CONCRETE AND ALLIED WORKS

GENERAL

a. The quality of materials and method and control of manufacture and transportation of all
concrete work irrespective of mix, whether reinforced or otherwise, shall conform to the
applicable portions of this specification.

b. The Engineer shall have the right to inspect the source/s of material/s, the layout and
operation of procurement and storage of materials, the concrete batching and mixing
equipment, and the quality control system. Such an inspection shall be arranged and
Engineer's approval obtained, prior to starting of concrete work.

2.47 MATERIALS FOR STANDARD CONCRETE

a. The ingredients to be used in the manufacture of concrete shall consist solely of portland
cement , clean sand, natural coarse aggregate, clean water, and admixtures, if specifically
called for on conditions at site warrant its use.

b. Cement

(i) Unless otherwise specified in the Specification or called for by the Engineer, cement shall be
ordinary portland cement in 50 kg. bags. The use of bulk cement will be permitted only with
the approval of the Engineer. Changing of brands or type of cement within the same structure
should be avoided as far as possible.

(ii) The Contractor will have to make his own arrangements for procurement and storage of
adequate quantity of cement. Cement in bulk may be stored in bins or silos which will provide
complete protection from dampness, contamination and minimize caking and false set.
Cement bags shall be stored in a dry enclosed shed (storage under tarpaulins will not be
permitted), well away from the outer walls and insulated from the floor to avoid contact with
moisture from the ground and so arranged as to provide ready access. Damaged or reclaimed
or partly set cement will not be permitted to be used and shall be removed from the Site. The
storage bins and storage arrangements shall be such that there is no dead storage. Not more
than 12 bags shall be stacked in any tier. The storage arrangement shall be approved by the
Engineer. Consignments of cement shall be stored as received and shall be consumed in the
order of their delivery.

(iii) Cement held in storage for a period of ninety (90) days or longer shall be tested. Should at
any time the Engineer have reasons to consider that any cement is defective, then irrespective
of its origin. date of manufacture and /or manufacturer's test certificate, such cement shall be
tested immediately at the Contractor's cost at an approved laboratory and until the results of
such tests are found satisfactory, it shall not be used in any work. The Contractor shall not be
entitled to any claim of any nature on this account.
c. Aggregates

(i) General

A "Aggregate" in general designates both fine and coarse inert materials used in the
manufacture of concrete.

B "Fine Aggregate" is aggregate most of which is retained on 4.75 mm IS sieve.

C "Coarse Aggregate" is aggregate most of which is passed through on 4.75 mm IS sieve.

D All fine and coarse aggregates proposed for use in the Works shall be subject to the
Engineer's approval and after specific materials have been accepted, the source of supply of
such materials shall not be changed without prior approval of the Engineer.

E Aggregates shall, except as noted above, consist of natural sands, crushed stone from a
source known to produce satisfactory aggregate for concrete and shall be chemically inert,
strong, hard, durable against weathering, of limited porosity and free from deleterious
materials that may cause corrosion of the reinforcement or may impair the strength and/or
durability of concrete. The grading of aggregates shall be such as to produce a dense concrete
of specified strength and consistency that will work readily into position without segregation
and shall be based on the "mix design" and preliminary tests on concrete specified later.

(ii) Sampling and Testing

A. Samples of the aggregates for mix design and determination of suitability shall be taken
under the supervision of Engineer and delivered to the laboratory, well in advance of the
scheduled placing of concrete. Records of tests which have been made on proposed
aggregates and on concrete made from this source of aggregates shall be furnished to
Engineer in advance or the work for use in determining aggregate suitability. The costs of all
such tests, sampling, etc., shall be borne by Contractor.

(iii) Storage of aggregates: All coarse and fine aggregates shall be stacked separately in stock
piles in the material yard near the work site in bins properly constructed to avoid inter mixing
of different aggregates. Contamination with foreign material and earth during storage and
while heaping the materials shall be avoided. The aggregate must be of specified quality not
only at the time of receiving at Site but more so at the time of loading into mixer. Rakers
shall be used for lifting the coarse aggregates from bins or stock piles. Coarse aggregate shall
be piled in layers not exceeding 1.20 meters in height to prevent coning or segregation. Each
layer shall cover the entire area of the stock pile before succeeding layers are started.
Aggregates that have become segregated shall be rejected. Rejected material after remixing
may be accepted, if subsequent tests demonstrate conformance with required gradation.

(iv) Specific Gravity: Aggregates having a specific gravity below 2.6 (saturated surface dry basis)
shall not be used without special permission of the Engineer.

2.48 FINE AGGREGATE

a. Fine aggregate shall consist of natural or crushed sand conforming to IS 383. The sand shall
be clean, sharp, hard, strong and durable and shall be free from dust, vegetable substances,
adherent coating, clay, alkali, organic matter, mica, salt, or other deleterious substances,
which can be injurious to the setting qualities/strength/durability of concrete.

(i) Machine-made Sand: Machine-made sand will be acceptable, provided the constituent
rock-gravel composition shall be sound, hard, dense, non-organic, uncoated and durable
against weathering.

(ii) Screening and Washing: Sand shall be prepared for use by such screening or washing, or
both, as necessary, to remove all objectionable foreign matter while separating the sand grains
to the required size fractions.

(iii) Foreign Material Limitations: The percentage of deleterious substances in sand delivered to
the mixer shall not exceed the following :

Percent by weight
 Uncrushed Crushed
(A) Material finer than 75 micron
I.S. Sieve 3.00 15.00

(B) Shale 1.00 1.00

(C) Coal and lignite 1.00 1.00

(D) Clay lumps

(E) Total of all above substances

including items (i) to (iv) for
uncrushed sand and items (iii)
and (iv) for crushed sand 5.00 2.00

b. Gradation

(i) Unless otherwise directed or approved by the Engineer, the grading of sand shall be within
the limits indicated hereunder :
Percentage passing for
IS Sieve
Grading Zone- Grading Zone- Grading Zone-
Designation Grading Zone-I
II III IV
10mm 100 100 100 100
4.75mm 90 – 100 90 – 100 90 – 100 95 – 100
2.36 60 – 95 75 – 100 85 – 100 95 – 100
1.18mm 30 – 70 55 – 90 75 – 100 90 – 100
600 micron 15 – 34 35 – 59 60 – 79 80 – 100
300 micron 5 – 20 8 – 30 12 – 40 15 – 50
150 micron 0 – 10 0 – 10 0 – 10 0 – 15

(ii) Where the grading falls outside the limits of any particular grading zone of sieves, other than
600 micron I.S sieve, by total amount not exceeding 5 percent, it shall be regarded as falling
within that grading zone. This tolerance, shall not be applied to percentage passing the 600
micron I.S. sieve or to percentage passing any other sieve size on the coarser limit of Grading
Zone I or the finer limit of Grading Zone IV. Fine aggregates conforming to Grading Zone
IV shall not be used. Mix designs and preliminary tests shall show its suitability for
producing concrete of specified strength and workability.

c. Fineness Modulus: The sand shall have a fineness modulus of not less than 2.2 or more
than 4.2. The fineness modulus is determined by adding the cumulative percentages retained
on the following I.S. sieve sizes (4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300 micron and
150 micron) and dividing the sum by 100.

2.49 COARSE AGGREGATE

a. Coarse aggregate for concrete, except as noted above, shall conform to I.S. 383. This shall
consist of crushed stone and shall be clean. and free from elongated, flaky or laminated
 pieces, adhering coatings, clay lumps, coal residue, clinkers, slag, alkali, mica, organic matter
or other deleterious matter.

b. Screening and Washing: Crushed rock shall be screened and /or washed for the removal of
dirt or dust coating, if so requested by the Engineer.
c. Grading: Coarse aggregate shall be either in single size or graded, in both cases the grading
shall be within the following limits :
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
IS Sieve Percentage passing for single- Percentage passing for
graded
Designa- sized aggregate of nominal size. aggregate of nominal size
tion 40mm 20mm 12.5mm 10mm 40mm 20mm 12.5mm
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
~

63mm 100 - - - 100 - -

40mm 85-100 100 - - 95-100 100 -

20mm 0-20 85-100 - - 30-70 95-100 100

16mm - - 100 - - - -

12.5mm - - 85-100 - 100 - -

95-100

10 mm 0-5 0-20 0-45 85-100 10-35 25-55 40-85

4.75 mm - - 0-5 0-10 0-45 0-5

0-10 0-10

2.36 - - - 0-5 - - -

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
~

d. The pieces shall be angular in shape and shall have granular or crystalline surfaces. Friable,
flaky and laminated pieces, mica and shale, if present, shall be only in such quantities that
will not, in the opinion of Engineer, affect adversely the strength and/or durability of
concrete. The maximum size of coarse aggregate shall be 40mm for M-10 concrete and 20
mm for M-15 to M-40 concrete, or as directed by the Engineer or specified otherwise. The
maximum size of coarse aggregate shall be the maximum size specified above, but in no case
greater than 1/4 of the minimum thickness of the member, provided that the concrete can be
placed without difficulty so as to surround all reinforcement thoroughly and fill the corners of
the form. For plain concrete the maximum size of aggregate shall be of 40 mm. For heavily
reinforced concrete members, the nominal maximum size of the aggregate shall be 5 mm less
than the minimum clear distance between the reinforcing main bars or 5 mm less than the
minimum cover to reinforcement whichever is smaller. The amount of fine particles occuring
in the free state or as loose adherent shall not exceed 1% when determined by laboratory
sedimentation tests as per I.S. 2386. After 24 hours immersion in water, a previously dried
sample shall not have gained more than 10% of its oven dry weight in air, as determined by
I.S. 2386.
e. Foreign Material Limitations: The percentage of deleterious materials in the aggregate
delivered to the mixer shall not exceed the following :

Percent by weight
Foreign Material
Uncrushed Crushed
i) Material finer than 75 micron I.S. Sieve 3.00 3.00

ii) Coal and Lignite 1.00 1.00

iii) Clay lumps 1.00 1.00

iv) Soft Fragments 3.00 --

v) Total of all the above substances 5.00 5.00

2.50 WATER

a. Water used for washing, mixing and curing shall be free from injurious amounts of
deleterious materials. Potable water is generally satisfactory for mixing and curing concrete.

b. In case of doubt, the suitability of water for making concrete shall be ascertained by the
compressive strength and initial setting time test specified in IS 456. The sample of water
taken for testing shall be typical of the water proposed to be used for concreting, due account
being paid to seasonal variation. The sample shall not receive any treatment before testing
other than that envisaged in the regular supply of water proposed for use in concrete. The
sample shall be stored in a clean container previously rinsed out with similar water.

c. Average 28 days compressive strength of at least three 15 cm concrete cubes prepared with
water proposed to be used shall not be less than 90% of the average strength of three similar
concrete cubes prepared with distilled water. The cubes shall be prepared, cured and tested in
accordance with the requirements of IS 516.

d. The initial setting time of test block made with the appropriate test cement and the water
proposed to be used shall not be less than 30 minutes and shall not differ by more than +30
minutes from the initial setting time of control test block prepared with the appropriate test
cement and distilled water. The test blocks shall be prepared and tested in accordance with
the requirements of IS 4031.

e. Where water can be shown to contain an excess of acid, alkali, sugar or salt, Engineer will
refuse to permit its use. As a guide, the following concentrations represent the maximum
permissible values :

i) To neutralise 200 ml. sample of water, using phenolpthalein as indicator, it should not require
more than 2 ml. of 0.1 Normal NaOH. The details of test shall be as given in IS 3025.
ii) To neutralise 200 ml. sample of water, using methyl orange as an indicator, it should not
require more than 10ml. of 0.1 Normal HCl. The details of test shall be as given in IS 3025.

f) Percentage of solids, when tested in accordance with the method indicated below shall not
exceed the following :

Solids Percent Method of test

(Ref.to Clause No: in IS 3025)
Organic 0.02 10 and 11 (organic solid = total solids minus
ignited residue)
Inorganic 0.30 11 (Ignited residue)

Sulphates (as So4) 0.05 20

Alkali Chlorides (as 0.20 24

C1)
Suspended matter 0.20 12

g) The pH value of water shall not generally be less than6.

2.51 STEEL MEMBERS ENCASED IN CONCRETE

Structural steel columns, beams, girders and bracings to be encased in concrete shall be
unpainted. The encasing shall be done in concrete with 10 mm maximum size aggregate and
a works cube strength not less than 150 kg/cm² at 28 days unless otherwise specified. The
steel member shall be wrapped with galvanised wire mesh of adequate size. The galvanised
wire mesh shall be kept 20 mm from the edge or surface of the steel member and shall be held
in position securely. The Steel member will have a minimum cover of 50 mm unless
otherwise indicated in the drawings. Where the clear cover to steel is more than 75 mm, mild
steel bar and concrete with 20 mm coarse aggregate can be used.

2.52 REINFORCED CEMENT CONCRETE

Reinforced Cement Concrete in the Works shall be "Design Mix Concrete" as defined in IS
456/2000, for M20 and M30 grades. Nominal mix concrete may be used for concrete of
lower grades i.e. lower than M20 grade concrete.

2.52.1 The specified characteristic compressive strength of 150 mm size cube at 28 days attained for M20

grade concrete shall be 20 N/sqmm and for M30 grade concrete shall be 30 N/sqmm respectively. The

contractor is required to carryout the mix design and the mix so designed need to be got approved by

the concerned General Manager(Engg), Projects Division, HMWSSB within the limitations of

parameters and other stipulations laid down in IS-456/2000. The mix shall be designed to produce the

grade of concrete having the required workability and a characteristic strength at 28 days not less than
 the appropriate values mentioned in Table-2 of IS-456/2000 i.e. 20 N/sqmm for M20 grade concrete

and 30 N/sqmm for M30 grade concrete respectively. The target mean strength of the concrete mix

should be equal to the characteristic strength plus 1.65 times the standard deviation.

2.52.2 IS-3370 (Part-I), 1965, prescribes that the minimum quantity of cement used for the
reinforced concrete work in the case of water retaining structures shall not be less than 330
Kg/cum. IS-456/2000 prescribes the minimum cement quantity to be used for M20 grade
reinforced cement concrete as 300 Kg/cum and M30 grade reinforced cement concrete as 320
Kg/cum respectively. The Ministry of Surface Transport (MOST) specifications prescribes
quantity of cement to be used in the case of M20 grade reinforced cement concrete 380
Kg/cum and in the case of M30 grade reinforced cement concrete as 420 Kg/cum. In the
preparation of estimates for this work, in the datas the said quantities of cement as prescribed
by MOST and as approved by Government vide G.O.Ms.No.30, dt: 19-3-2002, Irrigation &
CAD Department (Projects Wing: COD), has been adopted. The contractor shall use the
quantities of cement at site during execution of reinforced cement concrete work by design
mix not less than as adopted in the detailed estimates i.e. in the case of M20 grade reinforced
cement concrete 380 Kg/cum and in the case of M30 grade reinforced cement concrete 420
Kg/cum and shall use even more cement in both the cases if required for attaining not less
than the prescribed specified characteristic compressive strength of 150 mm cubes at 28 days
i.e. 20 N/sqmm for M20 grade concrete and 30 N/sqmm for M30 grade concrete respectively,
without any extra cost.

2.53 MIX DESIGN

a. General

(i) This is to investigate the grading of aggregates, water-cement ratio, workability and the
quality of cement required to give preliminary and works cubes of the minimum strength
specified. The proportions of the mix shall be determined by weight. Adjustment of
aggregate proportions due to moisture present in the aggregate shall be made. Determination
of mix proportions shall be carried out according to `Recommended guidelines for Concrete
Mix Design' conforming to IS 10262.

(ii) Whenever there is a change either in required strength of concrete, or water-cement ratio or
workability or the source of aggregates and/or cement, preliminary tests shall be repeated to
determine the revised proportions of the mix to suit the altered conditions. While designing
mix proportions, over-wet mixes shall always be avoided.

(iii) While fixing the value for water/cement ratio for preliminary mixes, assistance may be
derived from the graph (Appendix A, IS 456 showing the relationship between the 28-day
compressive strengths of concrete mixes with different water/cement ratios and the 7-day
compressive strength of cement tested in accordance with IS 269.

b. Preliminary Tests
(i) Test specimens shall be prepared with atleast two different water/cement ratios for each class
of concrete, consistent with workability required for the nature of the work. The materials
and proportions used in making preliminary tests shall be similar in all respects to those to be
actually employed in the works as the object of these tests is to determine the properties of
cement, aggregates and water necessary to produce concrete of required consistency and to
give the specified strength. It will be Contractor's sole responsibility to carry out these tests
 and he shall therefore furnish to Engineer a statement of proportions proposed to be used for
the various concrete mixes. For preliminary tests, the following procedure shall be followed :

(A) Materials shall be brought to the room temperature and all materials shall be in a dry
condition. The quantities of water, cement and aggregates for each batch shall be determined
by weight to an accuracy of 1 part in 1000 parts.

(B) Mixing Concrete: It shall be done by hand or in a small batch mixer as per IS 516 in such a
manner as to avoid loss of water. The cement and fine aggregate shall first be mixed dry until
the mixture is uniform in colour. The coarse aggregate shall then be added, mixed and water
added and the whole batch mixed thoroughly for a period of not less than two minutes until
the resulting concrete is uniform in appearance. Each batch of concrete shall be of such a size
as to leave about 10% excess concrete, after moulding the desired number of test specimens.

(C) Consistency: The consistency of each batch of concrete shall be measured immediately after
mixing, by the slump test in accordance with IS.1199. If in the slump test, care is taken to
ensure that no water or other material is lost, the material used for the slump test may be
remixed with the remainder of the concrete for making the specimen test cubes. The period
of re-mixing shall be as short as possible yet sufficient to produce a homogeneous mass.

(D) Size of Test Cubes: Compression tests of concrete cubes shall be made as per IS.516 on 15
cm cubes. Each mould shall be provided with a metal base plate having a plate surface so as
to support the mould during filling without leakage. The base plate shall be preferably
attached to the mould by springs or screws. The parts of the mould when assembled shall be
positively and rigidly held together. Before placing concrete, the mould and base plate shall
be cleaned and oiled. The dimensions and internal faces of the mould shall be accurate within
the following limits:

(1) Height and distance between the opposite faces of the mould shall be of specified size +0.2
mm. The angle between the adjacent internal faces and between internal faces and top and
bottom faces of mould shall be 90 o + 0.5 o. The interior faces of the mould shall be plane
surfaces with a permissible variation of 0.03 mm.

(E) Compacting: Concrete test cubes shall be moulded by placing fresh concrete in the mould
and compacted as specified in IS.516.

(F) Curing: Curing shall be as specified in IS.516. The cubes shall be kept in moist air of at
least 90% relative humidity at a temperature of 27 o C. + 2 o C. for 24 hours + 2 hour from
the time of adding water to the dry ingredients. Thereafter they shall be removed from the
moulds and kept immersed in clean, fresh water and kept at 27 o C. + 2 o C. temperature until
required for test. Curing water shall be renewed every seven days. A record of maximum
and minimum temperatures at the place of storage of the cubes shall be maintained during the
period they remain in storage.

(G) Testing of Specimens: The strength shall be determined based on not less than five cube test
specimens for each age and each water cement ratio. All these laboratory test results shall be
tabulated and furnished to the Engineer. The test results shall be accepted by the Engineer if
the average compressive strengths of the specimens tested is not less than the compressive
strength specified for the age at which specimens are tested subject to the condition that only
one out of the five consecutive tests may give a value less than the specified strength for that
age. The Engineer may direct the Contractor to repeat the tests if the results are not
satisfactory and also make such changes as he considers necessary to meet the requirements
specified. All these preliminary tests shall be conducted by the Contractor at his own cost in
an approved laboratory.
2.54. PROPORTIONING, CONSISTENCY, BATCHING AND MIXING OF CONCRETE

a. Proportioning

(i) Aggregate
The proportions which shall be decided by conducting preliminary tests shall be by weight.
These proportions of Cement, fine and coarse aggregates shall be maintained during
subsequent concrete batching by means of weigh batchers conforming to IS.2722 capable of
controlling the weights within one percent of the desired value. Except where it can be shown
to the satisfaction of the Engineer that supply of properly graded aggregate of uniform quality
can be maintained over the period of work, the grading of aggregate shall be controlled by
obtaining the coarse aggregate in different sizes and blending them in the right proportions.
The different sizes shall be stocked in separate stock piles. The grading of coarse and fine
aggregate shall be checked as frequently as possible, as determined by the Engineer, to ensure
maintaining of grading in accordance with the samples used in preliminary mix design. The
material shall be stock piled well in advance of use.

(ii) Cement shall be measured by weight.

(iii) Water: Only such quantity of water shall be added to the cement and aggregates in the
concrete mix as to ensure dense concrete, specified surface finish, satisfactory workability,
consistent with the strength stipulated for each class of concrete. The water added to the mix
shall be such as not to cause segregation of materials or the collection of excessive free water
on the surface of the concrete.

(iv) Definition of Water/Cement Ratio: The water cement (W/C) ratio is defined as the weight
of water in the mix (including the surface moisture of the aggregates) divided by the weight
of cement in the mix.

(v) Water/Cement Ratio: The actual water cement ratio to be adopted shall be determined in
each instance by the Contractor and approved by the Engineer.

(vi) Proportioning by Water/Cement Ratio: The W/C ratio specified for use by the Engineer shall
be maintained. The Contractor shall determine the water content of the aggregates as
frequently as directed by the Engineer as the work progresses and as specified in IS.2386
(Part III) and the amount of mixing water added at the mixer shall be adjusted as directed by
the Engineer so as to maintain the specified W/C Ratio. To allow for the variation in weight
of aggregates due to variation in their moisture content, suitable adjustments in the weights of
aggregates shall also be made.

b. Consistency and Slump

(i) Concrete shall be of a consistency and workability suitable for the conditions of the job.
After the amount of water required is determined, the consistency of the mix shall be
maintained throughout the progress of the corresponding parts of the work and approved tests
e.g. slump tests, compacting factor tests, in accordance with IS.1199, shall be conducted from
time to time to ensure the maintenance of such consistency.

(ii) The following tabulation gives a range of slumps which shall generally be used for various
types of construction unless otherwise instructed by the Engineer:

SLUMPS FOR VARIOUS TYPES OF CONSTRUCTION

Placing Conditions O of Workability Slump (mm)
(1) (2) (3)
Blinging concrete; Very low In the ‘very low’ category of workability where
Shallow sections; strict control is necessary, for example
Pavements using pavers pavement quality concrete, measurement of
workability by determination of compacting
factor will be more appropriate than slump (see
IS 1199) and a value of compacting factor of
0.75 to 0.80 suggested.

Mass concrete; Low 25 – 75

Lightly reinforced sections in
slabs, beams, walls, columns;
Floors;
Hand placed pavements;
Canal lining;
Strip footings

Heavily reinforced sections in Medium 50 – 100

slabs, beams, walls, columns;
Slipform work; 75 – 100
Pumped concrete

Trecnch fill; High 100 – 150

In-situ piling
Tremie concrete Very high In the ‘very high’ category of workability,
measurement of workability by determination
of flow will be appropriate (see IS 9103)

c. Batching and Mixing of Concrete

(i) The materials and proportions of concrete materials as established by the preliminary tests for the mix

designs shall be rigidly followed for all concrete on the Works and shall not be changed except when

specifically permitted by the Engineer.

(ii) Concrete shall be produced only by weigh batching the ingredients. The mixer and weigh
batchers shall be maintained in clean, serviceable condition. The accuracy of weigh batchers
shall be periodically checked. They shall be set up level on a firm base and the hopper shall
be loaded evenly. The needle shall be adjusted to zero when the hopper is empty. Fine and
coarse aggregates shall be weighed separately. Volume batching will not be permitted.
However, the Engineer may permit volume batching by subsequent conversion of the weights
of the aggregate into their equivalent volumes knowing their bulk densities, only in the case
of small and less important pours involving concrete of not more than 0.25 cubic metres, on
days when other pours involving weigh batching are not likely to be taken up. Concrete shall
be of strength stipulated in the respective items. All concrete shall be mixed in mechanically
operated batch mixers complying with IS:1791 and of the approved make with suitable
provision for correctly controlling the water delivered to the drum. The quantity of water
actually entering the drum shall be checked with the reading of the gauge or valve setting,
when starting a job. The test should be made while the mixer is running. The volume of the
mixed material shall not exceed the manufacturer's rated mixer capacity. The batch shall be
charged into the mixer so that some water will enter the drum in advance of cement and
aggregates. All water shall be in the drum by the end of the first 15 seconds of the specified
mixing time. Each batch shall be mixed until the concrete is uniform in colour, for a
minimum period of two minutes after all the materials and water are in the drum. The entire
contents of the drum shall be discharged in one operation before the raw materials for the
succeeding batches are fed into the drum.
(iii) Each time the work stops, the mixer shall be cleaned out and when next commencing the
mixing, the first batch shall have 10% additional cement to allow for sticking in the drum.

2.55 SAMPLING AND TESTING CONCRETE IN THE FIELD

a. Facilities required for sampling materials and concrete in the field, if the Engineer so desires,
shall be provided by the Contractor at no extra cost. The following equipment with operator
shall be made available at the Engineer's request (all must be in serviceable condition.) :

(i) Concrete cube testing machine suitable for

15 cm cubes of 100 tonnes capacity with
proving calibration ring 1 No.

(ii) Cast Iron cube moulds 15 cm size 6Nos.(min)

(iii) Slump cone complete with tamping rod 1 set

(iv) Laboratory balance to weigh upto 5 Kg.

with sensitivity of 10 gm 1 no.

(v) I.S. sieves for coarse and fine 1 set

aggregates

(vi) Set of measures from 5 litres to 0.1 1 set

litre.
(vii) Electric oven with thermostat upto 1 No.
120 o centigrade

(viii)Flakiness gauge 1 No.

(ix) Elongation index gauge 1 No.
(x) Sedimentation pipette 1 No.

(xi) pycnometer 1 No.

(xii) Calibrated glass jar 1 litre 2 Nos.

capacity

(xiii) Glass flasks and metal containers As required

(xiv) Chemical reagents like sodium hydroxide,

tannic acid, litmus papers, etc. As required

(xv ) Laboratory balance of 2 Kg, capacity

and sensitivity of 1 gm 1 No.

b. No concrete of any kind may be placed until the field concrete testing laboratory as specified
is provided to the satisfaction of the Engineer. The Contractor shall notify the Engineer in
advance of all concrete and concrete material testing as provided in the Clause to provide the
Engineer / his representative with an opportunity to witness all prescribed tests.

c. Sampling for Strength of Concrete: A random sampling procedure shall be adopted to ensure
that each concrete batch shall have a reasonable chance of being tested that is, the sampling
should be spread over the entire period of concreting and cover all mixing units.
 The minimum frequency of sampling of concrete of each grade shall be in accordance with
the following:
Quantity of Concrete in the Work, m3 Number of samples
1–5 1
6 – 15 2
16 – 30 3
31 – 50 4
51 and above 4 plus one additional sample for each additional 50
m3 or part thereof.

Note: At least one sample shall be taken from each shift. Where concrete is produced at
continuous production unit, such as ready-mixed concrete plant, frequency of sampling may
be agreed upon mutually by suppliers and purchasers.

Three test specimens shall be made for each sample for testing at 28 days. Additional
samples may be required for various purposes such as to determine the strength of concrete at
7 days or at the time of striking the formwork, or to determine the duration of curing, or to
check the testing error. Additional samples may also be required for testing samples cured by
accelerated methods as described in IS 9103. The specimen shall be tested as described in IS
516.

The laboratory test results shall be tabulated and furnished to the Engineer. The test results of
the sample shall be the average of the strength of three specimens. The individual variation
should not be more than  15 percent of the average. If more, the test results of the sample
are invalid.

d. Consistency: Slump tests shall be carried out as often as requested by the Engineer and
invariably from the same batch of concrete from which the test cubes are made. Slump tests
shall be done immediately after sampling.

2.56 OTHER TESTS

a. (i) If the work cubes do not give the required strengths, the Engineer reserves th right to
ask the Contractor to dismantle such portions of the work which in his opinion are
unacceptable and re-do the work to the standard required at the Contractor's cost.

(ii) The following tests shall be conducted whenever the required to be strength achieved on
cement, sand, coarse aggregate, water in accordance with the relevant Indian Standards. Tests
on cement shall include (i) fineness test, (ii) test for normal consistency, (iii) test for setting
time, (iv) test for soundness, (v) test for tensile strength , (vi) test for compressive strength,
(vii) test for heat of hydration (by experiment and by calculations) in accordance with I.S.
269. Tests on sand shall include (i) sieve test, (ii) test for organic impurities, (iii) decantation
test for determining clay and silt content, (iv) specific gravity test, (v) test for unit weight and
bulkage factor, (vi) test for sieve analysis and fineness modulus. Tests on coarse aggregate
shall include (i) sieve analysis, (ii) specific gravity and unit weight of dry, loose and rodded
aggregate, (iii) soundness and alkali aggregate reactivity, (iv) petrographic examination, (v)
deleterious materials and organic impurities, (vi) test for aggregate crushing value.

b. Load Test on Members or any other Tests

(i) In the event of any work being suspected of material or workmanship or both, the Engineer
requiring its removal and reconstruction may order, or the Contractor may request that it
should be load tested in accordance with the following provisions:
(ii) The test load shall be 125 percent of the maximum superimposed load for which the structure
was designed. Such test load shall not be applied before 56 days after the effective hardening
of concrete. During the test, struts strong enough to take the whole load shall be placed in
position leaving a gap under the members, The test load shall be maintained for 24 hours
before removal.

(iii) If within 24 hours of the removal of the load, the structure does not show a recovery of at
least 75 percent of the maximum deflection shown during the 24 hours under load, the test
loading shall be repeated after a lapse of at least 72 hours, The structure shall be considered
to have failed to pass the test if the recovery after the second test is not at least 75 percent of
the maximum deflection shown during the second test. If the structure is certified as failed by
the Engineer, the cost of the load test shall be borne by the Contractor.

(iv) Any other tests, e.g. taking out in an approved manner concrete cores, examination and tests
on such cores removed from such parts of the structure as directed by the Engineer, sonic
testing, etc., shall be carried out by the Contractor, if so directed, at no extra cost.

c. Unsatisfactory Tests: Should the results of any test prove unsatisfactory, or the structure
shows signs of weakness, undue deflection or faulty construction, the Contractor shall remove
and rebuild the member or members involved or carry out such other remedial measures as
may be required by the Engineer, without any additional cost.

2.57 ADMIXTURES

a. General: Admixtures may be used in concrete where required, only with the approval of the
Engineer based upon evidence that, with the passage of time, neither the compressive strength
nor its durability reduced. Calcium chloride shall not be used for accelerating set of the
cement for any concrete containing reinforcement, or embedded steel parts. When calcium
chloride is permitted to be used, such as in mass concrete works, it shall be dissolved in water
and added to the mixing water in an amount not to exceed 1.5 percent of the weight of the
cement in each batch of concrete. When admixtures are used, the designed concrete mix shall
be corrected accordingly. Admixtures shall be used as per manufacturer’s instruction and in
the manner and with the control specified by the Engineer.

b. Air Entraining Agents: Neutralized vinsol resin or other approved air entraining agent may
be used to produce the specified amount of air in the concrete mix and these agents shall
conform to the requirements of ASTM standard 6-260; Air Entraining Admixtures for
Concrete. The recommended total air content of the concrete is 4% ± 1%. The method of
measuring air content shall be as per I.S. 1199

c. Water Reducing Admixtures: Water reducing lignosulfonate admixture may be added in

quantities approved by the Engineer. The admixtures shall be added in the form of a
solution.

d. Retarding Admixtures: Retarding agents may be added to the concrete mix in quantities
approved by the Engineer.

e. Water-proofing Agent: Water proofing agents shall conform to I.S.2645.

f. Other Admixtures: The Engineer may at his discretion allow the Contractor to use any
other admixture in the concrete.

2.58 Not Used.

2.59 PREPARATION PRIOR TO CONCRETE PLACEMENT, FINAL INSPECTION AND
APPROVAL

a. Before the concrete is actually placed in position, the insides of the formwork shall be
inspected to see that they have been cleaned and oiled. Temporary openings shall be
provided to facilitate inspection, especially of bottoms of columns and wall forms, to permit
removal of sawdust, wood shavings, binding wire, dirt, etc. Openings shall be placed or
holes drilled so that these materials and water can be removed easily. Such openings/holes
shall be suitably plugged later.

b. The various trades shall be permitted ample time to install drainage and plumbing lines, floor
and trench drains, conduits, hangers, anchors, inserts, sleeves, bolts, frames and other
miscellaneous embedments to be cast in the concrete as specified or required or as is
necessary for the proper execution of the work.

c. All embedded parts, inserts, etc., supplied by the HMWSSB or the Contractor shall be
correctly positioned and securely held in the forms to prevent displacement during depositing
and vibrating of concrete.

d. All anchor bolts shall be positioned and kept in place with the help of properly manufactured
templates unless specifically waived in writing by the Engineer.

e. Slots, openings, holes, pockets, etc., shall be provided in the concrete work in the positions
specified or required or as directed by the Engineer.

f. Reinforcement and other items to be cast in concrete shall have clean surfaces that will not
impair bond.

g. Prior to concrete placement, all work shall be inspected and approved by the Engineer and if
found unsatisfactory, concrete shall not be poured until after all defects have been corrected.

h. Approval by the Engineer of any and all materials and work as required herein shall not
relieve the Contractor from his obligation to produce finished concrete in accordance with the
requirements of the Specifications.

j. Rain or Wash Water: No concrete shall be placed in wet weather or on a water-covered

surface. Any concrete that has been washed by heavy rains shall be entirely removed, if there
is any sign of cement and sand having been washed away from the concrete mixture. To
gaurd against damage which may be caused by rains, the works shall be covered with
tarpaulins immediately after the concrete has been placed and compacted before leaving the
work unattended. Any water accumulating on the surface of the newly placed concrete shall
be removed by approved means and no further concrete shall be placed thereon until such
water is removed. To avoid flow of water over/around freshly placed concrete, suitable
drains and sumps shall be provided.

k. Bonding Mortar: Where the concrete has not fully hardened, all laitance shall be removed
by scrubbing the west surface with wire or bristle brushes, care being taken to avoid
dislodgement of particles of aggregate. The surface shall be thoroughly wetted and all free
water removed. The surface shall then be coated with neat cement slurry. On this surface, a
layer of concrete not exceeding 150mm in thickness shall first be placed and shall well
rammed against old work, particular attention being paid to corners and close spots; work
thereafter shall proceed in the normal way.

2.60 TRANSPORTATION
a. General: All buckets, containers or conveyors used for transporting concrete shall be mortar-
tight. Irrespective of the method of transportation adopted, concrete shall be delivered with
the required consistency and plasticity without segregation or loss of slump. However, chutes
shall not be used for transport of concrete without the written permission of the Engineer and
concrete shall not be rehandled before placing.

b. Re-tempered or Contaminated Concrete: Concrete must be placed in its final position before
it becomes too stiff to work. On no account, water shall be added after the initial mixing.
Concrete which has become stiff or has been contaminated with foreign materials shall be
rejected and disposed off as directed by the Engineer.

c. Cleaning of Equipment: All equipment used for mixing, transporting and placing of
concrete shall be maintained in clean conditions. All pans, buckets, hoppers, chutes, pipelines
and other equipment shall be thoroughly cleaned after each period of placement.

2.61 PROCEDURE FOR PLACING OF CONCRETE

a. Engineer's approval of Equipment & Methods: Before any concrete is placed, the entire
placing programme, consisting of equipment, layout, proposed procedures and methods shall
be submitted to the Engineer for approval if so demanded by the Engineer and no concrete
shall be placed until Engineer's approval has been received. Equipment for conveying
concrete shall be of such size and design as to ensure a practically continuous flow of
concrete during depositing without segregation of materials, considering the size of the job
and placement location.

b. Time Interval between Mixing and Placing: Concrete shall be placed in its final position
before the cement reaches its initial set and concrete shall normally be compacted in its final
position within thirty minutes of leaving the mixer and once compacted, it shall not be
disturbed.

c. Avoiding Segregation: Concrete shall, in all cases, be deposited as nearly as practicable

directly, in its final position, and shall not be rehandled for caused to flow in a manner which
will cause segregation, loss of materials, displacement of reinforcement, shuttering or
embedded inserts, or impair its strength. For locations where direct placement is not possible,
and in narrow forms, the Contractor shall provide suitable drop and "Elephant Trunks" to
confine the movement of concrete. Special care shall be taken when concrete is dropped from
a height, especially if reinforcement is in the way, particularly in column and thin walls.

d. Placing by Mannual Labour: Except when otherwise approved by the Engineer, concrete
shall be placed in the shuttering by showels or other approved implements, and shall not be
dropped from a height more than 1.0 m or handled in a manner which will cause segregation.

e. Placing by Mechanical Equipment: The following specification shall apply when placing or
concrete by use of mechanical equipment is warranted considering the nature of work
involved. The control of placing shall begin at the mixer discharge. Concrete shall be
discharged by a vertical drop into the middle of the bucket or hopper and this principle of a
vertical discharge of concrete shall be adhered to throughout all stages of delivery until the
concrete comes to rest in its final position.

(i) Types of Buckets: Central-bottom-dump buckets of a type that provides for positive
regulation of the amount and rate of deposition of concrete in all dumping positions, shall be
employed.

(ii) Operation of Bucket: In placing concretes in large open areas, the bucket shall be spotted
directly over the position designated and then lowered for dumping. The open bucket shall
 clear the concrete already in place and the height of drop; shall not exceed 1.0 m. The bucket
shall be opened slowly to avoid high vertical bounce. Dumping of buckets on the swing or in
any manner which results in separation of ingredients of disturbance of previously placed
concrete will not be permitted.

f. Placement in Restricted Forms: Concrete placed in restricted forms by barrows, buggles,

cars, short chutes or hand shovelling shall be subject to the requirement for vertical delivery
of limited height to avoid segregation and shall be deposited as nearly as practicably in its
final position.

g. Chuting: Where it is necessary to use transfer chutes, specific approval of Engineer must be
obtained to type, length, slopes, baffles, vertical terminals and timing of operations. These
shall be so arranged than an almost continuous flow of concrete is obtained at the discharge
and without segregation. To allow for the loss of mortar against the sides of the chutes, the
first mixes shall have less coarse aggregate. During cleaning of chutes, the waste water shall
be kept clear of the forms. Concrete shall not be permitted to fall from the end of the chutes
by more than 1.0 m. Chutes, when approved for use, shall have slopes not flatter than 1 vert :
3 horiz. and not steeper than 1 vert. : 2 horiz. Chutes shall be of metal or metal lines end of
rounded cross section. The slopes of all chute sections shall be approximately the same. The
slopes of all chute sections shall be approximately the same. The discharge end of the chutes
shall be maintained above the surface of the concrete in the forms.

h. Placing by Pumping/Pneumatic Placers:

(i) Concrete may be conveyed and placed by mechanically operated equipment e.g., pumps or
pneumatic placers only with the written permission of the Engineer. The slump shall be held
to the minimum necessary for conveying concrete by this method.

(ii) When pumping is adopted, before pumping of concrete is started, the pipeline shall be
lubricated with one or two batches of mortar composed of one part cement and two parts
sand. Cars shall be taken to avoid stoppages in work once pumping has started.

(iii) When a pneumatic placer is used, the manufacturer's advice on layout of the pipeline shall be
followed to avoid blockages and excessive wear. Restraint shall be provided at the discharge
box to cater for the reaction at this end.

(iv) Manufacturer's recommendations shall be followed regarding concrete quality and all other
related matters when pumping/pneumatic placing equipment is used.

j. Concrete in Layers: Concreting, once started, shall be continuous untill the pour is completed.
Concrete shall be placed in successive horizontal layers of uniform thickness ranging from 15
cm to 90 cm as directed by Engineer. These shall be placed as rapidly practicable to prevent
the formation of cold joints or planes of weakness between each succeeding layer within the
pour. The thickness of each layer shall be such that it can be deposited before the previous
layer has stiffened. The bucket loads or other units of deposit, shall be spotted progressively
along the face of the layer with such overlap as will facilitate spreading the layer to uniform
depth and texture with a minimum shovelling. Any tendency to segregation shall be corrected
by shovelling stones into mortar rather than mortar on to stones. Such a condition shall be
corrected by redesign of mix or other means, as directed by the Engineer.

k. Bedding of Layers: The top surface of each pour and bedding planes shall be approximately
horizontal unless otherwise instructed.

m. Compaction: Concrete shall be compacted during placing, with approved vibrating

equipment until the concrete has been consolidated to the maximum practicable density, is
free of pockets of coarse aggregate and fits tightly against all form surfaces, reinforcement
 and embedded fixtures. Particular care shall be taken to ensure that all concrete placed
against the form faces and into corners of forms of against hardened concrete at joints is free
from voids or cavities. The use of vibrators shall be consistent with the concrete mix and
caution exercised not to over vibrate the concrete to the point that segregation results.

(i) Type of Vibrators: Vibrators shall conform to IS specifications. Type of vibrator to be used
shall depend on the structures where concrete is to be placed. Shutter vibrators to be
effective, shall be firmly secured to the form work which must be sufficiently rigid to transmit
the vibration and strong enough not to be damaged by it. Immersion vibrators in sufficient
numbers and each of adequate size shall be used to properly consolidate all concrete.
Tapping or external vibrating of forms by hand tools or immersion vibrators will not be
permitted.

(ii) Use of Vibrators: The exact manner of application and the most suitable machines for the
purpose must be carefully considered and operated by experienced men. Immersion vibrators
shall be inserted vertically at points not more than 450 mm apart and withdrawn when air
bubbles cease to come to the surface. Immersion vibrators shall be withdrawn very slowly.
In no case shall immersion vibrators be used to transport concrete inside the forms. Particular
attention be paid to vibration at the top of a lift e.g. in a column or wall.

(iii) Melding Successive Batches: When placing concrete in layers, which are advancing
horizontally as the work progresses, great care shall be exercised to ensure adequate vibration,
blending and melding of the concrete between the succeeding layers.

(iv) Penetration of Vibrators: The immersion vibrator shall penetrate the layer being placed and
also penetrate the layer below while the under layer is still plastic to ensure good bond and
homogeneity between the two layers and prevent the formation of cold joints.

(v) Vibrating against Reinforcement: Care shall be taken to prevent contact of immersion
vibrators against reinforcement steel. Immersion vibrators shall not be allowed to come in
contact with reinforcement steel after start of initial set. They shall also not be allowed to
come in contact with forms or finished surfaces.

(vi) Use of Form Attached Vibrators: Form attached vibrators shall be used only with specific
authorisation of the Engineer.

(vii) Use of Surface Vibrators: The use of surface vibrators will not be permitted under normal
conditions. However, for thin slabs and similar construction, surface vibrating by specially
designed vibrators may be permitted, upon approval of Engineer.

(viii) Stone Pockets and Mortar Pondages: The formation of stone pockets and mortar pondages
in corners and against faces of forms shall not be permitted. Should these occur, they shall be
dug out, reformed and refilled to sufficient depth and shape for thorough bonding, as directed
by the Engineer.

n. Placement Interval: Except when placing with slip forms, each placement of concrete in
multiple lift work, shall be allowed to set for atleast 24 hours after the final set of concrete
and before the start of a subsequent placement.

p. Special provision in placing: When placing concrete in walls with openings, in floors of
integral slabs and beam construction and other similar conditions, the placing shall stop when
the concrete reaches the top of the opening in walls or bottom horizontal surface of the slab,
as the case may be. Placing shall be resumed before the concrete in place takes initial set,
but not until it has had time to settle as determined by the Engineer.
q. Placing concrete through reinforcing steel: When placing concrete through reinforcing steel,
care shall be taken to prevent segregation of the coarse aggregate. Where the congestion of
steel makes placing difficult, it may be necessary to temporarily move the top steel aside to
get proper placement and restore reinforcing steel to design position and the Engineer's
approval shall be obtained prior to adopting this method.

r. Bleeding or free water on top of concrete being deposited into the forms, shall be cause to
stop the concrete pour and the conditions causing this defect corrected before any further
concreting is resumed.

2.62 APPLICATION OF ARALDITE FOR BONDING OF NEW AND OLD CONCRETE

a. General: Araldite epoxy resins may be used to bond fresh concrete to concrete that is fully
cured, to give a monolithic bond capable of transmitting high stresses when traditional
bonding agents such as cement slurry cannot always be relied upon to provide good adhesion
which is particularly the case when large areas are involved. The Araldite based formulation
shall be applied to a suitably prepared concrete substrata and the fresh concrete poured as
soon as possible, but always during the `open time' of the adhesive. Materials used shall be
only as approved by the Engineer. Manufacturer's instructions shall be followed in all
respects. General requirements pertaining to the use of Araldite for bonding of new and old
concrete are described therein.

b. Formulation:
Araldite GY250 100 Parts by weight.
Hardener HY825 20 - do -
Hardener HY830 20 - do -
Hardener HY850 20 - do -
Silica Flour 20 - do -

c. Application
(i) Preparation of the Substrata: To obtain good adhesion, it is necessary to have a clean and
sound substrata. Preparation can be carried out using a variety of techniques including
chemical treatment and mechanical methods such as grinding, milling, abrading, planning and
sand blasting. Dust and loose particles resulting from the pretreatment should be removed by
vacuum cleaning or oil-free or blast.

(ii) Mixing: The resin and hardener should be thoroughly mixed before mixing in the dry filler.
The mixed, ready to use adhesive should not contain lumps of unwetted filler and should be
of uniform colour. For a total weight of 1 Kg. or less, hand mixing should be sufficient. For
quantities in excess of 1 Kg., the use of a mechanical mixer is recommended.

(iii) Pot life and `Open Time':

A. The pot life is the period during which the ready to use ARALDITE based formulation must
be applied. After this period, the mix can no longer be worked and will have begun to set in
its container. The table below indicates the pot life at different temperatures :
Mix Temperature Pot life in Minutes
-------------------------- -------------------------
25 os centigrade 90 Minutes.
30 " " 60 "
35 " " 45 "
(The figures in this table are for batches less than 1 Kilogram.)

B. The `Open Time' is the maximum period of time allowable between application of the
ARALDITE adhesive and pouring the fresh concrete. Exceeding the `Open Time' would
 result in considerably reduced adhesion. The adhesive should be applied to the pretreated
substrata as soon as the components have been mixed and fresh concrete poured immediately
afterwards.

C. Accurate knowledge of the `Open Time' is essential in case the work is interrupted.

D. Table 9.9 gives the `Open Time' of ARALDITE based formulations as a function of substrata
temperature. In all cases, the adhesives shall be applied immediately after mixing. Any delay
between mixing and application will reduce the `Open Time'. Fresh concrete must be poured
before the adhesive begins to gel. New to old concrete bonding is not recommended at
temperatures below 5o C as adequate curing cannot be assured under these circumstances.

(iv) Methods of Application: The shape and size of the concrete structure will determine the
method of application used. The ARALDITE based adhesive may be applied by hand using
brushes, brooms or any other suitable applicator.

(v) Suitability of the fresh concrete: Best results are obtained when the water / cement ratio of
the new concrete is as low as is practicable.

(vi) Coverage: One kilogramme of the mixed ARALDITE adhesive including hardeners and
filler covers an area of 2 to 3 Sq.Mts. when applied with a stiff nylon bristle brush. However,
the coverage is very much dependent on the finish in the concrete.

d. Handling Precautions: Epoxy resins can cause irritation of the skin in sensitive persons if
incorrectly handled. Certain safety precautions must therefore be observed and those
handling the resins and hardeners should be given suitable instructions. Those working with
epoxy resins should, above all, be instructed that personal cleanliness at the place of work is
essential. The resin and hardener should not be allowed to come into direct contact with the
skin. The most effective protection is achieved by wearing rubber or polythene gloves, the
latter having the advantage that they can be replaced when dirty. They are more pleasant to
wear if cotton gloves are worn underneath. Parts of the skin which have come into contact
with the resin or hardener should be washed with lukewarm water and a mild soap. Special
cleaning creams have also proved to be highly suitable.

2.63 CONSTRUCTION JOINTS

a. A construction joint is defined as a joint in the concrete introduced for convenience in

construction at which special measures are taken to achieve subsequent continuity without
provision for further relative movement.

b. All the drawings submitted for the Engineer's approval shall indicate position of all
construction joints and lifts. No concreting shall be started until the Engineer has approved
the method of placing, the positions and form of the construction joints and lifts. The
construction joints shall be so located as not to impair the strength of the structure. Rebates,
keys or notches shall be formed and water stops inserted as the Engineer may require. The
position of construction joints and the size of the formwork panels shall be so co-ordinated
that where possible, the line of any construction joints coincides with the line of a formwork
joint and that in any case all construction joint lines and formwork joint lines appear as a
regular and uniform series. For all exposed horizontal joints and purposely inclined joints, a
uniform joint shall be formed with a batten of approved dimensions to give a straight and neat
joint line.

c. Concrete placed to form the face of a construction joint shall have all laitance removed and
the aggregate exposed prior to the placing of fresh concrete. The laitance shall wherever
practicable be removed by spraying the concrete surface with water under pressure and be
 removed while the concrete is still green. The whole of the concrete surface forming part of
the joint shall be hacked to expose the aggregate. Where aggregate is damaged during
hacking, it shall be removed from the concrete face by further hacking. All loose matter shall
be removed and the exposed surface thoroughly cleaned by wire brushing, air blasting or
washing, leaving the surface thoroughly cleaned by wire brushing, air blasting or washing,
leaving the surface clean and damp. Immediately before fresh concrete is placed, a 12 mm.
thick layer of sand/cement mortar mixed in the same proportions as in the concrete shall be
spread in the horizontal face of the construction joint. A drier mix shall be used for the top
lift of horizontal pours to avoid laitance. The new concrete shall be well worked against the
prepared face before the mortar sets. Special care shall be taken to obtain thorough
compaction and to avoid segregation of the concrete along the joint plane.

2.64 MOVEMENT JOINTS

a. Movement joints are defined as all joints intended to accommodate relative movement
between adjoining parts of a structure, special provision being made where necessary for
maintaining the water tightness of the joint. The Contractor shall comply with the
instructions of manufacturers of proprietary jointing materials and shall, if required by the
Engineer, demonstrate that the jointing materials can be applied satisfactorily.

b. The Contractor shall show locations of all movement joints and details thereof on drawings
submitted for the Engineer's approval.

c. The surface of set concrete in a movement joint shall, as shown on the Drawings, be painted
with two coats of bituminous paint and new concrete shall be placed against it only when the
paint is dry. Expansion joints shall be formed by a separating strip of approved preformed
joint filler.

d. Caulking grooves shall be provided as shown on the specification drawings. At all joints
where a caulking groove is formed, immediately prior to caulking, the groove shall be wire
brushed and loose material removed and blown out by compressed air. After the grove has
dried, it shall be primed and caulked with approved sealing compound applied in accordance
with the manufacturer's instructions. At all caulked joints, the face of the strip and a width of
concrete on either side shall be painted with two coats of paint having the same base as the
sealing compound.

2.65 WATER STOPS AND JOINT FILLLERS

a. At all construction, contraction and expansion joints in the water retaining structures and
wherever specified or directed by the Engineer, water stops shall be provided. The water
stops shall be P.V.C., type or of any other equivalent material as approved by the Engineer.
P.V.C., water stops shall have a tensile strength of not less than 14 MN/m2 and elongation at
break of not less than 300%. Water stops shall not be exposed to direct sunlight for long
periods. Before being concreted in, water stops shall be cleaned of all foreign materials.
Wherever provided, water stops shall be placed in such a manner that they are embedded in
the adjacent sections of the panels for equal width.

b. As far as possible, jointing on site shall be confined to the making of butt joints in straight runs of water

stops. Where it is agreed with the Engineer that it is necessary to make an intersection or change of

direction of any joint, other than a butt joint in a straight run on site, a preliminary joint, intersection or

change of direction piece shall be made and submitted to such tests as the Engineer may require.
c. Flexible water stops shall be fully supported in the formwork, free of nails and clear of
reinforcement and other fixtures. Damaged water stops shall be replaced and during
concreting care shall be taken to place the concrete so that water stops do not bend or distort.

d. The different types of water stops to be used in liquid retaining structures will be as follows :-

Type of Joint Type of Water Stops

------------- -------------------
(i) Partial/Complete contraction 150 mm wide, ribbed with
joint in walls and slabs. hollow centre bulb & 5 mm
minimum thickness.

(ii) Expansion joints in walls and 225 mm wide, ribbed with

slabs. hollow centre bulb & 9 mm
minimum thickness.
 Type of Joint Type of Water Stops
------------- -------------------

(iii)Construction joint in raft 225mm wide,ribbed without

hollow centre bulb & 9 mm
minimum thickness.

(iv) Construction joint in wall 150 mm wide, ribbed with

hollow centre bulb and
5 mm minimum thickness.

(v) Expansion joint raft 225 mm wide, ribbed with

hollow centre bulb & 9 mm
minimum thickness.

e. Jointing Fillers: Joint fillers shall be of durable, compressible, and non-extruding material.

2.66 SEALING COMPOUNDS

Horizontal joints shall, where used in water retaining structures be sealed with a cold pouring
polysulphide rubber sealing compound of quality equal to, or better than servicised
"Paraseal". Horizontal joints in roofs, floors and other non-water retaining structures shall be
sealed with an approved sealant with properties equal to or better than servicised "Paraplastic
41". Vertical joints and joints in the soffits of slabs in both water retaining as well as non-
water retaining structures shall be sealed with a trowel or gun applied polysulphide rubber
sealing compound such as servised "Vertiseal" or equivalent. Sealing compounds shall be
fully cured before water is permitted to come in contact. At 40o Centigrade, the curing time
would be approximately 7 weeks for polysulphide compound.

2.67 TOLERANCES IN CONCRETE SURFACES

a. Concrete surfaces for the various classes of unformed and formed finishes specified in
various clauses shall comply with the tolerances shown in Table 9.11 hereunder, except where
different tolerances are expressly required by the specification.

b. In the Table 9.11 `line and level' and `dimension' shall mean the lines, levels and cross-
sectional dimensions as specified and required.

c. Surface irregularities shall be classified as `abrupt' or `gradual'. Abrupt irregularities include,

but shall not be limited to, offsets and fins caused by displaced or misplaced formwork, loose
knots and other defects in formwork materials, and shall be tested by direct measurement.
Gradual irregularities shall be tested by means of a straight template for plane surfaces or its
suitable equivalent for curved surfaces, the template being 3 m long for unformed surfaces
and 1.5 m long formed surfaces.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ---
Class Maximum tolerance (mm) in :
of --------------------------------------------------------
finish Line and Abrupt Gradual Dimension
Level Irregularity Irregularity

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
U 1 12 6 6 -
U 2 6 3 3 -
U 3 6 3 3 -
F 1 12 6 6 + 12 - 6
F 2 6 6 6 + 12 - 6
F 3 3 3 3 + 6 -

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

2.68 UNFORMED SURFACE - CLASS OF FINISH

a. Finishes to unformed surface of concrete shall be classified as U 1, U 2, U 3, `speed' or
`bonded concrete'. Where the class of finish is not specified the concrete shall be finished to
Class - U 1.

b. Class - U 1 finish is the first stage for Class- U 2 and Class U 3 finishes and for a bonded
concrete surface. Class U 1 finish shall be a levelled and screeded, uniform plain or ridged,
finish which (unless it is being converted to Class U 2, U 3 or bonded concrete) shall not be
disturbed in any way after the initial set and during the period of curing, surplus concrete
being struck off immediately after compaction.

c. Where a bonded concrete surface is specified, the laitance shall be removed from the Class U
1 finished surface and the aggregate exposed while the concrete is still green.

d. A spaded finish shall be a surface free from voids and brought to a reasonably uniform
appearance by the use of shovels as it is placed in the works.

e. Class - U 2 finish shall be a wood float finish. Floating shall be done after the initial set of
the concrete has taken place and the surface had hardened sufficiently. The concrete shall be
worked no more than is necessary to produce a uniform surface free from screed marks.

f. Class - U 3 finish shall be a hard smooth steel - trowelled finish. Trowelling shall not
commence until the moisture film has disappeared and the concrete has hardened sufficiently
to prevent excess laitance from being worked into the surface. The surfaces shall be
trowelled under firm pressure and left free from trowel marks.

g. The addition of dry cement, mortar or water shall not be permitted during any of the above
operation.
2.69 CURING, PROTECTING, REPAIRING AND FINISHING

a. Curing
(i) All concrete shall be cured by keeping it continuously damp for the period of time required
for complete hydration and hardening to take place. Preference shall be given to the use of
continuous sprays, or ponded water, continuously saturated coverings of sacking, canvas,
hessianor other absorbent materials, or approved effective curing compounds applied with
spraying equipment capable of producing a smooth, even - textured coat. Extra precautions
shall be exercised in curing concrete during cold and hot weather as outlined hereinafter. The
quality of curing water shall be the same as that used for mixing concrete.

(ii) Certain types of finish or preparation for overflying concrete must be done at certain stages of
the curing process and special treatment may be required for specific concrete surface finish.

(iii) Curing of concretes made of high alumina cement and super-sulphated cement shall be
carried out as directed by the Engineer.
(A) Curing with Water: Fresh concrete shall be kept continuously wet for a minimum period of
10 days from the date of placing of concrete, following a lapse of 12 to 14 hours after laying
concrete. The curing of horizontal surfaces exposed to the drying winds shall however begin
as soon as the concrete has hardened. Water shall be applied to formed surfaces immediately
upon removal of forms. Quantity of water applied shall be controlled so as to prevent erosion
of freshly placed concrete.

(B) Continuous Spraying: Curing shall be assured by use of an ample water supply under
pressure in pipes, with all necessary appliance of hose, sprinklers and spraying devices.
Continuous fine mist spraying or sprinkling shall be used, unless otherwise specified or
approved by the Engineer.

(C) Alternate curing methods:

(1) Whenever, in the judgement of the Engineer, it is necessary to omit the continuous spray
method, a covering of clean sand or other approved means such as wet gunny bags, which
will prevent loss of moisture from the concrete, may be used. No type of covering will be
approved which would stain or damage the concrete during or after the curing period.
Covering shall be kept continuously wet during the curing period.

(2) For curing of concretes in pavements, side-walks, floors, flat roofs of other level surfaces, the
ponding method of curing is preferred. The method of containing the ponded water shall be
approved by the Engineer. Special attention shall be given to edges and corners of the slabs
to ensure proper protection to these areas. The ponded areas shall be kept continuously filled
with water during the curing period.

(3) Curing compound: Surface coating type curing cumpounds shall be used only by special
permission of Engineer. Curing compounds shall be liquid type white pigmented, conforming
to U.S. Bureau of Reclamation specification. No curing compound shall be used on surfaces
where future blending with concrete, water of acid proof membrane, or painting is specified.

(4) Curing equipment: All equipment and materials required for curing shall be on hand and
ready for use before concrete is placed.

b. Protecting Fresh Concrete

(i) Fresh concrete shall be protected from defacements and damage due to construction
operations by leaving forms in place for an ample period as specified later in this
specification. Newly placed concrete shall be protected by approved means such as tarpaulins
 from rain, sun and winds. Steps as approved by the Engineer shall also be taken to protect
immature concrete from damage by debris, excessive lading, vibration, abrasion or contact
with other materials, etc., that may impair the strength and/or durability of the concrete.
Workmen shall be warned against and prevented from disturbing green concrete during its
setting period. If it is necessary that the workmen enter the area of freshly placed concrete,
the Engineer may require that bridges be placed over the area.

c. Repair and Replacement of Unsatisfactory Concrete

(i) Immediately after the shuttering is removed, the surface of concrete shall be very carefully
gone over and all defective areas called to the attention of the Engineer who may permit
patching of the defective areas or also reject the concrete unit either partially or in its entirety.
Rejected concrete shall be removed and replaced by the contractor. Holes mortar composed
of one part of cement to one and half parts of sand passing 2.36 mm I.S. sieve after removing
any loose stones adhering to the concrete. Concrete surfaces shall be finished as described in
specifications or as directed by the Engineer.

(ii) Superficial honey combed surfaces and rough patches shall be similarly made good
immediately after removal of shuttering, in the presence of the Engineer and superficial water
and air holes shall be filled in. The mortar shall be well worked into the surface with a
wooden float. Excess water shall be avoided. Unless instructed otherwise by the Engineer,
the surface of the exposed concrete placed against shuttering shall be rubbed down
immediately on removal of shuttering to remove fine or other irregularities, care being taken
to avoid damaging the surface. Surface irregularities shall be removed by grinding.

(iii) If reinforcement is exposed or the honeycombing occurs at vulnerable positions e.g., ends of
beams or columns, it may be necessary to cut out the member completely or in part and
reconstruct. The decision of the Engineer shall be final in this regard. If only patching is
necessary, the edges being cut perpendicular to the affected surface or with a small under cut
if possible. Anchors, tees or dovetail slots shall be provided whenever necessary to attach the
new concrete securely in place. An area extending several centimetres beyond the edges and
the surfaces of the prepared voids shall be saturated with water for 24 hours immediately
before the patching material is placed.

(iv) Use of Epoxy: The use of epoxy for bonding fresh concrete used for repairs will be
permitted upon written approval of the Engineer. Epoxies shall be applied in strict
accordance with the instructions of the manufacturer.

(v) Method of Repair: Small size holes having surface dimensions about equal to the depth of
the hole, holes left after removal of form bolts, grout insert holes and slots cut for repair of
cracks shall be repaired as follows. The hole to be patched shall be roughened and thoroughly
soaked with clean water until absorption stops. A 5 mm thick layer of grout of equal parts of
cement and sand shall be well brushed into the surface to be patched, followed immediately
by the patching concrete which shall be well consolidated with a wooden float and left
slightly proud of the surrounding surface. The concrete patch shall be built up in 10 mm thick
layers. After an hour or more, depending upon weather conditions, it shall be worked off
flush with a wooden float and a smooth finish obtained by wiping with hessian. A steel
trowel shall be used for this purpose. The mix for patching shall be of the same materials and
in the same proportion as that used in the concrete being repaired, although some reduction in
the maximum size of the coarse aggregates may be necessary and the mix shall be kept as dry
as possible. Mortar filling by air pressure (guniting) shall be used for repair of areas too large
and / or too shallow for patching with mortar. Patched surfaces shall be given a final
treatment to match the colour and texture of the surrounding concrete. White cement shall be
substituted for ordinary cement, if so directed by the Engineer, to match the shade of the
patch with the original concrete.
(vi) Curing of Patched Work: The patched area shall be covered immediately with an approved
non-staining, water-saturated material such as gunny bags which shall be kept continuously
wet and protected against sun and wind for a period of 24 hours. Thereafter, the patched area
shall be kept wet continuously by a fine spray, or sprinkling for not less than 10 days. All
fillings shall be tightly bonded to the concrete and shall be sound, free from shrinkage cracks
after the fillings have been cured and dried.

(vii) Approval by the Engineer: All materials, procedures and operations used in the repair work
shall be subject to the approval of the Engineer.

d. Finishing

(i) The type of finish for formed concrete surfaces shall be as follows, unless varied by the
Engineer.

(ii) When the structure is in service all the surfaces shall receive no special finish, except repair of
damaged or defective concrete, removal of fine and abrupt irregularities, filling defective
concrete, removal of fins and abrupt irregularities, filling of holes left by form ties and rods
and clean up of loose or adhering debris.

(iii) Surfaces which will be exposed to the weather and which would normally be level, shall be
sloped for drainage. Unless a horizontal surface or the slope required is specified, the tops of
narrow surfaces such as stair treads, walls, curbs and parapets shall be sloped across the width
approximately 1 in 30. Broader surfaces such as walkways, roads, parking areas and
platforms shall be sloped about 1 in 50. Surfaces that will be covered by backfill or concrete,
subfloors to be covered with concrete topping, terrazzo or quarry tiles, and similar surfaces
shall be smooth screeded and levelled to produce even surfaces. Surface irregularities shall
not exceed 6 mm. Surfaces which will not be covered by backfill, concrete or tile toppings
such as outside decks, floors of galleries and sumps, parapets, gutters, side-walks, floors and
slabs, shall be consolidated, screeded and floated. Excess water and laitance shall be removed
before final finishing. Floating may be done with hand or power tools and started as soon as
the screeded surface has attained a stiffness to permit finishing operations and these shall be
the minimum required to produce a surface uniform in texture and free from screed marks or
other imperfections. Joints and edges shall be tooled as specified or as directed by the
Engineer.

(iv) Standard finish for exposed concrete: Exposed concrete shall mean any concrete, other than
floors or slabs, exposed to view upon completion of the works. Unless otherwise specified,
the standard finish for exposed concrete shall be a smooth finish. A smooth finish shall be
obtained with the use of lined or plywood forms having smooth and even surfacs and edges.
Panels of forms shall be of uniform size and be as large as practicable and installed with
closed joints. Upon removal of forms the joint marks shall be smoothed off and all
blemishes, projections etc., removed leaving the surfaces smooth.

(v) Integral cement concrete finish: When specified, an integral cement concrete finish of
specified thickness for floors and slabs shall be applied either monolithic or bonded, as
specified or directed by the Engineer. The surface shall be tested with a straight edge and any
high and low spots eliminated. Floating or trowelling of the finish shall be permitted only
after all surface water has evaporated. Dry cement or a mixture of dry cement and sand shall
not be sprinkled directly on the surface of the cement finish to absorb moisture or to stiffen
the mix.

(vi) Rubbed finish: A rubbed finish shall be provided only on exposed concrete surfaces. Upon
removal of forms, all fins and other projections on the surfaces shall be carefully removed,
offsets levelled and voids and/ or damaged sections immediately saturated with water and
 repaired by filling with a concrete or mortar of the same composition as was used in the
surface. The surfaces shall then be thoroughly wetted and rubbed with carborundum or other
abrasive. Cement mortar may be used in the rubbing, but the finished surfaces shall not be
brush coated with either cement or grout after rubbing. The finished surfaces shall present a
uniform and smooth appearance.

e. Protection: All concrete shall be protected against damage until final acceptance by the
Engineer.

2.70 PREPARATION OF EARTH STRATA FOR FOUNDATIONS

a. General: All earth surfaces upon which or against which concrete is to be placed, shall be
well compacted and free from standing water mud or debris. Soft, yielding soil shall be
removed and replaced with suitable earth well compacted or lean concrete as directed by
Engineer. Where speficied, lean concrete shall be provided on the earth stratum for receiving
concrete, the surface of absorptive soils against which concrete is to be placed shall be
moistened thoroughly so that no moisture will be drawn from the freshly placed concrete and
later shall help to cure the concrete.

b. The preparation of concrete surfaces upon which additional concrete is to be placed later,
shall preferably be done by scarifying and cleaning while the concrete is between its initial
and final set. This method shall be used wherever practicable and shall consist of cutting the
surface with picks and stiff brooms and by use of an approved combination of air and water
jet as directed by the Engineer. Great care shall be taken in performing this work to avoid
removal of too much mortar and the weakening of the surface by loosening of aggregate.
When it is not practicable to follow the above method, it will be necessary to employ air tools
to remove laitance and roughen the surface. The final required result shall be a pitted surface
from which all dirt, unsound concrete, laitance and glazed mortar have been removed.

c. Bonding treatment (Mortar)

(i) After rock and concrete surfaces upon which new concrete is to be placed have been scarfied,
cleaned and wetted as specified herein, they shall receive a bonding treatment, immediately
before placement of the concrete.

(ii) The bonding medium shall be a coat of cement-sand mortar. The mortar shall have the same
cement-sand proportions as the concrete which shall be placed on it. The water-cement ratio
shall be determined by placing conditions and as approved by the Engineer.

(iii) Bonding mortar shall be placed in sufficient quantity to completely cover the surface, about
10 mm thick for rock surface and about 5 mm thick for concrete surface. It shall be brushed
or broomed over the surface and worked thoroughly into all cracks, crevices and depressions.
Accumulations or puddles or mortar shall not be allowed to settle in depressions and shall be
brushed out to a satisfactory o, as determined by the Engineer.

(iv) Mortar shall be placed at such a rate that it can be brushed over the surface just in advance of
the placement of concrete only as much area shall be covered with mortar takes place. The
amount of motar that will be permitted to be placed at any one time, or the area which it is to
cover, shall be in accordance with the Engineer's directions.

d. Cleaning and Bonding formed construction joints: Vertical construction joints shall be
cleaned as specified above or by other methods approved by the Engineer. In placing
concrete against formed construction joints, the surface of the joints, where accessible, shall
be coated thoroughly with the specified bed-joints, bonding mortar immediately before they
are covered with concrete or by scrubbing with wire brushes dipped into the fresh concrete.
 Where it is impracticable to apply such a mortar coating, special precautions shall be taken to
ensure that the concrete is brought into intimate contact with the surface of the joint by
careful pudding and spading with the aid of vibrators and suitable tools.

e. Expansion and contraction joints: Provision shall be made for expansion and contraction in
concrete by use of special type joints located wherever necessary and as shown on approved
drawings.

2.71 HOT WEATHER REQUIREMENT

a. All concrete work performed in hot weather shall be in accordance with I.S. 456, except as
herein modified. Admixtures may be used only when approved by the Engineer. Adequate
provisions shall be made to lower concrete temperatures by cool ingredients, eliminating
excessive mixing, preventing exposure of mixers and conveyors to direct sunlight and the use
of reflective paint on mixers, etc. The temperature of the freshly placed concrete shall not be
permitted to exceed 38 o Centigrade.

b. Consideration shall be given to shading aggregate stock pilesfrom direct rays of the sun and
spraying stockpiles with water, use of cold water when available, and burying. insulating,
shading and / or painting white the pipelines and water storage tanks and conveyance. In
order to reduce loss of mixing water, the aggregate, wooden forms, subgrade, adjacent
concrete and other moisture absorbing surfaces shall be well wetted prior to concreting,
placement and finishing shall be done as quickly as possible. Extra precautions shall be taken
for the protection and curing of concrete. Consideration shall be given to continuous water
curing and protection against high temperatures and drying hot winds for a period of at least 7
days immediately after concrete has set and after which normal curing procedures may be
resumed.

2.72 PLACING CONCRETE UNDERWATER

a. Under all ordinary conditions, all foundations shall be completely dewatered and concrete
placed in the dry. However, when concrete placement under water is necessary, all work
shall conform to I.S. 456 and the procedure shall be as follows :-
(i) Method of Placement: Concrete shall be deposited underwater by means of tremies, or drop
bottom buckets of approved type.
(ii) Direction, Inspection and Approval: All work requiring placement of concrete underwater
shall be designed, directed and inspected with due regard to local circumstances and purposes.
All underwater concrete shall be placed according to plans or specifications approved by the
Engineer.

2.73 PRECAST CONCRETE

a. General: Precast concrete units, whether manufactured on or off site, shall comply in every
way with the provisions of the contract for in situ concrete. Wherever possible, precast units
shall be hydraulically pressed. When ready for incorporation in the works, precast units shall
be responsible for the accuracy of the level, shape of the bed or platform. A suitable serial
number and the date of casting shall be impressed or painted on each unit.

b. Striking Forms: Side shutters shall not be struck in less then 24 hours after depositing
concrete and no precast unit shall be lifted until the concrete reaches a strength of at least
twice the stress to which the concrete may be subjected to at the time of lifting.

c. Precast Units: The lifting and removal of precast units shall be undertaken without causing
shock, vibration or undue bending stresses to or in the units. Before lifting and removal takes
place, contractor shall satisfy the Engineer or his representative that the methods he proposes
to adopt for these operations will not over - stress or otherwise effect seriously the strength of
the precast units. The reinforced side of the units shall be distinctly marked.
d. Curing: All precast work shall be protected from the direct rays of the sun for at least 7
days after casting and during that period each unit shall be kept constantly watered or
preferably be compltely immersed in water if the size of the unit so permits.

2.74 PRECAST CONCRETE PIPES FOR GROUND WATER DRAINAGE

Concrete porous pipes for ground water drainage shall be made of porous concrete with
materials generally in accordance with I.S. 4350. The pipes shall be of uniform cross section
and bore and not more than 1 metre in length with square ends. The pipes shall have ogee or
rebated joints, the axial length of which shall not be less than (D/36 + 12) mm, where D is the
nominal internal diameter of the pipe in millimetres.

2.75 SLOTS, OPENINGS, GROUTING, Etc.

a. Slots, Openings or holes, pockets, etc., shall be provided in the concrete work in the approved
positions or as directed by Engineer. Any deviation from the approved drawings shall be
made good by contractor at his own expense, without damaging any other work. Sleeves,
bolts, inserts etc., shall also be provided in concrete work where so required.
b. Grouting-Standard Grout: Grout shall be provided as specified herein below.

(i) The proportions of grout shall one such as to produce a flowable mixture consistent with
minimum water content and shrinkage. The grout proportions shall be limited as follows:

Use Grout Thickness Mix proportions W/C ratio (Max)

A) Fluid Under 25mm One part portland cement 0.44
to one part sand.
B) General 25mm & over but less One part portland cement 0.53
than 50mm to 2 parts of sand
C) Stiff Mix. 50mm & over One part portland cement 0.53
to 3 parts of sand.

I. i) Sand shall be such as to produce a flowable grout without any tendency to segregate.

ii) Sand for general grouting purposes, shall be graded within the following limits :
Passing I.S. 2.36 mm sieve 95 to 100%
Passing I.S. 1.18 mm sieve 65 to 95%
Passing I.S. 300 micron sieve 10 to 30%
Passing I.S. 150 micron sieve 3 to 10%
iii) Sand for fluid grouts, shall have the fine material passing the 300 and 150 micron sieves at
the upper limits specified above.

iv) Sand, for stiff grouts, shall meet the usual grading specifications for concrete.

II. i) Surfaces to be grouted shall be thoroughly roughened and cleaned of all foreign matter and
laitance.

ii) Anchor bolts, anchor bolt holes and the bottoms for equipment and column base plates shall
be cleaned of all oil, grease, dirt and loose material. The use of hot, strong caustic solution
for this purpose will be permitted.

III. i) prior to grouting, the hardened concrete surfaces to be grouted shall be saturated with
water.

ii) Water in anchor bolt holes shall be removed before grouting is started.

(ii) Forms around base plates shall be reasonably tight to prevent leakage of the grout.
 (iii) Adequate clearance shall be provided between forms and base plate to permit grout to
be worked properly into place.

(iv) Grouting, once started, shall be done quickly and continuously to prevent segregation,
bleeding and breakdown of initial set. Grout shall be worked from one side of one
end to the other to prevent entrapment of air. To distribute the grout and to ensure
more complete contact between baseplate and foundation and to help release trapped
air, link chains can be used to work the grout into place.

(v) Grout through holes in base plates shall be by pressure grouting.

Variations in grout mixes and procedures shall be permitted if approved by the Engineer.

c. Non-shrinking Grout for Equipment Foundation

(i) Non-shrinking grout shall be used for grouting of machine base plates, anchor bolts,other
anchoring devices and at locations where ordinary grouts are ineffective due to shrinkage. It
shall be composed of a type of expansive hydraulic sheeting binder and select-graded
aggregates.It shall have properties as mentioned below :

A. Maximum grain size - 6

B. Water % (for 80% flow) - 15.17
C. Density of hardened grout gm/m1 - 2.27-2.30
D. Compressive strength N/mm²
-min 3 days - 23
7 days - 34
28 days - 45

E. Expansion%
- free - 0.15 - 0.2
- restrained - 0.08 - 0.12

(ii) Mixing, batching, cleaning, preparation of surface and curing of non-shrinking grout shall be
done as per Manufacturer's instructions.

2.76 INSPECTION
a. All materials, workmanship and finished construction shall be subject to continuous
inspection and approval of the Engineer.

b. All materials supplied by the Contractor and all work or construction performed by the
Contractor which is rejected as not being in conformity with the specifications and
requirements, shall be immediately replaced.

c. All concrete shall be protected against damage until final acceptance by the Engineer.

2.77 CLEAN-UP
Upon completion of the concrete work, all forms, equipment, construction tools, protective
coverings and any debris resulting from the work shall be removed from the premises. All
debris, i.e. empty containers, scrap wood, etc., shall be removed to "dump" daily, or as
directed by the Engineer. The finished concrete surfaces shall be left in a clean condition
satisfactory to the Engineer.
2.78 RECORDS OF CONCRETING
An accurate and uptodate record showing times, dates, weather and temperature conditions
when various positions of all the concrete structures forming the works were concreted will
be kept by the Engineer and shall be countersigned by the Contractor. If the Contractor fails
 to sign the Engineer's record, it shall nevertheless be regarded as correct and binding on the
Contractor.

2.79 SUPPLY OF CEMENT

Contractor shall make their own arrangements for the supply of cement. Further, the
Contractor shall be responsible for payments of applicable duties and taxes, port clearance,
inland transport etc.
2.80 FOUNDATION BEDDING, BONDING AND JOINTING
a. All surfaces upon or against which concrete will be placed shall be suitably prepared by
thoroughly cleaning, washing and dewatering, as specified or as the Engineer may direct, to
meet the various situations encountered in the work.
b. Soft or spongy areas shall be cleaned out and backfilled with either a soil-cement mixture,
lean concrete or clean sand fill compacted to a minimum density of 90% Modified proctor.
c. Prior to construction of form work for any item where soil will act as bottom form, approval
shall be obtained from the Engineer as to the suitability of the soil.

2.81 PREPARATION OF ROCK STRATA OF FOUNDATIONS

a. To provide tight bond with rock foundations, the rock surface shall be prepared and the
following general requirements shall be observed.

b. Concrete shall not be deposited on large sloping rock surfaces. Where required by the
Engineer, the rock shall be cut to form rough steps or benches to provide roughness or a more
suitable bearing surface.

c. Rock foundation stratum shall be prepared by picking, barring, wedging and similar methods
which will leave the rock in an entirely sound and unshattered condition.

d. Shortly before concrete is placed, the rock surface shall be cleaned with high pressure water
and air jet even though it may have been previously cleaned in that manner.

e. Prior to placing concrete, the rock surface shall be kept wet for a period of 2 to 4 hours unless
otherwise directed by the Engineer.

f. Before placing concrete on rock surfaces all water shall be removed from depressions to
permit thorough inspection and proper bonding of the concrete to the rock.