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Concrete Works CONCRETE WORKS CW.1 Concretor CW.1.1 The constituent material, manufacture and transport of all concrete for the Works shall comply with the requirements of BS EN 206, Concrete. The exposure class for all substructure work shall be XS2, and for all concrete on the exterior of the building it shall be XS1. The exposure class for protected concrete internal to the building shall be XC1. The relevant exposure class for each concrete element has to be identified depending on its location. The intended working life of the proposed structure is at least 50 years. Nominal covers to reinforcement shall be selected accordingly. In addition, it shall be ensured that the cover is adequate for fire resistance purposes. CW.1.2 All concrete works shall be carried out in strict accordance with the approved design drawings. Concrete work shall be in accordance with DD ENV 13670-1 Execution of Concrete Structures. Part 1. CW.2 Cement Materials, Batching and Mixing CW.2.1 Ready-mixed concrete shall be used for all in-situ concrete and shall be obtained from an approved plant. Each mix shall be obtained from only one source unless otherwise approved. The name and address of the supply depot(s) shall be confirmed to the Employer’s Representative in writing before any concrete is delivered. All delivery notes, test certificates, and other similar documentation shall be retained for inspection. Ready- mixed concrete shall be carried in purpose-made agitators, operating continuously, or truck mixers. The concrete shall be compacted and in its final position within 2 hours of the introduction of cement to the aggregate, unless appropriate retardants are used. CW.2.2 Cement shall be Type CEM I – 42.5 N (or R, where appropriate), conforming to BS EN 197-1, or SRPC. CW.2.3 Any cement delivered to Site shall be properly stored, in such a way so that separate consignments can be identified, and shall be consumed in order of delivery. CW.2.4 Any cement below the standard required shall be removed from the Site, or from the approved Ready-Mix supplier, and replaced by the Contractor at his expense. Partially set or damaged cement shall not be used in concrete works. Different brands of cement shall not be mixed in the same batch. The Engineer reserves the right to withdraw his approval of the Ready-Mix supplier, if any cement results below the standard required. CW.2.5 The Engineer has the right to request from the Contractor, for any consignment of cement used on the Works the cement manufacturer’s certificates in accordance with the relevant standard, which certificates shall be maintained by the Contractor and shall be attached to the Building File. CW.2.6 Notwithstanding any certificates submitted, the Contractor shall remain responsible for the quality of the cement, and should subsequent test results indicate that any part of the Works was not in accordance with the relevant specifications, or of approved quality, because of the quality of the cement, the Engineer may direct that the Contractor remove and replace at his own expense any concrete made with that consignment of cement. CW.2.7 Where the concrete is destined for special self-finished in-situ or pre-cast elements, no change in the type, and in the source, of cement shall be allowed during the course of production or construction, to ensure that, as far as possible, the colour of the concrete for the relative elements is constant. CW.3 Aggregates CW.3.1 Natural aggregates for designed mixes shall be suitable for producing a concrete with a drying shrinkage of concrete not exceeding 0.075%. Aggregates shall be of consistent colour, free from absorbent particles that may cause 'pop-outs', and other particles such as coal and iron sulphide that may be unsightly or cause unacceptable staining. Aggregates for concrete destined for special self-finished in-situ or pre-cast elements shall be obtained from one source, and it shall be ensured that adequate supplies, of a constant grading, can be maintained throughout the contract. Samples of the proposed aggregates shall be provided to the Engineer on request, where exposed aggregate finishes are envisaged. The Engineer may require that the Contractor arrange a visit to the quarry or other source of aggregate materials to inspect and approve the sources of such materials. The Contractor shall obtain approval from the Engineer before altering any constituent materials or proportions, for concrete that will be exposed in the finished work. CW.3.2 The Contractor shall obtain approval for the proposed aggregate sources, and shall select suitable aggregate and samples of sand and aggregate for specified testing before procuring the required materials. A similar standard shall be applied to aggregates and sand delivered to the approved Ready Mix Concrete Supplier, for use in this site. Laboratory tests shall be made at regular intervals by the aggregate supplier, to confirm the suitability of the aggregate. CW.3.3 The following criteria may be requested by the Engineer and shall be ascertained by testing to assess the suitability of aggregate: 1. Grading: Grading tests shall be carried out daily or per 100m3, whichever is the more frequent when concrete is being produced on a regular basis, or beforehand when production is irregular. The combined grading of aggregate shall be constant. The percentage passing any sieve size as determined by approved trial mixes shall be the target grading for all concrete of that type. The combined grading of the Works concrete shall not vary by more than 4% on any one sieve from that target. If the estimated or measured combined grading of the permanent Works concrete does not meet this requirement, then a new trial mix shall be prepared for approval. 2. Magnesium sulphate soundness; 3. Specific gravity and water absorption; 4. Clay, silt and dust content; 5. Organic impurities; 6. Sulphate ad chloride content; 7. Crushing value: alternatively 10% fines value or impact value as approved; 8. Elongation and flakiness; 9. Potential alkali reactivity; 10. Drying shrinkage in accordance with BRS Digest 35; Testing shall be carried out in accordance with the relevant EN, or if not available, the relevant EN standards, as appropriate, and the results shall comply with the limits given therein, or as otherwise stated herein. CW.3.4 Except where otherwise indicated for concrete destined for special self-finished in-situ or pre-cast elements, coarse aggregate shall consist of first quality crushed hard durable coralline limestone, of the quality known as “tal-prima”, free from earth, loam, clay, organic material, chlorides or other impurities, free from an excessive quantity of quarry dust, passing an 18mm test sieve and retained on a 6mm BS test sieve; the grading shall be within the prescribed limits, so that when mixed with the approved fine aggregate and cement, a workable concrete of maximum density is produced. The amount of material passing a 75 micron fine test sieve, when tested by a wet sieving method, shall not exceed 1% by weight. The flakiness and elongation indices of the predominant size fractions in each single-sized coarse aggregate shall not exceed 20% and 35% by weight respectively. CW.3.5 Unless otherwise indicated for concrete destined for special self-finished in-situ or pre-cast elements, the fine aggregate or sand used in all concrete work shall be obtained from approved coralline limestone quarries. It shall be clean, sharp, coarse and free from loamy matter or any other deleterious substances. The grains shall be varying uniformly in size to pass a 5mm mesh screen and retaining not less than 25% on a 3mm mesh screen, graded in between these limits. The sand shall be washed and screened. CW.3.6 The acid-soluble sulphate in aggregate (SO32-) level shall not exceed 0.4% by weight. The acid-soluble chloride level chloride ion (Cl-) in aggregate as a percentage by weight shall not exceed the limits given in the following table. Concrete Type Coarse Aggregate Fine Aggregate (Sand) CEM I - Reinforced 0.02% 0.04% These limits shall be subject to the overall limits given elsewhere for the concrete as mixed. CW.3.7 The Engineer may order that any aggregates that do not meet with his approval not be used in the Works. Aggregates rejected by the Engineer shall be removed from the site by the Contractor at the Contractor’s own expense. The Contractor shall remain responsible for the quality of the aggregates. Should subsequent test results indicate that aggregates used in any part of the Works were not in accordance with the relevant Specifications, nor of approved quality, the Engineer may direct that the Contractor shall remove and replace at his own expense any concrete made with that consignment of aggregates. CW.3.8 Coarse aggregate for concrete destined for special self-finished in-situ or pre-cast elements shall be obtained in at least two gradings, and such gradings shall be maintained constant over the period of the manufacture or construction of the relative elements. The aggregate shall be stored on a clean hard base in separate compartments or in approved hoppers in the place where the mixing of the concrete is envisaged. Suitable precautions shall be taken to prevent mixing of the sizes or types before they are batched. The storage area shall be clear of trees and care shall be taken to avoid contamination by organic or other material from whatever source. The aggregates shall always be free of pyrites or coal that may stain the surface of the concrete. The Contractor may be required to make test samples of concrete to demonstrate the uniformity and consistency of the colour of the concrete to be produced for these elements.
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