement, which is stored on site, shall be kept under cover, that provides adequate protection against moisture and other factors which may promote deterioration. When the cement is supplied in bags, they shall be closely and neatly stacked to a height not exceeding 12 bags and arranged so that they can be used in the order in which they were delivered to the site. Storage of cement in bulk in silos or similar containers shall be permitted provided that the cement drawn for use is measured by mass and not be volume. Cement shall not be kept in storage for longer than six weeks without the Engineer's permission and different brands and/or types of the same brand shall be stored separately. (b) Aggregates Aggregates of different nominal sizes shall be stored separately and in such a way that segregation is avoided. Intermixing of different materials and contamination by foreign matter shall be avoided. Aggregates exposed to a marine environment shall be covered to protect them from salt contamination. Where concrete is batched on site, the aggregates shall be stored in bins with a 3.0 m wide concrete apron slab constructed around the outer edge of the aggregated stockpile area to prevent contamination during the process of tippling and hoisting the aggregate. The aggregates shall be tipped on the concrete apron slab. The storage bin shall have a concrete floor of 150 mm thickness. (c) Storage Capacity The storage capacity provided and the amount of material stored (whether cement, aggregates, or water) shall be sufficient to ensure that no interruptions to the progress of the work are occasioned by lack of materials. Special Storage facility shall be provided for storing cement to ensure that cement does not get exposed to moisture. Engineer shall make the decision for the duration of storage. (d) Deteriorated Material Material that has deteriorated, or that has been contaminated or otherwise damaged, shall not be used in concrete. Such materials shall be removed from the site without delay.
Page8000-72
8404 CONCRETE FOR STRUCTURES (a) Concrete Grade and Class The Grade and/or Class of concrete used for structures shall be as described in the Contract. For each Grade of concrete the specified minimum 28-day cube compressive strength in N/mm2 shall be as given in Table 8404-1. The Class of concrete shall be defined by its Grade followed by the maximum size of aggregate. Table 8404-1 Grade of Concrete for Structures Grade 20 25 30 40 50 60 Minimum 28 days Cube Strength (N/mm2) 20.0 25.0 30.0 40.0 50.0 60.0
(b) Minimum Cement Content The minimum cement content shall be that which is required to ensure compliance with the minimum strength requirement in Table 8404-1. (c) Maximum Water/Cement Ratio The ratio of the weight of free water to the weight of cement in the mix shall not exceed 0.5 unless otherwise permitted by the Engineer. (d) Maximum Cement Content The cement content shall not exceed 550 kg/m3 unless otherwise described in the Contract or agreed by the Engineer. (e) Design of Concrete Mixes for Structures Unless otherwise specified, concrete mixes for structures shall be designed in accordance with an internationally approved method as approved by the Engineer. Prior to the design of the mix the Contractor shall notify the Engineer of the nature and source of each of the constituent materials that he proposes to use. The water content shall be the minimum required to provide the workability necessary for the placing and compaction of the concrete as determined by trial mixes. The 7 to 28 day strength relationship shall be established during the mix design procedure by making 6 pairs of cubes and testing of one from each pair to be tested at seven days and the other at 28 days.
Page 8000-73
The workability of the concrete shall be determined by the Contractor and shall be the optimum required for the proper placing and full compaction of the concrete around the reinforcement tendons and ducts and completely fills the formwork. The workability of the fresh concrete shall be determined by the slump test in accordance with the requirements of ASTM Cl43. (f) Prescribed mix When a "prescribed mix" is specified, the Engineer will specify the mix proportions and the Contractor, or the manufacturer, will undertake to provide properly mixed concrete containing the constituents in the specified proportions in accordance with the following: The Contractor shall be responsible for supplying the constituent materials for the concrete, and he shall, at least two months before the start of any concrete work on the site, supply to the Engineer samples of each aggregate for testing purposes. If the materials comply with the specification, the Contractor shall supply further samples of sizes indicated by the Engineer, for determination of the mix proportions for each class of concrete. The class of concrete is indicated by the characteristic 28 day cylinder crushing strength in MPa and the maximum size of coarse aggregate in the mix; e.g. Grade 30/40 concrete means concrete with the characteristic cylinder crushing strength of 30 MPa at 28 days and a maximum size of coarse aggregate of 40 mm. The classes of concrete for prescribed mixes shall be specified in the Special Provisions, except for the three "nominal" classes specified hereinafter. For each class the following shall be specified. The estimated minimum compressive strength in MPa at 28 days. The maximum nominal size of coarse aggregate in mm, and its proportions in the mix. The proportion of the fine aggregate in the mix. The type and proportion of cement in the mix. The cement/water ratio. The slump in mm. The Engineer shall have the right to vary, as the work proceeds, the proportions of the constituents of the concrete. Payment for variations shall be made at the tendered rates as specified in the Special Provisions. The nominal mixes specified for use where indicated on the drawings or in the Bills of Quantities or where ordered by the Engineer are given in Table 8404-2.
Page8000-74
Table 8404-2 Nominal Mixes Constituent or Property Grade 1:4:8 Concrete 50 0.40 50 8 Grade 1:3:6 Concrete 50 0.30 42 15 Grade 1:2:4 Concrete 50 0.20 30 20
Cement (kg) Total aggregate (cu. m) Max. total water (liter) Estimated 28 day compressive strength (MPa) Note:
The maximum size of coarse aggregate in mm required in a mix shall be designated as a suffix to the class, e.g. Grade 1:4:8/40. Numeral /40 indicates the nominal size of the coarse aggregate. The ratio of fine to coarse aggregate shall be adjusted to produce a dense workable mix. The total quantity of water shall include moisture content contained in the aggregates. The Grade showing proportions are approximately only. Such as 1:4:8 indicates approximation of one part cement:, four parts of fine aggregate and 8 parts of coarse aggregate, and are intended to be used for identification purposes only. 8405 CONSTRUCTION REQUIREMENTS (a) Storage and Handling of Material All material shall be stored and handled in a manner that prevents segregation, contamination, or other harmful effects. Aggregate shall be stored and handled in a manner that ensures uniform moisture content at the time of batching. Different cements and pozzolana shall be stored in separate silos. Alternatively these materials may be stored in bags under dry weatherproof covers on raised floors and each consignment shall be kept separate and distinct. Any cement that has become injuriously affected by damp or other causes shall be removed from the site immediately. No cement shall be stored on site for longer than 3 months. Aggregates shall be stored on site in different single sizes of coarse and fine aggregate which shall be kept separate from each other. All aggregates shall be kept free from contact with deleterious matter with adequate provision for drainage, and shall be stored and handled so as to avoid segregation. Aggregates shall be delivered and stored in such a way as to ensure that they can be used in the same order in which they are delivered. Fine aggregate shall be deposited at the site of mixing for at least 8 hours before use.
Page 8000-75
(b) Measuring Material. (i) Cement
Where cement is supplied in standard bags the bags shall be assumed to contain 50 kg. All cement taken from bulk storage containers and from partially used bags shall be batched by mass, to an accuracy of within 3 per cent. (ii) Water
Mixing water for each batch shall be measured, either by mass or by volume to an accuracy of within 3 per cent. (iii) Aggregates
All aggregates shall be measured separately by mass, except as otherwise provided in this Clause, to an accuracy of within 3 percent. Separate fine and coarse aggregates shall be used except for classes 7, 10, and 15 where all-in aggregate may be used. Aggregates for prescribed mix concrete as specified in sub-clause 8404(f), may be measured separately by volume. Batching boxes for volume batching shall be filled without tamping, ramming, or consolidation of any kind (other than that occurring naturally during the filling process), and shall be screeded off level with their topmost edges. Any adjustment of the volume shall be made by supplementary containers of a suitable size. Adjustments by the incomplete filling of batching boxes to marks on their inside faces shall not be permitted. Fine aggregate shall be tested for bulking at the beginning of and half way through each concreting shift, and adjustment shall be made to the batch volume to give the true volume required. The measurement of cement in gauge boxes will not be permitted and volume batching shall be planned to use whole bags of cement. (iv) Admixtures
Any solid admixtures to be added shall be measured by mass, but liquid or paste admixtures may be measured by volume or mass. The quantity shall be measured to an accuracy of within 5 per cent. (v) Adjustment to mix Proportions
During production adjustments of mix proportions may be made in order to minimize the variability of strength and to approach more closely the target mean strength. Such adjustments are regarded as part of the proper control of production but the specified limits of minimum cement content and maximum water/cement ratio shall be maintained. Changes in cement content shall be declared. Such adjustments to mix proportions shall not be taken to imply any change to the current margin. (c) Batching Plant, Mixers, and Agitators The batching plant, mixer, and agitator shall conform to AASHTO M 157. Continuous volumetric mixing equipment shall conform to AASHTO M 241.
(d) Mixing The concrete shall be mixed in a central-mix plant or in truck mixers. All equipment shall be operated within manufacturer's recommended capacity. The produced concrete shall be of uniform consistency. (i) Central-Mix Plant
Liquid admixtures shall be dispensed through a controlled flowmeter. Dispensers shall have sufficient capacity to measure, at one time, the full quantity of admixture required for each batch. If more than one admixture is used, each admixture shall be dispensed with separate equipment. The coarse aggregate, one third of the water, and all air entraining admixture shall be charged into the mixer first, then the remainder material shall be added. The batch shall be mixed for at least 50 seconds. The mixing time shall be counted after all cement and aggregate are in the drum. The contents of an individual mixer shall be removed before a succeeding batch is charged into the drum. (ii) Truck Mixer
Concrete shall be mixed in a truck mixer capable of combining the ingredients of the concrete within the specified number of mixing revolutions into a thoroughly mixed and uniform mass and discharging the concrete with a satisfactory degree of uniformity. The volume of mixed concrete permitted in the drum of truck mixers shall not exceed the manufacturer's ratting on the capacity plate. Agitators shall similarly be capable of producing concrete with a satisfactory degree of uniformity. Mixers with any section of the blades worn by 25 mm or more below the original manufactured height shall not be used. Mixers and agitators with accumulated hard concrete or mortar in the mixing drum shall not be used. Admixtures shall be added to the mix water before or during mixing. The batch shall be charged into the drum so a portion of the mixing water enters in advance of the cement. Each batch of concrete shall be mixed not less than 70 nor more than 100 revolutions of the drum or blades at mixing speed. The count of mixing revolutions shall begun as soon as all material, including water, is in the mixer drum. (e) Delivery Concrete shall be produced and delivered to permit a continuous placement with no concrete achieving initial set before the remaining concrete being placed adjacent to it. The methods of delivering, handling, and placing used shall minimize re-handling of the concrete and prevent any damage to the structure. Concrete that has developed an initial set shall not be used. Concrete shall not be re-tempered by adding water.
(i)
Truck mixer/agitator
The agitating speed shall be used for all rotation after mixing. When a truck mixer or truck agitator is used to transport concrete that is completely mixed in a stationary central construction mixer, mixing during transportation shall be done as per the manufacturer's recommended agitating speed. Water and admixtures (if in the approved mix design) may be added at the project to obtain the required slump or air content, provided that, the total of all water in the mix does not exceed the maximum water/cement ratio and the concrete has not obtained an initial set. If additional water is necessary, water shall be added only once and shall be re-mixed with 30 revolutions at mixing speed. Complete the re-mixing shall be completed within 45 minutes after the initial introduction of mixing water to cement or cement to aggregates. (ii) Non-Agitating Equipment
Non-agitating equipment may be used to deliver concrete if the concrete discharge is completed within 20 minutes from the beginning of the addition of the cement to the mixing drum. The equipment used shall have smooth, mortar tight, metal containers capable of discharging the concrete at a controlled rate without segregation. Covers shall be provided when needed for protection. (f) Batching and Mixing (i) General
Unless otherwise permitted by the Engineer, concrete shall be mixed on the Site. The quantities of cement, fine aggregate and the various sizes of coarse aggregate shall be measured by weight unless otherwise agreed by the Engineer. Alternatively, cementitious materials may be measured by using a whole number of bags in each mix. The quantity of water required to be added to the mix shall be measured by volume or weight. Any admixture to be added to the mix shall be measured by volume or weight and, if solid, shall be measured by weight. Different types of cement shall not be mixed. The batch weight of aggregate shall be adjusted to allow for the free moisture content of the aggregate being used. All constituent materials shall be thoroughly mixed and any admixtures uniformly distributed throughout the batch. Following the addition of water, the concrete shall be mixed for at least the minimum time recommended by the manufacturer of the mixing plant prior to discharge from the mixer. Mixers that have been out of use for more than 30 minutes shall be thoroughly cleaned before any fresh concrete is mixed. Mixing plants shall be thoroughly cleaned before changing from one type of cement to another. An experienced operator shall conduct mixing of materials for concrete. Unless otherwise approved, mixing shall be carried out in a mechanical batch mixer of approved type and capable of producing a uniform distribution of ingredients through the batch.
(ii)
Charging the Mixer
The Engineer shall approve the sequence of charging and, unless otherwise instructed, the same sequence shall be maintained. The volume of the mixed material per batch shall not exceed the manufacturers rated capacity of the mixer. (iii) Mixing and Discharge
The period of mixing shall be measured from the time when all materials are in the drum until the commencement of discharge. The mixing period shall be 90 seconds and may only be reduced if, on the basis of site tests, the Engineer is satisfied that the reduced mixing time will produce concrete having essentially the same strength and uniformity as concrete mixed for 90 seconds. The reduced mixing time shall, however, not be less than 50 seconds or the manufacturers recommended mixing time, whichever is the greater. A suitable timing device shall be attached to the mixer to ensure that the maximum mixing time is complied with. The first batch to be run when starting with a clean mixer, shall contain only 2/3 of the required amount of coarse aggregate to facilitate "coating" of the mixer drum. Discharge shall be so carried out that there is no segregation of the materials in the mix. The mixer shall be emptied completely before it is recharged. (iv) Maintenance and Cleaning of the Mixer
If the mixer has stopped running for any period in excess of 30 minutes, it shall be thoroughly cleaned out, particular attention being paid to the removal of any build up of materials in the drum, in the loader, and around the blades or paddles. Worn or bent blades and paddles shall be replaced. Before any concrete is mixed, the inner surfaces of the mixer shall be cleaned and all hardened concrete shall be removed. (v) Standby Mixer
When casting sections where it is important that casting should continue without interruption a standby mixer shall be held in readiness to run on 15 minutes notice in case of breakdown of the stock mixer. (vi) Ready Mixed Concrete
Ready mixed concrete as defined in BS 5328 batched off the site may be used only with the agreement of the Engineer and shall comply with all requirements of the contract. The concrete shall be carried in purpose made agitators, operating continuously, or truck mixers. The concrete shall be compacted and in its final position within two hours of the introduction of cement to the aggregates, unless a longer time is agreed by the Engineer. The time of such introduction shall be recorded on the delivery note, together with the weight of the constituents of each mix. When truck mixed concrete is used, water shall be added under supervision, either at the site or at the central batching plant, as agreed by the Engineer but in no circumstances shall water be added in transit. Unless otherwise agreed by the Engineer, truck mixer units and their mixing and discharge performance shall comply with the requirements of BS 4251 and/or ASTM C 94. Mixing shall
continue for the number and rate of revolutions recommended in accordance with item 9 in Appendix B of BS 4251 or, in the absence of the manufacturers instructions, mixing shall continue for not less than 100 revolutions at a rate of not less than 7 revolutions per minute. (g) Trial Mixes At least 60 days prior to commencing concrete work the Contractor shall carry out laboratory trials of designed mixes with the materials from all sources to be used in the Works including all admixtures. Trial mixes shall be made in the presence of the Engineer or his representative and shall be subject to the approval of the Engineer. Trial mixes shall be repeated if necessary until the proportions that will produce a concrete which complies in all respects with this Specification have been determined. The proportions determined as a result of the laboratory trial mixes may be adjusted if necessary during the construction of the trial length. Thereafter neither the materials nor the mix proportions shall be varied in any way except with the written approval of the Engineer. Any change in sources of materials or mix proportions that are proposed by the Contractor during the course of the works shall be assessed by making new laboratory trial mixes except that the Engineer may approve minor alterations to the mix. (h) Consistency and Workability The concrete shall be of suitable workability without the excessive use of water so that it can be readily compacted into the corners of the formwork and around reinforcement, tendons, and ducts without segregation of the material. Workability shall be assessed by means of the slump test, compacting factor test, or VB consistometer test as directed by the Engineer. The quantities of mixing water and admixtures to be used will be determined in each case by the Contractor and approved by the Engineer to obtain a consistency in the range of 25 mm to 100 mm and no changes shall be made without the Engineer's approval. Concrete shall be acceptable when the slump, as measured in accordance with AASHTO T119, or SC-T-42, is 25mm to 100mm. The Contractor shall have on hand at the job site a suitable amount of cement in bags for drying up over wet concrete and for other purposes. In the event additional water is required to obtain the specified slump at the job site, the Engineer may approve adding water normally at the rate of 5 liters per cubic meters, per 25 mm of desired slump provided a maximum water cement ratio is not exceeded. When additional cement or water is added, a minimum of 25 revolutions of the truck mixer drum at mixing speed shall be required before discharge of the concrete. (i) Temperature and Weather Conditions (i) General
The temperature of the concrete mixture just before placement shall be maintained between 11 degree C and 36 degree C., except for bridge decks between 11 degree C and 30 degree C.
Page8000-80
Work shall not proceed when the temperature of the concrete upon discharge from the delivery vehicle exceeds 30 degrees C. The temperature of the concrete shall be measured by the use of a suitable thermometer approved by the Engineer. The Contractor shall take all practical measures agreed with the Engineer to keep the temperature of the mixed concrete as low as possible at all times consistent with the requirements of this Sub-clause. No aggregates in a frozen condition shall be incorporated into the Works but it may be used if acceptable when thawed out. Before placing concrete, the formwork, reinforcement, pre-stressing steel and any surface with which the fresh concrete will be in contact shall be free from snow, ice and frost. The temperature of concrete shall not be less than 50C at the point of delivery. Concrete shall not be laid when the air temperature in the shade falls below 30C and laying shall not be resumed until the rising air temperature in the shade reaches 30C. During hot weather the Contractor shall ensure that the constituent materials of the concrete are sufficiently cool to prevent the concrete from stiffening in the interval between its discharge from the mixer and compaction in its final position. Cement shall not be allowed to come into contact with water at a temperature greater than 60oC. Concrete shall not be placed during rain. (ii) Cold Weather
Concrete shall not be placed during falling temperatures when the ambient air temperatures fall below 7o C or during rising temperatures when the ambient air temperature is below 3o C. When placing concrete at air temperature 5o C the concrete temperature shall not be below 10oC. The temperature of placed concrete shall not be allowed to fall below 5o C until the concrete has attained a strength of at least 5 MPa and the Contractor shall be responsible for all protective measure necessary to ensure this. When cold weather is reasonably expected or has occurred within 7 days of anticipated concrete placement, the Contractor shall submit a detailed plan for the production, transporting, placing, protecting, curing and temperature monitoring of concrete during cold weather. The Contractor shall also include procedures for accommodating abrupt changes in weather conditions. The placement of concrete shall not commence until the plan is accepted by the Engineer. The Engineer shall notify the acceptance or rejection of the plan within 3 days to the Contractor. All concrete that has been damaged by frost or the formation of ice in the concrete shall be removed and replaced by the Contractor at his own expense. The Contractor shall have all material and equipment required for protection available at or near the site before commencing cold weather concreting. (iii) Hot Weather
When the ambient air temperature exceeds 32o C during a concreting operation the Contractor shall take measures approved by the Engineer to control the temperature of the concrete ingredients so that the temperature of the placed concrete does not exceed 25o C.
Such measures will include spraying aggregate stock piles with water to promote cooling down by evaporation and where feasible shading of stock piles and the area where concreting is carried out. Curing shall commence immediately after placing of the concrete to prevent excessive moisture loss. In hot weather, all surfaces that will come in contact with the mix shall be cooled down to below 36 degree C. 8406 HANDLING, PLACING AND COMPACTION OF CONCRETE (a) General Before placing of concrete the Structural excavation and backfill, design and construction of flsework and forms, construction of reinforcing steel, Structural steel, Bearing devices jointing material and miscellaneous items shall be performed to the satisfaction of the Engineer according to the appropriate Sections of these specifications. Concrete shall not be placed until the forms, all materials to be embedded and, for spread footings, the adequacy of the foundation material have been inspected and approved by the Engineer. Concrete shall be transported and placed in a manner that will prevent segregation, or loss of constituent materials and contamination. Concrete shall not be placed in any part of the works until the Engineer's approval has been given. If concreting is not started within 24 hours of approval being given approval shall again be obtained from the Engineer. Concreting operations shall only be carried out during daylight hours unless proper lighting arrangements have been made and lights are in working order by noon. Workman shall not be allowed to work double shifts and the Contractor shall provide a fresh team for nightshifts. The placing and compaction of concrete shall at all times be under the direct supervision of an experienced concrete supervisor. Once concreting has begun it shall be carried out in a continuous process between construction or expansion joints. The delivery rate, placing sequence, and methods shall be such that fresh concrete is always placed and consolidated against previously placed concrete before initial set has occurred in the previously placed concrete. Concrete shall be placed within 15 minutes from completion of mixing and within one hour from the start of mixing. All excavations and other contact surfaces of an absorbent nature such as timber formwork shall be damp but no free water shall be permitted to remain on these surfaces. The formwork shall be cleaned internally. The method used shall not cause displacement of reinforcing steel or other embedded materials. Retempering the concrete by adding water to mix shall not be permitted. Temporary form spreader devices may be left in place until concrete placement precludes their need, after which they shall be removed. During and after placement of concrete, care shall be taken not to injure the concrete or break the bond with reinforcement.
Once the concrete is set, care shall be taken not to disturb the forms or reinforcing bars that project from the concrete until it is of sufficient strength to resist damage. (b) Placing (i) General
Whenever possible, concrete shall be deposited vertically into its final position. Where chutes are used the length and slope shall be such as not to cause segregation and suitable spouts or baffles shall be provided at the lower end to prevent segregation. The displacement of concrete by vibration instead of direct placing will not be allowed. Concrete shall not be allowed to fall freely through a height of more than 1.5m. Care shall be taken when casting bridge decks of substantial thickness to avoid layering of concrete and the whole thickness shall be placed in one pass. Fresh concrete shall not be placed against concrete that has been in position for more than 30 minutes unless a construction joint is formed. Pumping of concrete shall be subject to the approval of the Engineer. Aluminum pipes shall not be used for this purpose. In plain concrete of thickness more than 300 mm, hard clean stone "plums" of mass 15-55 kg may, if approved, be included to displace concrete for up to 20 per cent of the total volume provided that: Such plums have no adhering films or coatings; No plums have a dimension greater than one third of the smallest dimension of the concrete member or 300 mm whichever is less; and Each plum is surrounded by at least 75 mm of concrete. Concrete for columns, substructures and culvert walls, and other similar vertical members shall be placed and allowed to set and settle for a period of time before concrete for integral horizontal members, such as caps, slabs, or footing is placed. Such period shall be adequate to allow completion of settlement due to loss of bleed water and shall not be less than 12 hours for vertical members over 4.5 m height and not less than 30 minutes for members over 1.5 m but not over 4.5 m in height. The vertical members shall have been in place at least 7 days and shall have attained its specified strength before loads from horizontal members are applied. (ii) Sequence of Placement (1) Substructures
Loads shall not be placed on finished bents, piers, or abutments until concrete cylinder tests from the same concrete cured under the same conditions as the substructure element indicate that all concrete has at least 80 percent of its required 28-day compressive strength. (2) Vertical members For vertical members over 4.5 meters in height, the concrete shall be allowed to set for at least 4 hours before placing concrete for integral horizontal members. For vertical members less than 4.5 meters in height, the concrete shall be allowed to set for at least 30 minutes. Loads shall not be applied from horizontal members until the vertical member has attained its required strength.
(3)
Superstructures Concrete shall not be placed in the superstructure until substructure forms have been stripped sufficiently to determine the acceptability of the supporting substructure concrete. Concrete shall not be placed in the superstructure until the substructure has attained the required strength. Concrete shall be placed for T-beams in 2 separate operations. Concrete placing on the top deck slab concrete shall be done waiting at least 5 days after stem placement. Concrete for box girders may be placed in 2 or 3 separate operations consisting of bottom slab, girder webs, and top slab or as shown on the plans. However, the bottom slab shall be placed first and the top slab shall not be placed until the girder webs have been in place for at least 5 days.
(4)
Arches Concrete shall be placed in arch rings so that the centering is loaded uniformly and symmetrically.
(5)
Box culverts The base slab of box culverts shall be placed and allow to set 24 hours before the remainder of the culvert is constructed. For sidewall heights of 1.5 meters or less, the sidewalls and top slab may be placed in one continuous operation. For sidewalls greater than 1.5 meters but less than 4.5 meters in height, sidewall concrete shall be allowed to set at least 30 minutes before placing concrete in the top slab. For sidewalls 4.5 meters or higher, sidewall concrete shall be allowed to set at least 12 hours before placing concrete in the top slab.
(6)
Precast elements Concrete shall be placed and consolidated so that shrinkage cracks are not produced in the member.
(iii)
Placing underwater
Normally concrete shall only be placed in the dry. Placing under water shall be allowed only in exceptional circumstances where in the opinion of the Engineer it is not feasible to dewater before placing. No concrete shall be placed in flowing water. Underwater placement of concrete is permitted only for seal concrete and drilled shafts. If other than seal concrete is used, the minimum cement content shall be increased by 10 percent. The concrete mix used for under water placing shall be specifically designed and approved for this purpose to ensure good flowability, plasticity, and cohesion. Increased sand and cement contents over normal mixes will usually be required. Tremies, concrete pumps, or other approved methods shall be used for under water concrete placement. Full details of the method proposed shall be submitted in advance to the Engineer for his approval. Placing by skip or pipeline will also be considered in certain circumstances.
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(1)
Tremies Watertight tremies shall have a diameter of 250mm or more and the top shall be fitted with a hopper. Multiple tremies shall be used as required. Tremies shall be made capable of being rapidly lowered to retard or stop the flow of concrete. At the start of concrete placement, the discharge end shall be sealed and the tube shall be filled with concrete. The tremie tube shall be kept full of concrete to the bottom during placement. If water enters the tube, the tremie shall be withdrawn and the discharge end resealed. Continuous concrete flow shall be maintained until the placement is completed.
(2)
Concrete pumps Concrete pumps shall have a device at the end of the discharge tube to seal out water while the tube is first being filled with concrete. When concrete flow is started, the end of the discharge tube shall be kept full of concrete and below the surface of the deposited concrete until placement has been completed. Underwater concrete shall be placed continuously from start to finish in a dense mass. Each succeeding layer of concrete shall be placed before the preceding layer has taken initial set. The Contractor shall use more than one tremie or pump as necessary to ensure compliance with this requirement. The concrete surface shall be kept as horizontal as practicable. Dewatering shall be done after test specimens are cured under similar conditions and the concrete has gained sufficient strength to resist the expected loads. During and after concreting under water, pumping or dewatering operations in the immediate vicinity shall be suspended until the Engineer permits them to be continued. All laitance or other unsatisfactory material shall be removed from the exposed concrete.
(iv)
Placing Methods
Equipment used for placing of concrete shall have sufficient capacity that is designed and operated to prevent mix segregation and mortar loss. Equipment that causes vibrations that could damage the freshly placed concrete shall not be used. Equipment with aluminum parts that come in contact with the concrete shall not be used in placing of concrete. Set or dried mortar shall be removed from inside surfaces of placing equipment. Concrete shall be placed as near as possible to its final position. Concrete shall not be placed in horizontal layers greater than 0.45 meters thick. The vibrator capacity shall not exceed to consolidate and merge the new layer with the previous layer. Concrete shall not be placed at a rate that, when corrected for temperature, exceeds the design loading of the forms. Unconfined concrete shall not be dropped more than 4.5 meters when placing. Concrete may be confined by using a tube fitted with a hopper head or other approved device that prevents
mix segregation and mortar spattering. This does not apply to cast-in-place piling when concrete placement is completed before initial set occurs in the concrete placed first. Concrete pumps shall be operated so that a continuous stream of concrete without air pockets is delivered at the tube discharge. Conveyor belt systems longer than 165 meters when measured from end to end of the total belt assembly shall not be used for placing concrete. The belt assembly shall be arranged so that each section discharges into a vertical hopper to the next section without mortar adhering to the belt. A hopper, chute, and deflectors shall be used at the discharge end of the conveyor belt system to cause the concrete to drop vertically. (v) Compaction
Concrete shall be fully compacted by approved means during and immediately after placing. It shall be thoroughly worked against the formwork around the reinforcement tendons, ducts, and embedded fittings and into corners to form a solid mass free from voids. The concrete shall be free from honeycombing and planes of weakness and successive layers of the same lift shall be thoroughly bonded together. In no case shall the depth of a lift exceed 0.6 m. When placing operation would involve dropping the concrete more than 1.5 m, the concrete shall be dropped through a tremie or chute as required. Unless otherwise agreed by the Engineer concrete shall be compacted by means of vibrators. Internal vibrators shall be capable of producing not less than 10,000 cycles per minute and external vibrators not less than 3,000 cycles per minute. Sufficient standby vibrators shall be held available in case of breakdown. Vibrators shall be applied by experienced labor and over vibration resulting in segregation, surface water and leakage shall be avoided. Contact with reinforcement and formwork shall, as far as practicable be avoided when using internal vibrators. Concrete shall not be subjected to disturbance by vibration within 4 to 24 hours after compaction. Whenever vibration is applied externally, the design of the formwork and positioning of vibrator shall be such as to ensure efficient compaction and avoidance of surface blemishes all subject to prior approval of the Engineer. Special attention shall be given to the compaction of concrete in the anchorage zones and behind the anchor plates and in all places where high concentrations of reinforcing steel or cables occur. In such cases where the placing and compaction of concrete is difficult a mix containing small size aggregate may be used but only with the approval of the Engineer and after a mix containing such aggregate has been designed and tested. Sufficient number of vibrators shall be provided to consolidate each batch as it is placed. Provide. External form vibrators shall be used only when the forms have been designed for external vibration and when internal vibration is not possible. The concrete shall be vibrated at the point of deposit and at uniformly spaced points not farther apart than 1.5 times the radius over which the vibration is visibly effective. Vibrators shall not be used to move concrete and shall be inserted vertically and withdrawn slowly from the concrete. The vibration shall be of sufficient duration and intensity to thoroughly consolidate the concrete, but not to cause segregation and at any one point long enough to cause localized areas of grout to form.
Reinforcement bars shall not be vibrated in order to vibrate the concrete. Hand held vibrators shall conform to Table 8406-1. Rubber coated vibrators shall be provided when epoxy coated reinforcement is used. Table 8406-1 Hand Held Vibratory Requirements Head Diameter millimeters 19 to 38 31 to 63 50 to 88 Frequency vibrations/minute 10,000 to 15,000 9,000 to 13,500 8,000 to 12,000 Radius of Action millimeters 75 to 125 125 to 250 250 to 475
8407 CONSTRUCTION JOINTS (a) General Concreting shall be carried out continuously up to the construction joint shown on the working drawings or as approved, except that is, because of an emergency (such as breakdown of the mixing plant or the occurrence of unsuitable weather), concreting has to be interrupted, a construction joint shall be formed at the place of stoppage in the manner which will least impair the durability, appearance, and proper functioning of the concrete. Unless otherwise shown on the drawings the exact position of horizontal construction joints shall be marked on the formwork by means of grout checks in order to obtain truly horizontal joints. Stub columns or stub walls on footings shall be cast integrally with the footings and not afterwards. (b) Preparation of Surfaces When the concrete has set and while it is still green the surface film and all loose material shall be removed, without disturbing the aggregates, by means of a water jet assisted by light brushing to expose the aggregate and leave a sound, irregular surface. Where this is not possible the surface film should be removed after the concrete has hardened by mechanical means appropriate to the degree of hardness to the concrete so as to expose the aggregate and leave a sound, irregular surface. The roughened surface shall be washed with clean water to remove all latencies, dirt, and loose particles. (c) Placing Fresh Concrete at Construction Joints When fresh concrete is placed the same day as the construction joint was formed the fresh concrete shall be cast directly against the face of the construction joint. When concreting recommences a day or more after the forming of the construction joint the following procedure shall be followed: The construction joint shall be kept continuously wet for a period of at least two hours before concreting starts but shortly before reconcreting further
Page 8000-87
application of water shall cease so that the surface is just damp when further concreting has to commence. Any dirt, excess water, and loose particles shall be removed prior to starting reconcreting. For horizontal construction joint surfaces a freshly mixed slurry consisting of sand, cement and water mixed in the same proportions as used in the concrete shall be applied approximately 10 mm thick in the construction joint surface immediately ahead of concreting. The slurry must still be in a plastic state when applied. For vertical construction joint faces a thin coat of a freshly mixed paste of neat cement and water, using a little water as practical, shall be applied to the construction joint immediately ahead of concreting. Epoxy resins specially designed for bonding old concrete to new shall be used at construction joints where so directed by the Engineer. The preparation of the construction joint surface and the application of the epoxy resin shall be strictly in accordance with the manufacturers recommendations and the Engineer's instructions. The actual brand and type of resin used shall be subject to the Engineer's approval. (d) Bonding Unless otherwise shown on the plans, horizontal joints may be made without keys and vertical joints shall be constructed with shear keys. Surfaces of fresh concrete at horizontal joints construction joints shall be rough floated sufficient to thoroughly consolidate the surface and intentionally left in a roughened condition. Shear keys shall consist of formed depression in the surface covering approximately one third of the contact surface. The forms for key shall be beveled so that removal will not damage the concrete. All construction joints shall be cleaned of surface laitance, curing compound and other foreign materials before fresh concrete is placed against the surface of the joint. (e) Bonding and Doweling to Existing Structures When new concrete is shown on the plans to be bonded to existing concrete structures, the existing concrete shall be cleaned and flushed. When the plans show reinforcing dowels grouted into holes drilled in the existing concrete at such construction joints, the holes shall be drilled by methods that will not shatter or damage the concrete adjacent to the holes. The diameters of the drilled holes shall be 6 mm larger than the nominal diameter of the dowels unless shown otherwise on the drawings. The grout shall be neat cement paste of Portland cement and water. The water content shall be not more than 15 liter per 50 kg of cement. Sufficient grout shall be placed in the holes so that no voids remain after the dowels are inserted. Grout shall be cured for a period of at least 3 days or until dowels is encased in concrete. When specified or approved by the Engineer, epoxy may be used in lieu of Portland cement grout for bonding of dowels in existing concrete. When used, epoxy shall be mixed and placed in accordance with the manufacturer's recommendations.
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8408 EXPANSION AND CONTRACTION JOINTS (a) Open joints Open joints shall be formed with a wooden strip, metal plate, or other approved material. Joint forming material shall be removed without chipping or breaking the corners of the concrete. Reinforcement shall not be extended across an open joint. (b) Filled joints Premolded expansion joint filler shall be cut to the shape and size of the surface being jointed. The joint filler shall be secured on one surface of the joint using galvanized nails or other acceptable means and spliced according to the manufacturer's recommendations. After form removal, all concrete or mortar that has sealed across the joint shall be removed and neatly cut. All joint gaps 3 mm or wider shall be filled with hot asphalt or other approved filler. All necessary dowels, load transfer devices, and other devices shall be placed as shown on the plans or as directed. (c) Steel joints Plates, angles, or other structural shapes shall be fabricated accurately to conform to the concrete surface. Joint opening shall be set to conform to the ambient temperature at the time of concrete placement. Securely fasten. The joints shall be securely fastened to keep them in correct position. (d) Water stops Water stops shall be of copper, plastic or rubber water stops according to AASHTO requirements. (e) Compression joint seals One-piece compression joint seals shall be used for transverse joints and the longest practicable length for longitudinal joints. Joints shall be cleaned and dried and spalls and irregularities shall be removed. A lubricant- adhesive shall be applied as a covering film to both sides of the seal immediately before installation. The seal shall be compressed and placed in the joint as recommended by the manufacturer and the seal shall be in full contact with the joint walls throughout its length. All seals that are twisted, curled, nicked or improperly formed shall be removed and discarded. All joint seals that elongate more than 5 percent of their original length when compressed shall be removed and reinstalled. All excess lubricant adhesive shall be removed before it dries.
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(f) Elastomeric expansion joint seal Install the joint according to the manufacturer's recommendations and in conformance with the plans. 8409 FINISHING PLASTIC CONCRETE (a) General Finishing of plastic concrete shall be done in accordance with the requirements of Division 8200 of these specifications. (b) Striking of Formwork Formwork shall be removed in accordance with the minimum requirements stipulated in Table 8409-1 Table 8409-1 Minimum Period Before Striking Formwork for Concrete for Structures Minimum Period for Striking Surface Temperature of Concrete 7C tC (any temperature between 0C and 25C) 18 hours 6 days 15 days 14 days 21 days
Type of Formwork Vertical formwork to columns, walls and large beams Soffit formwork to slabs Props to slabs Soffit formwork to beams Props to beams
16C
12 hours 4 days 10 days 9 days 14 days
300 hours t + 10
100 hours t + 10 250 hours t + 10 230 hours t + 10 360 hours t + 10
8410 CURING CONCRETE (a) General Curing shall begin immediately after the free surface water has evaporated and the finishing is completed. If the surface of the concrete begins to dry before the selected cure method can be implemented, concrete surface shall be kept moist using a fog spray without damaging the surface. Surfaces to be rubbed shall be kept moist after forms are removed and curing shall commence immediately following the first rub.
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Top surfaces of bridge decks shall be cured using the liquid membrane curing compound method combined with the water method. Apply Liquid membrane curing compound shall be applied immediately after finishing. The water cure shall be applied within 4 hours after finishing. All concrete shall be cured uninterrupted for at least 7 days. If pozzolan is in excess of 10 percent by mass of the Portland cement is used in the mix, the concrete shall be cured uninterrupted for at least 10 days. (b) Forms inplace method For formed surfaces, the forms in place shall be left without loosening. If forms are removed during the curing period to facilitate rubbing, only strip forms from those areas able to be rubbed during the same shift. During rubbing, the surface of the exposed concrete shall be kept moist. After the rubbing is complete, curing process shall be continued using the water method or by applying a clear curing compound for the remainder of the curing period. (c) Water method The concrete surface shall be kept continuously wet by ponding, spraying, or covering with material that is kept continuously and thoroughly wet. Covering material may consist of cotton mats, multiple layers of burlap, or other approved material that does not discolor or otherwise damage the concrete. The covering material shall be covered with a waterproof sheet material that prevents moisture loss from the concrete. Adjacent sheets shall be lapped at least 150mm and tightly sealed all seams with pressure sensitive tape, mastic, glue, or other approved methods and all material shall be secured so that wind will not displace it. Sheets that are broken or damaged shall be immediately repaired. (d) Liquid membrane curing compound method Liquid membrane method shall not be used on surfaces to receive a rubbed finish. Liquid membrane shall be used construction joint surfaces only if the compound is removed by sandblasting before placement of concrete against the joint. Type 2, white pigmented, liquid membrane according to AASHTO shall be used only on the top surfaces of bridge decks or on surfaces not exposed to view in the completed work and Type 1 or 1-D clear curing compounds on other surfaces. Membrane curing solutions containing pigments shall be mixed before use and shall be continuously agitated during application and the equipment shall be capable of producing a fine spray. Curing compound shall be applied at a minimum rate of 3 liters per 10 square meters in one or two uniform applications. If the solution is applied in 2 applications, the first application shall be followed with the second application within 30 minutes and shall be applied at right angles to the first application. If the membrane is damaged by rain or other means during the curing period, a new coat shall be immediately applied over the damaged areas.
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(e) Steam curing (precast units) The method of curing adopted shall be subject to the Engineer's approval and shall not cause staining, contamination, or marring of the surface of the concrete. The curing period shall be continuous for at least 5 days for concrete made from Portland cement, at least 2 days for that made with rapid hardening Portland cement. When the temperature of concrete falls below 5o C these minimum-curing periods shall be extended by the period during which the temperature of the concrete was below 5o C. When using sliding formwork the concrete shall be protected against the weather and rapid drying out by means of a 4 m wide skirt attached to the lower perimeter of the formwork and hanging over the working platform. The skirt shall consist of Hessian in summer months but in winter months, canvass or other suitable material shall be used. The skirt shall be weighted at the bottom to prevent it flapping around in windy conditions. Curing of the concrete shall be accomplished by means of a fog spray to keep it wet continuously for the period stated above or until a curing compound is applied. Wetting of the concrete shall be by means of a fixed spray bar along the full length of the sliding formwork. The spray bar shall be connected to a suitable high pressure water supply. Wetting shall be discontinued when the ambient air temperature drops below 5o C and care shall be exercised to ensure that the water does not erode the fresh concrete surface. 8411 PIPES AND CONDUITS No pipes and conduits other than those shown on the drawings shall be embedded in the concrete without the Engineer's approval. The clear space between such pipes and any reinforcement shall be at least 40 mm or the maximum size of the aggregate plus 5 mm whichever is the greater. The amount of concrete cover over pipes and fittings shall be at least 25 mm. The ends of all ferrules used for bracing formwork shall be neatly finished off to the details shown on the Drawings. Where no details are given on the Drawings ferrules shall be cut back and the holes filled in with mortar and finished off flush with the concrete surface. 8412 PRECAST CONCRETE This clause applied to all reinforced and prestressed concrete members other than precast concrete piles, culverts and pipes in as far as they are dealt with separately elsewhere in the Specifications. All precast members shall be manufactured in accordance with the requirements specified for cast in situ members in as far as these requirements are relevant. In addition the following shall apply: The Contractor shall take all necessary safety measures and precautions during the handling and erection of precast members and for the stability of members as positioned prior to casting-in. Where concrete members are precast off site the manufacturer shall keep, and make available to the Engineer, full records of all concrete mixes and strength tests pertaining to the members cast. The Contractor shall notify the Engineer in advance of the casting dates to arrange for inspection and testing of precast members.
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For the purpose of identification all members shall be marked with paint in neat lettering with the member number shown on the Drawings or ordered by the Engineer and an identification number relating to the manufacturing records, letters etc. shall be so positioned as not to be visible when the member is placed in its final position in the completed structure. All precast members that have been chipped, cracked, warped or otherwise damaged to the extent that such damage will in the opinion of the Engineer prejudice the appearance, function or structural integrity of the members shall be rejected or where so allowed, repaired to the satisfaction of the Engineer. 8413 MEASUREMENT AND PAYMENT Item 84.01 Cast in situ concrete (a) (b) (Class of concrete and part of structure or use indicated) .................. cubic meter(m3) Etc for other classes of concrete and other uses or parts of the structure
The unit of measurement for cast in situ concrete shall be the cubic meter of concrete in place. Quantities shall be calculated from the dimensions shown on the drawings or as authorized. No deduction in volume measured for payment shall be made for the volume of any reinforcing steel, inserts and pipes or conduits up to 150 mm in diameter embedded in the concrete. The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the materials, providing all plant, mixing, transporting, placing and compacting the concrete, forming the inserts, construction joints (except mandatory construction joints), and contraction joints, curing and protecting the concrete, repairing defective surfaces, and finishing the concrete surfaces as specified. Payment shall distinguish between the different classes of concrete. Item 84.02 Manufacturing pre-cast concrete members .................................................. No (description of member with reference to drawing) The unit of measurement shall be the number of complete members or elements of each type and size in position in the works. The tendered rate for each pre-cast member shall include full compensation for concrete work, formwork, curing and safeguarding, and for reinforcing steel . Item 84.03 Transporting and erecting pre-cast concrete members................................ No (description of member and approximate mass to be given) The unit of measurement shall be the number of pre-cast concrete members of each type and size placed into position. The tendered rate for each pre-cast member shall include full compensation for all work, costs and equipment required for transporting, stacking, erecting and installing the pre-cast concrete member in its final position, complete as specified. Item 84.04 Epoxy bonding of new concrete surfaces to old .................. Square meter(m2) The unit of measurement shall be the square meter of new concrete surface bonded to old by means of an approved epoxy bonding agent as set out in the specifications.
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The tendered rate shall include full compensation for preparing the surfaces and for furnishing and applying the bonding agent, and for chamfering the concrete on visible joints, complete as shown on the drawings. Item 84.05 Demolishing existing concrete (a) (b) Plain concrete (Member indicated).....................................................cubic meter (m3) Reinforced concrete (Member indicated) ............................................cubic meter(m3)
The unit of measurement shall be the cubic meter of plain or reinforced concrete demolished for each member or portion thereof scheduled separately in the schedule of quantities. The tendered rate shall include full compensation for all labor, plant and equipment required to demolish the existing concrete and disposal of the product of the demolition to a borrow pit within a free-haul distance of 1 km. The tendered rate shall also include full compensation for any necessary measures to ensure no debris falls into rivers and for any debris that has fallen into rivers to be recovered.
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Series 8000: Structures Division 8500 : Timber Structures
DIVISION 8500 : TIMBER STRUCTURES

8501
SCOPE
This work consists of furnishing, preparing, erecting, and painting of structural timber of the stress values and sizes. It also includes all required yard lumber and hardware of the sizes and grade specified, all in accordance with the design shown on the plans or as directed by the Engineer. 8502 MATERIAL FOR TIMBER STRUCTURES (a) Untreated Structural Timber and Lumber Structural timber, lumber, and piling shall conform to AASHTO M 168. No boxed-heart pieces of Douglas fir or redwood shall be used in outside stringers, floor beams, caps, posts, sills, or rail posts. Boxed-heart pieces are defined as timber so sawed that at any point in the length of a sawed piece the pith lies entirely inside the four faces. (b) Treated Structural Timber and Lumber This work shall conform to Sub-clause 8502(a) above and make all dimensional cuts and incisions in the wood before pressure treatment. The wood shall be treated according to AASHTO M 133. When wood is to be painted, the contractor shall use water borne ammoniacal copper arsenate or chromated copper arsenate preservative. (c) Hardware Machine bolts, drift bolts and dowels may be medium steel. Washers shall be fabricated from gray iron or malleable iron castings unless structural washers are specified. Bolts and nuts shall be square headed and unless otherwise stated nails shall be cut or round nails of standard form. Spikes shall be cut or round, as specified. All hardware shall be galvanized according to AASHTO M 232 or cadmium plates all hardware according to ASTM B 766 class 12, type III. Ring or shear plate timber connectors shall be of approved design and made of no corrosive metal. (d) Yard lumber Yard lumber shall be of the kinds and grade called for on the plans. Round poles and posts shall be of the kinds indicated on the plans. (e) Structural Shapes, Rods, and plates All structural shapes, rods, and plates shall be of structural steel or wrought iron, as specified or indicated on the plans, meeting the requirements prescribed in Division 8300 of this specification. No welds will be permitted in truss rods, or in main members of trusses or girders.
(f) Paint Paint for Timber structures shall conform to : Primer. FSS TT-P-25, TT-P-96D, or TT-P-001984. Paint. FSS TT-P-102 class A, TT-P-96D, TT-P-102F, or TT-P 19D. The paint shall be white unless otherwise specified. (g) Preservative Treatment of Timber (i) Description
Treated timber shall be structural timber, lumber and piling conforming to the requirements of Sub-clause 8502(c). Preservative treatment for timber, lumber, guardrail posts and piling shall be in accordance with the following specifications. The material to be treated will normally be inspected prior to treatment and the inspection of the treatment process will be made while the process is actually taking place. (ii) Treating plant Equipment
Plants for treating lumber and timber shall be equipped with thermometers and gages necessary to indicate and record accurately the conditions at all stages of treatment, and all equipment shall be maintained in a condition satisfactory to the Engineer. The apparatus and chemicals necessary for making the analyses and tests required by the Engineer shall be provided by the Contractor. (iii) Preservatives
The Preservatives to be used shall conform to the following specifications: PRESERVATIVES Creosote Creosote-Coal Tar solution Creosote-Petroleum solution Petroleum for blending with Creosote Pentachlorophenol Solvents used in Pentachlorophenol solutions Acid copper chromate Ammoniacal copper Arsenite Chromated copper Arsenite Chromated Zinc chloride Flour Chromed Arsenate Phenol
SPECIFICATIONS
AWPA P 1 AWPA P 2 AWPA P 3 AWPA P 4 AWPA P 8 AWPA P 9 AWPA AWPA AWPA AWPA AWPA P5 P5 P5 P5 P5
Tests of the Preservatives shall be made in accordance with AASHTO M 133 for the particular preservative involved.
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8503 CONSTRUCTION REQUIREMENTS (a) General Excavation and backfill for timber structures shall be performed in accordance with Division 8100 of this specification. The Contractor shall furnish the required structural lumber and timber of stress grade. The ground under and in the vicinity of all stored material of stacks of weeds, rubbish, or other objectionable material shall be cleared by the Contractor. The bottom layer of material shall be placed at least 205 mm above the ground level. Sufficient support shall be provided to prevent sagging. Workmanship shall be first-class throughout. None but competent bridge carpenters shall be employed and all framing shall be true and exact. Unless otherwise specified, nails and spikes shall be driven with just sufficient force to set the heads flush with the surface of the wood. Deep hammer marks in wood surfaces shall be considered evidence of poor workmanship and sufficient cause for removal of the workman responsible for them. (b) Storage of Materials All lumber and timber on the site of the work shall be stacked to prevent warping. When required by the Engineer, it shall be protected from the weather by suitable covering. The materials shall not be covered with impervious membranes such as polyethylene film during dry weather. Individual wrappings shall be slitted full length or punctured on the lower side to permit drainage of water. Untreated Material shall be Open-stacked at least 310 mm above the ground surface and so piled to shed water. The material shall be stacked in layers on spacers (stickers) that extend across the full width of the stack to allow for free air circulation and all stickers shall be aligned vertically and spaced at regular intervals. Treated timber shall be close-stacked to shed water. (c) Treated Timber Treated timber shall be framed before treatment and shall be handled carefully without dropping, breaking of outer fibers, or bruising or penetrating the surface with tools. Cant dogs, hooks, or pike poles shall not be used. In coastal waters, cutting or boring timber below the high-water mark shall be avoided. All cuts and abrasions in timber or lumber shall be treated with 3 brush coats of the same type of preservative used in the original treatment. Before driving bolts, all holes bored after treatment shall be impregnated with the same preservative using equipment suitable for proper application of the preservative and all unused holes shall be plugged with preservative treated plugs.
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(d) Untreated Timber In structures of untreated timber, the surfaces named below shall be coated thoroughly with two coats of hot creosate oil or any preservative approved by the Engineer before the timber is assembled: Ends, tops, and all contact surfaces of posts, sills, and caps Ends, joints, and contact surfaces of bracing and truss members Surfaces of timber bumpers and the back faces of bulkheads Other timber that will be in contact with earth (e) Holes for Bolts, Dowels, Rods, and Lag Screws All holes shall be bored before using preservative to treat the wood. Bore holes for round drift bolts and dowels shall be bored 1.60 mm smaller in diameter than that of the bolt or dowel to be used. The diameter of holes for square drift bolts or dowels shall be equal to the side dimension of the bolt or dowel. Holes for machine bolts shall be bored with a bit of the same diameter as that of the bolt. Holes for lag screws shall be bored with a bit not larger than the body of the screw at the base of the thread and depth of lag screw boltholes shall be 26mm less than length under screw head. (f) Bolts and Washers Washers of the size and type specified shall be used under all bolt heads or nuts in contact with wood. Cast-iron washers shall be used when the timber is in contact with the ground. Cast-iron washers shall have a thickness equal to the diameter of the bolt, and the diameter of the washer shall be four times its thickness. All nuts shall be checked or burred effectively with a pointed tool after final tightening, to prevent turning. (g) Countersinking Countersinking of nuts and bolt heads shall be done wherever smooth faces are required by the contract. Recesses formed for countersinking, except in railings, shall be painted with an approved preservative and, after bolts or screws are in place, the holes shall be filled with hot pitch or other approved filler. (h) Framing Treated piles shall not be slabbed or trimmed for fitting sway or sash braces. All gaps that occur between braces and piles shall be filled with treated blocks so that the bracing is securely fastened to the piles (i) Framing Bents Mudsills shall be firmly and evenly bedded to solid bearing and tamped in place.
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Concrete pedestals for the support of framed bents shall be finished carefully so that sills or posts will bear evenly upon them. Dowels for anchoring sills and posts shall be set when the concrete is cast and shall project at least 154 mm above the tops of the pedestals. Sills shall have true and even bearing on mudsills, piles, or pedestals. They shall be driftbolted with bolts extending into the mud sills or piles for at least 154 mm. Where possible, all earth shall be removed in contact with sills for free circulation of air around the sills. (j) Caps for all Bents Timber caps shall be placed to obtain even and uniform bearing over the tops of the supporting posts or piles with their ends in alignment. All caps shall be secured with driftbolts and set approximately at the center of and extending at least 230 mm into the posts or piles. (k) Bracing The ends of bracing shall be bolted through the pile, post, cap, or sill. Bracing at intermediate interdivisions with posts or piles shall be bolted or spiked with wire or boat spikes, as required. In all cases galvanized spikes shall be used in addition to bolts. All bracing shall be secured firmly against the pile or cap to which it is bolted. Shims shall be provided and placed as necessary to prevent bending the bracing more than 26 mm out of line when bracing bolts are tightened. Shims shall not be used, where the space between the bracing and cap or pile is less than 26 mm. Where the space between the bracing and the cap or pile is 38.5 mm 13 mm, 2 ogee washers shall be placed with their narrow faces together or other approved washers on each bolt which passes through the space. Where the space between the bracing and the cap or pile is over 51 mm, wooden shims of the proper thickness shall be used. The wooden shims shall be fabricated from white oak or from the same treated wood used in the structure. Built-up wooden shims shall not be used. Wooden shims shall be made from a single piece of lumber with the width not less than 102.5 mm and the length not less than the width of the bracing measured along the cap or pile. Any treated member shall not be adzed, trimmed, or cut to avoid the use of shims. (l) Stringers Size Stringers shall be sized at bearings and shall be placed in position so that knots near edges will be in the top portions of the stringers. Outside stringers may have butt joints with the ends cut on a taper, but interior stringers shall be lapped to take bearing over the full width of the floor beam or cap at each end. The lapped ends of untreated stringers shall be separated by at least 13 mm for air circulation and shall be securely fastened by drift - bolting where specified. When stringers are 2 panels in length the joints shall be staggered. Cross bridging between stringers shall be securely toe nailed with at least 2 nails in each end.
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All cross-bridging members shall be cut for a full bearing at each end against the sides of the stringers. Unless otherwise specified in the contract, cross bridging shall be placed at the center of each span. (m) Plank Floors Use Plank shall be the grade specified and shall be surfaced on four sides (S4S). Single-ply timber floors shall consist of a single thickness of planks supported on stringers. The planks shall be laid heart side down with 6.4 mm space between them for seasoned material and with tight joints for unseasoned material. Each plank shall be securely spiked to each stringer. The planks shall be carefully graded as to thickness and so laid that no 2 adjacent planks vary in thickness by more than 1.6 mm. Two-ply timber floors shall consist of 2 layers of flooring supported on stringers. The lower layer shall be pressure- treated with creosote oil. The top layer may be laid either diagonally or parallel to the centerline of roadway, as specified, and each floor piece shall be securely fastened to the lower layer. Joints shall be staggered at least 0.9 meters. If the top layer is placed parallel to the centerline of the roadway, special care shall be taken to securely fasten the ends of the flooring. The ends of top layer members at each end of the structure shall be beveled. (n) Transversely Nail-Laminated Decks Pieces for laminated or strip floors shall have a nominal thickness of 51 mm laminations, and shall be surfaced one edge hit or miss 3 mm scant (SIE-H or M 1/8 inch scant), and one side hit or miss 3 mm scant (SIS-H or M 1/8 inch scant). The pieces shall be of the grade specified. They shall be placed on edge and at right angles to the centerline of roadway. Each piece shall be spiked to the preceding piece at each end and at approximately 461.5 mm intervals with the galvanized spikes driven alternately near the top and bottom edges. The spikes shall be of sufficient length to pass through 2 pieces and at least halfway through the third piece. The size of spikes shall be as shown on the plans. Where timber stringers are used, every other piece shall be toenailed to every other stringer. When steel stringers are used, they shall be securely attached to the pieces using approved galvanized metal clips. Pieces shall be of sufficient length to bear on at least 4 stringers. No splicing of pieces between stringers will be allowed. End joints on any one stringer shall be no closer than every third piece. End joints in adjoining pieces shall be no closer than every second stringer. (o) Wheel Guards and Railings Wheel Guards and Railings shall be accurately framed in accordance with the plans and erected true to line and grade. Unless otherwise specified, wheel guards, rails, and posts shall be surfaced on four sides (S4S). Place Wheel guards shall be placed in Divisions not less than 3.60 meter in length.
All rails shall be squarely butt-joined at the posts and the rails shall break joints. (p) Trusses Trusses, when completed, shall show no irregularities of line. Chords shall be straight and true from end to end in horizontal projection and, in vertical projection, shall show a smooth, corded curve through panel points conforming to the correct camber. All bearing surfaces and joints shall fit accurately. Uneven or rough cuts at the points of bearing shall be cause for rejection of the pieces containing the defect. (q) Drains Drains shall be provided where indicated on the plans. Drains shall be constructed with galvanize iron linings and shall be arranged to discharge free of the structure. (r) Painting Rails and rail posts shall be painted with three coats of white paint unless otherwise specified on the plans. Other parts of the structure shall be painted when so designated on the plans. (s) Acceptance Material for timber structures will be evaluated by visual inspection and Certification. Furnish a production certification with each shipment of structural timber and lumber. Construction of timber structures will be evaluated by Visual inspection and by Measurement as given under the construction tolerances Division T8000 of this specification. Painting will be evaluated under Series 9000 of this specification. 8504 MEASUREMENT AND PAYMENT Measure untreated and treated structural timber and lumber by the thousand meter board measure (MBM) in the structure. Compute the quantities from nominal dimensions and actual lengths; except for transversely nail laminated decks. Measure transversely nail-laminated decks in place after dressing. The accepted quantities, measured as provided above, will be paid at the contract price per unit of measurement for the pay items listed below that are shown in the bid schedule. Payment will be full compensation for the work prescribed in this Division. Payment will be made under: Item 85.01 Untreated structural timber and lumber The unit of measurement shall be in MBM Item 85.02 Treated structural timber and lumber The unit of measurement shall be in MBM
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Series 8000: Structures Division 8600: Prestressing
DIVISION 8600: PRESTRESSING

8601 SCOPE This Division covers the specification of materials, equipment and methods for the prestressing of structural concrete elements by means of pre-tensioning and post-tensioning in accordance with the dimensions and details shown in the Contract. 8602 MATERIALS (a) General All materials and prestressing systems used in the prestressing of structural concrete members shall be subject to approval. (b) Prestressing steel (i) General
The type of prestressing steel shall be designated in accordance with the requirements of subclauses 8602 5(b)(ii) and (iii) respectively. The contractor shall keep proper records of all material analyses and test certificates for the batches of prestressing steel used in the works. Where required by the Engineer, the contractor shall produce certificates from recognized testing authorities certifying compliance of the prestressing steel with the specified requirements. Where prestressing steel is available in weld-free lengths (production lengths) and lengths containing welds (standard lengths), the batches delivered at the site shall be clearly labeled for identifications purposes. In no circumstances shall prestressing steel after manufacture be subjected to heat treatment other than provided for in these specifications (ii) Bars
Cold-worked high-tensile alloy steel bars for prestressed concrete shall comply at least with the requirements of BS 4486. The type of prestressing steel shall be indicated in accordance with the requirements of clause 4.2 of BS 4486, e g BS 4486-RR-32-1230 for 32 mm diameter ribbed bar with a nominal tensile strength of 1 230 MPa. (iii) Wires and seven-wire steel strand
Steel wire and seven-wire steel strand for prestressed concrete shall comply at least with the requirements of BS 5896. The type of prestressing steel shall be indicated in accordance with the requirements of clauses 14 and 20 of BS 5896 for wire and strands respectively, e g: BS 5896/2 wire 1770-7-PE-relax 1 for a 7 mm nominal diameter straightened smooth wire of class I relaxation with a nominal tensile strength of 1 770 MPa; and BS 5896/3 superstrand
1860-12.9-relax 2 for a 12.9 mm nominal diameter seven-wire superstrand of class 2 relaxation with a nominal tensile strength of 1 860 MPa. (iv) Straightness
Prestressing bars delivered at the site shall be straight. Only small adjustments for straightness may be made, which shall be done by hand on the site at a temperature above 5oC and under the supervision of the engineer. Where heating of the bars is required, this shall be by means of steam or hot water. Bars bent in the threaded portion shall not be used. Prestressing wire and strand shall be supplied in coils with a sufficiently large diameter to ensure that the wire and strand will pay off straight. (v) Surface condition
Prestressing steel shall be clean, free from faults or defects, and without any harmful films and matter, which may impair adhesion to the grout of concrete. A film of rust is not necessarily harmful and may improve the bond. It may, however, increase the friction between the tendon and duct. The depth of imperfections or pits on the surface of prestressing steel shall not exceed 0.1 mm for wire with a diameter up to and including 8 mm, or 0.2 mm for bars or wire with a diameter exceeding 8 mm. Tendons may be cleaned by wire brushing or by passing through a pressure box containing carborundum powder. Solvent solutions shall not be used for cleaning without the approval of the engineer. Prestressing steel shall be delivered at the site suitably protected against damage and corrosion. Such protection or the use of a corrosion inhibitor where allowed by the Engineer, shall not have any deleterious effect on the steel or concrete or impair the bond between the two. (vi) Cutting of Pre-stressing Tendons
All cutting of tendons shall be carried out using either: A high-speed abrasive cutting disc or friction saw used at not less than one diameter from the anchor, or any other mechanical method approved by the Engineer. An oxyacetylene cutting flame, using excess oxygen to ensure a cutting rather than a melting action used not less than 75mm from the anchor, whilst the temperature of the tendon adjacent to the anchor shall not be greater than 200oC. Neither the flame nor splashes from the cutting operation shall come into contact with either the anchorages or tendons. (vii) Galvanising
Galvanised prestressing steel shall not be used unless specified. In no circumstances shall prestressing steel be subjected to galvanising after manufacture. (viii) Welds
Prestressing steel used in structural prestressed concrete shall be weld-free. Where the steel is supplied in standard lengths, the welds shall be cut out and delivered to the Engineer.
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(c) Anchorages and couplers Anchorages and couplers to be used in prestressed concrete shall comply with the requirements of BS 4447 and shall be of a proved and approved type, constructed from durable material completely free from imperfections and shall not damage, distort or kink the prestressing steel in a manner as will result in ultimate tensile strength reduction. They shall resist, without failure and/or excessive deformation or relaxation of the force in the tendons, the full ultimate tensile strength of the tendons. The characteristic value for anchorages and couplers, determined in accordance with BS 4447, shall not be less than 90%. The anchorages shall effectively distribute the force in the tendon to the structural member, and the resulting local stresses and strains in the member shall be so limited as to prevent damage. Unless otherwise approved by the engineer, all anchorages and couplers shall be provided with anchorage reinforcement. Wedges and the insides of barrels or cones shall be clean to allow the free movement and seating of the wedges inside the taper. The threads of bars, nuts, anchorages and couplers shall be suitably protected against damage and corrosion. The protection shall be removed at the last moment and the threads properly lubricated before use. (d) Sheaths Sheaths shall be grout-tight and of such material and configuration that bond forces can be transferred from the grout to the surrounding concrete. The properties of the sheath material shall be such that no corrosion attack of the prestressing steel will be induced. The sheath shall be sufficiently flexible to accept the required curvature without kinking, and strong enough to retain its cross-section and alignment and to resist damage on account of handling, transporting, tying and contact with vibrators during concreting. Unless otherwise approved by the engineer, the thickness of the metal of steel sheaths shall not be less than 0.4 mm. Metal sheathing shall be delivered at the site suitably protected against damage and corrosion. At the time of Incorporation into the structural member, the sheathing shall be free from loose mill scale, loose rust, lubricants and harmful matter. Galvanised sheathing shall not be used unless specified. Unless otherwise specified, the internal diameter of the sheath shall be at least 10 mm greater than the diameter of the tendon. For vertical tendons and where tendons are to be drawn into cast-in sheaths, the crosssectional duct area shall be at least three times the cross-sectional area of the tendon. (e) Cable supports Supports of reinforcing steel or structural steel suitably braced to prevent buckling under load shall be used to support the cables. The cable saddles shall be rigid and secured in position by welding or by equivalent mechanical means to resist both gravitational and buoyancy forces. Normal web reinforcement shall not be utilised to support cables.
Saddles for external cables shall be of special design and material to ensure low friction and to prevent the tendon or parts thereof from grooving the surface. The saddle plates shall be curved to the requisite radius to prevent the tendon or part thereof from bearing on the end of the plate and shall incorporate features to ensure that individual bars, wires and strands are seated separately. (f) Positioning of Tendons and Duct Formers for Pre-stressing Tendons Tendons and duct formers shall be accurately located and maintained in position both vertically and horizontally as described in the Contract. Unless otherwise described in the Contract the tolerance in the location of the centerline of sheath or duct shall be 5mm. Where tendons are described in the Contract as being debonded from the concrete, they shall be covered with sleeves approved by the Engineer. The ends of the sleeves shall be taped around the tendon to prevent the ingress of grout. (g) Tendon spacers Tendon spacers used inside the ducts to separate individual bars, wires or strands of the tendon shall be of a proved and approved type and manufactured from material which will not induce corrosion of the prestressing steel. (h) Grout (i) Materials
In addition to the requirements of sub-clause 8402 (d) of these specifications, water shall not contain more than 500 mg of Cl ions per ltre of water. Only ordinary Portland cement that complies with the requirements of AASHTO M-85 or blended hydraulic cement complying with the requirements of AASHTO M-240 shall be used. The temperature of the cement shall be less than 40oC, and the cement shall be stored In accordance with the requirements of sub-clause 8403(a) of these specifications. Fine aggregate shall comply with the requirements of sub-clause 8402(c)(ii) of these specifications. The use of fine aggregate shall be subject to the approval of the Engineer and shall be restricted to grout for ducts with a diameter exceeding 150 mm. The aggregate content in the grout shall not exceed 30% of the mass of the cement. The use of admixtures shall be subject to tests having shown that their use improves the properties of the grout, e g by increasing workability, reducing bleeding, entraining air, or expanding the grout. Admixtures shall be free from any product liable to damage the steel or the grout itself, such as halides, nitrates, sulphides, sulphates, etc. The quantity of admixture to be used shall be in accordance with the manufacturer's instructions. (ii) Properties of the grout
The mixed grout shall have the following properties: The Cl ions content shall not exceed 750 mg per liter. The viscosity of the grout measured in accordance with Division 10100 of these specifications, for horizontal cables shall be 500 to 2 500 cP and for vertical cables 400 to 1
500 cP. The viscosity of the grout, 20 minutes after mixing, shall not exceed 2 500 cP and 1 500 cP for horizontal and vertical cables respectively, Bleeding at 20 0 C measured in accordance with Division 10100 of these specifications, shall not exceed 2% by volume 3 hours after the grout has been mixed, and the maximum bleeding shall not exceed 4%. In addition, the separated (bleed) water must be reabsorbed after 24 hours. The cube compressive strength of 100 mm cubes made of the grout and cured in a moist atmosphere for the first 24 hours and then in water at 20 0 C shall exceed 20 MPa at 7 days. (i) Protecting agents for unbonded tendons The material used for permanent protection of unbonded tendons shall have the following properties: It shall remain free from cracks and shall not become brittle or fluid within the temperature range of -20oC to 70o C. It shall be chemically stable for the entire life of the structure. It shall be non-reactive with the surrounding materials, i.e. concrete, tendons, wrapping or sheathing. It shall be non-corrosive or corrosion inhibiting. It shall be impervious to moisture shall be sufficiently tough to withstand the abrasion caused when a tendon, precoated with the material, is drawn into the sheath. It shall have no appreciable shrinkage or excessive volume increase. It shall have a suitable viscosity at ambient temperature or require only moderate preheating to permit injection (j) Testing Prestressing steel, anchorages and couplers, and grout shall be tested in accordance with the requirements of Division 10100 of these specifications. Testing shall be carried out at the frequencies as directed by the engineer. 8603 CONSTRUCTION REQUIREMENTS (a) Equipment (i) General
All equipment used shall be in a good working order and properly maintained. (ii) Tensioning and measuring equipment
Tensioning and measuring equipment shall be such that the tendon force can be established to an accuracy of 2% during any stage of the tensioning operation. Unless otherwise authorised by the Engineer, the tensioning equipment shall be power driven and capable of gradually applying a controlled total force without inducing dangerous secondary stresses in the tendon, anchorage or concrete.
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The force in the tendon during tensioning shall be measured by a direct-reading dynamometer (load cell type) or obtained direct from pressure gauges fitted in the hydraulic system to determine the pressure in the jacks. Pressure gauges shall have concentric scale dials, which comply with the requirements of BS 1780. The dials shall not be less than 150 mm in diameter and the gauges shall be used within the range of 50 - 90% of their full capacity at maximum service pressure. When pressure gauges not using glycerine are used, a snubber or similar device shall be fitted to protect the gauge against any sudden release of pressure. Provision shall also be made for T-connections for the attachment, when required, of supplementary control gauges. Only self-sealing connections shall be used in the hydraulic circuit. Where the pressure input pipe is connected to the jack, a pipe rupture valve shall be installed in the circuit. Tensioning equipment shall be calibrated before the tensioning operation and thereafter at frequent intervals, as directed by the engineer, with a master gauge or proving ring, and the engineer shall be furnished with a calibration chart. The load-measuring devices shall be calibrated to an accuracy of 2%. The extension of tendons shall be measured to an accuracy of 2% or 2 mm, whichever is the more accurate, and pull-in and release to an accuracy of 2 mm. (iii) Grouting equipment (1) Mixer
Mechanically operated mixers only, of a type capable of producing high local turbulences while imparting only a slow motion to the body of the grout shall be used. The mixer shall be equipped with a screen with openings not exceeding 1 mm and shall be capable of consistently producing grout with a colloidal consistency. (2) Agitator Where the capacity of the mixer is insufficient to fill the duct completely with grout, an agitator shall be used. Mechanical agitators only shall be used, which are capable of maintaining the colloidal condition of the grout fill during the storing and injection processes. The grout shall be delivered at the structure from the agitator, and the system shall make provision for recirculating the grout from the pump back to the agitator. (3) Injection equipment The pump shall be of the positive displacement type (piston, screw or similar type), capable of exerting a constant pressure of at least 10 bars on completely grouted cables and shall incorporate a safety device for preventing the build-up of pressure above 20 bars. The pump shall be fitted with a pressure gauge and a valve, which can be locked-off without loss of pressure in the cable. The pump shall be capable of delivering grout at a speed as will produce a speed of the grout in the cable of between 6 and 12 m per min. All connections in the pipes and between the pipe and the cable shall be airtight. Only bayonet, threaded, or similar types of connectors shall be used.
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(b) Technical Data The following technical data for pre-tensioned and post-tensioned structural members required for the contract will be furnished on the drawings: (i) Tendon alignment
A diagram showing the alignment of each tendon or group of tendons in both the horizontal and vertical planes, together with the horizontal and vertical coordinates, and curve equations of the centroid of the tendon (s), as may be relevant. (ii) Tendon system
The design is based on the system shown on the drawings, but the contractor may use any suitable system, which will meet all the specified requirements, subject to approval by the Engineer. (iii) Tensioning the tendons
Full particulars regarding the partial tensioning of the tendons, the stage during which the tendons shall be tensioned, and the sequence of tensioning to be followed. (iv) Tensioning force
The maximum tensioning force and the effective force at the live anchorages, after transfer, as well as the corresponding stress level in the prestressing steel, for each tendon or group of tendons. The forces will be given in MN units, and the stress levels will be expressed as a percentage of the characteristic strength. (v) Extension
The extension per tendon or group of tendons under the maximum tensioning force, together with the modulus of elasticity (E) on which it has been based. The release to be attained at each live anchorage as well as the pull-in for which provision has been made. The contractor shall show on his drawings the expected extension based on the actual modulus of elasticity of the strand as well as the expected wedge pull-in and any provision for shimming. (vi) Prestressing losses in tendons (1) Friction loss
The losses allowed for in the design from the causes listed below will be given as follows: The formula used for determining the tendon/duct friction loss together with the values adopted for the friction coefficient (u) caused by curvature, and the wobble factor (k) caused by unintentional variation from the specified alignment. (2) Elastic deformation of concrete The elastic factor, which, when multiplied by the compressive stress in the concrete adjacent to the tendon, will give the loss caused by the deformation of the concrete. (3) Creep of the concrete The creep factor, which, when multiplied by the compressive stress in the concrete adjacent to the tendon, will give the loss caused by the creep of the concrete.
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(4) (5)
Shrinkage of the concrete Relaxation of prestressing steel
The stress loss in MPa caused by the shrinkage of the concrete. The stress loss in MPa at a stress level of 70% of the characteristic strength of the prestressing steel caused by the relaxation of the prestressing steel. (vii) Anchorages
The positions where loop or fan-type dead-end anchorage may be used, (viii) Bursting reinforcement
The bursting reinforcement for the prestressing system on which the design is based. (ix) Precamber
The precamber at intervals not exceeding 0.25 times the span length. (x) Compressive strength of the concrete during transfer
The compressive strength to be attained by the concrete in the relevant member before transfer may be effected. (c) Prestressing System The use of all prestressing systems will be subject to approval by the engineer. Within one month of the tender having been awarded, or within a period agreed on with the engineer, the contractor shall submit full details regarding the prestressing system(s), materials and equipment he intends using, as well as regarding the methods he proposed to adopt in the prestressing and related operations. The engineer, at his own discretion, may call for further information in the form of detailed drawings, proof of successful previous use, performance certificates from an approved independent testing authority, and calculations substantiating the adequacy of the system. The contractor shall furnish such information within 2 weeks of being called upon to do so or within a period agreed on with the Engineer. If, after investigating all the information, the engineer is not satisfied that the prestressing of the structural member can be carried out satisfactorily with the prestressing system offered by the contractor, the engineer reserves to himself the right to order the contractor to use any system which is suited to the work and which is readily available to the contractor. Only minor alterations to the concrete dimensions shown on the drawings will be considered in order to accommodate the prestressing system finally selected. Major alterations occasioned by the prestressing system offered by the contractor and which is at variance with the tendon system specified in sub-clause 8603 B (b) shall be treated as alternative designs and shall be dealt as per the contract. (d) Drawings Prepared By the Contractor All drawings prepared by the contractor and submitted to the engineer for consideration shall comply with the requirements of the Contract. The contractor shall submit to the Engineer at least 2 months before he intends commencing with the prestressing work, drawings detailing the layout and alignment for the individual
tendons, the cable supports, modifications to the bursting and other reinforcement, anchorage recesses, tensioning sequence, tensioning loads and extensions, as well as requirements for controlling the tensioning operations. For the prestressing system finally selected, the technical data, which are at variance with the information given on the drawings, shall be shown on the drawings. Each tendon shall be separately numbered for identification. Where required, the contractor shall submit calculations in respect of the variation of the tendon force along the length of the tendon, the expected extension and the bursting forces. After approval by the Engineer of the drawings and calculations prepared by the contractor, no departure shall be permitted from the forces, stresses and extensions shown thereon, without authorization by the Engineer. The prestressing work shall not be commenced before the relevant drawings have been accepted by the Engineer. (e) Precasting (i) Casting yard on the site
Subject to approval by the engineer, precast work may be done at any location selected by the contractor. Before the casting yard is established, the contractor shall submit plans to the Engineer, which demarcate the site and detail the layout of the works, together with a flow diagram of the construction stages and storage. (ii) Manufacture off the site
The contractor shall notify the engineer in advance of the dates when tensioning of tendons, casting of members and transfer, will be undertaken. Within 7 days of transfer, the contractor shall submit to the Engineer a certificate giving the tendon force(s) and extension(s) attained as well as records of the cube crushing strength and age of concrete at transfer. Test results relating to all aspects of the work shall be sent to the Engineer immediately upon their becoming available. Where the engineer requires tests to be conducted on completed members, no member to which the tests relate shall be dispatched to the site until the tests have been satisfactorily completed and the members accepted by the Engineer. (iii) Manufacture
Before work is commenced, details of the manufacture, curing and phasing of the work shall be submitted to the Engineer for approval. After approval no changes shall be made to the methods or systems without approval by the Engineer. The contractor shall ensure that the specified precamber is incorporated in the formwork. The magnitude of the precamber shown on the drawings shall be subject to variation depending on the contractor's construction programme, and the contractor shall, before manufacture, ascertain in writing from the Engineer, the increase or decrease in precamber. This procedure shall also apply to the cases where no precamber has been specified.
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Lifting and supporting the precast members shall be made only at the points marked and provided on the members. Precast members which have not been fully tensioned or fully stage-tensioned or which have ungrouted tensioned tendons shall not be handled without authorization by the Engineer. Where members with ungrouted tensioned tendons are handled, control shall be exercised to guard against possible slip of the tendon at the anchorage. Prestressed precast concrete members shall also comply with the requirements of clause 8412 of these specifications. (f) Pre-Tensioning During the period between tensioning and transfer, the force in the tendon shall be fully maintained by some positive means. At transfer, detensioning shall take place slowly to minimize any shock, which could adversely affect the transmission length of the tendon. In the long-line method of pre-tensioning, sufficient locator plates shall be distributed throughout the length of the bed to ensure that the straight tendons are maintained in their proper position during concreting. Where a number of units are manufactured in line, they shall be free to slide in the direction of their length so as to permit transfer of the tendon force to the concrete along the entire line. In the individual-mould system, the moulds shall be sufficiently rigid to provide the reaction to the tendon force without distortion. Where possible, the mechanism for holding clown or holding up deflected tendons shall ensure that the part in contact with the tendon will be free to move in the line of the tendon so that friction losses are eliminated. If, however, a system is used which develops a frictional force, this force shall be determined by test and due allowance made therefore. For single tendons, the deflector in contact with the tendon shall have a radius of not less than 5 times the tendon diameter for wire, or 10 times the tendon diameter for a strand, and the total angle of deflection shall not exceed 15o. Transfer of the tendon force to the concrete shall be effected in conjunction with the release of hold-down and hold-up forces in accordance with an approved method. Transfer shall not be effected until compressive-strength tests on the concrete show that the concrete of the particular member has attained a compressive strength of at least the compressive strength shown on the drawings. The transmission length is affected by the concrete strength, and the necessary modification for the concrete strength at transfer shall be made in conjunction with the Engineer. The tendons shall be cut off flush with the end of the member and the exposed ends covered with a heavy coat of approved bituminous material or epoxy resin. The cutting of the prestressing steel shall be performed with-4 high-speed abrasive cutting wheel. Flame cutting will not be permitted. (g) Post-Tensioning (i) Storage, handling and protection
During storage, transit, and construction after installation the sheaths, prestressing steel, anchorages and couplers shall be protected against corrosion, damage or permanent deformation. The manner and extent of protection required will depend on the environmental
factors and the length of time before permanent corrosion protection is applied, and shall be to the satisfaction of the engineer. Under severe corrosive conditions in coastal, damp and wet areas and under aggressive conditions the materials shall be stored in weatherproof sheds. All materials shall be stored clear of the ground and while in storage shall not be exposed to the weather. When prestressing steel has been stored for a prolonged period and there is evidence of its deterioration, the contractor may be called on to prove by tests that the quality of the steel has not been significantly impaired and that the prestressing steel still complies with the provisions of these specifications. Suitable protection shall be provided to the threaded ends of bars. After fabrication, the cable ends shall be covered with protective wrapping to prevent the ingress of moisture into the duct. When the tendon is to be left untensioned for a prolonged period after installation, precautions shall be taken to protect the tendon against corrosion. Corrosion inhibitors, oils or similar materials used as lubrication or to provide temporary protection shall be such that they can be completely removed before permanent protection is effected. (ii) Fabrication
All cutting of prestressing steel shall be performed with a high-speed abrasive cutting wheel or by a method approved by the engineer. Flame cutting will not be permitted. Care shall be taken to prevent the prestressing steel or anchorages from coming into contact with splashes from flame-cutting or welding processes in the vicinity. Where possible, all bars, wires or strands tensioned in one operation shall be taken from the same parcel of prestressing steel. The tendon or cable shall be labelled to show the tendon or cable number, as well as identify from which parcel the steel has been taken. Where bars, wires or strands in a tendon are not tensioned simultaneously, tendon spacers shall be used in accordance with the recommendations for the prestressing system or, in the absence thereof as directed by the Engineer. Cables shall be fitted at both ends with pipes with a diameter of at least 10 mm for the injection of grout or protection agents. The ends of the injection pipes shall be fitted with a clamp, valve or device capable of withstanding a pressure of at least 15 bars without loss of grout or protection agent. Vent pipes with a diameter of at least 25 mm shall be provided in the duct at every high point, change of sheath cross-section and at such intermediate positions as may be shown on the drawings or required by the engineer. The vent pipes shall extend to at least 500 mm above the concrete and shall comply with the requirements for injection pipes. Connections to, and joints in sheaths shall be made grout-tight by using special sheathing couplings and taping. With bonded cables, the length of taping shall not exceed six sheath diameters. Where over sleeves are used, equal overlaps shall be provided over each length of sheathing. Joints in adjacent sheaths shall be spaced at least 300 mm apart.
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(iii)
Installation
The installation of tendons shall not commence until the requirements of clause 8603(d) have been complied with. The cable, sheath or extractable core shall be accurately installed to the specified alignment and securely held in position both vertically and horizontally at intervals appropriate to its rigidity and so as not to be displaced during concreting, either by the weight of the concrete or by buoyancy. The spacing of the cable supports shall furthermore ensure that the tendon can be installed to a smooth alignment without kinks and within the tolerance specified in sub-clause T8000(g)(i). Cable sheaths shall be supported and held in position by means of separate reinforcing steel supports with a diameter of not less than 16 mm. The transverse bars must be welded to the vertical bars or must rest on lugs welded to the vertical bars. The spacing of the vertical supports shall not exceed 1 m. Extractable cores shall not be coated with release agent unless approved by the Engineer. Unless otherwise shown on the drawings, the alignment of the tendon within a distance of 1.0m from the live anchorage and/or coupler shall be straight, The tendon axis shall be set perpendicular to the bearing surface of its anchorage and firmly secured in position so as not to move during concreting. External anchorages shall be seated on a thin mortar bedding to bear evenly on the concrete bearing surface, and the tendon axis shall be perpendicular to the bearing surface of the anchorage. Unless otherwise shown on the drawings, the minimum concrete cover over the outside surface of the sheath or cable support shall comply with the requirements of sub-clause 8303(e), except that, for sheaths, the cover shall not be less than 50 mm. The spacing of cables will depend on the size of the cable and shall be such that the concrete can be properly placed and compacted. Immediately before concreting, the contractor shall inspect the sheaths for grout-tightness and shall seal all damaged and suspect sections. External tendons shall be installed to the same standards and accuracy specified herein for internal tendons. The tendons shall be temporarily supported at regular intervals along the straight length between saddles. The supports shall consist of rigidly constructed frames secured to the concrete face. (iv) Concrete strength
Full tensioning of all or some of the tendons shall not commence until the compressivestrength of the concrete is 35 MPa or the strength shown on the drawings, whichever is greater. The compressive strength of the concrete shall be determined from cubes manufactured and tested in accordance with sub-clause 10106(e) that have been cured under the same conditions as the structural member which is to be prestressed. The number of concrete cubes required for this purpose shall be as agreed on with the Engineer.
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Where initially all or some of the tendons are to be partially tensioned, tensioning shall not commence before the concrete has attained the compressive strength indicated on the drawings. (v) Tensioning (1) Preparation
Within 2 hours of the concrete having been placed, the contractor shall demonstrate that sheaths are free from obstructions, that extractable cores can be removed and, where the design permits, that all tendons are free to move in the ducts. All water in the ducts shall then be expelled with compressed air and the cables sealed until tensioning takes place. Before tensioning is commenced, the side forms and other restraining elements shall be released or removed to give the structural member the freedom to deform under the induced force. (2) Tensioning sequence The sequence of tensioning to be followed shall be as shown on the drawings and/or on drawings prepared by the contractor in terms of sub-clause 8603(d). Where partial tensioning of tendons is required, the work shall be executed in accordance with the details on the drawings or as specified. (3) Assembling the equipment, and safety precautions The tensioning and measuring equipment shall be assembled for tensioning in exactly the same way as they are combined for calibration. The contractor shall take all the necessary safety precautions to prevent accidents caused by the malfunctioning or failure of any part of the equipment or material and shall accept full responsibility for injury sustained by persons or damage to property resulting therefrom. (4) Friction The Engineer may require the contractor to perform friction tests on designated tendons and to revise the relevant theoretical extensions to compensate for the discrepancy between the values adopted in the design and the test results. Payment for these tests shall be borne by the contractor. Where applicable, allowance shall be made in the tensioning force to compensate for friction loss in the jack and in the anchorage. (5) Tensioning Tensioning shall be carried out under the supervision of a technician skilled in the use of the prestressing system and equipment and the methods of tensioning to be adopted. Tensioning shall not be commenced before the engineer has been advised of each tensioning operation and has given his approval for the work to be started. The technician and operators shall be supplied with a schedule listing the sequence of tensioning the various tendons and a tensioning record sheet showing the theoretical gauge readings, jacking forces, extensions, release and pull-in for each tensioning operation. The record sheet shall furthermore provide room for entering the corresponding information recorded and observations made during tensioning. A graph of the tensioning force and/or gauge reading versus theoretical extensions shall, where required, be appended to the record sheet and the actual extensions measured for each load increment shall be plotted on the graph.
Copies of the completed record sheets and graphs shall be submitted to the Engineer within 24 hours of each tensioning operation having been completed. The contractor shall note that the extensions shall be regarded as an indirect measurement of the tensioning force and shall serve as a control on the tensioning force applied. The protruding ends of all bars, wires and strands shall be clearly marked for the accurate measurement of extension, release and pull-in. Before tensioning is commenced on external tendons, a small load shall be applied to each tendon, commencing with the uppermost tendon. The force shall be sufficient to take up all slack and prevent entanglement of the tendons. The jacking force shall be increased to approximately 5 to 10% of the final jacking force to take up the tendon slack and to determine the zero Position for measuring the extension and to check the gripping devices and the position and alignment of the jacks. The load shall then be increased gradually to the full specified tensioning force while intermediate gauge readings and extensions are recorded at regular intervals. The final stage of tensioning shall be deemed to have been satisfactorily accomplished when all the following requirements have been complied with: The tendons have been tensioned to the required force. The measured extension on individual tendons is within 6% of the theoretical extensions. The average variation between the measured and theoretical extensions of all the tendons in a structural member is less than 3%. The release and/or pull-in is within 2 mm of the theoretical values. Where the above conditions are not met individually and collectively, the contractor shall immediately advise the Engineer and obtain a ruling as to the procedure to be followed. In the event of the tendon friction being too high, the contractor may, subject to approval by the Engineer, inject an approved lubricant into the sheath after first having detensioned the tendon. The cost of the remedial and corrective measures and of the release and retensioning of tendons, which have been occasioned by failure of the operations to meet the above requirements shall be for the contractor's account. After the tensioning has been accepted by the Engineer, the contractor may cut off the tendons behind the anchorage as described in sub-clause 8603(f). (vi) Permanent Protection and bonding of tendons (1) General
After tensioning, all tendons shall receive permanent protection against mechanical damage and corrosion. Internal tendons shall be protected and bonded to the structural member by cement grout or, when permitted by the engineer, by sand-cement grout. Where bond is not important, protection may be effected by the use of bitumen, petroleum-based compounds, epoxy resins, plastics and similar products, all complying with the requirements of sub-clause 8602(i) and subject to the approval of the Engineer. Tendons located outside the structural section (i. e external tendons) shall be encased with a dense concrete, dense mortar or material sufficiently stable and hard, all subject to approval. The encasement shall be of the thickness shown on the drawings.
Where bonding of the tendon to the structural concrete is required, this shall be achieved by bonding the concrete encasement to the structure with reinforcing steel as detailed on the drawings. Protection and bonding of the tendons shall be effected within 7 days of the final tensioning of the tendons, or as specified on the drawings, but shall not take place without the prior approval of the engineer having been obtained. After the permanent protection or bonding has been completed the anchorages shall be encased in concrete or grout, which shall be bonded to the old concrete with epoxy resin, designed for this purpose, or shall be completely coated with a corrosion-resistant material. The protection provided shall in all cases prevent the ingress of water or aggressive agents. (2) Preparation of ducts Before permanent protection and/or bonding of tendons is affected, the following precautions shall be taken: The cables shall be checked for blockages by water or compressed air, being injected. Unlined ducts, which are to be filled with grout, shall be flushed with water to wet the concrete. Temporary protection or lubricants, which are incompatible with the permanent protection or bonding, shall be removed by flushing the duct with water or an inert solution, or by any suitable approved method. On completion of the above, any excess fluid shall be expelled from the ducts by means of compressed air or shall be displaced by the protecting agent or grout, as may be relevant. Any blockages, leakages or factors, which in any way may affect the permanent protection or bonding, shall immediately be reported to the engineer. (3) Mixing The mixing of protecting agents shall be strictly in accordance with the manufacturer's instruction. The aggregate, if used, and the cement shall be measured by mass, and the water by mass or by volume. The water: cement ratio by mass shall be as low as possible within the range between 0.36 to 0.45, and shall be consistent with the fluidity requirements of sub-clause 8602(h)(ii). Where an admixture is used, it shall be dissolved in a part of the mixing water before it is added to the grout. Mixing shall be commenced by two-thirds of the cement being added to the greater part of the mixing water, and, if used, an additive predissolved in part of the mixing water, and finally the remainder of the cement. Mixing shall continue for not longer than 4 minutes after which the grout shall be continually agitated at slow speed throughout the injection operation. Where aggregate is used in the grout mix, the word "cement" in the preceding paragraph shall be replaced by the term "cement/aggregate component". (4) Strength of Grout The compressive strength of 100mm cubes made of the grout shall exceed 17 N/mm2 at 7 days. Cubes shall be made, cured and tested in accordance with the requirements of BS 1881.
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(5)
Injection General The injection of permanent protecting agents or grout shall not commence before approval has been granted that the work may start. Before injection commences all air shall be expelled from the injection equipment and hoses and all connections checked for air tightness. Injection shall take place from the anchorage or coupler, whichever is situated at the lower end of the cable. Grout Injection shall proceed without any interruption until the cable has been completely filled and closed off. Protecting agents The injection of protecting agents shall be strictly In accordance with the instructions, and with the equipment specified by the manufacturer. Grout Immediately after mixing, and also during injection, the fluidity of the grout shall be tested at regular intervals in accordance with sub-clause 8602(j). Injection shall be continuous at a rate of 6 m to 12 m per minute. As soon as grout with the original consistency flows from the intermediate vent pipes they shall be successively closed. Injection shall continue until the grout flowing from the vent at the free end is of the same consistency as that of the injected grout. At this stage the vent shall be closed and the final pressure or a pressure of 5 bars, whichever is the greater, shall have been maintained on the grout column for 5 minutes before the valve at the injection end is closed. All vents shall be kept closed and supported vertically until the grout has finally settled. On vertical cables, a riser pips with funnel shall be fitted to the top anchor to ensure that the separated water migrate upwards and will not remain in the cable. If an expanding agent is used in the grout mix, the air vents shall be re-opened after grouting to release any separated water, and shall then again be closed. Unless a retarder is used in the grout mix, the grout not used within 60 minutes of mixing shall be discarded. During the course of grouting 100 mm cubes shall be made for testing in accordance with sub-clause 8602(j). Whilst the grout is being poured into the cube mould, the sides of the mould shall be slightly tapped to permit any entrapped air to escape. Precautions shall be taken not to discharge the escaping grout onto railway lines, public roads or private property. If a blockage occurs during the course of grouting, the grouting shall be stopped before the maximum grouting pressure is reached. The duct shall then be flushed out immediately and the blockage cleared. Grouting shall not be carried out during very cold weather when the ambient air temperature drops below 5 0 C. Care shall be taken that the ducts are completely free from frost or ice before grouting commences after frosty weather.
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8604 LOSS OF PRESTRESS Any structural member which has lost all or part of its prestress through the failure or malfunctioning of any part of the prestressing component may be rejected by the Engineer and shall be removed from the works unless approved remedial measures have been successfully carried out on the member. No payment will be made in respect of such remedial work or loss suffered by the contractor in this regard. 8605 MEASUREMENT AND PAYMENT Item 86.01 Prestressing tendons (a) (b) (c) Longitudinal Tendons ...................................................... meganewton-metre (MN-m) Transverse Tendons.......................................................... meganewton-metre (MN-m) Vertical Tendons............................................................... meganewton-metre (MN-m)
The unit of measurement shall be the meganewton-metre which is calculated as the product of the nominal tensile strength in megapascals of the prestressing steel, the cross-sectional area of the tendon in square meters and the length of the tendon in meters between the faces of the anchorages. In the case of fan and loop anchorages the "length of the tendon" shall include the length of tendon forming the loop or fan. The tendered rates shall include full compensation for preparing and submitting the drawings, supplying, storing, handling and protecting all materials (excluding anchorages and couplers), fabricating, supporting and installing the cables; lubricating, permanently protecting and bonding the tendons, for the using of all the equipment, as well as for all work and incidentals required for completing the work as specified. Item 86.02 Anchorages and couplers (a) (b) (c) (d) Anchorage at jacking end ...............................................................meganewton (MN) Anchorage at dead end....................................................................meganewton (MN) Coupler at jacking end ....................................................................meganewton (MN) Coupler at dead end ........................................................................meganewton (MN)
The unit of measurement shall be the meganewton, which is calculated as the product of the nominal tensile strength in megapascals of the prestressing steel and the cross-sectional area of the tendon in square meters, effectively anchored or coupled. The tendered rates shall include full compensation for supplying, storing, handling, fabricating and protecting the complete anchorage or coupler assembly, anchorage reinforcing, constructing the recesses for the anchorage or coupler, tensioning, anchoring and/or coupling, trimming the tendon ends, using all the equipment, as well as for all work and incidentals required for completing the work as specified. The coupler shall include the complete assembly consisting of the anchorage built into the first-stage construction and the part coupled to it. The tendered rate for loop or fan anchorages shall exclude the cost of the length of tendon forming the loop or fan.
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Item 86.03 Extra over pay item 86.02 for partially tensioning the tendons The unit of measurement shall be the meganewton (MN), which is calculated as for pay item 86.02. The tendered rate shall include full compensation for the use of all equipment, as well as for all work and incidentals required for tensioning and anchoring the tendons to the specified partial force.
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Series 8000: Structures Division 8700 Bridge Bearings
DIVISION 8700 BRIDGE BEARINGS PARAPETS, RAILINGS, SIDEWALKS, NO-FINES CONCRETE, WATER PROOFING AND DRAINAGE FOR STRUCTURES
8701 SCOPE This Division covers: The construction, supply and installation of bearings for structures, the construction of parapets, railings and sidewalks on structures. The supply and installation of all permanent joints which will permit relative movement between contiguous structural members, The manufacture and placing of no-fines concrete used in the Works, and The construction and/or installation of drainage works such as weep holes, drainage pipes and gulleys, no-fines concrete blocks, filter lining and concrete channeling.
8702 BRIDGE BEARINGS Bridge bearings shall be either proprietary or purpose made bearings as described in the Contract. (a) Material (i) General
When requested by the Engineer, the Contractor shall submit test certificates from an approved, independent testing authority to show that the respective materials conform with the specified requirements, or a certificate from the patent holder or design certifying that the manufactured item complied in all respects with relevant product specifications. Unless otherwise specified, all the materials used for manufacturing the bearings shall comply with the requirements of BS 5400: part 9.2. or equivalent AASHTO or ASTM materials can be used if approved by the Engineer. (ii) Roofing Felt
Roofing felt shall be in 3-ply and comply with the requirements of the Engineer. (iii) Elastomer
The elastomer used in the manufacture of bearings shall be natural rubber or synthetic rubber. Natural rubber shall comply with the requirements of BS 1154 for Group Z13 or Z14 natural rubber and/ or AASHTO Elastomeric Bearing, Section 25. Synthetic rubber shall comply with the requirements of BS 2752, for Compounds C3 or C4 synthetic rubber.
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(iv)
Stainless steel plate (PTFE)
PTFE used in conjunction with stainless steel plates to form low friction sliding surfaces shall be unfilled (virgin) PTFE and comply with the requirements of BS 6564: Part 2 for Grade A Type 1 PTFE. The sliding surface of the PTFE may be either smooth or dimpled. (v) Stainless steel plate
Stainless steel plate used in conjunction with PTFE to form low friction sliding surfaces shall comply with the requirements of BS 1449: Part 2 for Steel 316S16. The texture of the sliding surface shall be equal to or better than 0.20 micron Ra in accordance with the requirements of BS 1134. (vi) Stainless steel dowels and bolts
Stainless steel used for the manufacture of dowels, holding down and anchor bolts shall comply with the requirements of BS 970: Part 1 for Steel 316S16. (vii) Steel plate
Steel used for plate reinforcement in laminated elastomeric bearings shall comply with the requirements of BS 4360 for Grade 43A Steel and/ or ASTM A 570, Grade 36 or ASTM A 611, Grade D. (viii) Mortar
Mortar bedding for seating of bearings shall be composed of an approved sand and either cement or epoxy resin, or may consist of an approved proprietary mortar. The mortar shall comply with the following strength requirements. (1) Sand-cement mortar The 7-day compressive strength of 150mm cylinders made of the mortar and cured in moist atmosphere for the first 24 hours and thereafter in water at 20oC shall not be less than 1.5 times the average contact stress under the bearing or 15 MPa whichever is the greater. (2) Sand-epoxy resin mortar The cured compressive cylinder strength of the mortar shall not be less than 2.0 times the average contact stress under the bearing or 20 MPa whichever is the greater. (3) Proprietary mortar The strength requirements for proprietary mortars shall be in accordance with either Subclause 8702(a) (viii) (1) or (2) above as may be relevant. (b) Concrete Hinges Concrete hinges shall be constructed in accordance with the details shown on the Drawings. The throat shall be formed to have rounded chamfers on all sides and with the upper and lower surfaces at a slight divergence. The concrete cover to reinforcing steel in the throat shall not be less than 25 mm. The concrete used in forming the throat of the hinge shall be as specified on the Drawings but shall not have a 28-day cylinder crushing strength of less than 40 MPa. The maximum size of coarse aggregate in the mix shall not be larger than 10 mm.
Construction joints shall not be formed in the throat area. Where a joint is necessary it shall be formed as a recess below the throat, level with the top reinforcement mat. The width of the recess shall be slightly greater than the width of the throat. Care shall be exercised to eliminate the formation of shrinkage cracks with the throat. During construction adequate bracing and support shall be provided to the satisfaction of the Engineer to prevent rotation in the throat from the time of casting to completion of the structure incorporating the hinge. During the coarse of construction the hinge shall not be subjected to conditions that will include tensile stresses in the throat area. (c) Roofing Felt Roofing felt used as bearing strips shall consist of at lest 3 layers, laid on the bearing surface to the dimensions shown on the Drawings. Where lubricated linings are specified, the roofing felt shall be saturated with vegetable oil and thereafter liberally dusted with graphite powder before it is laid on the bearing surface. (d) Elastomeric Bearings (i) Technical data
The following technical data for the elastomeric bearings required on the contract will be supplied on the Drawings, and shall also be supplied on drawings prepared by the Contractor for submission to the Engineer. (1) Design loads and deformations The critical design and load combination and co-existing rotations and horizontal displacements for each or each group of identical bearings. (2) Size and construction of bearing The size and construction of the bearing pad shall be designated by : L x B x (n1(t1) + n2 (t2)), where L = length of pad in the transverse direction in mm B = width of pad in the span direction in mm t = thickness of individual elastomer layers in mm n = number of elastomer layers of each thickness The thickness of the steel plate in reinforced elastomeric bearings shall not be less than 3 mm unless specified otherwise on the Drawings. The complete bearing shall be encased in a 3 mm thick elastomer layer consisting of the same elastomer as the rest of the bearing. (3) Hardness and type of elastomer The IRHD hardness and type of elastomer, i.e. natural or synthetic rubber, from which the specified bearings are to be manufactured. (4) Identification Each bearing shall be identified by a number.
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(ii)
Alternative bearings
Where alternative bearings are offered by the Contractor, they shall be designed in accordance with the requirements of ERA Bridge Design Manual-2002 for the loadings and deformations shown on the Drawings. Where a bearing consisting of a different rubber to that, which is specified, is offered, the bearing shall be redesigned to allow for the variation in hardness and/or type of rubber. (iii) Inspection and testing
On completion of manufacture of the bearings, the Contractor shall submit bearing pads selected by the Engineer, or specially manufacture sample pads authorized by the Engineer, to an independent testing authority for testing. The tests to be undertaken shall be as directed by the Engineer and in accordance with these specifications. A variation of + 20% shall be permitted between the actual and theoretical stiffness for compression and shear of the elastomer. Where this variation is exceeded, acceptance of the pads shall be at the sole discretion of the Engineer. Copies of test results and certificates for the above mentioned testing shall be submitted by the Contractor to the Engineer timeously to enable the Engineer to assess the information before the bearings are installed. The dimensional tolerances on bearing pads shall comply with the requirements of Division T8000 Construction tolerances for structures of these specifications. Before the bearings are dispatched to the site of works each bearing, with the exception of large bearings as provided for in the Special Provisions, shall be subjected simultaneously to a vertical load, equal to 150% of the maximum design load, and to a shear distortion equal to 150% of the maximum design value. The bearings shall be visually inspected for defects by the Engineer or his nominee and shall at no stage under this test show any cracks visible to the naked eye or other defects. The cost of this testing shall be included in the rate tendered for the supply and installation of the bearing pads. (e) Proprietary Bearings (i) General
This clause covers custom-built bearings, bearings manufactured under license except elastomeric bearings. Combined bearings, consisting of an assembly of an elastomeric bearing in conjunction with a low friction sliding or mechanical component shall fall under this clause. The Tenderer may base his tender on any bearing that complied with the specified requirements, provided that the efficacy of the bearings has been verified by tests and successful previous use. Evidence of these as well as information on the bearings durability and suitability for the specified use shall be submitted to the Engineer for his consideration. Details of the produce guarantee shall be submitted with the tender. (ii) Drawings and approval
Typical detail drawings showing clearly the construction of the bearings and information on the friction characteristics based on actual tests performed on the relevant materials shall be submitted with the tender.
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Prior to manufacture, the Contractor shall submit the following information to the Engineer for his consideration : Manufacturer's Specification containing detailed information on the design standards, materials, manufacture and technical data. Drawings showing the bearing construction and installation details. All bearings used in the permanent works shall be subject to the approval of the Engineer. (iii) Technical assistance
The following technical data for the proprietary bearings required on the Contract will be supplied on the Drawings, and shall also be supplied on the drawings prepared by the Contractor for submission to the Engineer. (1) Design loads and movement The maximum and minimum vertical loads and co- existing horizontal loads are well as the maximum horizontal load and co-existing vertical load. (2) Mechanical fit Mechanical fit on unidirectional and fixed bearings expressed as the maximum permissible slack (play) between the shear transfer members of the bearing that are required to resist the applied horizontal loads. (3) Identification Identification of each bearing by a number, the degree of freedom of movement (fixed, multidirectional or unidirectional) and the type of bearing (spherical, elastomer-pot, etc). (iv) Design
The bearings shall be designed to accept the specified load combinations in conjunction with the maximum eccentricity and rotation without over stressing any part in terms of "Working Load" requirements or exceeding the requirements for Serviceability Limit State. Unless specified otherwise in the Special Provisions or on the Drawings the following shall be complied with: The maximum average pressure on the projected area of the PTFE shall not exceed 45 MPa and 30 MPa under maximum load and under dead load respectively. The maximum peak pressure on the PTFE shall not exceed 60 MPa. The maximum average contact stress and maximum edge stress on the concrete or mortar bedding shall not exceed 20 MPa and 25 MPa respectively. The initial peak static coefficient of friction shall not exceed 0.06 and the final static coefficient of friction shall not exceed 0.04. The bearing shall be of overall dimension such that it will fit into the space allowed for the installation thereof. Major alterations to the contiguous member will not be considered. Construction
(v)
Unless specified otherwise in the Special Provisions or on the Drawings the following requirements shall be complied with:
The IRHD hardness of the elastomer disc in the pot type bearings shall 50 + 5 or 55 + 5. The elastomer shall be protected along the edge of the disc by either a metal sealing ring, or capping ring moulded integrally with the disc along the perimeter. The thickness of the elastomer disc shall not be less than 0.066 times its diameter. The PTFE shall be not less than 3 mm thick and be recessed into the supporting base to a depth of 0.5 times the thickness of the PTFE + 0.2 mm. The minimum dimension of individual PTFE areas shall not be less than 450 mm and their spacing shall be such as to ensure equal distribution of stress through contiguous members. The thickness of the stainless steel sliding plate shall be not less than 12.5 mm. The plate shall be either recessed into or bonded to the base and in addition riveted or bolted to the base. The edges of the plate shall be sealed to prevent the ingress of moisture between the plate and the base. The slack (play) between shear transfer members of undirectional and fixed bearings shall not exceed 2 mm unless specified otherwise. Only silicone grease of an approved type shall be used as lubricant between the sliding surfaces. The bearing shall be provided with tight fitting seals to prevent the ingress of dust or deleterious matter onto the moving parts. The seals shall be of an approved type and sufficiently durable to last in excess of 50 years. The assembled bearing shall be supplied with welded or bolted lugs or straps, temporarily securing the moving parts firmly in position to ensure that no undesirable relative movement occurs before or during construction. The bearing shall be recessed into adaptor plates or be of such construction as to facilitate removal of the bearing from the installed position without damage to any part of the bearing or the surrounding material after raising of the relevant structural member by 15 mm or the amount specified. Anchor and holding down bolts shall be of the material specified on the Drawings. Corrosion protection of the exposed steel surfaces, with the exception of the stainless steel sliding plate, shall consist of the following treatment: a/ Preparation of the surfaces by abrasive blasting or steel brushing to a finish equal to Sa3 finish of Swedish Standard SIS 05 59 00. b/ Metal spraying of the surfaces with zinc to comply with the requirements of BS 2569 for Zn 10. c/ Coating of the zinc sprayed surfaces within 4 hours with a sealer compatible with the zinc and subsequent coat of paint. d/ Application of a coat of high build chlorinated rubber paint of minimum 75 micron dry film thickness and of colour dissimilar to that of the final coat of paint. e/ Application of a final coat of high build chlorinated rubber paint a minimum 75 micron dry film thickness and a dark grey colour. Surfaces in contact with concrete shall receive at least the treatment described in Items a) and b) above.
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(vi)
Inspection and testing
The Engineer may require tests to be carried out to verify compliance of the bearing with the Specification and/or its performance under the design loads. Test certificates of all tests carried out shall be made available to the Engineer. The Contractor shall give the Engineer at least 7 days notice prior to final assembly of the bearings to enable the Engineering or his nominee to inspect the bearing at the factory. Under no circumstances shall bearings be taken apart and re-assembled on the site except when it is an unavoidable feature of the installation procedure, in which case the dismantling, installation and re-assembly shall be under the supervision of qualified personnel. Rehabilitation, modification and repair work to bearings shall be carried out only in the factory or in an approved Engineering works. (f) Dowels and Guides Dowels and guides shall be of such material, design and construction as is detailed on the Drawings. Where dowels and guides are used in conjunction with bearings they shall not complicate or prevent the removal of bearings. (g) Storage and Handling The bearings shall at all times be stored under cover and clear of the ground, away from sunlight, heat, oils and chemicals deleterious to the bearings. The bearings shall not be stacked in a manner or on a surface that will cause distortion of the bearings. The bearing shall be handled with care to ensure that they are not subjected to impact loads or any other condition that may be harmful. (h) Installation The concrete surface on elements required to receive bearings shall comply with the requirements of Division 8200 for concrete surface finish. Plastering of the surface will under no circumstances be permitted. Before the mortar bedding is constructed the concrete surface shall be chipped back to expose the aggregate and leave a sound irregular surface. Bonding of the mortar bedding to the concrete surface shall be in accordance with the manufacturer's recommendations and the Engineer's instructions. The bedding shall be of dimensions to permit the spreading of load at an angle of 45o through the bedding. However, the thickness of the bedding shall not be less than 15 mm and 25 mm for proprietary and elastomeric bearings respectively, nor shall the maximum thickness exceed 50 mm. Unless shown otherwise on the Drawings, the bearings shall be installed on a horizontal plane and shall be in full contact with the concrete and bedding surfaces. To accommodate soffit irregularities and camber in the case of precast members, the member shall be lowered onto a mortar skim on top of the bearing. The member shall thereafter be propped until the mortar skim has hardened into a wedge.
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The bearings shall be accurately installed to the specified level, alignment and orientation all within the construction tolerances in accordance with Division T8000 construction tolerances of these specifications and the details shown on the Drawings. Where the bearing has long sliding plates, these shall be rigidly supported to prevent distortion under the weight of the wet concrete and construction loads. Before the bearing is incorporated into the structure it shall be cleaned to remove all deleterious substances and adhering matter, and thereafter wrapped in polyethylene sheeting and adequately sealed to prevent the ingress of mortar and sluch onto the bearing during the course of construction. After installation, the polyethylene wrapping shall be removed, the bearing thoroughly cleaned and lugs removed as directed by the Engineer. On completion of installation of proprietary bearings the Contractor shall submit to the Engineer a certificate from the Manufacturer or Supplier of the bearing certifying acceptance of the installation. Notwithstanding the issuing of such a certificate, the Manufacturer or Supplier shall not accept any responsibility for the installation of the bearings and shall no relieve the Contractor of his responsibilities under the Contract. 8703 BRIDGE PARAPETS, RAILINGS AND SIDEWALKS (a) Materials (i) Concrete
All concrete work shall be carried out in accordance with the requirements of Division 8200, 8300 and 8400 of these Specifications. (ii) Structural steel
Structural steel work shall be carried out in accordance with the provisions of Division 8800 of these Specifications. (iii) Structural aluminium
Aluminium castings shall be from LM-6 alloy (BS designation) manufactured to BS 1490. Aluminium tubes shall be from HE-30 alloy (BS designation) manufactured to BS 1474. (b) Concrete Parapets Concrete parapets shall be either solid concrete parapets or open concrete parapets with concrete railings. Concrete railings shall be cast in-situ or pre-cast or a combination of the two as shown on the Drawings. Where possible pre-cast elements shall be placed with the unformed surface downwards or outwards. The pipes and fittings to be used for the construction of the ducting shall be rigid PVC pipes and fittings with flexible rubber joints which comply with AASHTO or ASTM requirements. Duct ends shall be provided with suitable conical wooden stoppers to prevent dirt, concrete, etc, from entering the ducts. Two strands of 2.5 mm diameter galvanized steel wire shall be threaded through each duct. The strands shall extend 2 m beyond each end and be wedged
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firmly into position with the wooden stoppers. Inspection eyes for the ducts shall be constructed in accordance with the details shown on the drawings. No separate payment will be made for service ducts in parapets and end blocks and the rates tendered for the parapets and end blocks shall include full compensation for the provision and installation of service ducts complete with stoppers, draw wires and inspections eyes. (c) Metal Railings Metal bridge railings shall be of steel or other material as shown on the Drawings. Unless otherwise indicated, all joints in fabricated metal work shall be welded using appropriate techniques to develop the full strength of the component parts. All fabricated metal works shall be neatly finished off without sharp edges and with sharp corners rounded off. Metal work shall be completed with all necessary connections, fastenings and anchor bolts. Steel work, which is to be cast or grouted into concrete, shall be unpainted and shall be cleaned of loose rust, scale, oil or other material, which may impair the bond between concrete and steel. All steelwork shall be painted in the shop and on Site in accordance with the provision of Division 9700 of these specifications and as shown on drawings. Surfaces which will be inaccessible after erection shall be painted before erection commences. If called for on the Drawings or in the Bill of Quantities steelwork shall be galvanized and painted; galvanizing shall be done after fabrication, in accordance with BS 729. Aluminium work which is to be cast or grouted into or be in contact with concrete shall be painted with two coats of approved bituminous aluminium paint or thoroughly coated with aluminium impregnated compound on the contact surfaces before installation. Where aluminium work is to be fixed to steelwork, the aluminium and steel shall be completely isolated from one another with plastic or other approved washers, gaskets and sleeves. Exposed aluminium work shall be left unpainted. (d) Bridge Number Plates Bridge number plates shall be fixed in the positions and according to the method of fixing shown on the Drawings. The concrete surface on which the plate is to be fixed shall be suitably prepared prior to the application of any adhesive by roughening and removing all surface laitance. (e) Concrete Sidewalks Prior to construction of the sidewalks, including kerbs and copings the bridge deck shall be accurately surveyed to establish final lines and levels. The previously cast bridge deck area shall be prepared as specified in Division 8400 of these specifications to receive sidewalk concrete. Forms shall be accurately set to final lines and levels and shall be firmly held in position during the placing of the concrete. Stops at the ends of sections shall be accurately placed to ensure that joints between adjacent sections are truly perpendicular to the surface of the concrete and at right angles to the edge of the road or to the skew angle of the deck at the expansion joint.
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After removal of the forms the exposed surfaces of the kerbs and copings shall be rubbed in accordance with the requirements of Division 8200 of these specifications. All edges shall be rounded to a radius of 20 mm unless otherwise shown on the Drawings. (f) Concrete Surface Finish Requirements All formed concrete surfaces shall have a Class F3 surface finish as specified in Division 8200 and all unformed concrete surfaces shall have a Class U3 surface finish in accordance with Division 8200. (g) Construction Tolerances The alignment levels and dimensions of the various items described in this Division shall conform to the requirements given in Division T8000 of these specifications. 8704 JOINTS IN STRUCTURES (a) General The Contractor shall not relocate or eliminate a construction joint, or make a construction joint not shown on the Drawings, without prior approval of the Engineer. This includes emergency construction joints made necessary by unforeseen interruptions to the concrete pour. Before fresh concrete is placed at a construction joint, the hardened concrete surface of the joint shall be roughened and cleaned so that all loose or soft material, free water, foreign matter and laitance is removed. Care shall be taken not to disturb any reinforcement or damage any adjoining concrete faces. Just prior to placement, the hardened concrete surface of the construction joint and the projecting reinforcement shall be washed clean, and the concrete surface saturated with water without leaving loose material or free water. Unless otherwise shown on the Drawings or specified, the surfaces of adjoining pours shall be butt joined. In visually important surfaces the joint shall be straight and true, and free from impermissible blemishes relevant to its surface finish class. (b) Movement joints Movement joints, where specified, shall be one of the following types shown in Table 8700-2: Table 8700-2 Types of movement joints Joint Contraction joint: Expansion joint: Control joint: Description An unreinforced joint with a bond-breaking coating separating the concrete joint surfaces. An unreinforced joint with the joint surfaces separated by a compressible filler. A weakened plane contraction joint created by forming a groove, extending at least one quarter of the depth of the section, either by means of a grooving tool, by sawing, or by inserting a premoulded strip. A joint without keying, dowelling, or reinforcement, which imposes no restraint on movement in any plane.
Isolation joint:
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(i)
Vertical Expansion Joints
Retaining walls shall be provided with vertical expansion joints as shown on the Drawings. The expansion joints shall consist of jointing material of approved quality, and of thickness shown on the drawings, and a depth sufficient to fill the joint. The jointing material shall be neatly cut to fit the surface of the concrete. (ii) Barrier Contraction Joints
Where barriers are extruded or cast in place, narrow transverse vertical grooves, 20mm deep, shall be formed neatly in the surface of the freshly placed concrete to produce contraction joints for the control of cracking. The contraction joints, shall be at intervals of not more than 3 meters. (iii) Barrier Expansion Joints
In barriers, unless shown otherwise on the Drawings, expansion joints, 15mm in width for the full depth of the barrier, shall be constructed at intervals not exceeding 15m and where the barrier abuts against gully pits (c) Materials (i) General
All materials used in the forming, construction and sealing of permanent joints as well as all proprietary or custom built expansion joint assemblies shall be subject to the approval of the Engineer. Jointing materials, shall be used in accordance with the manufacturers specifications for the location and type of joint. They shall be compatible when used together, and non-staining to concrete in visible locations. Foamed materials for use in compressible fillers shall be closed-cell or impregnated types which do not absorb water. Back-up materials for sealant, including backing rods and the like, shall not adhere to the sealant, or shall be faced with a non-adhering material. When required by the Engineer the Contractor shall submit test certificates from an approved, independent testing authority to show that the respective materials conform with the specified requirements, or a certificate from the patent holder or designer certifying that the manufactured item complies in all respects with relevant product specifications. (ii) Joint filler
Where joints are to be filled with jointing materials, including sealant, bond breakers, backing rods, preformed strips, and the like, the joint surfaces shall be dry and clean before application, and primed if and as recommended by the joint material manufacturer. The jointing materials shall be applied so that joints subject to ingress of water are made watertight where required. Visible jointing materials shall be finished neatly flush with the adjoining surfaces. Joint filler shall consist of sheets or strips of the following materials complying with the requirements of the relevant specifications listed:
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Bitumen impregnated fibreboard and bitumen impregnated corkboard-U.S. Federal Specification HH-F-341F or AASHTO Specification M 2213. The bituminous fibre sheet shall be about 12mm thick sheet specifically manufactured for concrete joints complying with AASHTO M153-60T and conforming to samples and specifications submitted by the Contractor and approved by the Engineer. Resin impregnated corkboard - U.S. Federal Specification HH-F-341F. Flexible foams of expanded polyethylene, polyurethane or polystyrene AASHTO Specification M153. Rigid foams of expanded polyethylene, polyurethane or polystyrene - BS 4840 or 3837. Other joint filler materials may be used if approved by the Engineer after submission of full specifications and information by the Contractor. (iii) Sealants
Thermoplastic hot-poured sealants shall comply with the requirements of U.S. Federal Specification SS-S- 1401B, BS 2499 or AASHTO Specification M173.The sealants shall be of the rubberised bituminous type containing a minimum of 20% natural or synthetic rubber. Thermoplastic cold-applied sealants shall comply with the requirements of U.S. Federal Specifications SS-S- 156.The sealant shall be of the rubberised bituminous type containing a minimum of 20% natural or synthetic rubber. Thermosetting chemically curing sealant shall comply with the requirements of U.S. Federal Specification SS-S- 195B, American National Standards Institute Specification ANSI A 116.1 (Formerly ASA A 116.1 and USASI A 116.1) or BS 4254. The final IRHS hardness of the sealant shall be 20 + 5. Other sealants may be used if approved by the Engineer after submission of full specifications and information by the Contractor. (iv) Preformed elastomeric compression seals
Preformed elastomeric compression seals shall comply with the requirements of ASTM D2628. (v) Water stops
Water stops shall be installed such that they are surrounded by fully compacted concrete, and located so that: Their correct positions in the finished work are ensured; The proper placing and compaction of the concrete is not inhibited; and reinforcement is not displaced from its correct position. Water stops shall be of natural rubber, or flexible PVC, and of the type specified or shown on the Drawings.
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(vi)
Accessory materials (1) Primers When a primer is to be used in conjunction with the sealant it shall be of the prescribed proprietary material. (2) Adhesives Adhesives used in conjunction with preformed seals shall be of a proved and approved type compatible with the material of the seal. (3) Bond breakers Polyethylene tape, coated papers, metal foils or similar material may be used where bond breakers are required. (4) Backup material Backup material shall consist of compressible materials of correct width and shape, to ensure that after installation it is in approximately 50% compression and the sealant can be formed to the specified depth. Backup materials shall be compatible with the sealant used. Material containing bitumen or volitions shall not be used with thermosetting chemically curing sealants.
(d) Filled and unfilled joints Wherever polystyrene or similar material susceptible to damage is used for forming joints, it shall be lined with a hard surface on the side to be concreted. The hard surface shall be sufficiently resilient to ensure that the joint and surfaces can be formed free from defects. (i) Filled Joints
Filled joints shall be accurately formed to the dimensions shown and with the filler material specified on the Drawings. The filler shall be secured in position not to displace during concreting, or thereafter if the filler is to remain permanently in the joint. Wherever polystryrene or similar material susceptible to damage is used to form joints, it shall be lined with a hard surface on the side to be concrete. The hard surface shall be sufficiently resilient to ensure that the joint and surfaces can be formed free from defects. (ii) Unfilled joints
Unfilled joints shall be accurately formed to the dimensions given on the drawings, and all external corners chamfered or rounded for at least 5 mm. The concrete face against which the fresh concrete is placed shall be treated in good time with an approved bond breaker. (e) Epoxy Mortar Nosings Epoxy mortar nosings shall not be used unless detailed on the Drawings and specified in the Special Provisions. Where epoxy mortar nosings are permitted, they shall be constructed in accordance with the requirements specified in the Special Provisions. (f) Concrete Nosings Concrete nosings forming the edges of expansion joints shall be constructed as follows:
After the concrete in the structural member has hardened sufficiently, the protruding ends of the reinforcing steel shall be bent flat onto the concrete surface of the formed recess. Before the asphalt surfacing is laid, the recess shall be filled with well-compacted crusher run, sand or weak mortar. Care shall be exercised to ensure that the concrete surfaces and reinforcing steel are not contaminated with bituminous agents. Thereafter, the asphalt surfacing shall be laid continuously over the joint. The asphalt surfacing corresponding to the width of the nosing shall be cut with a diamond saw blade and all material removed from the nosing recess. The concrete surfaces of the recess shall then be roughened to expose the aggregate and leave a sound, irregular surface. The reinforcing steel shall thereafter be bent, fixed and placed as detailed on the Drawings. The prepared concrete surfaces shall, immediately before the concrete nosing are cast, be treated with an approved epoxy resin adhesive. Opposite concrete nosing, separated by a 10 mm thick joint filler strip, shall be cast simultaneously in accordance with Division 8400 of this standard specification, and compacted by surface vibrator. The nosing shall be screeded flush with the premix surfacing and given a Class U2 surface finish. Curing shall be in accordance with Division 8400 of this standard specification, except that the curing period shall be 10 days. After the concrete in the nosing has cured for at least 3 days, the gap between the nosings shall be enlarged to the requisite dimensions by cutting both sides with parallel diamond saw blades. The depth of the saw cut shall be such that a ledge is formed along the lower edge of the cut on which the sealer unit can be supported. The exposed corners of the nosings shall be ground to have a 10 mm chamfer. After the joint has been sealed, the wearing surface of the nosings shall be treated with a bituminous primer to the satisfaction of the Engineer. Traffic shall not be permitted to pass over the joint before the concrete in the nosing has aged for at least 10 days. The concrete used in the construction of the nosings shall be Grade 40/20 and shall have a slump of not less than 50 mm and not exceeding 75 mm. (g) Plug type expansion joint systems Plug type expansion joint systems, eg Thormajoint, shall be constructed in accordance with the details on the drawings and the specifications and instructions of the licensees. (h) Sealing Of Joints (i) General
Sealed joints shall be made watertight over the full length of the joints unless permitted otherwise by the Engineer. Unless a water stop is equipped with an effective watertight interlocking system for the joining of sections, all joints in water stops shall be bonded or fused to have a tensile strength of at least 50% of that of the unjointed material. At intersections and abrupt changes of direction, water stops shall be jointed with prefabricated junction pieces. Restrictions on joint width and temperature at the time of installation of the sealant or seal will be shown on the Drawings. In the absence of these and unless specified otherwise, installation shall only be carried out within the temperature range of 5oC to 30oC.
(ii)
Preparation of joints
Sawing of joints shall be undertaken at such time as to avoid edge spalling or ravelling. After removal of the temporary filler material or breaking out of the excess concrete, the inside faces of the joint shall be wirebrushed or grit blasted to remove all laitance and contaminants; the joint shall thereafter be cleaned out and blown out with compressed air to remove all traces of dust. Solvents shall not be used to remove contaminants from concrete and porous surfaces. Care shall be exercised to ensure that primers or adhesives are applied only to surfaces that are absolutely dry. The primer or adhesive shall be applied strictly in accordance with the manufacturer's instructions. Unless specified otherwise the primer shall be applied within the temperature range of 10oC t 40oC and the sealant shall be applied after the curing period of the primer and within the period that the primer remains active. (iii) Sealants
Sealants shall be applied strictly in accordance with the manufacturer's instructions by a person skilled in the use of the particular type of sealant. Trapping of air and formation of voids in the sealant shall be avoided. The sealant shall be finished to a neat appearance flush with the edges of the concrete or to be specified depth. Thermoplastic hot-poured sealants shall not be poured into the joints when the temperature of the joint is below 10oC. The safe heating temperature shall not exceed the specified pouring temperature by more than 10oC. Two-part thermosetting chemically curing sealants shall not be applied after expiry of the specified pot-life period, which commences once the base and activator of the sealant have been combined. (iv) Preformed compression seals
The seal shall be inserted and secured with a lubricant adhesive covering both sides of the seal over the full area in contact with the inside faces of the joint. The lubricant adhesive shall be applied immediately ahead of inserting the seal. The seal shall be installed with the appropriate equipment in a compressed state such that under the most adverse condition the seal will remain in compression. The seal shall at all times be between 5 and 10 mm below the level of the pavement. The seal shall not be stretching which may occur shall not exceed 5%. Joints in seals shall be bonded or fused and shall be only at positions agreed by the Engineer. (v) Water stops
Water stops shall be securely and accurately located in position not to displace or deform during construction.
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(i) Proprietary Expansion Joints (i) General
The use of any type of expansion joint shall be subject to approval by the Engineer. Tenderers are advised to obtain approval for the type of expansion joint they intend using, prior to submitting their Tenders. (ii) Dimensions
Attention is drawn to the overall dimensions of the expansion joints and to the limiting concrete dimensions of that portion of the structure that is to accommodate the joints. No alterations to the concrete that will be visible in the final structure or major re-arrangement of the prestressing anchorages shall be permitted in order to accommodate joints of excessive size. All joints to be installed along a skew shall be accurately dimensioned to ensure compliance with Sub-clause 8703 (f) above. Unless specified otherwise, proprietary expansion joints shall include the complete expansion joint assembly, traversing the roadway, kerbs, sidewalks and median, and shall include the coping and parapet cover plates as well as the drainage system to drain the expansion joint. (iii) Design and manufacture
The expansion joint shall be designed to withstand the movements, displacements and rotations specified on the Drawings in conjunction with loads prescribed in the code of practice adopted for the design of the structure without overstressing any part in term of "Working Load" requirements or exceeding the requirement for Serviceability Limit State. Any strengthening required of the supporting member to resist forces imparted by the joint to the structure, shall be for the Contractor's account. The specified movements, displacements and rotations shall be accepted without impairment of efficacy or riding quality of the joint. The joint shall be vibration free, resistant to mechanical wear and other forms of abrasion, and resist corrosion; have good riding characteristics, be skid resistant and silent; be of watertight construction or have provision for the disposal of water, debris or grit collecting in the joint; and be of construction to facilitate easy inspection, maintenance and repair. Prior to manufacture of the joints, the Contractor shall submit to the Engineer for his acceptance detail drawings in accordance with the requirements of Clause 1202 of each expansion joint. The expansion joints delivered on the site shall be suitably marked to show clearly the sequence and position of installation. (j) Installation Of Expansion Joints No expansion joint or part thereof shall be installed prior to the establishment of final surfacing levels based on a complete level survey of the bridge deck(s). The survey shall be carried out before the construction of kerbs, channels or bituminous surfacing. The expansion joint shall form an even surface with the road surface on either side and the deviation across and along the expansion joint shall comply with the requirements of division T8000 of this specification for cross section and for surface regularity measured by ordinary straight edge.
On completion of installation of proprietary expansion joint(s) the Contractor shall submit to the Engineer a certificate from the Manufacturer or Supplier of the Joint(s), certifying acceptance of the installation. Notwithstanding the issuing of such a certificate, the Manufacturer or Supplier shall not accept any responsibility for the installation of the joint(s) and shall not relieve the Contractor of his responsibilities under the Contract. Payment for the inspection of the joints by the Manufacturer or Supplier and the issuing of the certificate will be made by the Contractor. 8705 NO-FINES CONCRETE (a) Materials Cement, aggregate and water shall comply with the requirements of Division 8400 of these specifications. Each size of aggregate shall be a single size aggregate graded in accordance with BS 882. (b) Grades on No-Fines Concrete No-fines concrete shall be classified by the prefix NF and the size of aggregate to be used Grade NF 19 means no-fines concrete with a 19 mm nominal size aggregate. The volume of aggregate per 50 kg of cement for each class of concrete shall be as follows: Table 8700-1 Grades of No-Fines concrete Grade NF 38 NF 19 NF 13 Aggregate per 50 kg cement 0.33 m3 0.30 m3 0.27 m3
(c) Batching and Mixing Cement shall be measured by mass or full bags of 50 kg each and aggregate shall be measured by volume in approved measuring boxes or barrows. The aggregate shall be moist or wetted before the cement is added. Where drum mixers are used, about 20% of the water shall be poured into the drum before the aggregate and cement are loaded. The mixing time in the drum shall be about 45 to 50 seconds. The quantity of water added shall be just sufficient to form a smooth grout which will adhere to and coat completely each and every particle of aggregate, and which is just wet enough to ensure that at points of contact of aggregate the grout will run together to form as small fillet to bond the aggregate together. The mix shall contain no more than 20 liters of water per 50 kg of cement. Mixing shall be carried out in an approved batch type mechanical mixer but small quantities may be hand mixed.
Page8000-136
(d) Placing No-fines concrete shall be placed in accordance with the procedure agreed by the Engineer. It shall be placed in its final position within 30 minutes of mixing. The concrete shall be worked sufficiently to ensure that it completely fills the space to the concreted and that adjacent aggregate particles are in contact with one another. Excessive tamping or ramming shall be avoided and under no circumstances shall the concrete be vibrated. (e) Protection All no-fines concrete shall be protected from the elements, and loss of moisture. Protection against loss of moisture shall be accomplished by one or more of the following: Retaining formwork in place. Covering exposed surfaces with sacking or other approved material kept continuously wet. Covering exposed surfaces with plastic sheeting. No-fines concrete placed during cold weather shall be adequately protected against frost for at least 3 days. 8706 DRAINAGE FOR STRUCTURES (a) Weep holes, drainage pipes and channelling Weep holes shall not be placed within 40 mm of any reinforcement and shall be carefully cleaned and kept clean. Drainage pipes shall be of the material prescribed on the drawings, and the interior surface shall, on completion, be smooth and clean. Cast in situ concrete channeling shall be provided next to the kerbing if shown on the drawings and according to the details provided. Concrete work shall be carried out in accordance with the provisions of Division 8400 and channeling shall be given a class U2 surface finish as specified in Division 8200 .The channeling shall be bonded to the bridge deck concrete in accordance with the provisions of Division 8400 of these specifications. (b) No-fines concrete blocks Blocks shall be of the class of prescribed no-fines concrete and to the required dimensions and shall be placed in advance of backfilling. No-fines concrete shall comply with the requirements of Clause 8705 of this Division. (c) Synthetic-fibre filter fabric Synthetic-fiber filter fabric shall be of the type and grade shown on the drawings or specified in the project specifications. Filter fabric shall be placed as shown on the drawings and shall be protected against sunlight and mechanical damage during storage and installation. Synthetic-fiber filter fabric shall comply with the requirements of Clause 3107 of this specification.
(d) Crushed stone in drainage strips behind walls The crushed stone used in drainage strips shall comply with the requirements of Clause 3210 of this specification for backfilling. The crushed stone may be wrapped in synthetic-fiber geo-textile and placed in accordance with the details shown on the drawings or as instructed by the Engineer. 8707 MEASUREMENT AND PAYMENT Item 87.01 Proprietary bearings: (a) (b) Prime cost sum allowed for purchasing and taking delivery of bearings .................... .............................................................................................................. prime cost sum Percentage on prime cost sum for charges and profit .......................... percentage (%)
Payment for purchasing and taking delivery of proprietary bearings, complete with anchor bolts and/or dowels, shall be in accordance with the provisions of the general conditions of contract. Item 87.02 Installing the proprietary bearings The unit of measurement shall be the number of complete bearings of each type and class installed. The tendered rate shall include full compensation for supplying all the materials not covered under Pay Item 87.01, constructing the bedding, transporting, handling and storing, and all labour, equipment and incidentals required for installing the bearings complete as detailed. The tendered rate shall be final and binding, irrespective of the type or make of bearing finally installed. Item 87.03 Bearings The unit of measurement shall be the number of complete bearings of each type and class installed. The tendered rate shall include full compensation for supplying all the materials, including anchor bolts and/or dowels, constructing the bedding, manufacturing the bearings, transporting, handling and storing, and all labour, equipment and incidentals required for installing the bearings complete as detailed. Item 87.04 Concrete hinges: (a) (b) (Description of hinge measured per meter) ...................................................meter (m) (Description of hinge measured by number) ............................................number (No)
The unit of measurement shall be either the meter of complete hinge of each type manufactured and installed or the number of complete hinges of each type manufactured and installed. The tendered rates shall include full compensation for supplying all materials, including formwork, manufacturing the hinges, transporting, handling and storing, sealing the hinges, and all labour, equipment and incidentals required for installing the hinges complete as detailed.
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Item 87.05 Bearing strips The unit of measurement shall be the square meter (m2) of bearing area lined with the specified material irrespective of the number of layers placed. The tendered rate shall include full compensation for supplying all the materials, transporting, handling and storing, and all labour and incidentals required for installing the bearing strips complete as detailed. Item 87.06 Dowels/guides The unit of measurement shall be the number of dowels/guides of each type installed. The tendered rate shall include full compensation for supplying all materials, including anchor bolts, manufacturing the dowels/guides, transporting, handling and storing, and all labour, equipment and incidentals required for installing the dowels/guides complete as detailed. Item 87.07 Concrete parapets The unit of measurement for concrete parapets shall be the meter (m) of concrete parapet complete in accordance with the drawings. Concrete parapets shall include all work above the top level of the sidewalks or, where not placed on a sidewalk, above the top of the bridge deck concrete, wing walls or retaining walls and shall also include any kerbing and coping forming an integral part of the concrete parapet. The tendered rate for concrete parapets shall include full compensation for all concrete, formwork, service ducts, drawing wires and accessories. The rates will exclude only the cost of reinforcing steel as this will be measured and paid for under another pay item. Item 87.08 Steel railings The unit of measurement for steel railings (type described) shall be the meter (m) of railing complete in accordance with the drawings. The tendered rate for steel railings shall include full compensation for all steelwork and corrosion protection, including fastenings, anchor bolts, mortar bedding, etc, as may be required, and for erecting the steel railings, complete as specified. Item 87.09 End blocks The unit of measurement of bridge end blocks shall be the number of end blocks constructed complete in accordance with the drawings. The tendered rate shall include full compensation for all materials, labour, plant, and other incidentals required for constructing the end blocks complete as specified, excluding only reinforcing steel. Item 87.10 Numbers for structures (a) (b) (c) Number plates........................................................................................... number (No) Painted numbers ....................................................................................... number (No) Numbers formed in concrete .................................................................... number (No)
The unit of measurement shall be either the number of bridge number plates provided and installed, or the number of complete numbers painted on the structures, or the number of complete numbers formed in concrete.
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The tendered rates shall include full compensation for providing and installing either the number plates, or preparing the surface and painting the numbers, or forming the numbers in concrete, and for all material, labour and equipment required in this connection.
Item 87.11 Proprietary expansion joints (a) (b) Prime cost sum allowed for purchasing and taking delivery of expansion joints......... .............................................................................................................. prime cost sum Percentage on prime cost sum for charges and profit ................................ percent (%)
Payment for purchasing and taking delivery of proprietary expansion joints shall be in accordance with the provisions of the general conditions of contract (see note 2 below). Item 87.12 Installation of proprietary expansion joints (a) (b) (Description of joint measured per meter) .................................................... meter (m) (Description of joint measured by number) ............................................ number (No)
The unit of measurement and payments shall be either the meter of complete joint of each type installed or the number of complete joints of each type installed. The tendered rates shall include full compensation for supplying all materials not covered under item Pay Item 87.11, transporting, handling and storing, and all labour, equipment, shaping the recesses, and incidentals required for installing the expansion joint complete in accordance with instructions (see notes 1 and 2 below). The tendered rate shall be final and binding, irrespective of the type or make of joint finally installed. Item 87.13 Expansion joints (a) (b) (Description of joint measured per meter) ................................................... meter (m) (Description of joint measured by number) ..............................................number (No)
The unit of measurement shall be the meter of complete expansion joint of each type installed or the number of completed joints of each type installed. The tendered rates shall include full compensation for supplying all the materials, manufacturing the expansion joint, transporting, handling and storing, and all labour, equipment, shaping the recesses, and incidentals required for installing the expansion joint complete in accordance with instructions (see notes 1 and 2 below). Item 87.14 Filled joints: (a) Filled joints (Description of joint and thickness of joint filler for joints measured per square meter)...................................................................................................square meter (m2) (b) Filled joints (Description of joint and thickness of joint filler for joints measured per meter) .......................................................................................................................meter (m) The unit of measurement shall be the square meter of filled joint calculated from the surface area of the joint Where the filled joint is 150 mm or less in depth, the unit of measurement shall be the meter of filled joints measured along the joint centerline. Concrete surfaces formed prior to the construction of the final surface for completing the filled joint shall be measured under the relevant Pay items mentioned in Division 8200 of these specifications, as may be applicable.
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The tendered rates shall include full compensation for supplying and installing the joint filler and all materials not - covered under Pay Item 87.16, and for all labour and incidentals required for completing the filled joint as - prescribed. Item 87.15 Unfilled joints (a) (b) Unfilled joints (Description of joint for joints measured per square meter) ................. .......................................................................................................... square meter (m2) Unfilled joints (Description of joint for joints measured per linear meter)... meter (m)
The unit of measurement shall be the square meter of - unfilled joint, calculated in accordance with the joint area. Where, however, the depth of the joint is 150 mm or less, the unit of measurement shall be the meter of unfilled joint measured along the joint centerline. Concrete areas formed before the final surface is constructed to complete the unfilled joint, shall be measured under Division 8200 payment items, as may be applicable. The tendered rates shall include full compensation for providing and applying the bond breaker and all materials - not paid for under Pay Item 87.16, also for the labour and incidentals required for completing the unfilled joint as - prescribed. Item 87.16 Sealing joints with: (a) (b) Sealant (description of joint, sealant and size) .............................................. meter (m) Water stop (description of joint, water stop and size) .................................. meter (m)
The unit of measurement shall be the meter of sealant, seal or water stop of each type installed. The tendered rates shall include full compensation for supplying all materials, forming or cutting the concrete to (the required shape and size, all labour, equipment and incidentals required for sealing the joint complete in accordance with the prescriptions, and for all waste materials (see note 2 below). Item 87.17 Cast in situ no- fines concrete The unit of measurement (class of concrete indicated) shall be the cubic meter (m3) of the in situ placed material. The provisions of Division 8400 shall apply. Item 87.18 Precast no-fines concrete units The unit of measurement (class of concrete and description of unit) shall be the number (No) of complete units of each size and type in position in the works. The tendered rate for each pre-cast concrete unit shall include full compensation for providing all the materials, labour, plant and formwork required for manufacturing the unit complete as shown on the drawings and for transporting and placing the unit in position. Item 87.19 Drainage pipes and weep holes (a) Drainage pipes: (Type and size indicated)............................................................................... meter (m) (Type and size indicated).......................................................................... number (No)
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(b)
Weep holes: (Type and size indicated) ...............................................................................meter (m) (Type and size indicated) ..........................................................................number (No)
The unit of measurement shall be either the meter of pipe/weep hole or the number of pipes/weep holes of each type and size of pipe/weep hole completed. The tendered rates shall include full compensation for supplying all the materials, manufacturing and installing the pipes and making weep holes. Item 87. 20 Drainage gulleys The unit of measurement shall be the number of drainage gulleys of each type installed. The tendered rate shall include full compensation for providing all the material and manufacturing and installing the drainage inlets. Item 87. 21 Synthetic-fiber filter fabric The unit of measurement shall be the square meter (m2) of filter fabric installed as specified, including the specified overlap. The tendered rate shall include full compensation for - supplying, cutting and installing the filter fabric, and for waste material. Item 87. 22 Concrete channeling The unit of measurement shall be the meter (m) of completed \ concrete channeling of each size constructed. The tendered rate shall include full compensation for providing all the material, all labour, equipment and expenses required for completing the work. Item 87. 23 Crushed stone in drainage strips The unit of measurement shall be the cubic meter (m3) of crushed stone placed in position as specified, in accordance with the details shown on the drawings or instructed by the Engineer. The tendered rate shall include full compensation for procuring, furnishing and placing the crushed stone, and for wrapping it in synthetic-fiber geotextile as specified. The geotextile will be measured for payment under Pay Item 87.21. Item 87. 24 Nose endings at balustrades The unit of measurement shall be the number of nose endings constructed complete in accordance with the details shown on the drawings. The tendered rate shall include full compensation for all labour, constructional plant and materials required, for filling the recesses with concrete or nosing material, 20 mm x 20 mm plastijoint seal between the end block and the transition block, steel cover plate complete with anchor bolts, and all incidentals required for constructing the nose, endings complete. Item 87.25 Concrete transition blocks The unit of measurement shall be the number of each size of concrete transition block constructed complete in accordance with the details shown on the drawings. The tendered rate shall include full compensation for all labour, constructional plant, materials and all incidentals required for constructing the transition blocks.
Notes: (1) The cost of forming the open joint(s) shall not be included in the rates tendered for items Pay Item 87.12 and Pay Item 87.13 as payment for this work shall be made under Division 8200. (2) Separate payment shall not be made for supplying and/or installing the seal in proprietary expansion joints or the seal between concrete or synthetic nosings. (3) Measurement of and payment for concrete sidewalks (including kerbing and coping) shall be made in accordance with Divisions 8200, 8400 and 8300.
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Series 8000: Structures Division 8800:Structural Steelwork
DIVISION 8800:STRUCTURAL STEELWORK

8801
SCOPE
This section covers the manufacture, transport and erection of structural steelwork for minor structures, e g overhead road-sign structures. It does not apply to major steel structures such as steel bridges, which will be covered in the project specifications where work of this nature is required. 8802 MATERIALS (a) Structural steel Structural steel shall comply with the following requirements: Mild steel : BS 4360, grade 453A High-yield stress steel : BS 4360, grade 508 The dimensions and properties of rolled steel sections shall comply with the prescriptions given in the structural steel tables issued by EN or BS. Steel tubes shall comply with the requirements of AASHTO or ASTM A3 type F EN10210-1 and EN10214-1. (b) Bolts, nuts and washers Ordinary bolts and nuts shall be bolts and nuts used for transferring forces by tensile stress, compressive stress and shear stress without any friction-grip action being considered. Ordinary bolts and nuts shall comply with ASTM A307or EN 24014 and EN24017. Washers for ordinary bolts and nuts shall comply with the requirements of ASTM A307 or EN24032 and EN24033. (c) Friction-grip fasteners: High-strength friction-grip bolts, nuts and washers shall comply with the requirements of AASTHO M164M or M253M. Other approved friction-grip fasteners equal to the above may be used. (d) Welding consumables Welding electrodes shall comply with the requirements of B55135. The quality, handling and storage of all consumables shall be so as to achieve the desirable properties of the weld metal. The welding consumables used shall be appropriate to produce weld metal which will yield all the weld-metal test specimens as specified in BS 709 having both minimum yield and minimum tensile strengths not less than those of the parent metal. (e) Test certificates The contractor shall submit test certificates, as required by the engineer, of the structural steel and anchor bolts that will be used.
8803 CODES OF PRACTICE The design, where undertaken by the contractor, of all work shall comply with the requirements of ERA Bridge Design Manual-2002. 8804 SHOP DETAILS Where shop details have not been furnished on the drawings, the contractor shall prepare his own shop details in accordance with the provisions of the Contract document. Shop details shall be approved and signed by the engineer prior to the fabrication of any items. 8805 FABRICATION AND ASSEMBLY (a) General All structural steel both before and after fabrication shall be within the tolerances specified in Division T800 of these specifications and shall be flat, straight (unless required to be formed to another shape) and free from twists. (b) Marking the steel At all stages of fabrication, all structural steel shall be clearly marked by grade by means of a suitable marking system. (c) Cutting Steel shall be cut by sawing, shearing with shears, cropping, or flame-cutting. Edges shall be free from any defects or distortions and all burrs, notches and similar defects shall be removed. (d) Holes for fasteners Holes for fasteners shall not be formed by flame cutting. Holes in light members not thicker than 12 mm or the diameter of the hole, whichever is the smaller, may be punched. Holes for fasteners of up to 25 mm in diameter shall not be more than 2 mm larger than the diameter of the fastener and holes for larger fasteners not more than 3 mm larger than the diameter of the fastener. Holes for friction-grip fasteners shall be in accordance with AASHTO or ASTM requirements. All burrs shall be removed from holes before assembly. (e) Joints in compression The abutting surfaces of joints dependent on contact for the transmission of load shall be accurately prepared so that the full area intended for bearing will be in contact as specified in Division T8000 of these specifications. (f) Hollow sections Unless protection against corrosion is provided by other means, the interior of any hollow section shall be sealed to prevent the ingress of moisture.
Where a sealed hollow member is holed for a fastener or pin, precautionary measures shall be taken to prevent the ingress of water to the interior of the member. Vent holes for galvanizing shall be sealed after galvanizing has been completed (g) Alignment of holes All matching holes for fasteners or pins shall be accurately aligned so that the fasteners can be inserted freely through the assembled members in a direction at right angles to the faces in contact. Drifting for aligning the holes shall not distort the metal or enlarge the holes. (h) Welding Welding shall be done in accordance with the requirements of BS 5135. The welding techniques shall be such as to avoid undue distortion and to minimize shrinking stresses. All slag shall be removed. Where required for certain welding The manufacturer shall hold a valid welding procedures certificate and the welding shall be done by a qualified welder. Or The welder shall hold a valid certificate of competency for the specified type of welding. All structural welds shall be full-strength joints. (i) Bolting The jointed parts shall be firmly drawn together. Where necessary, tapering washers shall be used for each bolt head and nut to transfer the compressive stress over its full surface. Where boltholes have greater than normal clearance, washers shall be placed under the bolt heads and nuts. The length of each bolt shall be such that, after tightening, at least one full thread projects through the nut on the outside and at least one full thread (in addition to the thread run-out) remains clear between the nut and the bolt head. (j) Welded Stud Shear Connectors Welded stud shear connections shall conform to AASHTO M 169 and AASHTO Standard Specifications for Highway Bridges Division II, article 11.3.3, Welded Stud Shear Connectors. (k) Friction-grip fastening The use of friction-grip bolts shall be in accordance with AASHTO or ASTM. Where use is made of equivalent types of friction-grip fasteners, they shall comply with the requirements of AASHTO or ASTM for equivalent fasteners and shall be installed in accordance with the appropriate requirements of AASHTO or ASTM.
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(l) Riveting Wherever possible, riveting shall be done with pneumatic equipment. Riveted units shall have all parts firmly drawn together and aligned before riveting. Every rivet shall, when driven, completely fill the hole and shall have a well-formed head - or, if countersunk, fill the countersink completely. All loose, eccentric-headed, badly formed, burnt or - otherwise defective rivets shall be cut out and replaced. (m) Trimming All fabricated steel work shall be neatly trimmed so as not to show any sharp edges. Acute angles shall be rounded off to a radius of at least 1 mm (n) Corrosion prevention (i) Painting
Before removal from the place of manufacture the steelwork shall be painted as specified in Division 9700 of these specifications. Where the finishing coats are to be applied on the site, the shop painting shall include the application of an undercoat as specified in Division 9700 of these specifications. Galvanized steel shall not be painted unless painting is specifically called for in the specifications. (ii) Sprayed metal coatings
Where the sprayed metal coating of steel surfaces is called for, it shall be done in accordance with the requirements of AASHTO or ASTM. The type of metal used shall be as specified, and, unless otherwise specified; the metal coating shall comply with the requirements of AASHTO or ASTM (iii) Galvanizing
Where the galvanizing of structural steelwork is required, the members shall be hot-dip galvanized. Structural steel members shall be given an 85-micrometer coating or such other thickness as may be specified, in accordance with AASHTO or ASTM. All nuts, bolts, screws and threaded articles shall be hot-dipped galvanized in accordance with the appropriate requirements of AASHTO or ASTM. Cut ends and small damaged areas shall be repaired by the application of a zinc-rich paint or by zinc spraying. 8806 ERECTION (a) General Where specified, details of the method of erection shall be submitted to the Engineer for approval.
All structural steel shall be stored, transported, handled and erected so as not to subject it to undue stress or damage. Erection over traffic is not permitted, and a temporary deviation for traffic shall be provided. Provision for traffic accommodation will be paid for in accordance with the appropriate items under Division 1500 of these specifications. (b) Safety during erection During the erection of a structure, the steelwork shall be bolted, braced or otherwise secured so as to make adequate provision for all erection loads. (c) Alignment Each part of a structure shall be aligned as soon as possible after erection. Members shall not be permanently connected until sufficiently large members of the structure have been aligned, plumbed, levelled, and temporarily secured to prevent their displacement during the erection or alignment of the remainder of the structure. (d) Corrections Drift pins, jacking equipment and the like shall not be used for bringing improperly fabricated members into place. A moderate degree of cutting and reaming may be done to correct minor misfits if, in the opinion of the Engineer, this will not be detrimental to the appearance or strength of the structure. The burning of holes will not be permitted without written approval. Repairs to painting and site painting shall be effected in accordance with the provisions of Division 9700 of these specifications. (e) Grouting The grout shall be poured under and around the base plates of columns after the steelwork has been finally checked for alignment and height and after the approval of the engineer has been obtained to proceed with the grouting. The column base plates shall be supported by the top and bottom nuts and by steel wedges. The area under the steel shall be thoroughly cleaned and shall be dust and oil-free, and the concrete shall be thoroughly rinsed with water to leave the surface clean and moist. The grout shall be an approved non-shrinking, pourable, cementitious grout. The grout shall be prepared and applied strictly in accordance with the manufacturer's recommendations and the engineer's directives. Leak-proof formwork shall be used for the pourable grout, and all corners shall be chamfered. The surface finish shall be class F2 and class U2 as applicable.
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8807 TESTING (a) Testing by the engineer The Engineer may nominate a testing authority to inspect the works and to conduct such tests as he may deem to be necessary to test compliance with the specifications. Where required, test samples of welds shall be prepared by the contractor, free of charge. Payment for these tests shall be made under Pay item 88.01. (b) Process control Welds shall be regularly inspected and tested by the contractor in terms of his obligations in regard to process control, as described in clause 1202 of these specifications. The inspection shall include visual inspection of welds to ensure that no undercutting, uneven lengths, porosity, or evidence of cracking occurs and that full fusion of the metals has been achieved. In doubtful areas, cores containing weld metal and adjacent parent material shall, if so required by the engineer, be cut out, polished and examined and the hole repaired. At least 30% of the welds shall be examined by ultrasonic or radiographic means. If more than 5% of the examined welds show unsatisfactory results, additional examinations covering all welds shall be performed. Certificates of the examination confirming that the steel plates and welds comply with the requirements of AASHTO or ASTM shall be submitted to the Engineer. The cost of testing shall be deemed to be included in the rate tendered for Pay item 88.01. 8808 MEASUREMENT AND PAYMENT Item 88.01 Structural steel: (Structure and steel quality described).................... .......................................................... ton (t) (Structure and steel quality described).................... .................................................... meter (m) (Structure and steel quality described).................... ............................................... number (No) The unit of measurement shall be either the ton or the meter of erected permanent steel structures or articles, or the number of erected permanent steel structures or articles. Where the unit of measurement is the ton, the mass of the steel waste caused by punching, drilling, sheared edges, milling or planning, or metal cut-outs shall not be deducted, and the mass of rivets, bolts, nuts, washers, welding fillets or temporary bracing shall not be added. In computing the mass of steel, the nominal mass per unit of length or area will be used and tolerances and other permissible deviations will be ignored. The tendered rates shall include full compensation for preparing shop details where not provided on the drawings, the supply of all the required materials, fabrication, process control, loading, transporting to the site, off-loading, and erecting. It shall also include full compensation for all welding, nuts, bolts, washers, rivets, cutting, waste, and any temporary bracing necessary for transporting and erecting The tendered rate shall also include full compensation for supplying and pouring the specified grout under and around the base plates of steel columns, for procuring and supplying all the necessary labour, constructional plant, tools and materials, as well as waste, formwork for the
grout, and finishing to obtain the required surface finish for the grout under and around base plates of steel columns. Item 88.02 Anchor bolts: ( Description of each assembly, and grade/type of steel, diameter and length indicated) .......... ................................................................................................................ kilogram (kg) (Description of each assembly, and grade/type of steel, diameter and length indicated) ........... ..................................................................................................................number (No) The unit of measurement shall be either the kilogram of installed anchor-bolt assemblies or the number of installed anchor-bolt assemblies. The tendered rates shall include full compensation for the materials, fabrication, handling, transporting and installing the anchor-bolt assemblies, including corrosion protection. Item 88.03 Corrosion protection (a) Sprayed-on metal: (Type of metal and thickness or type symbol of coatingindicated) .....................ton (t) (Type of metal and thickness or type symbol of coating indicated) ..............meter (m) (Type of metal and thickness or type symbol of coating indicated) .........number (No) (b) Hot-dip galvanizing: (Thickness or type symbol of zinc coat indicated) ..............................................ton (t) (Thickness or type symbol of zinc coat indicated) .......................................meter (m) (Thickness or type symbol of zinc coat indicated) ...................................number (No) The unit of measurement shall be either a ton or a meter of steel structures or articles protected against corrosion, or the number of steel structures or articles protected against corrosion. The quantities are calculated as specified in Pay item 88.01. The tendered rates shall be extra over the rates for Pay item 88.01 and shall include full compensation for applying the specified corrosion protection, including surface preparation, materials, labour, tools, equipment and all incidentals required. Note: Payment for painting shall be made under Division 9700 of these specifications.
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Series 8000: Structures Division 8900: Stone Masonry Structures
DIVISION 8900: STONE MASONRY STRUCTURES

8901
SCOPE
This work shall consist of stone masonry structures and the stone masonry portions of concrete, steel, timber, and composite structures, constructed in conformity with the lines, grades, dimensions, and design shown on the plans and in accordance with this and other specification items involved. 8902 STONE MASONRY WALLS Stone masonry walls may be plain packed stonewalls (un-mortared or Dry stone walling) with dry joints or otherwise mortared stonewalls with stones bedded in cement mortar as indicated on the drawings, as specified, or as may be ordered by the Engineer. The minimum mass of each stone used shall be 10 kg and its minimum dimension 75 mm. (i) Plain packed stonewalls
A foundation trench shall be excavated down to rock, or to material with an adequate bearing capacity at a minimum depth of 300 mm below ground level. Large selected stones shall be used for the foundation layer. Flat and stratified stones shall be laid with the largest dimension in the horizontal plane. Stones shall be packed individually to stagger the joints and to provide a minimum of voids, and shall be firmly bedded against adjoining stones. The spaces between the larger stones shall be filled with spalls securely rammed into place. The larger stones shall not bear on the spalls used for filling the voids. The top and ends of the wall shall be neatly finished with selected copingstones. The appearance of the completed wall shall present an even, tight surface. (ii) Cement-mortared stone walls
The walling shall be constructed as specified in (a) above, with the exception that the stones shall be wetted and set in a 6:1 sand: cement mortar. The exposed parts of the stones on the wall faces shall be cleaned of all mortar by washing or wire brushing. The mortar shall be flush pointed to the satisfaction of the Engineer, who may require a capping and end treatment of the same mortar. Weep holes shall be provided as prescribed and shall be cleaned of mortar or any other clogging material that may have entered during construction. The walling shall be protected from the elements and kept moist for a minimum period of four days after completion. 8903 CLASSES OF MASONRY The class of masonry used in each part of the structure shall be that called for on the plans. (i) Class A
Class A Masonry shall consist of stones shaped, dressed, and laid broken-coursed in cement mortar in accordance with Clause 8905 of these specifications.
Class A Masonry shall be more exacting than class B. Both classes of masonry are intended for use in any part of a structure, Class A Masonry shall be used primarily for major structures. (ii) Class B
Class B Masonry shall consist of stones shaped, dressed, and laid broken-coursed in cement mortar in accordance with Clause 8905 of these specifications. Class B Masonry shall be less exacting than class A. Both classes of masonry are intended for use in any part of a structure, Class B being used primarily for minor structures. (iii) Dimensioned Masonry
Dimensioned Masonry shall consist of broken-coursed ashlar masonry composed of stone having two or more dimensions shown on the plans. It is intended for use in any part of a masonry structure where appearance is an important factor, particularly in arch rings copings, corner trim, etc, 8904 MATERIAL REQUIREMENTS FOR STONE MASONRY STRUCTURES (a) Stone The stone shall be sound and durable, quarried, and shall be subject to the Engineer's approval. The stone shall preferably be native to the vicinity of the work and shall be of a kind that previous use has proven to be satisfactory for the specified purpose. The stones shall be properly protected at all times. In addition to the above requirements, stone for dimensioned masonry shall be free of reeds, rifts, seams, laminations, and minerals, which, by weathering, would cause discoloration or deterioration. (i) Sizes and shapes
Each stone shall be free from depressions and projections that might weaken it or prevent it from being properly bedded, and shall be of such shape as will meet both architecturally and structurally the requirements for the class of masonry specified. When dimensions for stones are shown on the plans, they shall be of the size shown. When no dimensions are shown on the plans the stones shall be furnished in the sizes and face areas necessary to produce the general characteristics and appearance as indicated on the plans. In general, stones shall have thickness of no less than 12 cm. widths of not less than l times their respective thickness, with minimum width of 30 cm. and lengths of not less than 1.5 times their respective widths. Where headers are required their lengths shall be not less than the width of bed of the widest adjacent stretcher plus 30 cm. At least 50 percent of the total volume of the masonry shall be of stone having a volume of least 0.03 cubic meters. (ii) Dressing
The stone shall be dressed to remove any thin or weak portions.

Face stones shall be dressed to provide bed and joint lines with a maximum variation from true line as follows: (1) Class B Masonry 2 cm. (2) Class A Masonry 5 mm. (3) Dimensioned Masonry True. (iii) Bed surface
Bed surfaces of face stones shall be normal to the faces of the stones for about 8 cm. and from this point may depart from normal not to exceed 2.5 cm. in 30 cm. for dimensioned masonry and 5 cm. in 30 cm. for all other classes. (iv) Joint surfaces
In all classes of masonry except dimensioned masonry, the joint surfaces of face stones shall form an angle with the bed surfaces of not less than 45 degrees. In dimensioned masonry, the joint surfaces shall be normal to the bed surfaces. They shall also be normal to the exposed faces of the stone for at least 5 cm from which point they may depart from normal not to exceed 2.5 cm in 30 cm. The corners at the meeting of the bed and joint lines shall not be rounded in excess of the following radii: (1) Class B Masonry ................. 2.5 cm. (2) Class A Masonry ....... No rounding (3) Dimensioned Masonry No rounding (v) Arch ring stone joint surfaces
Arch ring stone joint surfaces shall be radial and at right angles to the front faces of the stones. They shall be dressed for a distance of at least 8 cm. from the front faces and so fits, from which points they may depart from a plane normal to the face not to exceed 2 cm. to 30 cm The back surface in contact with the concrete of the arch barrel shall be parallel to the front face and shall be dressed for a distance of 15 cm. from the intrados. The top shall be cut perpendicular to the front face and shall be dressed for a distance of at least 8 cm. from the front. When concrete is to be placed after the masonry has been constructed, adjacent ring stones shall vary at least 15 cm. in depth. (vi) Stratification
Stratification in arch ring stones shall be parallel to the radial joints and in other stones shall be parallel to the beds. (vii) Finish for exposed faces
Face stones shall be pitched to line along all beds and joints. The kind of finish for exposed faces shall be as shown on the plans or the Special Provisions. The following symbols will be used and they shall be understood to represent the type of surface or dressing specified below:
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(1)
Fine Pointed ( F.P.) In which the point depressions shall be approximately 1 cm. apart with surface variation not to exceed 0.3 cm. from the pitch line.
(2)
Medium Pointed (M.P.) In which the point depressions shall be approximately 1 cm. apart with surface variations not to exceed 0.80 cm. from the pitch line.
(3)
Coarse Pointed ( C. P) In which the point depression shall be approximately 2.5 to 3 cm. apart with surface variations not to exceed 1 cm. from the pitch line.
(4)
Split or seam face (S.) In which the surface shall present a smooth appearance, be free from tool marks, with no depressions below the pitch line and no projection exceeding 2 cm. beyond the pitch line.
(5)
Rock faced ( R.F.) In which the face shall be an irregular projecting surface without indications of tool marks: with no concave surfaces below the pitch line, and with projections beyond the pitch line, when measured in centimeters, not exceeding the figure preceding the symbol as used on the plans or in the special provisions e.g., "1 R.F." means projections beyond the pitch line not exceeding 3.7 cm. Where a "variable rock face is specified, stones of the same height of projection shall be well distributed. Unless otherwise specified on the plans, all class B masonry shall be coarse pointed. Removal of drill and quarry marks from the faces of stones in cement rubble masonry will not be required.
(b) Quarry Operations Quarry operations and delivery of stone to the point of use shall be organized so as to insure keeping deliveries well ahead of masonry operations. A sufficiently large stock of stone of the kinds being used in the work shall be kept on the site at oil times, to permit adequate selection of stone by the masons. (c) Mortar Mortar shall consist of six parts by volume of fine aggregate or sand to one part by volume of cement complying with the requirements of Division 8400 of theses specifications. 8905 CONSTRUCTION REQUIREMENTS (a) Excavation and backfill Excavation and backfill shall conform to the requirements of Division 8100 of theses specifications, modified as follows: For filled spandrel arches the filling shall be carefully placed in such manner as to load the ring uniformly and symmetrically.
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The filling materials shall be mainly stone cut debris with preferably flat stone acceptable to the engineer and shall be placed in horizontal layers, carefully tamped, and brought up simultaneously from both haunches. Wedge-shaped sections of filling material against spandrels, wings, or abutments will not be permitted. Round gravel stone shall be avoided. (b) Falsework Arch centering shall be constructed in accordance with construction drawings submitted by the contractor as required by the Conditions of contact. Suitable wedges shall be provided for raising or lowering the forms to exact elevation and for taking up any settlement occurring during loading. Centering shall be lowered gradually and symmetrically so as to avoid overstresses in the arch. When directed, centering shall rest upon approved jocks in order to take up and correct any slight settlement, which may occur after the placing of masonry has begun. In general, centering shall be struck and the arch made self-supporting before the railing or coping is placed. For filled spandrel arches such portions of the spandrel walls shall be left for construction subsequent to the striking of centers as may be necessary to avoid jamming of the expansion joints. When, in the opinion of the engineer, additional falsework and bracing are necessary to hold the stones in proper position, the contractor shall construct such falsework and bracing in a manner satisfactory to the engineer, but failure of the engineer to order their construction shall not release the contractor from his obligation to build a satisfactory structure. (c) Selection and Placing When the masonry is to be placed on a prepared foundation bed, the bed shall be firm and normal to, or in steps normal to, the face of the wall, and shall have been approved by the engineer before any stone is placed. When it is to be placed on foundation masonry, the bearing surface of this masonry shall be cleaned thoroughly and wetted immediately before the mortar bed is spread. All Masonry shall be constructed by experienced workmen. Face stones shall be set in random bond so as to produce the effect shown on the plans and to correspond with the sample section approved by the engineer. Care shall be taken to prevent the bunching of small stones or stones of the same size. When weathered or colored stones or stones of varying texture, are being used care shall be exercised to distribute the various kinds of stones uniformly throughout the exposed faces of the work. Large stones shall be used for the bottom courses and large, selected, stones shall be used in the corners. In general, the stones shall decrease in size from the bottom to the top of work. All stones shall be cleaned thoroughly and wetted immediately before being set, and the bed which is to receive them shall be clean and moistened before the mortar is spread. They shall be laid with their longest faces horizontal. In full beds of mortar, and the joints shall be flushed with mortar.
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(1)
Class A Masonry All stones, excluding exposed faces of individual stones (Facing Stones), shall be laid with their longest axis normal to the face of the wall in which the stones are set. The exposed facing stones, excluding bond stones, shall be parallel to the face of the wall. Bond stones shall be provided at the rate of not less than one to every square meter of exposed face. Bond stones shall measure not less than 150mm by 150mm on the exposed face and not less than 450mm in length or the full thickness of the wall if the latter is less than 450mm.
(2)
Class B Masonry All stones, including exposed faces of individual stones and bond stones, shall be laid with their longest axis normal to the face of the wall in which the stones are set. Bond stones shall be provided at the rate of not less than one to every square meter of exposed face. Bond stones shall measure not less than 150mm by 150mm on the exposed face and not less than 450mm in length or the full thickness of the wall if the latter is less than 450mm. The stones shall be so handled as not to jar or displace the stones already set. Suitable equipment shall be provided for setting stones larger than those that can be handled by two men. The rolling or turning of stones on the walls will not be permitted. If a stone is loosened after the mortar has taken Initial set, it shall be removed, the mortar cleaned off, and the stone re-laid with fresh mortar. Arch ring stone shall be carefully set to exact position and hold in place with hardwood wedges until the joints are packed with mortar.
(d) Beds and Joints The thickness of Beds and joints for face stones shall be as follows: Class of Masonry Beds in mm Joints in mm Class A 20 to 100 20 to 70 Class B 20 to 120 20 to 100 Dimensioned (see note) 20 t0 50 Note: The thickness of beds in dimensioned masonry may vary from 2 cm. to 2.5 cm. from the bottom to the top of the work, but in each course the beds shall be of uniform thickness throughout. Unless shown otherwise on the plans, beds shall not extend in on unbroken line through more than 5 stones, and joints through more than 2 stones. Joints in dimensioned masonry shall be vertical. In all other masonry, joints may be at angles with the vertical from 0 to 45 degrees. Each face stone shall bond with all contiguous face stones at least 15 cm. longitudinally and 5 cm. vertically.
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At no place shall corners of four stones be adjacent to each other. Cross beds for vertical walls shall be level and for battered walls may vary from level to normal to the batter fine of the face of the wall. All arch ring joints shall be completely filled with mortar. (e) Headers When headers are required they shall be distributed uniformly throughout the walls of structures so as to form at least one-fifth of the faces. (f) Backing The backing shall be built mainly of large stones and in a workmanlike manner. The individual stones composing the backing and hearting, shall be well bonded with the stones in the face wall and with each other. All openings and interstices in the backing shall be filled completely with mortar or with spalls surrounded completely by mortar. (g) Coping Copings, if called for, shall be as shown on the plans. Where copings are not called for, the top of the wall shall be finished with stones wide enough to cover the top of the wall, from 0.5 to 1.5 m. in length, and of random heights, with a minimum height of 15 cm., Stones shall be laid in such a manner that the top course is an integral part of the wall. The tops of the top courses of stone shall be pitched to line in both vertical and horizontal planes. (h) Parapet walls Selected stones, squared and pitched to line and with heads dressed, shall be used in ends of parapet walls and in all exposed angles and corners. Headers shall be well interlocked and as many as possible shall extend entirely through the wall. Both the headers and stretchers in the two faces of the wall shall be well interlocked in the heart and shall comprise practically the whole volume of the wall. All interstices in the wall shall be completely filled with cement grout or with spalls completely surrounded with mortar or grout. (i) Facing for Concrete Unless otherwise specified, the stone masonry shall be constructed before placing concrete. When provided for in the special provisions or upon the approval of the engineer, the concrete may be placed before constructing the stone masonry. (i) Stone masonry constructed prior to placing concrete
Hooked steel anchors consisting of 12 bars each bent into an elongated letters S shall be spaced 60 cm. part both horizontally and vertically unless closer spacing is shown on the plans or ordered in writing by the engineer.
To improve the bond between the stone masonry and the concrete backing, the back of the former shall be made as uneven as the stones will permit. Each anchor shall be rigidly embedded in a horizontal joint of the masonry with one end 5 cm. from the faces of the stones. The other end shall project approximately 25 cm into the concrete backing. When the stone facing has been laid and the mortar has attained sufficient strength, all surfaces against which concrete is to be placed shall be cleaned carefully and all dirt, loose material, and accumulations of mortar dropping, removed. Picks, scrapers, and wire brooms shall be used for this purpose if necessary. If compressed air is available on the work, it shall be used to blow out the dust and dirt. Water shall be dashed forcibly against the stones and into the joints. Use of a stream from a hose is preferable for this purpose. In depositing concrete, the top surface immediately adjacent to the stones shall be held slightly low and a neat cement grout of the consistency of cream shall be carried on top of the concrete and against the masonry at all times, so that the entire exposed areas of all the stones are coated with grout. All interstices of the masonry shall be filled and the concrete thoroughly spaded and worked until it is brought into intimate contact with every part of the back of the masonry. (ii) Concrete Placed before constructing masonry
Except where otherwise shown on the plans, a thickness of 20 cm. shall be allowed for facing. Galvanized metal slots with anchors for the stone work, or other approved type of metal anchor, shall be set vertically in the concrete face at a horizontal spacing of not to exceed 60 cm. The slots shall have a temporary filling of felt or other material to prevent them from being filled with concrete. During the setting of the stone facing, the metal anchors shall be fitted tightly in the slots at an average vertical spacing of 60 cm. The Engineer will mark on the concrete backing the approximate location of the anchors, and the anchor shall be placed in the stone joint nearest to the mark. At least 25 percent of the metal anchors shall have a short right-angle bend to engage a recess to be cut into the stone. The anchors shall extend to within 8 centimeters of the exposed face of the stonework. Where the shape of the concrete face is unsuitable for the use of metal slots, ties consisting of AASHTO Standard Gauge No. 9 galvanized iron wire shall be placed as directed by the engineer, but there shall be no less than one wire tie for each 0. 15 square meter of exposed stone surface. In laying the stone, the concrete face shall be kept wet continuously for 2 hours preceeding the placing of the stone, and all spaces between the stone and concrete shall be thoroughly filled with mortar. Immediately after laying, all exposed stone surfaces shall be cleaned and kept clean of loose mortar and cement stains. (j) Pointing The Pointing or finishing of till joints shall be as shown on the plans or as specified in the Special Provisions.
Page8000-158
When raked joints are called for, all mortar in exposed face joints and beds shall be raked out squarely to the depth noted on the plans. Stone faces in the joints shall be cleaned free of mortar. When weather joints are called for, the beds shall be weather struck. The joints shall be slightly raked to conform to the bed weather joint and in no case shall the mortar be flush with the faces of the stones. The mortar in joints on top surfaces shall be crowned slightly at the center of the masonry to provide drainage. (k) Weep Holes All walls and abutments shall be provided with weep holes. Unless otherwise shown on the plans or directed by the Engineer, the weep holes shall be placed at the lowest points where free outlets can be obtained and shall be spaced not more than 3 meters center to center. (l) Cleaning Exposed Faces Immediately after being laid, and while the mortar is fresh, all face stone shall be thoroughly cleaned of mortar stains and shall be kept clean until the work is completed. Before final acceptance and if ordered by the Engineer, the surface of the masonry shall be cleaned using wire brushes and asetic acid if necessary. (m) Weather Limitations No placing of stone shall be done in freezing weather except by written permission from the Engineer and then only by the use of such precautionary methods as he may prescribe for doing the work and protecting it at all times, such permission and the use of the methods prescribed shall not, however, release the Contractor from his obligation to build a satisfactory structure. All work damaged by cold weather shall be removed and replaced. In hot or dry weather the masonry shall be satisfactorily protected from the sun and shall be cleaned using wire brushes and asetic acid if necessary. 8906 MEASUREMENT AND PAYMENT Item 89.01 Stone masonry walls: (a) (b) Plain packed stone masonry walls (Class of masonry described) ...... cubic meter (m3) Cement-mortared stone masonry walls (Class of masonry described) ......................... ............................................................................................................ cubic meter (m3)
The quantity to be paid for shall be the number of cubic meters of stone masonry of the various classes, complete in place and accepted. When shown as a separate pay item in the bid schedule, separate measurement shall be made for that portion of any class of masonry contained in a specifically designated part of the structure. In computing the volume for payment, the dimensions used shall be those determined by the payment lines or payment volumes shown on the plans or ordered in writing by the Engineer.
The computed volumes shall not include any concrete or stone masonry paid for under any other item. One-half the volume of the mortar joint between different classes of stone masonry will be included in the measurement for each adjoining class of masonry. The projections of face stones extending beyond the pitch lines will not be included. The volumes of stones labeled on the plans as "cap stones" shall be their actual volumes. No deductions will be made for weep holes, drain pipe, or other openings of less than 0.2 square meter or for chamfers or other ornamental cuts that amounts to 5 percent or less of the volume of the stone in which they occur. The tendered rate for each type of stonewall shall include [full compensation for furnishing all materials, trimming the areas, placing the stones and cement-mortared masonry where necessary, and all other work necessary for completing the walls in accordance with the specifications. The quantities of concrete, reinforcing steel, Excavation of foundation trenches and other contract pay item, which constitute the completed and accepted structure shall be measured for payment in the matter prescribed for. The quantity, determined as provided above, shall be paid for at the contract price per unit of measurement, respectively, for each of the particular pay items listed, that is shown in the bid schedule, which price and payment shall be full compensation for furnishing and placing all materials including mortar, and for all labor, tools equipment, and incidental necessary to complete the work prescribed in this and other divisions.
Page8000-160
Series 8000: Structures Division T8000: Construction Tolerances For Structures
DIVISION T8000: CONSTRUCTION TOLERANCES FOR STRUCTURES

T8001 SCOPE This Division covers the requirements with regard to the construction tolerances applicable to the various structures and structural elements. T8002 DEFINITIONS Except were otherwise specified the following aspects of construction to which tolerances apply shall have the meanings attributed to them below: (i) Position
The position of a structure or structural element shall be the horizontal position of its center line(s) and/or center point(s) in relation to the overall setting out of the Works as shown on the Drawings. (ii) Alignment
The alignment of a structure or structural element shall be the alignment of its center line(s) in relation to the overall setting out of the Works as shown on the Drawings. Deviation from true alignment shall be measured in degrees of an arc. (iii) Leading And Cross Sectional Dimensions
The leading and cross sectional dimensions of a structure or structural element shall be the dimensions relating to width, length, height, thickness, etc. which collectively determine its shape as shown on the Drawings. Dimensional tolerances not relating to leading or cross sectional elements shall be shown on the Drawings. (iv) Levels
The level of any structure or structural element shall be the level of the upper or lower surface as may be relevant with reference to an established datum level on site. (v) Surface Regularity
Surface regularity is the shape of a surface with reference to a 3m straight edge (or template in the case of curved surfaces) placed on the surface. The tolerance on surface regularity is expressed as a distance by which the surface tested may deviate from a straight edge (or template in the case of curved surfaces) held against the surface. T8003 TOLERANCES The tolerances given below shall be the maximum permissible deviations from the specified dimensions, levels, alignment, positions, etc. as shown on the Drawings of the structures or structural elements.
Page 8000-161
(a) Foundations (i) Piles: Item 1. Position 2. External dimensions 2.1 Prefabricated piles 2.2 Cast in situ piles 3. Pile head level: 3.1 Average level trimmed/cut pile head 3.2 Verticality or rake 4. Straightness: Tolerance 0.167 times the diameter of the pipe, or 100mm, whichever is greater + 25mm/ - 5 mm + not specified/ - 0 mm of + 25 mm/ - 25 mm 1.5% For the precast piles the permissible maximum deviation from straight is 5 mm for piles up to 3 m long and 1 mm more for each additional meter of pile length.
(ii) Item
Caissons: Tolerance 150 mm 1.5% + 25 mm/ - 5 mm + 25 mm/- 25 mm + 25 mm/ - 25 mm + 50 mm/ - 50 mm + 25 mm/ - 25 mm
1. Position of top of caisson 2. Verticality 3.Dimensions: 3.1 Wall thickness 3.2 Outer dimension of circular, rectangular or square cross-section 4. Level: Upper level of trimmed/cut caisson head levels 4.1 Maximum deviation of average level 4.2 Maximum deviation any individual level 5. Foundation fill : 5.1 Average level top of fill
Page8000-162
(b) Footings, pile capping slabs, caisson cover slabs, etc. Item 1. Position 2.Alignment: 2.1 Alignment of individual elements 2.2 Alignment of elements as they collectively determine alignment of structure as a whole 3. Dimensions: 3.1 Leading dimensions in plan 3.2 Thickness 4. Level: Average level of slabs, footings, etc 15 mm 5 1 minute +25mm/ - 25 mm +25mm/ - 15 mm + 25 mm/ - 25 mm Tolerance
(c) Columns, walls, pier, abutments, etc Item 1. Position 10 mm Tolerance
2.Alignment: 2.1 Alignment of walls, piers, abutments and of column groups 2 minute 3. Dimensions:
3.1 Leading dimensions walls, piers and abutments
3.2 Thickness of walls, piers and abutments and cross sectional dimensions of columns: 4. Levels: Average levels of finished or trimmed/cut columns, piers, walls, abutments etc 5.Verticality: 5.1Using ordinary formwork 5.2 Using sliding formwork 6. Surface regularity: 6.1Using ordinary formwork 6.2 Using sliding formwork
+25mm/ - 25 mm + 25mm/ - 3% of the specified dimensions within the range 5 mm to 25 mm + 10 mm/ - 10 mm
1 in 400: Maximum 25mm 1 in 200: Maximum 50mm. 3 mm 6 mm
Page 8000-163
(d) Bridge And Culvert Superstructure Item 1. Position 2.Alignment: 2.1 Alignment Superstructure as a whole Tolerance 10 mm 1 minute
3. Dimensions: 3.1 Leading dimension in plan +25mm/ - 25 mm 3.2Thickness of slabs, width and depth of beams + 15mm/ - 3% of the specified dimensions within the range 5 mm to 15 mm 4. Surface regularity: 3 mm (all elements other than upper surface of deck)
(e) Precast Beams The following tolerances shall apply to pre-cast beams in addition to the requirements stated in Sub-clause T8003(d) above for superstructure. The width of the gap between contiguous beams shall not exceed twice the specified nominal gap shown on the Drawings or the nominal gap plus 40 mm, whichever is the lesser and the overall width between the outer most beams on the bridge deck shall be within 40 mm of the specified width. Item 1. Straightness or bow: The deviation from the intended line measured on the overall length of the beam or part thereof shall not exceed the following: 1.1 In the horizontal plane Tolerance
0.5 mm per metre length of the beam within the tolerance range of 6 mm to 15 mm. 2 mm per metre length of the beam within the tolerance range of 6 mm to 20 mm. 1 mm per metre length of the beam within the tolerance range of 3 mm to 20 mm.
1.2 In the vertical plane 1.2.a I-beams 1.2.b Other beams 2. Camber: 2.1 The soffits of adjacent beams when placed side by side on the bridge deck:
Shall not at any place differ by more than 2 mm per metre length of the beam within the tolerance range of 6 mm to 20 mm. 2.2 The lengths of precast beams before stressing Shall be: + 0.1% of the total length within the tolerance range of: + 5 mm to: + 20 mm. 3. Surface regularity: 3 mm
Page8000-164
(f) Precast Beams And Panels (i) Members Other Than Flat Panels: Item 1. Cross-section 1.1 overall dimensions - less than 600 mm; 1.2 not less than 600 mm, but less than 150 mm; 1.3 not less than 1500 mm Tolerance 003 mm 006 mm + 10 mm, -6 mm
2. Cross-section, dimension of sections such as webs, ribs and flanges: 2.1 less than 1500 mm; 006 mm 2.2 not less than 1500 mm + 10 mm, -6 mm 3.Length, critical dimensions of abutting members. 4. Length, non-critical 4.1less than 6 m; 4.2 not less than 6 m. 5. Twist. + 0, -6 mm
0002 length/1000 0006 mm 10 mm/m width per 3 m of length
Page 8000-165
(ii)
All Units: Item 1. Straightness of edges and flatness of surfaces. Length/1000 2. Warp 2.1 up to 5 m diagonal; 2.2 over 5 m diagonal. 3. Squareness of corners 3.1 up to 2 m on shorter side; 3.2 over 2 m, up to 4 m, 3.3 over 4 m. 4. Holes or openings and the like, diameter or side dimensions. 5. Location of holes or openings 6. Grooves, width and depth. 7. Position of individual connecting bolts, bolt holes, projecting metal or other devices in any associated grout (e.g. the joint of two precast units). 8. Longitudinal locations of any such groups (mentioned in item (7)) Tolerance
6 mm 10 mm 3 mm 5 mm 6 mm 3 mm 7 mm 2 mm With 3 mm of their true positions in the group in which they are cast.
Within 6 mm of its true position in the unit in which it is cast, if the tolerance does not adversely affect the proper assembly of the whole structure.
(g) Precast Prestressed Concrete Structural Elements The length, cross sectional dimensions and straightness of all precast prestressed concrete structural elements shall comply with the requirements of measurements for determining compliance with these requirements shall be taken at 28 2 days after the stress has been applied.
Page8000-166
Item 1. Length 1.1 Up to 3 m 1.2 3 to 4.5 m 1.3 4.5 to 6 m 1.4 Additional for every subsequent 1 m 2. Cross section (each direction)2.1 up to 500mm 2.2 500 to 750mm 2.3 Additional for every subsequent 250mm 3. Straightness or bow (deviation from intended line). 3.1 Up to 3 m 3.2 3 to 6 m 3.3 6 to 12 m 3.4 Additional for every subsequent 1 m (h) Reinforcing Steel 6 mm 9 mm 12 mm 1 mm 6 mm 9 mm 3 mm 6 mm 9 mm 12 mm 1 mm
Tolerance
Except for the requirements given hereunder no tolerances are given for the placing and fixing of reinforcing steel. Steel shall, however, be neatly and accurately fixed in a manner that is consistent with proper workmanship and the structural integrity of the member. Specifically the following requirements shall apply: (i) Tension Steel
The actual position of tension steel shall not deviate from the true position by an amount that would reduce the effective lever arm by more than 2% of the overall depth of the member or 10 m, whichever is the greater. (ii) Concrete Cover
The concrete cover on reinforcing steel shall nowhere be less than the specified cover. (iii) Spacing between Bars
The spacing between closely spaced parallel bars, especially in beams and columns, shall, unless otherwise detailed, not be less than the maximum size of aggregate used in the concrete. (iv) Bending of Reinforcement
The requirement of BS 4466 regarding dimensional tolerances for the cutting and bending of reinforcing steel shall apply with the proviso that the other requirements stated in this clause must be met even if the tolerances in BS 4466 are not exceeded.
Page 8000-167
(i) Prestressing Prestressing tendons shall be placed and maintained in position within the following accuracy's: Item 1. In the direction of the width of the member 1.1 For members of up to 200 mm in depth + 20 mm 1.2 For members exceeding 200 mm in depth + 10 2. In the direction of the depth of the member 2.1 For members of up to 200 mm in depth + 0.025 x depth 2.2 For members exceeding 200 mm in depth + 0.010 x depth within the tolerance range of + 5 mm to+ 25 mm Tolerance
(j) Bridge Bearings Item 1. Position and level: Tolerance Within 5mm of the position shown on the drawings and with in 2 mm of the required level. 3mm - 2mm 10% 2% 1.5mm
2. Dimensional tolerance elastomeric bearings 2.1Overall plan dimensions 2.2Thickness of individual elastomeric layers 2.3Overall thickness bearing pad 2.4 Variation of one major surface out of parallel with other major surfaces
Page8000-168
(k) Fabrication And Assembly Tolerances For Structural Steel Item Tolerance
1. General 1.1 Fabrication and assembly tolerances + 2 mm. on all dimensions for structural steel 1.2 Holes for fasteners of up to 25 mm in 2 mm larger than the diameter of the fastener and diameter holes for larger fasteners not more than 3 mm larger than the diameter of the fastener. 2. Cross section The tolerances cross sectional dimensions of rolled sections shall be as specified in BS 4 or BS 4848 as appropriate. 3. Straightness 3.1 For compression members and beams (other than purlins and sheeting rails). 3.2 For other members 4. Length 4.1 For compression members faced at both ends for bearing. 4.2 For other members 5. Bearing surfaces Where two steel surfaces are required to be in contact in bearing the maximum clearance between the bearing surfaces 6.Accuracy of erection Steelwork shall not be out of plumb over any vertical distance 1/1000 of the length between the points which are laterally restrained 1/500 of Overall length but not more than 25 mm
+ 1 mm + 0, - 4 mm shall not exceed 1 mm when the members in contact are aligned.
by more than 5 mm or 1/1000 of the distance whichever is greater.
(l) Concrete Pavement Slab The work described in this sub-section shall be constructed to the tolerances given below. (i) Level and Grade
The finished surface of completed paving shall be within 10mm of design level at all points. The lot shall be deemed to comply with the requirements specified for surface levels if at least 90 % of the level measurements are within + 15 mm of the specified levels. The level on the finished surface of the base course for road pavements to be overlain with segmental paving shall be trimmed within + 10mm or - 0mm of design levels. Hangs of grade both longitudinally and transversely shall be eased over to avoid protuberance of adjoining units. The minimum length of ease shall be 3 unit lengths. Subject to easing constraints, the surface shall not deviate more than 5mm from a 3 metre straight edge. Sand bedding material shall not be used as a levelling material to compensate for base finishing outside the above tolerances.
Page 8000-169
Paving abutting a gutter to which it drains shall be laid to finish 4-6mm above the edge of the gutter. Other paving edges shall be laid to finish within -0mm to +2mm of the level of abutting paving or structures. The difference in level (lipping) between adjacent paving units shall not be more than 2mm. The finished surface of the base material shall drain freely without ponding. Isolated spots, where the surface levels deviate by more than 20 mm of the specified levels shall be repaired to bring the deviation to within the + 15 mm tolerance. Deviation from the specified longitudinal grade due to deviations from level shall not exceed the following: Length of Grade Measured in meter 2 5 10 20 30 (ii) Maximum Variation from Specified Grade (%) 0.34 0.27 0.21 0.13 0.08
Width of Pavement and the Position of Pavement Edges
The average width of each pavement shall be at least equal to the specified width, and the edge of the pavement shall not deviate by more than 25 mm from the specified position. (iii) Joints
Transverse joints shall be installed within the tolerances given in Clause 7112. Longitudinal joints shall be installed within the tolerances given in Clause 7113. The tolerance for the groove width of sawn joints shall be +/- 0.5 mm. (iv) Thickness At least 90 % of all the thickness measurements taken before any thickness repairs are made is equal to or greater than the specified thickness minus 14 mm; and The mean layer thickness of the lot is not less than the specified thickness minus 0.5 mm Isolated spots where the actual thickness is less than the specified thickness less 18 mm shall be repaired so as to fall within the 14 mm tolerance. The thickness of the slab shall be determined by accurate levelling in the same positions at random selected points before and after construction of the slab, and also by measuring (an average of 4 measurements per core) on cores drilled from the slab. (v) Cross Section
The lot will be considered to comply with the requirements for layer thickness if:
When tested with a 3 m straightedge placed at right angles to the road centerline, the surface shall not deviate from the bottom of the straightedge by more than 6 mm.
(vi)
Surface Regularity
When tested with a rolling straightedge, the number of surface irregularities in excess of 3 mm shall not exceed any of the following: Average number of surface irregularities per 100 m taken over 300 m - 600 m sections : 5 Number of surface irregularities taken over 100 m sections: 8 The maximum value of any individual irregularity when measured with the rolling straightedge or a 3 m straightedge laid parallel to the road centerline shall not exceed 7 mm. (vii) Dowels
Dowels shall be positioned within the tolerances given in Clause 7115 (b). Random checks of the dowels shall be ordered by the Engineer by taking cores at the position of the bar ends. (viii) Joint Sealers
Dimensional tolerances for preformed self-expanding cork joint sealer in the unexpanded state shall be 1.5mm in width and 3.0mm in depth. (ix) Subbase
The level of the subbase bedding layer shall not deviate by more than 5mm above or 10mm below the specified level. The surface of the subbase bedding layer shall not deviate by more than 10mm from a 3m straightedge or 10mm in 3m from the true vertical curve on vertical curves. (x) Kerbs and Inverts
Finished concrete shall be within 10mm of the specified alignment and level, at all points. The relative deviation of any two points on the surface from their true position shall not exceed 5mrn in 3m. Deviation on vertical curves shall not exceed 5mrn in 3m from the true vertical curve. These tolerances are subject to the non-accumulation of water at any point. (xi) Footpaths and Paving
Footpaths and paving shall be within 25mm of the specified alignment and level at all points. The finished surface shall be free from abrupt irregularities. The relative deviation of any two points on the surface from their true position shall not exceed 3mm or 1 in 270 of the distance between them, whichever is the greater. These tolerances are subject to the non-accumulation of water at any point. (xii) Mower Strips and Edging
Finished concrete shall be within 25mm of the specified alignment and level at all points. The finished surface shall be free from abrupt irregularities.
Page 8000-171
(m) Miscellaneous (i) Chamfers
Fillets used to form chamfers shall be made of hardwood, plastic or metal to a tolerance of 1 mm in cross sectional dimensions and the actual chamfer on the concrete shall not vary by more than 3 mm from the specified dimensions. (ii) Kerbs, copings, sidewalks, bridge railings, parapets, Guard rails, etc.
The elements shall be constructed to the specified dimensions within a tolerance of + 5 mm on any dimension. The alignment shall not deviate from the true alignment by more than 10 mm in any place nor shall the alignment deviate by more than 5 mm from the true alignment over any length of 5 m. (iii) Natural Stone, Precast and In-situ Concrete, and Asphalt Kerbs
Natural stone, precast and in-situ concrete and asphalt kerbs shall be constructed to the lines and levels shown in the contract to within the tolerances given below. Construction Tolerances for Kerbs Type of Kerb Natural stone Precast concrete In-situ concrete Asphalt
1 2
Alignment1 25mm. 25mm 25mm 50mm
Tolerances Level1 10mm 10mm 10mm 5mm
Straightness2 Max.10mm.in 3m -Ditto- DittoMax.20mm.in 3m
Relative to design line and level Maximum deviation measured horizontally and vertically relative to a 3m. Straightedge.
In addition to complying with the requirements of the Table above there shall be no difference in alignment between the ends of individual elements of natural stone or precast concrete kerbs of more than 3mm. (iv) Metal Beam Guardrails
Metal beam guardrails shall be constructed in the positions shown in the contract within the following tolerances:(1) Alignment The installed position of guardrails shall not depart from the design alignment by more than 30mm nor deviate from the straight or required radius by more 15mm. in any 10m. length. (2) Height Except for ramps, the beams shall be erected at the design height above the edge of the nearest adjacent carriageway, or, if the guardrail is located more than 1.5m. from the edge of the carriageway, above the level of the surface vertically beneath the beam, within a tolerance of 30mm.
Page8000-172

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Standard Technical Specification - 2002 Series 8000: Structures Content

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Standard Technical Specification - 2002

Series 8000: Structures Content

SERIES 8000: STRUCTURES

Series 8000: Structures Content