TIOXTDE AUSTRALTA PTY LTD GENERAL CONCRETE SPECIFICATION INDEX SECTION DESCRIPTION PAGE © 1 scope 1 ) : 2 Definition of Terms L 3 General 2 4 Excavation 4 5 Coneutting, Breaking and Joining 4 - 6 Materials and Storage 5 7 Conerete 6 8 ‘rransporting and Placing 10 ) 9 curing 12 10 Admixtures to Concrete 12 a Construction Joints in Floors and Walls 13 2 Reinforcement 23 13 setting Tn 1s 14 Fomnwork 4s pia2.2 SCOPE 7 3 ‘The General Concrete Specification, cxausigt 20° Ly) shall be vead in conjunction with and shall’ form part.of, the specification Clause 2.3 below. DEPINETION-OF TERMS Engineer ¢ Whenever the term ‘Engineer is applied, it shall mean the Chief Engineer, ‘THoxide australia Pty Ltd, of such person or persons whom he may from time to time nominate. Purchaser { Whenever the term 'Purchaser''is applied, it shall mean Tioxide Australia Pty Ltd, Whenever the term ‘Specification’ is used, it shall be taken to mean all the fender Documents and will include some or all of the following, in the stated order of reference: 2.3.1 The accompanying Technical Specification and associated arawings, together with such Tioxide Australia Pty Ltd Standard specifications as are referred to within. 2,3.2 This General Concrete Specification (AU-01-06-01) . 2.3.3. The following AS Codes: AS1012 ~ Methods for the Testing of Concrete. AS1302 - Steel Reinforcing Bars fox Concrete. AS1304 - Hard Drawn Steel wire Reinforcing Fabric for Concrete. AS1315 ~ Specification and Methods of Tests for Portland Cement. i AS1379 - Ready Mixed Concrete. AS275B.[- Dense Natuxal Aggregates for Concrete. 1 AS1478-9 - Chemical Admixtures for Concrete. aS 3400 - Concrete structures Code. AS15092 - Formwork Code. AS1510: - Control of Concrete Surfaces ~ Formyork.3.2 3.2 3.3 3.4 3.5 GENERAL Materials and Workmanship, z Materials and workmanship. shall be of the quality specified but where no particular quality is specified it shall be not ess than that required by the current aditions of aS3G00- 1966 SAA-Concrete Structures Code. Dimensions Dingnsions indicated on the Structural drawings are concrete sizes ‘and do not include any added finishes. puila ‘The Contractor in consultation with the trades and sub-contractors concerned shall accurately predetermine and then build in all openings, sleeves, brackets, flashings, fixings and chases as necessary for trades following on. Provision for Services and Openings 3.4.1 3.4.2 3.4.3 Wherever piping, conduits and openings are required in conerete.work, theix position shall be accurately pre~ determined by the Contractor in consultation with the trade and sub-contractor concemed. ‘he Contractor shall be responsible for obteining all cores and sleeves of the required sizes from the trade or sub-contractor concerned and shall carefully set and fix them in their correct position. The Contractor shall ensure that conduit and pipes are not placed in conerete cover. All embedded pipes, conduits, etc shall be arranged such that there is a clear distance of 40 mm between them and shall be supported by approved bar chairs or other means compatible with the surface finish to be achieved in the area. ‘The Contractor shall also ensure that, except where specifically detailed otherwise, reinforcement is not cut at openings or where provision is made for sexvices. displaced At these positions reinforcing rods may be laterally subject to approval by the Engineer. Supervision and Inspection 3.5.1 The Contractor shall supervise all concrete work to ensure tha The necessary accuracy is achieved. he work is constructed in accordance with the Specifications and the Drawings.3.8 3.8 a eatet Supervision and Inspection (Cont'd) : 3.8.2 3.5.3 3.5.4 3.5.5 3.6.2 No concrete shall be poured until the area concerned is clear of all debris, foreign matter and free water, and has beeli inspected and approved by the Engineer. ‘The Contractor shall: - Give the Engineer at least 24 hours notice of his intentions to pour concrete. - Arrange for him to inspect the area concerned. - Ensure that reinforcement, walkways, platforms and barrow runs’ are in position and that formork is cleared of all debris and free water before the inspection is made. In areas containing heavy reinforcement, by pre- arrangement .the Contractor may request inspections in stages as work proceeds, Such inspection shall require 24 hours notice. Approval to pour will only be given after satisfactory inspection of the area concerned. Should the Contractor fail to comply with these provisions, the Engineer may direct the Contractor to: (a) Remove any unapproved poured conerete, and (>) Replace and refit reinforcing, service openings, build ins, etc all at no extra cost to the Purchaser. ‘The Contractor shall keep accurate records on the followin ~ The date of placement of each batch of concrete. ~ The area in which the concrete was placed. - The nunber of samples taken from each batch. ~ The result of any test carried out on the samples, ‘The Contractor shall ensure that these records are progressively checked and endorsed, Structural Sufficiency of False ork Associated with reinforced concrete construction the Contractor shall be responsible for: ~ The structural sufficiency of all formwork -and falsework. - The capacity of all propping systems. Protection of Work in Progress 3.8.1 ALL foot or vehicle traffic shall be kept off new laid conerete until it is hardened sufficiently in the opinion of the Engineer to avoid damage.3.8 4.3 5.1 Protection of Work in Progress 3.8.2 Minimum approval time will be 36 Nours after completion of concreting. All parts of the work Liable to injury shall be protected until completed by means of batriers, screens, tarpaulins, covers or other means as necessary. EXCAVATION ‘The Contractor shall concut existing floor'where necessary and excavate as shown on the drawing. The Contractor ‘shall accurately set out his. excavation lines so as to give minimum wall thicknesses and base thickness. any over-breaking or over excavation shall be made up’ with concrete of the same specification as the structural concrete at the Contractor's expense. Under no circumstances is over excavation“) ing the excavated material. to be made good by u: Accurate location and levels are to be maintained throughout this Contract. Surplus soi] and materials from the excavations shall becone the property of the Contractor and shall be zemoved from the site. ‘The Contractor shall keep all excavations free from water. ‘The Contractor shall give the Engineer notice of his intention to start concreting. The Engineer will then inspect the excavations and give approval. ‘The Contractor shell backfill around concrete work if necessary. Excavated material may be used for backfilling subject to the Backfill shall he well compacted using Engineer's approval mechanical equipment, CONCUTIING, BREAKING AND JOINING Unless approved to the contrary, all cutting of concrete shall be performed with a water cooled diamond saw. Dry abrasive disc type cutters shall. NoT be used without specific-approval from the Engineer and where the use of such cutters is approved, the Contractor shall take all necessary precautions to control dust and grit.5.3 5.4 Coneutting, Breaking and Joining (Cont'd) Drilling in cofterete shall be performed with g diamond tube cutter, water cooled. Jack-hammers and carbérundum bit drills shall be used only on approvel from the Engineer. and where theix use is approved the job shall be kept wetted-down.to control dust. A wet bag shall be wrapped around the bit~of non-xotary action tools and against the concrete surface. Water used for cooling or dust control shall be retained within the area of the job by sand or earth dams and shall be cleaned up progressively and removed from the site. Water shall not be permitted to lie in locations where it could be absorbed by the earth beneath existing floors or structures.and where this situation could arise the Contractor shall provide and use a suitable pump to collect the water, An approved bonding adhesive such as Nonporite Epicrete MV shall. be used where joining to an existing surface is required. The surface shall be scabblea, and cleaned of all loosely adhering matter an@ laitance, The base concrete must be sound, clean and superficially dry. MATERIALS AND STORAGE Cement Shall be ordinary Portland Coment manufactured in Tasmania complying with the requirements of AS1315 - Portland Cement, unless specified otherwise in the Technical Specification. Cement stocks shall be kapt dry in an enclosed area that will ensure it is kept dry and is effectively protected against the weather and damp air. Aggregates Fine and coarse aggregates shall comply with the requirements of AS27SG!- Dense Natural Aggregates for Concrete. Maximum aggregates size shall be that passing 2 19 mm Australian Standard Sieve. Aggregates shall be stored separately in defined and prepared areas. Precautions shall be taken to prevent the intrusion of foreign material. Reinforcement, Steel reinforcement shall comply with the applicable requirements of AS1302 and 1304, Refer structural Drawings for grade and type of steel reinforcenent to particular areas and the key list of symbols on the structural Drawings to denote each particular grede of steel xeinforcenent.Td Mater whe water used shall be clear and free from oil and from injurious emounts of acid, alkali, organic matter or other deleterious substances and shall be pure enough to drink. Aémixture: See under. CONCRETE Ready Mix Concrete Ready mixed concrete only as defined below shall be used on site. Site batched conercte shall not be used. 7.1.1 Use of Ready Mixed Concretes Ready mixed concrete shall mean mixed concrete delivered to the site ready for use and batched by an approved commercial batching plant. Ready mixed concrete shall be used in the work subject to approval of the supplier thereof, of. the. particular plant and of the means of transport. Ready mixed concrete shall be supplied to guarantee mininum strengths and certified to comply with other requirements. See also 7.1.4 below. 7.1.2 Approval of Supplier Concrete shall not be delivered to the site until the plant from which the concrete is to be obtained is approved. The Builder shall submit the name and address of the supplier and the plant fourteen days prior to ordering. ‘The Engineer may approve or disapprove any supplier of plant. ‘he supplier of xeady mixed concrete shall permit inspections of all plant, all materials used and if so required, shall permit the taking of samples for testing purposes, together with inspection during the batching and mixing and delivery of concrete. 7.1.3 Code Requixements, ALL plant and equipment, measurements of materials, mixing and delivery shall be in accordance with AS1379.1.2 23 -7- 7.1.4 Methéd of Ordering » when ordering the concrete from the approved ready mixed concrete supplier, the Builder shall state the strength required, and the slump of the concrete at the tine of the delivery. the sippiler shall supply a docket with each batch delivered stating: (a) Concrete contains not less than "X" kg of cement per cubic metre. (b) Designated strength (r'c) and grade. (c) Time batcning took place. (a). slump. (e) Grade names and quantities of approved admixtures. Pumped Concrete Shall not be used without the prior consent of the Engineer and supject to: ~ Use of 100 mm diameter steel lines with a maximum length of 6 metres of 100 mn diameter rubber hosing. = cement content of 320 kg/cubic metre, air entrainment of "Onoda NN" to restrict the water cement ratio to 0.50. Delivery dockets shall be endorsed as such. Concrete Grades Each concrete class shall have the properties stated below and shall be used in the areas indicated on Structural Drawings and specified in individual clauses, Generally, concrete classes shall be used to the following areas. (Refer to Structural Drawings for details.) Grade 25, 32, 40 To beams, slabs, footings, columns and stairs. Grade 10 Encasement of drains, filling over excavations, ete as directed. Concrete strengths and Consistency Conerete is specified by required properties in accordance with Clause 6.1 AS.3600- 19.38, The Contractor shall be responsible for producing concrete of the specified strengths as tabulated below. A water reducing additive, such as WRDA shall be used for Grades 25, 30 and 40 concrete, at the dosage rate recommended by the Manufacturer:- (WRDA dose at 440 1/100 kg cement). Air entrainment additive (ABA) shall be used to give a final total of 48 entrainment.2S Donerete Strengths and Consistency (Cont'd) purther, the maximum water cement ratio shall not exceed 0.54 for grade 25, 34.and 40 concrete, The supplier shall not ada cement additional to strength requixements to achieve that maximam water cement xatio, but shall limit the total amount of water in the mix as far as possible with appropriate selection of aggregates and mix design. Use “Onoda NN" plasticiser up to the recommended dosage to assist in achieving this requirement. The concrete supplier will be required to produce evidence of his capability to produce concrete to the above criteria, pricy to supplying any concrete to the site, ox at any time during the currency of the Contract, : sive wsnamuin concrete Compressive, Mats Size "Conn stump Grade Soret ot Content {remy is at 28 Days Aggregate sapien MPa (kg/ca.m) 40 20 G0 columns, pedestals walis 200" thick oF 32 ae ao less, pad footings as 2 20 285 20 20 20 40. strip footings, slab walls more than 220 thick, stair flights Sampling, Testing and Acceptance of Concrete Testing shall be carried out on all classes of concrete strictly in accordance with ¢£CT/~ Tok AS.3600- 1982 Acceptance criteria shall be defined in that section for "Project Control" testing. ‘All sampling, moulding, curing, stripping, transporting and testing of specimens shall be carried out under the direction of the Engineer. neraoved ALL testing shall be carried out at an...» Laboratory. The Contractox shall hold the following equipment on site at all tines during concreting operations and available to the Engineer. 2 Ne Standard slump mould. 6 No Standara cylinder moulds complete with base plates and tamping rod. 2No Insulated boxes to initially store al] test cylinders a the first 24 hours after moulding.wd Sampling, Testing and Acceptance of Conerete (Cont'd) Additional numbers of test cylinders may be taken at the dascretion of the Engineer for testing at seven days to determine safe formwork stripping times and-as, anvearly indication of faulty concrete. The cost of. testing: by an approved laboratory shall be borne hy the Contractor. ‘he Contractor shall allow fox taking samples, handling and transporting cylinders as directed. Me shall also ensure prompt and regular conveyance of test results from the testing laboratory to the Engineer. ‘he ‘Contractor shall keep on site a log book in which is recorded the following information: (a) Test cylinder number or identifying mark. (b) Date of sampling. (c) Portion of structure represented by sample. (a) Date when tested. (e) Results. ‘This log book shall be available for inspection by the Engineer at all times. Rejection of Concrete and Load Tests Grade.25,. 32, 40 concrete, Concrete which has.-failed:to satisfy the requirements of the specification for compressive strength or which is othervise faulty, ie porous, segregated, honeyconbed, ete is subject to further test. Any concrete not satisfying strength test specified above ox any other tests that may be required, shall be removed and replaced by the Contractor at no extra cost. The Engincer shall define the limits of concrete to be removed and his decision shall be final and binding, No cutting back or patching work shall be undertaken by the Contractor prior to inspection by and/or approva? of the Engineer. Repair of Defective Surfaces (Grade 25, 31, 40 Concrete Only) Make good any voids, bony areas, fins, burrs or mortar runs immediately after formork is removed and inspection has been carried out by the Engineer. Preparation: Clean off surfaces of areas to be made good. Remove ‘any loose material, hack surfaces to provide key and saturate with water. Remove any excess water immediately before applying cement mortar. Cement Mortar: Use same aggregate ag in concrete: 2 parts sand, 1 part cement.7.7 Repair of Defective Surfaces (Cont'd) Mix with minimum quantity of water to provide stiff but workable mix. Apply to prepared voids and bony areas, and finish to natch adjacent concrete surfaces. Cure and protect as specified for concrete. TRANSPORTING AND PLACING General 8.1.1 AL methods of transporting concxete, including chuting and placing shall be in accordance with the requirements @ of CLAvsE INISof AS.3¢90 - 19°82. 8.1.2 The use of mechanical vibrators is mandatory. Concrete shall be placed in accordance with the requirements of unos Di30E BS H6OC~ SFE 8.1.3 Placing shall be continuous within each section and sections shall terminate at construction joints. the @istance between construction joints shall not exceed 10 metres in each direction. 8.1.4 tn vertical sections placing shall be in layers not ‘exceeding 550 mm deép and each layer shall be thoroughly compacted before the next is placed. 8.1.5 No concrete which has partially hardened or has been contaminated by foreign materials shall be deposited in the forms. 8.1.6 Retempered concrete shall not be used. 8.1.7 1£ tain commences during operations, the Contractor shall take inmediate and adequate measures to protect concrete from damage. 8.1.8 Pour Lifts to walls and columns shall be limited to a maximum of 3.5 metres in height or as indicated by construction joints on the plans. Rate of replacement vertically shall not be less than 2 metres per hour. the free fal) of concrete shall not exceed 2 metres in massive sections or 1 metre in sections containing Yeinforcenent. ‘Tremmies shall be used for the pouring of walls and columns to achieve this requirement. 8.1.9 Free falling concrete shall not be directed against forms. concrete that has not been placed in position in ‘the forms within two hours' of having been batched shall not be used, Such conerete shall be taken away from the site and dumped.a ape ‘| F¥ansporting and Placi 8.1.10 Seneral (cont "ay 8.2022 concrete overnight. fold, Hot and wet Weather Precautions Sold, Hot and | cheese 8.2.2 8.2.2 note that g ubetatures less than 32°C, when An conjunction 5.2.3 In general, concrete tances nett not be commenced under the following circumstances without the specitic approval of the Engineer: (a) Tf it is xaining (®) If rain can reasonably be expected to conence (ec) 0£ the forms are fare ind frost, ice or snow, ox tne air temperature is at 4 eke or less, 83.1 approved nernanically operated immersion type vibrators wnden iMd At NOE Jess than go00 cycles per minute when wee tote Allow for at leave two extra vibrators on oresacok Smergency use, one of which is not electrically operated, 83.2 All conexete shat pe vibrated during placing. 8-3.3° a sufficient numer of Yibrators shall be used such {hats at the required rate of Placement, vibration fhreushout the entire volume of each layer of concrete 8-3-4 compaction shall start as Soon as there ig suf ficient8.3 9.2 20. 10.3 ease Vibration of Concrete (Cont'd) CURING General, uncompacted concrete in the formwork. where rate of placing ‘concrete exceeds 3.5 cubic metzes per hour, moxe than one vibrator shall be used. Vibrators shall not be placed between the reinforcement and the adjacent form face. Vibrate with immersion type to top of lift. Apply external vibration to top 300 mm of lift one hour after pour is complete with the use of a "Kango" hammer. Only experienced operators shall use vibrators. Vibrators shall be kept moving continuously and slowly, and shall be used in a manner to produce uniformly plastic concrete free from segregation of materials and air bubbles. Hand rodding shall supplement vibration where necessary. Vibrators shall not bear on the formwork ox reinforcement and shall not be used for spreading concrete. Immediately after its initial set all concrete surfaces shall be cured in accordance with chavse'Wof AS 249 for a minimum period of 7 days, The method of curing will be selected for the following: (a) Where formwork remains in position for 7 days no other curing will be required, (>) All other surfaces shall be cured with Calcure B unless alternative methods are approved or directed by the Engineer, All curing compounds shall be applied in accordance with manufacturers instructions using proper spraying equipment. A second application may be required at the discretion of the Engineer. ADMIXTURES TO CONCRETE General 10.2.2 20.1.2 Water reducing and air entraining admixtures shall be used as specified for Grades 25, 32 and 40 concrete. No substitution or change in dosage shall be made without the written approval of the Engineer. Onoda NN (Blue nabel), Darataré or Rapidard admixtures may be used-with the approval of the Engineer, if used strictly in accordance with the manufacturers instructions and if not specified outrightaL. 1a 12. 1 - a3 - Bos CONSTRUCTION JOINTS IN FLOORS AND WALLS ne General 14.1.1 Construction joints formed in accofdance with AS, oo Clause /%.f positions shown on drawings. .i Reinforcenent to be continuous through construction joints. Method of forming joints to be such that concrete does not leak away. * £ 41.1.2 Stop end battens notched to take réinforcement and sealed with a proprietary foam tape. 11.1.3, Curing Period: ‘Concrete to formed face shall cure for 3 days before concrete to the other face of joint is placed and stop’ends shall not be stripped for 36 hours after placing concrete. 11.1.4 All joints axe subject to approval before pouring. Location of additional joints must be approved by the Engineer prior to formwork to the section being erected. 21,1.5 Joints formed to ensure that edges are straight ~ protect and maintain edges until placing of adjacent concrete is complete. 311.6 The surface of all construction joints shall be scabbled back, wire brushed and cleaned up while concrete is still, green, 12.2.7 Cement slurry, applied to a joint immediately before pouring, shall be used only when specifically directed. At the time of placing fresh concrete against the joint surface of hardened concrete, the surface shall be damp but there shall be no free water. REINFORCEMENT Cleaning Reinforcement shall be stored clear of ground when delivered to the site and immediately before placing the concrete it shall be i free from loose mill scale, loose rust, oil, paint, grease, dirt or other matter which may reduce its bond to the concrete. Fabrication 12.2.2 ‘The reinforcement shall be fabricated in accordance with the Technical Specification.12.2 12.3 Fabrication (Cont'd) 22.2.2 12.2.3 12.2.4 12.2.5 12.2.6 12.2.7 12.2.8 Placing 12.3.1 12.3.2 12.3.3 12.3.4 ahe Contractor shall be xesponsible for the detailed scheduling of reinforcement to suit actual dimensions on site. All reinforcement shall be bent cold and fabricated accurately in accordance with the details. Cold worked bars shall not be straightened and rebent. Generally reinforcenént shall be held together with soft iron tie wire. Units fabricated from Structural Grade Steel may be welded, provided the Contractor optains the Engineer's approval prior to fabrication of the particular unit. Strain hardened steel. including cold worked bars, drawn wires and mesh shall never be welded or heated by other means. Splices shall be formed where shown. where additional splices are required by the Contractor, he shall submit details of the proposed splices to the Engineer for approval. Splice details shall conform to AS1480., In forming a splice: - ‘The longitudal bars shall be offset one bar diameter. _ qghe slope of the inclined section of the bar shall not exceed 1:6 in relation to.the axis of the member. Laps in beams shall be made in the vertical plane. Shop fabricated units shall be clearly identified with strong tags wired on. Grades 25, 32 and 40 Concrete: Annealed soft ixon tie cive - not less than No 18 SWG or approved patent binders. Grey plastic tipped steel bar chains to owit reinforcement size and cover. Chaix Supports: Provide suitable supports to prevent penetration of waterproof membrane. spacers and Hangers; In addition to chairs, provide 2)? Epacers and hangers necessary to accurately position and support reinforcement. The use of wooden spacers shall have the same concrete cover as adjacent reinforcement. Reinforcement accurately placed and supported from formwork and firmly held together Maximum spacing for chairs, spacers and hangers, 100 ber @jameters, For mesh 1 metre centres each way oF as directed by the Engineer.12.4 12.5 Bb 23.2 13.2 14. 14.2 14.2 Cover to Reinforcement Conerete cover to main reinforcing steel is generally detailed in the Technical specification. Where cover is not detailed it shall be in accordance with the requirements of Section 4.10: of AS.7600- 1988 Approval. ‘The Contractor shall arrange with the Bngineer to inspect and give his approval of reinforcement in position, before concrete is placed. Refer section 3.5. SETTING IN When setting in any foundation bolts, bed plates or other specified inclusions, the Contractor shall provide and use substantial and accurate holding fixtures or jigs to ensure that true horizontal and vertical positioning, (as specified by any accompanying drawings or other Specification documents) is maintained during pouring and setting. ‘The Contractor may be reguired to make good any inaccurately positioned inclusion at no extra cost to the Purchaser. FORMWORK General 14,1,1 All formork shall satisfy the requirements of AS1SO9 - SAA Formwork Code and where special finishes are required, the relevant xequirements of ASISI0 Part 1 - Control of Concrete Surfaces ~ Formwork. 14.1.2 The Contractor's attention is drawn to the requirements of this document to produce the surface finish and colour uniformity of the concrete specified. Tenderers shall note that the requirements of these Codes will be enforced except where expressly over-ridden by this Specification. Construction and Materials 14.2.1 Grades 25, 32 and 40 Concrete: The selection of materials, the design*of formwork in accoxdance with AS1509 and its installation is the responsibility of the Contractor and shall incorporate the following:14.2 Construction and Materials (Cont 'a) 14.2.2 14.2.2 14.2.3 14.2.4 14.2.5 14.2.6 (cont 'a) (a) Tolerances shall be within the limits set down in Section 4 of asisoa. (>) Minimum structural requirenents will be deemed to be met when: (3) Forms axe sufficiently tight to prevent grout loss. (44) al1 joints against existing concrete surfaces are sealed with gaskets or tapes to prevent grout loss. (c) Deflection of unsupported areas of form facing shall not exceed the Limit sct down in Clause 3.13 of AS150¥ and the Contractor may be required to produce calculations to justify his proposals in this respect. The sides’ of beams in the ground shall be formed with formork complying with AS1509. The soffits shall he formed against “Fortecon" to prevent grout loss. Pans and ribbed or waffle floors shall be carefully installed true to line and fixed as required to the main formwork deck to prevent misalignment or deformation during concrete pouring. Asbestos cement pans shall Nor be usea, All formmork shall be carefully cleaned, checked and repaired before re-use. Damaged formwork shall not be xe-used. Damaged or bent props shall be removed from the site. The removal of forms generally shall be based on Table 4.2 of AS15039.