General Specification

Section 2e Concrete

SECTION 2e CONCRETE
2e.01 General Requirement
Structural concrete works shall be carried out in accordance with
the Building (Construction) Regulations and the Code of Practice
for the Structural Use of Concrete 2004.
2e.02 Cement
Unless specified otherwise, cement shall be Ordinary Portland
Cement complying with BS12:1996. Other cements shall conform
to the following British Standards:
Sulphate Resisting Portland
Portland Pulverized-fuel Ash

BS 4027:1996
BS 6588:1985

The manufacturer's test certificate shall be submitted to the

Engineer before using cement in the work. The Engineer may
require tests to be made on samples of cement taken from the
site and such tests shall be at the Contractor's expense.
All cement shall be delivered in the sealed and branded bags of
the manufacturer or in properly designed and approved bulk
containers and shall be perfectly cool and ready for use. The
cement shall be stored in a suitable building or silo, well
protected from the weather and from dampness, in a manner
which will prevent deterioration or contamination. The cement
store shall be arranged so that batches of cement can be used in
the order in which they have been delivered.
No cement which is in any way affected by dampness or aeration
shall be used in the work. Any cement which the Engineer
considers unfit for use shall be removed from the site promptly.
2e.03 Aggregates
Aggregates shall comply with the requirements of BS 882:1992.
Coarse aggregate is aggregate which will be retained on a 5mm
sieve; fine aggregate is aggregate which will pass a 5mm sieve.
The fine and coarse aggregate shall be combined in such
proportions as will give a well-graded mixture capable of
producing a dense concrete with a workability suitable for the
type of work and for the means of compaction to be used.
Coarse aggregate shall be clean sound crushed granite of the
sizes required for the various mixes. It shall be of a good shape
with not more than 10 per cent of elongated or flakey particles. It
shall be hard and free from weathered rock.

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Fine aggregate shall be clean sand, free from shells silt, clay, salt
and other impurities. If considered necessary by the Engineer,
the sand shall be rewashed at the Contractor's expense. Subject
to satisfactory grading tests and trial mixes, the Engineer may
approve the use of manufactured sand in place of natural sand.
Aggregates shall be stored on clean hard surfaces or in bunkers in
such a manner as will effectively keep the different sizes separate
and will prevent contamination and excessive segregation.
Provision shall be made to drain off rainwater from the stockpiles.
The Engineer may require samples of aggregates to be taken
from the stockpiles and tested either on site or by an approved
local testing authority. Such tests shall be at the Contractor's
expenses. Periodic tests shall be made to determine the moisture
content of the aggregate.
The Engineer shall be notified
immediately of any alteration in the source of supply of
aggregate.
2e.04 Water
Water shall be clean fresh water free from chemical or organic
impurities.
It shall be obtained by metered supply from
Government mains or from another source approved by the
Engineer, who may require the water to be tested before giving
his approval. If it should be necessary to store water on site, care
shall be taken to prevent contamination.
2e.05 Admixtures
If the Contractor wishes to use any admixtures, he shall first
obtain the approval of the Engineer. Admixtures shall be used
strictly in accordance with the manufacturer's instructions and at
approved dosage levels. When admixtures are used the amount
of water added to the mix shall be adjusted to maintain suitable
workability for placement.
Unless specified otherwise, admixtures when used shall comply
with the following standards:
Pigment for colouring cement and concrete
Accelerators, retarders, normal waterreducing
admixtures and combination of
these
Superplasticising admixtures

BS 1014:1975
BS 5075-1:1982
BS 5075-3:1985

For waterproofing admixtures, the cement content of the

concrete shall be no less than 360 kg per cu m.

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Details of any admixtures to be used shall be submitted for

approval before using:
(i)

Brand name and manufacturers literature.

(ii) Proposed dosage and detrimental

underdosage and overdosage.

effects,

if

any,

of

(iii) The chloride content which shall not exceed 2% by weight of

the admixture or 0.03% by weight of the cementitious
material, whichever is the smaller.
(iv) Method of adding to the concrete mix.
(v) The supplier shall satisfy the Engineer that any admixture or
ingredient used, or their combination, do not detrimentally
affect the strength or other properties of the concrete.
2e.06 Reinforcement
Reinforcement for concrete shall be either mild steel or high
tensile steel bars or mesh as shown on the detail drawings or bar
schedules. It shall be free from rolling defects and of the full
specified size. It shall be clean and free from loose rust, scale, oil
and grease.
Before placing orders for reinforcement, the Contractor shall
obtain the approval of the Engineer for the source of supply and
all reinforcement delivered to the site must come from the
approved source. Should the Contractor wish to change the
source of supply, he shall apply in writing to the Engineer and
obtain his approval.
The manufacturer's Certificate of Origin and test certificates for
each consignment for use in the work shall be submitted to the
Engineer. The certificates must show the chemical analysis of the
steel and the results of tensile and bending tests.
Mild steel reinforcement shall have a minimum characteristic strength of
250 MPa and shall comply with Hong Kong Construction Standard
CS2:1995.
High tensile steel reinforcement shall be hot rolled deformed bars
with a minimum characteristic strength of 460 MPa. It shall
comply with Hong Kong Construction Standard CS2:1995.
Steel mesh or fabric reinforcement shall comply with BS
4483:1998.
Reinforcing bars shall be sampled and tested in accordance with
Hong Kong Construction Standard CS2:1995.
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2e.07 Mixes
Concrete mixes shall be designed by the Contractor to have the
specified strength or grades shown on the drawings or in the
concrete schedule. Designed mixes (denoted by the suffix D) are
specified by strength and shall comply with the requirements
given in Table 1. Prescribed mixes (denoted by the suffix P) are
specified by grade and shall comply with the requirements of the
Building (Construction) Regulations.
The workability shall be selected with regard to the size of section
to be concreted, the amount of reinforcement and the means of
compaction so that the concrete can be well compacted without
causing segregation of the aggregate or bringing excess water to
the surface. A guide to workability is given in Table 2.
The wet concrete shall be sufficiently cohesive to prevent
segregation during transporting and placing operations. Mixes
which segregate easily shall not be used in the work.
The maximum size of aggregate for structural work shall
generally be 20mm. For thin sections and where reinforcement is
congested 10mm aggregate may be approved or required. For
large sections where the reinforcement is widely spaced and for
mass concrete 40mm aggregate may be approved or required.
The water/cement ratio will generally be chosen to suit strength
and workability requirements but may be limited by the
considerations of durability in accordance with Table 3.
The concrete shall contain the minimum amount of cement for durability
in accordance with Table 3A.
The Contractor shall obtain the Engineer's approval for mix
proportions proposed and for any adjustments which may be
necessary to maintain the required strength and workability
throughout the work. No concreting will be permitted until
approval of the mix proportions and trial mix results has been
given by the Engineer.

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TABLE 1
DESIGNED CONCRETE MIXES
Specified Grade
Strength (MPa)
Grade

Min Average
Preliminary Cube
Strength (MPa)
At 28
At 28
Days
Days
(150mm) (100mm)

At 3
Days

At 7
Days

At 28
Days

25D

15

20

25

35

30D

18

24

30

35D

21

28

40D

24

45D
50D

Limits of
Aggregate/Cement
Ratio (by Weight)
Max.

Min.

37

6.5 : 1

4:1

40

42

5.0 : 1

3:1

35

45

47

5.0 : 1

3:1

32

40

50

52

4.5 : 1

3:1

27

36

45

55

57

4.5 : 1

3:1

30

40

50

60

62

4.5 : 1

3:1

NOTES :
1.

Specified grade strengths at 3 and 7 days are estimated values only.

2.

Works cube strengths shall comply with the Building (Construction)

Regulations, or the Code of Practice for the Structural Use of Concrete
2004 (for 100mm cubes and C2 acceptance criteria) if accepted by the
Engineer.

3.

Requirements for preliminary cube strengths specified in Table 1 are part of

the requirements for plant trial mixes only. See Clause 2e.12.

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TABLE 2
GUIDE TO WORKABILITY
Approximate Value of Consistency
Tests
Vebe
Slump
Compactin Consistomet
(mm)
g Factor
er
(Seconds)

Conditions of Placing

Degree of
Workabilit
y

Sections subject to a high

level of vibration

Very low

0 10

0.76

More than 12

Lightly reinforced
sections with vibration

Low

10 50

0.85

4 12

Heavily reinforced
sections with vibration

Medium

50 100

0.92

24

High

100 200

0.95

02

Sections with congested

reinforcement (not
formally suitable for
vibration), tremie and
self-compacting concrete,
eg. in piles
NOTES :

1. The consistency tests are useful for comparing different mixes within
certain limits, but are not always reliable as a measure of
workabilitysuitable for the conditions under which the concrete will be
placed.
2. Compacting Factor and Vebe Tests in accordance with Hong Kong
Construction Standard CS1:2010.

TABLE 3
MAXIMUM WATER/CEMENT RATIO
Low

Exposure
Medium

High

Thin sections 100mm thick or less

and sections with less than 25mm
cover

0.50

0.45

0.40

Medium sections

0.55

0.50

0.45

Heavy sections, mass concrete and

concrete placed under water

0.60

0.55

0.50

Type of Structure

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TABLE 3A
MINIMUM CEMENT CONTENT kg/cu m
Maximum Aggregate Size
Reinforced Concrete :
- 20mm
- 10mm
Prestressed Concrete :
- 20mm
- 10mm
Plain Concrete :
- 40mm
- 20mm
Tremie Concrete :
- All sizes

Low

Exposure
Medium

290
340

360
410

300
340

360
410

220
250

270
310

400

400

High

To be
Determined
by the
Engineer

In Tables 3 and 3A, types of exposure have the following

meaning:
Low - Internal concrete, concrete exposed to the weather but not
directly to driving rain, buried concrete.
MediumConcrete wet in fresh or sea water, subject to heavy
condensation or exposed directly to driving rain.
High -

Concrete exposed to sea spray or tidal conditions.

2e.08 Control of Alkali-Silica Reaction in Concrete

The reactive alkali of concrete expressed as the equivalent
sodium oxide per cubic metre of concrete shall not exceed 3.0 kg.
The equivalent sodium oxide (Na2O) content of the concrete shall
be determined in accordance with the following steps:
(1) The equivalent Na2O shall be calculated by the expression
Equivalent Na2O = A + B + C
where
A
B
C

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is the sum of the acid-soluble alkalis (expressed as

equivalent Na2O) of cement, admixtures and water;
is equal to 1/6 the total alkalis of pulverized fuel ash
(PFA) (expressed as equivalent Na2O); and
is equal to 0.76 times the chloride ion (Cl-) of the
aggregate.

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(2) The acid-soluble alkali content of the cement shall be

determined in accordance with BS 4550-2:1970 (excl. AMD
7285, July 1992) or BS EN 196-2:2005 and shall be taken as
the average of the latest 25 daily determinations of
equivalent sodium oxide plus twice the standard deviation of
the results.
(3) The acid-soluble alkali content of admixtures shall be
determined in accordance with BS 1881-124:1988.
(4) The acid-soluble alkali content of water shall be determined
in accordance with American Public Health Association
(APHA) (17th Edition 1989) Sections 3500-K and 3500-Na.
(5) The total alkali content of the PFA shall be determined in
accordance with BS 4550-2:1970 (excl. AMD 7285, July 1992)
or BS EN 196-2:2005 and shall be taken as the average of 25
weekly determinations plus twice the standard deviation of
the results.
(6) The equivalent sodium oxide content of the coarse and fine
aggregates shall be calculated from the quantity of chloride
ion present which shall be measured in accordance with BS
812-4:1976 or BS EN 1744-1:2009.
The following particulars of the concrete mix should be submitted
by the Contractor to the Engineer:
(a) HOKLAS-endorsed test certificates not older than six months
giving the results of tests required in Clause 2e.08 (2) to (6);
(b) Calculation of the reactive alkali of the proposed mix; and
(c) New HOKLAS-endorsed test certificates giving the results of
tests required in Clause 2e.08 (2) to (6) to be submitted at
quarterly intervals together with any necessary further
calculations to demonstrate that the mix continues to comply
with the limit on reactive alkali.
2e.09 Total Chloride Content of Concrete
The total chloride content of the concrete shall not exceed the
limits shown in the following table. The total chloride content is
the total chloride ion in the concrete mix expressed as a
percentage by weight of the cementitious material.

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Type of Concrete
Prestressed concrete; steam cured
structural concrete
Reinforced concrete with sulphate resisting
Portland cement
Reinforced concrete; concrete with
embedded metal

Max Total Chloride

Content
% by Weight of Cement
0.1
0.2
0.35

2e.10 Ready-Mixed Concrete

Ready-mixed concrete shall be supplied from a source approved
by the Engineer and shall comply with the requirements of BS
8500-1:2002 and BS 8500-2:2002.
The Contractor shall be
responsible for ensuring that the concrete complies with this
specification including quality control, regularity of delivery and
continuous supply of concrete. If any of the requirements of this
specification are not complied with the Engineer may withdraw
his approval and require the Contractor to change the supplier or
stop using ready-mixed concrete.
The Contractor shall provide on site a drum mixer of minimum
half cubic metre capacity and keep it in working order in case of
an interruption of the supply of ready-mixed concrete during
concreting. A good fresh stock of materials shall always be kept
by the Contractor on site for use with the standby mixer.
The Contractor shall ensure that proper records are kept. Records
of the cement, aggregate and water contents of each batch shall
be submitted to the Engineer daily. The weights of cement and of
coarse and fine aggregates shall be continuously recorded at the
batching plant by scaled recording heads cross referenced to the
delivery dockets. Periodic tests shall be made to determine the
water content of the aggregates and the amount of water added
to each batch shall be adjusted accordingly.
Keep on site a record containing the following particulars:
(a)
(b)
(c)
(d)

Time of arrival of lorry.

Time of batching and adding water.
Registration number of lorry and name of depot.
Time when the concrete has been placed and left
undisturbed.
(e) The grade or specified strength of the concrete and
maximum size of aggregate.
(f) Position where the concrete is placed.
(g) The reference marks of any test cubes taken from this
delivery.
(h) The slump (or compacting factor).
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The concrete shall be placed, compacted and left undisturbed in

its final position within one hour or the time when the cement
first comes into contact with the mixing water.
The record book shall be available for inspection by the Engineer
or his representative at all times.
2e.11 Batching and Mixing on Site
All concrete shall be batched by weight and mixed in drum or pan
mixers of approved type unless the Engineer orders or permits in
writing another method.
The Concretor shall provide and maintain in good working order
enough mixers of suitable capacity to produce concrete at the
required rate with an appropriate reserve or standby in case of
breakdowns. A reliable weight-batcher of suitable capacity for
each mixer on site shall also be provided and maintained in good
working order.
Each mixer shall be operated at the speed recommended by the
manufacturer. All batches and mixers shall be kept clean and
free from accumulations of spilled materials. Mixer blades shall
be replaced when they are worn.
Cement shall be measured by the whole bag or by weight. Fine
and coarse aggregate shall be measured separately with due
allowance for any free water. Water shall be measured for each
batch and the amount added shall be adjusted to allow for
moisture contained in the aggregates. Admixtures shall be
accurately measured by means of suitable dispensers. When
more than one admixture is used, each shall be batched
separately and they are not to be mixed together before entering
the mixer.
The size of each batch shall not exceed the rated capacity of the
mixer. The mixer shall be charged in a manner which will assist
the blending of the materials. If it should be necessary to charge
cement separately from the other ingredients a longer mixing
time may be required to obtain proper uniformity of the mix.
The time of mixing shall be sufficient to ensure the production of
uniform concrete throughout the batch. In drum mixers, the
concrete shall be mixed for not less than 2 minutes. In pan
mixers of one cubic metre capacity or less the mixing time shall
not less than 80 sec. and the minimum time shall be increased by
20 sec. for each cubic metre of additional capacity.
All the concrete of one batch shall be discharged before the
materials for the next batch are charged. No water shall be
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added to the concrete after it has been discharged from the

mixer.
If the Engineer has given permission in writing for batching by
volume, the materials shall be measured in properly constructed
gauge boxes which shall be filled level. In measuring the fine
aggregate due allowance shall be made for the bulking which
occurs when it is damp.
If the Engineer has given permission in writing for mixing by
hand, the heap of materials shall be turned at least three times
before the addition of water. The water shall then be added by
sprinkling while the materials are being turned and the concrete
shall be turned at least three more times after the addition of the
water so that it is thoroughly and uniformly mixed throughout.
2e.12 Trial Mixes
Unless previous cube strength records of the same mix produced
at the same plant are found satisfactory, before concrete is
placed in the works trial mixes shall be made and tested to
confirm that the strength, workability and cohesion of the various
mixes of structural concrete comply with the specification. If any
change in the approved mix proportions becomes necessary, the
Engineer may require additional trial mixes to be made and
tested.
The necessary labour, materials and plant for making and testing
the trial mixes shall be provided at the Contractor's expense.
More than one trial for each grade of concrete may be necessary
at the beginning of the work. The concrete from trial mixes shall
not be used in any permanent structural work.
The concrete from the trial mixes shall first be inspected for
cohesion and segregation and the workability shall be checked to
ensure that it is suitable for the type of work and means of
compaction to be used. If these properties are satisfactory, these
cubes shall be made in accordance with Hong Kong Construction
Standard CS1:2010 and the consistence of the concrete tested by
means of the slump cone, the compacting factor apparatus or the
Vebe consistometer.
The following records of each trial mix shall be submitted to the
Engineer:
(a)
(b)
(c)
(d)

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Type and grading of aggregates.

Source or aggregate.
Type and brand of cement.
Quantity of each constituent used in the trial mix and the
equivalent weights required for one cubic metre of
concrete.
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(e)
(f)

Brief description of appearance and properties

workability, cohesion, aggregation) of the concrete.
The results of all tests.

(e.g.

Procedures and Compliance Criteria

(1) One batch of concrete of a proposed designed mix shall be
made on each of three days in each plant proposed to be
used. The batch shall be at least 60% of the mixer's nominal
capacity. If the concrete is batched in a central plant and
mixed in a truck mixer, three different truck mixers shall be
used.
(2) Three samples of concrete shall be provided from each batch
at approximately 1/6, 1/2 and 5/6 of the discharge from the
mixer. Each sample shall be of sufficient size to perform a
slump test or a flow table test, and make two test cubes. The
method of sampling shall be as stated in Hong Kong
Construction Standard CS1:2010.
(3) Each sample taken in accordance with Clause 2e.12(2) above
shall be tested to determine its slump value or its flow value
in accordance with Hong Kong Construction Standard
CS1:2010.
(4) Two test cubes shall be made from each sample taken in
accordance with Clause 2e.12(2) above and stored, cured
and tested to determine the compressive strength at 28 days
in accordance with Hong Kong Construction Standard
CS1:2010.
(5) The size of the test cube shall be 100mm for concrete with
the maximum aggregate size not exceeding 20mm and
150mm with the maximum aggregate size exceeding 20mm.
(6) The results of tests on concrete taken from the plant or
plants proposed in accordance with Clause 2e.12(1) to (5)
above shall comply with the following requirements:
(i)

The average of the nine measured slump values shall be

within +/- 20mm or +/- 25%, whichever is the greater, of
the designed slump value. The average of the nine
measured flow values shall be within +/- 50mm of the
designed flow value.

(ii) The range of the three measured slump values for each
batch of concrete shall not exceed 20% of the average of
the three measured slump values for that batch. For flow
table tests, the range of the three measured flow values
for each batch of concrete shall be within 70mm.

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(iii) The average compressive strength at 28 days of the 18

test cubes shall exceed the specified grade strength by
at least 12 MPa for 100mm test cubes or 10 MPa for
150mm test cubes.
The compressive strength of each individual test cube
shall exceed the specified grade strength by at least 5
MPa for 100mm test cubes or 4 MPa for 150mm test
cubes.
(iv) The range of the compressive strength of the six test
cubes from each batch of concrete shall not exceed 20%
of the average compressive strength of the six test
cubes from that batch.
Laboratory Trial Mixes
If accepted by the Engineer, trial mixes may be carried out in the
Suppliers laboratory in accordance with the following procedures
and to the following compliance criteria:
(1) Laboratory trial mixes shall be carried out in accordance with
Section 11 of CS1:2010. Three separate batches shall be
made, each of sufficient size to provide samples for carrying
out two slump tests or two flow table tests, and to make six
test cubes, which shall be tested for compressive strength at
28 days in accordance with CS1:2010.
(2) The compliance criteria for laboratory trial mixes are:
(i)

The average of the six measured slump values shall be

within +/- 20mm or +/- 25%, whichever is the greater, of
the designed slump value. The average of the six
measured flow values shall be within +/- 50mm of the
designed flow value.

(ii) The results of the compressive tests on test cubes shall

satisfy the table below:
Standard deviation of
test data of proposed
plant

Average of 18 cube
results to exceed
specified grade strength
by at least

Individual cube
result to exceed
specified grade
strength by at
least

14 MPa
10 MPa

7 MPa
3 MPa

12 MPa
8 MPa

6 MPa
2 MPa

100mm cubes
5.5 MPa or above
Below 5.5 MPa
150mm cubes
5.0 MPa or above
Below 5.0 MPa

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2e.13 Transporting Concrete

Concrete shall be transported from the mixer to the point of
placing in such a manner as will prevent significant alteration in
its properties, i.e. uniformity, cohesion, workability and final
strength.
The Contractor shall provide sufficient plant, equipment and
labour to transport the concrete continuously and without delay.
He shall also provide suitable barrow runs, platforms and
temporary screens and covers to prevent displacement of
reinforcement in slabs and to prevent any droppings falling into
the forms.
Care shall be taken to avoid segregation or contamination.
Suitable baffles and/or drop chutes shall be provided to make the
concrete drop vertically at the points of discharge from mixers,
conveyors, included chutes and hoppers. Concrete shall be
charged into the centre of hoppers and discharged from a central
opening in the bottom. All plant, equipment and tools shall be
kept clean and free from accumulation of mortar.
Should segregation occur the affected concrete shall be either
remixed before being placed or discarded. Any concrete which
becomes contaminated shall be discarded.
If the Contractor intends to pump concrete to the point of placing,
he shall submit such particulars as the Engineer may require of:
(a)
(b)
(c)
(d)
(e)

Type of equipment.
General arrangement and methods of support of pipe lines.
Procedure for charging and emptying pipelines.
Organisation for ensuring a continuous supply of concrete
at the required rate.
Procedures in case of delays and breakdowns.

The inside diameter of the pipes and hoses shall not be less than
three times the maximum size of the aggregate. Aluminium
pipes shall not be used. Extra strong couplings shall be used on
vertical runs and on sections which are not easily accessible.
The grout or mortar used to lubricate the pipe line before
charging it with concrete shall not be deposited in the forms and
suitable means of disposal must be provided.
Water shall be used for emptying pipe lines supplied by piston or
squeeze pressure pumps. When the pipe line is emptied towards
the point of placement a suitable arrangement shall be made to
collect the water and prevent it from flowing over the freshly
placed concrete.

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When compressed air is used to empty a pipeline supplied by a

pneumatic pump the air supply shall be carefully regulated and a
trap shall be provided to prevent the plug from being ejected
dangerously from the end of the pipe.
Samples of concrete for making test cubes shall be taken from
the point of discharge from the pipeline.
2e.14 Placing Concrete
No concrete shall be placed until the reinforcement has been
checked and approved by the or his representative. The forms
shall be cleaned before concrete is placed.
Concrete shall be placed without delay and within fifteen minutes
of leaving the mixer. It shall be placed in such a manner as will
avoid
segregation
and
prevent
displacement
of
the
reinforcement. Concrete from barrows shall be tipped towards
the working face. Drop chutes shall be provided to guide the
concrete vertically into deep forms such as columns and walls. A
gang of steel fixers shall be in attendance during concreting to
maintain the reinforcement in its correct position.
Concrete shall be placed continuously between construction
joints. The working face shall be kept plastic and free from cold
joints; fresh concrete shall be placed against it before the initial
set of the previously placed concrete.
In deep sections, the concrete shall be placed in layers of about
500mm depth without inclined layers. In long walls, it may be
necessary to work two or more lifts at the same time by the step
method.
In very deep sections such as walls, the water content of the
concrete for the upper layers should be reduced to counteract
water gain from the lower layers and to reduce settlement
shrinkage.
The Contractor shall have materials and labour available to make
additional construction joints in case of rain or breakdown in
concrete supply.
2e.15 Compaction
The Contractor shall provide and maintain in good working order
sufficient number of power driven vibrators for the rate at which
concrete is to be placed. the vibrators shall be of types, sizes and
powers suitable for the various parts of the work on which they
will be used.

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All concrete shall be carefully compacted by vibration to the

maximum practicable density and to thoroughly fill the forms and
surround and embed the reinforcement without voids.
Compaction by hand is not permitted without the express
approval of the Engineer; for reinforced concrete such approval
will only be given where the reinforcement is particularly
congested and when special mixes suitable for hand compaction
have been designed and tested.
In general, vibration shall be continued until the mass of concrete
becomes plastic, mortar begins to come to the surfaces and air
bubbles cease to appear. Over-vibration causing segregation or
surface laitance shall be avoided. If signs of over-vibration should
occur before the concrete is fully compacted, the water content
of the concrete shall be reduced appropriately.
The vibrators shall be worked systematically so that all the
concrete is properly vibrated.
In deep sections, immersion
vibrators shall be inserted vertically and penetrate through the
layer of concrete into the previous layer in order to work the
successive layers together. They shall be withdrawn slowly to
prevent the formation of voids. They shall not be placed against
the reinforcement or other embedded fixtures.
The upper sections of walls and, when directed by the Engineer,
other deep sections shall be revibrated at an interval after the
initial vibration but before the concrete has set.
Vibrators must not be used to make the concrete flow
horizontally; they must be kept a sufficient distance back from
the working face to prevent horizontal flow.
External vibrators clamped onto the formwork and surface
vibrators shall be used only with the Engineer's prior approval.
After the concrete has been properly vibrated, it shall be left
completely undisturbed while setting.
2e.16 Construction Joints
The position of any construction joints shown on the drawings
shall not be altered without the Engineer's approval.
The
Contractor shall submit for the Engineer's approval drawings
showing his proposals and details of construction joints. No
casting shall commence until approval has been given.
Unless sloping joints are required for a particular purpose, all
joints shall be either vertical or horizontal. Vertical joints shall be
made against rebated or battened stop boards to provide a
suitable key. Stop boards shall be firmly fixed and braced in
position. Horizontal joints shall be straight and level.
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When the concrete has sufficient strength and before placing new
concrete, the surface of the joint shall be thoroughly roughened
and cleaned. Any laitance or scum on horizontal joints shall be
removed by brushing, spraying with water and compressed air,
chipping or sand blasting.
Immediately before placing concrete against the joint, the surface
shall be wetted and in horizontal joints in walls and columns, a
layer of freshly mixed mortar of the same proportions of cement
and sand as the concrete mix shall be placed along the joint to a
depth of about 40mm.
Special care shall be taken in compacting concrete against a
joint.
2e.17 Expansion Joint
Expansion joints shall be formed in the locations and of the
widths shown on the drawings.
Unless other materials are shown on the drawings expansion join
gaps shall be formed with bitumen impregnated soft board of
approved quality wherever the filler is to remain in place and of
expanded polystyrene sheets where the filler has to be removed
to form an open gap.
2e.18 Contraction Joints
Contraction joints shall be formed in the locations indicated on
the drawings. Stop boards for contraction joints shall be as
specified for construction joints. The surface of the joint shall be
coated with an approved compound to prevent adhesion of the
new concrete. Contraction joints in slabs laid on the ground may
be made with approved crack inducers set in the forms or by saw
cuts after the concrete has gained sufficient strength. Chases
shall be formed for joint sealers where required.
2e.19 The Junction of Different Concretes in Monolithic Works
The change from one grade of concrete to another will generally
be made at a construction joint. Where the drawings require
different grades of concrete to be cast together without
construction joints the higher strength concrete shall be placed
first. The lower strength concrete shall be placed before the high
strength concrete has set and the two shall be well vibrated
together.
The high strength concrete shall extend at least 600mm or such
distance as is shown on the drawings beyond the junction of the
two members, towards the area of the lower strength concrete.
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Where a different concrete mix is required for facing work, it shall

be separated during placing by means of a temporary shutter
which shall be gradually withdrawn during the vibration of the
concrete.
2e.20 Concreting in Hot Weather
The Contractor shall take precautions to avoid the harmful effects
of hot weather on the properties of the plastic concrete and on
the quality and strength of the hardened concrete.
In very hot weather, the Engineer may require concreting to stop
or may order additional precautions before continuing concrete
work.
When the temperature of the surrounding air exceeds 300C, the
temperature of the concrete when it is placed shall be kept as low
as possible by shading the aggregate and the mixer from the sun
and by cooling the mixing water if necessary. The formwork shall
be sprayed with cold water in advance of the concrete and excess
water removed from the forms immediately prior to the placing of
the concrete. When directed by the Engineer, the temperature of
the concrete shall be measured and recorded. No concrete shall
be placed when its temperature exceeds 300C.
Special attention shall be given to planning the work so that the
concrete is placed as quickly as possible after mixing. Standby
equipment shall be provided to avoid delay due to breakdowns.
Concreting shall be preferably started in the afternoon to
minimise the drying effect of the sun. Special care shall be taken
to protect and cure the concrete. Exposed surfaces shall be
covered immediately after compacting and kept continuously
damp to control evaporation.
If ingredients are to be specially cooled or if ice is to be used as a
substitute for all or part of the water content, then details of the
scheme shall be submitted to the Engineer for approval before
use.
Special attention shall be given to large pours. The mass or
concrete large enough to produce cracks and other problems
associated with heat of hydration, may be considerably smaller
during hot weather.
2e.21 Curing and Protection of Concrete
During its initial hardening period of not less than seven days, the
concrete shall be protected from the harmful effects of sun wind,
rain or running water and from mechanical injury. All exposed
surfaces shall be kept continuously damp during this period.
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Intermittent wetting and drying will not be acceptable. Special

care should be taken when column forms are stripped early.
When required or approved by the Engineer curing compounds
shall be used. The surface of the concrete shall be damp when
the compounds are applied.
Different compounds may be
necessary in different parts of the work. Unless it has been
demonstrated that a compound forms a satisfactory base for
subsequent finishes, it shall be completely removed before
finishes are applied.
Curing compounds shall form an effective seal shortly after
application and shall have no injurious effect on Portland cement.
They shall not affect the appearance of fair-faced concrete nor
the bond of subsequent finishes with the concrete base. Curing
compounds shall be suitably coloured to enable easy inspection
of areas covered. Colouring shall be of the fading or removable
type so that there is no detrimental effect to fair-face concrete.
Curing may be effected by ponding, fog spraying, sprinkling with
water, covering with wet sacking or damp earth or sand or by
covering with impervious membranes such as plastic sheeting or
waterproof paper.
Spraying or sprinkling shall be done
continuously or at very frequent intervals and absorbent
coverings shall be damped down required to ensure that the
surface of the concrete does not dry out. Impervious films shall
be placed over the wet concrete as soon as possible without
marring the surface. When films are applied after stripping the
forms (e.g. on columns), the surface of the concrete shall be
wetted immediately before being covered by the film.
The method of curing adopted shall be suitable for the part of the
work and the prevailing weather conditions.
Under certain
conditions of sun, humidity and/or drying wind, it may be
necessary to cover the freshly placed concrete immediately after
compacting before the surface moisture dries out.
2e.22 Testing Concrete
The Contractor shall provide all materials equipment and labour
for testing concrete and carry out such tests as are specified or
directed by the Engineer. Tests on fresh concrete and on concrete
cubes shall be performed in accordance with Hong Kong
Construction Standard CS1:2010. All routine tests and additional
tests required upon evidence of work not in accordance with this
specification shall be at the Contractor's expense.
Slump tests or compacting factor tests shall be made at such
frequent intervals as are necessary to control the consistency of
the concrete.

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Test cubes shall be 150mm cubes, which may be replaced by

100mm cubes if accepted by the Engineer, made in steel moulds.
The sides of the moulds shall be true and square to adjacent
sides. The moulds shall be strong and stiff enough to accurately
hold their shape under all conditions to which they will be
subjected. Samples of concrete shall be taken at the point of
discharge from the mixer or at the point of placing as directed by
the Engineer. The cubes shall be made and cured in accordance
with the requirements of Hong Kong Construction Standard
CS1:2010.
All cubes shall be clearly and indelibly marked with a serial
number to identify each sample and a letter to identify each cube
made from that sample. Records shall be kept of the serial
number and letter, date of casting, mix, part of work in which the
concrete is placed, slump, the results of crushing tests and such
other information as the Engineer may from time to time
required.
Serial numbers shall be consecutive with no overlapping, and
cubes to be tested at days other than 28, if any, shall be
numbered separately.
The cubes shall be tested by a HOKLAS accredited testing
laboratory and all cubes shall be sent to the same laboratory for
testing. Should the Contractor wish to test three days old (or
some other age less than 7 days) cubes on site, he must first
obtain the Engineer's approval of the type of machine and its
calibration and all such tests must be witnessed by the Engineer
or his representative. Two copies of all cube test results shall be
sent to the Engineer immediately after testing.
The frequency of sampling concrete shall be in accordance with
the following table:
Type of Structure
Critical structures such as masts,
columns, whichever shear walls,
cantilevers of more than 3m span
and prestressed elements
Intermediate structures: whichever
Structures other than of the
Critical and Massive type
Massive structures such as solid
rafts, pile caps, caisson caps and
mass concrete volume retaining
walls

Concrete Quantity
Represented by Each Sample
10 cu m or 10 batches is the
smaller volume
25 cu m or 25 batches is the
smaller volume
100 cu m or 100
whichever is the smaller

batches

Generally, 2 cubes shall be made from each sample, which shall

be tested at 28 days to the acceptance criteria of the Building
(Construction) Regulations. The average strength of the 2 cubes
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shall be taken as the test result. The C2 acceptance criteria of

the Code of Practice for the Structural Use of Concrete 2004 may
be applied only if accepted by the Engineer.
If the cube tests do not meet the standard of acceptance, the
Engineer may require non-destructive tests and/or the taking and
testing of cores.
Rebound hammer tests may be required. They shall be made in
the following manner. The surface of the concrete to be tested
shall be ground or rubbed down to expose the aggregate. The
tests shall be applied to the areas between the particles of coarse
aggregate. Twelve tests shall be made at each location; the
highest and the lowest readings shall be discarded and the result
for the location shall be the average of the remaining ten
readings.
Concrete Coring
When specified, concrete cores shall be taken from designated
locations in the structure. The frequency of coring shall not be
less than:
Twice (once if there is only one casting) for pile caps and footings
Once every 3 floors for slabs, beams and staircases
Once every 3 floors for walls and columns
At each coring test, 3 cores shall be taken if the concrete cast in
one day does not exceed the volume stated below. Otherwise, 12
cores shall be taken.
Pile caps and footings: 800 cu m per day
Slabs, beams and staircases: 400 cu m per day
Walls and columns: 400 cu m per day
The diameter of cores shall preferably be 150mm for 40mm
aggregates and 100mm for 20mm or smaller aggregates. The
diameter may be reduced to an absolute minimum of 75mm if
the ratio of diameter to maximum aggregate size does not
exceed 3. The length of the test sample cut from the core shall be
at least 95% of the diameter. Cores may be non-through for
waterproofing or other purposes.
All tests shall be done in accordance with Hong Kong Construction
Standard CS1:2010 by a HOKLAS accredited laboratory and the
Building (Construction) Regulations, and the acceptance criteria
shall be:
(a) Cores shall not show signs of segregation or honeycombing.
(b) The estimated in-situ cube strength, calculated in accordance
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with CS1, of each core shall not be less than 75% of the
specified grade strength, and the average estimated in-situ
cube strength of each set of 3 or 12 cores shall not be less
than 85% of the specified grade strength.
2e.23 Defective Work
The Contractor shall inspect the concrete immediately after
stripping the forms and report any honeycombing or other
defects to the Engineer or his representative.
If tests show that the strength of the concrete is less than the
specified strength or if there should be serious honeycombing,
cracking or excessive creep, or shrinkage, or other defects, the
Engineer may order the defective work to be cut out and properly
reconstructed at the Contractor's expense. Such cutting out shall
extend to a position suitable, in the opinion of the Engineer, for a
construction joint.
When defective work is to be made good without reconstruction,
the Contractor shall first obtain the Engineer's approval of his
proposals for remedial work. No patching shall be done until the
defect has been inspected and the patching approved by the
Engineer or his representative.
If the concrete strength is less than the specified strength, the
Engineer may stop concreting in other parts of the structure
which may be relevant to the design.
2e.24 Load Test
The Engineer may order a load test:
(a) in the event of defective work;
(b) in the event of premature removal of props or the gross
overloading of any part of the structure; or
(c) for any other reason.
In the cases (a) and (b), the test shall be at the Contractor's
expense, in the third case (c), the Contractor shall be reimbursed
the cost of the test.
Such load test shall not be carried out until at least 28 days after
the date of concreting of the part of the structure to be load
tested.
The Contractor shall erect adequate struts and props to take the
whole of the test loads under the members to be tested and
leaving an adequate gap. The Contractor shall carry out all
proper safety precautions during the load test.

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Both the test loads and the test shall be conducted in accordance
with the recommendation of the Code of Practice for Structural
Use of Concrete 2004 issued by the Buildings Department unless
otherwise specified, or as directed by the Engineer.
2e.25 Waterstop
Waterstops shall be installed where shown on the drawings or
where directed by the Engineer.
They shall be of proprietary brands approved by the Engineer.
Waterstops for walls and slabs below ground shall be of the
ribbed type suitable for installing on the outer face. Waterstops
for expansion or construction joints shall be types suitable to
accommodate movement.
Waterstops shall be mitred and jointed as required and shall be
carefully positioned to allow concrete to be placed and
compacted to form water tight joints.
The Contractor shall submit details of the waterstop types and
method of installation prior to construction for the approval of the
Engineer.
2e.26 Bending and Fixing Reinforcement
Reinforcement shall be bent to the dimensions shown on the
drawings or in the bar schedules in a manner which will not injure
the material. All bending shall be done cold unless the written
approval of the Engineer is obtained. If approval is given the bars
shall be bent at a cherry-red heat (not exceeding 8400C) and
shall be cooled slowly.
Re-bending of high yield bars will not be permitted. Where it is
necessary to bend mild steel reinforcement already cast in the
concrete, the internal radius of the bend shall be not less then
twice the diameter of the bar.
All cutting, bends and bending tolerances shall conform to B.S.
8666:2000. Where bars are cranked at laps the slope of the
crank shall not be more than 1 in 12.
All reinforcement shall be securely tied together with soft
annealed iron wire of sufficient strength and at sufficient
intersections to prevent displacement during concreting. The
ends of the binding wire shall be turned inwards and shall not
project into the concrete cover.
The cover provided to the reinforcement shall not be less than
the minimum shown on the drawings or specified in Table 4 after
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all tolerances in formwork and in cutting and bending

reinforcement have been taken up. Subject to the provision of
minimum cover, the main bars in any structural member shall not
deviate from the required locations by more than:
3mm in sections less than 150mm thick
6mm in sections more than 150mm thick
25mm in footings and pile caps
No splices shall be made in the reinforcement except where
shown on the drawings or approved by the Engineer.
Precast spacer blocks shall be as small as possible and consistent
with their purpose, and designed so that they will not overturn
when the concrete is placed.
They shall be made of 1:2
cement/sand mortar. Wire cast in the block for the purpose of
tying it to the reinforcement shall be as above.
Proprietary spacers shall be of a design suitable for the location in
which they are to be used, and of a type approved by the
Engineer.
Steel chairs shall not be placed in direct contact with the
formwork unless suitably protected against corrosion.
Reinforcement left projecting from the concrete (e.g. starter bars)
and reinforcement which has been fixed long before concreting
shall be protected from corrosion at the direction of the Engineer.
Adequate notice shall be given to the Engineer whenever
reinforcement is ready for inspection. Reinforcement shall not be
disturbed after inspection without the approval of the Engineer.
TABLE 4
MINIMUM NOMINAL COVER TO REINFORCEMENT
Location

Concrete in contact with water

or ground without formwork
Concrete in contact with ground
with formwork/blinding
Concrete in contact with water
in watertanks
At end of bars in all members

289981923.doc

Minimum Cover (to all

reinforcement unless otherwise
stated but not less than diameter
of bar)
75mm
50mm
40mm
30mm but not less than 2 x bar dia
nor less than 75mm where concrete
in contact with ground

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At foot of chairs

Not less than cover to member main

bars
30mm
30mm
30mm FRP = 1 hour
Main bars
50mm FRP = 2 hours*
Main bars
80mm FRP = 4 hours*
30mm FRP = 1 hour
35mm FRP = 2 hours
55mm FRP = 4 hours*
40mm

Columns
Walls
Beams
Slabs/Stairs

External surface of concrete

of/with
- Fair-faced construction
- Dry fixed cladding
- Curtain wall
*
Wire fabric of 2 mm dia wire at 100 mm c/c to be placed in cover
at 20mm from face.

NOTE: More than the minimum cover may be required for marine works.
2e.27 Welding Reinforcement
The Engineer's approval must first be obtained before welding
reinforcement. In general, mild steel bars are reaily weldable.
High yield steel bars are weldable if the carbon equivalent is not
more than 0.51. When welding is permitted care shall be taken to
prevent fires and suitable fire extinguishers shall be provided
close to each working point. Where there is a risk of sparks or
hot weld metal falling on flammable material below, a man with a
portable fire extinguisher shall be on watch at the lower level.
Only skilled welders shall be employed on the work. For all welds
other than tack welds, full details of the welding procedure
(including type of electrode the preparation of the joint) shall be
submitted for the Engineer's approval.
2e.28 Use of Mechanical Couplers
Where the use of mechanical couplers is specified or approved,
the couplers shall be of a proprietary type, approved by the
Engineer and shall be installed strictly in accordance with the
manufacturer's instructions and the Code of Practice for
Structural Use of Concrete 2004 issued by the Buildings
Department.
Unless otherwise stated, mechanical couplers shall be capable of
splicing bars in tension. They shall also be suitable for the
conditions of the bars with respect to rotation. Where mechanical
couplers are left in place for future connection, they shall be
adequately protected against ingress of grout during concreting
and subsequently against corrosion.
The position of splices shall be as shown on the drawings. The
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splices shall preferably be staggered so that not more than half

the bars are coupled at any location and the distance between
staggered splices shall not be less than 30 times the diameter of
the bars.
A sample of each type of mechanical coupler shall be submitted
to the Engineer for testing and approval prior to the use of any
coupler in the works.
2e.29 Formwork and Falsework Generally
Formwork shall include all temporary or permanent forms
required for forming the concrete together with all soldiers,
ledgers, walings, ties and clamps required to hold the forms
securely in position and maintain the tolerances specified.
Falsework shall include all props, posts, cribs, beams, joists,
braces, grillages and any temporary foundation which may be
required to support the formwork.
Formwork and falsework shall be designed by the Contractor to
support the weight or pressure of the wet concrete with due
allowance for equipment, impact and vibration.
It shall be
planned to simplify erection and stripping procedures, to allow
adjustment after erection, to allow cleaning before placing
concrete and to enable props to remain in place where required
when the formwork is stripped.
Falsework shall be designed and constructed to provide the
necessary rigidity and strength to support the loads without
appreciable settlement. It shall be stressed only to conservative
low limits.
The deflections of any single supporting beam
member under load shall not exceed 1/900 of its span and of any
cantilever beam, the deflection shall not exceed 1/300 of its free
length.
Adequate bracing shall be provided transversely, longitudinally
and in the horizontal plane.
Provision shall be made, by means of wedges or jacks, for
adjusting the height of the formwork supported by the falsework.
This is to allow for settlement and to provide camber and to
permit the gradual lowering of the formwork during striking.
Drawings showing typical details of formwork and falsework and
such other details and calculations as he may require shall be
submitted to the Engineer for his record. Drawing showing
elevations of formwork for fair-faced concrete shall be submitted
to the Architect for approval of the pattern of joints.
2e.30 Materials for Formwork and Falsework
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Formwork for insitu concrete shall be constructed of seasoned

timber, waterproof plywood, steel or other material approved by
the Engineer.
Timber boarding shall be not less than 25mm thick. Plywood
shall be not less than 20mm thick and the edges of the panels
shall be sealed against the absorption of moisture. Steel moulds
shall be made up from sheet steel suitably framed and stiffened
with angles, tees and/or flats.
Waffle slab moulds shall be a type approved by the Engineer.
Moulds for precast units shall be so constructed as to produce
units within the tolerances given in the Code of Practice for
Precast Concrete Construction 2003 issued by the Buildings
Department unless otherwise specified with a fair-faced finish.
Internal metal wall ties shall be of a type that will permit the
removable parts to be extrated without damage to the concrete.
No permanently embedded metal part shall have less than 25
mm cover to the finished concrete surface.
In basement wall and water tank construction, internal metal wall
ties shall be such that the end of pieces can be removed leaving
the central piece in the concrete. Details of the wall ties shall be
to the Engineer's approval.
Where watertight construction is specified, such as basements,
lift and escalator pits, etc., ensure that the work is free from
leaks. Use only formwork ties which do not leave holes through
the concrete.
No internal wall ties will be allowed for construction of basement
walls with external face of which is inaccessible. Any raking
props, posts or bracing elements required for supporting the
formwork shall not be connected to any plankings, sheetpiles,
pipe pile walls, soldier pile walls, etc. of the ELS works.
Mould oil or release agent shall be of a type which will have no
adverse effect on any finishes to be applied to the concrete nor
on the appearance of fair-faced concrete. Release agent shall be
applied strictly in accordance with the manufacturer's instructions
and shall not come into contact with reinforcement or
prestressing tendons and anchorages.
Formwork materials shall be cleaned after use and maintained in
good condition. Any timber which has shrunk, wrapped or split
and any forms which are damaged to such an extent as to
weaken the form or to affect the quality or appearance of the
concrete shall be replaced or repaired.

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Falsework shall be constructed of sound timber, tubular steel or

rolled steel sections.
For heavy construction temporary concrete foundations or
temporary piles may be required to support the falsework.
2e.31 Formwork for Fair-faced Concrete
All timber for fair-faced concrete shall be wrot on all faces.
The formwork shall be made up in the pattern shown on the
drawings. Where no special pattern is shown the joints in the
forms shall be arranged in a neat regular repetitive pattern.
The forms for exterior faces of concrete walls shall be of plywood
with a pattern of groove formed by fixing tapered battens over
the joints between the plywood panels.
Forms for interior
concrete surfaces shall be flush jointed.
Form ties shall be arranged in a neat, regular consistent pattern
throughout the work.
Misalignment of joints shall generally not exceed 1.5mm and shall
in no case exceed 3 mm. At construction joints, the formwork
shall be sealed or caulked to prevent cement slurry from running
down and spoiling the adjacent concrete.
2e.32 Construction of Formwork and Falsework
Plywood panels shall be supported along each edge and at such
intermediate spacings as may be required by the loading. Joists,
studs and wales shall be thickened to facilitate the alignment of
joints. The formwork shall be securely nailed, screwed and/or
bolted to prevent any part of it from being displaced or dislodged
during the placing and vibration of the concrete.
Allowance shall be made for settlement of forms due to elastic
compression of props, taking up of joints and biting of end grain
into side grain. Wedges may be used at top or bottom of props
but not at both ends. After adjustment wedge shall be secured to
prevent them from coming loose during vibration.
Adjustable steel props shall have a minimum of 200mm
embedment in the pipe or sleeve. All pins and adjusting screws
shall be secured or locked against loosening or falling out.
All props shall be plumb and adequately braced both laterally and
diagonally. Lateral bracing shall be provided on both directions
and diagonal bracing shall be provided on both vertical and
horizontal planes. Particular attention shall be given to bracing
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when it is necessary for the props to be spliced.

All props shall bear on a firm seating. Adequate provision shall be
made for spreading the load of props supported on the ground;
any soft spots under the seating shall be removed and replaced
with firm well compacted material; precautions shall be taken to
prevent softening or weakening of the ground after erection of
the props.
Splices in studs, wales and props shall be kept to a minimum,
located away from position of high stress and designed and
constructed to carry safely all loads and forces to which they will
be subjected.
Formwork for waffle slabs shall be constructed so that the waffle
moulds can be removed without removing the props.
Formwork for prestressed concrete members shall be so
constructed as to provide no restraint to the concrete during
stressing operations.
Where permanent voids are to be formed in the concrete the void
formers shall be maintained rigidly in position. The Contractor
shall submit to the Engineer for his approval details of the
measures he proposes to take to ensure accurate formation of
the voids.
Formwork shall be so constructed that it will be tight enough to
prevent leakage of grout or mortar from the concrete and will
hold its shape and alignment until the concrete has hardened.
Before placing concrete, all inserts, conduit and other items to be
embedded shall be fixed accurately in position and the forms
thoroughly cleaned of all dirt and rubbish.
Rolled steel beams and channels for falsework supporting heavy
or eccentric loads shall be provided with adequate web stiffeners,
particularly at points of concentrated loading, to prevent the
buckling of the webs and to ensure lateral stability.
Formwork and falsework shall be inspected before placing
concrete to check that all wedges, clamps, and ties have been
tightened and secured and that the bracing is adequate. During
the placing of the concrete, the formwork shall be inspected for
excessive deflection or other signs of distress.
2e.33 Removal of Formwork
Formwork shall be left in place until it can be removed without
injury to the concrete and then removed without shock in a
manner which will not damage the concrete.

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The periods for which the formwork and props for concrete made
with Ordinary Portland Cement shall be left in place will depend
on the weather conditions, methods of curing, gain in strength,
type of member and subsequent loading but shall not be less
than the following:
Vertical formwork for sides of Beams, Columns, 12 Hrs
Walls and similar locations (Unloaded)
(to
be
increased if
concrete
with PFA)
Soffit formwork of Slabs (with props left in 4 Days
place)
Waffle Slab moulds (with props to Ribs left in 4 Days
place)
Soffit formwork of Beams (with props left in 7 Days
place)
Props for Slabs between Beams
10 Days
Props to Beams, Flat Slabs & Waffle Slab Ribs
14 Days
Props to Cantilevers
14 Days
When construction loads will exceed the design loads or cause
deflections which may affect the tolerance specified for
subsequent work, sufficient props shall be left in place to
distribute the loads over a number of storeys as directed by the
Engineer.
2e.34 Propping and Reshoring
Adequate props shall be retained in position until new
construction has sufficient strength to support its designed load
or any temporary load to be placed on it during subsequent
construction operations.
In multi-storey construction, particularly where long span or
cantilevers occur, propping to successive floors shall be left in
place and carried down far enough to distribute the construction
loads to avoid overstress or excessive deflection.
Whenever possible, the formwork shall be constructed so that it
can be removed without disturbing the props which are required
to be left in place. Where this is not practicable, the structure
shall be reshored immediately after removing the formwork.
During the stripping and reshoring operation, no construction
loads shall be placed on the new construction. The operation
shall be planned and performed so that no large areas are left
unsupported at any time. The shores replaced shall be positioned
over the shores on the floow below. Care shall be taken to
tighten them sufficiently to prevent significant shortening under
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load without overloading the floor below or causing upward

deflection of the new construction.
2e.35 Finishing of Permanently Exposed Surfaces
Where concrete will be permanently exposed or will have a
colourless or painted finish which will not obscure the form marks
or texture, all prominent mortar ridges or grout runs shall be cut
or ribbed off. If an excessive number of blow holes should occur,
they shall be filled. Care shall be taken to maintain the general
texture and appearance of the surface.
Blow holes less than 3mm in diameter will be acceptable when
they are dispersed and do not occur closely spaced in groups.
Blow holes more than 3mm but less than 20mm in diameter shall
not total more than 0.5 per cent of the surface area (i.e.
approximately 40 blow holes of 12mm average diameter in one
square metre is permitted). Blow holes larger than 20mm are not
acceptable.
Where surfaces are not to be painted the mortar used for
repairing surface defects shall be matched to the colour of the
surrounding concrete. Samples shall be made to test the colour
before any patching is done.
Where a local defect or patch mars the appearance of a panel,
the whole panel shall be treated in a manner approved by the
Architect to produce an uniform appearance.
Unless otherwise ordered, all exterior walls shall be cleaned from
the top downwards. Where cleaning or making good from an
intermediate level is required or approved any dirt or dropping
from subsequent work above shall be removed during the final
cleaning down.
Before any defective work is made good, the Contractor must
notify the Engineer in writing of his intention and methods to
rectify the defective work.
2e.36 Finish to Slab
The surface of slabs shall be brought to a compact level surface
within the specified tolerances without pitting or projecting
aggregate and without bringing excess mortar to the surface.
The finishing operation shall be done when the concrete has
stiffened enough for a compact surface to be obtained without
causing laitance.
When a topping is to be placed on the same day before the
concrete has fully hardened, all laitence, water and any foreign
matter shall be removed by brushing taking care not to displace
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the aggregate.
When slabs are to be finished without a topping, they shall be
trowelled with a rotary trowel or tamped to produce a rough finish
as required by the schedule of finishes.
When slabs are to have a topping applied after the concrete has
hardened, they shall be finished with a wooden float.
Top surface to concrete floors and roofs which are to receive
finishes direct (i.e. without cement and sand screeds) shall be
finished to provide the same standard of finish as would be given
by a normal cement and sand screed. Normal structural
tolerances will apply but additionally no lips, bumps or hollows
will be permitted.
The Contractor's attention is drawn to the problems inherent in
achieving this kind of finish. A special concrete mix design which
is suitable for finishing may be required. Special precautions shall
be taken to prevent inclement weather affecting the surfaces
during placing and subsequently until the concrete is fully cured.
Care shall be taken to avoid damaging the surface during
subsequent construction. Before construction commences, the
Contractor shall submit for approval his proposals and methods
for carrying out this section of the work.
The first area of concrete cast by the Contractor with this finish
shall be submitted for approval. Immediately after the sample
bay has sufficiently matured, the Contractor shall obtain evidence
that his Flooring Sub-Contractor is satisfied that the standard of
finish is suitable for flooring to be laid directly on to the surface.
2e.37 Tolerances for In-Situ Construction
Unless shown otherwise on the drawings, tolerances shall not
exceed the values shown in the schedules for the respective parts
of the work. The tolerances shown shall not be considered
cumulatively. The tolerances shown shall not include deflection of
the structure.
In general, the provisions of this clause must be complied in full.
Wherever any construction tolerance limits specified in Section
10 of the Code of Practice for Structural Use of Concrete 2004 are
not covered in this clause, the tolerance limits specified in
Section 10 of the Code of Practice for Structural Use of Concrete
2004 shall be adopted.
Schedule of Tolerances for Insitu Construction
(a)
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of columns and bearing walls in plan:

(b)

5mm in 3 metres of length with a maximum of 25mm.

Provided that no building face shall protrude over a
boundary line.

Footings and Pile Caps

Misalignment or eccentricity with respect to the centre line
of the wall or column:
2 per cent of the width of the footing with a maximum of
50mm.
Dimensions in Plan:
Thickness

(c)

Minus 10mm plus 50mm

Minus 5 per cent plus 10 per cent
with a maximum of plus or minus
50mm.

Verticals and Batters

Deviation of the lines and surface of walls, piers columns
and arrises from the vertical or from the required batter:
-

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5mm in 5 metres with a maximum of 12mm.

Deviation of columns and bearing walls from the plumb
over the height of the building.
12mm up to 30 metres in height
20mm up to 60 metres in height
25mm up to 90 metres in height and over.

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(d)

Means Levels
Maximum deviation of mean level from the level:

(e)

i)

In a height of 3 metres from the next

lower floor or other distinctive feature.

6mm

ii)

In a height of 6 metres from the next

lower floor or other distinctive feature.

12 mm

iii)

In a height of 12 metres or more from

the next lower floor or other distinctive
feature.

20 mm

iv)

In any upper floor from the datum level

(i.e. the accumulation of tolerances from
successive floors must not exceed
20mm).

20 mm

Levels and Gradients

Deviation of the surface of a floor, ceiling or beam soffit
from the required the mean level or from the required
gradient:
- 6mm in any 3 metres of length
- 10mm in any 6 metres of length
With a maximum of 20mm for the whole length.

(f)

Conspicuous Horizontals
Deviation of edges of exposed lintels, sills, parapets,
horizontal grooves and other conspicuous lines from the
horizontal:
- 6mm in any 6 metres of length
- 10mm in any 12 metres or more

(g)

Cross Sections
Maximum deviation from the values of the cross section
dimensions of columns, beams, walls, floors, roof slabs, and
other structures:

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(i)

Dimensions less than 150mm

+10mm
3mm

(ii)

Dimensions 150 mm and over

+12mm
6mm

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(h)

Openings
Maximum deviation from the sizes and locations of openings
in floors and walls:
6 mm
Notwithstanding the above tolerances, the Contractor will
be responsible for providing for any additional margin as
may be required for window, door or lift door frame,
installation.

(i)

Stairs
Deviation in risers:
- In consecutive steps
- In any flight
Deviation in treads:
- In consecutive steps
- In any flight

(j)

3 mm
6 mm

Paving in Yards, Footpaths and Access Roads

(i)
Deviation from the alignment of the centre
line
(ii)
Deviation from the level or gradient at any
point
(iii) Deviation from thickness

(k)

2 mm
6 mm

25 mm
6 mm
+12m
m
6mm

Special Requirements for Prestressed Structural Members

(i)

(ii)

Maximum deviation from any cross section

dimension:
- Cross section not exceeding 75 mm
1 mm
- Cross section not exceeding 450 mm
3 mm
- Cross section over 450 mm
6 mm
Maximum deviation from the straight per 3
metres of length

2e.38 Cast-In-Place Lightweight Concrete

Non-structural lightweight concrete for insulation or making up
levels or falls shall be cellular concrete made with an approved
foaming agent which shall be used in accordance with the
manufacturers recommendations. The Contractors shall provide
full particulars of the foaming agent, equipment, proportions of
the mix, methods of mixing, placing and curing, and when
required by the Engineer, such samples as may be appropriate to
the type of work. These particulars must be submitted for
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approval in good time to allow alternative materials and

procedures to be selected if the first submission is not approved.
The lightweight concrete may contain mineral aggregates such as
perlite, vermiculite pulverized fuel ash or fine sand as fillers.
Coarse sand is generally not suitable.
Two test cubes shall be made for each day's work to check the
density and strength of the lightweight concrete. The strengths
expected at 28 days are:
Density Kg/cu m
320
400
480
560
640

400
480
560
640
800

Strength at 28 Days MPa

0.68
0.86
1.55
2.40
3.10

0.86
1.55
2.40
3.10
5.20

Lightweight concrete shall be laid in alternate bays to allow for

shrinkage and shall be cured by covering with sacking which shall
be kept wet for at least 3 days.
2e.39 Fixings, Openings and Indentations in Concrete
No openings, chases, holes or voids other than those shown on
the drawings shall be formed or cut in the concrete without the
approval of the Engineer.
Where approval is given, the
reinforcement shall, if necessary, be adjusted to maintain the
strength of the concrete and the cover to the reinforcement.
Fixing plugs, timber or breeze plugs and all fixings shall be of
such type and in such positions as will not weaken the structural
concrete nor encourage corrosion of the reinforcement.
No fixings shall be inserted into the structural concrete by means
of explosives without the approval of the Engineer. Approval may
be given for low velocity, piston type fastening systems such as
Ramet JP50, Hilti etc. High velocity gun type tools will not be
approved.
In cavity wall construction where one leaf of the wall is of
reinforced concrete, a system of vertical metal inserts shall be
cast in the concrete. The inserts shall be arranged as detailed
such that wall ties can be incorporated at the desired locations to
suit the horizontal courses of the blockwork or brickwork leaf.

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2e.40 Contractor's Plant Attached to Buildings

Where the Contractor proposes to use climbing tower cranes, or
any type of plant which places any load on the reinforced
concrete structure, he must furnish full details of such plant to the
Engineer for approval before the work is actually commenced.
Loads from such plant or equipment shall only be imposed on
such completed plant or equipment storeys of the structure
where the concrete has already attained the minimum 28 days
crushing strength. If necessary and architecturally acceptable, the
structure may be strengthened in order to carry such loads in a
manner approved by the Engineer at the Contractor's expense.
The Contractor shall be responsible for making good to the
satisfaction of the Engineer, any damage to the permanent
structure which may be caused by his plant.
If the Contractor desires to leave permanently embedded in the
concrete, any supports for the shuttering, scaffolding and/or
hoists, he must furnish in writing exact details of his proposals
and such supports shall be subject to the approval of the
Engineer.
2e.41 Loading in Excess of Design Load
No loading in excess of the design loading shall be placed on any
portion of the structure without the written permission of the
Engineer. If such permission is granted, all beams or other
members of the structure which are subjected to loading other
than the designed loading shall be strengthened and supported to
the satisfaction of the Engineer, and the Contractor shall be
responsible for any extra expense.
The Contractor shall be responsible for making good to the
satisfaction of the Engineer any damage to the permanent
structure which may be caused by such excess loading.
2e.42 Filling Holes for Pipes Etc.
Where holes have been left through floors and walls to allow
pipes, conduits and trunking to pass from one compartment to
the other, the holes shall be filled after the installation of the
services.
Larger holes, such as at the pipe ducts through floors, shall be
filled with reinforced concrete of the same strength as the
adjacent slabs. Smaller holes, such as for individual pipes shall
be filled with 1:3 cement sand mortar well packed in. Before
filling the pipes or trunking shall be painted with bituminous paint
or wrapped with anticorrosive tape. Where it is necessary to
allow for expansion of the pipes, they shall be wrapped with
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several layers of building paper after painting.

2e.43 Blinding
Where concrete is to be laid on the ground or where specified, a
binding layer of concrete not less than 50 mm thick of Grade 15P
shall be laid to provide a firm, reasonably level surface on which
to place the reinforcement.
2e.44 Slipform Construction
If the Contractor wishes to use slipforms for any part of the work,
he shall first submit full particulars and details of the equipment
and procedure and obtain the approval of the Engineer.
2e.45 Construction Sequence
For some structures or parts of a structure, the Engineer may
require a particular construction sequence for the purpose of:
(a) ensuring stability during construction;
(b) ensuring the integrity of the completed structures;
(c) reducing losses due to restraints in post- tensioned concrete
work; and
(d) reducing the adverse effects of shrinkage;
and all the requirements shall be carried out at the Contractor's
expense.
2e.46 Lintels
If not detailed on the drawings, lintels shall be precast or insitu
concrete grade of 30D reinforced with high tensile steel bars with
hooked ends so placed that not less than a minimum cover of
30mm all round.
The bearing at each end of the lintels is not to be less than
150mm. Unless otherwise specified, lintels are to be of the
following basic dimensions:
Clear Span
Not
1m

exceeding

Exceeding 1m,
but not
exceeding 2m
Exceeding 2m,
289981923.doc

Depth of
Lintel
(mm)
150

No. and Diameter

of Bars per 115mm
(or part) in width
One 12mm bottom
One 10mm top

225

One 16mm bottom

One 10mm top

8mm dia.

300

One 20mm bottom

10mm dia.

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General Specification
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but not
exceeding 3m

One 10mm top

***

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