os (Pea 188) MEMORANDUM RASMI . Pengarah Kerja Raya, Sarawak . Northern Zone Manager DARIPADA : (pan Borneo Highway Unit) meas (up: Ir. Siaw Ming Chian) : SALINAN PERKARA : Sila lihat di bawah | KEPADA : RUJ. KAMI: ~=PWD/PBHU/QAQC/PT. 1(66) RUJ.TUAN: TARIKH =: = 11/06/2021 TARIKH : DEVELOPMENT AND UPGRADING OF THE PROPOSED PAN BORNEO HIGHWAY IN THE STATE OF SARAWAK MALAYSIA — PHASE 4 Works Package Contract No: PDP/PBHS/BJT/2016/WPC-10 Observations of Non-Compliance to the Requirements for Designed Mixes Concrete submitted by WPC10, With reference to the above-mentioned subject, please be informed that we have observed some non-compliance to the requirement for Designed Mixed Concrete for your reference and further action. Kindly please refer to the average 28 days test results in Nyabau Section (G60), in Bakun Section (G25) and in Niah Section (G25, G30 and G40), 2 Based on the enclosed Specification on the CLASSIFICATION OF CONCRETE MIXES (Ciause 9.3 of JKR/SPJ/1988) and COMPLIANCE WITH SPECIFIC REQUIREMENTS (Clause 9.4 of JKR/SPJ/1988), below are the compliance requirement for each Designed Mixed Concrete: Compliance for 28 days CONCRETE GRADE rength 20 625 G30_ | G40 | G50 | 655 Minimum average test result (from any group of four consecutive samples) (faa + 0.5 current margin) (N/mm?) Minimum individual sample test result (85% fay (N/mm2) 26.00 | 31.00 | 36.00 | 46.00 | 56.00 | 61.00 17.00 | 2125 | 25.50 | 34.00 | 42.50 | 46.75 3. Greatly appreciated on your attention to this matter. Thank you. “ BERSATU BERUSAHA BERBAKTI" "AN HONOUR TO SERVE ' (Sudin Bin Jaya) b.p. Pengarah Kerja Raya, Sarawak Note:- Pegawai untuk dihubungi Ir. Ts. Tan Seong Lim, 019-3832413Our Ref: PWD/PBHU/QAQCIPT. 1(66) Internal Di 1. HOP PBHU 2, SEE (Siti) 3. SEE (Liew) 4, SCE (Tan)Our Ref: PWD/PBHU/QAQC/PT.1(66) JKRISPJ/A988 1. Clause 9.3: CLASSIFICATION OF CONCRETE MIXES 2. Clause 9.4: COMPLIANCE WITH SPECIFIED REQUIREMENTS:+ U&GUUL 285 om 93 932 93.21 (KR /SP1/3988) CLASSIFICATION OF CONCRETE MIXES ‘The concrete mixes shall be classified as :- @) Prescribed Mix ‘The Contractor shall provide concrete that contains constituents.in the specified proportions. () Designed Stix ‘The Contractor shall select the mix proportions and unless otherwise specitied, the workability, in order ta satisfy the strength and ather requirements of the Contract Requirements for Prescribed Mixes Unless otherwise specified, the concrete mix shall be as detailed in Table 9.5, ‘which shows the weights of coment and (otal dry agaregates, in kilograms, to produce approximately one cubic metre of fully compacted concrete, together with the percentages by weight of fine aggregates. total dry aggregates. Requirements for Designed Mixes Targcl Mean Strengs ‘The concrete mis shall be designed to have at least the required minimum cement content and (9 have a target mean strength greater than the required characteristic strength by at least the current margin, ‘The current margin for cach particular type of concrete shall be determined by the Contractor and shall be taken as the lesser of = {) 1.64 times the standard deviation of cube tests on a least 300 separate batches of concrete of naminally similar proportion of similar materials and produced aver a period not exceeding 12 months by the same plant under similar supervision, but not less than 2.5 N/sq.mm for concrete of grade 15 or 3.75 N/squmm for eonercte of grade 20 or above; i) 166 times the standard deviation of cube tests on at least 40 separate boatches of concrete of nominally similar proportions of similar matetiak and produced over a period exceeding 5 days but not exceeding 6 months by the same plant under similar supervision, but not less than 5 N/sqamm for concrete of grade 15 oF 75 N/sq.mm for concrete of grade 20 or above, Where there are insufficient data to satisfy (i) oF (ii) above, the margin for the initial mix design shal be taken as 7.5 N/sq.mma for concrete of grade 15 and 121N/sq.mm for conerete of grade 20 or above. This margin shall be used as the current margin only uncil sufficient dat able to satisty (i) oF (i) above. However, subject to the approval of the S.0., when the specified characteristic strength approaches the maximum possible strength of concrete made with a particular aggregate, a smaller raargin not less than 51N/sq.mm for concrete of grade 15 ot 7.5 N/sq.mm for concrete of grade 20 oF above may be used for the initial mix design 59.7(OKR/SP5/1988) ‘TABLE 9.5 - PRESCRIBED MIXES FOR GENERAL USE PER CUBIC METRE OF CONCRETE, Nominal Max. ” » Bitsy Ske of Grade | Charact- Aggregate of | critic (sim) Concrete} Strength of Concrete (/eqmm) _ Sturop Lists (mmm) Cement (kg) 70 280 0 SP 15 | Total aggregate (kg) 1850 | 1800 1800 1750 Fine aggregate (%) | 30 - 45 | 30 - 45 | 35 -50 | 35-50 ‘Cement (ke) 300 320 320 390 OP 20 | Total aggregate (kg)| 1850 1750 1800 1750 Fine aggregate (%) | 25 -35 | 25 - 40 | 25 - 40 | 20 - 45 + Cement (kg) 0 360 360 390 2P 25 | Total aggregate (kg)| 1800 1750 3750 179 Fine aggregate (%) | 25 - 35 | 25 - 40 | 25 = 40 | 30-45 Fine aggrogale is expressed as a percentage by weight (o the total dry aggregates. The lower value shall be used for finer gradingG2200T 042 9322 93.23 9324 (KR /SPI/1988) ‘The Contractor shall submit for the approval of the S. of any designed mix, the following = » prior to the supply i) the nature and source of each material; ii) appropriate existing data es evidence of satisfactory previous performance for target mean strength, current margin, workability and water/cement ratio; OR full details of tests on rial mixes carried out in accordance with Sub- Section 93.23; the proposed quantities of each material per cubic metre of fully compacted concrete, Trial Mixes ‘The Contractor shal give notice to enable the S.O. to be preseat at the making of trial mixes and preliminary testing of the cubes. The Contractor shall prepare trial mixes, using samples of approved material typical of those he proposes to use in the Works, for all grades to the satisfaction of the S.0. prior to commencement of concreting. ‘Sampling and testing procedures shall be in accordance with M.S. 26, Three separsie batches of conerete shall be made, The workability of cach of the three trial batches determined by means of the stump tesl, compacting factor test of vebe consistometer test in accordance with M.S. 26, shall be appropriate 1o the proposed uses and methods of placing an compaction of the mix and shall be approved by the S.0. Six cubes shall be made from eack batch, Thrce from each set of six shall be tested at an age of 7 days and three atan age of 28 days. The average strength of the nine cubes tested at 28 days shall exceed the specified characteristic strength by the current margia minus 3.51N/sq.inmo. The approved trial mix shall then be designated as the “designed mis and its corresponding workability as he "designed workability During production, the §.0. may require additional trial mixes to be made before a substantial change is made in the matcrials or in the proportion ofthe materials (0 be used. ‘Trial mixes nced not be carried out when adjustments are made to the mix proportions in accordance with Sub-Section 93.24, Conirol of Strength of Designed Mixes (@) Adjustment fo Mix Proportions ‘Adjustment to mix proportions shall be made subject to the approval of the S.0. in order to minimise the variability of streagth and to maintain the target mean strength. The specified limits of miaimum cement content and ‘maximum water /cement ratio shall be maintained. Changes in cement have to bbe declared, Such adjustment shall not be taken to imply any change in the current margin. (©) Change of Curent Margin ‘A change in the current margin used for judging compliance with specified characteristic strengths becomes appropriate when vs 2 sufficiently S $9.9O0T 7 ILE 9 (TKR /SPS/1988) large number of tests show that the previously established maraia is significantly too large or too smal Recalculation ofthe margin shall be carried out in accordance with Sub-Section 93.2.1. Although a recaleulated margin is almost certain to differ numerically from the previous value, the edoption of the recalculated value will not sgencrally be justified ifthe two values differ by less than 18% when based on tests om 2 separate batches or less than 11% when based oa tests on 100 separate batches, or less than 5% when based on (ests on S00 separate batches. On the adoption of a recalculated margio it shall become the curreat margin for the judgemest of compliance with the specified characteristic strength of concrete produced subseauent to the change. 933 Reguirements for Concrsi¢ 9331 Workability ‘The workability ofthe fresh concrete shall be such that the conerete is suitable for the conditions of handling and placiog so that afier compaction, it surrounds ail reinforcement, tendons and ducts and completely fills the formwork. Workability of the concrete shall be within one of the following lr i) Slump 4 25 man or + one-third of the “designed workability’, whichever ie The greater, Compacting Facto: £003 where the “designed workability is 0.9 of more. 4 0.04 where the “designed worksbility’ is between 08 and 09, £0.05 where the “designed workability’ is 0.8 or Jess. iit) Mabe 3 seconds or + one-fifth of the “designed workability", whichever is less. 9332 Goncrsis Grade ‘The grade of concrcis to be used in the Works shall be zs stated on the Drawings and i the Bill of Quantities. (Concrete grade shall be designated as GRADE X/Y where ‘X" is the ‘umerical valuc of the characteristic strength in N/sq.mm as determined from test cubes at 28 days, and “Y" is the oominal size of aggregate in tim, For a prescribed mix, x suffix 'P shall be added after ‘X). S910L£GUUL 15 (JKR/SP3/1988) 9333 Minimum Cement Content ‘The minimum cement content hall be in accordance with Table 9.6 unless otherwise shown on the Drawings. 9334 ‘Maximum Cement Contsat ‘The maximum cement content shall not excced 550 kg/cu.m unless otherwise deserved in the Contract of agreed by the S.0. ‘TABLE 9. - MINIMUM CEMENT CONTENT AND MAXIMUM FREE WATER/CEMENT RATIO FOR DESIGNED MIX Prestressed | Reinforced | Plain Conereie | Concrete | Concrete Exposure Max: Free Water/ Cemest aggregate | Ratio Ga mm) “2 Surfaces sheltered from (kg/m) | (ke/eum) | e/ovn) 4) surface protected by 's water-proof membrane; 2) internal surfaces, Whether or not subject so -320 | 0-300 | 250 28 | OS to condensation; 3) surfaces continu Ruel nd/or subnet under water. ng sm 30 | 30 030 | mo xm | oO wetting and drying eg. in contact with backfill, 1) surfaces exposed to the action of sea water 350-3 | 350 © 380 | 32 380 | 04S with abrasion having & pH of 45 o less. 9-11a0 9335 9336 (QKR/SPI/1988) 1 jie. ‘The total chloride content of the concrete mix arising from the aggregate or any other source shall not io any circumstances exceed the limits in Table 9.7 ese s a pecelagereatlonship betwen corde ons and weight of cement in the mix ‘Vests shall be carried out in accordance with BS. 1881 for each grade of concrete, to demonstrate that these limits are not exceeded. ‘TABLE 9.7 - MAXIMUM TOTAL CHLORIDE ‘Type of Concrete Maximum Total Chl (%) Reinforced Concrete rade with cement complying with MS, $22. 035 for 95% of test results with no result Plain Concrete greater than 0.50. ‘containing embedded metal and made with cement complying with MS. 522, Concrete made with ‘cement complying with B.S. 4027. 02 Prestressed Concrete and Structural Conerete. that is steam cured, ot Notes on Table 9.7 (0) % Chloride iocs x 1.648 = % equivalent sodium chloride, @) % Chloride ions x 1.55 = % equivalent anhydrous calcium chloride. Maximum Sulphats Contens ‘The total estimated sulphate content of any mix, including that preseat in the Cement shall not exceed 40% by weight of cement inthe ma. ‘Tess shal be carried out in accordance with BS. 1881, for each grade of conercic to demonstrate that these limits are nox exoeoded. 9-1260T tw 6 a O48 9AL 942 9421 9.422 (KR /SP 5/1988) COMPLIANCE WITH SPECIFIED REQUIREMENTS Breseribed Mix A prescribed mix shall be judged oa the basis of the specified | mix proportions. The workability. shall be chosen 10 suit the construction requirements, Notwithstanding ths, strength fess shall be carried out during tbe progsest of ‘work. The rale of sampling shall be as per Rate 2. for ordinary structural Concrete as in Table 88. For each sampling, three test cubes sball be made, ‘One test cybe from each sample-batch shal be tested for the 7-day compressive strength.” Ifthe cube strength falls below 75% of the 28-day compressive Strength, then the 8.0, may direc the Contractor to take necessary steps 10 review the process of the production of concrete for future use. ‘The remaining two test cubes from the sample-batch shall be tested for the ‘ieday compressive strength. The appropriate strength requirement shall be considered to be satisfied if at least one of the following is complied with 1) aoe ofthe two test cubes below the specified com pressive strengths fi) the average strength of the two test cubes is not less than the specified compressive strength and the difference between the two strengths is not more than 20% of the average sirengtb. In the event that the results ofthe test do not mect the specified requirements, the SO, shall determine the action to be taken in respect of the concrete member represented by the sample-batch test cubes. Such action may include ‘Semolition of the member. The Contractor shall, if requited by the S.O. take cored samples from the hardened concrete member and carry out the ‘compressive strengtl test. Designed Mix Characteristic Strength ‘The characteristic strength of concrete is that 28-day cube strength, below which not more than 5% of the test results may be expected to fall, Compliance with the specified characteristic strength shall be judged by lests made on cubes at an age of 28 days. Sampling and Testing ‘All sampling and testing of consinvent materials shall be carried out. in fecordance ‘with the provisions of the appropriate available Malaysian Standards. In particular, sampling and testing of fresh and of hardesed ‘concrete shall be cartied out in accordance with the provisions of M.S. 26. ‘The rate of sampling sball be as given in Table 9.8, but not less than one sample shall be taken from cach source of production on each day that ‘concrete of any particular grade is used.292, be ww 3 9423 (UKR/SPI/1983) ‘TABLE 9.8 - MINIMUM RATE OF SAMPLING Rate Volume of concrete from which 1 sample shall be taken Rate 1 Every 10 cum (Prestressed Concrete) ot every group of 10 batches * 1 Rate 2 Every 200 cum (Ordinary Structural or every group of 20 batches * Concrete) Rate 3 Every 50 cum (Mass Concrete) or every group of 50 batches * * ‘The sample shall be taken from one single batch randomly selected from the group of batches. Testing ‘Three test cubes shall be made from a single sample taken from a randomly selected batch of concrete, The samples shall be taken at the point of discharge {com the mixer or, in the case of ready-mixed concrete, at the poi of discharge from the delivery vehicle. ‘One test cube from each sample shall be tested for'the 7-day compressive strength. If the cube strength falls below the 7-day strength as defermined {rom the irial mixes, then the Contractor shall take the necessary steps to review the process ofthe production of coverete and make certain adjustments where applicable, ‘The remaining two test cubes from the same sample shall be tested for the 2-day compressive strength. The average strength of the two cubes shall constitute the 28-day compressive strength of the sample. For compliance purposes := i) the average 2-day strength determined from any group of four consecutive samples shall ‘The CEREONIMTARESR shall be taken 2s_7.5.N/ea.mm_for concrete of grade 15 or in accordance with SubSection 932.1 or 93.24 (b), a smaller ‘margin bas been established to the satisfaction of the $.0. In this respect, consecutive sarmples arc samples taken at intervals pot exceeding 14days. In all cases, at least four samples shall be taken of concrete on the First day of concreting for each grade of coneroteS00T é 293 943 (KR /SPI/1988) to be used in the Works, irrespective of the volume of concrete produced or the sampling rate. i) Each in on ge a ch a 1eany one sample test result fails to meet the second requirement (ji), then that result may be considered to represent oaly the particular batch of concrete from which the sample test cubes were taken. Wf the average strength of any group of four consecutive sample test results fails to meet the first requirement (i), or more than one sample test result in a proup fails to meet the second requirement (ji), then all the concrete io all the batches represented by all such sample test results shall be deesied not to comply with the strength requirements. For the purpose of this Sub-Section, batches of concrete represented by groupe: of four consecutive sample test results shall include the batches from which Samaples were taken to obtain the first end the last sample results in the group of four, together with all the intervening batches. os ‘Additional cubes may be reugired for various purposes. These shall be mad: ‘and tested in accordance with M.S. 26 but the methods of sampling and the ‘Conditions under which the cubes are stored shall be varied according to the purpose for which they are required. For determining the cube strength of prestressed concrete before transer or of couerete in a member before sitiking formwork, sampling shall be at the joint of placing and the cubes shall be stored as far as possible under the same Conditions as the concrete in Uke members. ‘The extra cubes shall be indentified at the time of making and shall not be used for the normal quality control or compliance procedures.Our Ref: PWD/PBHU/QAQC/PT.1(66) PART OF CONCRETE CUBES TESTING SUMMARY FOR NYABAU SECTION Average 28 days strength (Nimm?) Individual sample test result (N/mm?) Conerete tem Grade |“ Lowest Lowest result | Requirement | Compliance | result | Requirement | Compliance observed observed [4 30N 36.29 36.00 Yes 34.65 25.50 Yes 2 | 40N | 48.31 46.00 Yes 47.73 34.00 Yes 3 | 50N | 54.94 56.00 No 53.69 42.50 Yesfonrt:2p soos ‘auerunmcrmwevanewsise ones ousting aon 96-Nouanncanavaner wast oautstomea om _eneronne nuns non onnOR NY DION MLD SMONDNNCN HORNER (eek)swe ‘soe A ‘ ese 805 eo re 68 008 ‘wear seunwi gt hain coe | te0e yea et ‘srssaan/9] ‘sve ‘swe A * tree oe wos Pe we wise ese ‘reat oven at coat | tror yosew tr resiaaw/o] soa ue A ‘ seer ve ise Per a ware Toe ‘reo Wau AT sor | reo yao | | ease nna nen va sve A ‘ wer = ors Pe we ose vst or oe ‘Tatts td TES eB UO a _tessaorio} = | =~ [a]. |e wo, = ax | ee ernst | ns RET [we | roms | oe ‘sova ‘save a a over me wer fpcer ‘or ae oe ‘Teo sauevi eT rem zodeaeg sang ser ‘Tron ase 9 orsisar/9} sve A * = woos froos we ne one “reoe seven 21 ae. so Trot ews ‘e5/400/ — | Si/td 165 'S6/Ta OBS som ase wean rave sionl9} ‘seve ‘sve a . wer =r wor foser we see eee ‘reoe ue TT ser ‘or arene ces/eav/o] seve ‘sve A a wen = eros, * we wre 898 08 He TT so ‘or eens ‘sessaan/o] ‘sswa ‘sows A - eran ome wos RF ce e69e ee “Teor ue TT em sadereg ty ‘002 ‘rear aun ‘sesssar/o] = [om le) [ewe | = | oe P| monn | we we ornate oases er mameons| | _Reemne | velo ‘sve ‘swe a . wer we se Teor wove 6 west west Teor que ‘on/d VES “986/26 085 eIe9 UNON | OB eae waren t ‘eessaonio] sus save A a eer re we ‘Wor ypu ex seve sere reo pu ost ‘ror eT ‘ressdar/o] oe | we [apo we ae [come | we | we Tee? oo | wocamsce | veer = [om [eps [0 | ee |e [ow | weve [ow | oe ve sc | sow soe a ‘ 966" a wos | PO wear woven sz out roe wen cet | tro Aenages ce ‘szsjaors9} sow sve a A ore = sce el eae Waren wese 33 Ror PRE cer | rr0z Areuges pe exsjaort9] ova sue ’ A 96" oe we ‘Teor puen zz ror EW er | ree Aeragey te | a Tar SRT Those 2 fgorora amen lam a tec jem moses fen ae ry vewons lee, we | eon | stew | gang sry aa — aa STE foot pe vss omnes ous NN mH wes PHL 9 NOM FEN BRON _ayens OMS 3809 L380N09 fe a rae seenea os erm oe oe we ma venwe [ew | ee | ee = ca Taree [ww [eon] ee mm | meme | waa Tomas [ew [ese Temes] etieinerrne Loe [rem | vem Tree [ee | aw] Tawra] arte momen |e | emreanse | em Tamara [wa fea | manemne aevew [em | reonet [anima] es ce ce won [we [ron | | weer Pea [we | enone | ewtamnteeasona [ew | reromne | val ‘reo may ot an com Troe waa 9 ‘asT/ea yea aad 28d ser ‘rroz auew st ~~ pssvaor9| reese Pow [aw | ewemnn | earanemmenen Per | reremnar | a tan [ee | ee = veanemmns ew | rare | vel Se a cd cc tearm [ea [aw [ aren | eatammunnteona [an] nreanat | ero a cee | reramor | areerarenaovamun [ow [ ecoenae | asawe ve sve wos oe PF erse ese ‘reoe yam oF yom eae ay sot] reo ew er ‘svs/eov/5] — po ap a TE et wwnwe [ome meen row roomn [ams] tana [oven omis a = a — ous nat owen oRaes —" ONL 96-NOUDNNY NRE NH BARN a aoe wom, =)iru ys © 289 onp pesihed yfbays sbop ve tears ot a arama st sewn PSE] eae aaa a t ‘st on er ea ‘Sel — we — [9 1 a es ener + eer) were oon sore awh gnonsemamn| wanna eerste svonrrener aens] — tneoama Sa ‘= = TATE "swi- rvs 402053. 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