KMC CONSTRUCTIONS LTD.

UPGRADATION OF ROADS – CONTRACT PACKAGE TNRSP-01

METHODOLOGY FOR STRUCTURAL CONCRETE

1.0 DESCRIPTION
The work covered by this section consists of supplying, placing, finishing and
curing concrete in bridges, culverts, other drainage structures and incidental
construction in accordance with the Specifications of the contract and in
conformity with the lines, grades and dimensions, as shown on the drawings or as
directed by the Engineer. The work includes structural elements constructed by
cast-in-place and pre-cast methods using plain, reinforced or pre-stressed concrete
or any combination thereof.

2.0 GRADES OF CONCRETE

1) The various concrete grades required are shown on the Drawings and/or as
specified in MoRT&H Specifications for the different items of which structural
concrete is an integral part.
2) The concrete grade is denoted by the 28-day characteristic compressive strength
specified, expressed in MPa, based on concrete cube specimens 150 mm. x 150
mm. x 150 mm in size cured and tested at 28 days of age in accordance with
MoRT&H specifications. The characteristic strength is defined as the strength of
concrete below which not more than 5 percent of the test results are expected to
fall.

Table-1 Grades of concrete as per MoRT&H

For Pre-stressed Concrete Bridges and Bridges with Individual spans greater than 30 m. or Bridges
designed and constructed innovatively
Sl.No Structural Grade of concrete Minimum Cement Max. Water cement
Member content (kg /cu m) ratio
Moderate Severe Moderate Severe
Exposure Exposure Exposure Exposure
1 PCC members M 25 M 30 360 0.45 0.45
2 RCC members M35 M40 400 0.45 0.40
3 PSC members M35 M40 400 0.40 0.40
For Bridges Other than those mentioned above and for Culverts and other incidental construction
Sl.No Structural Grade of concrete Minimum Cement Max. Water cement
Member content (kg /cu m) ratio
Moderate Severe Moderate Severe Moderate Severe
Exposure Exposure Exposure Exposure Exposure Exposure
1 PCC members M 15 M 20 250 310 0.50 0.45
2 RCC members M 20 M 25 310 400 0.45 0.40
Note: 1. Minimum cement content is based on 20 mm maximum nominal size of aggregates. For 40 mm
and larger size of aggregates, cement content may be suitably reduced, but the reduction shall not
be more than 10 percent.
2. For underwater concreting, cement content may be increased by 10 percent.
3. Severe exposure shall mean alternate wetting and drying due to sea spray, alternate wetting and
drying combined with freezing and buried in soil having corrosive effect.
 4. Moderate exposure shall mean other than those mentioned in Note 3 above.

Table-1 Grades of concrete as per Contract Package TNSRP01

For Pre-stressed Concrete Bridges and Bridges with total length greater than 60 m. or Bridges
designed and constructed innovatively
Sl.No Structural Grade of concrete Minimum Cement Max. Water cement
. Member content (kg /cu m) ratio
Moderate Severe Moderate Severe
Exposure Exposure Exposure Exposure
1 PCC members M 25 M 30 360 0.45 0.45
2 RCC members M30 M35 380 0.45 0.40
For Bridges Other than those mentioned above and for Culverts and other incidental construction
Sl.No Structural Grade of concrete Minimum Cement Max. Water cement
Member content (kg /cu m) ratio
Moderate Severe Moderate Severe Moderate Severe
Exposure Exposure Exposure Exposure Exposure Exposure
1 PCC members M 15 M 20 250 310 0.50 0.45
2 RCC members M 20 M 25 310 360 0.45 0.40
Note: 1. Minimum cement content is based on 20 mm maximum nominal size of aggregates. For 40 mm
and larger size of aggregates, cement content may be suitably reduced, but the reduction shall not
be more than 10 percent. Similarly for smaller size aggregates, it may be suitably increased, but
not more than 10 percent.
2. For underwater concreting, cement content may be increased by 10 percent.
3. Severe exposure shall mean alternate wetting and drying due to sea spray, alternate wetting and
drying combined with freezing and buried in soil having corrosive effect.
4. Moderate exposure shall mean other than those mentioned in Note 3 above.

3.0 MATERIALS
The materials shall be approved combination of coarse aggregate, fine aggregate,
cement and cement conforming to the requirements of CL 1700 of the MoRT&H
Specifications and the relevant IS Codes such as IS 383, IS 2386, IS 8112 and IS
12269.
3.1 Test Methods
1) The standard test methods to be adopted shall be those stipulated herein.
3.2 Aggregates
1) The combined aggregate should be as coarse-grained and densely-graded as
possible. It shall be well-graded between the limits and the size or sizes specified
in IS 383.
2) The maximum nominal size of coarse aggregates should be chosen so as to be
compatible with mixing, handling, placing and working the concrete.
Sl. Components Max.Nom,Size
No. of Aggregate
1 RCC Well Curb 20
2 RCC / PCC Well Steining 40
3 Well Cap or Pile Cap Solid type piers and abutments 40
4 RCC work in girders, slabs, wearing coat, kerb, approach slab, hollow piers 20
and abutments, pier / abutment caps, piles
5 PSC work 20
6 Any other item As specified by
the Engineer
Maximum nominal size of aggregates shall be restricted to the smaller of:
a) 10 mm less than the minimum lateral clear distance between reinforcements
 b) 10 mm less than the minimum clear cover to the reinforcements
3) Aggregate shall not contain harmful materials such as Iron pyrites, coal, mica,
shale or similar laminated materials such as flat and elongated particles, or any
materials which may attack the reinforcement, in such a form or in sufficient
quantity to affect adversely the strength and durability of the concrete. If
necessary, aggregate shall be washed and sieved to remove deleterious
substances.

3.3 Fine Aggregate

(1) Fine aggregate shall conform to the requirements of MoRT&H Specifications and
IS 383 except as otherwise specified herein, and shall consist of natural sand or,
subject to the approval of the Engineer, of a suitable combination of stone
screenings and natural sand, having clean, hard, strong, durable particles. They
shall not consist of dust, lumps, soft or flaky particles, mica or other deleterious
materials in such quantities as to reduce the strength and durability of concrete, or
to attack the embedded steel.
(2) Fine aggregate from different sources shall neither be mixed nor stored in the
same stockpile and nor used alternatively in the class of construction or mix
without written permission from the Engineer.
(3) Fine aggregate shall have the grading as specified in MoRT&H Specifications and
IS 383.
Grading Requirements of Fine aggregates
IS Sieve Size Percent by Weight passing the Sieve
Zone I Zone II Zone III
10 mm 100 100 100
4.75 mm 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100
1.18 mm 30-70 55-90 75-100
600 micron 15-34 35-59 60-79
300 micron 5-20 8-30 12-40
150 micron 0-10 0-10 0-10

(4) The above grading requirements represent the extreme limits which shall
determine suitability for use from all sources of supply. The grading from any one
source shall be reasonably uniform, and not subject to the extreme percentages of
grading specified.
(5) To determine the degree of uniformity, a fineness modulus determination shall be
made on representative samples from such sources proposed to use. Fine
aggregate from any one source having a variation in fineness modulus greater
than 0.20 either way from the fineness modulus of the representative samples
submitted shall be rejected, until suitable adjustments can be made in the mix
proportions to compensate. The fineness modulus shall be determined in
accordance with IS 383 and shall be between 2.0 and 3.5.
(6) The content of clay lumps, friable particles, soil and foreign matter in fine
aggregate, when tested by IS: 2386 shall not be more than 2% by weight.
(7) When tested by the colorimetric method for organic matter according to
AASHTO T 21, the color shall be lighter than standard. The content of sulphide
and sulphate(converted into SO3) shall be more than 0.5% by weight.
(8) The maximum loss when tested to 5 cycles for sodium sulphate soundness
according to IS: 2386 shall be 12%.
(9) Fine aggregates having positive alkali-silica reaction shall not be used.

3.4 Coarse Aggregate

(1) Coarse Aggregate shall conform to IS: 383 except as otherwise specified herein,
and shall consist of gravel, crushed stone free from clay or other deleterious
substances.
(2) Coarse aggregates shall consist of clean, hard, strong, dense, nonporous and
durable pieces of crushed stone, crushed gravel, natural gravel or a combination
thereof or other approved inert material
(3) Crushed stones of lime-rock corroded by mineral water, especially acid water, and
stone material containing such irremovable foreign matter as coal, cinder coal,
lime, broken bricks or burnt stones not be used.
(4) Coarse aggregate shall have one of the following grading as specified in IS:383
depending on the permissible maximum particle size:
Grading Requirements of Coarse aggregates:
IS Sieve Size Percent by Weight passing the Sieve
40 mm 20 mm 12.5 mm
63 mm 100 ------- -------
40 mm 95-100 100 ------
20 mm 30-70 95-100 100
12.5 mm ----- ------ 90-100
10 mm 10-35 25-55 40-85
4.75 mm 0-5 0-10 0-10
(5) The content of clay lumps and friable particles when tested according to IS: 383
shall be more than 1% by weight.
(6) Flakiness index shall not exceed 35% when tested in accordance with BS 812.
(7) The maximum loss when tested according to IS: 2386 (5 cycles) for sodium
sulphate soundness shall be 12%.
(8) When tested for aggregate impact value according to IS: 2386, the aggregate
impact value shall not be more than 30%
(9) Coarse aggregates having positive alkali-silica reaction shall not be used.

3.5 Mixing Water

(1) A thorough chemical water analysis shall be made before using water from any
particular source for concrete mixing and curing.
(2) Water used for mixing and curing shall be clean and free from injurious amounts
of oils, acids, alkalis, salts, sugar, organic materials or other substances that may
be deleterious to concrete or steel.
(3) Water known to be of potable quality is generally considered satisfactory for
mixing and curing concrete.
(4) Water obtained from a source which is liable to seasonal variation in water quality
shall be re-tested at intervals of 3 months or as required by the Engineer.
(5) In case of doubt regarding development of strength, the suitability of water for
making concrete shall be ascertained by the compressive strength and initial
setting time tests.
(6) The sample of water taken for testing shall represent the water proposed to be
used for concreting, due account being paid to seasonal variation. The sample
shall not receive any treatment before testing other than that envisaged in the
regular supply of water proposed to be used in concrete. The sample shall be
stored in a clean container previously rinsed out with similar water.
(7) Average 28 days strength of at least three 150 mm concrete cube specimens
prepared with water proposed to be used shall not be less than 90 percent of the
average strength of three similar concrete cubes prepared with distilled water. The
cubes shall be prepared cured and tested in accordance with the requirements of
IS: 516.
(8) The initial setting time of test block made with the appropriate cement and the
water proposed to be used shall not be less than 30 minutes and shall not be more
than +30 minutes from the initial setting time of control test block prepared with
the same cement and distilled water. The test blocks shall be prepared and tested
in accordance with the requirements of IS: 4031(Part5)
(9) As a guide, the following concentrations represent the maximum permissible
values:
(a) To neutralize 100 ml sample of water, using pnenolphthalein as an
indicator, it should not require more than 5 ml of 0.02 normal NaOH.
Details are given in 8.1 of IS : 3025(Part 22)
(b) To neutralize 100 ml sample of water, using mixed indicator, it should
not require more than 25 ml of 0.02 normal H 2SO4. Details are given in
Clause 8 of IS : 3025(Part 23)
(c) The permissible limits for solids shall be as follows when tested in
accordance with IS : 3025 :
Description Tested as per Max. Permissible Limits
Organic IS 3025 (Part 18) 200 mg/litre
Inorganic IS 3025 (Part 18) 3000 mg/litre
Sulphates ( SO3 ) IS 3025 (Part 28) 500 mg/litre
Chlorides (Cl) IS 3025 (Part 32) 500 mg/litre * for PSC
/RCC work
2000 mg/litre for
concretework not
containing embedded steel
Suspended matter IS 3025 (Part 17) 2000 mg/litre
 * In case of structures of lengths 30 m and below, the permissible limit of
chlorides may be increased upto 1000mg/litre.
 All samples of water (including potable water) shall be tested and suitable
measures taken where necessary to ensure that water conforms to the
requirements stated herein.
(10) Mixing or curing of concrete with sea water is not permitted because of presence
of harmful salts in sea water.

3.6 Cement
(1) Cement used in concrete shall be ordinary Portland cement, 43 grade conforming
to IS: 8112 and 53 grade conforming to IS: 12269.
(2) Blast furnace cement (slag cement) shall not be used without the written
permission of the Engineer.
(3) Test reports from the manufacturer shall be attached when cement is delivered at
the Site and checked for brand, grade and test results.
(4) Cement stored older than 3 months shall be re-tested and got approved by the
Engineer before use.
(5) Independent tests or relevant tests shall be carried out if required by the Engineer
on the cement stored on site

3.7 Admixtures and Additives

(1) The consent of the Engineer shall be obtained in writing prior to the use of
admixtures or cement containing additives.
(2) Chemical admixtures shall conform to the requirements of IS: 9103. Plasticizers
and super-plasticizers shall meet the requirements indicated for Water reducing
Admixture.
(3) Admixtures shall not impair the durability of concrete; they shall not combine
with the ingredients to form harmful compounds of endanger the protection of
reinforcement against corrosion. Only chloride free admixtures shall be used.
(4) For all admixtures being used, the packing shall be marked with the name of the
manufacturer/supplier, brand name of the product and main effect. A certificate
shall be submitted for the admixture in question which includes the following
information.
(i) Chemical name of the active component in the admixture.
(ii) Values of dry material, ash content and relative density of admixture
which can be used for uniformity tests.
(iii) Chloride ion content expressed as a percentage of weight of cement
(iv) pH value and color
(v) Normal side effects like air entrapment at recommended dosage and if so
to what extent
(vi) Side effects when overdosed
(vii) If two or more admixtures have to be used in one mix, their compatibility
(viii) Increase in risk of corrosion to reinforcements
(ix) Embodiments due to the use of admixture
(x) Latest date of test and name of test laboratory
(xi) Shelf life
(xii) Max. & min. allowable temperature
(xiii) Other instructions like requirements of stirring
(xiv) Max. & min. dosage to be specified as a percentage by weight of cement.
(5) The air content of freshly mixed concrete in accordance with the pressure method
given in IS : 1199 shall not be more than 2 percent higher than that of the
corresponding control mix and in any case shall not be more than 3 percent of the
test mix.
(6) The chloride content of the admixture shall not exceed 0.2 percent when tested in
accordance with IS: 6925. In addition, it shall be ensured that the total chloride
content of all constituents of concrete mix as a percentage of mass of cement in
mix shall be limited to the values given below:
  For Pre-stressed concrete : 0.1 percent
 RCC exposed to chlorides in service
(Structures in coastal regions) : 0.2 percent
 Other RCC construction : 0.3 percent
(7) The total sulphuric anhydride (SO3) content of all the constituents of concrete as a
percentage of mass of cement in the mix shall be restricted to 4 percent.
(8) Uniformity tests on admixtures are essential to compare qualitatively the
composition of different samples taken from batch to batch or from the same
batch at different times.
The tests that shall be performed along with the permissible variations in the same
are:
 Dry material content: to be within 3 percent and 5 percent of liquid and solid
admixtures respectively of the value stated by the manufacturer.
 Ash content: to be within 1 percent of the value stated by the manufacturer.
 Relative density (for liquid admixture): to be within 2 percent of the value stated by
the manufacturer.
(9) All tests relating to the concrete admixtures shall be conducted periodically at an
independent laboratory and compared with the data given by the manufacturer.
(10) A number of trial mixes shall be designed using the different proportions of
admixtures/cement/water etc. to establish data bank on the behavior of admixture
for the project site conditions after establishing the basic acceptability of
admixtures using the strength criteria and using the approved combinations of
cement/sand/aggregates intended for use in the project. Retrials should be
conducted with change in source/ type of cement
(11) The dosage shall be finalized on the basis of field trials and special mechanical
devises should be used for dispensing admixture in the batching / mixing plant.
No further addition of admixture after dosage is permitted (including addition in
transit mixers)
(12) Admixtures generating Hydrogen or Nitrogen and containing Chlorides,
nitrates, sulphates, sulphides and any other material liable to adversely affect the
steel or concrete shall not be permitted.

3.8 Reinforcement Steel:

(1) For plain and reinforced cement concrete (PCC and RCC) works, the
reinforcement steel shall consist of the following grades of reinforcing bars.
Grade Bar type conforming to Characteristic Elastic Modulus GPa
designation governing IS Specification Strength f y
S 240 IS:432 Part1 Mild steel bar 240 200
S 415 IS:1786 High Yield strength 415 200
Deformed Bars (HYSD)
(2) All steel shall be procured from original producers; no re-rolled steel shall be
incorporated in the work.
(3) Only new steel shall be delivered to site. Every bar shall be got inspected from
Engineer’s representatives before assembling on the work and all defective, brittle
or burnt bars shall be discarded. Cracked ends of bars shall be discarded.

4.0 EQUIPMENTS:
 Weigh batchers
Electrical or petrol driven Vibrators
Shoring and shuttering Materials
Dewatering pumps
Earth Excavators with dumpers to convey soils
Crane (5 T capacity) for handling shuttering, reinforcement and materials.
All necessary pumps and Compressors for cleaning inside shutters

5.0 CONCRETE MIX DESIGN

5.1 General Requirements:

(1) The mix shall be proportioned so as to secure a workable, finish-able, durable,

water weight and wear resistant concrete of the required strength.
(2) Mixes for the grades of concrete shown on the Drawings shall be designed.
(3) Durable concrete of suitably low permeability shall be obtained by the use of
strong dense aggregates, a sufficiently low water/cement ratio, complete
compaction and proper curing methods to ensure sufficient hydration of the
cement.

5.2 Strength Requirements

(1) The mixes for the grades of concrete shown below shall be designed when
specified for use in any part of the Works in accordance with MoRT&H
Specifications.
2) In calculating the water/cement ratio of the mix, the weight of water shall be total
free water in the mix which includes the mixing water, the water in any admixture
solution and any water in the aggregates.
(3) The consistency of fresh concrete shall be monitored by testing the slump in
accordance with IS: 516. The quantity of water used shall not exceed that
required to produce a concrete with sufficient workability to be placed and
compacted in the particular location as required, and to produce concrete of the
consistencies in accordance with MoRT&H Specifications.
Sl.No Type Slump (mm)
1 (a) Structures with exposed inclined surface requiring low slump 25
concrete to allow proper compaction
(b) Plain cement concrete 25
2 RCC structures with widely spaced reinforcements; e.g. solid 40-50
columns, piers, abutments, footings, well steining.
3 RCC structures with fair degree of congestion of reinforcement; 50-75
e.g., pier and abutment caps, box culverts, well curb, well cap,
walls with thickness greater than 300 mm.
4 RCC and PSC structures with highly congested reinforcements; 75-125
e.g., deck slab girders, box girders, walls with thickness less than
300 mm.
5 Underwater concreting through tremie e.g. bottom plug, cast-in- 100-200
 situ piling

(4) The cement content in any mix shall not exceed 540 kg/m3 if not otherwise
specified or directed.
(5) Unless otherwise approved by the Engineer, the mix designs shall be on the basis
of continuously graded aggregates and all mix designs shall be submitted to the
Engineer for approval.
(6) The various grades of concrete are intended to be used as indicated in MoRT&H
Specifications or shown on the Drawings.
(7) Requirements for nominal mix concrete unless otherwise specified, shall be as detailed in the
following table
Concrete Total Quantity of dry aggregate by weight per 50 kg of Proportion of fine to
Grade cement to be taken as the sum of individual weights of fine coarse aggregate (by
and coarse aggregates (kg) weight)
M15 350 Generally 1:2, subject to
upper limit 1:1.5 and
lower limit of 1:2.5
M20 250 Generally 1:2, subject to
upper limit 1:1.5 and
lower limit of 1:2.5

5.3 Trial Mixes

(1) Well in advance before the commencement of concreting, trial mixes shall be
designed and prepared in the laboratory and submitted for the approval of the
Engineer. The concrete from each mix shall be tested in accordance with IS: 516
and shall satisfy the strength requirements specified.
(2) A minimum of a set of six test cubes taken from each of the three consecutive
batches of proposed mix shall be made with materials approved for use by the
engineer. Three cubes from each set of six shall be tested at an early age approved
by the Engineer. The cubes shall be made, cured, stored, transported and tested in
accordance with the specifications. The average strength of the nine cubes at 28
days shall exceed the specified characteristic strength by the current margin minus
3.5 MPa.
(3) The average strength of the cubes tested at 28 days shall correspond to the
specified target mean strength which shall exceed the characteristic compressive
strength by at least the current margin as specified in MoRT&H Specifications as
follows:
Sl. No. Concrete Current Margin Target Mean
Grade (Mpa) Strength (MPa)
1 M 15 10 25
2 M 20 10 30
3 M 25 11 36
4 M 30 12 42
5 M 35 12 47
6 M 40 12 52
7 M 45 13 58
8 M 50 13 63
9 M 55 14 69
(4) The 7-day compressive strengths shall not be less than 70% of the specified 28-
day strengths.
(5) The engineer will review the contractor’s trial mixes and test the test cubes at 7
and 28 days for compressive strength. The engineer will then determine which of
the trial mixes shall be used. If none of the mixes for a given grade meets the
specification, additional trial mixes shall be prepared. The cubes shall be made,
cured, stored, transported and tested in accordance with the specifications. The
average strength of the nine cubes at 28 days shall exceed the specified
characteristic strength by the current margin minus 3.5 MPa.
(6) When the trial mix has been approved, no variations shall be made in the
proportions, the source of the cement and aggregates or in the type, size and
grading of the latter without the consent of the engineer, who may require further
tests to be made.
(7) No structural concrete shall be placed in the Works until the relevant trial mix has
been approved by the engineer.
(8) When it is intended to purchase factory-made pre-cast concrete units, the engineer
may dispense with trial mixes and laboratory tests provided that evidence is given
which satisfies him that the factory regularly produces concrete which complies
with the workability and strength obtained 28 days.

6.0 BATCHING AND MIXING CONCRETE

6.1 Delivery and Storage of materials

(1) The batching site shall be of adequate size to permit the stockpiling of sufficient,
not segregated materials, having proper and uniform moisture content to ensure
continuous and uniform operation.
(2) Aggregate shall be assembled in such quantities that sufficient material approved
by the engineer is available to complete any continuous pour necessary for
structures.
(3) All aggregates shall be stockpiled before use in order to prevent segregation of
material, to promote uniform moisture content and to provide uniform conditions
for proportioning plant control.
(4) Aggregates for concrete shall not be contaminated by other materials during
transport and during storage on site. Aggregates shall be stockpiled in such a
manner that will prevent the intrusion of foreign material, preferably on a ground
that is denuded of any vegetation and is hard and well drained. If required, the
ground shall be covered with 50mm thick plank. If aggregates are stored on the
ground, the bottom 300 mm minimum thickness layer of aggregates shall not be
disturbed or used without re-cleaning, and an approved system of permanent
gauges shall be installed to indicate that minimum thickness.
(5) Coarse aggregate, unless otherwise permitted by the Engineer, shall be delivered
to the site in separate sizes.
(6) Aggregates of different sizes shall be stored in different hoppers or different
stockpiles which shall be separated from each other.
(7) Stockpiles of coarse aggregate shall be built in horizontal layers not exceeding
one metre in depth to avoid aggregation. Should the coarse aggregate become
segregated it shall be remixed to conform to the grading requirements.
(8) Fine aggregate from different sources of supply shall not be mixed or stored in the
same stockpiles nor used alternatively in the same class of construction or mix
without written permission from the Engineer.
(9) Cement shall be transported, handled and stored on the site in such a manner as to
avoid deterioration or contamination. Cement shall be stored above ground level
in perfectly dry and water-tight sheds and shall be stacked not more than eight
bags high.
(10) Cement shall be protected from moisture during transport and storage. Bulk
transport vehicles and bins or silos for cement shall not contain any residues of a
different type, or of a lower strength class or of any other materials.
(11) Cement shall be delivered and stored in quantities sufficient to ensure that there is
no suspension or interruption of the work at any time. Each consignment shall be
kept separate and distinct in accordance with its mark, grade and date of
production so that it may be readily identified and inspected and cement shall be
used in the sequence in which it is delivered at site.
(12) Cement shall be delivered and stored in a suitable weatherproof structure which
shall be as airtight as practicable. Floors shall be wooden and elevated above the
ground a sufficient distance to prevent the absorption of moisture. Sacks shall be
stacked close together to reduce circulation of air but shall not be stacked against
outside walls. The manner of storage shall permit easy access for inspection and
identification of each consignment.
(13) Bulk cement shall be transferred to elevated airtight and weatherproof bins.
(14) At the time of use all cement shall be free-flowing and free of lumps. Cement that
has been in storage for a period of 3 months if bagged, or 6 months if bulk, or if
the engineer is in doubt about its quality, shall be tested by the standard mortar
test of IS:516 to determine its suitability for use and such cement shall not be used
without approval by the engineer.
(15) For small structures, storage in the open may be permitted by the Engineer, in
which case a raised platform and ample waterproof covering shall be provided.
(16) Proper records shall be prepared on site in respect of delivery, handling, storage
and use of cement and maintained at all times such that these records are available
for inspection by the Engineer.
(17) A monthly submission shall be made to the Engineer showing the quantities of
cement, received and issued during the month and in stock at the end of the month

6.2 Mixing concrete

(1) Concrete shall be mixed either in a batching and mixing plant or in a site weigh-
batcher as per specifications. Hand mixing shall not be used. All weighing and
water-dispensing plant shall be maintained in good order. Their accuracy shall be
checked against accurate weights and volumes when required by the engineer.
(2) The weight of cement, each size of aggregate and water indicated by the
weighing mechanisms employed shall be within tolerance of +3 % of the
 respective weight per batch agreed by the engineer. Quantities of water-reducing
admixture shall be within a tolerance of + 5% respectively.
(3) The weight of the fine and coarse aggregates shall be adjusted to allow for the
free water contained in them. The water to be added to the mix shall be reduced
by the quantity of free water contained in the fine aggregates and coarse
aggregates which shall be determined by the method of IS: 10262 immediately
before mixing begins.
(4) Concrete shall be mixed only in the quantities required for immediate use.
Concrete shall not be used which developed initial has set. Re-tempering concrete
by adding water or by other means will not be permitted. Concrete that is not
within the specified slump limits at the time of placement shall not be used and
shall be disposed of as directed by the engineer.
(5) Concrete may be mixed at the site of the work, in a central-mix plant or in truck
mixers. The mixer shall be of an approved type and capacity. Mixing time shall be
measured from the time all materials are in the drum. Ready-mixed concrete shall
be mixed and delivered in accordance with the requirements of sub-section 5.3.
(6) Mixing of concrete shall be performed until a well-dispersed mixture of the
various constituent materials appears with identical color and each individual
particle of the coarse aggregate shows complete coating of mortar containing its
proportionate amount of cement.
(7) When mixed at the job site or in a central-mixing plant, the mixing time shall not
be less than 2 minutes. Five seconds shall be added to the specified mixing time if
timing starts the instant the skip reaches its minimum raised position. Mixing
time ends when the discharge chute opens. Different limiting mixing times may
be allowed or directed by the engineer, based on field trials or the experience of
production. It shall be ensured that mixing time for all concrete mixes shall be
strictly adhered to.
(8) The mixer shall be operated at the drum speed shown on the manufacturer’s rating
plate on the mixer.
(9) The volume of concrete mixed per batch should not exceed the mixer’s nominal
capacity as shown on the manufacturer’s rating plate on the mixer. The mixer
shall have a rated capacity sufficient to mix a batch of concrete containing one
full bag of cement.
(10) The batch shall be so discharged into the drum that a portion of the mixing water
shall enter in advance of the cement and aggregates. The flow of water shall be
uniform and all water shall be in the drum by the end of the first 15 seconds of the
mixing period. The throat of the drum shall be kept free of such accumulations as
may restrict the free flow of materials into the drum.
(11) Unless otherwise agreed by the engineer immediately before any session of
batching concrete a preliminary part batch shall be mixed having the masses of
fine aggregate, cement and water in correct proportion and no coarse aggregate.
The purpose of this is to avoid loss of mortar from the first batch of concrete as
specified. The preliminary batch shall be passed through all delivery equipment
but not placed in the forms except with the specific approval of the engineer.
(12) The entire contents of the mixer shall be removed from the drum before materials
for the next batch are placed therein. Mixers which have been out of use for more
 than 30 minutes shall be thoroughly cleaned before any fresh concrete is mixed.
Mixing plant shall be thoroughly cleaned before changing from the mixer and
compaction in its final position.
(13) 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.
(14) Manual mixing shall be only permitted for plastic concrete in small amounts, if
necessary. Mixing concrete by hand shall be performed on a steel plate or other
plate impermeable to water. Cement and fine aggregates shall be mixed uniformly
in advance and then mixed coarse aggregate and water. The mixing shall continue
until a well-dispersed mixture of the constituent materials with uniform color is
obtained.

6.3 Ready-Mixed Concrete

1) Ready-mixed concrete batch off the site may be used only with the approval of
the Engineer and shall comply with all the requirements for structural concrete.
2) The concrete shall be carried in purpose made agitators (transit mixers), operating
continuously or truck mixers. The concrete shall be compacted in its final position
within one hour of the introduction of water, unless a longer time is permitted by
the Engineer. The time of water introduction shall be recorded on the delivery
note together with the weight of the constituents of each mix.
3) 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, and in no
circumstances shall the water be added during transit.
4) Truck mixer units and their mixing and discharge performance shall be approved
by the Engineer.

7.0 PROTECTION OF CONCRETE

7.1 General
1) Precautions shall be taken to protect concrete structures from damage due to
weather or other environmental conditions during placing and curing operations.
2) The temperature of the concrete mixture immediately before placement shall be
between +5oC and +40oC

7.2 Hot Weather Concreting

1) When depositing concrete in very hot weather, precautions shall be taken so that
the temperature of wet concrete does not exceed 40oC while placing. This shall
be achieved by stacking the aggregates under the shade and keeping them moist
using cold water, reducing the time between mixing and placing to the minimum,
cooling the formwork by sprinkling water, starting curing before concrete dries
out and restricting concreting as far as possible to early mornings and late
evenings.
2) The temperature of the concrete at the time of placing shall not exceed +40oC.
(3) The temperature of concrete at the time of placement shall be maintained within
the specified temperature range by any combination of shading the materials
storage areas or production equipment; cooling the aggregates by sprinkling with
water: cooling the aggregates or water by refrigeration or replacing the mix water
with ice that is flaked or crushed. In no case shall the mixing operation be
considered complete until all ice in the mixing drum has melted.
(4) The time available for handling and placing concrete during periods of high
temperature may be considerably reduced. Concrete shall be protected during
transportation by use of damp Hessian cloth or similar arrangements.
(5) No additional water shall be added at the time of mixing without the approval of
the engineer, as this may lead to additional shrinkage of the concrete. On no
account shall water be added during transportation or placing of the concrete.
(6) Water-reducing and retarding admixtures to facilities placing and finishing of the
concrete shall conform to IS: 9103, and may be used only if approved by the
engineer.

8.0 HANDLING AND PLACING CONCRETE

8.1 General

1) The methods of transporting and placing concrete shall be got approved from the
Engineer. Concrete shall be so transported and placed that there is no
contamination, segregation or loss of the constituent materials. Concrete shall not
be freely dropped into place from a height exceeding 1.5 metres.
2) The rate of delivery of concrete during concreting operations shall be such as to
provide for the proper handling, placing and finishing of the concrete. The method
of delivery and handling shall be such as will facilitate placing with a minimum of
re-handling and without damage to the structure or the concrete.
3) The mixing and placing of concrete at any job site may be suspended or delayed if
the delivery and compaction equipment is considered inadequate, until such time
as the required additional approved delivery and compaction equipment is
provided for.
4) The form work and reinforcement shall be clean and free from standing water
immediately before the placing of the concrete and all sawdust, construction
debris and other extraneous matter shall have been removed.
5) Concrete shall not be placed in any part of the structure until the engineer’s
approval has been obtained.
6) The pouring operation shall be performed continuously, should an intermission
occur, it shall immediately be reported to the engineer.
7) Concrete shall be compacted in its final position within 30 minutes of discharge
from the mixer unless, with the approval of the engineer, it is placed in a purpose-
made agitator operating continuously, in which case it shall be compacted in its
final position within 1 hour of the introduction of cement to the mix and within 30
minutes of discharge from the agitator. These limiting times may be adjusted by
the Engineer to take into account factors such as temperature and mix design
including admixtures.
8.2 Handling concrete

(1) A leak proof non-absorbent vessel shall be used for transporting concrete. It
should be cleaned frequently from the remains of adhering concrete.
(2) If necessary a cover shall be provided for the vessel in order to prevent sunshine,
rain or cold weather affecting the quality of the concrete.

8.3 Placing concrete

(1) When operations would involve dropping the concrete more than 1.5 m the
concrete shall be dropped through a tube fitted with a hopper head, or through
approved devices. This requirement does not apply to cast-in-place piling when
concrete placement is completed before initial set occurs in the first placed
concrete.
(2) When concrete is conveyed by chute, the plant shall be of such size and design as
to ensure practically continuous flow. Slope of the chute shall be so adjusted that
the concrete flows without the use of excessive quantity of water and without
segregation of its ingredients. The delivery end of the chute shall be as close as
possible to the point of deposit. The chute shall be thoroughly flushed with water
before and after each working period and the water used for this purpose shall be
discharged outside the formwork.
(3) All formwork and reinforcement contained in it shall be cleaned and made free
from standing water and dust immediately before placing concrete.
(4) Except where otherwise agreed by the engineer concrete shall be deposited in
horizontal layers to a compacted depth not exceeding 450 mm where internal
vibrators are used, and 300 mm in all other cases. Each layer shall be placed and
consolidated before the preceding batch has taken its initial set to prevent injury
to the green concrete and to avoid surfaces of separation between the batches.
(5) After the initial set of the concrete, the forms shall not be jarred and no force shall
be applied to projecting reinforcing bars.
(6) When concreting the bottom layer of footings, precautions shall be taken to
prevent the concrete from absorbing moisture from the foundation or being
permeated. Drainage measures shall be provided in the foundation trench. No
standing water on the bottom of the trench shall be allowed prior to concreting. A
100 mm. thick layer of blinding concrete shall generally be used unless otherwise
permitted by the Engineer, such as in the case of a foundation of clean, hard,
impermeable rock.
(7) Pumping shall not be permitted from the inside of the foundation forms while
concrete is being placed. If necessary to prevent flooding, a seal of concrete shall
be placed through a closed chute or tremie and allowed to set.
(8) Where there is dense top reinforcement, some straight bars may be displaced
temporarily to facilitate the casting. The bars shall be replaced before casting the
top layer.
(9) Concrete for columns, substructure and culvert walls and other similar vertical
members shall be placed and allowed to set and settle for a period of time before
 concrete for integral horizontal members such as caps, slabs or footings is placed.
These shall be not less than 12 hours for vertical members over 4.5 m. in height
and not less than 30 minutes for members over 1.5 m. but not over 4.5 m. in
height.
8) Concrete for T-beam or deck girder spans whose depth is les than 1.2 m may be
placed in one continuous operation or may be in two separate operations; first, to
the top of girder stems, and second to completion for T-beam or deck girder. For
spans whose depth is greater than 1.2 m, such concrete shall be placed in two
operations and the deck slab concrete is placed after at least five days have
elapsed after concrete placement of stems.
9) Embedded items (bolts and anchor) shall be inspected regularly during the casting
operation and any displacements shall be rectified. Care shall be taken to ensure
the concrete fills up properly under horizontal plates. e.g., Expansion of joint
plates.

8.4 Additional requirements for pre-stressed concrete members

1) No concrete shall be used more than 45 minutes after the water being introduced.
This interval can be prolonged to one hour when water-reducing admixture with a
retarding effect is used.
2) Concrete shall be placed continuously in one operation and in horizontal layers with a
sloping edge. The time between depositing two adjacent layers of concrete shall
not be more than 1 hour with an ambient temperature of more than +30oC and 1.5
hours when the ambient temperature is less than +30 oC, unless otherwise
permitted by the engineer. With a longer intermission the relevant provisions of
section 14 shall be followed and records shall be kept.
3) Vibrators shall be handled with care in order not to displace or deform the pre-formed
ducts.
4) In the anchoring zones at the ends of girders enhanced vibrating by means of
approved external vibrators shall be used if necessary to ensure the density of the
concrete.

8.5 Placing concrete under water

1) Concrete shall be deposited in water only with the permission of the Engineer and
under his supervision.
2) The minimum cement content of the grade of concrete being deposited in water
shall be increased by at least 10% without further compensation.
3) When depositing in water is allowed, the concrete shall be carefully placed in the
space in which it is to remain in a compact mass, by means of a tremie, concrete
pump or other approved method.
4) The concrete shall not be disturbed after being deposited. No concrete shall be
placed in running water. Forms which are not reasonably watertight shall not be
used for holding concrete deposited under water.
8.6 Pumping Concrete

1) Placement of concrete by pumping will be permitted only when it is authorized by

the Engineer in writing after approval of a modified mix design and preliminary
trials as specified.

2) Where concrete is conveyed and placed by mechanically applied pressure the

equipment shall be suitable in kind and adequate in capacity for the work, and
shall be so arranged that no vibrations result that might damage freshly placed
concrete. The operation of the pump shall be such that a continuous stream of
concrete without air pockets is produced, when pumping is completed .the
concrete remaining in the pipeline, if it is to be used , shall be ejected in such a
manner that there will be no contamination of the concrete or separation of the
ingredients. After the operation, the entire equipment shall be thoroughly cleaned.

8.7 Compaction of Concrete

1) All concrete, except concrete placed under water, during and immediately after
depositing, shall be thoroughly compacted to produce a dense homogeneous mass.
Unless otherwise permitted by the Engineer, it shall be compacted with the
assistance of mechanical vibration during placing and worked around the
reinforcement, tendons or duct formers, embedded fixtures and into corners of the
formwork to produce a dense homogeneous void-free mass having the required
surface finish subject to the following provisions.
2) When vibrators are used, vibration shall be done continuously during the placing
of each batch of concrete until the expulsion of air has practically ceased and in a
manner that does not promote segregation. Over-vibration shall be avoided to
minimize the risk of formation of a weak layer.
3) The internal vibrators shall be inserted in an orderly manner and the distance
between insertions should be about one and a half times the radius of the area
visibly affected by vibration.
4) The vibration shall be internal except that external vibrators may be used for thin
sections when forms have been designed for external vibration and disposition of
form vibrators shall be such as to ensure efficient compaction and to avoid surface
blemishes.
5) Vibrators shall be of a type and design approved by the Engineer. They shall be
capable of transmitting vibrations to the concrete at frequencies of not less than
4500 impulses per minute. The intensity of vibration shall be such as visibly to
affect a mass of concrete of 50 mm. slump over a radius of at least 450 mm.
6) A sufficient number of vibrators in serviceable condition shall be on site so that
spare equipment is always available in the event of breakdown. At least two
vibrators shall be immediately on hand whenever concrete is being placed.
7) Vibration shall be applied at the point of deposit and in the area of freshly
deposited concrete. The vibrators shall be inserted and withdrawn slowly to avoid
creating voids.
8) Vibrators shall be inserted vertically into the concrete and to a sufficient depth to
ensure that the newly-poured concrete is worked into the previous layer. The
penetration of the vibrator into the previous layer should be approximately 50
mm.
9) Application of vibrators shall be at points uniformly spaced and not further apart
than one and a half times the radius over which the vibration is visibly effective.
10) The vibration shall be of sufficient duration and intensity to thoroughly compact
the concrete, but shall not be continued so as to cause segregation. Vibration shall
not be continued at any one point to the extent that localized areas of grout are
formed.
11) Where immersion type vibrators are used, contact with reinforcement, formwork
and all inserts shall be avoided, so far as is practicable.
12) Vibration shall not be applied directly to or by way of reinforcement, to sections
or layers of concrete which have hardened to the degree that the concrete ceases
to be plastic under vibration.
13) Vibrators shall not be used to make concrete flow in the forms over distances so
great as to cause segregation, and vibrators shall not be used to transport concrete
in the forms. Where necessary, concrete shall be redistributed in the forms by
spading.
14) Vibration shall be supplemented by such prodding as is necessary to ensure
smooth surfaces and dense concrete, along surfaces and in corners and locations
impossible to reach with the vibrators.
15) Concrete shall not be subjected to vibration between two and twenty four hours
after compaction, unless otherwise permitted by the Engineer.

9.0 CONSTRUCTION JOINTS

9.1 General

1) If not detailed on the drawings, or in an emergency, construction joint locations

shall be provided at locations shown on the drawings or as approved by the
Engineer.
2) Shear keys or inclined reinforcement shall be used where necessary to transmit,
shear and bond the two sections together. When shear keys or inclined
reinforcement are not provided, the concrete shall be roughened as directed.

9.2 Location
In cases where additional / new joints are approved by the Engineer, the following
considerations for their location shall be taken into account:
1) Joints shall be provided in non-aggressive zones or in non-flash zones. If not
feasible, the joints shall be sealed.
2) Joints should be positioned where they are readily accessible for preparation and
concreting, such as location where the cross-section is relatively small, and where
reinforcement is not congested.
3) In beams and slabs, joints should not be near supports. Construction joints
between slabs and ribs in composite beams should be avoided.
4) For box girders, it is preferable to cast the soffit and webs without any joint.
5) Location of the joints shall minimize the effects of the discontinuity on the
durability, structural integrity and the appearance.

9.3 Construction Requirements

1) The upper surface of lifts of concrete walls and columns shall be horizontal unless
otherwise described on the Drawings. It the formwork extends above the joint on
the exposed face, it shall be cleaned of adhering concrete before the next lift is
placed.
2) Where a construction joint contains a formed surface, that surface shall be roughened
to expose the aggregate without damaging the aggregate and the arrises( arrise
means sharp edge or salient angle formed by the meeting of two surfacing
specially in moldings) of the joint. The roughened surface shall then be washed
with clean water under pressure to remove loose particles.
3) Where sections of the work are carried out in lifts, the reinforcement projecting above
the lift being cast shall be adequately supported so as to prevent movement of the
bars during the casting and setting of the concrete.
4) Whenever possible laitance and all loose material shall be removed by mechanical
means when the concrete has been in position for more than 24 hours, the
roughened surface shall then be washed with clean water under pressure.
5) To compensate for loss of mortar at the juncture of the hardened and the newly
deposited concrete, the cleaned and saturated surfaces, including vertical and
inclined surfaces, shall first be thoroughly painted with a thick coat of 1:2
cement /sand mortar or neat cement grout against which the new concrete shall be
placed before the grout has attained its initial set. Where this is not possible, as in
walls other approved means shall be adopted.
6) The placing of concrete shall be carried continuously from joint to joint. The face
edges of all joints that are exposed to view shall be carefully finished true to line
and elevation.
7) In general, suitable keys may be formed by the use of timber blocks approximately
50mm deep by 100mm wide in cross section and having in length of 100mm less
than the width of the member. The key blocks shall be spaced along the member
as required, but the spacing shall be not greater than 300mm center to center. The
blocks shall be beveled and oiled in such manner as to ensure their ready removal,
and they shall be removed as soon as the concrete has set sufficiently to retain its
shape.
8) Immediately following the discontinuation of placing concrete, all accumulations of
mortar splashed on the reinforcing steel and the surface of forms shall be
removed. Dried mortar chips and dust shall not be puddle into the unset concrete,
if the accumulations are not removed prior to the concrete setting, care shall be
exercised not to injure or break the concrete–steel bond at and near the surface of
the concrete, while cleaning the reinforcing steel.
9) In case the concrete has partially hardened, it shall be treated by wire brushing or with
a stiff water jet followed by drying with air jet immediately.
10) Fully hardened concrete shall be treated with mechanical hand tools or grit blasting,
taking care not to split or crack aggregate particles. Before further concrete is
cast, the surface should be thoroughly cleaned to remove debris and accumulated
rubbish, one effective method being by air jet.

10.0 FINISHING PLASTIC CONCRETE

10.1 General

1) After the concrete has been compacted and prior to the starting of curing, all
surfaces of concrete which are not placed against forms shall be struck–off to the
given grade, super-elevation or crown specified on the drawings and the surface
finished by floating with wooden float.
2) Exposed surfaces of substructure caps, curbs and other surfaces, if directed by the
Engineer, shall be finished with a wooden float, when the moisture film has
disappeared and the concrete has hardened sufficiently to prevent laitance from
being worked to the surface, it shall be steel–toweled under firm pressure to
produce a dense, smooth, uniform surface free from trowel marks.

10.2 Roadway surface finish

1) Bridge deck, and other concrete surfaces for use by traffic shall be finished to a
smooth skid- resistant surface
2) During finishing operations, suitable and adequate work bridges shall be provided for
facilitating performance of the work.

10.3 Striking off and floating

1) After the concrete is placed and compacted, bridge decks or top slabs of structures
serving as finished pavements shall be finished using approved power driven
finishing machines.
2) All surfaces shall be struck-off by equipment supported by and traveling on rails or
headers. Rails or headers shall be adjustable for elevation and shall be set to
allow for anticipated settlement, camber, and deflection of false-work, as
necessary to obtain a finished surface true to the required grade and cross section.
3) Before the delivery of concrete is begun, the finishing machine, or if used, the hand
operated strike-off tool shall be operated over the entire area to be finished to
check for excessive rail deflections, for proper deck thickness and cover of the
reinforcing steel.
4) A slight excess of concrete shall be kept in front of the cutting edge of the screed
at all times. This excess concrete shall be carried all the way to the edge of the
pour or form and shall not be worked into the slab, but shall be wasted.
5) After strike-off the surface shall be finished with a float, roller or approved device
as necessary to remove any local irregularities and to leave sufficient mortar at the
surface of the concrete for later texturing.
6) During finishing operations, excess water, laitance or foreign materials brought to the
surface shall not be re-worked into the slab, but shall be removed immediately
upon appearance.
7) After finishing, the levels of entire surface shall be checked by the use of a 3 m metal
straightedge operated parallel to the centerline of the bridge and the surface shall
show no deviation in excess of 3 mm from the testing edge. Deviations in excess
of these requirements shall be corrected before the concrete sets.

10.4 Texturing

1) The surfaces shall be given a skid-resistant texture by burlap or carpet dragging,

application of broom, tining(losing of surface particles by using wire broom,
comb) or by a combination of these methods. This operation shall be done after
floating.
2) If the surface is to be drag finished, the surface shall be finished by dragging a
seamless strip of damp burlap over the full width of the surface. The burlap drag
shall consist of sufficient layers of burlap and have sufficient length in contact
with the concrete to slightly groove the surface.
3) If the surface texture is to be broom finished, the surface shall be broomed when
the surface has hardened sufficiently. The strokes shall be square across the slab,
from edge to edge, with adjacent strokes slightly overlapped , and shall be made
by drawing the broom without tearing the concrete , but so as to produce regular
corrugations not over 3 mm in depth , the surface as thus finished shall be free
from porous spots, irregularities, depressions, and small pockets.
4) If the surface is to be tined, the tining shall be in transverse direction using a wire
broom, comb or finned float having a single row of tines or tins. The tining
grooves shall between 2 mm deep, spaced 12mm to 40m on centres.

10.5 Surface testing and correction

1) After the concrete has hardened, the finished deck roadway surfaces shall be got
inspected by the Engineer. The surface shall be tested with a 3 m straight-edge.
Areas showing high spots of more than 3 mm but not exceeding 12 mm in 3 m
between any two contact points shall be marked. Such irregularities shall be
corrected by the use of concrete planing or grooving equipment which produces a
textured surface in equal roughness to the surrounding unground concrete.
2) Where the departure from correct cross section exceeds 12 mm, the defective
work shall be removed and redone as directed by the Engineer.
3) All finished surfaces shall be got approved from the Engineer.

11.0 CURING CONCRETE

11.1 General

1) Concreting operations shall not start until adequate arrangements for concrete
curing have been made.
2) Curing and protection of concrete shall start immediately after compaction of the
concrete to protect it from :
(i) Premature drying out particularly by solar radiation and wind
(ii) High internal thermal gradients
(iii) Leaching out by rain and flowing water
(iv) Rapid cooling during the first few days after placing
(v) Low temperature or frost
(vi) Vibrations and impact which may disrupt the concrete and interface with its bond to
the reinforcement
Where members are of considerable size and length, with high cement content,
accelerated curing methods may be applied, as approved by the Engineer.
3) Curing shall start immediately after the free water has left the surface and finishing
operations are completed. Curing by methods other than steam method shall
continue for 7 days thereafter, or as directed by the engineer. The concrete shall
be protected against harmful effects of weather, including rain, rapid temperature
changes and from drying out.
4) For other than top slabs of structures serving as finished roadway pavements, the
above curing periods may be reduced and curing terminated when test cubes
cured under the same conditions as the structure indicate that concrete strength of
not less than 70% of that specified have been reached.
5) The methods of curing and their duration shall be such that the concrete will have
satisfactory durability and strength and the member will suffer a minimum of
distortion, be free from excessive efflorescence and will not leak, due to shrinkage
cracking in the structure. If necessary the concrete shall be insulated such that it is
maintained at a suitable temperature or such that the rates of evaporation of
moisture from the surfaces are kept to appropriate values. Different curing or
drying, treatments will be appropriate to different members and products. Where
necessary, special care should be taken to ensure that similar components are
cured as far as practicable under the same conditions.
6) The top surfaces of bridge decks shall be cured by the water curing method. The
water cure shall not later than 4 hours after completion of deck finishing.

11.2 Water curing

1) Water curing shall consist of maintaining the formwork in place and closely
covering the unformed concrete surface with a material such as straw, Hessian,
sand or with an absorbent material which is kept continually damp. The type of
covering provided shall be that which in the opinion of the engineer is best suited
to the conditions.
2) On formed surfaces, if the forms are removed before the end of the curing period,
curing shall be continued as far on the unformed surfaces.
3) When sand, burlap or other approved fabric materials are used they shall not
cause any undesirable finish such as a rough surface and discoloring of parts
which will be exposed to view.
4) Formed structure members, prior to removal of forms, shall be kept continually
wet regardless of the method of curing.
5) For pre-stressed concrete, the period of curing may have to be extended until pre-
stressing force sufficient to overcome shrinkage and temperature strains can be
applied.
6) Where structural members are of considerable depth or bulk or have high
proportion of cement or are pre-cast units subjected to special or accelerated
curing methods, the method of curing shall be as directed by the engineer.

11.3 Liquid membrane curing

(1) The liquid membrane curing method shall not be used on surfaces where a rubbed
finish is required or for surfaces of construction joint or for concrete surfaces
which are required to be bonded together.
(2) On surfaces other than those specifically noted as requiring water or stream curing
only, curing may be accomplished by the use of liquid curing membrane. The
curing membrane used shall be in accordance with the requirements specified for
curing membrane material. AASHTO M 148, Type 2.
(3) The curing membrane shall be applied in 2 applications in conformance with the
manufacturer’s instructions and to the satisfaction of the Engineer.
(4) The first coat shall be applied immediately after removal of the forms and
Engineer’s acceptance of the finish and after the disappearance of free water on
unformed surfaces.
(5) If the concrete is dry or becomes dry, it shall be thoroughly wet with water and
the curing compound applied just as the surface film of water disappears.
(6) The second application shall be applied after the first application has set.
(7) During the curing operations, any unsprayed surfaces shall be kept wet with
water. The curing membranes shall be protected against marring for the entire
specified curing period. Any coating marred or otherwise disturbed shall be made
good. Placement in more than two coats may be required to prevent streaking.

12.0 FINISHING FORMED CONCRETE SURFACES

12.1 General

(1) If on the removal of the forms there is any honeycombing or other defect apparent
in the concrete, the Engineer shall be informed immediately. No making good or
other treatment shall be carried out except with the prior approval of the Engineer.
(2) If in the opinion of the Engineer, rock pockets are of such extent or character as to
materially affect the strength of the structure or to endanger the life of the steel
reinforcement, he may declare the concrete defective and require the removal and
replacement of the part of the structure affected.
(3) Any injury and damage arising from removal of the work shall be made good.
(4) All concrete shall be given an ordinary surface finish and in addition if further
finishing is required, such other type of finish shall be as specified by the
Engineer.
12.2 Ordinary Surface Finish.

(1) Immediately after the removal of forms. Fins and irregular projections shall be
removed from the surfaces, except those which are not to be exposed. On all
surfaces the cavities produced by form ties and all other holes, broken corners or
edges and other defects shall be thoroughly cleaned and after thorough saturation
with water shall be carefully pointed and made good with mortar of cement and
the fine aggregate mixed in the proportions used in the grade of the concrete
being finished. Mortar used in pointing shall be not more than 1 hour old.
(2) Any mortar or concrete patching or pointing to make good holes or depressions
shall only be allowed when and as directed by the Engineer.
(3) Exposed surfaces not protected by forms shall be struck-off with a straight–edge
and finished with a wood float to a true and even surface. The use of additional
mortar to provide a grout finish will not be permitted.
(4) The resulting surfaces shall be true and uniform. Repaired surfaces of which the
appearance is not satisfactory shall be rubbed as specified in rubbed finish.

12.3 Rubbed Finish.

(1) In addition to ordinary finish, if specified by the Engineer, exposed concrete

surfaces except the soffits of superstructures and the interior faces and bottoms of
concrete girders shall also be given a rubbed finish.
(2) After removal of forms, the rubbing of concrete shall be started as soon as its
condition will permit. Surfaces to be finished shall be rubbed with a medium
coarse carborundum stone, using a small amount of mortar on its face. The mortar
shall be composed of cement and lime sand mixed in proportion used in the grade
of the concrete being finished.
(3) Rubbing shall be continued until marks, projections, and irregularities have been
removed, voids have been filled and a uniform surface has been obtained. After
other work which could affect the surface has been completed, the final finish
shall be obtained by rubbing with a fine carborundum stone and water. This
rubbing is continued until the entire surface is of smooth texture and uniform
colour.
(4) After the final rubbing is finished and the surface has dried, it shall be rubbed
with burlap to remove loose powder.

13.0 PRECAST CONCRETE MEMBERS.

13.1 General

(1) Pre-cast concrete members shall be constructed and placed in the work in
conformity with the details shown on the Drawings, specified or shown on the
approved working drawings.
(2) Whenever specified or requested by the Engineer, it shall be ensured that working
drawings shall be provided for pre-cast members. Such drawings shall include all
 details not shown on the drawings for the construction and erection of the
members.
(3) The method of manufacture shall be approved by the Engineer before work is
started. No changes shall subsequently be made without the consent of the
Engineer.
(4) The Engineer shall be informed in advance of the date of commencement of
manufacture for each type of pre-cast member.

13.2 Material and Manufacture

(1) The materials and manufacturing processes used for pre-cast concrete members
shall conform to the requirements of the other relevant Sections of the
Specification.
(2) The foundation for the pre-casting moulds shall be solid, cast on unyielding beds
or pallets and if necessary, improved and drained to obtain sufficient bearing
capacity to avoid settlements and subsequent deformation of the members.
(3) Pre-cast pre-stressed units may be cast in one continuous line and stresses at one
time.
(4) The side forms may be removed as soon as their removal will not cause distortion
of the concrete surface and provide that curing is not interrupted. Members shall
not be lifted from their casting beds until their strength is sufficient to prevent
damage.
5) When cast-in-place concrete will later be cast against the top surfaces of pre-cast
beams or girders, these surfaces shall be finished to a coarse texture by the
application of a stiff coarse broom. Prior to transport, such surfaces shall be
cleaned of laitance or other foreign materials by sandblasting or other approved
methods.
6) When pre-cast members are designed to be abutted together in the finished work,
each member shall be match cast with its adjacent segments to ensure proper fit.
The segments must be precisely aligned to achieve final structure geometry and
during alignments, adjustments to compensate for deflections shall be made.
7) Unless otherwise specified, pre-cast members shall be cured by the water method
or steam method.

13.3 Storage and Handling

(1) Members shall be firmly supported at such bearing positions as will ensure that
the stresses induced in them are always less than the permissible design stresses.
Members shall be lifted or supported only at the points specified on the drawings
and shall be handled and placed without impact.
(2) Pre-cast girders should be transported in an upright position and points of support
and directions of the reactions with respect to the girder should be approximately
the same during transportation and storage as when the girder is in its final
position.
(3) Care shall be taken during storage, hoisting and handling of the pre-cast units to
prevent cracking or damage. Units damaged by improper storing or handling shall
be replaced.

13.4 Erection

(1) Lifting devices shall be used in a manner that does not cause damaging bending
stresses or torsion stresses. After the member has been erected and until it is
secured to the structure, temporary braces shall be provided as necessary to resist
wind or other loads.
(2) Pre-cast deck from panels, if used, shall be erected and placed so that the fit of
mating surfaces shall be such that excessive grout leakage will not occur. If such
fit is not provided, joints be dry–packed or sealed with acceptable caulking
compound prior to placing the cast-in-place concrete. End panels of skewed
structures may be sawed to fit the skew.

13.5 Tolerances.

(1) The following tolerances shall apply:

Length + / - 12mm
Width and depth + / - 6mm
Bow in the vertical plane + / - 15mm
Difference between longest and shortest
Dimensions in any plane 6 mm
Twist (measured by the deviation
of any corner from the plane
containing the other three corners ) 6 mm
Flatness (the maximum deviation from a 1.5 m
straight edge placed in any position
on a nominally plane surface ) 6 mm
Cover to reinforcement 0 / + 5 mm
Pre-stressing tendons (in any direction) 3 mm
Dowel holes (in any direction) 3 mm

14.0 MORTAR AND GROUT

(1) This work consists of making and placing of mortar and grout for use in concrete
structures other than in pre-stressing ducts.
(2) Materials for mortar and grout shall conform to the requirements of sub-section
3.0. The grading of sand for use in mortar or grout when the width and depth of
void to be filled is less than 40 mm shall be modified so that all material passes
the 2.36 mm sieve.
(3) Unless otherwise specified or ordered by the engineer, the proportion of cement to
sand for mortar shall be 1 to 2 and for grout shall be 1 to 1, by loose volume.
(4) Sufficient water shall be used to permit placing and packing. Mixing shall be by
hand methods or with rotating paddle–type mixing machines and shall be
continued until all ingredients are thoroughly mixed. Once mixed, mortar or grout
shall not be re–tempered by the addition of water and shall be placed within one
hour.
(5) No load shall be allowed on mortar until after 72 hours, unless otherwise
permitted by the engineer.

15.0 EARLY LOADING

15.1 General

(1) It shall be ensured that no loads are applied until the concrete has attained
sufficient strength and when applicable, sufficient pre-stressing has been
completed, so that it will not cause damage to newly constructed work. Any
damage caused by such overloading shall be made good to the satisfaction of the
Engineer.

15.2 Earth Loads

(1) When the placement of back fill will cause flexural stresses in the concrete, the
placement shall not begin until the concrete has reached 80% of its specified
strength.

15.3 Construction Loads

(1) Light equipment and materials may be carried on the bridge decks only after the
concrete has been in place at least 24 hours, providing curing is not interfered
with and the texture is not damaged.
(2) Pre-cast concrete or steel girders shall not be placed on substructure concrete has
attained 70% of its specified strength.
(3) Construction vehicles weighing between 500 and 1500 kg., and comparable
material loads, will be allowed on the bridge deck only after the last concrete
placed has attained a compressive strength of at least 17 MPa.
(4) Loads imposed on existing, new or partially completed portions of structures due
to construction operations shall not exceed the load carrying capacity of the
structure as determined by the load factor design methods of AASHTO using
Load Group IB. the concrete comprehensive strength (fc’) to be used shall be the
smaller of the actual compressive strength at the time of loading or the specified
compressive strength of concrete.

15.4 Opening to Traffic

(1) Traffic shall not be permitted on concrete bridge decks until 21 days after the last
placement of concrete and until such concrete has attained its specified strength
and the written permission of the Engineer shall be obtained prior to opening.
16.0 TESTING

16.1 General
(1) Concrete shall conform to the surface finish and tolerance as prescribed in the
contract Specifications for respective components.
(2) Random sampling and lot by lot acceptance inspection shall be made for the 28
days cube compressive strength of concrete.
(3) Concrete under acceptance shall conceptually be divided into lots for the purpose
of sampling, before the commencement of work. The delimitation of shall be
determined by the following:
(i) No individual lot shall be more than 30 cu. m. in volume
(ii) At least one cube forming an item of the sample representing the lot shall be
taken from concrete of the same grade and mix proportions cast on any day.
(iii) Different grades of mixes of concrete shall be divided into separate lots.
(iv) Concrete of a lot shall be used in the same identifiable component of the bridge

16.2 Sampling

(1) At least one set of test specimens shall be taken once every day on which
concreting work is in progress.
(2) Test specimens shall be made from each separate concrete grade and mix ratio
and shall be typical for the portion of concrete they represent.
(3) Concrete for making 3 test cubes shall be taken from a batch at point of delivery
into construction, according to procedure laid down in IS: 1199.
(4) A random sampling procedure to ensure that each of the concrete batches forming
the lot under acceptance has equal chance being chosen for taking the cubes shall
be adopted.
(5) 150 mm cubes shall be made, cured and tested at the age of 28 days for
compressive strength in accordance with IS: 516. The 28 days compressive
strength test result for each cube shall form an item of the sample.
(6) Three test specimens shall be made from each sample for testing at 28 days.
Additional cubes may be required for various purposes such as to determine the
strength of concrete at 7 days of for some other purpose.
(7) The test strength of the sample shall be the average of the strength of 3 cubes. The
individual variation should not be more than + 15 percent of the average.
(8) The minimum frequency of sampling of concrete of each grade shall be in accordance with the
following table:
Sl. No. Quantity of Concrete in work, m3 No. of samples
1 1-5 1
2 6-15 2
3 16-30 3
4 31-50 4
5 51 and above 4 plus one additional sample for each additional 50
m3 or part thereof
At least one sample shall be taken from each shift of work.
16.3 Strength Requirements

When both the following conditions are met, the concrete complies with the
specified compressive strength:
(1) The mean strength determined from any group of four consecutive samples
should exceed the specified compressive strength by 3 Mpa.
(2) Strength of any sample is not less than the specified characteristic
compressive strength minus 3 MPa.
The quantity of concrete represented by the test results include the batches from
which the first and last samples were taken, together with all intervening batches.

16.4 Test Results & Additional Tests

(1) Any concrete which gives results below the specified limits in relevant codes or
becomes severely damaged due to cracking or shows excessive honeycombing
and exposure of reinforcements or exhibits any fault which in the opinion of the
Engineer, so seriously impairs the its function that it cannot be accepted as sub-
standard work, shall be declared defective concrete. Such concrete shall be cut
out, removed and replaced by fresh concrete of the specified quality to the
satisfaction of the Engineer.
(2) In case of doubt regarding grade of concrete used, either due to poor
workmanship or based on results of cube crushing strength, core tests on concrete
(three cores shall be cut from the defective areas) as per IS: 516 or any other
nondestructive tests like Rebound hammer tests or ultrasonic tests shall be carried
out on specific instructions from the Engineer. In case of core tests, the concrete
in the member represented by the core tests shall be considered acceptable if the
average equivalent strength of 85% of the corresponding specified grade of
concrete is achieved. The areas from which cores were cut shall be made good to
the satisfaction of the Engineer.

17.0 FINISHING AND MAKING GOOD SURFACE DEFECTS

1) Immediately after removal of forms, exposed bars or bolts if any, shall be cut
inside the concrete member to a depth of at least 50 mm below the surface of
concrete and the corresponding holes filled with cement mortar.
2) All fins caused by form joints, all cavities produced by the removal of form ties
and all other holes and depressions, honeycomb spots broken edges or corners,
and other defects, shall be thoroughly cleaned, saturated with water, and carefully
pointed and rendered true with mortar of cement and fine aggregate mixed in the
proportions used in the grade of concrete that is finished and of a dry consistency
as is possible to use. Considerable pressure shall be applied in filling and pointing
to ensure that all the voids are thoroughly filled.
3) Surfaces which have been pointed shall be kept moist for a period of twenty four
hours. Special pre-packed proprietary mortars shall be used where appropriate or
where specified in the drawing.
4) All construction and expansion joints in the completed work shall be left carefully
tooled and free from any mortar and concrete. Expansion joint filler shall be left
exposed for its full length with clean and true edges.
5) Immediately on removal of forms, the concrete work shall be got examined by the
Engineer before any defects are made good.
6) Bulges and ridges shall be removed by careful chipping or tooling and the surface
rubbed with a grinding stone.
7) Honeycombed and other defective areas shall be chipped out, the edges being cut
as straight as possible and perpendicular to the surface, or slight undercut to
provide a key at the edge of the patch.
8) Shallow patches shall be treated with a coat of thin grout composed of one part of
cement and one part of sand then filled with mortar of the same mix as the one
used in parent concrete. The mortar shall be placed in layers of not more than 10
mm thick and the surface of each layer roughened to provide a key for the
subsequent layer. The final layer shall be finished to match the surrounding
concrete by floating, rubbing or rolling on formed surfaces by pressing the form
material against the patch while the mortar is still plastic
9) Where necessary, formwork shall be provided to contain concrete in large voids.
Such patches shall be treated with epoxy to provide an effective bond between the
fresh concrete and the hardened concrete
10) Remedial work to defective concrete shall be cured in a like manner as the parent
concrete to the satisfaction of the Engineer.

18.0 SITE RECORDS:

Sl.No Type of record To be submitted by Time period
1 Laboratory test results on Senior Materials Within two days
materials Engineer/ Lab. Engineer from the day of
concreting
2 Field test results on mix Senior Materials Within two days
Engineer/ Lab. Engineer from the day of
concreting
3 Cube Test Results Senior Materials Within twenty
Engineer/ Lab. Engineer eight days from
the day of
concreting
4 Level check sheets Senior Bridge Engineer Within one day
from the day of
concreting
5 Operation records including Senior Bridge Engineer On the same day
location, layer, lane, time, load, of concreting
temperature, weather and operation
observation on materials
performance
6 Measurement sheets Senior Quantity Within two days
Surveyor from the day of
concreting
7 Overall Responsibility of Senior Bridge Engineer Within two days
submission of all Records from the day of
concreting
19.0 QUALITY CONTROL
Routine testing shall be carried out as stipulated within relevant IS codes and any
errors reduced to acceptable levels during continuous production.
Cube compressive strength shall be used for determination for strength achieved.
Test Frequency (Minimum)
(i) Quality of cement Two samples per lot to be subjected to Setting time,
Consistency, Mortar Cube compressive strength tests,
(ii) Aggregate Impact Value One test for each source of supply and subsequently
on monthly basis As required and as and when Source
is changed
(iii)Flakiness Index One test for each source of supply and subsequently
on monthly basis As required and as and when Source
is changed
(iv)Soundness Test Before approving the aggregates and every month
subsequently
(v) Alkali aggregate reactivity Before approving the aggregates and every month
subsequently
(v) Water Absorption of Aggregate Regularly as required subject to a minimum of one test
a day for coarse aggregate and two tests per day for
fine aggregates.
(vi) Chemical tests on water Once for approval of source of supply, subsequently
as and when source is changed and in case of doubt
(vi) Sand Equivalent Test As required and as and when Source is changed
(vii)Mix Grading As required and as and when Source is changed
(viii)Slump Tests on Mix At regular close intervals- One test per load
(xi) Cube compressive test As per subsection 16.2 above

20.0 INSPECTION AND TEST PLAN

NO Activity Inspection Test Required Remarks

1 Reinforcement By consultants Yes Acceptance by

Checking, Formwork Consultants.
checking
2 Cube Compressive ------ Cube Test
Strength in Lab.
3 Surface Yes Levels Joint Survey

4 Physical Properties Yes AIV, FI Lab tests/ Field

EI, Gradation, Tests
Tests on
Cement, slump
tests, Cube
Tests
21.0 LIST OF FORMS
a) Request for inspection.
b) Gradation Chart
c) Aggregate Impact Value Test ( AIV )
d) Flakiness index
e) Data sheet for determination of Cement Tests
f) Compressive Strength on concrete cubes.
22.0 CHECK LIST :

MATERIAL QUALITY CHECK CONTRACTOR

Name and location of site

BATCHING OPERATIONS AND POURING OF CONCRETE

FORM NO: BR/24

1. Mixing of concrete

- Check the concrete class and respective mix design already approved
- Check the condition of the aggregate to be used
- Check the weighting and water dispensing methods adopted during the mixing
- Check that the mixer machine has been cleaned properly
- Check that the required mixing time is allowed.

2. Placing of concrete : Check the following

- Concrete is not segregated during pour, control the height of dropping. It should not exceed 2m.
- Concrete is poured in layers of about 400mm
- Vibrator shall be applied systematically to compact uniformly and adequately. Avoid over
vibration
- Concrete shall not be pulled or pushed. Pouring should be done close to the final position
- Don’t allow any cold joint
- Underwater concrete shall be poured only by tremies or pipe line
- The forms are not displaced or deformed during the concrete pour and vibrating
- No grout loss, suitable no. of carpenters should be present and watch formwork during pour.
- The concrete is poured within the allowable time limit from the time of batching
- Concrete cubes are taken as required
- The curing arrangements must be satisfactory.

CONTRACTOR CONSULTANT
 FORMWORK INSPECTION CHECK LIST
(REF I R C SP 47)

FORM NO: BR/21

Name of Bridge:

Location:

CONTRACTORS INSPECTION REQUEST NO:

CONTRACTORS DRG OR SKETCH NO:

YES NO N.A
1. Formwork design/drawing/sketch approved including de-shuttering arrangements.

2. Formwork alignment correct.

3. Formwork level correction including screeds

4. Formwork dimensions correct

5. Formwork member spacing correct

6. Formwork member material quality acceptable

7. Falsework member size correct

8. Falsework member spacing correct

9. Falsework member material quality acceptable

10. Gaps between primary and secondary member closed / wedged

11. Face boarding / plywood / metal thickness correct

12. Joints between panels closed (no gaps)

13. Joints between panels flush (no steps / lips)

14. Panel flatness acceptable

15. Gaps between secondary members and face panels closed

16. Tie rod material and sizes correct

17. Tie rod spacing correct

18. Tie rods tight, face cones flush

19. Spacers between shutter surface tightly fitting

20. Box outs cast in items, ducts fixed correct, securely …contd

21. Prestressing sheathing & Vents, alignments & spacing of supports acceptable.

22. Empty sheathing secured against Floatation

23. Prestressing anchorage positions and fixing acceptable

24. Chamfers / filters sizes, straightness, fixing acceptable

25. Formwork clean

26. Formwork release oil material approved

27. Formwork release oil applied correctly

28. Construction joint preparation satisfactory

29. Contract / expansion joint preparation satisfactory

30. Safe access constructed

31. Adequate work space provided for labour equipment

32. Shutter vibrators ( if required) location and fixing arrangements approved.

CONTRACTOR CONSULTANT

INSPECTION CHECK LIST BEFORE APPROVAL TOCONCRETE

 (REF I R C SP 47)

FORM NO: BR/23

Name of Bridge:

Location : Dated:

CONTRACTORS INSPECTION REQUEST NO:

YES NO N.A

1. Method statement approved

2. Batching plant mixers in working order

(Separate dispenser for admixture if required available)

3. Standby batcher in working order

4. Water, cement, sand, coarse aggregate, admixture approved

5. Water, sand, coarse aggregate, admixture cement stock sufficient

6. Concrete conveying arrangement (including transit mixers) available in working condition and of

sufficient capacity

7. Formwork approved

8. Reinforcement approved

9. Pre-stressing sheathing approved

10. Concreting equipment working order

11. Stand by cranes, vibrators present

12. Tremie in working order (for under water work)

13. Concrete gang present including carpenter, steel fixture, mechanics and electricians

14. Access provided

15. Safety arrangements adequate

16. Lighting provided

17. Communication between various points provided

18. Arrangements for arranging suspension / stoppage of concrete provided

19. Curing arrangements made ….contd

 YES NO N.A.
20. Laboratory notified

21. Cube moulds 15cms * 15cms * 15cms

22. Slump cone

23. Stove

24. Frying pan

CONTRACTOR CONSULTANT

PROFORMA FOR CONCRETE AND POUR RECORD

 (REF I R C SP 47)
FORM NO: BR/25

Name of bridge:

1. Concrete batching delivery

Location of Pour: Dated

Concrete Grade Slump:

W/C ratio No. of cubes:

Taken

Cement content

Max., Aggregate size

Admixture (Type & Dosage)

Batching started, Hrs Batching finished, Hrs

Checking of formwork

Quantity Batched, Cu.m. Truck no:

2. Truck arrived on site: hrs.

Slump test Results (S) _____mm at ____hrs

Discharge Started _____hrs

Placement completed _____hrs

No. of Site cubes taken _____hrs

Place where cubes taken

Cement consumption

a) Theoretical
b) Actuals

Weather condition

CONTRACTOR CONSULTANT