Project Number : 3206 Document Name.

: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries
DIVISION 3 CONCRETE SECTION 03400 CAST-IN PLACE CONCRETE SUBSECTION: INDEX PART 1 GENERAL 1.01 1.02 Description Quality Assurance

PART 2 PRODUCTS 2.01 2.02 Materials Mixing

PART 3 - EXECUTION 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 General Preparatory Work Weather Conditions Acceptance of Concrete Depositing Concrete Joints Protection Remove of Forms and Shoring Setting Bearing Devices

Part 1 - General 1.01 Description A. Description of Work Work under this Section consists of furnishing all on-site concrete including, but not limited to the following: 1. 2. 3. B. Building and process structure foundations. Building and process structure. Light weight concrete toppings shown on drawing.

Related Work Specified Elsewhere 1. Temporary Concrete Forms: Section 03000. Steel bar and wire fabric reinforcing: Section 03100. Concrete accessories. Section 03202.

2.

3.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries

4.

Expansion and construction joint. Section 03300. Concrete finishing and curing. Section 03500. Portland cement concrete. Section 03800.

5.

6.

1.02

Quality Assurance A. Tests 1. All testing, including request, reports, etc. are the responsibility of the Contractor, or an agency employed by the contractor. Consultant reserves the right to verify the tests with an independent agency. Failure to detect defective work or materials during testing will neither prevent rejection letter when such defects are discovered, nor will if obligate consultant to make final acceptance. a) Conduct Strength Test: Strength of concrete shall be conducted by the Contractor. This services shall include making specimens in field. Each strength test shall consist of 4 cylinders; 1 tested at 3 days, 1 tested at 7 days and 2 tested at 28 days. For each class of concrete, one strength test for each pour of 50 cubic meters shall be made. When this schedule of testing provide less than 5 tests for given class of concrete, at least 5 randomly selected batches shall be tested; if fewer than 5 batches are used, each batch shall be tested. Additional strength test may be required to justify removal of formwork. Specimens shall be secured in accordance with ASTM C172, made and cured in accordance with ASTM C31, and tested in accordance with ASTM C39. Conduct Slump Test: For each strength test, one air content test shall be made in accordance with ASTM C143. Conduct Air Content Test: For each strength test, one air content test shall be made in accordance with ASTM C173 or C231. Report Test Results: Contractor shall furnish the Consultants Representative with 2 copies of all test results. Maintain Records: Complete records of specimens will be maintained; records will include detailed location of each pour represented.

2.

b)

c)

d)

e)

3.

Responsibilities and Duties of Contractor a) Labor and tools: Furnish labor and tools necessary to obtain and handle samples at project site or at other sources of material.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries

b)

Samples: Secure and deliver to Contractors Testing Laboratory representative samples of materials proposed for use which require testing. Secure samples in accordance with ASTM C183 and D75. Design Mixes: Design concrete mixes to product strengths specified as per section 03800.

c)

4.

Authority and Duties of Contractors Testing Laboratory a) Test Aggregates: Test fine and course aggregates for compliance with specifications. Design Mixes: Design or check Contractors proposed mixes. Strength Test: Before placing any concrete conduct strength tests using design mix proposed for each class (strength) of concrete. Each strength test shall consist of 4 cylinders; 1 tested at 3 days, 1 tested at 7 days and 2 tested at 28 days. If 7 days breaks are not satisfactory, revise design mixes and conduct additional strength tests until it established that mixes produce required strength in accordance with Section 4 of ACI 318. Make and cure specimens in accordance with ASTM C192 and test in accordance with ASTM C39. Slump Test: Using proposed design mixes make one slump test in accordance with ASTM C143 for each strength test made. Air Content Test: Using proposed design mixes, make one air content in accordance with ASTM C173 or C231 for each strength test made. Test Reports: Promptly report all test results to Consultant and Contractor.

b) c)

d)

e)

f)

5.

Evaluation of Field Strength Test Strength level of concrete will be satisfactory, if average of 3 consecutive 28 days strength test (6 cylinders) equals or exceeds required minimum comprehensive strength and no individual 28 days strength test (average of 2 companion cylinders) falls below required minimum comprehensive strength by more than 500 psi. However, consultant reserve the right to void 500 psi allowance when, in its opinion, safety of structure is jeopardized by failure of an individual 28 days strength test to equal or exceed required minimum comprehensive strength. Concrete not meeting strength level stated above will be considered questionable. If concrete is questionable, at expense of contractor, re-test concrete or remove and replace with satisfactory concrete. Conduct additional test in accordance with ASTM C42 or as approved by Consultant and evaluate in accordance with ACI 318. If core test indicate that concrete meets strength specified, results of tests cylinder will be waived. If core fail to meet requirements of ACI

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries
318, at expense of Contractor, Consultant may order load test or other appropriate action such as removal and replacement of defective concrete. Part 2 - Products 2.01 Materials A. Portland Cement Concrete: All concrete shall be in accordance with Section 03800. Form Work: Form work shall be in accordance with Section 03000.

B. 2.02 Mixing A.

Ready-Mixed Concrete: Concrete shall be in accordance with Section 03800. Minimum compressive strength of concrete after 28days to be used for buildings is 4000 Psi grade Mixing at Site If concrete is to be mixed at Project Site, conform to: 1. General Mix concrete is a batch mixer. Mixer shall bear manufacturers rating plate indicating rated capacity and recommended revolutions per minute. Operate mixer in accordance with these recommendations. Use only mixers capable of thoroughly mixing concrete into a uniform mass within specified mixing time, discharging mix without segregation, and equipped with suitable charging hopper, water storage tank and water measuring device. No site mixing is allowed without the due approval of the Consultant or his representative. 2. Admixtures When liquid admixtures are approved for use, dispense by means of an automatic dispenser of similar metering device. Weigh or measure powdered admixtures by volume as recommended by manufacturer. Accurately measure all admixtures to within + 5 %. Provide suitable agitating equipment to insure uniform distribution of ingredients. 3. Mixing Charge batch into mixer so that some water enters before cement and aggregates. Allow water to flow into mixer until end of first 25% of specified mixing time. Provide controls to insure that batch is not discharge until specified mixing time has elapsed. Provide controls to insure that no additional water is added during mixing. Discharge entire batch before re-charging.

B.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries
4. Mixing Mix each batch of 2 cubic yards of less than 1 minutes. Increase mixing time 15 seconds for each additional cubic yard or fraction threreof. 5. Maintenance Keep mixer clean. Replace mixer pick-up and throw-over blades when they have lost 10% of their original depth.

C.

Re-Tempering Mix concrete is quantities for immediate use only. Discard concrete which has set; do not re-temper. Adding water to ready-mixed at Project Site will not be permitted.

D.

Weather Conditions 1. Hot Weather In hot weather, a retarding admixture shall be added to mix. If necessary, cool ingredients to prevent flash set, cold joints or loss of slump. Comply with ACI 305.

Part 3 - Execution 3.01 General A. Quality Standard Unless, otherwise specified, place all concrete in accordance with ACI 304. B. Review of Test Breaks Do not place any concrete until Consultants Representative has reviewed results of design mix seven days test breaks and has given approval to proceed. C. No concrete shall be placed until all form work embedded parts, steel reinforcement, excavated surfaces, mud mats, foundation surface, joints, slab cut outs, pockets, holes involved in the placing have been approved by Consultant.

3.02

Preparatory Work A. Cleaning Equipment Removing hardened concrete and foreign materials from mixing and conveying equipment.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries
B. Installation of Other Materials Prior to placing concrete install formwork, preformed joint fillers, vapor barrier, polyethylene film and reinforcing. Between erection of forms and placing of concrete, allow sufficient time for other trades to install and test their work. Before placing concrete floors on grade, inspect and test piping and other utilities under slabs and compacted backfilled excavations to solid bearing. Set and secure against displacement edge forms and intermediate screed strips to produce required elevations and contours. C. Slabs on Grade Secure and brace bulkheads to prevent displacement. Terminate all reinforcement and other embedded items as specified in Section 03100. Secure dowels as specified in Section 03200. D. Building Other Materials and Fixtures Into Concrete 1. 2. Anchor Bolt Miscellaneous Items Accurately place and secure against displacement all steel, pockets, inserts, anchors, blocking, nailer strips and similar items. Installation of anchors, inserts for electrical, mechanical, plumbing, hearing, ventilating and air condition work is subject to inspection and approval by supervisors of particular trade involved. Temporarily fill voids is sleeves and inserts with readily removable material. E. Subgrades Place concrete on subgrades that are well compacted to level and true grade. Before concrete is deposited between slabs on grade previously placed, recheck compaction of subgrades and, if necessary, re-compact to avoid settlement of slabs at joints. Sprinkle semi-porous subgrades sufficiently to eliminate absorption. Seal extremely porous subgrades in a manner approved by Consultants Representative. Remove all debris and excess from subgrades. 3.03 Weather Condition A. Protection Do not place concrete when it is raining. B. Placing in Hot Weather: Placement of concrete in hot weather shall be in accordance with recommend practice of ACI 305R and the procedure submitted by the Contractor and approved by Consultant, unless otherwise specified herein. The temperature of concrete at the point of placement shall not exceed 30OC. Any concrete which has reached a temperature greater than 300C shall not be used.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries
Reinforcing steel and forms shall be protected from direct sun rays. Whenever ice is used in the concrete, reinforcing steel and forms shall be cooled off by misting with potable water immediately before concrete placing unless provision is made for night time concreting. Concrete shall not be placed when the work will be affected by wind blown sand conditions. Recommendations by the manufacturer of pozzolan and special care, in placing, consolidating and curing shall be taken when pozzolan is used in the mix.

3.04

Acceptance of Concrete A. Upon arrival of concrete at the place of deposition, the Contractor shall receive from the driver, prior to acceptance, a delivery ticket for the concrete. The Contractor shall verify if concrete, as received, meets the requirements of this Specification and Section 03800 PORTLAND CEMENT CONCRETE. The Contractor shall complete and sign the ticket and fill in those items for which he is responsible. The concrete shall be placed and consolidated in its final position within two (2) hours forms the time of introduction of the cement into the aggregates, but in all cases at least thirty (30) minutes less than the certified initial set time of the cement. Concrete shall be rejected if it has stiffened due to hot weather conditions and could not be made workable without exceeding the specified w/c ratio. Temperature of concrete at the time of actual placement shall not exceed 30OC. Where the slump is deemed inappropriate for acceptable workability, the Contractor may recommend dosing the concrete mix with superplasticizer, measured by truck mounted dispenser, in accordance with manufacturers recommendations. The superplasticizer shall be added by a qualified technician of the concrete batch plant supplying the mix. The addition of the superplasticizer shall be properly mixed with the concrete prior to discharge of concrete.

B.

C.

D.

3.05

Depositing A. General Do not deposit concrete which has partially hardened or has been contaminated by foreign matter. Remove all temporary spreaders in forms when concrete has reached an elevation rendering their service unnecessary. However, temporary spreaders may remain in place if made of metal or concrete and approval has obtained from the consultant. B. Segregation To avoid segregation, deposit concrete as near to its final position as possible. Do not subject concrete to any procedure which will cause segregation. Do not drop concrete more than 1.00 meter.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries

C.

Placing 1. General Deposit concrete continuously in 0.30 m thick layers so that no concrete will be deposited on concrete which has hardened sufficiently to cause seams or planes of weakness. If a section cannot be placed continuously, locate construction joints at points approved by the Consultants Representative. Except for floor slabs on grade, allow at least 7 days between placing adjacent section of concrete. 2. Slabs on Grade Unless, otherwise indicated on drawings, place slabs on grade in strip sections with jointing along column lines.

D.

Consolidation 1. General Thoroughly consolidate all concrete by vibrating, spading, rodding, or forking until concrete is thoroughly worked around reinforcement, embedded items and into corners of forms. Consolidate each layer of concrete with previously placed layers to eliminate all air or stone pockets which may cause honey-combing, pitting or planes of weakness. Do not use vibrators to transport concrete.

2.

Formed Elements Use internal vibrators.

3.

Slabs on Grade Consolidate slabs on grade with mechanical vibrating equipment. Use internal vibration along joints.

3.06

Concrete Joints A. Construction joints shall be clean with exposed sound aggregate, rough profile and damp, but not wet, before adjoining with fresh concrete. Cleaning shall consist of the removal of all laitance, loose or defective concrete, coatings, sand, sealing compound, and/or other foreign material. Joints shall be washed thoroughly with air-water jets immediately before fresh concrete is placed. Alternatively, the contractor may propose for approval by Consultant the use of surface set retarders followed by air-water jettings. Contraction Joints, Expansion Joints and Control Joints shall be provided at the locations and in accordance with the details shown on the contract drawings. In absence of such details, the contractor shall propose practical location following the guidelines in ACI 302.1R and obtain Consultant approval prior to implementation.

B.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries
3.07 Protection A. Concrete Immediately after placement, protect concrete from premature drying, excessively hot or cold temper and mechanical disturbances. Make all arrangement for protecting concrete prior to placing concrete. Protect floor from damage after placing; do not permit concrete truck traffic on floors. 3.08 Removal of Forms and Shoring A. Forms shall be removed carefully so as to prevent damage to the concrete. Any concrete damage in the process of removing the forms shall be repaired in accordance with the provisions of this specification. All non-supporting forms shall be loosened and removed as soon as the concrete has hardened sufficiently to prevent damage from form removal. All forms supporting concrete beams and slabs, or other members subject to direct bending areas, shall not be removed or released for seven days, unless indicated otherwise in 3.08c, or until job-cured test cylinders are tested to show a strength of not less than 85% of the design strength. Any required repairs of required finish treatment shall be performed as soon as the forms have been removed, and shall then be followed immediately by the specified curing. In no case shall forms be stripped in less than the following minimum periods. 1. 2. 3. 4. Walls Columns Sides of beams and girders Pan joist forms: * 5. 6. 750 mm wide or less over 750 mm wide 3 days 4 days 12 hrs 12 hrs 12 hrs

B.

C.

Arch centers * Joist, beam or girder soffits: * Under 3 meters clean span Between structural supports 3 meters to 6 meters clear span between structural supports over 6 meters span between structural supports 4 days

7 days

10 days

Extend specified period for form removal by additional 4 days when utilizing concrete with fly ash.

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Project Number : 3206 Document Name.: Civil Specifications Date: March 7, 2009 Project : Cut & Bend Processing Bldg. Owner : Rajhi Steel Industries
D. No construction loads exceeding the combination of superimposed dead load plus specified live load shall be supported on any un-shored portion of the structure under construction, unless analysis indicates adequate strength to support such additional loads. Forms shall be removed in such manner so as not to impair safety and serviceability of the structure. All concrete to be exposed by form removal shall have sufficient strength so as not to be damaged thereby. All concrete members shall be shored after form removal until concrete has gained its specified strength.

E.

F.

3.09

Setting Bearing Devices A. Line and Grade Establish proper line and grade for all bearing devices with surveying instrument. B. Quality Control After bearing devices has been set and adjusted, check for proper line and grade using surveying instrument. Set bearing devices level within 0.25 mm across length and width of device and within 1.5 mm required elevation.

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