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1.0 SCOPE

This specification covers quality and workmanship requirements for the construction of concrete works as shown on the
drawings.

2.0 GOVERNING STANDARDS

The work shall be constructed in accordance with the current issue, including all parts and amendments, of the standards listed
below:

AS 1012 Methods of testing concrete

AS 1141 Methods for sampling and testing aggregates

AS 1289 Methods of testing soils for engineering purposes

AS 1379 The specification and supply of concrete

AS 1478 Chemical admixtures for concrete, mortar and grout

AS 2758.1 Aggregates and rock for engineering purposes – Concrete aggregates

AS 3600 Concrete structures

AS 3610 Formwork for concrete

AS 3972 Portland and blended cements

ASTM C156-03 Standard test method for water retention by concrete curing materials

The Engineer will consider the adoption of alternative standards, where appropriate, upon review and approval.

3.0 SETTING OUT

All setting out shall be carried out from permanent markers provided by the Engineer at the job site.

The installation shall however not proceed until the setting out has been surveyed by the Contractor and checked and verified by
the Engineer, which shall not relieve the Contractor of his responsibility for the work.

4.0 MATERIALS

4.1 Cement

All cement shall comply with the requirements of AS 3972 unless otherwise approved in writing. Type GP cement shall be used
unless sulphate resistant cement is nominated, in which case Type SR cement shall be used.

Test certificates shall be provided, if requested by the Engineer, to confirm that the cement supplied to the batching plant
conforms in all respects with AS 3972.

4.2 Aggregate

All aggregate shall comply with the requirements of AS 2758.1.

4.3 Water

All water shall comply with the requirements of AS 1379.

4.4 Reinforcement

All reinforcement, whether reinforcing bars or wire fabric, shall comply with the requirements of Civil Specification CS03.

4.5 Anchor Bolts

All anchor bolts shall comply with the requirements of Civil Specification CS04.

4.6 Joint Sealants

All joints to receive sealant shall be wire brushed and blown clean to remove surface laitance and all loose matter. An approved [1]
primer shall then be applied to the joint, followed after the recommended elapsed time, by the approved sealant which is to be
applied strictly in accordance with the manufacturer's recommendations.

The joint backing rods and joint filler shall be preformed and of closed cell expanded polyethylene.

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The following joint sealants, or approved equivalents, shall be used: [1]

• Emer Seal PU40 - General concrete.

• Emer Seal CR - Concrete in acid or chemical environments.

• Thioflex 600 - Concrete exposed to hydrocarbons.

4.7 Water Stops

Where shown on the drawings, PVC water stops shall be Fosroc Supercast or approved equivalent. All wall to floor water stop
connections shall be made using Supercast intersections and welded using Fosroc PVC heat welding equipment. Installation
shall be carried out strictly in accordance with the manufacturer’s recommendations.

4.8 Waterproof Membranes

Waterproof membranes for use below ground slabs and for concrete curing shall be pigmented polythene sheeting of minimum [1]
thickness 0.20 mm.

4.9 Curing Compounds

Curing compounds shall be of the chlorinated rubber type and shall be such that moisture loss over 72 hours at 32 % relative
2
humidity and 38 ºC should not exceed 0.055 g/cm when tested in accordance with ASTM C156.

5.0 CONCRETE MIXES AND CLASSES

5.1 General

All concrete mixes shall be designed to meet the requirements of this specification.

Mix designs, to produce a dense and durable concrete of the required strength, shall aim to produce a workable mix having a
minimum water / cement ratio and a maximum aggregate / cement ratio consistent with:

• proper transport

• placement and compaction of the concrete without segregation.

The technical requirements for commonly used concrete classes are listed in Table 1.

Table 1 Concrete Classes and Their Typical Characteristics

Maximum Slump
Character Nominal Minimum
at Point of Maximum
Compress Maximum Cement
Class Discharge from Fines
Strength Aggregate Content
Truck Ratio
F'c at 28 Days Size, mm kg/m3
mm
15/20 15 20 120 - -
25/20 25 20 80 300 0.4
32/20 32 20 80 350 0.4
40/20 40 20 80 360 0.4
15/40 15 40 120 - -
25/40 25 40 80 275 0.35
32/40 32 40 80 320 0.35

The areas in which the classes shall be used are:

• Class 15/20 - shall only be used as blinding concrete.

• Class 25/20 - shall be used generally for normally reinforced concrete work unless otherwise stated.

• Class 32/20 - shall be used generally for locations requiring a special protection to reinforcement as noted on the
drawings.

• Class 40/20 - shall only be used where indicated on the drawings or as directed by the Engineer.

• Class X/40 - shall only be used where indicated on the drawings or as directed by the Engineer.

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For concrete in process plant areas and in situations where durability of concrete is identified as a prime [1]
consideration, the maximum water / cement ratio shall not exceed 0.45. In general, for durability and curing
requirements, the water / cement ratio in all other applications shall not exceed 0.50 for concrete strength F'c = 25 MPa
and higher.

Details of the concrete mixes proposed for each particular class of concrete shall be submitted for approval at least 2 weeks in
advance of placing any concrete or as otherwise agreed. Approval in writing shall be obtained prior to commencement of the
production of concrete.

For any particular class of concrete the properties of the materials used or their relative proportions shall not be varied from
those of the approved mix unless authorised in writing.

If at any time during the contract the mix is found to be unsatisfactory or it becomes necessary to use materials differing from
those originally approved, then the revised mix designs and results of trial mixes shall be submitted for approval prior to varying
the mix.

5.2 Workability

The workability of all concrete shall be checked via the slump test.

No concrete shall be accepted which has a slump which varies from that specified by more than ±20 mm, unless otherwise
approved.

The mix shall be designed for the specified slump. Any loss of slump due to temperature or time shall be compensated for by
use of admixture added at the time of batching.

6.0 FORMWORK

6.1 General

All concrete shall be placed in formwork except on the underside of slabs, foundations, ground beams and the like which are
placed directly on the ground, and where suitable precautions have been taken to ensure no loss of moisture to the ground.

6.2 Construction

Design and construction of formwork shall be in accordance with the requirements of AS 3610.

Calculation and/or drawings may be called for to prove compliance with AS 3610.

All formwork shall be mortar tight and shall produce the concrete surfaces as specified which shall also be generally free from
fins, offsets, local bellying and other noticeable deviations from the designed shape, line or level.

Formwork tolerances shall be in accordance with AS 3610.

6.3 Formwork Accessories

Formwork accessories which are to be partially or wholly embedded in the concrete, such as ties or hangers, shall be of an
approved commercially manufactured type. Wire is not acceptable.

The portion remaining within the concrete shall leave no metal within 40 mm of the surface of the concrete.

Spreader cones on formwork ties shall not exceed 25 mm in diameter. Accessories which pass through the surface to the
concrete shall be fixed in accordance with the requirements of AS 3610.

Cone holes shall be plugged with precast plugs set in epoxy mortar with 3 mm set back.

6.4 Cleaning of Formwork

Immediately prior to placing concrete in any section of the formwork the interior of that section shall be completely drained of
any water and cleared of all extraneous material.

6.5 Treatment of Formwork

The internal faces of the formwork shall be coated with an approved form fluid to prevent adhesion of the concrete to the forms.
The form fluid shall be applied before the reinforcement is fixed. Reinforcement shall be kept free of oil.

6.6 Access and Inspection Openings

Temporary openings shall be provided at the base of wall forms and at other points where necessary to facilitate cleaning and
inspection immediately before the placing of concrete.

6.7 Stripping of Formwork

The minimum stripping times for formwork shall be as listed in Table 2.

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Table 2 Minimum Formwork Stripping Times

Average Air Walls and Walls and

Temperature Pedestals Pedestals Suspended Slabs Beams
Since Casting unloaded loaded
> 20°C 2 days 5 days 7 days 10 days
10ºC to 20°C 3 days 6 days 10 days 14 days
5°C to 10°C 5 days 7 days 14 days 28 days
< 5ºC 7 days 9 days 21 days 28 days

Beams spanning greater than 5 m shall remain propped until the 28 day concrete strength has been attained.

Notwithstanding the specified minimum stripping times, all formwork shall remain in position until the strength of the concrete is
such that form removal will not result in perceptible cracking, spalling or breaking of edges or surfaces, or other damage to the
concrete.

If non-permanent construction loads are to be imposed on suspended slabs, temporary supports shall be installed under the
slabs after the removal of the formwork and left in position until the concrete has developed the specified 28 day strength.

6.8 Finishes and Colours

Concrete surfaces shall comply with the requirements of AS 3610 and shall have the surface finish and colour uniformity as
listed in Table 3.

Surface Finishes and Colours

Location Surface Finish Class Colour Uniformity Type

Footings 4 C
Rear Face of Retaining Walls or Tunnels 4 C
Exposed Face of Retaining Walls or Tunnels 3 B
Pedestals 3 B
Edges of Slabs (on ground or suspended) 2 B
Soffits of Slabs or Beams 3 B
Columns 2 B

Free surfaces of slabs and kerbs shall be steel trowelled with a non-slip (broom) finish unless noted otherwise on the drawings.

6.9 Tolerances

Tolerances for concrete work shall be as listed in Table 4.

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Table 4 Tolerances for Concrete Work

Tolerances for Concrete Work

Tolerances for Formwork Class, mm
Variation Component Measured Distance
2 and 3 4 5*
Variation of plan dimensions Whole or part of structure except In any bay or 6 m max. + 12 + 15 + 15
footings In 12 m or more + 20 + 25 + 25
Variation from plumb and from Lines and surface of columns, 5 in 3,000/max 25 5 in 1,000/max 35
dimensions of upper storeys piers, walls and arises
Exposed corner columns control In any bay or 6 m max. +5 +10 -12
joint grooves and other visible In 12 m or more +12 +15 -20
lines
Variation from surface levels and Any concrete member +3 6 in 3,000 max
grades indicated on drawings
Slab soffits, ceilings In 3 m. +5 +5
Beam soffits, arises In any bay or 6 m max. +10 +20
In 12 m or more +20 +30
Exposed lintels, sills, parapets, In any bay or 6 m max. +5 +15
horizontal grooves and other In 12 m or more +12 +25
visible lines
Variation in cross sectional Columns, beams, thickness of +12 -0 +15 -0 +25 -0
dimensions slabs, walls, footings
Variation in size in plan Footings +50 -12
Misplacement or eccentricity Footings 2% of footing width/50 max
Variation in size Floor and wall openings +20 -0 +25 -0 +25 -0
Variation in location Floor and wall openings +25
Rise of any 1 step from average +3 +3
rise of whole flight
Variation in steps specified having Rise in any 2 consecutive steps +3 +3
monolithic finish Tread in direction travel +5 +5
Tread in any 2 consecutive steps +5 +5
Variation in steps specified having Rise of any one step tread +3 -5 +3 -5
topping applied +3 -5 +3 -5

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Tolerances for Concrete Work

Variation
Variation in concrete cover
Variation in location
(Not controlled by cover)
Variation in lateral location
(in the plane of reinforcing)
Deviation in position of embedded
items
Tolerances for Formwork Class, mm
Component Measured Distance
2 and 3 4 5*
Any reinforcement (including Measured in direction of Cover < 50, +5 -0
fitments) except at end of bar thickness or depth Cover >50, +10 -0
End of bar or edge of bent bar Measured in direction of bar +15 -0
length
End of bar or edge of bent bar Measured in direction of bar ±50
length
Any one bar or any one fitment Measured in direction of +25% of specified spacing
specified spacing
Any items embedded in concrete Measured from specified +3
including anchor bolts location

Notes:

i) This specification shall be read in conjunction with AS 3600 to determine full requirements for tolerances. In cases of conflict, this specification shall take precedence.

ii) Tabulated tolerances apply both to tolerances on individual member and to cumulative tolerances.

iii) ‘Measured Distance’ is the distance over which the specified tolerance is measured and shall be the full length, width, depth or height unless otherwise noted.

iv) Variations in level of suspended floors shall be measured before the removal of supporting shores.

v) Tolerances for Class 5 formwork shall also apply to concrete deposited in contact with the ground, including floor slabs with membrane under.

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7.0 FIXING OF REINFORCEMENT

All reinforcement shall be securely fixed in position by means of approved stirrups, stools, chairs, distribution bars, approved
concrete or plastic blocks or similar, to prevent displacement during the placement and compaction of concrete.

Where wire mesh is used, chairs shall be provided at a minimum of 600 mm centres in each direction.

The following conditions shall apply to the approval of the type of spacer the Contractor proposes to use:

• Supports and spacers made entirely from plastic shall be used in all pedestals and walls.

• Where steel supports are approved, they shall be plastic tipped.

• Concrete block supports shall not be used as supports in suspended slabs or beams.

All reinforcement shall be securely tied at laps, at alternate intersections in slab reinforcement and all intersections in the case
of ligatures and stirrups, with 1.2 mm diameter annealed soft steel wire.

All reinforcement shall be placed in its intended position within the following tolerances:

• Vertical misalignment

- cover < 24 mm, -0 +5 mm

- cover > 24 mm, -0 +3 mm

• Lateral misalignment, ±12 mm

All exposed reinforcement ends shall be fitted with fabricated end caps until such time that they constitute part of the current
pour.

8.0 PLACING OF CONCRETE

8.1 General

Concrete shall not be placed in any section of the work until all preparations for that section have been inspected and approved.
The Contractor shall give the Engineer two working days notice in writing for inspection and approval.

Concrete placement shall not commence until all necessary equipment and manpower required for placement, compaction and
finishing are at the location of the pour and in good condition.

All walkways and barrow runs shall be supported from the blinding concrete or shuttering to a point clear of the reinforcement
and service ducts. All placement operations shall be carried out without imposing any load on the reinforcement or any other
embedded item which might cause its distortion or dislocation.

During placement, a competent steel fixer and carpenter shall be in attendance to adjust and correct the reinforcement and
formwork respectively, if necessary.

The supply of concrete at the point of placement shall be as continuous as practicable with the available equipment. Care shall
be taken to ensure that no segregation of materials occurs.

8.2 Pouring

Care shall be taken to ensure that concrete already poured is not damaged or otherwise disturbed by operations in adjacent
areas. The concrete shall be placed in a planned manner continuously between construction joints, generally progressing in
one direction and where the bay is inclined, in the rising direction, unless otherwise approved by the Engineer or as shown on
the drawings.

Concrete shall be deposited directly in its final position and not made to flow in a manner which promotes segregation.
Concrete shall not be deposited from a height greater than two metres unless suitable chutes and baffles or other devices are
provided to confine and control the falling concrete to prevent segregation.

Concrete shall be placed in its final location within 60 minutes of the water being added to the mix. Concrete shall be
transported in water tight containers which shall be cleaned at the end of each day's work and whenever the containers are
empty for more than 40 minutes. All concrete shall be placed in its final position and compacted within 15 minutes of
discharging from the transporter. The Engineer shall have the final say on any concrete not placed within these times.

During each concrete pour, the work shall be adequately supervised to ensure that all reinforcement and other embedded
fixtures are accurately and adequately maintained in position.

Concrete shall not be placed in layers exceeding 500 mm thickness in one operation without prior approval.

The finished work shall be a dense and uniform mass free from voids, segregation and honeycombing and shall show a uniform
face as specified when the forms are removed.

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The compaction of concrete shall be carried out by means of internal vibrators or vibrating screeds or a combination of these as
approved.

Before the commencement of each concrete pour a sufficient number of tested vibrators and spares shall be available.

8.3 Hot or Cold Weather Concreting

When air temperatures of 35°C or higher are forecast, the Contractor shall not place concrete unless prior approval is obtained.
Such approval will normally only be considered if suitable steps to shade the aggregate and cooling water are proposed.

The Contractor shall submit, for the Engineer's approval, details of proposed arrangements for the placing of all concrete where
the temperature of the air surrounding concrete pours is in excess of 35°C or below 5°C.

The temperature of the concrete at the time of delivery at the point of placement shall be kept within the range of 20° ±10°C,
unless otherwise approved by the Engineer.

Concrete temperatures shall be recorded at the time of placing, as directed by the Engineer.

For placement of concrete in ambient temperatures below 5°C, adequate protection of the concrete after placement shall be
provided by covering with insulation.

For placement of concrete in ambient temperatures above 35°C, the Contractor shall ensure that the holding time in the transit
mixer is kept to a minimum.

Delivery of concrete from distant batch plants shall be done on an advisory basis. Any ready mixed concrete not placed within
60 minutes of adding water may be rejected by the Engineer. Concrete delivery shall be constant during a scheduled pour.
Any interruptions to the delivery shall result in rejection by the Engineer of any part of the concrete and its removal carried out at
the Contractor's expense.

9.0 CURING OF CONCRETE

9.1 General

All structural concrete shall be cured in accordance with the requirements of AS 3600.

All curing procedures shall be continued for a minimum of 10 days from the time of casting.

Provided no additional concrete or finishes have to be applied to the cured surface, curing shall be achieved by spraying all
surfaces with curing compound directly after screeding.

Only coloured curing compounds approved by the Engineer may be used. Slabs must be covered with a membrane after
finishing.

Where additional concrete or non-compatible finish is required to be applied to the cured surface, either water curing shall be
used or surfaces shall be wrapped with an impervious plastic membrane. However, in the latter case, the membrane must be
completely sealed, on all sides, by plastic welding or clamping along the edges.

9.2 Hot Weather

When the ambient temperatures exceeds 35°C, the Contractor shall carry out curing around initial set by fog sprays and
commence water curing for 14 days, as soon as is practicable. No curing compound shall be used in hot weather placement.
Vertical surfaces shall be protected by impermeable shutters and shaded from the direct heat of the sun.

Incipient plastic shrinkage cracks shall be removed by revibrating or reworking of the surface up to the time of initial set.

9.3 Specific Requirements

9.3.1 Formed Surfaces

After placing of concrete, forms shall be tightened and protected from direct sunlight by the provision of suitable shading.

Formwork may remain in place for the full curing period of 10 days, or if stripped earlier, the curing of the concrete shall be
continued immediately by covering with polythene sheeting or the application of a curing compound.

9.3.2 Unformed Surfaces

Unformed surfaces shall be subjected to moist curing or membrane curing for the full curing period.

The curing treatment shall be applied immediately following the completion of finishing operations.

9.4 Saw Cut Control Joints

Control joints for slabs on grade shall be saw cut within 24 hours of placement. Care shall be taken to ensure that only the
reinforcing mesh, and not the reinforcing steel, is cut.

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Saw cut control joints shall be cleaned and sealed using Emerseal Chemproof joint sealant or approved equivalent. The
sealant shall be installed strictly in accordance with the manufacturer’s recommendations.

The Contractor shall submit their preferred control joint locations to the Engineer two weeks prior to concrete placement for
approval.

10.0 FINISHES

10.1 Formed Surfaces

The qualities of formed surface finish shall be as indicated on the drawings and in accordance with the classification system of
AS 3610. All exposed corners shall be finished with 20 mm x 20 mm chamfer.

10.2 Upper Surfaces

Upper surface finishes shall be in accordance with the following classes.

10.3 Class U1 - Screeded

This is a screeded finish for surfaces of roads or foundation beds, slabs and structural members to be covered by backfill,
subsequent stages of construction, bonded concrete topping or cement mortar beds to receive pavings and on exposed
surfaces where a superior finish is not required. It is also the first stage for finishes U2 and U3.

The finishing operations shall consist of levelling and screeding the concrete to produce a uniform, plain or ridged surface,
surplus concrete being struck off by a straight edge immediately after compaction.

10.3.1 Class U2 - Wood Float

This is a floated finish for surfaces of beds and slabs to receive mastic pavings, block paving bedded in mastic and for exposed
surfaces or paving where a hard smooth steel trowelled surface is not required.

Floating shall be carried out after the concrete has hardened sufficiently and may be by hand or machine. Care shall be taken
that the concrete is worked no more than necessary to produce a uniform surface free from screed marks.

10.3.2 Class U3 - Steel Trowel

This is a hard, smooth steel trowelled finish for surfaces of concrete paving, tops of walls, copings and other members exposed
to weathering, surfaces of beds and slabs to receive thin flexible sheet, tile paving bedded in adhesive and seatings for bearing
plates and the like where the metal is in direct contact with the concrete.

Trowelling shall not commence until the moisture film has disappeared and the concrete has hardened sufficiently to prevent
excess laitance from being worked to the surface. The surfaces shall be trowelled under firm pressure and left free from trowel
marks.

10.3.3 Class U4 - Broomed

This is a brushed finish for surfaces of paving. It shall be finished as specified for smooth steel trowelled finish, except that the
hard steel trowelling shall be omitted. After the machine trowelling is completed, the surface shall be brushed with a fibre bristle
brush or broom across the direction of traffic.

10.4 Hardeners

Hardeners shall be as specified and applied to the surfaces indicated on the drawings, in accordance with the manufacturer's
instructions.

11.0 TESTING

11.1 Tests

All concrete shall be subject to ‘Project Assessment of Strength Grade’ as specified in Clause 20.7 of AS 3600 and this
specification.

Concrete samples shall be taken at the point of discharge from the mixing plant by the Contractor, at the frequency described in
Table 5.

A concrete sample shall consist of:

• a slump test

• 3 standard cylinders, 1 tested at 7 days and 2 at 28 days

• temperature measurement of the mix at the point of discharge from the truck, when required.

Additional slump tests may be required as determined on site.

Equipment for slump testing shall be made available by the Contractor at the site during all concreting work.

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Slump tests shall be carried out in accordance with AS 1012. The test strength of samples shall be calculated as the average
of the 28 day cylinder strengths.

11.2 Sampling Frequency

The sampling frequency will generally be as set out in Table 5.

Table 5 Sampling Frequency

Location of Concrete Frequency of Sampling

Normal Minimum
3
Footings 1 per 25 m 1 per building
3
Slabs on Ground 1 per 25 m 1 per slab
3
Walls 1 per 25 m 1 per slab
3
Columns 1 per 5 m 1 per building
3
Suspended Slabs 1 per 23 m 1 per slab
Precast Units
3
<2 m /unit 1 per truck
3
>2 m /unit 1 per precast unit
Blinding not required

11.3 Acceptance of Concrete

Concrete from any class shall be deemed to comply with the strength requirements of this specification if it meets the
requirements of AS 1379.

12.0 JOINTING OF CONCRETE

All control joints shall be in the positions and formed in accordance with the typical details as shown on the drawings.

Recesses for control joint sealants shall be accurately formed and filled with the sealant nominated on the drawings in strict
accordance with the manufacturer's recommendations. If curing compounds have been used on concrete any compound film
on concrete faces where a sealant bond is required shall be cleaned off and removed to the satisfaction of the Engineer to
provide clean fresh concrete surfaces for contact with sealant compounds.

Where a construction joint is required by the Contractor, the Contractor shall obtain approval for the proposed location from the
Engineer prior to pouring that portion of the works, and all costs for the approved joints shall be borne by the Contractor.

Construction joints in slabs shall be positioned at the discretion of the Engineer.

Construction joints shall be formed by inserting a temporary vertical stopping board against which concrete can be properly
consolidated, and at the discretion of the Engineer, an arrised edge shall be formed along the exposed edge to ensure a
straight line joint on the finished surface.

Exposed faces of all construction joints to be connected to new concrete shall be properly cleaned and roughened by air, water,
wire brushing or scabbling to show the tips of the coarse aggregate within twelve hours of casting. If the set has progressed too
far and this is not possible the previous work shall be scabbled and cleaned to present a suitable surface to cast new work
against. Reinforcement shall continue through construction joints.

Immediately prior to placing new concrete, the exposed face of existing concrete shall be washed and while still wet, coated
with a neat cement grout.

13.0 SITE RECORDS

A record book shall be maintained at the site of works containing the following information for each load of concrete delivered to
the site:

• Batch number

• Delivery number

• Date

• Time of discharge from the mixing plant

• Class of concrete

• Quantity discharged from the mixing plant

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• Admixtures used

• Description of position of placing of concrete in works in sufficient detail to enable the concrete to be located at a
later date.

The record shall be made available to the Engineer on request during the period of the contract.

14.0 DEFECTIVE CONCRETE

Any portion of the concrete placed in the works may be classed as defective if any of the following faults are applicable to that
portion of the works:

• The materials used do not conform with the acceptance criteria as specified and defined in the applicable
documents.

• Prior approval of materials and work as specified herein was not obtained.

• The finished dimensions do not conform with those shown on the drawings.

• There is evidence of segregation of the components within the mix, or air voids in the concrete, mortar or grout.

• There is evidence of damage caused by removal of formwork, or operation of plant, or storage or transporting of
materials.

• There are shrinkage cracks in the concrete, mortar or grout caused by insufficient curing or any other reason.

• Any of the performance criteria specified in this specification, AS 3600, any other applicable document or the
drawings are not attained.

All defective concrete shall be removed and disposed of by the Contractor, as directed by the Engineer.

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